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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application Ser. No. 60/232,023, filed Sep. 12, 2000.
TECHNICAL FIELD
[0002] The present invention relates to a variable sun screen for a vehicle in which first and second relatively movable sheet members are provided with selectively alignable opaque and transparent matrices for adjusting the level of opacity of the sun screen.
BACKGROUND ART
[0003] Vehicle sun screening members, such as sun visors, are required to “block the sun” to improve visibility for the driver, but it may be advantageous at times to have a certain percentage visibility through the visor. For example, it may be desirable to see an overhead traffic signal when the sun is directly ahead and low in the sky. At other times, the visor may need to be totally opaque.
[0004] It may also be desirable to selectively vary the percentage of visibility through a sunroof or overhead vehicle window. This may be necessary to reduce glare inside the vehicle, or to reduce heat build-up inside the vehicle which results from unobstructed sunlight through a window or sunroof.
DISCLOSURE OF INVENTION
[0005] The present invention provides a variable shade sun screen having first and second relatively movable sheets with alignable or offsetable matrices of translucent and opaque portions to selectively vary the opacity of the sun screen. This invention can be used in a sun visor, a sunroof, or adjacent any vehicle window surface.
[0006] In one embodiment, the invention allows for adjustment of a matrix of matching shapes, opaque in nature, printed or otherwise applied to two clear sheets of material, one sheet being stationary within a sun visor body, the second being adjustable laterally by means of an adjuster on the periphery of the visor.
[0007] In another embodiment, a movable clear film is imprinted with a dot pattern, and two transparent fixed blades are bonded to an opaque bottom edge extrusion. A hole pattern is printed on an inside surface of one of the blades. The dot pattern and hole pattern may be selectively aligned or misaligned to adjust opacity of the assembly. Various embodiments for implementing this structure are contemplated and described herein.
[0008] In a further embodiment of the invention, a movable inner panel is applied against an outer glass panel on the roof of a vehicle. The inner movable panel includes a matrix of matching opaque shapes for adjustment with respect to a corresponding matrix of translucent portions on the outer glass panel. The matrix of translucent portions may be formed by silk-screening on an inside surface of the outer glass panel.
[0009] Accordingly, an object of the invention is to provide a method and apparatus for variably adjusting the opacity of a vehicle window sun screen.
[0010] The above objects and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0011] [0011]FIG. 1 shows a plan view of a sun visor in accordance with a first embodiment of the invention;
[0012] [0012]FIG. 2 shows a partially cut-away perspective view of a stationary shade member corresponding with FIG. 1;
[0013] [0013]FIG. 3 shows a partially cut-away perspective view of a movable shade corresponding with the embodiment of FIG. 1;
[0014] [0014]FIG. 4 shows a plan view of a sun visor in accordance with a second embodiment of the invention;
[0015] [0015]FIG. 5 shows a vertical cross-sectional view taken through the sun visor of FIG. 4;
[0016] [0016]FIG. 6 shows a perspective view of a movable shade corresponding with the embodiment of FIG. 4;
[0017] [0017]FIG. 7 shows an exploded perspective view of transparent fixed blades and a bottom edge extrusion corresponding with the embodiment of FIG. 4;
[0018] [0018]FIG. 8 shows a perspective view of a clamshell sun visor housing in accordance with the embodiment of FIG. 4;
[0019] [0019]FIG. 9 shows an exploded perspective view of a sun visor assembly in accordance with a third embodiment of the invention;
[0020] [0020]FIG. 10 shows an exploded perspective view of a sun visor assembly in accordance with a fourth embodiment of the invention;
[0021] [0021]FIG. 11 shows a partial exploded view of a fifth embodiment in accordance with the present invention;
[0022] [0022]FIG. 12 shows a cut-away vertical cross-sectional view of a sun screen on a roof glass panel of a vehicle in accordance with a six embodiment of the invention; and
[0023] [0023]FIG. 13 shows a schematic plan view of an adjustment mechanism for the sun screen of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Referring to FIGS. 1 - 3 , a first embodiment of a variable shade sun visor 10 is shown in accordance with the present invention. The variable shade sun visor 10 includes a support arm 12 which supports a visor body 14 . The visor body 14 encloses a stationary shade 16 having a support rod 18 which is slidably received within a sleeve 20 which supports the movable shade 22 .
[0025] An adjuster 27 cooperates with threads 26 on the sleeve 20 for selectively moving the movable shade 22 fore and aft along the visor body 14 with respect to the stationary shade 16 to selectively adjust the position of the dot matrix 26 with respect to the corresponding hole matrix 28 on the stationary shade 16 .
[0026] When the dot matrix 26 is aligned with the hole matrix 28 , the sun visor 14 is 100% opaque, and when the dot matrix 28 is adjusted to a position out of alignment with the hole matrix 28 , approximately 80% opacity is achieved. The dot matrix 26 and hole matrix 28 may be silk-screened onto the stationary shade 16 and movable shade 22 , which are both translucent sheets.
[0027] Of course, a variety of configurations are contemplated under the present invention for the arrangement and shape of the dot matrix and hole matrix. Also, the hole matrix 28 may be actual holes through the stationary shade 16 , or may be an opaque pattern which is silk-screened onto a translucent sheet forming the stationary shade 16 . The opaque pattern 29 would be absent in the dots or translucent portions to form the hole matrix 28 . Furthermore, the dot matrix 26 and hole matrix 28 may alternatively be on the stationary or movable component.
[0028] Additionally, the shape of the dots in the dot matrix 26 and the holes in the hole matrix 28 need not be round. They may be diamond-shaped, square, etc.
[0029] Referring now to FIGS. 4 - 8 , a second embodiment of a variable shade sun visor 40 is shown. As shown, the variable shade sun visor includes a visor body 42 which houses a variable opacity sun screen 44 . As shown, the variable opacity sun screen 44 comprises a clear film 46 imprinted with a dot matrix 48 and supported by a molded rod 50 . The molded rod 50 is slidably supported within the sleeve 52 , which is an extruded component which supports two transparent fixed blades 54 , 56 , one of which has a hole pattern imprinted on an inside surface thereof. The sleeve 52 is preferably opaque. The visor body 42 is hinged at the lower edge to form a clamshell-type configuration.
[0030] In order to adjust the opacity of the sun screen 44 , the clear film 46 is selectively moved longitudinally along the visor body 42 to adjust the dot matrix 48 with respect to a corresponding hole matrix formed on one of the translucent fixed blades 54 , 56 .
[0031] [0031]FIG. 9 shows an exploded perspective view of a variable shade sun visor 60 in accordance with a third embodiment of the invention, which is a slight variation of that shown in FIGS. 4 - 8 . As shown, the variable shade sun visor 60 includes a non-structural foam body 62 , and the fixed blades 64 , 66 are molded together as a single component and attached by the detent spring 68 to the arm 70 and bracket 72 for attachment to the vehicle roof. The prior art D-ring is replaced by the rod 74 which is selectively attachable to the vehicle overhead check (not shown).
[0032] The movable shade 76 is provided with a dot matrix 78 , and a threaded adjuster 80 is provided for selectively adjusting the longitudinal position of the movable shade 76 with respect to the fixed blades 64 , 66 , one of which will have a hole matrix imprinted thereon. The rod 82 of the movable shade 76 is slidably disposed within the sleeve 84 , which is integral with the fixed blades 64 , 66 . The fixed blades 64 , 66 are preferably a thermally formed matte-finished acrylic or other transparent material.
[0033] The fourth embodiment shown in FIG. 10 differs from the embodiment of FIG. 9 in that the variable shade sun visor 90 includes a structural visor body 92 having a D-ring 94 such that the D-ring and visor body 92 support the load of the sun visor. The visor body 92 is a clamshell member pivoted at the top edge 93 . The fixed blades 96 , 98 are molded separately and glued together at a bottom edge 100 . The movable blade 102 includes the dot matrix pattern 104 for selective adjustment with respect to a hole pattern on one of the fixed blades 96 , 98 . A threader adjuster 106 is provided for selectively adjusting the movable blade 102 with respect to the fixed blades 96 , 98 . Also, the standard detent spring 108 and arm 110 with bracket 112 are also provided.
[0034] Referring now to FIG. 11, a fifth embodiment of the invention is shown. A frame is comprised of an upper member 201 , a lower member 202 , an inboard endcap 208 , and an outboard endcap 209 . The upper and lower members are preferably extruded out of metal or plastic. Other processes, such as injection molding, may also be used to manufacture the parts. The endcaps are preferably injection molded. At least the upper member 201 and the lower member 202 comprise two slots therein 220 and 221 for receiving the fixed blade 203 and the adjustable blade 204 respectively. The fixed blade 203 is fixed to the upper and lower members 201 , 202 with, for example, an adhesive. The blades are adjustable by means of a screw adjuster assembly 225 which comprises an adjuster rod 206 having a thread 230 , a bushing 215 , and an adjuster wheel 207 . The thread 230 fits inside protrusion 231 of the movable blade 204 . To prevent movement of the screw adjuster assembly 225 , the screw adjuster assembly abuts endcap 208 and upper member 201 . When the adjuster wheel 207 is turned, the movable blade 204 moves fore and aft in groove 221 . One or more blade rollers 205 may be attached to the movable blade 204 to reduce friction.
[0035] Alternative to the rollers, a plurality of slots 245 in one blade can be engaged by a matching number of pins 240 protruding from the other blade to align one matrix to the other and prevent excessive friction within the frame components.
[0036] As discussed above, the fixed blade 203 and the movable blade 204 comprise dot and hole matrices.
[0037] Referring to FIGS. 12 and 13, a sixth embodiment of the invention is shown, wherein an inner movable panel 150 cooperates with an outer glass panel 152 on a vehicle roof 154 to form a sun screen assembly 156 . Preferably, the inner movable panel 150 is provided with a dot matrix thereon, and a hole matrix is silk-screened or otherwise applied to an inside surface 158 of the outer glass panel 152 to provide selective adjustability of the dot matrix with respect to the hole matrix when the movable panel 150 is slid along the outer glass panel 152 .
[0038] [0038]FIG. 12 shows an adjustment lever 160 which provides a long moment arm between a pivot point 162 and an adjustment point 164 to provide minor adjustment of an attachment point 166 which is fixed to the movable shade 150 for selectively moving the movable shade 150 when the adjustment point 164 is actuated by a vehicle occupant to adjust the relationship of the dot matrix and hole matrix for adjusting opacity of the sun screen assembly 156 .
[0039] While various embodiments of the invention have been shown and described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention without departing from the spirit and scope of the invention as described herein. | A variable shade sun screen having first and second relatively movable sheets with alignable or offsetable matrices of translucent and opaque portions to selectively vary the opacity of the sun screen. The invention can be used in a sun visor, a sunroof, or adjacent any vehicle surface. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 09/054,809 filed Apr. 3, 1998, which is incorporated herein by reference.
[[0002]] This invention was made with Government support under contract number DE-AC02-98CH 10886, awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The present invention generally relates to the field of atomic force microscopy and, more particularly, to control of an atomic force microscope.
BACKGROUND OF THE INVENTION
[0004] The present invention relates generally to atomic force microscopy and more particularly relates to an atomic force microscope and controller which minimize contact forces between a probe tip and a specimen and is well suited for the study of biological specimens.
[0005] In the study of biology, it is desirable to observe biological specimens under very high magnification in a native environment. Such observations allow scientists to monitor, in real time, biological processes at the molecular and sub-molecular level. Such processes include the interaction of proteins with DNA and with each other. Currently, these processes cannot be observed in real time with electron microscopes or x-ray crystallography techniques which are known in the art, as the specimens are not in their native environment when using these apparatuses. Accordingly, scientists have sought alternate methods to observe biological specimens. One such alternative is known as the atomic force microscope.
[0006] Atomic force microscopes (AFM), which are generally known in the art, physically probe a specimen to create an image of the specimen's surface. FIG. 1 illustrates a typical embodiment of an AFM known in the art. The AFM has two primary components, a scanner 10 and a flexible cantilever 12 having a probe tip 14 on a free end. The scanner 10 has a top surface 16 on which a specimen 18 to be imaged is placed. The scanner 10 typically employs three piezoelectric elements 20 , 22 , 24 to move the specimen 18 in three dimensions, X Y and Z, relative to the position of the probe tip 14 . The probe tip 14 is affixed to the free end of the flexible cantilever 12 and contacts the specimen 18 . The AFM includes a laser 26 directed onto the cantilever 12 and a photo detector 28 which is responsive to laser light to measure the deflection of the cantilever 12 . As the degree of cantilever deflection is proportional to the contacting force between the probe tip 14 and the specimen 18 , such force can accurately be calculated based on the angle of cantilever deflection.
[0007] To create an image of a specimen, the scanner 10 directs the specimen 18 in a raster-scan fashion in the X-Y direction while continuously sampling the contour of the specimen 18 in the Z direction. The sampling is generally performed using one of two techniques known in the art, namely contact mode or tapping mode. In contact mode, the scanner 10 is controlled in the Z direction such that the contacting force between the probe tip 14 and the specimen 18 is substantially constant. As the contour of the specimen changes, the deflection of the cantilever 12 also changes and a servo system driving the scanner 10 adjusts the Z coordinate of the scanner 10 to restore the desired constant force. At each specimen point, the coordinate of the Z axis is indicative of the specimen contour. Because the probe is constantly contacting (i.e. it drags along) the surface of the specimen during the X-Y raster scan, significant lateral forces are applied to both the specimen 18 and the probe tip 14 . The probe tip 14 , which is typically 200-300 Angstroms in diameter is subject to rapid wear and breakage under these forces. Also, when used on soft specimens, such as biological specimens, the probe tip is likely to destroy the surface of the specimen, making accurate and repeatable measurements impossible.
[0008] In tapping mode, the cantilever 12 is driven in an oscillatory fashion at the resonant frequency of the cantilever. This may be achieved by affixing the cantilever to a piezoelectric element 30 and driving the piezoelectric element 30 with a voltage signal at the resonant frequency of the cantilever. To determine the contour of the specimen in tapping mode, the scanner 10 moves the specimen in the Z direction until a predetermined reduction in oscillation amplitude is detected. The reduction in oscillation amplitude is the result of the probe tip 14 contacting the surface of the specimen 18 during each cycle of oscillation. Because the probe tip 14 repeatedly, but only momentarily contacts the specimen 18 at each point during the X-Y raster scan, the lateral force present during contact mode is substantially reduced. However, because the probe tip 14 is moving rapidly on arrival at the specimen surface, the contacting force, while short in duration, is large in magnitude. The force that results from tapping mode tends to be destructive to biological specimens. Thus, tapping mode is most useful in sampling hard surfaces, such as those found in integrated circuit manufacturing processes and the like. Also, tapping mode is difficult to use when measuring a fluid-based specimen. When the cantilever assembly is submerged into a fluid environment, the desired oscillation of the cantilever can be dampened and additional resonances are developed which can adversely affect operation and accuracy. Also, fluid flow induced by the tapping oscillation tends to erode the specimen. Because biological specimens tend to reside in a fluid environment, tapping mode is not well suited for measuring these specimens. Tapping mode is also incapable of separately measuring the contacting force and adhesion force at each pixel. Because tapping mode cannot separate the two forces, concurrent mapping of each force during scanning is presently not possible with AFM's employing tapping mode.
[0009] An alternative operating mode to both contact mode and tapping mode is described in U.S. Pat. No. 5,229,606 to Elings et al. Elings et al. refers to “jump scanning” where the probe is momentarily brought into contact with the surface to be measured. The probe is then lifted away from the surface as the specimen is moved in the X direction and the probe tip is then brought back down into contact to take the next specimen. By jumping over the surface of the specimen, Elings et al. teach a method of increasing scanning speed with reduced risk of probe damage. However, when the probe tip and specimen contact one another, an attractive force tends to hold the probe tip in contact with the specimen. To ensure that the probe tip is able to release, the cantilever 12 must be formed with a sufficient spring constant to overcome this attractive force. Unfortunately, increasing the spring constant of the cantilever 12 increases the magnitude of the contact force between the probe tip 14 and specimen 18 which is required to achieve a measurable cantilever 12 deflection. Such stiff cantilevers, i.e., in the range greater than 0.1 Newtons per meter (N/m), which are required for jump mode, are incompatible with the more sensitive biological specimens which are easily damaged under the application of such forces.
[0010] The problem of overcoming the attractive forces between an AFM probe tip 14 and specimen surface was addressed in U.S. Pat. No. 5,515,719 to Lindsay. Lindsay operates in a mode where contact between the probe tip 14 and specimen surface is considered to be undesirable and recognized that when soft (low spring constant) cantilevers are used, the attractive interaction between the specimen 18 and probe tip 14 tends to draw the probe tip in and the probe tip 14 will contact and stick to the surface until enough force is applied to the cantilever base to release the probe tip 14 . To address this problem, Lindsay teaches the addition of a magnetic particle attached to the cantilever in combination with a magnetic solenoid located proximate to the cantilever. The solenoid generates a magnetic field which is variable and precisely regulated by a servo circuit. The servo circuit monitors the deflection of the cantilever and continuously adjusts the magnetic field such that the attractive force between the probe tip 14 and specimen 18 is substantially neutralized. In this way, the probe tip 14 , as taught by Lindsay, is kept at a distance from the specimen and never makes contact with the specimen. Therefore, it is impossible to measure an adhesion force using this method and difficult to measure the specimen profile at high lateral resolution because of the tip-specimen separation.
[0011] The use of a magnetic particle affixed to a flexible cantilever and controlled by a magnetic coil as used by Lindsay was first disclosed in an article by Florin et al., entitled “Atomic Force Microscope with Magnetic Force Modulation”, published in the Review of Scientific Instrument, 65(3), March 1994. Florin et al. teach the use of a magnetic control system to drive the cantilever in an oscillating fashion such that the probe tip momentarily and adversely contacts a specimen, in a manner similar to tapping mode.
[0012] Current AFM techniques tend to be destructive to biological specimens. Therefore, there remains a need for an improved atomic force microscope adapted for use in a fluid medium: for the observation of biological specimens in their native environment under conditions completely controlling and quantitatively measuring the interaction forces between tip and specimen.
SUMMARY OF THE INVENTION
[0013] We have created an advance in the atomic force microscope field which improves operability and/or enables atomic force microscope usability in material science, genomics, proteomics, polymer science, and biomedicine by allowing observation of and data collection from biological specimens in their native environment.
[0014] It is another object of the present invention to provide an atomic force microscope which provides a controlled, angstrom by angstrom approach of the probe tip to the specimen.
[0015] It is yet another object of the present invention to provide an atomic force microscope which applies minimal vertical force to the specimen being measured.
[0016] It is still another object of the present invention to provide an atomic force microscope featuring substantially zero lateral force applied to the specimen during a raster scan.
[0017] It is a further object of the present invention to provide an atomic force microscope using a low spring force cantilever which overcomes the problem of probe tip retention resulting from adhesive forces between the probe tip and specimen.
[0018] It is still a further object of the present invention to provide an atomic force microscope capable of using a probe tip with a diameter less than 100 Angstroms.
[0019] It is still another object of the present invention to provide an atomic force microscope which is able to generate repeatable scan to scan measurement results on biological specimens.
[0020] It is yet another object of the present invention to provide an atomic force microscope suitable for monitoring biological processes in real time.
[0021] It is still another object of the present invention to provide an atomic force microscope which substantially continuously monitors both cantilever displacement relative to specimen and cantilever deflection.
[0022] It is yet another object of the present invention to provide an atomic force microscope which is responsive to changes in cantilever deflection within five microseconds.
[0023] It is yet a further object of the present invention to provide an atomic force microscope capable of recording and outputting complete force curves for all pixels in a specimen scan.
[0024] For better understanding of the present invention, together with other and further objects and advantages, reference is made to the following description, taken in conjunction with the accompanying drawings, and its scope will be pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a block diagram of an atomic force microscope formed in a manner known in the prior art;
[0026] FIG. 2 is a block diagram of a sensing mode atomic force microscope formed in accordance with the present invention;
[0027] FIG. 3 is perspective view of a cantilever and cantilever pulse release system, formed in accordance with the present invention;
[0028] FIGS. 4 A-C are flow charts illustrating the operation of a sensing mode atomic force microscope formed in accordance with a method of the present invention;
[0029] FIG. 5A is a graph depicting the full range of cantilever base motion;
[0030] FIG. 5B is a graph depicting cantilever base motion truncated by the detection of probe tip contact;
[0031] FIG. 5C is a graph depicting cantilever deflection versus time and corresponds in time with the graph in FIG. 5B ;
[0032] FIG. 5D is a graph depicting cantilever deflection versus time with the application of a reverse polarity pulse release signal, restoring the cantilever to a neutral position;
[0033] FIG. 5E is a graph depicting the full range of cantilever base motion incorporating a pause for incremental ramp up of the magnetic withdrawal force;
[0034] FIG. 5F is a graph depicting cantilever base motion truncated by the detection of probe tip contact and incorporating a pause after contact. The deflection occurring in FIG. 5F is stopped by contact with the specimen at a point intermediate to the full deflection illustrated in FIG. 5E ;
[0035] FIG. 5G is a graph depicting cantilever deflection versus time and corresponds in time with the graph in FIG. 5F ;
[0036] FIG. 6 shows a sequence of responses of the cantilever to a given release force during engagement;
[0037] FIG. 7A is an example display of concurrent light and adhesion force information obtained from scanning a DNA sample available through use of the invention;
[0038] FIG. 7B is an enlarged view of image 772 of FIG. 7A ;
[0039] FIG. 8 is an enlarged view of the graphs of FIG. 7A ;
[0040] FIG. 9 is an image of several segments of DNA helix obtained using the techniques described herein; and
[0041] FIG. 10 is a higher magnification image of DNA obtained using the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0042] FIG. 2 is a block diagram generally depicting an atomic force microscope (AFM) formed in accordance with the present invention. The AFM includes a scanner 10 formed in a conventional manner having an X-piezo element 22 , a Y-piezo element 20 and a Z-piezo element 24 . The scanner 10 has an upper specimen surface 16 on which a specimen 18 to be measured is placed. The X, Y and Z piezo elements each change dimension, in a conventional fashion, in three mutually perpendicular axes, in response to a received control voltage signal. An X-Y controller circuit 38 is included. The X-Y controller circuit 38 controls the X-piezo element 22 and the Y-piezo element 20 , generating a conventional raster scan of the specimen surface 16 . Several commercially available controllers can provide this function. For example, the NanoScope E controller, manufactured by Digital Instruments, Inc. of Santa Barbara, Calif. is suitable for this application.
[0043] A sensing mode controller circuit 40 is also included and controls the Z-piezo element 24 in accordance with a method of the present invention. The sensing mode controller 40 can be implemented using a Pentium II Personal Computer and a DT3809 multifunction Input/Output Card, having a Texas Instruments C40 Digital Signal Processor (DSP) Integrated Circuit. It is contemplated by the inventors, and will be appreciated by those skilled in the art, that the functions of the X-Y controller circuit 38 and sensing mode controller circuit 40 can be performed by a single controller unit.
[0044] The AFM further includes a flexible cantilever 12 which has a first end affixed to a vertically displaceable (Z-axis) cantilever base 30 . The cantilever base 30 preferably takes the form of a piezoelectric element which changes dimension in the Z-axis in a controlled fashion in response to a received control voltage signal provided by the sensing mode controller circuit 40 . The flexible cantilever 12 , shown in detail in FIG. 3 , has a free end on which a probe tip 14 is affixed. The probe tip 14 is formed from a material such as silicon nitride or silicon, and is generally sharpened to a diameter less than 20 nanometers (nm). Suitable probe tips are currently manufactured by Digital Instruments, of Santa Barbara, Calif. Alternatively, single wall (1 nm diameter) or multiwall carbon nanotubes (5-20 nm diameter) or non-carbon nanotubes such as molybdenum sulfide (MoS 2, ) and tungsten sulfide (WS 2 ) (20-40 nm down to 1 nm diameter) can also be used. Advantageously, the nanotubes can be used in underivatized form or derivatized form. For example, defined functional groups can be added covalently at the end of the nanotube which has been oxidized, using known crosslinking reagents and linker molecules. A suitable coupling reagent could use carbodimide chemistry. Examples of functional groups include amines, methyls, benzyls and nucleosides. These defined functional groups will allow chemical-force probing on a molecular or pixel-by-pixel basis, i.e. at full resolution and in exact register with the height map. Advantageously, by using a single defined molecule on the probe tip, the binding energy between the molecule on the tip and the specimen can be measured.
[0045] The 1 nm (10 Angstroms) single wall carbon nanotubes have great potential as probe tips. Mounted on the end of a cantilever, these tips can provide for force measurements and profile height measurements especially in fluids at a resolution previously unachievable with prior art AFM technology. In particular, interstitial molecular force measurement within lattice-type structures can be studied.
[0046] As a general matter, Si tips have proved difficult to use in biological AFM. However, in applying the principles described herein, Si tips can be used to image DNA topography well even in buffer and with rescanning and a nominal force constant of the Si cantilever as low as 0.05 N/m.
[0047] As noted above, probe tips made up of multiwall or single wall nanotubes can be used. Notably, when used as probe tips, nanotubes are susceptible to buckling rendering them less effective at detecting a surface contact. Advantageously, by applying the principles described herein a sufficiently low compressive force is needed to sense the surface of the specimen that even single-wall nanotubes can be used.
[0048] During a specimen height measurement, the probe tip 14 is brought into contact with the specimen and a force results which deflects the flexible cantilever 12 . The magnitude of the force applied by the probe tip 14 onto the specimen 18 is proportional to the angle of cantilever 12 deflection. To measure the degree of cantilever deflection, the AFM further includes the laser source 26 which generates a light signal that is directed onto the surface of the flexible cantilever 12 . The light signal is reflected from the cantilever 12 and is directed by a mirror (not shown) onto a photo detector 28 . The photo detector 28 is preferably divided into four light responsive quadrants, a, b, c and d. Each light responsive quadrant generates an analog voltage signal which is proportional to the magnitude of reflected light incident upon it. A difference signal, which is equal to the signals (a+b)−(c+d), is calculated to determine the magnitude of deflection of the cantilever 12 .
[0049] The scanner 10 , cantilever 12 , cantilever base 30 , laser 26 and photo detector 28 are conventional elements known in the art. These components are sold as an assembly by Digital Instruments of Santa Barbara, Calif. under the trademark, MultiMode SPM.
[0050] As the probe tip 14 approaches a specimen, damping forces act upon the probe tip 14 owing to an effective viscosity increase of the fluid near the surface.
[0051] When the probe tip 14 contacts the surface of the specimen, adhesive forces frequently result which capture and retain the probe tip 14 . This problem is exacerbated when the cantilever 12 is formed with a very low spring constant, which is required for the measurement of biological specimens. Therefore, an important aspect of the present invention resides in the ability to disengage the probe tip 14 from the surface of the specimen. To accomplish this, a magnetic particle 32 is affixed proximate the free end of the cantilever 12 , as illustrated in FIG. 3 . In a preferred embodiment, the magnetic particle is formed by bonding a particle of Samarium Cobalt to the cantilever 12 with a thermal epoxy. The particle can be previously magnetized by placing it in a magnetic field of approximately 3.5 Tesla.
[0052] The AFM also includes an electromagnetic coil 34 which receives current drive from a pulse release circuit 36 and generates an inhomogeneous magnetic field in response thereto. The magnetic particle 32 and electromagnetic coil 34 are arranged such that the magnetic field generated by the coil 34 when energized drives the magnetic particle 32 away from the surface of the specimen 18 . Preferably, the coil 34 is formed and placed proximate the scanner 10 and the magnetic field is selected to repel the magnetic particle 32 . In other embodiments, the coil can be placed above the cantilever 12 and generate an attractive magnetic force with the magnetic particle 32 . In either placement, an opposite force used for restoring the cantilever 12 to a neutral position, can be generated by reversing the polarity of the current in the coil. The magnetic force is selected to be sufficient to overcome the adhesive force between the probe tip 14 and specimen 18 . Such a force is generally achievable when the coil is formed with 50 turns of 22 gauge wire about a 0.25 in. diameter core, and is energized with a current on the order of 200 milliamps. However, as the adhesive forces encountered are variable, it is preferred that the level of magnetic field also be variable to insure that the probe tip 14 can always be released from the specimen 18 .
[0053] To achieve the desired objectives, the present invention employs a novel control method for an atomic force microscope, such as that illustrated in FIG. 2 . The control method, which generally takes the form of a computer program, is illustrated in the flow charts of FIGS. 4 A-C. The control method of FIGS. 4 A-C results in a controlled approach of the probe tip 14 to the specimen 18 , a substantially constant range of motion of the probe tip 14 during successive measurement samples, very low contact force upon the probe tip 14 with no lateral force resulting between the probe tip 14 and specimen 18 and a sure release of probe tip 14 from adhesive forces presented by the specimen 18 . Accordingly, the method of the present invention is ideal for use when working with biological specimens.
[0054] Through the above described continuous dual control of the cantilever base 30 and probe tip 14 , at each pixel, both contact force can be reliably measured and profile height of the specimen can be obtained as the specimen is scanned. Additionally, since release is obtained by incrementally increasing a magnetic field, the adhesion force is automatically available for determination and recording in memory at the increment preceding the release. As a result, adhesion force mapping can also be performed on a pixel by pixel basis during scanning. Thus, as the scan proceeds, complete data regarding the contact force, profile height and adhesion force of the specimen at every point in the raster scan is immediately and visually available.
[0055] Measuring compressive (contact) and tensile (adhesion) force along with sample height at each pixel further allows for analysis of single-molecule reactions. To do so, the tensile (chemical) force inherently measured by the release pulse at each increment of the magnetic force ramp is calculated and stored. Thus, forces can be accurately measured at sub-nanometer intervals of separation between tip and specimen. Feedback may optionally also be introduced in order to stabilize the probe position after release, as the chemical force begins to decrease. In this way, the entire force/separation curve of two reacting molecules is measurable, with the integral of that curve being the reaction energy.
[0056] Commercial DSP's provide a pixel scan rate of 400 Hz in a present embodiment and with obvious modifications can cover the range of scan rates between 100 pixels/sec or less and up to 1000 pixels/sec. Moreover DSP's becoming available are 30 times faster and will allow pixel scan rates well in excess of 1000 pixels/sec. The computer program implements both the force sensing and control aspects of the cantilever during the incremental approach and contact with the specimen, creates the magnetic force ramp during the first part of the withdraw cycle (while holding the specimen base fixed) and detects separation of the tip from the specimen while storing the adhesion force=magnetic force measured at that time.
[0057] Referring now to FIGS. 4 A-C, operation of the AFM begins with the initialization of the X, Y and Z positions of the scanner 10 (step 42 ). The X and Y piezo elements are driven to a datum coordinate (0,0) and the Z-piezo element 24 is placed approximately the center of the range of motion. The approach value, which is provided by the sensing mode controller 40 to the cantilever base 30 , is also initialized to zero (step 44 ).
[0058] After initialization, the sensing mode controller circuit 40 increments the approach value, thereby moving the cantilever base 30 in a direction towards the specimen surface 16 (step 46 ). After incrementing the approach value, the sensing mode controller 40 monitors the signals from the photo detector 28 and determines the cantilever 12 deflection angle (step 48 ). From the measured deflection angle, the sensing mode controller 40 calculates the force on the probe tip 14 (step 50 ). The sensing mode controller 40 then compares the measured force against a predetermined maximum force value to determine whether the probe tip has contacted the specimen (step 52 ). The maximum force value is preferably selected to be the minimum value which will reliably indicate a contacting force between the probe tip 14 and specimen. Suitable thresholds of between 35 and 150 piconewtons (pN) have been successfully practiced. Typically 70 pN provides an adequate threshold level. Advantageously, sensing mode permits selection of compressive force at detection of contact (i.e. detection threshold) typically in the range 35 to 150 piconewtons, although a lower threshold can be used. As a result, a lower compressive force on approach results in a lower adhesive force on pull-off, aiding in preservation of biological specimen structure. Threshold values lower than 35 pN are considered achievable as significantly softer cantilevers become commercially available.
[0059] If the probe tip 14 has contacted the specimen, the approach value is stored as the detection coordinate to calculate the profile height of the specimen (step 54 ). The specimen profile height is then determined by combining the current Z coordinate position of the scanner 10 with the detection coordinate (step 56 ). At contact, a lower Z-value for scanner 10 , and a lower detection coordinate on the ramp, each signifies a higher profile height. So these two variables must be added (after multiplying each by a constant to convert digital value to height) and finally the sign changed. The specimen profile height value represents the height of the specimen at the current X, Y position and can be displayed graphically as the intensity and/or color of a pixel at that two dimensional coordinate, in a manner well known in the art of atomic force microscopy.
[0060] Returning to step 52 , if the probe tip 14 has not contacted the specimen, the controller then determines whether the approach value has exceeded an allowable limit (step 58 ). The range of approach values is determined by the required force resolution and the range of motion achievable from the cantilever base 30 . Preferably, a digital to analog converter within the sensing mode controller 40 provides at least 200 incremental approach values as illustrated in FIG. 5A (approach maximum=200). This allows an angstrom by angstrom approach of the cantilever base 30 toward the specimen at every pixel. In general, the timing is such that each 5 μsec the DSP issues a command to the piezo that drives the cantilever base, and also to the coil that provides the magnetic coil drive. Accordingly, there are typically about 200 pairs of commands during the advance part of the cycle alone. Also each 5 μsec, the DSP learns the cantilever deflection angle by analog to digital conversion of the reflected laser beam's detector output, and the cantilever base position by similarly reading the cantilever base piezo voltage.
[0061] If the approach value is within the acceptable range, generally between 10-50 nm (typically 15 nm), the program returns to step 46 where the approach value is incremented.
[0062] Steps 46 - 52 and step 58 are performed in such a way as to generate a controlled approach of the cantilever base 30 towards the specimen 18 , as illustrated in the graphs of FIGS. 5A and 5B . The approach begins with a gradually descending portion 84 . The curved initial approach, which can be generated by a sinusoidal function or other suitable function, minimizes the initial acceleration of the cantilever base 30 . This minimizes the excitation of oscillations in the free end of the cantilever 12 and enhances measurement accuracy. The approach then is characterized by a linear segment 86 . The linear approach of the present invention together with a minimum practical approach distance minimizes the velocity of the cantilever at contact and allows the probe tip 14 to contact the specimen with minimal contact force, essential for low damage to biological specimens and the soft high polymers of materials science.
[0063] If the approach value exceeds the maximum value (step 58 is true) the sensing mode controller 40 withdraws the cantilever base and applies a signal to the Z-piezo element 24 of the scanner 10 to reduce the separation between the cantilever base 30 and specimen surface 16 . A high voltage amplifier 42 is preferably interposed between the sensing mode controller 40 and scanner 10 to generate the ±200 volt signal required to drive the piezoelectric element. A suitable high voltage amplifier, model number PA87, is manufactured by Apex Microtechnology of Tucson, Ariz. After adjusting the scanner height (step 60 ), program control is directed to step 44 where the approach value is again initialized to zero.
[0064] After the probe tip 14 contacts the specimen 18 , adhesive forces act to hold the probe tip in place, even when the cantilever base 30 and specimen 18 are moved away from each other. This problem is especially acute when soft cantilevers (k<0.1 N/m) are used. The method of the present invention overcomes this problem by coordinating the withdrawal of the cantilever base 30 with the application of a force on the probe tip 14 . Moreover, the magnetic force can be applied in precise increments enabling the measurement of adhesion force versus separation.
[0065] After the specimen profile height is determined (step 56 ), the magnitude of the approach signal is reduced, thereby moving the cantilever base 30 away from the specimen (step 62 ). Preferably, the approach signal is initially reduced ( FIG. 5A ) or paused and then reduced ( FIG. 5E ) gradually to effect a gradual change in slope, thus avoiding instability of the cantilever 12 . In order to release the probe tip 14 from the specimen 18 either during the pause ( FIGS. 5F and 5G ) or when the cantilever base 30 starts to withdraw ( FIG. 5C ), the sensing mode controller 40 applies a pulse release signal to the pulse release circuit 36 .
[0066] In response to the pulse release signal, the pulse release circuit 36 generates a suitable current pulse which energizes the electromagnetic coil 34 . The electromagnetic coil 34 generates a magnetic field which repels the magnetic particle 32 , and thus the probe tip 14 , away from the specimen 18 . The sensing mode controller circuit 40 monitors the deflection angle of the cantilever to ensure that the probe tip 14 in fact is released (step 66 ). If not, the sensing mode controller circuit 40 either requests intervention by the operator to increase the pulse size for this experiment or increments the value of the release pulse release signal (step 68 ) and reapplies the pulse (step 64 ). When the sensing mode controller circuit 40 is adjusting the pulse release signal, steps 64 - 68 are repeated, typically for a maximum of 64 increments, until the magnetic force overcomes the adhesive force between the specimen 18 and the probe tip 14 or a predetermined maximum pulse release signal is reached. The speed of commercially available DSPs allows the use of 64 levels of current in the coil which provides a measurement precision of approximately 2%. If higher precision is desired, faster DSPs are becoming available and can be employed.
[0067] The coil current is increased from zero in a defined stepwise manner at defined time intervals under program control. The force scale is calibrated by measuring the cantilever deflection voltage at the maximum (i.e. kth level current where k=the maximum number of levels) and separately producing the same deflection voltage by advancing the specimen piezo—which is calibrated absolutely in nm. In this way the nm deflection of the cantilever at maximum coil current is determined. Multiplying by the force constant of the cantilever gives the magnetic force at maximum coil current, with the steps being in increments of 1/k of the total if all levels are used. Although the magnetic force required to achieve release is a function of tip 14 to specimen adhesion, typically a few hundred pN or less will suffice. Moreover, for non-low adhesion probe tips, a magnetic release force of approximately 10 times the contacting force has been found to be a useful estimate of the actual release force.
[0068] As will be described in greater detail below, a maximum of 64 steps may be chosen to encompass 100 pN and up to 1000 pN or more. At the lower setting, sensitivity (1.5 pN) and precision of approximately 2% provides very satisfactory knowledge of the adhesion force in the range exerted for weak chemical forces such as the hydrogen bond. The upper ranges are appropriate for covalent force interactions. These force ranges are appropriate for detecting non-covalent forces between molecules and characterizing covalent bond formation during chemical reactions.
[0069] FIG. 5C illustrates exemplary cantilever deflection versus time for the approach depicted in FIG. 5B . During the linear portion of the approach 86 the cantilever 12 experiences little deflection from a neutral position 92 . Depending on the material being sampled and the construction of the probe tip 14 , attractive forces may be present which draw the probe tip into the specimen. This results in a negative deflection 94 of the cantilever 12 . Upon contact of the probe tip 14 , the cantilever 12 begins positive deflection 96 . This is the condition detected by the sensing mode controller 40 at step 52 . At that point the cantilever base 30 is withdrawn and the pulse release signal is applied, deflecting the cantilever 12 in a positive direction 98 . Because the cantilever 12 is operating in a fluid environment, the cantilever deflection 98 is damped and is characterized by an exponential function. Upon termination of the release pulse 100 , the cantilever returns to the neutral position in an exponentially decaying fashion 102 . In order to accelerate the return to the neutral position, a reverse polarity pulse signal can be applied to the coil 34 . This creates an attractive force sufficient to overcome the spring constant of the cantilever 12 as well as the fluid damping. An example of this is illustrated in FIG. 5D .
[0070] After the probe tip 14 is released and the approach signal is decremented to zero ( 90 , FIG. 5B ), the program determines the distance traveled by the cantilever base 30 during the last sample. Since it is preferable for limiting the contact force on the specimen during measurement to use a minimum practical approach distance, the specimen height change that can be stored in the variable representing the detect position is limited. Therefore, the sensing mode controller circuit 40 generates a delta value by subtracting a predetermined “set value” from the actual value traveled by the cantilever base 30 during the last approach (step 70 ). The set value is normally chosen near the midpoint of the linear ramp of FIG. 5A . The sensing mode controller 40 then adjusts the height of the Z-piezo element 24 of the scanner 10 to reduce the delta value to zero on the next approach (step 72 ). In this way the Z-piezo element 24 functions as the accumulator or integrator of deltas generated by the detect position which therefore equals the Z-value or specimen height at this particular x-y position or pixel. Z is stored for each of the X-Y pixels in memory contained in Sensing Mode Controller 40 , where it is available for analysis and display. The range of heights that can be generated by the Z-piezo element 24 is several thousand nanometers, which is entirely adequate for the range of specimen heights encountered in biological experiments. A useful by-product of this method of operation is the achievement of substantially constant timing and substantially constant distance of travel in the approach of the cantilever base 30 to the specimen 18 during successive samples.
[0071] While the method of FIGS. 4 A-C has been described with the cantilever base 30 being controlled to effect the approach and withdrawal of the probe tip 14 and the scanner 10 being controlled to minimize the delta value, those skilled in the art will readily appreciate that these functions can be exchanged without deviating from the improved methods of the present invention. To effect such a change, the range of motion of the cantilever base 30 is preferably increased from several hundred nanometers which is commonly used, to several thousand nanometers so that a broad range of delta values can be corrected.
[0072] Upon completion of step 72 , the X-Y controller 38 then operates to effect a conventional raster scan of the specimen relative to the probe tip 14 . The X-Y controller 38 increments the X coordinate value (step 74 ) of the scanner 10 and determines whether the end of the row has been reached (step 76 ). Typically, each row contains either 256 or 512 coordinate values.
[0073] If the end of the row has not been reached, the program control returns to step 44 . If the end of the row has been reached, the X coordinate value is reset to zero and the Y coordinate value is incremented (step 78 ).
[0074] Alternatively, the program can increment the Y coordinate value and decrement the X coordinate value for successive measurements until X=0. In this way, a serpentine scan is achieved. The X-Y controller 38 then determines if the final Y coordinate value has been reached (step 80 ). Generally, the Y axis will include the same number of coordinate values as the X-axis, thereby generating a square image matrix. If the final Y coordinate value has not been reached, control returns to step 44 . If the final Y coordinate value has been reached, the image scan is complete and the program ends (step 82 ).
[0075] The process described in FIGS. 4 A-C is referred to by the inventors as “sensing mode.” This is because the sensing mode controller 40 senses when initial contact is made between the specimen and probe tip 14 and immediately (typically within 5 microseconds) begins retraction of the cantilever base 30 and probe tip 14 . The method and apparatus of the present invention significantly reduces the velocity of the probe tip 14 at contact with the specimen 18 and therefore reduces the resulting contact force between the probe tip 14 and the specimen 18 . By reducing the contact force, specimen destruction is minimized. The inclusion of the magnetic particle 32 and pulse release coil 34 , operated in accordance with the sensing mode method of the present invention, allows the use of a cantilever 12 with a spring constant significantly less than 0.1 Newtons per meter (N/m) without the risk of the probe tip 14 being retained by the adhesive forces exhibited by the specimen. With sensing mode, the lower limit on acceptable cantilever spring force is bounded only by cantilever manufacturing constraints. The use of such a soft cantilever further reduces the compressive force between the probe tip 14 and the specimen 18 during contact, making it possible to reduce specimen damage even further.
[0076] As an additional benefit of the significantly reduced contact force, significantly smaller probe tips 14 can be used in sensing mode with reduced risk of tip breakage. Probe tips significantly less than 10 nm, for example, 6 nm (60 Angstroms) in diameter have been successfully used in fluids with the sensing mode scanning method of the present invention.
[0077] As a further advantage resulting from the continuous sensing process of sensing mode, a high-speed algorithm can compute a running linear least squares fit for as many as 20 or more successive readouts of the cantilever deflection signal (angle), with update of the least squares fit each 5 microseconds as a new digital value for deflection value is presented to the program. Thus, continuous sensing makes possible a low-noise running fitted average to both tip position and tip velocity (slope of the least squares fit). Because the averaging time of the fit can extend over several cycles of the damped vibrational period of the cantilever, thermal noise in the averaged cantilever signal is strongly reduced and noise in the detected position of the surface is lowered correspondingly. The running least squares fit can be used in a variety of sensitive algorithms for detecting contact with the surface at low force. One such is to define contact with the surface as that point during the approach where the velocity of the tip, which is the same as the slope of the least squares fit, changes from negative (down) to positive (up). Tests with this definition have shown an ability to detect the surface with substantially smaller force exerted on the specimen.
[0078] Still another advantage of the present invention is in the mode of adjusting the specimen piezo Z to reduce the deviation in contact position from the set position. In contrast to contact mode and tapping mode, sensing mode as described herein can be configured to carry out adjustments to the Z specimen piezo without a differential equation. Once each x-y location, the electronics determines how far the surface detection point deviates from a pre-assigned vertical or Z set point (typically at the midpoint of the total approach distance) and immediately corrects the deviation by adjusting the specimen piezo. One measured constant, the ratio of sensitivities in nm/volt of the cantilever base piezo and specimen piezo suffices to determine quantitatively the correction.
[0079] Depending upon the particular implementation, it may be desirable to make corrections over a multiple of pixels to avoid the introduction of noise associated with making the entire correction at once. Thus, correction can be introduced over a few pixels, e.g., 80% the first pixel, arriving at 96% correction the second pixel, etc. A simple, but exact, theory enables one to know the final correct height at the first pixel even though the lower piezo has not yet reached the final height. Therefore the corrected height can be recorded each pixel along with the achieved height. The formula for the correction is S n =Z n +D n (γ 0 −γ); where S n is the corrected surface height, Z n is the height actually reached after one application of the partial correction (80% in the example), and D n is the deviation of the surface detection point from the set point, all at pixel “n”. By convention, S n and Z n are in volts applied to the specimen piezo or in counts applied to the D/A converter that produces that voltage. Similarly, D n is volts applied to the piezo attached to the cantilever base or counts applied to its converter. γ 0 is the factor converting cantilever piezo counts to sample piezo counts, measured experimentally and found to be within a factor of 2 either way of unity. If the sample piezo is corrected by γ o D n for a deviation D n , then the whole height deviation would be corrected at once by the specimen piezo motion. γ is the factor, smaller than γ o , that produces the correction actually used, 80% of γ 0 in the example. As a result, the true height, S n , is the actual height Z n plus the extra correction not yet applied in the first correction because γ was chosen too small. In practice, Z n contains the low frequency variation of the specimen surface and D n the high frequency. D n and S n can be displayed in neighboring windows for visual analysis.
[0080] By employing the techniques described herein, relating to adhesion force, through iterative application of an increasing coil current to effect release of the probe tip at each pixel, we necessarily identify the time at which the release force is overcome. Advantageously, measuring the force at the time of pull-off quantifies the adhesion force. Moreover, since the adhesion force is measured during the same approach/withdraw cycle that measures specimen height, the adhesion force can be mapped in exact register with the topography and at the same resolution, whatever resolution is used. As a further advantage resulting from the continuous sensing process of sensing mode, since a quantitatively ramped magnetic force is applied just after surface detection, determination of the point at which the adhesion force is overcome also isolates and quantitatively measures the adhesion force. Moreover, because both the approach and release are done incrementally, storing the forces for each increment at each pixel enables mapping of force as a function of distance from the surface of a specimen. This feature thus provides concurrent mapping of topography with adhesion force at high resolution.
[0081] An atomic force microscope formed and operated in accordance with the present invention can also be used to reduce the time for the cantilever to approach an equilibrium angle at certain phases of the approach/withdraw cycle. By applying a reverse current pulse in magnetic drive coil at the termination of the cantilever pulse release signal, the return of the cantilever to its equilibrium angle is accelerated so the next approach can begin immediately. A brief current pulse of the same sign as the main release pulse but at the beginning of the main approach ramp speeds up arrival at the new equilibrium angle associated with linear approach, simplifying subsequent detection of the surface.
[0082] Another valuable feature is an optional pre-scanning or zoom mode. Since the detailed behavior of the cantilever is controlled by the DSP program for each pixel, one can make a change to the x or y position corresponding to each pixel simply by changing the appropriate variable at the end of tip withdrawal and before the next advance. In this manner, areas of interest can be quickly located. To do so, the program that controls the tip advance and withdrawal maintains a running count of the 1 through 256 pixel number, for example, and the 1 through 256 scan line number and creates a 256×256 table in memory. This allows looking up in the table the voltages that should be applied at any given pixel to the piezo scanner of the microscope. These voltages are output to the microscope, first x and then y, by a single D to A converter and are held separately in two sample-and-hold circuits for application to the microscope. The lookup table itself is prepared by having the microscope scan a calibration grid. Separate lookup tables can be stored and used for each scan size and for any other scan variables found necessary, since the storage required is minimal.
[0083] After a molecule or interaction region of interest is located in a field, reduction in the scan size to encompass just the event of interest can be done. This makes the machine more responsive in studying biological function. In one embodiment, a scan of 400 pixels per second is equivalent to a field of 40×40 pixels (200 Angstrom×200 Angstrom at 5 Angstrom pixel separation) each 4 seconds, for example, to allow following the evolution of structure in biochemical reactions. Since biological rates can often be manipulated by changes in temperature, pH or concentration, this invention provides means of observing changes in physiologically relevant biological structures.
[0084] A further advantageous byproduct of the sensing mode configuration and method is that it also reduces the possibility of damaging a probe tip on initial engagement. We have been able to make use of a highly characteristic change in cantilever response to the magnetic release pulse (which occurs each pixel) related to the increase in effective viscosity near the surface. This change allows reliable prediction of when contact with the surface of the specimen will occur. Initial tip engagement occurs only once each measurement session. Activation of the stepping motor for engagement requires repeating a sequence of four pulses phased properly in time. However, according to prior art systems, the operator has no way of knowing when the surface will be encountered, which can induce a painfully slow approach to avoid tip damage. With sensing mode operation, this problem is overcome. A repeated approach/withdraw cycle, typically 15 nm in amplitude of the format shown in FIG. 5E , is initiated by the program before engagement starts. The cycle includes the magnetic release pulse as part of each withdrawal. FIG. 6 shows the cantilever deflection signal for approach/withdraw cycles at several stages of engagement.
[0085] When the cantilever tip is nowhere near the specimen, the cantilever response as indicated by the deflection signal, has a certain shape, 662 , that includes one or a few cycles of ‘ringing’ after the release pulse is over. However, as the engagement motor continues to run and the tip approaches the sample, the ringing decreases 664 and nearly disappears, 666 , just before contact, 668 , is made. This is due to the increased viscosity seen by the cantilever in the immediate vicinity of the sample owing to restriction of flow lines. While the initial engagement portion of the program is running, the program looks once each approach/withdraw cycle for the amount of cantilever ringing and reduces the engage motor speed appropriately. In addition, because the approach/withdraw cycle is in continuous operation, feedback from the position (fraction of the 15 nm range) at which the tip encounters the surface to the position of the specimen piezo, can also be in operation so that when the surface is encountered, the specimen piezo retracts smoothly to keep the surface encounter position at the set point. The net effect is that it is practically impossible to crash the tip into the specimen or damage it by excessive force.
[0086] FIG. 7A is an example display of information available through use of the invention to scan a DNA sample. As shown, the upper graph is the force data at pixel 3 of scan line 93 (where pixel zero is to the left and scan line zero is at the top) out of a 256×256 pixel image. The lower graph contains a representation of the specimen piezo position and the deviation from a set position.
[0087] FIG. 7B is an enlarged version of the Height image 772 from FIG. 7A . The image area, 776 , is contained within a field of 256 by 256 points (i.e. pixels). To the right of the image area, 776 , is a scale, 778 , correlating a shade (color) with a count value, representing, in counts, the height of the specimen at each of the points.
[0088] Above the graphs in FIG. 7A are pull-down menus through which the various program features may be accessed. Along side the graphs are three images which are obtained concurrently during scanning. The upper image, 770 , labeled “Detect” plots the surface detection position at each pixel expressed as deviation from the set position. The middle image, 772 , labeled “Height” plots the specimen height at each pixel using the corrected specimen piezo position (Sn referred to above). The lower image, 774 , labelled “Adhesion” plots the measured adhesion force at each pixel using the pull off step, converted to piconewtons. In each, the corresponding scan line 93 is indicated.
[0089] FIG. 8 is an excerpt of the graphs of FIG. 7 . In the upper graph, the “Force Curve” is the heavy black line, 882 , plot of cantilever deflection vs. time. Each unit of the abscissa represents 5 μsec, which is the interval between computer interactions with the microscope. The units of the ordinate represent picoNewtons. The horizontal dashed line, 884 , (red), is the detect threshold. As shown, for a 15 nm approach distance, each interval represents ¾ of an Angstrom. From 0 to 98 units the cantilever is approaching the specimen under control of the cantilever piezo. At 98 units, cantilever deflection crosses the detect threshold (here 70 pN), and the program brings the cantilever base piezo smoothly to a halt. The magnetic force ramp then begins incrementally increasing. At approximately 138 units, i.e. after approximately 40 steps in the ramp, the tip pulls loose, 886 , and the cantilever in this case goes to 2 Volts. This 10-fold increase in deflection is detected by the program. The increment or step at which the deflection crosses a second threshold (here set at twice the height of the detect threshold line) is defined as the pull-off step, and the magnetic force at this point is the measured adhesion force for this pixel.
[0090] The lower graph in FIG. 8 describes what happens over the entire scan line 93 . Two lines are superimposed over each other. The fine line (blue), 188 , records the deviation of the detect position ( 98 units for pixel 3 above) from a set position, typically 120 units. The heavy black line, 890 , is the specimen piezo position, which is obtained by feedback from the detect position as described above. Line 93 passes through three segments of DNA in the Height image, 772 , and these crossings appear as three pronounced dips in the lower graph.
[0091] FIG. 9 is an image of several DNA strands imaged in Hepes-Ni 2+ buffer on Aptes-mica with Si3N4 tips obtained using the techniques described herein. As shown, the image 904 , on the left is a height profile of a portion of the DNA. The bar 906 represents 24 nanometers for the x or y directions. Original field size was 220 nm. The scale, 908 , below the height profile image 904 represents the heights in nanometers (nm) converted in a color or grey-scale representation. Image 902 is an enlarged portion of the adhesion force image 910 , showing structure in a segment of DNA occurring at the highly significant spacing of the 10 base pair repeat distance of DNA. An adhesion force image 910 is in the same register and x-y scale as the height profile image, 904 . The scale 911 below the adhesion force profile image 910 represents the adhesion force in nanonewtons (nN) converted in a color or grey-scale representation. The adhesion force map of FIG. 9 (right panel) was acquired simultaneously with the topography map of FIG. 9 (left panel) in real time at the same resolution as the topography. Such maps provided by this invention, to our knowledge, represent the first real time high resolution adhesion maps available as a consistently present adjunct to topography for interpretation of the image.
[0092] FIG. 10 is a higher magnification image of one DNA strand imaged in FIG. 9 , which was obtained by a new scan done at a smaller field size. The five ridges marked “A” in the height image of FIG. 10 correspond to the five repeats of the double helix marked “B” in the X-ray image of the DNA. This rescan demonstrates that the initial scan using the dually controlled cantilever of this invention leaves the DNA sufficiently intact to provide higher resolution on the succeeding scan. The original field was 50 nm. The bar represents 5 nm.
[0093] While there have been described what are presently believed to be the preferred embodiments of the invention, those skilled in the art will realize that various changes and modifications may be to the invention without the departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. | An atomic force microscope is described having a cantilever comprising a base and a probe tip on an end opposite the base; a cantilever drive device connected to the base; a magnetic material coupled to the probe tip, such that when an incrementally increasing magnetic field is applied to the magnetic material an incrementally increasing force will be applied to the probe tip; a moveable specimen base; and a controller constructed to obtain a profile height of a specimen at a point based upon a contact between the probe tip and a specimen, and measure an adhesion force between the probe tip and the specimen by, under control of a program, incrementally increasing an amount of a magnetic field until a release force, sufficient to break the contact, is applied. An imaging method for atomic force microscopy involving measuring a specimen profile height and adhesion force at multiple points within an area and concurrently displaying the profile and adhesion force for each of the points is also described. A microscope controller is also described and is constructed to, for a group of points, calculate a specimen height at a point based upon a cantilever deflection, a cantilever base position and a specimen piezo position; calculate an adhesion force between a probe tip and a specimen at the point by causing an incrementally increasing force to be applied to the probe tip until the probe tip separates from a specimen; and move the probe tip to a new point in the group. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
The present application is a divisional of commonly owned and U.S. patent application Ser. No. 09/722,070 filed Nov. 24, 2000, now U.S. Pat. No. 7,470,236, which claims benefit under 35 U.S.C. §119(e) from U.S. Provisional Application Ser. No. 60/167,416 filed Nov. 24, 1999, the entire contents of which are all hereby expressly incorporated by reference into this disclosure as if set forth fully herein.
TECHNICAL FIELD
The present invention relates to electromyography (EMG) and to systems for detecting the presence of nerves during surgical procedures.
BACKGROUND OF THE INVENTION
It is important to avoid unintentionally contacting a patient's nerves when performing surgical procedures, especially when using surgical tools and procedures that involve cutting or boring through tissue. Moreover, it is especially important to sense the presence of spinal nerves when performing spinal surgery, since these nerves are responsible for the control of major body functions. However, avoiding inadvertent contact with these nerves is especially difficult due to the high nerve density in the region of the spine and cauda equina.
The advent of minimally invasive surgery offers great benefits to patients through reduced tissue disruption and trauma during surgical procedures. Unfortunately, a downside of such minimally invasive surgical procedures is that they tend to offer a somewhat reduced visibility of the patient's tissues during the surgery. Accordingly, the danger of inadvertently contacting and/or severing a patient's nerves can be increased.
Systems exist that provide remote optical viewing of a surgical site during minimally invasive surgical procedures. However, such systems cannot be used when initially penetrating into the tissue. Moreover, such optical viewing systems cannot reliably be used to detect the location of small diameter peripheral nerves.
Consequently, a need exists for a system that alerts an operator that a particular surgical tool, which is being minimally invasively inserted into a patient's body, is in close proximity to a nerve. As such, the operator may then redirect the path of the tool to avoid inadvertent contact with the nerve. It is especially important that such a system alerts an operator that a nerve is being approached as the surgical tool is advanced into the patient's body prior to contact with the nerve, such that a safety distance margin between the surgical tool and the nerve can be maintained.
A variety of antiquated, existing electrical systems are adapted to sense whether a surgical tool is positioned adjacent to a patient's nerve. Such systems have proven to be particularly advantageous in positioning a hypodermic needle adjacent to a nerve such that the needle can be used to deliver anesthetic to the region of the body adjacent the nerve. Such systems rely on electrifying the needle itself such that as a nerve is approached, the electrical potential of the needle will depolarize the nerve causing the muscle fibers coupled to the nerve to contract and relax, resulting in a visible muscular reaction, seen as a “twitch”.
A disadvantage of such systems is that they rely on a visual indication, being seen as a “twitch” in the patient's body. During precision minimally invasive surgery, uncontrollable patient movement caused by patient twitching, is not at all desirable, since such movement may itself be injurious. In addition, such systems rely on the operator to visually detect the twitch. Accordingly, such systems are quite limited, and are not particularly well adapted for use in minimally invasive surgery.
SUMMARY OF THE INVENTION
The present invention provides methods and apparatus for informing an operator that a surgical tool or probe is approaching a nerve. In preferred aspects, the surgical tool or probe may be introduced into the patient in a minimally invasive cannulated approach. In alternate aspects, the surgical tool or probe comprises the minimally invasive cannula itself.
In a first aspect, the present invention provides a system for detecting the presence of a nerve near a surgical tool or probe, based upon the current intensity level of a stimulus pulse applied to the surgical tool or probe. When a measurable neuro-muscular (EMG) response is detected from a stimulus pulse having a current intensity level at or below a predetermined onset level, the nerve is considered to be near the tool or probe and thus, detected.
In an optional second aspect of the invention, the onset level (i.e.: the stimulus current level at which a neuro-muscular response is detected for a particular nerve) may be based on EMG responses measured for a probe at a predetermined location relative to the nerve. Specifically, onset levels may first be measured for each of a plurality of spinal nerves, (yielding an initial “baseline” set of neuro-muscular response onset threshold levels), which are then used in the first (nerve detection) aspect of the invention. Therefore, in accordance with this optional second aspect of the invention, a system for determining relative neuro-muscular onset values (i.e.: EMG response thresholds), for a plurality of spinal nerves is also provided. Accordingly, the pre-determined onset level may be compared to the current level required to generate a measurable EMG response for a tool or probe being advanced toward one or more nerves of interest.
In alternate aspects, however, the neuro-muscular onset values that are used to accomplish the first (nerve detection) aspect of the invention are not measured for each of the patient's plurality of spinal nerves. Rather, pre-determined levels of current intensity (below which neuro-muscular responses are detected in accordance with the first aspect of the invention) can instead be directly pre-set into the system. Such levels preferably correspond to specific expected or desired onset threshold values, which may have been determined beforehand by experimentation on other patients.
In the aspect of the invention where initial “baseline” neuro-muscular onset values are determined prior to nerve detection, such onset values can optionally be used to calibrate the present nerve-detection system (which in turn operates to detect whether an minimally invasive surgical tool or probe is positioned adjacent to a spinal nerve).
It is to be understood, therefore, that the present invention is not limited to systems that first determine relative neuro-muscular onset values, and then use these neuro-muscular onset values to detect the presence of a nerve. Rather, the present invention includes an optional system to first determine relative neuro-muscular onset values and a system to detect the presence of a nerve (using the neuro-muscular onset values which have been previously determined). As such, the present invention encompasses systems that also use fixed neuro-muscular onset values (which may simply be input into the system hardware/software by the operator prior to use) when performing electromyographic monitoring of spinal nerves to detect the presence of a spinal nerve adjacent a tool or probe.
In optional aspects, the preferred method of sensing for the presence of a nerve may be continuously repeated as the probe/surgical tool is physically advanced further into the patient such that the operator is warned quickly when the probe/surgical tool is closely approaching the nerve.
In the first (nerve sensing) aspect of the invention, the present nerve-detection system comprises an electrode or electrodes positioned on the distal end of the surgical tool or probe, with an electromyographic system used to detect whether a spinal nerve is positioned adjacent to the surgical tool or probe. A conclusion is made that the surgical tool or probe is positioned adjacent to a spinal nerve when a neuro-muscular (e.g.: EMG) response to a stimulus pulse emitted by the electrode or electrodes on the surgical tool or probe is detected (at a distant myotome location, such as on the patient's legs) at or below certain neuro-muscular response onset values (i.e.: pre-determined current intensity levels) for each of the plurality of spinal nerves. The stimulus pulse itself may be emitted from a single probe, but in an optional aspect, the stimulus pulse may be emitted from separate left and right probes with the signals being multiplexed. As stated above, such pre-determined levels may be pre-input by the operator (or be pre-set into the system's hardware or software) and may thus optionally correspond to known or expected values. (For example, values as measured by experimentation on other patients).
In accordance with the optional second (neuro-muscular response onset value determination) aspect of the invention, the neuro-muscular response onset values used in nerve detection may instead be measured for the particular patient's various nerves, as follows.
Prior to attempting to detect the presence of a nerve, an EMG stimulus pulse is first used to depolarize a portion of the patient's cauda equina. This stimulus pulse may be carried out with a pulse passing between an epidural stimulating electrode and a corresponding skin surface return electrode, or alternatively, between a pair of electrodes disposed adjacent to the patient's spine, or alternatively, or alternatively, by a non-invasive magnetic stimulation means. It is to be understood that any suitable means for stimulating (and depolarizing a portion of) the patient's cauda equina can be used in this regard.
After the stimulus pulse depolarizes a portion of the patient's cauda equina, neuro-muscular (i.e., EMG) responses to the stimulus pulse are then detected at various myotome locations corresponding to a plurality of spinal nerves, with the current intensity level of the stimulus pulse at which each neuro-muscular response is first detected being the neuro-muscular response “onset values” for each of the plurality of spinal nerves.
It is to be understood that the term “onset” as used herein is not limited to a condition in which all of the muscle fibers in a bundle of muscle fibers associated with a particular nerve exhibit a neuro-muscular response. Rather, an “onset” condition may comprise any pre-defined majority of the muscle fibers associated with a particular nerve exhibit a neuro-muscular response.
In an additional aspect of the invention, the relative neuro-muscular response onset values can be repeatedly re-determined (at automatic intervals or at intervals determined by the operator) so as to account for any changes to the response onset values caused by the surgical procedure itself. Accordingly, a further advantage of the present invention is that it permits automatic re-assessment of the nerve status, with the relative neuro-muscular response onset values for each of the plurality of spinal nerves being re-determined before, during and after the surgical procedure, or repeatedly determined again and again during the surgical procedure. This optional aspect is advantageous during spinal surgery as the surgery itself may change the relative neuro-muscular response onset values for each of the plurality of nerves, such as would be caused by reducing the pressure on an exiting spinal nerve positioned between two adjacent vertebrae. This periodic re-determination of the onset values can be carried out concurrently with the nerve sensing function.
Accordingly, an advantageous feature of the present invention is that it can simultaneously indicate to an operator both: (1) nerve detection (i.e.: whether the surgical tool/probe is near a nerve); and (2) nerve status changes (i.e.: the change in each nerve's neuro-muscular response onset values over time). The surgeon is thus able to better interpret the accuracy of nerve detection warnings by simultaneously viewing changes in the various onset levels. For example, should the surgeon note that a particular onset value (i.e.: the current level of a stimulus pulse required to elicit an EMG response for a particular nerve) is increasing, this would tend to show that this nerve pathway is becoming less sensitive. Accordingly, a “low” warning may be interpreted to more accurately correspond to a “medium” likelihood of nerve contact; or a “medium” warning may be interpreted to more accurately correspond to a “high” likelihood of nerve contact.
Optionally, such re-assessment of the nerve status can be used to automatically re-calibrate the present nerve detection system. This can be accomplished by continually updating the onset values that are then used in the nerve detection function.
In preferred aspects, the neuro-muscular response onset values for each of the plurality of spinal nerves are measured at each of the spaced-apart myotome locations, and are visually indicated to an operator (for example, by way of an LED scale). Most preferably, the measuring of each of the various neuro-muscular response onset values is repeatedly carried out with the present and previously measured onset value levels being simultaneously visually indicated to an operator such as by way of the LED scale.
Accordingly, in one preferred aspect, for example, different LED lights can be used to indicate whether the value of each of the various neuro-muscular response onset values is remaining constant over time, increasing or decreasing. An advantage of this optional feature of the invention is that a surgeon operating the device can be quickly alerted to the fact that a neuro-muscular response onset value of one or more of the spinal nerves has changed. Should the onset value decrease for a particular nerve, this may indicate that the nerve was previously compressed or impaired, but become uncompressed or no longer impaired.
In a particular preferred embodiment, example, a blue LED can be emitted at a baseline value (i.e.: when the neuro-muscular response onset value remains the same as previously measured); and a yellow light can be emitted when'the neuro-muscular response onset value has increased from that previously measured; and a green light being emitted when the neuro-muscular response onset value has decreased from that previously measured.
In an alternate design, different colors of lights may be simultaneously displayed to indicate currently measured onset values for each of the plurality of spinal nerve myotome locations, as compared to previously measured onset values. For example, the present measured onset value levels for each of the plurality of spinal nerve myotome locations can appear as yellow LED lights on the LED scale, with the immediately previously measured onset value levels simultaneously appearing as green LED lights on the LED scale. This also allows the operator to compare presently measured (i.e. just updated) neuro-muscular response onset values to the previously measured neuro-muscular response onset values.
In preferred aspects, the present system also audibly alerts the operator to the presence of a nerve. In addition, the volume or frequency of the alarm may change as the probe/tool moves closer to the nerve.
In a preferred aspect of the present invention, the neuro-muscular onset values, (which may be detected both when initially determining the relative neuro-muscular response onset values in accordance with the second aspect of the invention, and also when detecting a neuro-muscular onset response to the emitted stimulus pulse from the probe/tool in accordance with the first aspect of the invention), are detected by monitoring a plurality of distally spaced-apart myotome locations which anatomically correspond to each of the spinal nerves. Most preferably, these myotome locations are selected to correspond to the associated spinal nerves that are near the surgical site. Therefore, these myotome locations preferably correspond with distally spaced-apart on the patient's legs (when the operating site is in the lower vertebral range), but may also include myotome locations on the patient's arms (when the operating site is in the upper vertebral range). It is to be understood, however, that the present system therefore encompasses monitoring of any relevant myotome locations that are innervated by nerves in the area of surgery. Therefore, the present invention can be adapted for use in cervical, thoracic or lumbar spine applications.
During both the optional initial determination of the relative neuro-muscular response onset values for each of the plurality of spinal nerves (i.e.: the second aspect of the invention) and also during the detection of neuro-muscular onset responses to the stimulus pulse from the surgical probe/tool (i.e.: the first aspect of the invention), the emission of the stimulus pulse is preferably-of a varying current intensity. Most preferably, the stimulus pulse is incrementally increased step-by-step in a “staircase” fashion over time, at least until a neuro-muscular response signal is detected. The stimulus pulse itself may be delivered either between a midline epidural electrode and a return electrode, or between two electrodes disposed adjacent the patient's spine, or from an electrode disposed directly on the probe/tool, or by other means.
An important advantage of the present system of increasing the level of stimulus pulse to a level at which a response is first detected is that it avoids overstimulating a nerve (which may cause a patient to “twitch”), or cause other potential nerve damage.
In optional preferred aspects, the “steps” of the staircase of increasing current intensity of the stimulus pulse are carried out in rapid succession, most preferably within the refractory period of the spinal nerves. An advantage of rapidly delivering the stimulus pulses within the refractory period of the spinal nerves is that, at most, only a single “twitch” will be exhibited by the patient, as opposed to a muscular “twitching” response to each level of the stimulation pulse as would be the case if the increasing levels of stimulus pulse were instead delivered at intervals of time greater than the refractory period of the nerves.
In another optional preferred aspect, a second probe is added to the present system, functioning as a “confirmation electrode”. In this optional aspect, an electrode or electroded surface on the second probe is also used to detect the presence of a nerve, (using the same system as was used for the first probe to detect a nerve). Such a second “confirmation electrode” probe is especially useful when the first probe is an electrified cannula itself, and the second “confirmation electrode” probe is a separate probe that can be advanced through the electrified cannula. For example, as the operating (electrified) cannula is advanced into the patient, this operating cannula itself functions as a nerve detection probe. As such, the operating cannula can be advanced to the operating site without causing any nerve damage. After this cannula has been positioned at the surgical site, it may then be used as the operating cannula through which various surgical tools are then advanced. At this stage, its nerve-sensing feature may be optionally disabled, should this feature interfere with other surgical tools or procedures. Thereafter, (and at periodic intervals, if desired) the second “confirmation electrode” probe can be re-advanced through the operating cannula to confirm that a nerve has not slipped into the operating space during the surgical procedure. In the intervals of time during which this second “confirmation electrode” probe is removed from the operating cannula, access is permitted for other surgical tools and procedures. The second “confirmation electrode” probe of the present invention preferably comprises a probe having an electrode on its distal end. This confirmation electrode may either be mono-polar or bi-polar.
In an optional preferred aspect, the second “confirmation electrode” probe may also be used as a “screw test” probe. Specifically, the electrode on the secondary “confirmation” probe may be placed in contact with a pedicle screw, thereby electrifying the pedicle screw. Should the present invention detect a nerve adjacent such an electrified pedicle screw, this would indicate that pedicle wall is cracked (since the electrical stimulus pulse has passed out through the crack in the pedicle wall and stimulated a nerve adjacent the pedicle).
An advantage of the present system is that it may provide both nerve “detection” (i.e.: sensing for the presence of nerves as the probe/tool is being advanced) and nerve “surveillance” (i.e.: sensing for the presence of nerves when the probe/tool had been positioned).
A further important advantage of the present invention is that it simultaneously monitors neuro-muscular responses in a plurality of different nerves. This is especially advantageous when operating in the region of the spinal cord due to the high concentration of different nerves in this region of the body. Moreover, by simultaneously monitoring a plurality of different nerves, the present system can be used to indicate when relative nerve response onset values have changed among the various nerves. This information can be especially important when the surgical procedure being performed can alter the relative nerve response onset value of one or more nerves with respect to one another.
A further advantage of the present system is that a weaker current intensity can be applied at the nerve detecting electrodes (on the probe) than at the stimulus (i.e.: nerve status) electrodes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of various components of the present invention in operation.
FIG. 2 shows a current intensity staircase for an electromyographic stimulation (nerve status) electrode.
FIG. 3 shows a current intensity staircase for an electromyographic stimulation pulse for a nerve detection electrode disposed on a probe.
FIG. 4 corresponds to FIG. 1 , but also shows exemplary “high”, “medium” and “low” warning levels corresponding to exemplary neuro-muscular response onset levels.
FIG. 5 shows a patient's spinal nerves, and corresponding myotome monitoring locations.
FIG. 6 is an illustration of the waveform characteristics of a stimulus pulse and a corresponding neuro-muscular (EMG) response as detected at a myotome location.
FIG. 7 is a schematic diagram of a nerve detection system.
FIG. 8A is an illustration of the front panel of one design of the present nerve status and detection system.
FIG. 8B is an illustration of the front panel of another design of the present nerve status and detection system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention sets forth systems for detecting when a nerve is near or adjacent to an electrified surgical tool, probe, cannula, or other surgical instrument. The present invention also involves optional systems for simultaneously determining the “status” (e.g.: sensitivity) of a plurality of nerves.
As will be explained, the present system involves applying a signal with a current level to a probe near a nerve and determining whether an electromyographic “EMG” (i.e.: neuro-muscular) response for a muscle coupled to the nerve is present.
In preferred aspects, the present system applies a signal with a known current level (mA) to a “probe” (which could be midline probe, a cannula, a needle, etc.) Depending on the current level, distance to the nerve, and health of the nerve, an EMG may be detected in a muscle coupled to the nerve. In accordance with preferred aspects, an EMG response is determined to have been detected when the peak-to-peak response of the EMG signal is greater than some level (mVolts). In other words, an EMG response is determined to have been detected when the stimulus current level generates an EMG having a peak-to-peak value greater than a pre-determined level (for example, 60 mV or 80 mV in spinal nerve applications.) Such stimulus current level at which an EMG response is detected is termed the “onset” current level for the nerve.
In optional aspects, the present invention also sets forth systems for determining these onset current values (i.e.: determining the stimulus current level at which an EMG response is detected with a maximum peak-to-peak value greater than a predetermined level). Such onset values may be determined for a plurality of nerves either in absolute terms, or in relation to one another.
The first aspect of the present invention involves nerve detection. In the optional second aspect of the invention, nerve status information may be used to aid nerve detection. The nerve status aspect determines the minimum current level of a signal applied to a probe near a nerve needed to generate onset EMG response for a muscle coupled to a nerve of interest. The present invention may use this determined minimum current level when determining whether a probe is near the same nerve.
In optional aspects, the present invention may involve determining an initial set of “baseline” neuro-muscular response onset values for a plurality of different spinal nerve pathways. This optional second (nerve status) aspect of the present invention is preferably carried out prior to the first (nerve detection) aspect of the invention, with the initial set of “baseline” neuro-muscular onset values then optionally being used in the nerve detection function, as will be explained below. As the optional second aspect of the invention is carried out prior to carrying out the first aspect of the invention, it will be described first.
In the nerve status determination, the minimum current level of a signal applied to a probe needed to generate an onset neuro-muscular response (i.e.: EMG response) is first determined for each of a plurality of nerves, as follows. Referring to FIG. 1 , a patient's vertebrae L 1 , L 2 , L 3 , L 4 , L 5 , and S 1 are shown. In a preferred aspect of the present invention, a portion of the patient's cauda equina is stimulated (i.e. depolarized). This depolarization of a portion of the patient's cauda equina may be achieved by conducting a stimulus pulse having a known current level between an epidural stimulating electrode 11 and a patient return electrode 13 . Electrodes 11 and 13 are referred to herein as “status” electrodes, as they assist in determining the initial status of the various nerve pathways). The epidural electrode is placed in the epidural space of the spine. Alternatively, the depolarization of a portion of the patient's cauda equina may be achieved by conducting a stimulus pulse having a known current level between a pair of status (baseline) electrodes 12 and 14 , which may be positioned adjacent the (thoracic/lumbar) T/L junction (above vertebra L 1 ), as shown. Status electrodes 12 and 14 may be positioned in-line at the T/L junction, (as shown in FIG. 1 ). Status electrodes 12 and 14 could also be positioned on opposite lateral sides of the T/L junction.
In a preferred aspect, neuro-muscular (i.e., EMG), responses to the stimulus pulse by muscles coupled to nerves near the stimulating electrode are detected by electrodes positioned at each of a plurality of myotome locations MR 1 , MR 2 , and MR 3 on the patient's right leg, and myotome locations ML 1 , ML 2 , and ML 3 on the patient's left leg. The sensing of neuro-muscular responses at these locations may be performed with needle electrodes, or electrodes placed on the surface of the patient's skin, as desired. An EMG response at each location MR 1 to MR 6 is detected when the maximum peak-to-peak height of the EMG response to the stimulus pulse is greater than a predetermined mV value (called “onset”). Accordingly, the current level required to elicit an onset EMG response is called the “onset” current level. As described below, the current level of the stimulus pulse or signal applied to the electrode 11 or electrodes 12 , 14 may be incremented from a low level until an onset EMG response is detected for one or more of the myotome locations MR 1 to ML 3 .
It is to be understood that myotome sensing may be carried out at more than the three distal locations illustrated on each of the patient's legs in FIG. 1 . Generally, as greater numbers of distal myotome locations are monitored, a greater number of spinal nerves corresponding to each of these myotome locations can be individually monitored, thereby enhancing the present system's nerve detection ability over a larger section of the patient's spinal column.
It is also to be understood that the present invention can be easily adapted to cervical or thoracic spinal applications (in addition to the illustrated lumbar application of FIG. 1 ). In this case an appropriate portion of the spinal column is depolarized and myotome-sensing locations are selected according to the physiology of the associated nerves for portion of the spinal column of interest. In exemplary aspects, therefore, preferred myotome-sensing locations may therefore include locations on the patient's arms, anal sphincter, bladder, and other areas, depending upon the vertebrae level where the spinal surgery is to be performed.
In a preferred aspect, the current level of the stimulus signal conducted between status electrodes 11 and 13 (or 12 and 14 ) is incrementally increased in a staircase fashion as shown in the current staircase of FIG. 2 from a low value until an onset EMG response is detected at one or more myotome locations. In a preferred embodiment, onset EMG response peak-to-peak value is between 60 mV and 80 mV. (It is noted, however, that depending on the location the stimulating electrode relative to the nerve corresponding to a myotome and the nerve health/status, an onset EMG response may not be detected as the current level is incremented from the lowest level to the highest level shown in FIG. 2 .) In the illustrated exemplary aspect, the current level is shown as increasing from 4 mA to 32 mA, in eight 4 mA increments where the current level is incremented until an onset EMG response is detected. The present invention is not limited to these values and other current ranges (and other numbers “steps” in the staircase) may also be used, as is desired.
At lower current levels, an onset neuro-muscular (i.e., EMG) responses to the stimulus pulse may not be detected at each myotome ML 1 to MR 3 location. However, as the current level of the stimulus signal is incrementally increased (i.e.: moving up the staircase, step-by-step), an onset neuro-muscular (i.e., EMG) response may eventually be detected at each of the various myotome locations ML 1 through MR 3 for each of the six associated spinal nerves. As noted whether an onset EMG response is detected for myotome depends on the location of the electrode relative to the corresponding nerve and the nerve status/health. For example, when a nerve is compressed or impaired, the current level required to generate an onset EMG response may be greater than the similar, non-compressed nerve at a similar distance from the stimulating electrode. Accordingly, he onset neuro-muscular response for each of the various myotome ML 1 to MR 3 locations may be elicited at different stimulus current levels due at least in part to the various individual spinal nerves being compressed, impaired, etc., and also due simply to differences in the individual nerve pathway sensitivities.
For example, referring to the example illustrated in FIG. 1 , a stimulus signal having an initial current level is conducted between electrodes 11 and 13 (or between electrodes 12 and 14 ). The current level of the stimulus pulse is increased step-by-step according to the intensity staircase shown in FIG. 2 until an onset EMG response is detected at one or more selected myotomes. In particular, a response to the increasing current level stimulus pulse is detected at each of the various myotome locations ML 1 through MR 3 . Because each of the spinal nerve paths corresponding to the various myotome locations ML 1 through MR 3 may have different sensitivities (as noted), different onset EMG responses may be detected at the different onset current levels for different myotome locations.
For example, Table 1 illustrates the current level required to elicit an onset EMG response for myotome location. As seen in Table 1, myotome location ML 1 detected an onset EMG response to the stimulus pulse for a current level of 4 mA. Similarly, myotome MR 2 detected an onset neuro-muscular/EMG response to the stimulus pulse for a current level of 24 mA, etc. Summarizing in tabular form:
TABLE 1
Stimulus Current Level at Which Onset EMG Response is Detected:
ML1 - 4 mA
MR1 - 16 mA
ML2 - 16 mA
MR2 - 24 mA
ML3 - 20 mA
MR3 - 12 mA
The above detected stimulus current levels may then be optionally scaled to correspond to stimulus staircase levels 1 through 8, with the maximum signal strength of 32 mA corresponding to “8”, as follows, and as illustrated for each of Myotome locations ML 1 to MR 3 , as shown in Table 2 based on the levels shown in Table 1.
TABLE 2
Scaled Neuro-muscular Response Onset Values:
ML1 - 1
MR1 - 4
ML2 - 4
MR2 - 6
ML3 - 5
MR3 - 3
Accordingly, by depolarizing a portion of the patient's cauda equina and by then measuring the current amplitude at which an onset neuro-muscular (i.e., EMG) response to the depolarization of the cauda equina is detected in each of a plurality of spinal nerves, (i.e.: at each of the myotome locations corresponding to each of the individual spinal nerves), a method for determining the relative neuro-muscular response for each of the plurality of spinal nerves is provided. As such, the relative sensitivities of the various spinal nerve pathways with respect to one another can initially be determined. This information may represent the relative health or status of the nerves coupled to each myotome location where the stimulating electrode is approximately the same distance from each of the corresponding nerves. For example, the nerve corresponding to myotome location MR 2 required 24 mA to elicit an onset EMG response in the corresponding muscle. Accordingly, this nerve may be compressed or otherwise physiologically inhibited.
These respective stimulus pulse current levels at which an onset neuro-muscular response is detected for each of myotome locations ML 1 through MR 3 are detected may then be electronically stored (as an initial “baseline” set of onset EMG response current levels). In a preferred aspect, these stored levels may then be used to perform nerve detection for a probe at a location other than the midline as will be explained. As noted, once an onset neuro-muscular or EMG-response has been detected for each of the myotome locations, it is not necessary to apply further increased current level signals. As such, it may not be necessary for the current level of the signal to reach the top of the current level staircase (as shown in FIG. 2 ) (provided a response has been detected at each of the myotome locations).
By either reaching the end of the increasing current amplitude staircase, (or by simply proceeding as far up the staircase as is necessary to detect a response at each myotome location), the present system obtains and stores an initial “baseline” set of current level onset values for each myotome location. These onset values may be stored either as absolute (i.e.: mA) or scaled (i.e.: 1 to 8) values. As noted these values represent the baseline or initial nerve status for each nerve corresponding to one of the myotome locations. This baseline onset current level may be displayed as a fixed value on a bar graft of LEDs such as shown in FIG. 8A or 8 B. At a later point, the nerve status of the nerves corresponding to the myotomes may be determined again by applying a varying current level signal to the midline electrodes. If a procedure is being performed on the patient, the onset current level for one or more of the corresponding nerves may change.
When the onset current level increases for a nerve this may indicate that a nerve has been impacted by the procedure. The increased onset current level may also be displayed on the bar graft for the respective myotome (FIG. 8 A/ 8 B). In one embodiment, the baseline onset current level is shown as a particular color LED in the bar graph for each myotome location and the increased onset current level value is shown as a different color LED on the bar graph. When the onset current level decreases for a nerve this may indicate that a nerve has been aided by the procedure. The decreased onset current level may also be displayed on the bar graft for the respective myotome. In a preferred embodiment, the decreased onset current level value is shown as a third color LED on the bar graph. When the onset current level remains constant, only the first color for the baseline onset current level is shown on the bar graph. In one embodiment, a blue LED is depicted for the baseline onset current level, an orange LED is depicted for an increased (over the baseline) onset current level, and a green LED is depicted for a decreased onset current level. In one embodiment when the maximum current level in the staircase does not elicit an onset EMG response for a myotome, the baseline LED may be set to flash to indicate this condition. Accordingly, a clinician may periodically request nerve status (midline stimulation) readings to determine what impact, positive, negative, or neutral, a procedure has had on a patient. The clinician can make this assessment by viewing the bar graphs on the display shown in FIG. 8 for each of the myotome locations.
The above determined initial set baseline neuro-muscular response onset current levels for each nerve pathway (myotome location) may then be used in the first (i.e.: nerve sensing) aspect of the present invention, in which a system is provided for detecting the presence of a spinal nerve adjacent to the distal end of a single probe 20 , or either of probes 20 or 22 . (It is to be understood, however, that the forgoing nerve status system (which may experimentally determine neuro-muscular response onset values) is an optional aspect of the present nerve detection system. As such, it is not necessary to determine such relative or absolute neuro-muscular response baseline onset current levels as set forth above prior to nerve detection. Rather, generally expected or previously known current onset levels may instead be used instead. Such generally expected or previously known current onset levels may have been determined by experiments performed previously on other patients.
In accordance with the first aspect of the present invention, nerve detection (performed as the surgical tool or probe is advancing toward the operative site), or nerve surveillance (performed in an ongoing fashion when the surgical tool or probe is stationary has already reached the operative site) may be carried out, as follows.
The first (nerve detection/surveillance) aspect of the invention will now be set forth.
Returning to FIG. 1 , a system is provided to determine whether a nerve is positioned closely adjacent to either of two probes 20 and 22 . In accordance with the present invention, probes 20 and 22 can be any manner of surgical tool, including (electrified) cannulae through which other surgical tools are introduced into the patient. In one aspect of the invention only one probe (e.g.: probe 20 ) is used. In another aspect, as illustrated, two probes (e.g.: 20 and 22 ) are used. Keeping within the scope of the present invention, more than two probes may also be used. In one preferred aspect, probe 20 is an electrified cannula and probe 22 is a “confirmation electrode” which can be inserted through cannula/probe 20 , as will be explained. Probes 20 and 22 may have electrified distal ends, with electrodes 21 and 23 positioned thereon, respectively. (In the case of probe 20 being a cannula, electrode 21 may be positioned on an electrified distal end of the cannula, or alternatively, the entire surface of the electrified cannula may function as the electrode).
Nerve detection is accomplished as follows. A stimulus pulse is passed between electrode 21 (disposed on the distal end of a probe 20 ) and patient return electrode 30 . In instances where a second probe ( 22 ) is also used, a stimulus pulse is passed between electrode 23 (disposed on the distal end of a probe 22 ) and patient return electrode 30 . In one aspect, electrodes 21 or 23 operate as cathodes and patient return electrode 30 is an anode. In this case, probes 20 and 22 are monopolar. Preferably, when simultaneously using two probes ( 20 and 22 ) the stimulus pulse emitted by each of electrodes 21 and 23 is multiplexed, so as to distinguish between their signals.
It should be understood that electrodes 21 and 23 could be replaced by any combination of multiple electrodes, operating either in monopolar or bipolar mode. In the case where a single probe has multiple electrodes (replacing a single electrode such as electrode 21 ) probe 20 could instead be bi-polar with patient return electrode 30 no longer being required.
Subsequent to the emission of a stimulus pulse from either of electrodes 21 or 23 , each of myotome locations ML 1 through MR 3 are monitored to determine if they exhibit an EMG response.
In a preferred aspect, as shown in FIG. 3 , the intensity of the stimulus pulse passing between electrodes 21 and 30 or between 22 and 30 is preferably varied over time. Most preferably, the current intensity level of the stimulus pulse is incrementally increased step-by-step in a “staircase” fashion. As can be seen, the current may be increased in ten 0.5 mA steps from 0.5 mA to 5.0 mA. This stimulus pulse is preferably increased one step at a time until a neuro-muscular (i.e., EMG) response to the stimulus pulse is detected in each of myotome locations ML 1 through MR 3 .
For myotome locations that exhibit ah EMG response as a result of the stimulus pulse, the present invention then records the lowest amplitude of current required to elicit such a response. Subsequently, this stimulus level is interpreted so as to produce an appropriate warning indication to the user that the surgical tool/probe is in close proximity to the nerve.
For example, in a simplified preferred aspect, the staircase of stimulus pulses may comprise only three levels, (rather than the 8 levels which are illustrated in FIG. 3 ). If an EMG response is recorded at a particular myotome location for only the highest level of stimulation (i.e.: the third step on a 3-step staircase), then the system could indicate a “low” alarm condition (since it took a relatively high level of stimulation to produce an EMG response, it is therefore unlikely that the tool/probe distal tip(s) are in close proximity to a nerve). If an EMG response is instead first recorded when the middle level of stimulation (i.e.: the second step on the 3-step staircase) is reached, then the system could indicate a “medium” alarm condition. Similarly, if an EMG response is recorded when the lowest level of stimulation (i.e.: the first step on the 3-step staircase) is reached, then it is likely that the probe tips(s) are positioned very close to a nerve, and the system, could indicate a “high” alarm condition.
As can be appreciated, an important advantage of increasing the stimtilus current intensity in a “staircase” function, increasing from lower to higher levels of current intensity is that a “high” alarm condition would be reached prior to a “low” alarm condition being reached, providing an early warning to the surgeon. Moreover, as soon as a “high” alarm condition is reached, the present invention need not continue through to the end (third step) of the staircase function. In preferred aspects, when the current level of the applied signal to the probe ( 20 or 22 ) elicits an EMG response greater than the pre-determined onset EMG response, the current level is not increased.
In the above-described simplified (only three levels of stimulation) illustration of the invention, it was assumed that all nerves respond similarly to similar levels of stimulation, and the proximity (nerve detection) warning was based upon this assumption. Specifically, in the above-described simplified (three levels of stimulation) illustration, there was an assumed one-to-one (i.e. linear) mapping of the EMG onset value data onto the response data when determining what level of proximity warning indication should be elicited, if any. However, in the case of actual spinal nerve roots, there is not only a natural variability in response onset value threshold, but there is often a substantial variation in neuro-muscular response onset values between the nerve pathways caused as a result of certain disease states, such as nerve root compression resulting from a herniated intervertebral disc.
Accordingly, in a preferred aspect of the present invention, the initial “baseline” neuro-muscular EMG response onset value data set which characterizes the relative EMG onset values of the various nerve roots of interest, (as described above), is used to guide the interpretation of EMG response data and any subsequent proximity warning indication, as follows.
Referring back to FIG. 1 and Table 1, the stimulation staircase transmitted between electrodes 11 and 13 (or 12 and 14 ) resulted in measures neuro-muscular (i.e.: EMG) response onset values of 4, 16, 20, 16, 24 and 12 mA at myotome locations ML 1 , ML 2 , ML 3 , MR 1 , MR 2 and MR 3 , respectively. As can be seen, twice the intensity of current was required to produce a neuro-muscular response at MR 2 as was required to produce a neuro-muscular response at MR 3 (since “24” mA is twice as big as “12” mA). Thus, the nerve pathway to MR 3 is more “sensitive” than to MR 2 (since MR 3 is able to exhibit a neuro-muscular response at ½ of the current intensity required to exhibit a neuro-muscular response at MR 2 ). Consequently, during nerve detection, when electrode 21 or 23 (positioned on the distal end of tool/probe 20 or 22 ) is positioned adjacent the nerve root affiliated with MR 3 , twice the current stimulation intensity was required to produce an EMG response. In contrast, when electrode 21 or 23 (on the distal end of tool/probe 20 or 22 ) was positioned adjacent to the nerve root affiliated with MR 2 , the same level of stimulation that produced a response at MR 3 would not produce a response at MR 2 .
In accordance with preferred aspects of the present invention, the sensitivities of the various spinal nerve pathways (to their associated myotomes) are incorporated into the nerve detection function of the invention by incorporating the various neuro-muscular response onset values, as follows.
A decision is made that either of electrodes 21 or 23 are positioned adjacent to a spinal nerve when a neuro-muscular response is detected at a particular myotome location at a current intensity level that is less than, (or optionally equal to), the previously measured or input EMG response onset value for the particular spinal nerve corresponding to that myotome. For example, referring to myotome location ML 1 , the previously determined neuro-muscular response onset level was 4 mA, as shown in Table 1. Should a neuro-muscular response to the stimulus pulse be detected at a current intensity level at or below 4 mA, this would signal the operator that the respective probe electrode 21 (or 23 ) emitting the stimulus pulse is in close proximity to the spinal nerve. Similarly, the neuro-muscular response onset value for myotome location ML 2 was determined to be 16 mA, as shown in Table 1. Accordingly, should a neuro-muscular response be detected at a current intensity level of less than or equal to 16 mA, this would indicate that respective probe electrode 21 (or 23 ) emitting the stimulus pulse is in close proximity to the spinal nerve.
In addition, as illustrated in FIG. 4 , “high”, “medium” and “low” warning levels may preferably be mapped onto each stimulation staircase level for each myotome location. For example, the neuro-muscular onset level for ML 1 was 4 mA, corresponding to the first level of the 8-level status electrode current staircase of FIG. 2 . Thus, the first (4 mA) step on the staircase is assigned a “high” warning level. Level two (8 mA) is assigned a “medium” warning level and level three (12 mA) is assigned a “low” warning level. Thus, if an EMG response is recorded at ML 1 at the first stimulation level, (4 mA), a “high” proximity warning is given. If a response is detected at the second level (8 mA), then a “medium” proximity warning is given. If a response is detected at the third level (12 mA), then a “low” proximity warning is given. If responses are detected only above the third level, or if no responses are detected, than no warning indication is given.
Similarly, for ML 2 , with a onset value of 16 mA, (i.e.: the fourth level in the status electrode current staircase sequence), the “high”, “medium” and “low” warning levels are assigned starting at the fourth step on the status electrode current staircase, with the fourth step being “high”, the fifth level being “medium” and the sixth level being “low”, respectively, as shown. Accordingly, if an EMG response is detected for ML 2 at (or above) the first, second, third, or fourth surveillance levels, (i.e.: 4, 18, 12 or 16 mA), then a “high” warning indication will be given. For a response initially detected at the fifth level (i.e.: 20 mA), then a “medium” warning indication is given. If a response is not detected until the sixth level (i.e.: 24 mA), then a “low” warning indication is given. If responses are detected only above the sixth level, or not at all, then no indication is given. Preferably, each of myotome locations ML 1 through MR 3 are monitored at conditions indicating “high”, “medium” and “low” likelihood of a nerve being disposed adjacent the surgical tool/probe.
As can be seen in FIG. 4 , ten levels are shown for each of the myotome locations, whereas the illustrated status electrode current staircase has only eight levels. These optional levels “9” and “10” are useful as follows. Should scaled level 8 be the minimum onset level at which a neuro-muscular response is detected, levels “9” and “10” can be used to indicate “medium” and “low” warning levels, respectively.
As explained above, the various neuro-muscular response current onset levels used in detection of spinal nerves may either have been either determined in accordance with the second aspect of the present invention, or may simply correspond to a set of known or expected values input by the user, or pre-set into the system's hardware/software. In either case, an advantage of the present system is that different neuro-muscular response onset value levels may be used when simultaneously sensing for different nerves. An advantage of this is that the present invention is able to compensate for different sensitivities among the various spinal nerves.
As can be seen comparing the current intensities of stimulus electrodes 11 and 13 (or 12 and 14 ) as shown in FIG. 2 (i.e.: up to 32 mA) to the current intensities of probe electrodes 21 and 23 as shown in FIG. 3 (i.e.: up to 5.0 mA), the current intensities emitted by probe electrodes 21 and 23 are less than that of electrodes 12 and 14 . This feature of the present invention is very advantageous in that electrodes 21 and 23 are positioned much closer to the spinal nerves. As such, electrodes 21 and 23 do not depolarize a large portion of the cauda equina, as do electrodes 12 and 14 . In addition, the placement of electrode 11 in the epidural space ensures that the electrode is at a relatively known distance from the spinal nerves.
In an optional preferred aspect of the invention, if a neuro-muscular response (greater than the onset EMG response) is detected for all six myotome sensing locations ML 1 through MR 3 before all of the steps on the staircase is completed, the remaining steps need not be executed.
Moreover, if it has been determined that a maximal level of stimulation is required to elicit an EMG response at a particular myotome sensing location, then only the top three stimulation levels need to be monitored during the neuro-muscular response detection sequence. In this case, the top three monitored levels will correspond to “high”, “medium”, and “low” probabilities of the surgical tool/probe being disposed adjacent the a nerve. In another optional aspect, if any of the myotome locations do not respond to the maximum stimulation level (i.e.: top step on the staircase), they are assigned the maximum scale value (i.e.: a “low” warning indication).
Preferably, each of the spinal nerves monitored at myotome locations ML 1 through MR 3 will correspond to nerves exiting from successive vertebrae along the spine. For example, as shown in FIG. 5 , a main spinal nerve 50 will continuously branch out downwardly along the spinal column with spinal nerve 51 exiting between vertebrae L 2 and L 3 while nerve 52 passes downwardly. Spinal nerve 53 exits between vertebrae L 3 and L 4 while spinal nerve 54 passes downwardly to L 4 . Lastly, spinal nerve 55 will exit between vertebrae L 4 and L 5 while spinal nerve 56 passes downwardly. As can be seen, neuro-muscular (i.e., EMG) response measurements taken at myotome location MR 1 will correspond to EMG signals in spinal nerve 51 , response measurements taken at myotome location MR 2 correspond to EMG signals in spinal nerve 53 , and response measurements taken at myotome location MR 3 correspond to EMG signals in spinal nerve 55 .
In accordance with the present invention, the detection of a neuro-muscular (EMG) response, whether in accordance with the first (i.e.: nerve detection), or second (i.e.: establishing initial “baseline” neuro-muscular response onset values) aspect of the invention, may be accomplished as follows.
Referring to FIG. 6 , an illustration of the waveform characteristics of a stimulus pulse and a corresponding neuro-muscular (EMG) response as detected at a myotome location is shown. An “EMG sampling window” 200 may be defined at a fixed internal of time after the stimulus pulse 202 is emitted. The boundaries of window 200 may be determined by the earliest and latest times that an EMG response may occur relative to stimulus pulse 202 . In the case of stimulation near the lumbar spine, these times are, for example, about 10 milliseconds and 50 milliseconds, respectively.
During EMG sampling window 101 , the EMG signal may optionally be amplified and filtered in accordance with guidelines known to those skilled in the art. The signal may then be rectified and passed through a threshold detector to produce a train of pulses representing the number of “humps” of certain amplitudes contained in the EMG waveform. A re-settable counting circuit may then count the number of humps and a comparator may determine whether the number of pulses is within an acceptable range. By way of example only, the number of acceptable pulses for EMG responses elicited by stimulation in the lumbar spine region may range from about two to about five. If only one pulse is counted, then it is unlikely that a true EMG response has occurred, since true EMG waveforms are typically biphasic (having at least one positive curved pulse response and one negative curved pulse response) resulting in at least two pulses. This pulse-counting scheme helps to discriminate between true EMG waveforms and noise, since noise signals are typically either sporadic and monophasic (and therefore produce only one pulse) or repetitive (producing a high number of pulses during the EMG sampling window).
In a further optional refinement, a separate noise-sampling window may be established to remove noise present in the EMG responses to increase the ability of the system to discriminate between true EMG responses and false responses caused by noise. The boundaries of noise sampling window are chosen such that there is no significant change of a true EMG signal occurring during the window. For example, it may be deemed acceptable that one curved pulse of an EMG response may be comprised primarily of noise, but if more than one curved pulse of an EMG response is primarily comprised of noise, an alarm would be triggered indicating that excess noise is present on that particular channel.
In preferred aspects of the present invention, both the optional second aspect of determining the neuro-muscular response onset values for each of the plurality of spinal nerves and the first aspect of sensing to detect if a nerve is positioned adjacent to a surgical tool/probe are repeated over time. Preferably, the sensing of whether a nerve is positioned adjacent to a surgical tool/probe is continuously repeated in very short intervals of time, such that the operator can be warned in real time as the surgical tool/probe is advanced toward the nerve. The present system of determining the neuro-muscular response onset values for each of the plurality of spinal nerves is also preferably repeated, and may be repeated automatically, or under operator control.
Typically, the above two aspects of the present invention will not be carried out simultaneously. Rather, when the neuro-muscular response onset values are being determined (using electrodes 11 and 13 or 12 and 14 ), the operation of probe electrodes 21 and 23 will be suspended. Conversely, when sensing to determine whether a nerve is positioned adjacent either of probes 20 or 22 , the operation of stimulation electrodes 11 and 13 or 12 and 14 will be suspended. A standard reference electrode 32 may be used for grounding the recording electrodes at the myotomes.
FIG. 6 depicts a particular exemplary embodiment of the present invention. Other embodiments are also possible, and are encompassed by the present invention. Pulse generator 100 creates pulse trains of an appropriate frequency and duration when instructed to do so by controller 118 . By way of example, the pulse frequency may be between 1 pulse-per-second and 10 pulses-per-second, and the pulse duration may be between 20 μsec and 300 μsec. Pulse generator 100 may be implemented using an integrated circuit (IC), such as an ICL75556 (Intensity) or generated by a software module. Amplitude modulator 102 produces a pulse of appropriate amplitude as instructed by controller 118 , and may comprise a digital-to-analog converter such as a DAC08 (National Semiconductor). The output of amplitude modulator 102 drives output stage 103 , which puts out a pulse of the desired amplitude. Output stage 103 may comprise a transformer coupled, constant-current output circuit. The output of output stage 103 is directed through output multiplexer 106 by controller 118 to the appropriate electrodes, either to status (baseline) electrodes 11 and 13 , or to a combination of screw test probe 109 , probe electrode 21 , 23 and patient return electrode 13 . Impedance monitor 104 senses the voltage and current characteristics of the output pulses and controller 118 elicits an error indication on error display 127 if the impedance falls above or below certain pre-set limits. Input keys 116 may be present on a front panel of a control unit of the present invention, as depicted in FIG. 8 , to allow the user to shift between modes of operation.
EMG inputs 128 to 138 comprise the six pairs of electrodes used to detect EMG activity at six different myotome locations. It will be appreciated that the number of channels may vary depending upon the number of nerve roots and affiliated myotomes that need to be monitored. A reference electrode 140 may also be attached to the patient at a location roughly central to the groupings of EMG electrodes 128 to 138 to serve as a ground reference for the EMG input signals. Electrodes 128 to 140 may either be of the needle-type or of the gelled foam type, or of any type appropriate for detecting low-level physiological signals. EMG input stage 142 may contain input protection circuit comprising, for example, gas discharge elements (to suppress high-voltage transients) and/or clamping diodes. Such clamping diodes are preferably of the low-leakage types, such as SST-pads (Siliconix). The signal is then passed through amplifier/filter 144 , which may amplify the signal differentially using an instrumentation amplifier such as an AD620 (Analog Devices). The overall gain may be on the order of about 10,000:1 to about 1,000,000:1, and the low and high filter bands may be in the range of about 1-100 Hz and 500 to 5,000 Hz, respectively. Such filtering may be accomplished digitally, in software, or with discrete components using techniques well known to those skilled in the art. The amplified and filtered signal then passes through rectifier 141 , which may be either a software rectifier or a hardware rectifier. The output of rectifier 146 goes to threshold detector 147 which may be implemented either in electronic hardware or in software. The output of threshold detector 147 then goes to counter 148 which may also be implemented by either software or hardware.
Controller 118 may be a microcomputer or microcontroller, or it may be a programmable gate array, or other hardware logic device. Display elements 120 to 127 may be of any appropriate type, either individually implemented (such as with multicolor LEDs) or as an integrated display (such as an LCD). | An electromyography system and related method for performing automated screw test procedures, involving automatically determining an onset neuro-muscular response to the application of an electrical stimulus to a portion of pediculur bone and communicating to a user an onset electrical stimulus level which causes the onset neuro-muscular response. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a vehicle seat structure, and more particularly, to a means for varying the height and tilt of a seat in an easy and simple way. Such a structure offers greater operator comfort, an important consideration in vehicles designed to be operated in rough terrain.
Conventional seat designs, especially in off-high-way construction vehicles, tend to operate inadequately due to the excessive weight of the seat assembly, such weight caused in part by the seat being designed to give greater seat stability in rough terrain. Also, height and tilt adjustment linkages in past designs have tended to be complex and as a result prone to failure, or tend to lack the stability required to provide operator comfort and safety. Of general interest are U.S. Pat. Nos. 3,218,020; 2,949,153; and 3,788,697. However, none of these cited patents anticipate applicant's invention.
Summary of the Invention
In accordance with the above discussion, an object of this invention is to provide an easy and simple means for varying the height and tilt of a seat requiring only a single lever for operation.
Another object of this invention is to provide a height and tilt adjustment system that diminishes seat weight problems by allowing the operator to vary the height and tilt of the seat merely by shifting his weight therein.
A further object of this invention is to provide a height and tilt adjustment system whose linkages are such that the seat has greater stability than conventional seat designs.
Other objects and advantages of the present invention will become more apparent upon reference to the accompanying drawings and the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the seat embodying the principles of the present invention;
FIG. 2 is a rear view of the seat of the present invention;
FIG. 3 is an enlarged sectional view taken along the line III--III of FIG. 2; and
FIG. 4 is an enlarged sectional view taken along the line IV--IV of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a vehicle seat incorporating the principles of this invention is shown at 10. The seat is adapted to be mounted on a fixed frame 12 of a vehicle, not shown, such as an off-highway earth-moving machine or the like.
The vehicle seat 10 includes a base 14 having a pair of brackets 16 connected to the base and extending upward therefrom. A parallelogram linkage 17 is pivotally attached to the brackets 16 at pins 18 and 20 and comprises a pair of upper links 22 and a pair of lower links 24. The lower links 24 are oriented substantially parallel to the upper links 22. These links 22, 24 connect the brackets 16 to a pair of swing links 26, with upper links 22 pivotally attached to the swing links 26 at pin 28 and lower links 24 pivotally attached to the swing links 26 at pin 30. The swing links 26 are further pivotally connected to the seat 32 at pivot pin 34. Thus, the structure comprises the bracket 16, the links 22, 24, the swing links 26 which act to allow the seat 32 to move relative to the base 14 either upwardly or downwardly, and the pin 34 rotatably connecting the seat to the swing links 26 and acting as a pivot point to allow the seat 32 to tilt with respect to the base 14.
Referring now particularly to FIG. 2, the assembly for controlling the degree of tilt of the seat 32 with respect to the base 14 includes a pair of links 40 also pivotally attached to the swing links 26 at pin 30. These links 40 further act to maintain a tilt select pin 42 at an attitude substantially parallel along its centerline axis to that of the pin 30. As shown more clearly in FIGS. 1 and 3, the tilt select pin 42 determines a given tilt for the seat 32 by being seated in one of a plurality of notches defined in a tilt position member 44 which is anchored to the bottom of the seat 32. The notches of the tilt position member 44 are positioned such that the seating of the tilt select pin 42 in a given notch creates a different tilt disposition of the seat 32 with respect to the base 14 for each notch.
Referring again to FIG. 2, the assembly for controlling the height of the seat 32 with respect to the base 14 includes a pair of links 50 also pivotally mounted to the swing links 26 at pin 30. These links 50 further act to maintain a height select pin 52 at an attitude substantially parallel along its centerline axis to that of the pin 30. As shown more clearly in FIGS. 1 and 3, the height select pin 52 determines a given height for the seat 32 by being seated in one of a plurality of notches defined in a height position member 54 which is anchored to the base 14. The notches of the height position member 54 are positioned such that the seating of the height select pin 52 in a given notch creates a different level of height of the seat 32 above the base 14 for each notch.
As shown in FIG. 3, to allow the single spring 60 to hold both the tilt select pin 42 and the height select pin 52 in their respective given notches, the notches of the tilt position member 44 opens substantially in a downward direction towards the base 14, and the notches of the height position member 54 open substantially in an upward direction toward the seat 32, whereas the tilt select pin 42 and its corresponding link 40 are positioned beneath the height select pin 52 and its corresponding links 50. Thus, connecting the spring 60 between one of the links 40 and one of the links 50 acts to normally exert a sufficiently high pulling force therebetween to thereby hold the tilt select pin 42 in its given notch and the height select pin 52 in its given notch. The result is that holding by the spring 60 causes both the height and the tilt disposition of the seat 32 with respect to the base 14 to remain fixed.
The means for changing the position of the seat 32 with respect to the base 14 comprise a lever 70 fixed to an actuating bar 72 rotatably mounted on the pin 30 between the links 40 and the links 50. As shown in FIGS. 3 and 4, the actuating bar is shaped so that it sits between the tilt select pin 42 and the height select pin 52.
In operation, when the lever 70 is pulled down, the actuating bar 72 rotates about the pin 30 and is caused to contact the height select pin 52. When sufficient force is applied to the lever 70 to counteract spring 60, the result is that the height select pin 52 is forced out of its present notch in the height position member 54 by the actuating bar 72. This allows, by the means of the swing links 26, the upper links 22 and the lower links 24 pivotally connected thereto as described above, for the positioning of the height select pin 52 over a new notch in the height position member 54, to thus reposition the height of the seat 32 with respect to the base 14. When the lever 70 is released, the height select pin is drawn into the new notch by the spring 60 which thereby also returns the actuating bar 72 and the lever 70 to their original positions, and as a result a new height disposition of the seat 32 becomes fixed.
When the lever 70 is pushed up, the actuating bar 72 rotates about the pin 30 and is caused to contact the tilt select pin 42. When sufficient force is applied to the lever 70 to counteract spring 60, the result is that the tilt select pin 42 is forced out of its present notch in the tilt position member 44 by the actuating bar 72. This allows, by means of the pivot pin 34, for the positioning of the tilt select pin 42 over a new notch on the tilt position member 44 to thus reposition the tilt of the seat 32 with respect to the base 14. When the lever 70 is released, the tilt select pin is drawn into the new notch by the spring 60 which thereby also returns the actuating bar 72 and the lever 70 to their original positions, and as a result the new tilt position of the seat 32 becomes fixed.
The ability of an operator to perform a height or tilt adjustment to the seat 32 is facilitated by means of compression spring 80 and compression spring 82. As shown in FIGS. 1 and 4, compression spring 80 is connected between an arcuate flange 84 formed in the base 14 and a stiffening member 86 connected between the two upper links 22. The spring 80 is rotatably attached to the stiffening member 86 by means of a pin 88. In operation, the spring 80 increases its resistance to motion as the seat 32 is lowered. This is because the upper links 22, since they are part of the means for allowing the raising and lowering of the seat 32 as described above, draws closer to the base 14 in conjunction with the seat 32 as it gets lower. This movement thus tends to increase the compression of the spring 80 as the upper links 22 approach the base 14 and thereby increasing the resistance felt by the operator to further lowering of the seat 32. As a result, an operator can control the extent of lowering of the seat 32, i.e. its height, merely by varying the weight he exerts on the seat itself.
Similarly, in adjusting the tilt of the seat 32, compression spring 82 serves the same function as spring 80. As shown in FIG. 1, spring 82 is connected between the seat 32 and the swing links 26. The spring 82 is rotatably attached to a flange 90 extending out from the swing links 26, as shown in FIG. 2, by means of a pin 92. The other end of the spring 82 is attached to the seat 32 by means of a flange 94. In operation, the spring 82 increases its resistance to motion as the degree of tilt of the seat 32 with respect to the base 14 is increased. This is because the seat 32 tilts about the pivot point 34, as described above, which is also a connecting point of the swing links 26 to the seat 32. Thus, as tilt increases with respect to the base, the flange 94 connected to the seat 32 draws closer to the swing links 26, and as a result compresses the spring 82 lying therebetween. This spring 82 compression tends to increase as the seat 32 tilt increases thereby increasing the resistance felt by the operator to greater tilting of the seat 32. As a result, again an operator can control the extent of seat 32 tilt with respect to the base 14 merely by varying the weight he exerts on the seat itself.
The present embodiment of this invention is to be considered in all respects as illustrative and not restrictive; the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims therefore are intended to be embraced therein. | A vehicle seat structure comprises a seat pivotally connected to swing link means which are in turn pivotally connected to the base by substantially parallel links to allow the vehicle seat to be both raised and lowered or tilted with respect to the base. A height select pin and a tilt select pin are normally restrained within notches in respective height and tilt position members to fix thereby a given height and tilt attitude of the seat. An actuating bar controlled by a control lever acts to disengage either the height select or tilt select pin to permit the pin to be seated in a different notch, thereby enabling seat position to be varied. Compression springs act, for both tilt and height seat position variations, to provide means whereby the weight of the seat operator can be used to adjust seat position. | 1 |
BACKGROUND OF THE INVENTION
Knee orthesis appliances are used to stabilise the ligamentous apparatus in the knee.
Where knee orthesis appliances were previously prescribed mainly pre-operatively as a measure to prevent further damage to torn or overstretched ligaments and post-operatively after ligament surgery as protection, nowadays sportsmen from the most varied of disciplines use these knee splints more or less at will to protect against knee or ligament injuries.
The simplest version of the knee orthesis device has a monocentric joint; but it cannot correctly imitate the anatomical movement of the knee joint. The movement or the interplay between all elements of the knee involved in anatomical movement (joint surfaces of the femur and the tibia, cruciate ligaments, patella) is much more complex. This means that knee orthesis appliances having monocentric joints cannot move in synchrony with the thigh and the tibia. The result is annoying frictions, which reduce comfort when wearing one. Since monocentric joints are something of a temporary solution, they are not suitable for sportsmen.
The rolling/sliding movement of the knee joints which actually occurs physiologically and the particular position of the cruciate ligaments was studied and described by Menshik. The result is a so-called "linkover four bar chain" which has been named after him (hereinafter simply referred to as a four bar chain), which imitates the rolling/sliding movement very well and therefore effectively relieves the knee. However this is still far from constructing a knee splint which combines a high level of worn comfort and good management of the ligaments, preconditions which are considered to be self-evident in high performance sport today.
STATE OF THE ART
Today, ready-made splints are available for attaching to four bar chains which can be obtained separately. These knee splints are secured to the knee joint by ready to use bandages. These bandages have pockets into which the ready-made splints are inserted. However, the splints have a not inconsiderable amount of play in the pockets, therefore they move backwards and forwards, which is why the knee is badly managed in conventional splints. The security required by the ligament is therefore not available under heavy or extreme loads.
To now achieve a more exactly fitting shape, the most modern production techniques are exploited: with CAD/CAM support, knee splints can be milled out of a massive single block of carbon fibre, after measurements of the knee joint and associated parts of the femur and tibia have been taken by a laser scanner and digitised. However, knee splints manufactured in this way do not have a four bar chain and have the positive disadvantage of being very expensive due to the enormous technical expense (integrated CAD/CAM manufacturing station).
SUMMARY OF THE INVENTION
The new carbon-fiber composite layer construction knee orthesis appliances are an extremely good fit and achieve their objective in an excellent manner thanks to the Menshik four bar chain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the overall view of the knee orthesis appliance,
FIG. 2 shows the construction/manufacture of the knee orthesis appliance
FIGS. 3a, 3b, 3c and 3d show parts of the four bar chain.
FIGS. 4a, 4b, 4c and 4d show the four bar chain assembled and its method of operation;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Its low weight (approx 360 g) and simple manufacture based on a simple positive plaster cast (1) of the knee, are excellent additional characteristics of the carbon-fiber composite material knee orthesis appliance (7) (FIG. (1)). Because a simple plaster cast (1) serves as a base, this guarantees that the carbon-fiber composite construction knee orthesis appliance (7) can be manufactured at low prices and with consistently good quality in specially equipped orthopaedic workshops.
In detail, production is as follows: firstly a negative plaster cast is made of the leg which will wear the knee splint. The knee splint will involve three-quarters of the leg. After hardening, the negative plaster cast is cut laterally and removed from the leg. It is then put together again and bound with plaster bandages. This negative mould is then filled with liquid plaster, which provides a positive plaster cast (1) as shown in FIG. 2, and we therefore achieve an exact imitation of the patient's knee joint. Any possible irregularities can then be smoothed out by subsequent modelling.
Now two basic shaping plates 2 are placed in the positive plaster cast (1) in the lateral and medial area of the knee joint, in which the four bar chains (21), shown in FIG. 4a, are to be located. To this end, two holes (3) in which the retaining pins (4) of the basic shaping plates (2) are screwed as shown in FIG. 2, are bored in the positive plaster cast. It is now decisive that in a procedure (described later), the crescent-shaped lower joint plate (5) as shown in FIG. 3 and the upper trapezoidal joint plate (6) of the four bar chain can be pre-positioned and completely integrated into the carbon-fiber composite construction knee orthesis appliance (7) itself. The four bar chains (21) which finally result are absolutely free of play and exactly positioned, which guarantees a previously unheard-of level of security for the knee joint ligamentous apparatus. It is self-evident that the level of wearer comfort is considerably increased; a highly accurate fit allows the patient to forget the knee orthesis. It should be pointed out here that the basic shaping plates 2 for positioning the joint plates (5,6) have positioning pins (8) shown in FIG. 2 whose position must match that of the boreholes (9) shown in FIG. 3 in the joint plates. The additional significance of the basic shaping plate will be dealt with later. Additionally, the hollow space necessarily created between the plaster cast (1) and the inserted basic shaping plates (2), is filled with plasticine. A knitted cotton sock (not shown in FIG. 2) must be pulled on over the positive plaster cast before we begin manufacturing the carbon-fiber composite. The knitted cotton sock is ultimately is removed at the end of the process of making the orthotic, and its sole function is to keep residual moisture in the plaster cast (1) away from the PVA (polyvinyl acetate) foil. A carbon-fiber layer (11) now follows. This is a carbon-fiber mat netting with 200 strands per square centimeter. This mat is placed axially around the plaster cast and glued together at the posterior side of the leg (that is "at the back" of the leg). Now the tubular knitted glass fiber (12) which serves to provide mechanical strength, can be pulled on. The first half of the carbon-fiber composite layer is now ready. The joint plates (5,6) shown in FIG. 2 can now be fitted on the positioning pins in the basic shaping plate (1) as discussed above. This is very easy to do, because the positioning pins penetrate well through the thin PVA foil (10), the carbon-fiber layer (11) and the knitted glass fiber (12). It is now essential for the joint plates (5,6) to be glued onto the knitted glass fiber lying below, in order that they do not subsequently move. Knitted glass fiber has the added advantage over glass fiber matting, that it does not break up into fibers when pulled. This directly increases the quality of the carbon-fiber composite since, viewed mechanically, the load-bearing mat shows no breaks, which would restrict the load-bearing capacity of the carbon-fiber composite layer.
Now the second, outer half of the carbon-fiber composite is layered, by applying a second layer of knitted glass fiber (12) as shown in FIG. 2. In order to stiffen the area of the four bar chain mechanically (to achieve the stability required for joint splint areas), glass fiber matting (not shown in FIG. 2) is wound twice crossways around the area of the joint. This is followed by a further, all-covering layer of knitted glass fiber (12). A further layer of carbon-fiber netting is laid over this, upon which a covering layer of PVA foil is laid. In summary, we then have a "composite sandwich", whose inner layers have been laid between two PVA foils around the plaster cast.
Now, a liquid laminate (resin and hardener) is poured between these foils. The rough poured mold is then connected to a vacuum and the air evacuated. Doing this presses the layered parcel firmly against the plaster cast and also completely removes the air between the layers of material; the layers of material are evenly saturated by the flowing laminate. This process is best known as the vacuum procedure and is excellently suited, according to experience, to special designs on plaster molds. It is now quite clear why, as discussed above, the hollow space between the basic shaping plates (2) and the positive plaster cast (1) are filled with plasticine. We have to prevent the inner PVA foil being torn by the evacuation of any residual air bubbles which, with the flowing laminate, would lead to the basic shaping plates also being incorporated in the orthotic. Curing in the vacuum procedure takes place at room temperature and lasts for approximately one hour. The splint mold is now ready for final working.
Firstly, the contours of the knee joint (13) is shown in FIG. 1 are cut out on the front and rear of the knee orthesis. This frees the parts of the knee which have to move. The knee orthesis can now be cut down to the final length. After this, the plaster cast is no longer required and is subsequently destroyed after the orthesis has been delivered. The (re-usable) basic shaping plates are removed. The cotton stocking and plasticine are likewise removed. The result is that we obtain the knee orthesis as a still rigid semi-finished product. The orthesis is sawn through between both joint plates (5,6), so that the upper and lower halves can be worked on independently. Now, for example, excess carbon-fiber composite material can be ground down, principally between the joint plates. Both halves are cut open along their length at the back, in order that the knee orthesis appliance can be pulled on. Slots (14) are cut for the fastenings (15) and a tibia cushion (not shown) is put in to increase wearer comfort. Finally, the inner sidepiece (16) and the outer sidepiece (17) are riveted, with the integrated joint plates, to the finished four bar chain (21) shown in FIG. 4 and, at the same time, to the finished knee orthesis appliance (7) shown in FIG. 1. The fact that the sidepieces (16,17) and the joint plates (5,6) are made of titanium, which is well-known to combine the best tensile strengths with astoundingly low weight, contributes to the low weight of approx. 360 g. Use of carbon-fiber composite material for the knee orthesis appliance also results in the lowest weight with very high strength in relation to the necessary material thickness.
We have to look more closely at the basic shaping plates (2) and the function of the four bar chain (21), shown in FIG. 4a, to see the additional advantages of the new knee orthesis. As discussed, the joint plates (5,6) are positioned thanks to the basic shaping plate (2). The mutual position of the joint plates in manufacturing the knee orthesis depends on how greatly the patient's knee can be straightened. A straightened leg with a corresponding angle of bend of 0°, which is never obtained following surgery, would be ideal. (The angle of bend (22) shown in FIG. 4d is the assumed angle between the axis of the upper femur and the assumed lengthening of the lower femur beyond the knee.) Basic shaping plates are therefore made for angles of bend of 20°, 30°, 40° and 45° at least. Basic shaping plates can, of course, be made for any angle desired. This guarantees that the joint plates (5,6) are positioned, at the time the knee splint is produced, at the present angle of bend which suits the patient for whom the plaster cast (1) was made.
Furthermore, the new knee orthesis appliance cannot be hyperextended (negative angle of bend). FIG. 4 shows that with the leg fully extended (angle of bend 0°), the straight flank (18) of the crescent-shaped lower joint plate (5) (FIG. 3) serves as a point for the flank (18) to be attached to the upper joint plates (6). In addition, the joint plates of the individual four bar chains which are opposite each other respectively, must be positioned exactly parallel and identically, in order to prevent the knee orthesis appliance from so-called opening up when bending the knee. There will be positioning tolerances despite careful manufacture; these can be very easily evened out by subsequently grinding the stop flanks (18) shown in FIG. 3. Another decisive advantage of the new knee orthesis appliance is that the angle of bend (22) can be limited in a very easy manner. This is respectively required if the surgeon orders that the patient should only bend the knee in a range between 20° and 60°. The first method of limiting the angle consists of not removing all the residues when subsequently machining the composite material between the joint plates (5,6). This automatically produces limited freedom of movement in the joint plates and therefore a limited angle of bend. Once the patient is allowed to bend the knee more strongly after a certain period, we only have to grind the composite material further down. The second method consists of inserting a stop screw (20) (cylinder head or self-tapping screw) in the holes (19) provided for this in the upper joint plates and allowing its thread to stick out so far as to serve as a stop for the inner sidepiece (14) of the four bar chain. Of course, you must ensure that the screw is prevented from unscrewing and that it cannot injure the skin of the knee. It can now be seen that the straightening movement of the knee is limited if the upper joint plate (6) moves towards the lower joint plate (5), a movement which is only possible to a certain extent due to the stop screw (20). FIG. 4c shows how the upper edge of the inner sidepiece (16) rests on the stop screw (20) when the knee is straightened in direction (23), and limits the extension angle (25), which we again find between the flanks of both joint plates. To make this more clear, FIG. 4b shows the position of the joint plates (5,6) at a angle of bend of 0° (upper joint plate pulled out) and at a selected angle of bend (upper joint plate (6) is the dotted line). The extension angle (25) and the angle of bend (22) can be adapted individually, because we only have to select the position of the holes and determine the side on which the thread should protrude. In doing so, it is self-evident that one of the two four bar chains limits the angle of bend, while the other limits the extension angle.
Patients can be released from hospital care earlier thanks to the new composite layer design knee orthesis appliance. The healing process is markedly accelerated which allows the patient to return to work more quickly. In addition, expensive follow-up treatments can be omitted, thanks to the excellent stability which the knee is given. Joint arthroses will not occur very often, with the likelihood of a subsequent, very expensive artificial knee-joint implant falling to a minimum. This will more than compensate for the costs of such a knee orthesis appliance.
The new knee orthesis appliance can also be worn without difficulty under jeans, due to the low weight and the snug-fitting shape. These advantages are also appreciated by sportsmen in all disciplines. For example, the close fitting knee orthesis appliance fits into a skier's racing suit without difficulty. Ice hockey players, rowers, tennis players, weight lifters and footbailers, to name but a few, will certainly use the knee orthesis appliance as a preventive measure because it effectively protects the knee joint, fits completely and is comfortable to wear due to the low weight. The new knee orthesis appliance will replace all existing products of this nature, because it represents a truly progressive step in orthopaedic engineering due to the systematic use of the most modern materials.
REFERENCE NUMBER INDEX
1. Plaster Cast
2. Basic Shaping Plate
3. Hole
4. Retaining Pin
5. Lower Joint Plate
6. Upper Joint Plate
7. Knee Orthesis Appliance
8. Positioning Pin
9. Borehole
10. PVA foil
11. Carbon Fiber Matting Layer
12. Knitted Glass Fiber
13. Contour of Knee Orthesis Appliance
14. Slots
15. Fastening
16. Inner Sidepiece
17. Outer Sidepiece
18. Stop Flank
19. Borehole for the Stop Screw
20. Stop Screw
21. Four Bar Chain
22. Angle of Bend
23. Direction of Extension
24. Upper Edge of the Inner Sidepiece 16
25. Extension Angle | The knee orthesis appliance is made of carbon-fiber composite material with an integral Menshik linkover four bar chain (21) made of titanium. It provides the knee joint with secure and reliable support. Owing to its low weight, it is extremely comfortable to wear. The angle of bend (22) can be adjusted to suit the individual as prescribed by the doctor. The shells of the appliance are made from a positive plaster cast (1), using vacuum composite production techniques. This simple process enables the appliance to be manufactured to a high standard of quality in orthopaedic workshops. The joint plates (5,6) are inserted between the individual layers of the composite. Following filling and curing, the sidepieces (16,17) only have to be riveted to the joint plates to complete the four bar chains and hence the finished appliance. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates to a method of making an ultrathin silicon dioxide gate with improved dielectric properties by nitriding the silicon dioxide gate using NH 3 .
BACKGROUND OF THE INVENTION
[0002] The ultrathin gate dielectric has been emerged as one of the hardest challenges for further device scaling. Direct tunneling currents restrict the utilization of SiO 2 films below approximately 1.5 nm thickness where tunneling currents larger than 1A/ cm 2 are observed. Further reduction in thickness will increase tunneling current exponentially. Unacceptable gate leakage currents phase-out this gate dielectric material as early as the 0.1 μm CMOS process. The requirements summarized in the International Roadmap for Semiconductors (ITRS 1999) indicate the equivalent oxide thickness (EOT) progressing to substantially 1.0-1.5 nm for the 0.1 μm notes. No suitable alternative high dielectric constant material and interface layer has been identified with the stability and interface characteristics to serve as a gate dielectric.
[0003] To reduce the gate leakage current while maintaining the same gate capacitance, a thicker film with higher dielectric constant is required. Because the direct quantum-mechanical tunneling is exponentially dependent upon the dielectric thickness while the capacitance is only linearly dependent on thickness. For so-call high-K metal oxides, such as HfO 2 , ZrO 2 , Ta 2 O 5 , TiO 2 , unfortunately most of these materials have thermal stability issues. The formation of SiO 2 and/or metal silicides takes place when they are deposited on the silicon. Post-deposition annealing is found to be necessary in efforts to further reduce gate leakage current and to densify the film. However, annealing causes the further growth of the SiO 2 and silicide, which reduces the effectiveness of any high-K materials. Furthermore, these materials can't endure subsequent high-temperature source/drain and gate activation, which will crystallize the high-K films and thus results in large leakage increase. It is also not clear if any of these materials are compatible with poly-Si gate due to the chemical reactivity with the poly-Si. Therefore, the obstacles for high-K material are not only the discovery and development of a new material, but possibly a complete re-engineering of ever more complicated CMOS processing.
[0004] Nitrided oxide or nitride/oxide stack has been emerged as the promising candidate to replace conventional oxide for the urgent requirement in 0.1 μm notes. Nitride/oxide stack preserves the excellent Si/oxide interface and takes the advantages of nitride film. However, there still exists some problems including the significant amount of traps at the oxide/nitride interface and nitride bulk in conventional CVD nitride process, and nitrogen diffuses into and piles up at Si/SiO 2 interface during the post-deposition annealing. These problems result in degradation of carrier mobility and become more severe when reducing base oxide thickness. An 8-10 A ° oxide base layer has been reported as the optimized base oxide thickness. Further reducing the base oxide thickness results in poor Si/SiO 2 interface and thus unacceptable performance degradation. The requirement of a base oxide restricts the down-scaling of nitride/oxide stack. Till now, high performance nitride/oxide stacks with EOT less than 15 A ° have not been reported.
[0005] For nitrided oxide, many methods have been developed in the past time, such as N 2 O, NO nitridation, remote plasma nitridation (RPN) on deposited oxide. Oxide films that were either annealed in NO or N 2 O typically have total integrated nitrogen concentrations less then 1%. Such small amount of nitrogen concentration is desirable to improve channel hot-carrier degradation effects in transistor. However, it is insufficient to reduce the effects of boron penetration from P+ poly-Si gate into the gate dielectric, especially when oxide thickness down to less than 15 A °. Also, such a small nitrogen concentration didn't effectively reduce the EOT to solve the problem of excess high gate leakage current in ultrathin gate dielectric. Even more, it was observed that NO or N 2 O nitridation not only incorporated nitrogen within the film, but also increased the film thickness. In general, this was not viewed as a desirable effect for ultrathin oxide.
[0006] Remote plasma nitrided oxides, involving nitridation of thermally grown oxides with a remote high-density nitrogen discharge, are comprised of a thin layer of uniform and high nitrogen concentration at the poly/dielectric interface for an effective barrier to suppress boron diffusion. Through this nitridation, EOT can be effectively reduced due to an increase of dielectric constant. However, when oxide thickness becomes thinner, remote plasma nitridation meets a crucial bottleneck. High-energetic and active nitrogen will easily penetrate through ultrathin oxide, resulting in dramatic thickness increase and unacceptable mobility degradation. Radical induced reoxidation more than offset the EOT reduction from the nitrogen incorporation and limits the down-scaling of remote plasma nitrided oxide.
SUMMARY OF THE INVENTION
[0007] One embodiment of the invention includes a method of reducing the equivalent oxide thickness of a silicon dioxide based gate on a semiconductor device includes a silicon based substrate having active areas defined therein including providing a silicon based substrate having active areas defined therein and a silicon dioxide based gate, and introducing nitrogen into the silicon dioxide based gate to increase the dielectric constant of the silicon dioxide based gate to provide a nitrided silicon dioxide based gate.
[0008] Another embodiment of the invention includes a method of reducing the equivalent oxide thickness of a silicon dioxide based gate wherein the introducing of the nitrogen into the silicon dioxide based gate comprises heating the silicon dioxide based gate in an atmospheric high concentration of NH 3 .
[0009] Another embodiment of the invention includes a method of reducing the equivalent oxide thickness of a silicon dioxide based gate wherein the introducing of the nitrogen into the silicon dioxide based gate comprises heating the silicon dioxide based gate to a temperature of at least 800° C. in an atmosphere having a high concentration of NH 3 .
[0010] Another embodiment of the invention includes a method of reducing the equivalent oxide thickness of a silicon dioxide based gate further includes annealing the nitrided silicon dioxide based gate to a temperature of at least 900° C. or greater.
[0011] Another embodiment of the invention includes a method of reducing the equivalent oxide thickness of a silicon dioxide based gate wherein the annealing of the nitrided silicon dioxide based gate includes heating the nitrided silicon dioxide based gate to a temperature of at least 900° C. in the presence of an atmosphere that prevents the further growth of silicon dioxide and thereby prevents the substantial increase in the thickness of the silicon based dioxide gate.
[0012] Another embodiment of the invention includes a method of reducing the equivalent oxide thickness of a silicon dioxide based gate wherein the annealing of the nitrided silicon dioxide based gate includes heating the nitrided silicon dioxide based gate to a temperature of at least 900° C. in the presence of N 2 .
[0013] Another embodiment of the invention includes a method of reducing the equivalent oxide thickness of a silicon dioxide based gate wherein the annealing of the nitrided silicon dioxide based gate includes heating the nitrided silicon dioxide based gate to a temperature of at least 900° C. in the presence of NO.
[0014] Another embodiment of the invention includes a method of reducing the equivalent oxide thickness of a silicon dioxide based gate and further including a second annealing of the nitrided silicon dioxide based gate including heating the nitrided silicon dioxide based gate to a temperature of at least 900° C. in the presence of NO.
[0015] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by doping the silicon dioxide based gate including providing a silicon based substrate having active areas defined therein. Thermally growing a silicon dioxide based gate from the silicon based substrate. Doping the silicon dioxide based gate to provide a doped silicon dioxide based gate and to increase the dielectric constant of the silicon dioxide based gate without substantially increasing the thickness of the silicon dioxide based gate.
[0016] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by doping the silicon dioxide based gate and further includes annealing the doped silicon dioxide based gate to a temperature of at least 900° C. or greater.
[0017] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by doping the silicon dioxide based gate wherein the silicon dioxide based gate has a crystalline structure and wherein the doping of the silicon dioxide based gate includes adding nitrogen into the crystalline structure.
[0018] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by doping the silicon dioxide based gate wherein said annealing of the doped silicon dioxide based gate includes heating the doped silicon dioxide based gate to a temperature of at least 900° C. in the presence of an atmosphere that prevents the further growth of silicon dioxide and further prevents the substantial increase in the thickness of the silicon dioxide based gate.
[0019] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by doping the silicon dioxide based gate wherein said annealing of the doped silicon dioxide based gate includes heating the doped silicon dioxide based gate to a temperature of at least 900° C. in the presence of nitrogen.
[0020] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by doping the silicon dioxide based gate wherein said annealing of the doped silicon dioxide based gate includes heating the doped silicon dioxide based gate to a temperature of at least 900° C. in the presence of nitrogen monoxide.
[0021] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by doping the silicon dioxide based gate wherein said growing of the silicon dioxide based gate is conducted so that the silicon dioxide based gate has a thickness less than 22 angstroms.
[0022] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by doping the silicon dioxide based gate wherein said growing of the silicon dioxide based gate is conducted so the silicon dioxide based gate has a thickness ranging from 10-20 angstroms.
[0023] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by nitriding the silicon dioxide based gate including providing a silicon based substrate having active areas defined therein. Thermally growing a silicon dioxide based gate from the silicon based substrate. Nitriding the silicon dioxide based gate to provide a nitrided silicon dioxide based gate and to increase the dielectric constant of the silicon dioxide based gate without substantially increasing the thickness of the silicon dioxide based gate.
[0024] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by nitriding the silicon dioxide based gate wherein said growing of the silicon dioxide based gate includes heating the silicon based substrate in a wet oxygen atmosphere.
[0025] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by nitriding the silicon dioxide based gate wherein said heating of the silicon based substrate is conducted so that the silicon based substrate has a temperature of at least 900° C.
[0026] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by nitriding the silicon dioxide based gate further including annealing the nitrided silicon dioxide based gate to a temperature of at least 900° C. or greater.
[0027] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by nitriding the silicon dioxide based gate wherein said annealing of the nitrided silicon dioxide based gate includes heating the nitrided silicon dioxide based gate to temperature of at least 900° C. in the presence of an atmosphere that prevents the further growth of silicon dioxide and thereby prevents substantial increase in the thickness of the silicon dioxide based gate.
[0028] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by nitriding the silicon dioxide based gate wherein said annealing of the nitrided silicon dioxide based gate includes heating the nitrided silicon dioxide based gate to a temperature of at least 900° C. in the presence of nitrogen.
[0029] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by nitriding the silicon dioxide based gate wherein said annealing of the nitrided silicon dioxide based gate includes heating the nitrided silicon dioxide based gate to a temperature of at least 900° C. in the presence of nitrogen monoxide.
[0030] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by nitriding the silicon dioxide based gate wherein said growing of the silicon dioxide based gate is conducted so that the silicon dioxide based gate has a thickness less than 22 angstroms.
[0031] Another embodiment of the invention the includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties by nitriding the silicon dioxide based gate wherein thermally growing of the silicon dioxide based gate is conducted so that the silicon dioxide based gate has a thickness ranging from 10-20 angstroms.
[0032] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties including providing the silicon based substrate having active areas defined therein. Heating the silicon based substrate in the presence of wet oxygen to grow a silicon dioxide based gate. Heating the silicon dioxide based gate in the presence of NH 3 to provide a nitrided silicon dioxide based gate and to increase the dielectric constant of the silicon dioxide based gate without substantially increasing the thickness of the silicon dioxide based gate.
[0033] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties and further including driving out any hydrogen remaining in the nitrided silicon dioxide based gate.
[0034] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties and further including heating the nitrided silicon dioxide based gate to a temperature of at least 900° C. in the presence of nitrogen.
[0035] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties and further includes heating the nitrided silicon dioxide based gate to a temperature of at least 900° C. in the presence of nitrogen monoxide.
[0036] Another embodiment of the invention includes a method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties and further includes heating the nitrided silicon dioxide based gate to a temperature of at least 900° C. in the presence of nitrogen, and thereafter heating the nitrided silicon dioxide based gate to a temperature of at least 900° C. in the presence of nitrogen monoxide.
[0037] These and other objects, features and advantages of the present invention will be apparent from the following brief description of the drawings, detailed description of the preferred embodiments, and appended claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] [0038]FIG. 1 shows the variation of equivalent oxide thickness (EOT) under different NH 3 nitridation conditions according to the present invention;
[0039] [0039]FIG. 2 illustrates the flat-band voltage (Vfb) shift for both NMOS and PMOS with NH 3 nitrided oxide under different NH 3 nitridation treatment;
[0040] [0040]FIG. 3 illustrates the hysteresis characteristic of NH 3 nitrided oxide and the insert demonstrates the gate leakage current under different temperature (30-150° C.) wherein NH 3 nitrided oxide exhibits little amount of hysteresis and shows very weak temperature dependence on gate leakage current;
[0041] [0041]FIG. 4 shows the measured gate leakage current density (Jg) in inversion region as a function of equivalent oxide thickness (EOT) for NH 3 nitrided PMOS;
[0042] [0042]FIG. 5 shows the measured gate leakage current density (Jg) in inversion region as a function of equivalent oxide thickness (EOT) for NH 3 nitrided NMOS;
[0043] [0043]FIG. 6 shows the normalized drain current drivability for NH 3 nitrided oxides compared to control oxides;
[0044] [0044]FIG. 7 illustrates the normalized drain current driveability under different NH 3 nitridation recipes; and
[0045] [0045]FIG. 8 shows the time to breakdown characteristics of ultrathin NH 3 nitrided oxide.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] In this work, we profoundly investigate the feasibility and characteristics of ultrathin (EOT 13-16 A°) NH 3 nitrided oxides. Oxide thickness was thick in the past time, and most of the studies of NH 3 nitridation performed on these thick oxides were focused on the reliability improvement accompany with the nitrogen incorporation. No attention was paid on the EOT reduction through nitridation. For thick oxide (˜100 A°), 2-3 A ° EOT reduction shows little influence on the characteristics. However, for oxide thickness down to the range of 10-20 A ° in direct tunneling region, 2 A ° EOT reduction can contribute to one order lower in gate leakage current. Opposite to the N 2 O nitridation and RPN which will cause an increase in film physical thickness, NH 3 nitridation not only effectively introduce the nitrogen into gate oxide but also essentially keep unchanged in physical thickness. This property indicates the promising for NH 3 nitridation in oxide equivalent thickness downscaling. The results in this study show that 2-3 A ° EOT reduction can be obtain through NH 3 nitridation at 900° C. for about 2 minutes. More than one order improvement in reducing gate leakage current is observed, depending on the nitridation recipe. Also, we deeply investigate the origins of different behaviors in gate leakage current and in flatband voltage shift between NMOS and PMOS after performing NH 3 nitridaton. Significant larger barrier height lowering in valence band than in conduction and sub-oxide band modification contribute to inferior gate leakage current reduction for PMOS. Boron penetration in ultrathin oxide and the gate type-dependence on nitrided oxide result in larger flatband voltage shift in PMOS. For the performance concern, NH 3 nitrided oxide shows significant improvement in drain driving current for NMOS. However, drivability degradation in PMOS was observed, and become the critical limit for the feasibility of NH 3 nitridation. Fortunately, through the optimized nitridation duration and subsequent post-deposition annealing, this driveability degradation can be largely reduced to meet the process target. Finally, the time to breakdown characteristic of NH 3 nitrided oxide was exanimate to guarantee the reliability for 0.1 μm CMOS process application.
Experimental
[0047] N-and P-channel MOSFETs samples were fabricated on p-type Si(100) wafer using dual gate, twin-well CMOS technology. After trench isolation and active area definition, oxide films of 15-18 A ° thickness were thermally grown in wet oxygen. The oxides were then nitrided at 900° C. for 1-4 minutes in NH 3 ambient. Hereafter, some of these nitrided oxides were annealed in N 2 or NO gas at 1050° C. for 2-4 minutes. After the preparation of gate dielectrics, undoped polysilicon deposition, As/BF 2 implantation, and patterning, source/drain junction formation was performed respectively. The source/drain activation annealing was done at 1075° C. by spike annealing. Then, Cobalt salicide formation, PSG deposition, and contacts defining were executed on sequence. Finally, copper metalization was done to prepare samples for electrical characterization.
[0048] [0048]FIG. 1 shows the variation of equivalent oxide thickness (EOT) under different NH 3 nitridation conditions. EOT is extracted from the measured high-frequency (100 KHz) C-V curves by CV simulator, which takes into account poly-Si gate depletion effect and quantum mechanis. Obviously, increasing NH 3 nitridation duration can effectively reduce the EOT. Through NH 3 nitridation, the physical thickness of the film remains essentially unchanged, as shown in the insert of FIG. 1. It is opposite to the N 2 O nitridation or temperature enhanced remote plasma nitridation (TE-RPN) on ultrathin oxide, which cause the oxide physical thickness (T physical ) increase largely due to the oxygen or radical induced reoxidation. The NH 3 nitridation treatment effectively introduces the nitrogen into the oxide, increases the dielectric constant, keeps the physical thickness unchanged, and thus lowers the EOT. The EOT decreases with NH 3 nitridation time, but the amount of EOT reduction is slightly retarded for longer nitridation duration. This is contributed to the self-limitation property of the nitrogen, which the increase of incorporated nitrogen concentration slows as nitridation time increase. Although this self-limitation, as illustrated in the FIG. 1, the gate dielectric with EOT less than 14 A ° can be easily achieved to meet the 0.1 μm CMOS process notes. Furthermore, as gate dielectric thickness down to direct tunnel region, the advantage of one order lower in gate leakage can be obtained for 2 A ° EOT reduction.
[0049] On other hand, post-nitridation anneals (PNA) in N 2 or NO ambiences are performed for structure stabilization and defect minimization. However, in the consideration of the EOT reduction for 0.1 μm CMOS applications, the N 2 PNA exhibits superior behavior than NO PNA. N 2 PNA keeps EOT unchanged, while the NO PNA results in the large thickness increase, due to the oxygen induced reoxidation. The thickness increases by NO PNA even more than offsets the EOT reduction by NH 3 nitridation treatment.
[0050] FIG. 2 illustrates the flat-band voltage (Vfb) shift for both NMOS and PMOS with NH 3 nitrided oxide under different NH 3 nitridation treatment. Vfb shift is extracted from measured C-V curves and is defined as the Vfb difference between control oxide and NH 3 nitride oxide. Vfb is shift negatively due to the fixed positive charges generation accompany with the incorporated nitrogen. Vfb shift increases with the increase of nitridation time and with the decrease of initial oxide thickness. Longer nitridation time results in larger amount of nitrogen incorporation. The thinner initial oxide makes the nitrogen easily diffuse into and pile up at the Si-oxide interface. Furthermore, PNA shows the large influence on the Vfb shift. Post-nitridation anneals (PNA) in N 2 or NO ambiences are performed to stabilize the film structure, drive the hydrogen out, and minimize the electrical defects. It has been reported that the hydrogen reduction is independent of annealing gas, indicating thermally activated out-diffusion of hydrogen from the film. Hence, both N 2 and NO PNA can effectively reduce the Vfb shift in the NH 3 nitrided oxide, since the positive fixed charges in the films is due to N—H bond at the interface.
[0051] Through NH 3 nitridation treatment, it is worthy to note the flat-band voltage shifts in PMOS are larger than that in NMOS. The similar results have been observed in remote plasma oxynitride and Nitride/Oxide stacks. The following mechanisms are attribute to these phenomena. As proposed by Wu et al., “ The performance and reliability of PMOSFETs with ultrathin silicon nitride/oxide stacked gate dielectrics with nitrided Si—SiO 2 interfaces prepared by remote plasma enhanced CVD and post-deposition rapid thermal annealing,” IEEE Transactions on Electron Devices, vol. 47, NO.7, p.1361-1362, 2000, the larger flat-band voltage shift in PMOS comes from the boron penetration in the oxide device, verifying by the anticipated value of flat-band voltage as calculated from the poly-Si gate and substrate doping concentration in control oxide device. Furthermore, it has been claimed that there is a high density of empty donor-like interface states at the nitride/P+ poly gate interface, resulting in a net positive charge for PMOS.
[0052] The C-V traces of the NH 3 nitrided oxide are shown in FIG. 3. The trace/retrace indicated by the arrows show negligible amount of hysteresis in C-V curves. No hysteresis implies little amount of bulk traps was contained in the nitrided oxide. The limited of traps is probably contributed to the post-deposition annealing on the thin film, which effectively reduces excess Si atoms and H-related species, such as Si—H bonds in the nitrided film. In general, the dominant current in conventional CVD nitride is the Frenkel-Poole (F-P) conduction mechanism due to a high density of traps and is very sensitive to temperature variation. As the insert of FIG. 3 shows, NH 3 nitrided oxide shows week temperature dependence. This indicates the face that the dominant conduction mechanism in NH 3 nitrided oxide is tunneling and also verifies a relatively low density of traps in the bulk.
[0053] [0053]FIG. 4 and FIG. 5 show the measured gate leakage current density (Jg) in inversion region as a function of equivalent oxide thickness (EOT) for NH3 nitrided PMOS and NMOS respectively. The gate leakage currents are compared at normalized voltages ∥V g −V threshold |=1V, which can normalize the differences in V fb ( and thus threshold voltage) among the various gate dielectric recipes. As the nitridation time increases, the Jg of PMOS is profoundly raised in contrast to the slightly change in NMOS. In the case of 1.5 nm oxide with longer nitridation, the Jg in PMOS is even larger than that in NMOS. This means that the nitrided oxide's scaling limit for excessive tunneling leakage current may be faster attended in PMOS, which is opposite to the observation for conventional oxide. Although the Jg increases during NH 3 nitridation treatment, the advantages of the EOT decrease still more than offset the Jg increase. Comparing to conventional oxide with identical EOT, nitrided oxide exhibits larger physical thickness thus ends in superior behavior in gate leakage. One order magnitude of leakage current reduction can be obtained through NH 3 nitridation treatment.
[0054] In an effort to interpret the different Jg behavior between NMOS and PMOS, the direct tunneling models are applied. The gate current in the inversion region is predominately due to the direct tunneling from the inversion layer to the gate electrode and is supplied by source and drain. As illustrated in the insert of FIG. 4 and FIG. 5, hole (or electron) tunneling form the valence (or conduction) bands in the channel of PMOS (or NMOS) dominants the gate leakage current. It has been reported that the tunneling probability is qualitatively related to the area of the tunneling barrier. The barrier heights of oxynitride decrease monotonically with increasing nitrogen concentration. Increasing NH 3 nitridaton time results in lower barrier height but the physical thickness is not affected, so that the gate leakage current is increased with the increasing nitridation time.
[0055] Furthermore, the barrier heights in valence band (Φv) and in conduction band (Φ c ) of MOS with Si 3 N 4 gate dielectric are 1.9 eV and 2.1 eV respectively. Thus, during NH 3 nitridation on oxide, (Φv) will be dramatically decreased from 4.5 toward 1.9 eV while (Φ c ) only slightly decreased form 3.1 toward 2.1 eV. The amount of barrier height lowing depends on the nitridation duration. The decreasing degree of (Φv) is significantly larger than (Φ c ) The significant lowering of (Φv) leads to the increasing of the hole tunneling probability for PMOS profoundly.
[0056] It is interesting that the Jg in NMOS didn't increase with the NH 3 nitridation time.
[0057] As Hanyang Yang et al. “The effects of interfacial sub-oxide transition regions and monolayer level nitridation on tunneling currents in silicon devices,” IEEE Electron Device Letter , vol. 21, no.2, p. 76-78, 2000, reported that the interface nitridation can modify the band structure at interfacial sub-oxide transition region to reduce tunneling probability. NH 3 nitridation causes nitrogen pile-up at the interface, hence, this band modification effect probably offsets the slightly conduction band lowering in NMOS, thus no Jg increase in NMOS during NH 3 nitridation. In PMOS, however, the significant (Φv) lowering dominates the Jg, resulting in larger gate leakage increasing in PMOS than in NMOS while increase nitridation time.
[0058] The mobility behaviors of oxynitride have been well investigated for decades, where the lowering of the low field peak mobility is attributed to an increase in the scattering rate due to the present of nitrogen. And as Hori et al.“Improved transconductance under high normal field in MOSFET's with ultrathin nitrided oxides,” IEEE Transactions on Electron Devices, vol. 10, p.195, 1989 hypothesized that the nitrogen incorporation at the interface reduces the acceptor interfacial states above the conduction band while increasing the donor interfacial states below the valence band. This contributes to the improvement of electron high filed mobility and the deterioration of hole high filed mobility. Similar phenomena can be observed in transconductance (Gm) characteristics of NH 3 nitrided oxide in linear region. The improvement in NMOS and the degradation in PMOS become more obvious in saturation region, as demonstrated in FIG. 5.
[0059] [0059]FIG. 6 shows the normalized drain current drivability for NH 3 nitrided oxides compared to control oxides. Drain currents are determined from long channel devices (W/L=10/0.5 μm) to avoid the short channel effects and the uncertainties in source/drain series resistance. Drain currents are measured at |Vg−Vth|=|1V| in inversion ( operating condition for 0.1 μm process ), and normalized with electrical thickness. For transistors with ultrathin gate dielectrics, the gate electrical fields are quit large under operating condition. This indicates that the operating drain current is dominated by the high field mobility. Comparing to control oxide devices, as illustrated in the FIG. 6, NMOS's with NH 3 nitrided oxides show remarkable improvements for current drivability. NH 3 nitridation results in an increase in driving current over control oxide, however, longer nitridation times end in smaller amount of improvement. For 4 minutes nitridation, current drivability is even inferior to control oxide. Hence, too severe nitridation should be avoided to preserve superior drivability. In case of PMOS, driving current in NH 3 nitrided device is lower than control oxide due to an increase in donor interfacial states below the valence band. The driving current is observed to decrease with increasing nitridation time and with decreasing initial oxide thickness. This drivability deterioration is more progressive in PMOS than in NMOS.
[0060] Fortunately, drivability degradation can be significantly improved by post-nitridation annealing, as FIG. 6 shown. In case of 15.5 A ° initial oxide with 4 minutes nitridation, unacceptable drivability degradation (21%) in PMOS can be relieved to 11% by N 2 PNA and to 7% by NO PNA. In NMOS, slightly degradation (2%) can be eliminated and turns to 5-6% improvement by PNA. Obviously, 2 minutes nitridation with N2 or NO PNA can be chose as the optimized receipt to meet acceptable driveability degradation (5%) for 0.1 μm CMOS process notes. Also, it is worth to note that NO PNA shows higher efficiency than N 2 PNA in improving driving current. That is because NO PNA not only stabilizes the film, drives out the hydrogen but also reoxidize the substrate/oxide interface. However, this oxidization causes the film thickness to increase.
[0061] [0061]FIG. 7 illustrates the normalized drain current drivability under different NH 3 nitridation recipes. Significant drivability improvement is obtained in NMOS. The drivability degradation can be largely relieved by PNA.
[0062] [0062]FIG. 8 shows the time to breakdown characteristics of ultrathin NH 3 nitrided oxide. For ultra-thin oxide reliability evaluation, because of the occurrence of so-called soft breakdown modes, the definition of oxide breakdown events becomes questionable. In addition, significantly larger direct tunneling currents can complicated the definition of oxide breakdown. Furthermore, for oxides less than 5 nm in ballistic FN tunneling and direct tunneling regimes, the constant voltage stress should be used rather than constant current stress . Oxide breakdown in this work is taken strictly to be the first sudden change in stress current under constant voltage stress. As FIG. 8 shows, both under substrate and gate injection, NH 3 nitrided oxide shows quite good reliability characteristics. Projected gate voltage for 10 year lifetime of NH 3 nitrided oxide is as high as 1.7-1.9 V, which is much higher than the operating voltage for 0.1 μm process (1 V). This guarantees the reliability properties of NH 3 nitrided oxide for 0.1 μm notes. | A method of making a semiconductor device having a silicon dioxide based gate with improved dielectric properties including providing a silicon based substrate having active areas defined therein. Thermally growing a silicon dioxide based gate from the silicon based substrate. Nitriding the silicon dioxide based gate to provide a nitrided silicon dioxide based gate and to increase the dielectric constant of the silicon dioxide based gate without substantially increasing thickness of the silicon dioxide based gate. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a 371 of PCT/IB2014/060434, filed Apr. 4, 2014, which claims the benefit of Italian Patent Application No. FI2013A000084, filed Apr. 16, 2013.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a casement window with controlled opening and possibility of locking the hung sash in open position, so as to avoid the accidental closing thereof. It also encompasses a mounting kit for realizing such a window.
BACKGROUND OF THE INVENTION
This type of casings is commonly used for the aeration of environments and it is associated, on the inner part, to nets or mosquito nets. Considering the frequent use in multi-storey buildings, such as skyscrapers, these casings are subject to constraining safety requirements. In particular, it is required that the hung sash opens in a controlled manner (i.e. it is not subject to abrupt opening due, for example, to sudden wind blows) and that it has a limited displacement angle away from the fixed frame (so as to not allow people to lean out therefrom). In addition, it is required that, once at maximum opening position, the hung sash is permanently locked, so that it cannot close accidentally (again, for example, due to sudden wind blows).
Some examples of window casings like the one described above are known. International patent publication WO2011/036639 discloses a casing which provides a fixed frame and a hung sash which opens with respect to it. The casing can be opened by means of a handle, whose first rotation determines the unlocking of the hung sash, while a second and subsequent rotation determines the opening displacement thereof. The hung sash is connected to the fixed frame by means of articulation devices which allow for the hung sash to have a roto-translation movement with respect to the fixed frame. Further in detail, the devices allow for a roto-translation along top and lower crosspieces of, respectively, the hung sash and the fixed frame, about a vertical axis so that—in the opening position—the hung sash becomes spaced apart from the fixed frame also at the jamb closest to the articulation devices, towards the outside of the room in which the casing is mounted.
The opening and the locking of the hung sash in open position is assisted by a driving arm connected to the handle by means of a kinematic pair made up of a variable pitch rack and by a relative pinion, also of the variable pitch type. The pinion and rack engagement, not only permits the controlled opening of the hung sash but it also prevents for an accidental movement of the arm when completely open (thus preventing the inadvertent locking of the hung sash).
The casing as described has a complex construction, hence is quite expensive in terms of manufacturing. Besides, the structural complexity makes the casing poorly adaptable to be used with conventional and standard solutions such as for example rotational hinges of the traditional kind. Moreover, the opening system applied to the casing of WO2011/036639 is not adapted to be used on very heavy casings; indeed, the articulation devices used in such casing have a limited load capacity and the number thereof cannot be increased (with the aim of distributing the load) when the weight to be supported increases.
Further examples are known from patents CN101131061 and U.S. Pat. No. 7,464,619. In both documents, devices for the manual opening of a hung sash are described, comprising a manoeuvre lever which uses, for driving the movement of the hung sash, a gear mechanism which prevents the accidental closing of the hung sash from the opening position.
Also document GB2183723 describes an opening system which makes use of a gear mechanism of the pinion/rack type. The latter is connected to a crank handle which, under the manual actuation of a user, drives the gear mechanism for the actuation of a pantograph linkage which opens the window.
Further examples of similar known devices are disclosed by German publications DE1708449 and DE681093.
Generally speaking, all the aforementioned further examples are in turn structurally complex and expensive from a productive point of view. The actuation is troublesome and uncomfortable for the user, in comparison with a conventional window, i.e. a window having a traditional opening using a handle which, besides to being more comfortable to grip and easy to use, it would be more appreciated by the user also from an aesthetical standpoint.
SUMMARY OF THE INVENTION
Thus, an object of the present invention is to overcome the drawbacks shown by the currently known casings. In particular, an object of the present invention is to provide a device for the opening and/or the closing of a casing in a casement window, and casing itself, that can be cost-effectively produced and has a simple construction, namely making use of components that are standard and easy to find on the market.
More generally, an object of the present invention is to provide a casement of the above mentioned type, representing an effective construction alternative to what is currently known.
These and other objects are attained by casing according to the invention, whose essential features are defined by the attached independent claim. Further important characteristics are defined by the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics and advantages of the casing according to the present invention shall become apparent from the description that follows of an embodiment thereof provided by way of non-limiting example with reference to the attached drawings wherein:
FIG. 1 shows, in a perspective and isolated view, a casing according to the invention with a hung sash in maximum opening position;
FIG. 2 shows in isolation means for locking/unlocking the hung sash with respect to the fixed frame;
FIG. 2 a is an enlarged view of a detail of the locking/unlocking means of FIG. 2 while the FIG. 2 b is an exploded view of FIG. 2 a;
FIG. 3 shows a cross section (i.e. according to a plane parallel to the ground surface, when the casing is mounted) of the casing of the previous figures, the casing in this case being mounted on a wall, again with the hung sash in maximum opening position;
FIG. 3 a is an enlargement of an end of an opening arm connected to the hung sash by means of a spherical coupling, shown in sectional view;
FIG. 3 b is an enlargement of a detail of the FIG. 3 , representing however with a cut-away view of parts that were not sectioned in FIG. 3 , so as to better show means for opening/closing the hung sash and in particular the connection thereof to the fixed frame;
FIG. 4 shows in longitudinal section (i.e. with respect to a plane perpendicular to the ground surface, with the casing in the mounted arrangement), the casing with hung sash in the closing position; in addition, the aforementioned locking/unlocking means can be observed operatively connected to the opening/closing means of the hung sash;
FIG. 5 is a front view (with a covering element omitted for the sake of greater clarity) of the aforementioned opening/closing means of the casing operatively connected to the aforementioned opening arm, the latter being represented in the position corresponding to the closed hung sash;
FIG. 6 shows the opening/closing means and the opening arm of FIG. 5 in an opening step of the hung sash;
FIG. 7 shows the opening/closing means and the opening arm in the position corresponding to the hung sash completely open, with the arm arranged horizontally (i.e. parallel to the ground surface);
FIG. 8 is an exploded view of the opening/closing means of the hung sash in which a covering element omitted in the previous figures is also visible;
FIG. 9 shows a variant of the casing having in this case two groups of the aforementioned opening/closing means, as well as a respective number of opening arms; and
FIG. 10 represents in isolation the means for locking/unlocking the hung sash of FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
In the present description, for the sake of clarity, the terms “vertical” and “horizontal” refer to the ground surface and hence to a typical working configuration of the casing mounted on a wall raising from the ground in which the hung sash opens with respect to the fixed frame according to a rotation movement around an axis perpendicular to the ground surface. The development in height of the hung sash corresponds to a direction referred to as “longitudinal”, while the width development corresponds to a “transversal” direction. Similarly, also the terms “lower” and “upper” are used with reference to the ground surface, for indicating elements which are, respectively, closer thereto or more distant therefrom. However, these indications are not to be considered limitative, being it clear that the casing according to the invention can have different spatial orientations (e.g. the one of a yawn window).
More in detail, with reference to the aforementioned figure, the casing according to the invention comprises a fixed frame 1 adapted to be mounted in an aperture formed in a wall (for example the perimeter wall of a building) to which a hung sash 2 is pivotly connected by means of hinges 3 of the known type. The hinges 3 allow the rotation of the hung sash 2 about an axis X defined by the hinges and perpendicular to the ground surface, when the casing is in use.
In particular, the fixed frame 1 is defined by hollow profiles (usually aluminium, but also wood, plastic, etc) mounted to form a rectangular framework, with sides parallel two by two. Two crosspieces are arranged horizontally, one of which 10 a is at the top and one 10 b at a lower side and two jambs arranged vertically of which a first jamb 11 a and a second jamb 11 b . The first jamb 11 a is the one along which a hinging of the hung sash 2 is obtained by means of the hinges 3 about the axis X, while the second jamb 11 b is the one along which the locking and the opening of the hung sash is obtained. The second jamb 11 b runs according to a longitudinal axis X′ which is clearly parallel with X.
Similarly, also the hung sash 2 is obtained by profiles which define two horizontal crosspieces, one 20 a at the top and one 20 b at the lower part respectively, and two vertical uprights, of which a first upright 21 a is the one for connection with the hinges 3 , and a second upright 21 b which is the one along which the locking and the opening of the hung sash 2 is obtained.
On the second jamb 11 b of the fixed frame a lateral face 110 b is also identified which, when the casing is in a closed arrangement, becomes side by side with a respective lateral face 210 b of the second upright of the hung sash 2 .
A handle 4 is mounted on an inner face 111 b of the second jamb 11 b (i.e. the face towards the indoor room of the environment in which the casing is mounted). Starting from a closed arrangement of the casing, (as explained more in detail hereafter), the handle allows first for the unlocking of the hung sash with respect to the frame, and then the opening thereof.
The handle 4 is operatively connected to a control rod 5 which on the second jamb 11 b is slidably placed on the lateral face 110 b so as to slide along the longitudinal axis X′. In fact, on the lateral face 110 b a longitudinal groove 110 b ′ is formed which runs over the entire length of the jamb and in which sliders 50 a are slidably engaged, the sliders having, for such purpose, suitable ribs complementary with the groove. Each slider is integral with the rod 5 so as to obtain the slidable connection between the jamb and the rod. The fixing between the sliders and the rod is obtained by means of respective protrusions 500 a which penetrate suitable holes formed at mutually opposite ends of the rod so as to project beyond a front face of the rod. A spring locking system of the known type (thus not described in detail) prevents the protrusions from disengaging from the respective holes. In order to obtain the locking of the hung sash in the closed position, the two protrusions 500 a become engaged with respective retaining members 5 b fixed on the second upright 21 b of the movable hung sash, and in particular on the lateral face 210 b thereof.
In the closed casing configuration the rod 5 is in a locking position i.e. in a position such that each protrusion 500 a is engaged with the corresponding retaining member 5 b . Due to such engagement, the hung sash is prevented from opening. To a rotation of the handle of 90° responds a translation according to the axis of the rod 5 upwards, until an unlocking position is reached, i.e. a position of disengagement of each protrusions 500 a from the respective retaining member 5 b , thus allowing the opening of the hung sash.
Particular reference shall be made now to figures from 4 to 8 . Means 6 for opening/closing the hung sash are operatively linked with the rod 5 . Such means are in turn operatively connected to an arm 7 capable, through a rotational movement, of driving the opening or closing of the hung sash in a controlled manner. To this purpose, the arm 7 is slidably connected at its mutually opposite ends thereof respectively to the aforementioned opening/closing means 6 and to the hung sash 2 .
In further detail, the opening/closing means 6 comprise a fixed element 8 fixed to the second jamb 11 b . This fixed element is locked in the longitudinal groove 110 b ′, projecting with respect to the lateral face 110 b; hence, on the rod 3 an aperture 50 for the passage and the housing of the fixed element is also formed. Moreover, the fixed element supports a pin 80 to which the arm 7 , and in particular a first or lower end 70 thereof, is pivotally connected.
Besides to the fixed element 8 , the opening/closing means 6 comprise a movable element 9 slidable on the fixed element 8 and integral with the rod 5 (so as to be driven thereby in a translation with respect to the fixed element). The movable element 9 is precisely engaged, without clearances, in the aperture 50 by means of coupling teeth 90 a , 90 b.
Besides being engaged with the fixed element, the lower end 70 of the arm, is linked with the movable element. In particular, on the movable element 9 a slot 91 is formed having a vertical or longitudinal 91 a straight segment arranged parallel to the axis X′ and thus according to the sliding direction of the rod 5 . From at least one of the ends of the vertical straight segment, at least one horizontal diverging segment 91 b extends, preferably a straight or transversal segment (thus arranged orthogonally with respect to the axis X′) which is joined with the longitudinal straight segment via a bend 91 c . In the described example there are two transversal straight segments, so that the slot is C-shaped, with the concavity facing towards the inside of the room environment and thus opposite with respect to the opening side of the hung sash.
A peg 71 of the arm is slidably and rotatably engaged in the slot 91 . The peg projects from the arm 7 at the lower end 70 thereof, in proximity and beneath the pin 80 . With reference to FIG. 6 , the slot 91 and the pin 80 are at positions that are both transversely and longitudinally staggered or misaligned with respect to each other.
The above is sufficient to understand the basing casing operation, which is detailed as follows. With reference to FIG. 5 , in the closed casing arrangement the rod 5 is completely lowered so that the protrusions 500 a are engaged in the respective retaining members 5 b . Furthermore, in such position the movable element 9 (and in particular an upper coupling tooth 90 a ) abuts on a top shoulder 81 of the fixed element 8 . The arm 7 in the closing configuration is instead in a substantially vertical rest position i.e. arranged parallel with respect to the axis X′.
Starting from such closed arrangement of the casing, in order to open the hung sash 2 , a user must firstly rotate the handle 4 by 90°. Such first rotation causes a first translation of the rod 5 upwards and the unlocking of the hung sash 2 as mentioned above. At the same time, the upwards translation of the rod 5 drives the movable element 9 with respect to the fixed element 8 causing the sliding of the slot 91 with respect to the peg 71 over the entire length of the vertical straight segment 91 a . During this movement the arm is still stationary in the rest position.
A second rotation of the handle 4 by further 90° produces the further translation of the rod 5 (and hence of the movable element 9 ) beyond the unlocking position until an abutment of the peg 71 on the bend 91 c is reached. In this way, the arm 7 starts rotating around the pin 80 (as shown in FIG. 6 ) driving the controlled opening of the hung sash 2 .
The translation of the rod 5 and the simultaneous rotation of the arm 7 causes the sliding of the peg 71 within the horizontal straight segment 91 b up to the end thereof, corresponding to a stop of the run. In such a position ( FIG. 7 ), corresponding to that of maximum opening of the hung sash 2 , the arm is arranged crosswise with respect to the axis X′, in particular as in this embodiment in a horizontal configuration or orthogonal with X′, and the movable element 9 (and in particular a lower coupling tooth 90 b ) abuts on a lower shoulder 82 of the fixed element 8 .
The positioning of the peg 71 at the end stop and the abutment of the movable element on the lower shoulder of the fixed element leads to a rigid locking of the hung sash 2 in the maximum opening position so as to efficiently prevent the accidental closure of the hung sash. In addition, being the handle is provided with snap locks of the known type, the rod 5 is prevented from moving inadvertently, with further contribution to the stable positioning of the hung sash 2 .
The aperture 50 formed in the rod 5 has a longitudinal extension suitable to allow for the entire translation run of the rod (corresponding to all the 180° of rotation of the handle 4 ), without the same rod interfering with the fixed element 8 .
Closing the hung sash requires rotating the handle in the reverse direction; thus, the rod 5 shall slide in the opposite direction, i.e. downwards, firstly causing the reverse rotation of the arm 7 from the horizontal position up to the vertical position with simultaneous drive of controlled closing of the hung sash 2 . Secondly, the further downward sliding of the rod causes the engagement of the protrusions 500 a in the respective retaining members, leading to the locking of the hung sash in the closing position.
This clarified, a more detailed overview of the construction solutions in connection with some aspects of the invention will now be provided, also and particularly with reference to FIG. 8 . The fixed element 8 comprises a substantially rectangular plate-like body 8 a with two opposite main faces. Feet 8 b for the stable resting of the element in the groove 110 b ′, and a parallelepiped-shaped projection 8 c adapted to slidably engage with the movable element 9 extend from either main face of the fixed element. Aside the projection 8 c , on the body 8 a , holes 8 d are formed for allowing the introduction of screws 12 coupling the element 8 to the jamb. According to a preferred embodiment, the screws are engaged with elongated, cam shaped counter-plates 8 e . The counter plates assist a stable positioning of the fixed element 8 in the aforementioned groove 110 b ′ of the jamb of the fixed frame; indeed, as observable also from FIG. 3 b , by fastening the screws on the counter-plates, these rotate in the space left free between the feet 8 b , becoming arranged crosswise in the groove so as to come in abutment with lips 110 b ″ which partially shut the aperture of the groove. As the counter-plates 8 e become tightened on the lips 110 b ″, a stable mounting of the fixed element 8 is attained.
On a flat surface of the projection 8 c , a hole 81 c is formed for the insertion of the pin 80 . The parallelepiped-shaped projection 8 c also has step-like grooves 80 c on the sides.
The movable element 9 is in turn substantially rectangular-shaped and plate-like, with greater dimensions with respect to the fixed element. On the movable element 9 , with the aforementioned slot 91 , a strip-like channel 92 is formed running in a vertical direction. At the long sides of the channel 92 , ribs 92 a project towards the inside of the same, for matching with the step-like grooves 80 c (when, clearly, the movable and the fixed element are mutually coupled). The mutual locking between the movable element and the fixed element is obtained through a plate 13 which is held in an abutment position above the ribs 92 a by the pin 80 and in particular by an enlarged portion 80 b thereof. In this way, the plate 13 forms, with the step-like grooves 80 c , a guide system within which the ribs 92 a are free to slide, in response to the movement of the rod 5 .
The pin 80 has a stem 80 a on which the enlarged portion 80 b is obtained eccentrically with respect to the same stem. The stem 80 a has a length sufficient to penetrate the hole 81 c of the fixed element, thus allowing for a stable locking of the pin 80 . The enlarged portion is instead disk-shaped with a spheroidal peripheral surface 800 b . As apparent from the drawing, the arm 7 is engaged on the enlarged portion 80 b and in particular around its spheroidal peripheral surface 800 b . The engagement between the arm and the spheroidal peripheral surface is indeed akin to a ball joint. Such a kind of engagement is also carried out on a second end 72 of the arm 7 , which is connected to the second upright 21 b of the hung sash 2 by means of a clasp 21 with spheroidal head 22 . As mentioned, the relevant end of the arm 7 is slidably linked with the hung sash, and to this purpose the clasp 21 is free to slide inside a groove 21 c suitably obtained along the second upright, so as to assist the movement of opening or closing of the sash.
As a consequence, the arm 7 shall be free to adapt to the movement of opening of the hung sash 2 , thus also being able to move in misalignment with respect to the axis of the pin 80 defined by the stem 80 a , as shown in FIG. 4 .
The head of the pin 80 provides for a slot 80 d for the introduction of an adjustment instrument such as an Allen wrench (not shown). In this way, the pin can be rotated to vary the positioning of the enlarged portion, hence adjusting the position of the arm in the vertical rest configuration and allowing for the recovery of any machining clearances or positioning errors.
The movable element 9 is protected by a covering member 14 mounted thereon by means of threaded means such as screws 15 . Besides protecting the opening/closing means against infiltration of dirt or moisture, such member also serves an aesthetic function. The covering member 14 has—on a face intended to abut with the movable element 9 —a C-shaped slot (not visible in the figures) analogous to the slot 91 so that the peg 71 , during actuation, is moved within and constrained by both slots. This allows reducing the wear of the contact surfaces.
Finally, according to a preferred solution that is obvious as such, the arm is obtained as two segments connected to each other ( FIG. 8 ).
The casing according to the invention reaches all the aforementioned objects. In particular, it can be surely noted that all the components that serve to the drive of the hung sash can in this case be arranged without requiring heavy and/or complex interventions on the profiles which define the fixed frame and hung sash. Indeed, all the components can be fixed to the profiles by means of simple threaded elements, thus with considerably savings in terms of manufacturing costs and times. This result is specially due to the particular ball joint-like constraint system between the arm 7 and the fixed element 8 of the means 6 for opening/closing the hung sash.
In addition, the casing uses absolutely conventional and traditional rotation hinges, with high reduction of production costs. The use of such hinges also allows for the casing according to the invention to be used for applications which require large dimensions and thus high load, given that the number of hinges may be multiplied up to attaining a number of hinges suitable to sustain the weight of the hung sash.
A casing with rightwards opening has been described. However, for inverting the opening direction (i.e. leftwards), it will be sufficient to invert the direction of rotation of the arm, overturning it. It is also clear that the invention encompasses the device when provided in a mounting kit intended for realizing a casing as described and including at least the means 5 for locking or unlocking the hung sash 2 , at least one arm 7 and the opening or closing means 6 .
Casings with a plurality of opening/closing means, and thus two or more arms can also be provided. For example, FIG. 10 shows a casing with two opening arms controlled by respective groups of the aforementioned opening/locking means. It is obvious that the rod 5 shall have a suitable number of apertures 50 , as shown in FIG. 11 . This variant is particularly suitable in case of windows of great dimensions and high weight, for opposing to the wind action, which may cause the hung sash to suffer a warp. In addition, further points for locking the hung sash can also be applied, possibly at a central position, by adding retaining members 5 b and protrusions 500 a.
The present invention has been described with reference to the preferred embodiments. It should be understood that there can be other embodiments falling within the same inventive concept, as defined by the scope of protection of the following claims. | The present invention regards a casement window, and more in particular it is directed to a casement window with controlled opening and the possibility of locking the hung sash in open position, to prevent the inadvertent return of the hung sash. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a device for feeding and adjusting a continuous web and for cutting it into portions, and in particular a web on which is printed a plurality of motifs which have to be centred precisely and always identically on each portion which is cut.
In order to obtain good constant centering of the printed motif on each portion, an adjustment operation has to be carried out before the cutting operation.
In this respect, it is well known that the distance between the centres of printed motifs on a continuous web is not exactly constant for various reasons deriving from the actual printing process, from the variation in the tension to which the web is subjected during its unwinding, and from variations in ambient conditions which can cause it to contract or elongate.
For these reasons, when a web printed on one or both of its faces has to be divided into portions, each cutting operation is of necessity preceded by an operation in which the position of the printed motif is checked, which is followed if necessary by an adjustment operation. By means of these operations, portions are obtained which, although they may not be of precisely constant length, carry on their surface printed motifs which are perfectly centred.
For this purpose, according to the known art, reference marks (colour marks, holes, slots) are provided on the continuous web during its printing and at the same distance apart as the printed motifs, such as to correspond with each length which is to constitute an individual portion. The checking and adjustment operation is therefore carried out using these marks for reference purposes.
Some of the known devices therefore comprise means for feeding the web, constituted by rollers which are driven intermittently to unwind, during each cycle, a length of web which is approximately equal to but greater than the length of one portion. As the reference mark passes through its reading zone, a photoelectric cell provides a signal. If this signal is in synchronism with a second signal generated by a cyclic machine cam in fixed phase relationship with the periodic cutting means, this signifies that it is not necessary to adjust the web before the cutting operation. If said signals do not coincide, then an adjustment operation is necessary.
In these known devices, because of the fact that the cyclic feed is excessive by an amount greater than any variation in the distance between the reference marks, a phase displacement between the two signals occurs after a certain number of cycles starting from a condition of perfect adjustment, and more precisely the photoelectric cell reading signal occurs before the signal provided by the cyclic machine cam. At this point, there is automatic energisation of an electromagnet, which, by way for example of deviation rollers over which the web runs, resets the adjustment by dragging the length of web lying between the cutting device and photoelectric cell through a predetermined fixed distance in the direction opposite the direction in which the web runs.
This system, which is based on the condition of having centering errors always of the same sign, and which can thus be corrected by a simple electromagnet, has however the drawback of limited accuracy. In practice, there is continuous oscillation of the effective cutting line about its ideal position, thus always determining a certain centering error, even though minimal, for each portion.
In addition, in devices of the described type, the adjustment errors must be detected in proximity to the cutting line, and preferably not more than one pitch upstream of the cutting means. If not, then because of the pitch variations between one motif and the next, and thus between the reference marks, any adjustment operation which is carried out a certain number of pitches or portions upstream of the cutting means can give rise to an incorrect centering of the printed motifs on the individual portions. In other words, under such operating conditions, the known described device detects a centering error relative to a certain reference mark but makes its correction relative to a reference mark which is different from the former.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a device for feeding and adjusting a continuous web and for cutting it into portions, which overcomes the drawback of limited accuracy of known devices, and is thus able not only to detect adjustment or centering errors, but is also able to quantify such errors and to correct them for each individual portion.
A further object of the present invention is to provide a device for feeding and adjusting a continuous web and for cutting it into portions, which is able to take account of the pitch variations between one motif and another, i.e. a device in which means for detecting the reference marks can be fitted according to requirements or according to space availability in any position along the path of the continuous web.
Further objects and advantages of the device according to the present invention will be apparent from the description given hereinafter.
The present invention therefore provides a device for feeding and adjusting a continuous web and for cutting it into portions, said portions to be cut in a predetermined zone on said web, said device comprising means for periodically cutting in accordance with operational cycles which correspond to the formation of a portion of said web, means for feeding said web to said cutting means, and means for detecting at least one reference mark for said zone on said web, comprising first means for checking the position of said predetermined cutting zone relative to a cutting zone consequent on the action of said cutting means and to quantify any diversity between said two zones, and second means for controlling and correcting said any diversity relative to each portion cutting operation, arranged to directly or indirectly receive signals from said first means as a function of said any diversity, and to act on said feed means and/or said cutting means in order to eliminate said any diversity relative to each portion cutting operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more apparent from the description given hereinafter by way of non-limiting example of one embodiment thereof with reference to the accompanying drawings, in which:
FIG. 1 is an indicative plan view of a continuous web to be cut into portions by the device of the present invention;
FIG. 2 is a partly sectional indicative side view of the continuous web with the web cutting means and feed means;
FIG. 3 is a block diagram of the device according to the present invention;
FIGS. 4 and 6 are detailed representations of two circuit blocks of FIG. 3; and
FIGS. 5 and 7 are indicative representations of some signals present at points in the schematic diagrams of FIGS. 4 and 6 respectively.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 1 and 2, the reference numeral 1 indicates a continuous web which is to be cut into portions 2, 2 I , 2 II , 2 III , 2 IV , . . . , by periodic cutting means 3 of known type constituted by two rotating knives disposed on the two faces of the web 1 (FIG. 2). The web 1 is fed towards the cutting means 3 by feed means 4 of known type, constituted by two drive rollers disposed on the two faces of the web 1. On each portion 2, 2 I , 2 II , 2 III , 2 IV of the web 1 motifs (not shown) are printed, and reference marks 5 are provided in known manner for detection as they pass into a zone 6, by detection means 7 of known type for example in the form of a photoelectric cell device. In FIG. 1, the reference numeral 9 indicates the predetermined zones on the web 1 in which the portions must be cut in order for their printed motifs to be centred on them. These cutting zones 9 are in a defined position with respect to the reference marks 5.
In FIG. 1, the differences in pitch between the various reference marks of the various portions have been exaggerated for purposes of example.
Again in FIG. 1, the reference numerals 10 indicate the cutting zones which would arise as a consequence of the formation of a first cutting zone 11 if no adjustment operation was carried out on the various successive portions. In the illustrated example of the device according to the present invention, the rotational speed of the periodic cutting means 3 is assumed constant, and said cutting zones 10 are therefore equally spaced along the web 1 (assuming that the length fed for each cycle by the feed means 4 is constant).
With reference to FIG. 3, the reference numeral 12 indicates a machine shaft, of known type, which is able both to rotate the cutting means 3 and to drive all the various mobile members of a machine with the required motion ratios. This machine can be a machine of known type, for example a cigarette packaging machine. To the shaft 12 there is coupled a device 13 of known type, able to feed to a processing block 14 signals 15 which have a frequency and phase which are related to the speed and phase of rotation of the shaft 12. In particular, the device 13 can comprise toothed discs coupled to the shaft 12, and detector devices of photoelectric, magnetic or other type. The device 13 is able to determine the speed, direction and phase of rotation of the shaft 12 by way of said means. The processing block 14 comprises three output terminals 16, 17 and 18, at which a first, a second and a third signal are present respectively.
The first signal, at the terminal 16, is an activation signal constituted by a two level logic signal, which is a function of two phases of the operating cycle corresponding to the formation of a portion, namely a first phase relative to the checking of the cut and a second phase relative to any required correction. This first phase is substantially centred, with a range of about 120°, about the moment of cutting by said means 3, whereas the second phase is complementary to said first phase within an arc of 360° of the rotation of said cutting means 3. At the terminal 17 a second signal is present which is repeated periodically at each operating cycle for the formation of a portion, and substantially coincides with the moment of cutting by said means 3. The third signal, at the terminal 18, is a pulse signal the frequency of which is a function of the speed of rotation of said cutting means 3, and serves to quantify the cutting error as is explained hereinafter. The third signal therefore comprises a predetermined number of equally spaced pulses for each complete revolution of the cutting means 3. The number of these pulses can for example be 200. The frequency of the third signal is therefore related to the speed of rotation of the shaft 12, and the phases of said first and second signal are related to the phase of rotation of the shaft 12 which rotates the cutting means 3, and are therefore related to the phase (angular position) of the cutting means 3.
The terminal 16 is connected both to a terminal 21 of a first block 22 and to a terminal 23 of a second block 24. The terminal 17 is connected to a terminal 25 of the block 22, and the terminal 18 is connected both to a terminal 26 of the block 22 and to a terminal 27 of the block 24. The output of the detection means 7 is connected to a terminal 28 of the block 22.
With reference to FIG. 4, which shows the first block 22 in detail, the terminal 25 is connected, by way of a block 31 which provides a rectangular output signal corresponding to the rising front of a signal at its input, to a first input of a double input NAND gate 32, belonging to a block 33 in the form of a priority logic circuit.
The terminal 28 is connected by way of a block 34 similar to the block 31, to an input of another double input NAND gate 35 also belonging to the block 33. The terminal 21 is connected to the other input both of the gate 32 and of the gate 35, and, by way of a block 36 similar to the block 31, to a zeroing input 37 of an increasing binary counter 38. The outputs of the two gates 32 and 35 are fed respectively to two inputs of two NAND gates 40 and 41 and to the two inputs of a NAND gate 42, the output of which is fed to the input of a frequency divider block 43 formed from a J-K flip-flop, the output of which is fed to an activation input 44 of the counter 38. The output of the NAND gate 41 is connected to the other input of the NAND gate 40, the output of which is connected both to the other input of the NAND gate 41, and to an output terminal 45 of the block 33. The terminal 26 is also connected to the input of the counter 38, from which there are four outputs 46 which supply logic signals representative of a number in binary code.
With reference to FIG. 3, the outputs 46 and terminal 45 are connected to inputs 80 and 81 of a block 82 comprising shift registers and to inputs, 47 and 48 respectively, of a block 49 which calculates the algebraic difference between signals which arrive as an absolute value and sign at the inputs 47 and 48 respectively and at inputs 50 and 51 which are connected to the outputs of the block 82, corresponding to the inputs 80 and 81 respectively. The block 49 therefore provides this difference between the two input signals in the form of a value and sign at outputs 52 and 53 respectively, which are fed to a block 54 similar to the block 82 and comprising shift registers, its outputs, for the corresponding input data, being fed to inputs 55 and 56 of a block 57 similar to the block 54, and also being fed, by way of a further block 58 similar to the blocks 57 and 54, respectively to inputs 60 of a decreasing binary counter 61 and to an input 62 of a control circuit 63 of known type, for controlling a stepper motor 64 (see FIG. 6). The terminal 23 is connected, by way of a block 66 similar to the blocks 31, 34 and 36 of FIG. 4, to the activation input 65 of the counter 61 belonging to the block 24, and the terminal 27 is connected both to the input 67 of the counter 61 and to an input of a double input NAND gate 68. The outputs of the counter 61 are connected to the input of an OR gate 69, the output of which is connected to the other input of the gate 68. The output of the gate 68 is fed to a further input 70 of the control circuit 63. The mechanical output of the stepper motor 64 (see FIG. 3) is fed to a mechanical differential 71, to which is also fed the mechanical output of a main motor 72 preferably connected to the shaft 12, and the output of the differential 71 is used to rotate the feed means 4.
The operation of the device described by the present invention is as follows.
With reference to FIG. 1, it will be assumed that the cutting means 3 have made a cut in the cutting zone 11 indicated by the continuous line. Consequently, in the case of the portion 2 III on which the detection means 7 detect the reference mark 5, if there were no variation in the speed of the cutting means and feed means 4, there would be a cutting zone 10 which was different from the predetermined cutting zone 9.
The device of the present invention operates in such a manner as to annul this difference in order to cause the cutting zone 10 to coincide with the cutting zone 9, i.e. with the cut on that portion, when the portion 2 is moved into the position shown. In this respect, with reference to FIGS. 3, 4 and 5, at time t o , the activation signal for the cutting check stage (signal C; stage from t o to t 3 ) produces, by way of the block 36, a signal G which zeros the counter 38. When at time t 1 the reference mark 5 reaches the detection means 7, a signal arises which is fed from the output of the block 34 (signal A) to the block 33 to provide an output signal D (at logic level 0 in the case considered) which is present at the terminal 45, and which indicates that the signal A has reached the block 33 before the signal B. The signal B is obtained from the block 31 at time t 2 , as the cutting zone 10 passes into the zone 6. The output of block 43 (signal E) is consequently at logic level 1 between times t 1 and t 2 , and over this time interval it therefore activates the counter 38 so that it counts the number of pulses (signal F) which reach it from the terminal 26. This number of pulses appears at the outputs 46 as a number in binary code, and is fed, both in terms of its absolute value and sign, from the outputs 46 and terminal 45 to the inputs 47 and 48 of the block 49 and to the inputs 80 and 81 of the block 82 respectively. This number of pulses, in combination with the sign, therefore quantifies the difference between the position of the predetermined cutting zone 9 and the cutting zone 10 consequent on the operation of the cutting means 3. The signals present at the inputs 47 and 48 which quantify the error between the cutting zones 9 and 10, assuming that the signals at the inputs 50 and 51 are zero, i.e. that the cutting zones 9 and 10 calculated on the preceding portion coincide, are fed to three successive blocks 54, 57 and 58 which delay them each by one portion cutting cycle. After three delay cycles, i.e. when the portion 2 III has been moved into a position corresponding with the portion 2, the signal C generates the signal H by way of block 66 at time t 3 of that cycle (FIGS. 6 and 7), i.e. at the commencement of the correction stage defined by the signal C, and this allows the pulses (signal F) present at the terminal 27 to be loaded into the counter 61. These pulses are loaded until the total number of pulses defined in binary code by the signals present at the inputs 60 is reached, so that at the output of the gate 69 there is a signal (signal L) which activates the gate 68. The signal L is of logic level 1 during the time interval t 3 -t 4 , defined by a number of pulses equal to the number lying in the interval t 1 -t 2 , and this therefore allows a corresponding number of pulses (signal M) to be fed to the input 70 of the control circuit 63. The control circuit 63 causes the position of the stepper motor 64 to vary as a function of the number of pulses received at the input 70 and of the signal at the input 62 which determines the direction, and this, by way of the differential 71, varies the rotational speed of the feed means 4 by an amount corresponding to the difference detected for the portion 2 III between the cutting zones 9 and 10, and by varying the feed speed of the web 1 in the section preceding the cutting of the portion by the cutting means 3, this difference is annulled so making the cutting zones 9 and 10 coincide. In this manner, with the device according to the present invention, there is the advantage of quantifying the difference between the cutting zones 9 and 10 for each portion, and eliminating this difference for each portion cutting operation. Moreover, the detection means 7 can be disposed at a considerable distance upstream of the cutting means 3, with the assurance that the exact correction necessary for each portion cutting operation will always be obtained. This is attained by means of a corresponding number of shift registers similar to the blocks 54, 57 and 58.
Furthermore, as the error quantification is made by way of the pulses which reach the terminals 26 and 27, any difference in the rotational speed of the cutting means 3 between the time when the reference mark 5 is detected and the cutting of the portion some cycles afterwards has no influence, in that although there is a difference between the respective time intervals t 1 -t 2 and t 3 -t 4 , the number of pulses lying within these two intervals is always identical. The accuracy of the correction made is also a function of the number of pulses contained within one correction interval, and is therefore greater the higher the pulse frequency. The effective correction accuracy which can be obtained is also a function of the number of steps of the stepper motor 64.
As can be seen from FIG. 3, the block 49 takes the difference between the detected error signals for two successive portions, so that if these two portions have the same difference, both in terms of absolute value and sign, between the cutting zones 9 and 10, no variation in the stepper motor 64 takes place between the first and second portion. In this respect, if for example it is assumed that for the portion 2 the difference between the cutting zones 9 and 10 corresponds to 10 pulses within the interval t 1 -t 2 , and it is assumed that this difference between the cutting zones is also the same for the portion 2 I , there will be identical values at the inputs 50 and 51 corresponding to the difference between the zones 9 and 10 of the portion 2, and at the inputs 47 and 48 corresponding to the zones 9 and 10 of the portion 2 I , so that at the outputs 52 and 53, corresponding to the correction values for the portion 2 I relative to the portion 2, there will be respective values which indicate a zero variation. Thus, if for the portion 2 II the cutting zones 9 and 10 coincide, the successive signals at the outputs 52 and 53 for the portion 2 II will be equal and opposite to those for the portion 2, so as to return the cutting zones 9 and 10 to coincidence.
Finally, it is apparent that modifications can be made to the described embodiment of the device according to the present invention which do not leave the scope of the inventive idea. In particular, instead of keeping the speed of the cutting means 3 constant, and controlling the rotation of the feed means 4 by the differential 71, the opposite could be done, or alternatively both the cutting means 3 and the feed means 4 could be simultaneously controlled. Moreover, the number of blocks 54, 57 and 58 could be different, provided this number is related to the number of portions preceding that on which the reading is made by the detection means 7. Again, the stepper motor 64 could be controlled by the error value for each portion instead of being controlled by the error difference between two successive portions. Finally, said periodic cutting means and/or said feed means for the web could be operated intermittently instead of continuously, so that the pulse signal at the terminal 18 could be a function of the frequency of operation, or more generally of the duration of the operating cycle of said means, rather than of the speed. | A device for feeding, adjusting and cutting a continuous web in predetermined zones to obtain portions is described. The device comprises periodically cutting apparatus, apparatus for feeding the web to said cutting apparatus, and a device for detecting at least one reference mark for the zone on the web. The main characteristic of the device is to comprise first device for checking the position of the predetermined cutting zone relative to a cutting apparatus and to quantify any diversity between the two zones, and second apparatus driven by the first device for controlling and correcting any diversity relative to each portion cutting operation, to act on the feed device and/or on the cutting apparatus in order to eliminate any diversity relative to each portion cutting operation. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a suction spout or nozzle suitable for connection to equipment for drilling carbon-fiber reinforced resin and/or titanium or alluminum plates. The invention is applicable to industrial installations for removing dust by means of suction, in particular, but not exclusively, in the aircraft manufacturing field.
According to the prior art, in order to form holes in plates and parts made of carbon-fiber reinforced resin, the boring machine tools (drills) are associated with drilling templates consisting of plates in which multiple through-openings are formed. These openings define predetermined locations wherein the holes are to be formed through one or more carbon-fiber reinforced resin plates, which may be arranged on top of each other.
In the aircraft construction sector, for example for the construction of large-size structural parts such as stabilizers, on occasions it is required to provide a plurality of holes in plates arranged horizontally, by operating from below. From this position, which is uncomfortable from an ergonomic point of view, the operator is conventionally obliged to operate the drilling from below and at the same time must manually hold a pipe for suction and removal of the dust and chips which are produced by drilling. The presence of a second operator who assists the first operator may be required in order to hold the suction pipe.
SUMMARY OF THE INVENTION
The object of the invention is to overcome the above mentioned drawback, optimizing and making as efficient and as easy as possible the operations of removing the dust and chips resulting from drilling, with a suction system.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the invention will become clear from the following detailed description of an exemplary embodiment thereof with reference to the accompanying drawings provided by way of a non-limiting example, in which:
FIG. 1 is a partially cross-sectioned isometric view, which shows a step of a method for drilling and removing the dust with the suction system, in which a nozzle or magnetic spout system is used;
FIG. 2 is an isometric view of a drilling template in which a suction spout connected to a hose for removal of the dust and chips, resulting from the drilling operation, is applied;
FIG. 3 is a front view of a spout or nozzle according to an embodiment of the invention;
FIG. 4 is a cross-sectional view along the line IV-IV of FIG. 3 ; and
FIG. 5 is a schematic, perspective, partly cut-away view of the spout according to FIGS. 3 and 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Initially referring to FIGS. 1 and 2 , the number 10 designates a drilling template (or drilling jig) in which a plurality of cylindrical through-openings 11 are formed. A cylindrical bushing 12 made of iron or steel is fixed inside each opening 11 and is the seat for a stable and precise drilling device 13 in a position axially aligned with the axis of the bushing 12 and the opening 11 . Two screws 15 are fixed close to each bushing 12 , on the drilling template surface 14 situated on the side where the drilling machine is applied, i.e. on the surface called in this document the “accessible” surface of the template. The screws 15 , which are positioned in a diametrical opposite position respect to the edges of the bushing and project out of the surface 14 , are used to fixed the drilling machine for as long as drilling is performed in the same position of the bushing. Each bushing has a flange 16 , which is on the accessible surface 14 of the drilling template 10 . Both the drilling machine and the drilling template shown in FIGS. 1 and 2 are known in the art and therefore are not described here in greater detail. In the remainder description, only the elements of specific interest for the purposes of implementing the invention will be described. For the design of the parts and elements not shown or described in detail reference may be made to any industrial drilling system of the known type.
The bushings 12 , in addition to acting as seats for the drilling motor, are also used as seats for positioning a suction nozzle 20 which can be connected to a suction apparatus or system (not shown) for removing the chips and dust which are produced during the drilling operation.
In the preferred embodiment, the nozzle 20 has an overall tubular cylindrical shape with a straight axis and includes a terminal portion 21 with a tubular cylindrical wall, which is inserted through the bushing 12 so as to project beyond the opposite surface or side 17 , referred to herein as “non-accessible” side, of the drilling template 10 . Considering the direction of the suction flow of the nozzle, in this context the terminal portion 21 is also called “upstream” portion, while the opposite end portion of the nozzle, denoted by the reference number 22 , is called “downstream” end portion.
In the operating condition, the portion 22 of the nozzle arranged downstream projects beyond the surface 14 (or “accessible” side) of the template. The portion 22 with a tubular cylindrical shape has externally a series of annular fishbone reliefs 23 for connection to a suction tube or hose 18 of the plant suction system ( FIG. 2 ) leading to the fixed suction system (not shown).
Externally, about halfway along its length, the nozzle 20 in the example shown has a flange 24 which projects in a radially external direction and is intended to bear against the accessible surface 14 of the drilling template. The bearing surface of the flange 24 ensures that, in the operating position, the end of the nozzle which projects beyond the non-accessible surface 17 of the template is situated at a suitable distance both from the non-accessible surface 17 of the template and from the facing surface 19 of the plate 30 which is being drilled, in order to suck up in an optimum manner the dust and chips produced by drilling.
The nozzle 20 incorporates a permanent magnet 25 , in this example with an annular shape, which allows the nozzle to be engaged and retained in a stable and removable manner upon the ferromagnetic bushing 12 , in the condition where the flange 24 bears against the outer surface 14 of the drilling template. It will be noted that, when the nozzle is in the assembled condition on the drilling template ( FIG. 1 ), the magnet 25 is in contact with the bushing 12 , in particular with the flange 16 therefore.
In the embodiment shown, the annular magnet 25 is fixed inside a corresponding annular circular groove 26 which is formed in the flange 24 . The locking or retaining action produced by the magnet 25 has the function of both preventing removal of the nozzle from the template in the axial direction (i.e. away from the drilling template) and maintaining the angular orientation of the nozzle in a plane parallel to the main surfaces 14 , 17 of the drilling template. In other words, the magnet 25 keeps the nozzle in the chosen angular position around the axis of the bush. The capacity of the nozzle to assume and maintain a given angular orientation is important for directing the suction flow towards the drilling zone (indicated by A in FIG. 1 ) where the chips and dust to be removed by suction are produced.
A through-opening or through-slot 27 extends over a given angular section or segment of the terminal portion with tubular cylindrical wall 21 , thus defining the preferred radial direction in which suction of the chips and the dust is performed. In the particular embodiment shown, the slot extends as far as the free end of the portion 21 . In order to reduce the noisiness of the suction flow, the contour of the slot is rounded and without corners.
In the preferred embodiment, the nozzle has a visible reference mark, for example a notch or relief 28 (or other mark) situated on the outside of the nozzle, opposite the slot, i.e. in a position axially aligned with the slot 27 . This visible reference mark, shown in FIG. 5 , is located on a part of the nozzle arranged “downstream”, i.e. intended to remain in the environment where the operator is situated and allows the latter to know and if necessary to adjust the angular orientation of the slot and therefore of suction, directing it towards the position of the drilling machine or in any case the zone where drilling is performed. The advantage of this is that that operator does not need to remove every time the nozzle from the drilling template in order to find out exactly the orientation of the suction slot 27 .
In order to apply more easily the nozzle 20 onto the drilling template, the flange 24 has preferably two opposite, smaller-width, lateral segments or zones 29 . In the embodiment shown in the drawings, the smaller-width zones 29 consist of two parallel lateral flattened surfaces lying in planes formed parallel and opposite to the central longitudinal axis x of the nozzle 20 . Owing to the flattened surfaces 29 , the nozzle may be inserted correctly through the bushing 12 , bringing the magnet 25 into contact against the bushing 12 without the flange 24 of the nozzle interfering with the heads of the screws 15 . In other words, it is not required to disassemble before by hand the screws 15 in order to apply the nozzle into the drilling template. As an alternative to the flattened surfaces 29 the flanges 24 may be designed differently, for example with zones radially projecting by a different amount around the nozzle, so as to define flange zones which have a width smaller than the minimum distance between the heads of two screws situated close to the same bush. For example, the opposite smaller-width lateral zones may be defined by opposite curved convex surfaces.
As can be understood, the invention makes advantageous the use of the bushing already provided in the conventional drilling templates in order to receive the boring devices (drilling motor) using them as seats for the suction spouts. Conveniently the ferromagnetic property of the bushings (made of iron or steel or in any case another ferromagnetic material) is exploited in order to retain in a sufficiently stable manner the nozzle on the drilling template, both as regards the distance separating the nozzle from the template and as regards any angular displacements thereof.
Although an example of embodiment has been illustrated in the above detailed description, it should be noted that a large number of variants exist. It may also be understood that the embodiment illustrated constitutes just one example and is not to be regarded as limiting in any way the scope, applicability or configuration. For example, the nozzle may have a slightly inwardly curved shape instead of a shape with a straight axis as in the example illustrated. The drawings and the detailed description provided above, instead, will provide persons skilled in the art with a convenient guide for implementing the invention, it being understood that various modifications may be made to the functions and configuration of the parts described in the example of embodiment, without departing from the scope of the invention as defined in the accompanying claims and their legal equivalents. | A nozzle removes by suction dust and chips from a drilling machine in an industrial plant. The nozzle has a first tubular portion for connection to a suction tube communicating with an opposite second tubular portion with an intake opening. An outer flange extends transversely from an intermediate position between the first and second tubular portions. The intake opening is directed in a lateral direction, parallel to the transverse direction of the flange. A magnetic element is incorporated in the flange. The nozzle can be applied to a drilling template having cylindrical through-openings in which respective bushings made of ferromagnetic material are fixed. When the second tubular portion is inserted through a cylindrical bushing, the magnetic element acts on the bushing, opposing axial and rotational movements of the nozzle. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of allowed U.S. application Ser. No. 13/361,015, filed Jan. 30, 2012, now issued as U.S. Pat. No. 9,101,703, the disclosure of which is incorporated by reference as if fully set forth herein. The aforementioned U.S. application Ser. No. 13/361,015 claims benefit of U.S. Provisional Application 61/457,220.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to a medical appliance, in particular an apparatus for the extracorporeal blood treatment, having a housing including a door, and with a handle mechanism arranged at the door, via which the door can be locked with the housing via a locking mechanism.
2. Description of the Prior Art
Medical appliances, such as apparatuses for the extracorporeal blood treatment, usually have a housing which for cost reasons very often is made of a simple sheet-metal construction. The housing might also be a supporting plastic construction. In particular, it is conceivable that the housing includes a supporting sheet metal construction which is framed with plastic parts. In the housing at least one door generally is provided, which leaves an inspection opening for the service technician. Usually, a corresponding handle for opening the door is arranged at the door.
Apparatuses for the extracorporeal blood treatment are known as so-called acute dialysis machines, which serve for use in intensive care units and for this purpose are designed to be movable on rollers. To move such acute dialysis machine with a weight of approximately 85 kg, the same usually is held by the door handle.
Thus, the door handle has a dual function. On the one hand, it serves the service technician for opening and closing the door and on the other hand it serves the user of the dialysis machine in the hospital as a handle for pushing the entire dialysis machine. While pushing the machine, forces are transmitted from the handle mechanism to the housing.
In some cases of use, the door constitutes the entire housing front and is provided with a circumferential elastic seal which on closing is pressed against the frame of the stationary housing. In doing so, the seal should not be pressed against the frame either too strongly or too weakly. In addition, manufacturing tolerances must be compensated, which are inevitable due to the use of the canted inexpensive sheet-metal construction.
Despite these manufacturing tolerances, the door on the one hand should circumferentially abut in a sealing manner without distortion and on the other hand the handle should not have a noticeable clearance on pushing the dialysis machine. When using known door handles, the seal is deformed in addition when pushing the dialysis machine. The fact that the handle noticeably yields while being pushed by the user provides the entire dialysis machine with a negative quality impression, which should be avoided.
SUMMARY OF THE INVENTION
Accordingly, it is the object of the present invention to provide a medical appliance which includes a door handle which despite a simple construction should feel massive and should not yield on pushing the medical appliance. At the same time it should be possible to open and close the door of the medical appliance via the handle.
In accordance with the invention, this object is solved by a medical appliance having the features described herein. Accordingly, the medical appliance has a housing comprising a door and a handle mechanism arranged at the door, by means of which the door can be locked with the housing via a locking mechanism. At the handle mechanism a part of the locking mechanism is formed in its part protruding into the housing, which cooperates with the other part of the locking mechanism on the side of the housing. It is provided that at the handle mechanism, in its part protruding into the housing, a part of the locking mechanism is formed and that at least one form-fit unit is provided which includes at least one form-fit means and at least one form-fit means counterpart, wherein on locking and/or closing the door that at least one form-fit means at least partly engages in the at least one form-fit means counterpart.
This involves the advantage that a defined positioning of the door with respect to the housing can be achieved. In particular it is advantageous that correct closing thereby can be ensured in a safe and simple way, with a simple construction being possible at the same time.
The housing can be fabricated of a simple sheet-metal construction. The housing might also be a supporting plastic construction. Advantageously, it is conceivable in particular that the housing includes a supporting sheet metal construction which is framed with plastic parts. In an advantageous aspect, the medical appliance can be a dialysis machine, e.g. an acute dialysis machine.
Advantageous aspects of the invention are described in the following detailed description.
It can be provided that at least one form-fit means and/or at least one form-fit means counterpart is arranged at and/or integrally molded and/or attached to the handle mechanism.
It is furthermore conceivable that at least one form-fit means and/or at least one form-fit means counterpart is arranged and/or integrally molded and/or attached on the side of the housing.
In particular, it is advantageously possible that on the side of the housing and on the side of the handle mechanism both at least one form-fit means and at least one form-fit means counterpart are provided. Just as well it is, however, also possible that on the side of the housing the form-fit means is provided and on the side of the handle mechanism the form-fit means counterpart is provided. As a further equally advantageous possibility it is, however, also conceivable that on the side of the handle mechanism the form-fit means is provided and on the side of the housing the form-fit means counterpart is provided.
In addition, it can be provided that the at least one form-fit means and/or at least one form-fit means counterpart is elastically mounted.
It is furthermore possible that the form-fit unit includes a tapered spigot as form-fit means and a conical receptacle as form-fit means counterpart.
It is conceivable that on closing the handle mechanism engages in at least one tapered spigot elastically mounted on the side of the housing via at least one conical receptacle and/or that on closing the handle mechanism engages in at least one conical receptacle on the side of the housing via at least one tapered spigot elastically mounted on the side of the handle mechanism. On closing the door by means of the locking mechanism, the at least one conical receptacle thus advantageously is pretensioned into the at least one tapered spigot elastically mounted on the side of the housing and/or on the side of the handle mechanism such that on pushing the medical appliance the usual thrust forces received by the handle can be transmitted to the housing, without the handle being displaced with respect to the housing. At the same time, the at least one elastically mounted tapered spigot advantageously can compensate the manufacturing tolerances in all directions.
It is furthermore possible that at least one spring means is provided, by means of which the at least one form-fit means can be pretensioned.
Advantageously it can be provided that the spring means is and/or comprises a compression spring, a coil spring and/or a disk spring and/or that the spring means is at least partly formed by elastic regions of the housing.
It is in particular conceivable that the at least one tapered spigot is pretensioned via at least one disk spring. By using the disk springs, the tapered spigots advantageously can elastically be mounted on the housing, more exactly on the housing frame, in a three-dimensional way.
The disk springs can be pretensioned by a desired amount, in order to nevertheless provide for a sufficiently rigid transmission of force from the handle to the housing after closing the door and elastically compensating possible tolerances.
In accordance with a further preferred aspect of the invention a plurality of tapered spigots are arranged in the housing in at least two planes. Preferably, four tapered spigots are present here in two different planes of the housing frames. An alternative configuration can, however, also consist in that in one plane two tapered spigots are present and in a second plane a single tapered spigot is present.
The locking mechanism can include a pivotable hook which cooperates with a tension bolt in a known way for locking and unlocking the door. The pivotable hook can be provided with a latch in the usual way, by means of which the locking mechanism can be opened.
In accordance with one configuration variant the handle mechanism is firmly connected with the door. In another configuration variant the handle mechanism extends through the door in a longitudinally movable manner. In accordance with this configuration variant the handle mechanism includes at least one tension spring which can be tensioned on closing the door.
Due to the spring force of the at least one tension spring a defined compression of a seal arranged between the door and the housing, to be more exact the housing frame, is effected. In accordance with a further preferred aspect the pressing force is designed in dependence on the seal used. In so far, a uniform compression of the seal additionally is ensured by this configuration variant.
It is furthermore conceivable that at least a part of the housing front is formed as door.
In accordance with an advantageous configuration variant the entire housing front is formed as door. The door can be rotatably mounted about its lower edge, as is known for example from a baking oven door, whereas the handle mechanism is arranged on the opposite side of the door, i.e. close to the upper edge.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features, details and advantages of the invention will be explained in detail with reference to an embodiment illustrated in the drawing, in which:
FIG. 1 : shows a sectional representation through a part of the medical appliance in accordance with one configuration variant of the present invention,
FIG. 2 : shows a further sectional representation of the detail of FIG. 1 in an open position,
FIG. 3 : shows the detail representation of the medical appliance of FIG. 2 in a closed, but not yet locked position,
FIG. 4 : shows a perspective, partly sectional representation of the medical appliance corresponding to FIG. 2 in an open position,
FIG. 5 : shows a representation according to FIG. 4 in a closed position, and
FIG. 6 : shows a detail section through another part of the medical appliance.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
The Figures merely show the handle region or closure mechanism of a door 12 closing a housing of a non-illustrated medical appliance. The medical appliance advantageously, but not exclusively, can be an acute dialysis machine, which usually is mounted on rollers, so as to be able to move the same to the respective intensive care bed for use in an intensive care unit.
For this purpose, the entire device is seized by the handle 14 . The handle 14 includes a handle bar 16 which is attached to the free end of a handle web 18 protruding from the door 12 . The handle web 18 extends through the door 12 and is movably mounted in the same, as can be taken in particular from FIG. 1 . In the handle web 18 , a tension bolt 20 is inserted at the free end protruding into the housing 10 , which is part of a locking means 22 .
This locking means 22 substantially includes a pivotable hook 24 which cooperates with the tension bolt 20 and secures the door after correspondingly locking the tension bolt 20 . The construction of the locking means 22 is of the conventional type and can be purchased as a toggle latch for a butt-joint lock. It provides for the hook 24 automatically snapping into the tension bolt on closing the door 12 and for a release of the tension bolt 20 by the hook 24 after correspondingly opening the door by a manipulation not shown here in detail.
Both the entire housing 10 and the door 12 are made of a canted sheet-metal construction. At the upper edge of the door 12 a circumferential seal 26 is provided, which is directed towards the housing 10 .
The seal should rather uniformly rest against the canted supporting edge or frame of the housing 10 .
To ensure a safe and completely closed contact of the seal 26 in the region between the door 12 and the housing 10 , the handle 14 movably mounted in the door 12 in direction of the double arrow A as shown in FIG. 1 can be pretensioned via springs 28 . For closing the door 12 , the handle thus is pressed into the door against the spring force of the springs 28 , until the hook 24 secures the tension bolt 20 . The spring force of the springs 28 is chosen such that a rather uniform pressure is exerted on the door 12 , so that the seal 26 reliably rests on the circumferential edge of the housing 10 and performs its sealing function.
In the embodiment shown here, four tension springs 28 are provided. Thus, on closing the door the door 12 first meets with the circumferential frame of the housing 10 , while the handle 14 continues to move through the lead-through into its locking position and thereby tensions the tension springs 28 . The pressing force of the tension springs should be designed for the defined pressing of the door with the housing frame, each in dependence on the seal used. For a medium-soft seal a pressing force between 150 and 200 N can be chosen. In this way, relatively large manufacturing tolerances which are due to the fabrication of the sheet-metal parts can be compensated.
From FIGS. 2, 3, 4 and 5 it can furthermore be taken that conical receptacles 30 are recessed at the handle web 18 . On closing the door 12 , the same cooperate with corresponding tapered spigots 32 . In the embodiment shown here, the form-fit unit comprises the conical receptacles 30 and the corresponding tapered spigots 32 . The form-fit means are formed by the tapered spigots 32 and the form-fit means counterparts are formed by the conical receptacles 30 .
With reference to FIG. 6 the mode of action of the interlocking conical receptacles 30 and of the tapered spigot 32 can be explained. On its bottom surface the tapered spigot 32 includes a threaded bolt 38 via which it can be put through the frame 36 of the housing 10 and be fixed with a nut 40 . On the opposite side of the frame 36 , disk springs are pushed onto the threaded bolt 38 , which can be pretensioned via the nut 40 . As can furthermore be taken from FIG. 6 , a sufficient radial clearance is present around the threaded bolt 38 in the bore extending through the frame 36 . Due to the pretensioned disk springs via which the threaded bolt 38 supports on the frame 36 of the housing 10 and the radial clearance in the region of the bore, a three-dimensional elastic bearing is ensured, as is indicated by the movement arrows in FIG. 6 .
As can now be taken from FIGS. 2, 3, 4 and 5 , corresponding tapered spigots 32 and conical receptacles 30 are provided at several points of the housing 10 and/or of the handle 14 . In this configuration variant two tapered spigots 32 are arranged in the set-back part of the housing, in which the hook 24 is rotatably mounted. As can clearly be seen in the Figures, the associated conical receptacles 30 are formed in the corresponding region of the handle web 18 , wherein in FIGS. 2 and 4 the conical 30 do not yet sit on the tapered spigots 32 . In FIGS. 3 and 5 , on the other hand, the conical receptacles 30 are already coupled with the tapered spigots 32 elastically mounted on the side of the housing. Two tapered spigots 32 also are coupled with further conical receptacles 30 arranged at the handle web 18 , which are arranged in the outer frame region of the housing 10 and hence are arranged in a different plane than the above-described tapered spigots 32 .
The spring rigidity of the disk springs 34 used in the tapered bolts is designed such that the usual thrust forces on pushing the medical appliance, i.e. in the present example the dialysis machine, cannot lead to noticeable elastic deformations of the disk springs. This results in the haptic feeling of a “massive” and rigid handle 14 and a direct force transmission of the thrust forces to the medical appliance. Furthermore, the three-dimensionally elastically mounted tapered spigots 32 compensate the manufacturing tolerances in all directions. Beside the four tapered spigots 32 illustrated in this configuration variant one embodiment might also consist of only three or two tapered spigots which are arranged on two planes. Correspondingly dimensioned, an embodiment with a single tapered spigot also can already provide the effect in accordance with the invention.
The invention being thus described, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be recognized by one skilled in the art are intended to be included within the scope of the following claims. | A medical appliance, in particular an apparatus for extracorporeal blood treatment, has a housing including a door and with a handle mechanism arranged at the door, via which the door can be locked with the housing via a locking mechanism. A part of the locking mechanism is formed at the handle mechanism in a part thereof that protrudes into the housing. A form-fit unit includes at least one form-fit element and at least one form-fit element counterpart, such that on locking and/or closing the door, the at least one form-fit element at least partly engages in the at least one form-fit element counterpart. | 4 |
BACKGROUND INFORMATION
[0001] Fully-integrated plus and minus output elements having diagnostic functions for ignition circuits on a common substrate are already known. Furthermore, it is known that such an IC can trigger multiple ignition circuits.
SUMMARY OF THE INVENTION
[0002] The device according to the present invention for triggering ignition circuits has the advantage over the related art, that the safety of the device is increased without additional hardware and wiring, because the plus and minus output elements with their associated ignition circuit diagnosis are implemented independently of one another, and the plus and minus output elements for one ignition circuit can be located on two identical integrated circuits that are independent of one another. A separate implementation of plus and minus output elements is therefore possible.
[0003] Furthermore, it is advantageous to have plus and minus output elements present on one substrate, giving the integrated circuit designer the option of choosing the suitable wiring regarding plus and minus output elements for any given ignition circuit, depending on the situation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIG. 1 is a block diagram of the device according to the present invention.
[0005] [0005]FIG. 2 is a diagnostic circuit.
DETAILED DESCRIPTION
[0006] In order to be able to wire ignition circuits with increased safety and without additional outlay, the ignition circuits are provided, according to the present invention, with plus and minus output elements of different ICs and, therefore, substrates. Here, the term substrate designates an IC, which today is made primarily of silicon. However, it is possible to use other semiconductor materials to form a substrate, on which the circuit design can be implemented.
[0007] [0007]FIG. 1 shows a diagram of the device according to the present invention. A processor 1 is connected via data inputs/outputs to substrate 2 and substrate 3 , each of which represents an ignition circuit triggering IC. It is possible for processor 1 to be connected to more than two substrates. Processor 1 controls and monitors the components of ignition circuit ICs 2 and 3 via the data inputs/outputs. Ignition circuit IC 2 has a plus output element transistor 11 , a minus output element transistor 10 , a diagnostic block 5 , and another diagnostic block 4 . In addition, ignition circuit triggering IC 2 is connected to the supply voltage via connector 14 , and to the ground via connector 17 .
[0008] An ignition circuit is supplied by plus and minus output element transistors or, in short, plus and minus output elements, that are switched through when triggered, in order to supply the ignition circuit with ignition current. The plus output element transistor gets its name from the fact that it is connected to the supply voltage, while the minus output element transistor is connected to the ground.
[0009] Ignition circuit IC 3 is built analogously to ignition circuit IC 2 . Ignition circuit IC 3 has a plus output element transistor 8 , a minus output element transistor 9 , and two diagnostic blocks 6 and 7 . Plus output element transistor 8 is connected on one side (here the collector) to the supply voltage at connector 15 . Minus output element transistor 9 is connected to the ground via connector 17 . On the other side, plus output element transistor 8 is connected to ignitor 13 and diagnostic block 6 . Ignitor 13 is located outside of ignition circuit triggering IC 3 . Minus output element transistor 9 is connected on its other side to ignitor 12 and diagnostic block 7 .
[0010] Minus output element transistor 10 is connected, on one side, to the ground at connector 17 , and on the other side, to diagnostic block 4 and ignitor 13 . This places ignitor 13 between plus output element transistor 8 and minus output element transistor 10 , or diagnostic block 6 and diagnostic block 4 .
[0011] Plus output element transistor 11 is connected on one side, as described above, to the supply voltage at connector 14 , and on its other side, with diagnostic block 5 and ignitor 12 , so that ignitor 12 lies between plus output element transistor 11 and minus output element transistor 9 , or between diagnostic block 5 and diagnostic block 7 . The bases, or gates, of transistors 8 , 9 , 10 and 11 are triggered by processor 1 , in order to switch these transistors through accordingly. Transistors 8 , 9 , 10 and 1 1 are switched through in order to fire ignitors 12 and 13 , in case restraining devices are to be deployed. Normally, i.e., when ignitors 12 and 13 are not supposed to be fired, diagnostic blocks 4 , 5 , 6 and 7 perform diagnostic measurements of ignitors 12 and 13 , during which ignitors 12 and 13 are measured for resistances that are either too large or too small. The resistances are measured via voltages that decrease due to diagnostic currents across ignitors 12 and 13 . If the voltages exceed or fall below the given values across ignitors 12 and 13 , there is a malfunction of ignitors 12 and 13 , the functionality of ignitors 12 and 13 is jeopardized and, therefore, also the use of the restraints. This can lead to a warning or disconnection of the restraints.
[0012] [0012]FIG. 2 shows an example of a simple voltage measurement via ignitor 12 . A battery voltage Vbat is applied to an input of a constant current source 18 . Constant current source 18 supplies a constant diagnostic current coming from battery voltage Vbat. Constant current source 18 would thus correspond to diagnostic block 5 or diagnostic block 6 . Constant current source 18 is triggered by processor 1 . Processor 1 can, if need be, disconnect constant current source 18 or switch higher or lower currents in a later version. On one side, the output of constant current source 18 is connected to ignitor 12 , and on the other to a positive input of a comparator 21 . Since comparator 21 has a very high input resistance, all of the diagnostic current flows via ignitor 12 , which is connected on its other side to a constant current sink 19 . It is also possible to simply use a resistor here.
[0013] Constant current sink 19 itself is connected on its other side to the ground and is also controlled by processor 1 . A constant voltage V 1 is applied to a negative input of comparator 21 via voltage source 20 , with which the voltage applied to the positive input of comparator 21 is compared. The shape of output signal 22 depends on whether voltage V 1 is greater or smaller than the voltage at the positive input. This makes it possible to check the resistance via the decreasing voltage at ignitor 12 .
[0014] Constant current source 18 and constant current sink 19 are each made up of current balancing circuits. Ignition circuit ICs 2 and 3 can also have several plus and minus output elements and thus supply several ignition circuits. | A device for triggering ignition circuits is used to increase safety without additional expenditures in the form of hardware or wiring. Plus and minus output elements of various ICs are used for this purpose. Ignition circuit diagnosis is now also distributed over two ICs. Ignition circuit diagnosis includes, in particular, the resistance measurement of the respective ignition circuit. Each substrate, in other words IC, therefore has at least one plus and one minus output element. | 5 |
This is a continuation of application Ser. No. 820,825 filed Aug. 1, 1977, now abandoned.
BACKGROUND OF THE INVENTION
The present invention is generally related to lithographic duplicators and, more particularly, to a versatile system for controlling ink and moisture feed rates during printing.
The production of quality copies by lithographic means requires that the ink and moisture each be supplied at a rate proper for the demands of the lithographic master. It is also necessary that a proper balance be maintained between the ink and moisture at all times. If the amount of ink or moisture, or the balance therebetween, is not maintained within predetermined ranges, noticeable copy degradation will result. For example, excessive moisture or an excessive moisture/ink ratio will reduce the ink transferred, resulting in copies with low optical density image areas. On the other hand, low moisture or excessive ink will cause the image areas to be blurred and may result in background toning.
In general terms, one of the primary problems over the years has been that the ink and moisture requirements for producing quality copies vary significantly with changes in operating and environmental conditions. For example, variations in temperature and humidity will change the amount of moisture required by the master for quality copies. Also, certain plates or masters, both referred to herein generally as "masters" such as those of the zinc oxide type, undergo changes during copy runs which have an effect upon the amount of moisture required. The moisture/ink requirements also may be affected by the presence of additional moisture introduced into the system as new masters are loaded in sequence for relatively short copy runs, wherein each new master is "wet" and adds moisture to the system.
The present invention addresses the specific problem of master condition changes during copy runs. A large volume of modern day lithographic duplicating is done with the use of masters of the paper base type. Such masters are relatively inexpensive compared to metal plates or the like which are intended primarily for long runs or for graphic arts applications. However, one disadvantage of many paper base masters, particularly the ZnO type, is they tend to pick up moisture by absorption, or otherwise, during a course of a copy run. This often resulted in a high moisture condition which adversely affected copy quality unless the moisture feed rate was reduced to a proper level. Thus, it was necessary for an operator to monitor the copy quality and adjust the moisture feed rate during the copy run. The image areas of such masters also tend to become somewhat less oleophilic as moisture is absorbed. Therefore, it was necessary to increase the ink feed rate during the copy run. This required further operator intervention if acceptable copy quality was to be maintained.
It would be desirable to provide a control system which eliminates the necessity for operator assistance to adjust the ink and moisture feed rates when printing with paper base type masters.
Therefore, it is an object of the present invention to provide a unique ink and moisture control system for lithographic duplicators which compensates for changes in master conditions during the course of copy runs.
Another object of the present invention is to provide a novel control system which adjusts the ink and moisture feed rate during a copy run in accordance with predicted changes in master conditions due to moisture absorption or the like.
It is a further object of the present invention to provide a versatile control system with circuit means for adjusting the ink and moisture feed rates as a function of the number of copies which have been made from a particular master in order to compensate for predicted changes in master conditions during the copy run.
SUMMARY OF THE INVENTION
The foregoing and other objectives are achieved in accordance with the present invention by providing input signals to the ink and moisture controls which are generally indicative of the number of copies which have been made during the copy run. These signals gradually reduce the moisture feed rate and increase the ink feed rate during the copy run. The circuitry is initialized or reset each time a new master is inserted at the beginning of a copy run. In addition to compensating for master conditions, the control system may adjust the feed rates in response to other operating and environmental conditions, such as temperature, predicted ink transferability, moisture evaporation, and copy run lengths.
In the preferred embodiment disclosed herein, the charge level on a capacitive circuit is utilized to provide signals indicative of the number of copies which have been made. The resultant signal, referred to herein as the taper compensation, is applied to the ink and moisture control circuits together with various other input signals to appropriately adjust each of the feed rates. These adjustments provide proper ink and moisture to the master for predicted changes in master conditions.
The control circuitry is also provided with feed-back signals from the ink and moisture supply rolls. These signals are utilized to adjust the respective feed rates to maintain such at the proper levels for the existing conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration of the ink/moisture control system of the present invention.
FIG. 2 is a graphical representation of motor temperature and relative ink transferability v. the run/rest time of the duplicator.
FIG. 3 is a graphical representation of changes in V ref of the control circuit v. run/rest time of the duplicator.
FIG. 4 is a graphical representation of changes in the ink and moisture feed rates v. number of copies.
FIG. 5 is a graphical representation of changes in the ink and moisture feed rate v. run/rest time.
FIG. 6 is a block diagram of the ink/moisture control system of the present invention.
FIGS. 7a, 7b, 7c are schematic diagrams of the circuitry associated with the control system of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now, more particularly, to FIG. 1 of the drawings, the control system of the present invention is illustrated in diagrammatic form together with a master cylinder 10 of a lithographic duplicator. A master (not illustrated) is mounted on cylinder 10 for producing copies by well known lithographic processes. A suitable wetting solution, commonly referred to in the art as "moisture", is delivered to the master cylinder from a moisture fountain 12, provided with a fountain roll 14 having a hydrophilic surface. An appropriate fountain drive motor 16 rotates fountain roll 14 at a speed determined by signals from a moisture control 18.
A ductor roll 20 is rotatably mounted to an oscillating arm 22 for movement by a conventional mechanism between fountain roll 14 and a moisture transfer roll 24 having a hydrophylic surface. The transfer roll is in contact with a moisture form roll 26 having an oleophilic surface and which runs in contact with the master on cylinder 10. Preferably, a reciprocating distributor roll 28 is provided, which also has an oleophilic surface, and rides in contact with form roll 26. Reciprocation is achieved by a conventional internal cam mechanism, not illustrated, which effects axial shifting of the distribution roll to level the ink and moisture present on the surface of roll 26. A more detailed description of the moisture rolls and their operation appears in U.S. Pat. No. 4,029,008, issued June 14, 1977, for Moisture Control System, in the name of S. A. Mabrouk and assigned to the assignee of the present invention.
The system is provided with a speed sensor 30 which provides input signals to the moisture control indicative of the rotational speed of transfer roll 24 which, in turn, is indicative of the amount of moisture on the roll. Generally, this is an inverse relationship, but not necessarily linear. In the preferred embodiment, sensor 30 comprises a switch operated upon each revolution of the transfer roll to provide a pulse to the moisture control circuit. Alternately, other types of sensors may be utilized to produce the input signals. If desired, the transfer roll 24 may be mounted for axial oscillation, whereby each oscillation is sensed by a micro switch. Such an arrangement is described in the above listed U.S. patent.
The moisture feed rate control signals to fountain motor 16 are provided by moisture control 18 in accordance with the input signals from sensor 30 and additional signals provided from a main control circuit 32. A detailed description of the main control circuit and the conditions to which it responds are described hereinafter.
The system is also provided with an ink control 33 which provides ink feed rate control signals to an ink supply means, including a ductor solenoid 34 which causes oscillation of a ductor roll 36. The ink is furnished to the system from a fountain 38 including a fountain roll 40 driven at a predetermined speed by an appropriate motive means, not illustrated. A pair of ink form rolls 42 and 44 serve to deliver ink to the master carried on cylinder 10. Ink is delivered to form rolls 42 and 44 by a series of ink transfer rolls 46, 48, 50, 52 and 54. Preferably, transfer roll 54 oscillates or reciprocates axially during rotation to provide a more uniform distribution of the ink to the form rolls. This reciprocal motion may be achieved by well-known cam mechanism or other appropriate means. The surfaces of the transfer and form rolls are ink receptive and, preferably, are of rubber or other elastomeric materials. The geometry and number of rolls illustrated is simplified for the purposes of the description. In actual practice it may be desirable to have more rolls and arrange such a different geometry.
The control system includes an optical sensor 56 which furnishes signals to ink control 33 indicative of the ink film thickness at the nip of rolls 52 and 54. The otpical sensor detects changes in the surface characteristics of the ink on roll 54, which characteristics are indicative of the thickness of the ink. Such a sensor is disclosed in a copending U.S. Pat. application Ser. No. 709,666 for Ink Thickness Control and Method, assigned to the assignee of the present invention. If the ink film thickness increases beyond some predetermined value, determined in part by signals from main control 32, ink control 33 is effective to decrease the ductor oscillation rate and thus decrease the rate at which ink is added to the system. On the other hand, should the ink film thickness fall below some predetermined minimum value, the controls will increase the ductor oscillation rate to increase the ink film thickness to an acceptable level.
It will be appreciated that the thickness of the ink film on roll 54 is indicative of the rate at which ink is being used by the master. Since signals from the sensor 56 are related to the ink film thickness, changes in such signals are also indicative of the changes in the rate at which ink is used by the master. In the preferred embodiment, this is generally an inverse relationship, but not necessarily linear.
Referring to the graphic illustration in FIG. 2, the general relationships of motor temperature and relative ink transferability to operation of the duplicator may be understood. Two curves are illustrated, namely motor temperature and relative ink transferability. The vertical axis is representative of sensed motor temperature for one curve and relative transferability for the other curve. The horizontal axis generally represents the run/rest time of the duplicator for both curves and is expressed in terms of the number of copies and cooling or rest time in minutes. The motor temperature curve, generally indicated by numeral 58, is the result of data obtained from actual test measurements made while a lithographic duplicator was operated at a speed of 9500 copies per hour (cph) and at an ambient temperature of approximately 72° F. Changes in the temperature of the main motor were sensed through a thermistor embedded in the motor housing. The resultant curve rises most rapidly at the beginning of the copy run and increases at a lesser slope as the number of copies increases. When a duplicator is shut down after approximately 5000 copies, at a point indicated at 60, the motor temperature follows a cooling curve indicated by numeral 62 which slowly decreases toward room temperature. If the duplicator is left idle for a long period, say 6-10 hours, the motor temperature will approach or reach room temperature. For the purpose of this description, the cooling curve in FIG. 2 is not illustrated beyond 80 minutes.
It was observed that the transferability characteristics of pseudo-plastic lithographic inks change significantly during initial operation of the duplicator after shutdown for a relatively long period. It is during this stage of operation that it has been most difficult to obtain proper ink/moisture balance with conventional controls. Thus, it was necessary to make "dry runs", during which the operator set up or conditioned the ink and moisture levels. In FIG. 2, the ink transferability curve indicated by numeral 64 is generally representative of changes in relative ink transferability as a function of the ink's work/rest history. This curve is not the result of actual test measurement, but rather is an approximation based upon observations in copy quality and corresponding adjustments in the ink and moisture feed rates necessary to maintain acceptable copy quality. The curve is illustrated for the purpose of understanding the operation of the control of the present invention.
It was observed that when the duplicator was started up "cold" after a long shutdown, say overnight (as is quite common), the copy quality was unsatisfactory in spite of the fact that several conditions explained hereinafter were being monitored by the control, absent the ink transferability compensation circuitry. One of the several conditions monitored included ink temperature, since such is a significant factor in ink viscosity and tack. Thus, temperature has a direct effect upon the ink's transferability characteristics. Curve 64 is intended to be generally representative of changes in transferability attributable to working of the ink rather than attributable directly to the temperature of the ink, although it is recognized that the ink will heat up slightly due to working. The relative ink transferability characteristics are lowest at start up. After approximately 1,000 copies, the transferability improves significantly and approaches a maximum or steady state condition after approximately 1,500 copies. If the duplicator is shut down, say after 5,000 copies as illustrated at 65, the relative transferability gradually decreases as shown by the portion of the curve indicated at 66.
In the tests conducted, the ink and moisture levels were adjusted until acceptable copies were obtained, and corresponding curves were generated empirically which approximate necessary changes in the ink and moisture feed levels to compensate for changes in ink transferability due to working. It will be appreciated that the relative ink transferability curve 64 generally parallels the sensed motor temperature curve 58 within limits, at least during the initial 1,000 copies and again after the duplicator has been shut down for an hour or so. The control circuitry described hereinafter includes means for adjusting the ink and moisture feed rates to compensate for predicted changes in relative ink transferability in accordance with the ink's work/rest history within predetermined time intervals. This is achieved by monitoring the motor temperature and utilizing such as an input to the control circuitry. The input signals are tailored by the circuitry to provide a variable reference signal V ref , which approximates the ideal control signal for adjusting the feed rates to maintain acceptable copy quality.
The ideal and actual control signal curves are illustrated in FIG. 3. The ideal curve is illustrated in broken line and is indicated by numeral 68. It will be appreciated that this curve represents the signal equivalent to the relative transferability curve 64 of FIG. 2. For the sake of simplicity and reduced manufacturing cost, it has been found desirable to provide circuitry, hereinafter described, which approximates the ideal curve 68 by providing a control signal V ref which follows a pair of curves 70 and 72 during warm up of the duplicator with a transition at 74. After shut down, which is indicated at numeral 76, V ref follows curve 78 for several hours of cooling down and is shifted to curve 80 through transition 82. As hereinafter explained, the V ref signals are utilized by the control to effect adjustment of the ink and moisture feed rates to compensate for predicted changes in ink transferability due to the ink's work/rest history.
In addition to compensating for changes in ink transferability, the control adjusts the ink and moisture feed rates to accomodate predicted changes in master conditions. Many masters of the type having "paper" bases tend to become moisture laden during the course of a copy run. The amount of moisture required by such masters decreases somewhat during the run. The exact reasons for this change in moisture demand are not known. However, it is believed that moisture is picked up by the master by absorption, or otherwise, as copies are run and, as such, it is necessary to provide more moisture early in the copy run and taper the moisture off until the occurrence of what is believed to be a saturation condition.
The control of the present invention is provided with a taper compensation circuit which offsets this adverse effect. Curves 84 and 86 are representative of the ink and moisture and feed rate changes which are effected by the taper compensation circuit to maintain proper ink/moisture balance. This circuitry, which is hereinafter described in detail, is tailored to provide control signals to offset predicted adverse conditions encountered with use of a particular type of master. The illustrated curves and the circuitry disclosed herein are the results of data compiled from test runs utilizing ZnO type masters which are sold under the Addressograph Multigraph trademark and identified as type 8-2004. It will be appreciated that the moisture feed rate is gradually decreased while the ink feed rate is increased gradually during the copy run until steady state rates are reached after approximately 1,000 copies. Of course, it is not intended that the present invention be limited to a particular type of master or to the curve illustrated in FIG. 4, as the compensation circuit and associated parameters may be selected to accomodate various types of masters and conditions.
It has been observed that when a lithographic duplicator is shut down momentarily, some of the moisture introduced into the system evaporates to the surrounding atmosphere. This causes a momentary moisture imbalance condition upon restart which adversely affects copy quality. The amount of moisture lost during shutdown depends to a large extent upon the duration of the shutdown, although other factors, such as humidity and temperature also affect the evaporation rate. In order to eliminate the need for operation assistance to obtain the proper balance after such shutdowns, the control of the present invention is provided an evaporation compensation circuit which offsets to a large degree the moisture imbalance normally experienced upon restart. The degree to which the compensation circuit increases the moisture feed rate is related to the duration of the shutdown time within limits. The addition of large amounts of moisture results in erroneous signals from the ink sensor due to a film of water on the ink sensor roll. The circuitry is effective to compensate for this condition and the fact that the ink is drier and more transferable until the predicted imbalance condition has been fully corrected. Since evaporation is not significant when the machine is cold (i.e., below 82° F. motor temperature), the evaporation compensation circuit is in effect inhibited below a predetermined threshold motor temperature and does not influence the ink or moisture feed rates.
Referring to FIG. 5, operation of the moisture evaporation compensation circuit may be generally understood. The percentage change in moisture feed rate is illustrated by curve 88 in FIG. 5. The circuitry also causes a corresponding decrease in the ink feed rate, as illustrated by curve 90 to compensate for transient conditions at the ink sensor and for the fact that the drier ink is more transferable, requiring less ink. These curves and the parameters for the associated circuitry were arrived at empirically as the result of data compiled utilizing type 8-2004 masters.
It will be observed from the curve that under the worst evaporation conditions, normal ink and moisture feed rates are restored within approximately 120 copies after start up. Shutdown of the duplicator is indicated at 92. Curves 94 and 96 indicate the initial moisture compensation provided by the circuitry depending upon the rest or evaporation time. For example, if the duplicator were shut down for 2 minutes, the circuitry would increase the moisture feed rate approximately 12% as indicated at point 98 and follow dash line curve 100. Similarly, the ink feed rate would be reduced approximately 10% as indicated at point 102 and would follow dash line curve 104.
Referring now, more particularly, to FIG. 6 of the drawings, operation of the control system and the circuitry thereof may be more fully understood. As explained above, the moisture control circuit serves to provide moisture feed rate signals to the moisture fountain motor 16. This is achieved through an appropriate drive amplifier circuit 110 and in response to signals received from moisture sensor 30 and from various other control circuits described herein. The ink control 33 also responds to input signals from the various control circuits and to the signals received from ink sensor 56. The ink ductor solenoid 34 is controlled by a drive amplifier 112 which receives control pulses from a voltage-to-frequency converter 114.
Since both the ink and moisture requirements of the duplicator are dependent upon the speed at which the duplicator is operated, signals indicative of the machine speed are provided by an appropriate speed sensor 116. These signals are fed to a Motor Temperature and RPM Reference circuit 118 and have the influence of increasing the ink and moisture feed rates with an increase in machine speed. Input signals are also provided to circuit 118 from temperature sensor 120, which signals are indicative of an operating temperature of the machine and reflect changes in ink transferability due to working of the lithographic ink.
A taper compensation circuit 122 is provided for altering the ink and moisture levels in anticipation of predictable changes in master conditions during a run. After a new master has been inserted at the beginning of a run, signals from compensation circuit 122 serve to gradually decrease the moisture reference level while increasing the ink reference level. As illustrated in FIG. 4, as the number of copies increases in a run, the rate of change of the taper compensation signal descreases. It will be appreciated that the circuitry is tailored to match the type of master and ink being utilized, and the circuit values may be determined empirically by observing copy quality produced under various ink/moisture feed rate conditions.
A short-run compensation circuit 124 is provided for reducing the amount of moisture added to the system in the event of multiple short-runs. It has been found that several consecutive short-runs produces excessive moisture in the system, part of which is introduced with each newly inserted master carrying considerable conversion solution. The short-run compensation circuit in effect keeps track of the length of each run and reduces the moisture reference level under predetermined multiple short-run conditions. This circuit also is effective to increase the ink level under multiple short-run conditions when the machine is below a predetermined operating temperature. Preferably, the effects of this circuit are inhibited by the occurrence of a long copy run which would use up the excess moisture and allow the system to reach a steady state condition.
An evaporation compensation circuit 126 is provided for adjusting the ink and moisture reference levels based upon predicted evaporation of moisture from the machine during short shut-downs. The circuit is effective only when the machine is operating above a predetermined temperature indicative of warm operating conditions. Under such conditions, when the machine is not running, moisture evaporates from the ink/moisture emulsion and the various machine components. This results in a more or less "dry" layer of ink on the ink sensing roll. When a new master is introduced, moisture brought with it tends to lie on top of the ink which has dried on the ink sensing roll. This produces erroneous ink demand condition signals due to the higher than normal reflectivity of the surface moisture detected by the optical sensor. Signals from the compensation circuit 126 are effective to decrease the ink reference level during this transient period. Also, since various rolls and other system components have dried during the shut-down period, signals from this circuit cause a change in the moisture reference level to increase the moisture feed rate.
It has been found that the moisture feed back signals from the transfer roll sensor are not adequate for maintaining proper balance when running high coverage masters. Since such masters require a large amount of ink, the system must respond with a corresponding amount of moisture in order to maintain proper balance at the point of printing. The moisture sensing roll is spaced from the printing location and, as such, the resultant signals only approximate the actual moisture conditions existing at the printing location. When running masters of average coverage, the moisture gradient between the sensing and pringing locations is relatively low, such that the feed back signals closely approximate the actual conditions at the master and adjustments in the moisture feed rate are effective to maintain balance within acceptable limits. However, when running high coverage masters, the moisture demand is much higher, creating a large moisture gradient between the sensing and printing locations. Thus, the moisture feed back signals do not closely approximate the actual moisture conditions at the master. This results in supplying less moisture than the master actually requires.
In order to correct for this deficiency, the control system of the present invention is provided with means for automatically increasing the moisture feed rate to a greater extent than indicated by the moisture feed back signals under high coverage conditions. This is achieved by way of an ink/moisture interface circuit 128, which receives pulses from voltage-to-frequency converter 114 and effects momentary increase in the moisture feed rate through moisture control 18.
When running high coverage masters, the ink feed back circuitry responds to provide a corresponding ink ductor rate. Thus, the ink ductor rate is generally indicative of the coverage requirements of the master. The control of the present invention utilizes this factor to effect a momentary increase in the moisture feed rate each time the ink ductor is pulsed. Since the ductor is pulsed at a greater rate as the master coverage is increased, the amount of moisture added to the system is correspondingly increased to help maintain proper ink/moisture balance.
An ink ambient temperature circuit 130 is provided for furnishing signals to Voltage-to-Frequency Converter 114 which are indicative of the temperature sensed in the vicinity of the ink rolls. These signals are generally representative of the temperature of the ink present on the ink supply rolls. This has been found to be necessary since the ink transferability is dependent to a significant extent upon the temperature of the ink. A pair of flip flops FF1 and FF2 are shown in the block diagram of FIG. 6 to provide logic control to reset or enable the various compensation circuits. The details of such operation and the circuitry are explained hereinafter.
MOISTURE CONTROL
Referring to FIG. 7a, it will be appreciated that rotation of the moisture transfer roll 24 causes operation of switch 30, which produces a pulse for each revolution. This triggers a one-shot circuit 132, producing a pulse of predetermined duration, during which the voltage stored across a capacitor 134 is sampled. The output pulse of one-shot circuit 132 defines a sample period, at the end of which a second one-shot circuit 136 is fired to apply a pulse to the base of transistor 138, causing such to conduct and discharge capacitor 134. At the end of this discharge pulse, the transistor 138 is rendered non-conductive and capacitor 134 will begin recharging through line 140 connected to a voltage source through an adjustable resistor 142. The capacitor will continue to charge for the remainder of the revolution of transfer roll 24.
The output pulse of one-shot circuit 132 is applied to the base of transistor 144, the collector of which is connected to one-shot circuit 136. Transistor 144 is rendered conductive, which inhibits operation of the one-shot circuit 136 during the sample pulse from one-shot circuit 132. The sample pulse also renders transistor 145 conductive, which in turn causes a unijunction transistor 148 to conduct. During this time, the voltage previously built up on capacitor 134 is stored on capacitor 150 through an operational amplifier 152. The voltage stored on capacitor 150 is passed through amplifier 156 to a summing junction 155 where it is combined with the TAP level from the taper compensation circuit to provide a reference level to the negative input of a comparator 154.
COMPENSATION FOR WORK/REST HISTORY COMPONENT OF INK TRANSFERABILITY CONDITION
A combined speed and temperature reference level, denoted as V ref is applied to the positive input of comparator 154. Machine speed input signals, denoted as RPM, are provided from means hereinafter described. These signal are applied to a thermistor 158 which, preferably, is embedded in the motor winding or housing to sense changes in motor temperature during warm-up. It is possible that this thermistor, or an equivalent device, might be mounted at a different location within the duplicator and still provide signals which are indicative of the run-rest history of the machine and thus furnish useful data or information indicative of predicted changes in ink transferability due to working of the ink. As the motor temperature increases, the resistance of the thermistor decreases. The thermistor forms a voltage divider with resistor 160, such that as the motor temperature increases, the V ref level impressed upon the positive input of amplifier 154 increases. This increases the motor drive level MD which increases the speed of the moisture fountain motor, thereby increasing the rate at which moisture is added to the system.
An ink reference level IR is obtained through amplifier 178, the positive input of which is connected to junction 176 and follows V ref . When the machine is cold (i.e. below predetermined warm temperature) the level of IR is such that the ink control circuit responds to increase the ink supply rate. This has been found necessary in order to provide satisfactory copy quality during machine warm-up. It will be appreciated that after the duplicator is shut-down, the ink's transferability decreases with its rest time. The motor temperature sensed by the thermistor 158 is used to provide signals indicative of the rest time of the ink. Thus, when the machine is restarted, the level of V ref , as determined by the thermistor, will approximately adjust the ink and moisture levels to reflect predicted changes in ink transferability due to non-working of the ink during shut-down.
A WARM/COLD temperature circuit is comprised of a comparator 182, the negative input of which is connected to a voltage divider defined in part by resistors 184, 186 and 188. The positive input of comparator 182 is connected to junction 190 which is at the V ref level. The values of resistors 184, 186 and 188 are selected such that when the sensed temperature reaches a predetermined warm level, the output of comparator 182 goes high. As the motor temperature increases further, a clipping diode 192 conducts and clamps V ref and reduces the slope as illustrated in FIG. 3. This will cause an increase in the level of V ref due to diode 194 being rendered non-conductive.
TAPER COMPENSATION FOR MOISTURE
Input signals, denoted as TAP, received from the taper compensation circuit and are applied to the negative input of amplifier 154 through resistor 162 and junction 155. At the beginning of a run, the level of TAP is lowest and, since such is applied to the negative input of the amplifier 128, tends to increase the moisture feed rate. As the run continues, TAP decreases, causing a gradual increase in the moisture feed rate.
RUN-LENGTH COMPENSATION
The multiple short-run compensation circuit includes a storage capacitor 164, which is partially charged by an input pulse MIM through diode 165 after each new master is inserted. The capacitor discharges slowly to ground through a resistor 166. The charge level on capacitor 164 is applied to the positive input of comparator 168, the output of which is fed to a summing junction 170. The time constant defined by capacitor 164 and resistor 166 is such that if a small number of copies is run per master (for example, 25 copies or less) the capacitor will be only partly discharge during that time. When the next master is inserted, the charge on capacitor 164 is increased slightly by another MIM pulse. This occurs for each new master inserted after a short run until the level impressed upon the positive input of the comparator 168 becomes greater than that applied to the negative input, in which event the output goes high. When this is applied to summing junction 170, such has the effect of decreasing the resultant moisture reference level and moisture feed rate.
As mentioned above, operation of the multiple short-run compensation circuit is inhibited upon occurrence of a long run, for example, after a predetermined number of copies has been made from a single master. This inhibit operation is achieved by monitoring the level of the taper compensation signals TAP which are applied to the negative input of comparator 172. The TAP level increases during each run on a new master and such reflects the number of copies which have been made with the master. When TAP reaches a level corresponding to the number of copies defined for a long run, the output of comparator 172 goes low. This causes diode 174 to conduct, thereby discharging the capacitor 164. Thus, any charge build-up on capacitor 164 due to prior short runs is removed upon the occurrence of a long copy run.
Ink reference level signals IR are provided from junction 176 through amplifier 178. It will be appreciated that this level is changed in response to a multiple short-run condition when the machine is cold. Under these conditions, the high output of amplifier 168 renders transistor 180 conductive to ground, thereby reducing the level of IR. When the machine is warm, the output of comparator 182 is high and renders transistor 193 conductive to ground. This inhibits operation of transistor 180 thereby inhibiting change in the IR level due to multiple short runs when the machine is warm.
Preferably, the duplicator includes means for inking and wetting each new master after such has been placed on the master cylinder. Each wetting cycle tends to introduce some moisture to the system in addition to the conversion solution on each master. After this has been completed, the ink blanket roll is inked for several cycles of the machine. This preprint sequence is executed each time a new master is introduced and is necessary in order to prepare the master and duplicator for proper printing. Such pre-print sequences are well-known and in many cases are performed automatically, as is the case with the duplicator of applicant's invention. A detailed description of the pre-print sequence and the associated circuitry and mechansim is felt to be unnecessary for the purposes of this disclosure. However, it should be noted that during the pre-print sequence, the MIM level goes high momentarily to effect charging of capacitor 164 associated with the multi short-run compensation circuit. In addition, transistor 196 conducts to ground thereby decreasing the signal to the negative input of amplifier 154. This increases the moisture feed rate.
INK-MOISTURE INTERFACE
As mentioned above, the ink/moisture interface circuit is effective to increase the moisture supply rate when the ink ductor solenoid is pulsed. Upon each operation of the ductor solenoid, ink/moisture interface signals IMI are fed to an invertor and pulse stretcher generally indicated by the numeral 198. This produces negative pulses of longer duration which are fed to the positive input of amplifier 152 and changes the resultant moisture reference level in a manner which causes the moisture fountain motor to be driven faster during the pulse.
EVAPORATION COMPENSATION FOR MOISTURE
Evaporation compensation signals EVC are provided by the circuitry illustrated in FIG. 7b and are impressed upon junction 170 through resistor 200. At the beginning of a new run when the machine is warm, the level of EVC will tend to increase the moisture feed rate to compensate for moisture which has evaporated during shutdown.
It will be appreciated that the moisture control circuit is disabled when the machine motor is shut down. This is achieved in response to stop/run signal S/R which goes high when the motor is shut down. This causes transistor 202 to conduct to ground, thereby inhibiting passage of the motor drive signals MD. The S/R level is also applied to the base of transistor 138, causing such to conduct to ground to discharge storage capacitor 134 in preparation for recharging when the machine is re-started.
INK CONTROL
Referring now, more particularly to FIG. 7b, operation of the ink control and associated components may be more fully understood. Preferably, the ink sensor is comprised of a pair of optical detectors, generally indicated by the numeral 56, which receive radiation reflected from the ink surface on sensing roll 54. Generally, these signals are inversely related to the ink film thickness. A more detailed description of the optical sensor arrangement is disclosed in co-pending application, Ser. No. 709,666, incorporated herein by reference. The sensitivity setting of the optical sensor may be adjusted by way of a potentiometer 204. A resistor 206, together with a capacitor 208, define an RC filter which passes signals from the optical sensor to the positive input of an operational amplifier 210. An ink level potentiometer 212 is connected to the negative input of amplifier 210 through a resistor 214. In effect, the setting of potentiometer 212 determines the gain of amplifier 210.
A comparator 216 compares the output of amplifier 210 with the ink reference level IR. As mentioned above relative to FIG. 6, the IR level follows V ref and is indicative of the sensed motor temperature, and thus, the run/rest history of the duplicator within predetermined limits. When the duplicator is cold, such as occurs with a morning start-up, IR is relatively low and tends to drive the output of comparator 216 low. The actual output of the comparator of course, also depends upon the optical sensor signals furnished through amplifier 210. When the output of comparator 216 is high, such is indicative of a condition requiring a faster ink feed rate. The output of comparator 216 is passed by diode 218 to an RC delay circuit defined by capacitor 220 and resistor 222. The delayed signals are applied to the base of a transistor 224 associated with the voltage-to-frequency converter. A transistor 226 provides a charging current to capacitor 228 through a diode 230. When transistor 224 is conductive, at least part of the current from transistor 226 passes to the collector of transitor 224 through diode 232. Thus, transistor 224 controls the charging rate of capacitor 228, bypassing a portion of the charging current to ground through a thermistor 234 and resistor 236.
Thermistor 234 is mounted in the duplicator at a location in the vicinity of the ink carrying rolls and, as such, its resistance is indicative generally of the temperature of the ink on the rolls. The indication given by this thermistor is representative of a temperature value referred to herein as the "ink ambient temperature" which is close enough to serve as a practical measure of the temperature of the ink on the rolls. It has been found that this enhances the operation of the control considerably since the transferability of the ink is dependent to a significant extent upon ink temperature, as well as working. When the sensed ink ambient temperature increases, the resistance value of thermistor 234 decreases, thereby causing more of the charging current to flow to ground, reducing the charge rate of capacitor 228 and decreasing the ink feed rate. Charging current is also provided by a one-shot circuit 238 which produces positive pulses of predetermined width to capacitor 228 through a diode 240. Each master cylinder revolution, switch 242 produces a negative going pulse which is differentiated by circuit 243 and triggers one-shot 238.
When capacitor 228 reaches a predetermined charge level, a uni-junction transistor 244 generates a trigger pulse which is applied to the base of transistor 246 through resistor 248. The trigger pulse renders transistor 246 conductive. This produces an inverted pulse at the collector of transistor 246 causing diode 250 to conduct. This pulls junction 252 low, together with line 254 connected to the negative input of comparator 256. The RPM reference level is applied to the positive input of comparator 256 and is inversely related to the machine speed, as hereinafter described.
When the charge on capacitor 228 reaches the level necessary to fire uni-junction transistor 244, such is indicative of a condition requiring the addition of ink to the system. In most cases this will be the result of signals from the ink sensor. However, when running very low coverage masters, charging of the capacitor 228 will be caused solely by pulses from one-shot 238. This assures that ink is always added to the system after a predetermined number of copies (say 50 copies) has been run. It has been found that this aids in maintaining the ink/moisture balance under low coverage conditions. This results in a negative going pulse applied to the negative input of comparator 256, producing a positive output pulse ID which is fed to the ink drive circuit for pulsing the ductor solenoid. A corresponding negative going pulse is provided at the output of amplifier 258 to define the ink/moisture interface signal IMI, which momentarily increases the moisture feed rate.
When the machine is not printing, the PRINT level is low. This causes transistor 259 to conduct to ground, thereby inhibiting operation of the ink ductor until the machine goes to the PRINT condition. The RPM reference signal is produced as a result of the output pulses from one-shot circuit 238. These pulses are inverted by amplifier 260, and applied to the positive input of amplifier 262 through RC integration circuit 264. The output of amplifier 262 defines the RPM reference level which is applied to the positive input of amplifier 256 and provided to the moisture control circuit shown in FIG. 7a.
TAPER AND EVAPORATION COMPENSATION FOR INK
The output pulses from one-shot circuit 238 are also fed to the evaporation compensation circuit through resistor 266 and diode 268. These pulses incrementally charge capacitor 270, the level of which is applied to the positive input of amplifier 272. When the machine is shut off, capacitor 270 discharges slowly through a resistor 274. In the preferred embodiment the time constant is approximately five minutes. The discharge corresponds to the predicted moisture evaporation which occurs while the machine is shut down. Upon restart, the reduced charge level on capacitor 270 effects the corresponding level of evaporation compensation signal EVC. As mentioned above, the evaporation compensation circuit is effective only when the machine is warm, or in other words, when the W/C is high.
The taper compensation circuit which adjusts the feed rates for changes in master condition receives pulses from one-shot 238 through the diode 276 which normally charges a capacitor 278. The charge level impressed upon the positive input of amplifier 280, the output of which provides the taper compensation signal TAP. This is applied to a summing junction 282 together with EVC from amplifier 272 and the result applied to the negative input of amplifier 216 to adjust the ink level accordingly.
When the machine is shut down, S/R goes high, causing transistor 284 to conduct, which sets FF1 and resets FF2. After the machine is restarted and a new master is inserted, the output of FF1 remains high and FF2 goes high. This renders transistors 286 and 288 conductive during the inking and wetting pre-print cycles. Under these conditions, the previous charge on capacitor 270 is retained, while any charge present on capacitor 278 is removed. However, if the machine is cold, W/C will reset FF1 during the pre-print cycles. This renders transistor 286 non-conductive and capacitor 270 is allowed to become fully charged during the pre-print sequence. This neutralizes the effect of the evaporation compensation circuit when printing is begun.
After the pre-print sequence is completed, and copying begun, the print signal goes low, resetting FF2 to render transistor 288 non-conductive. FF1 is also reset if such has not already been done by W/C. At this point in time, if the machine is warm, the charge level remaining on capacitor 270 is indicative of the time interval during which the machine was shut down and representative of the moisture loss due to evaporation. As copies are run, the charge level on both capacitors is incrementally increased to gradually reduce the effects of both the taper and evaporation compensation circuits.
POWER SUPPLY
Referring to FIG. 7c, the power supply associated with present invention may be understood. A full wave rectifier generally indicated by the numeral 290 provides 24VDC, which is applied across a filter capacitor 292. A Zener diode 294 is connected between ground and 24VDC through resistor 296. The Zenner diode is also connected to the base of a power transistor 298, which together with capacitors 300 and 302 provide a regulated 14VDC source.
The moisture drive circuit, generally indicated by the numeral 304, receives MD signals which are applied to the base of transistor 306. These signals are amplified through transistor 308, which in turn drives power transistor 310 to furnish drive signals to the moisture fountain motor.
The ink drive circuit, generally indicated by the numeral 312, receives ID signals which are applied to the base of power transistor 314. When ID goes high, transistor 314 conducts to ground and energizes the ink ductor solenoid.
The stop/run signal S/R is provided by a 14VDC source connected to line 316 through resistor 318. When the machine is shut down and the main motor is not energized S/R is high. When the main motor is energized through appropriate switching means, not illustrated, a light emitting diode 320 causes this photo transistor 322 to conduct, which pulls line 316 and S/R low. Under these conditions, transistor 324 is rendered non-conductive, causing power transistor 326 to conduct to complete the circuit to the moisture ductor. An RC circuit 327 is provided which delays start of the moisture ducting operation. This allows wetting of the ductor which is held in contact with the fountain roll during shutdown. It will be appreciated that moisture ductor is provided with appropriate mechanism, not illustrated, which controls the ductor rate while the machine is running. When the main motor is de-energized, S/R goes high, causing transistor 324 to conduct, which turns off power transistor 326 to de-energize the moisture ductor circuit | A lithographic ink and moisture control system is provided for maintaining copy quality over a wide range of operating and environmental conditions without special operator assistance. The control system, among other things, adjusts the ink and moisture feed rates to compensate for predicted changes in master conditions associated with the absorption of moisture by the master during the course of a copy run. | 1 |
BACKGROUND AND SUMMARY OF THE INVENTION
This is a division of application Ser. No. 08/336,141 filed Nov. 8, 1994; which is a continuation of Ser. No. 07/894,501 filed Jun. 4, 1992, now abandoned.
This application relates to the discovery that mesophase pitch containing quinoline insoluble materials can be converted to a solvated mesophase pitch suitable for producing carbon fibers and carbon artifacts. Solvated mesophase pitch which has a substantial quinoline insoluble content can be prepared from feedstocks which are mesophase pitch in part or in total and which contain quinoline insoluble materials. Certain advantages are achieved with solvated mesophase pitch obtained by this process including the ability to use otherwise undesirable feed stocks in the solvent extraction process to produce a solvated mesophase pitch, and the ability to produce a mesophase pitch which, when solvated, melts at a temperature suitable for spinning into fibers or forming other structures but, when dried (non-solvated), will not melt on heating to temperatures suitable for carbonization.
STATEMENT OF THE ART
It has long been known that mesophase pitch can be used to produce carbon fibers and carbon artifacts having excellent mechanical properties. The mesophase pitch used to make these items is commonly obtained by converting isotropic pitch to anisotropic (mesophase) pitch. The conversion process involves either a thermal or catalytic growth step to form large mesophase-forming molecules (mesogens) from an isotropic pitch or aromatic feed, and an isolation step to concentrate the mesogens in a mesophase pitch. The isolation of the mesophase pitch may be accomplished by settling, sparging the pitch with an inert gas to remove unwanted materials, or by extracting the unwanted materials with a solvent.
Fibers and other artifacts are formed from the resulting mesophase pitch by extrusion of molten mesophase pitch through a spinnerette or by molding techniques. The pitch is then converted to a non-meltable form, typically by oxidative stabilization. The stabilized pitch is then converted to carbon by prolonged heating at temperatures in the range of from 500° to 2000° C. in an inert or largely inert atmosphere. If higher performance properties are desired, the carbonized items may then be graphitized by additional prolonged heating at temperatures above 2000° C. in an inert or largely inert atmosphere.
There is a great amount of art on improved processes for making a preferred mesophase pitch for forming into useful artifacts. One frequent measure of mesophase pitch quality is the quinoline insolubles (QI) content. High optical anisotropy (OA) combined with low QI is taught to be preferred.
It is generally recognized that QI and OA tend to be formed together in processes that form mesogens. High OA is desired to form highly structured mesophase artifacts. High QI, on the other hand, is associated with excessively high spinning temperatures, plugging of spinning equipment and strength-limiting defects in fibers. In practice, it is often necessary to accept only moderate OA development in order to limit QI when making a mesophase pitch. This is especially true when making thermal mesogens.
As a consequence of the desire to hold the QI content of mesophase pitch low, much inventive effort has been expended in devising ways of limiting or removing quinoline insoluble materials in mesophase pitch. Also, as a result of the desire to limit the QI content of mesophase pitch, the choice of feedstocks is naturally reduced to those feedstocks having a low QI content.
One especially novel approach to making a low QI mesophase pitch was the disclosure in U.S. Pat. No. 4,208,267 that certain isotropic pitches contain mesophase-formers (mesogens) that can be isolated by extraction. The isotropic pitch feeds for extraction are selected from among low QI mesogen containing materials. The extracted pitch products contain greater than 75% OA and less than 25% QI.
In PCT Appln. 91/09290 solvent/pitch systems were disclosed that form a heavy solvent insoluble phase which contains, or which itself is, mesophase pitch in a solvated form. The solvated mesophase is disclosed as a new type of mesophase pitch consisting of solvent dissolved in a heavy aromatic pitch. Solvated mesophase is distinguished from other pitches because it is substantially anisotropic and melts at least 40° C. lower than the melting temperature of the heavy aromatic pitch when it is not solvated. Appln. 91/09290 teaches that the presence of quinoline insolubles in the solvated mesophase pitch is undesirable and that the quinoline insoluble content is controlled by preparing the solvated mesophase pitch from isotropic pitch which is also low in quinoline insoluble materials. This is consistent with the art teaching that QI components are not soluble in extracted mesophase pitch or in extraction systems and therefore would tend to clog processing equipment and form weak points in the finished product.
However, the inventor has found that mesophase pitch feedstocks having even a substantial quinoline insoluble content can be advantageously used to make solvated mesophase especially suitable for making carbon fibers and artifacts. The process of this invention has several advantages, including the ability to utilize feedstocks which are otherwise unsuitable for extraction. By the method of the invention, mesophase pitches and mesophase containing pitches, including those containing substantial amounts of QI, can be extracted to yield homogenous, spinnable solvated mesophase. Therefore, many of the mesophase pitches referred to in the art as unusable because of their high QI content can be used to make carbon artifacts by the process of this invention. Also, the invention permits spinning of QI mesogens in their solvated state at a temperature below their melting temperature when in their non-solvated state. Once stripped of solvent, the melting temperature of the mesophase pitch is dramatically increased thus permitting the artifacts to retain their structural stability during carbonization.
DETAILED DESCRIPTION OF THE INVENTION
Although the art places all QI materials into a single category, the inventor finds it is necessary to distinguish some quinoline insoluble materials found in mesophase pitch from other quinoline insoluble materials. In the present invention, foreign object QI (catalyst fines, metal filings, etc.) and certain naturally occurring QI (coke particles, carbon black particles, etc.) are considered to be detrimental to the mesophase pitch and to products made therefrom. These materials generally are referred to by the inventor as "bad QI". The naturally occurring QI which is characterized as a high melting point or no melting point organic material which is insoluble in quinoline, but soluble in the mesophase pitch itself is desirable in the mesophase pitch. This material is referred to by the inventor as "good QI", or preferably, "MSQI", for mesophase soluble quinoline insolubles. MSQI is a desirable component of mesophase pitch. Specifically, the inventor has found that the presence of certain materials in mesophase pitch, i.e. those materials found in mesophase pitch which are characterized as having a high melting temperature, or are non-melting, organic materials naturally occurring in mesophase pitch which are both insoluble in quinoline and soluble in the mesophase pitch itself are desirable components of mesophase pitch and provide advantages over a mesophase pitch which is free of these components.
In spite of the teachings of the art the inventor discovered that mesophase pitches, even those pitches which contain substantial amounts of quinoline insolubles, can successfully be used as feed stock for making solvated mesophase pitches suitable for making carbon fibers and carbon artifacts. The resulting mesophase pitch, when solvent is removed, has a high melting point, or may be unmeltable, which permits the formation of fibers and artifacts which are structurally stable when heated to effect carbonization and do not always require the application of oxidative stabilization techniques. As a result of this invention feedstocks which heretofore had been rejected because of their quinoline insolubles content or high melting temperature may now be successfully used to produce extracted solvated mesophasa pitch and carbon fibers and artifacts, and it is no longer always necessary to use oxygen to stabilize pitch prior to the carbonization process.
One aspect of the invention is the isolation by extraction of a fraction of a feed mesophase pitch which would otherwise be unsuitable for forming into mesophase artifacts. Mesogen-type fractions that are, in the non-solvated form, unmeltable can be isolated by extraction. These unmeltable fractions cannot be formed into artifacts by conventional melt processing. However, as solvated mesophase, these fractions can be melted, formed and then the solvent can be removed to make formed mesophase artifacts from otherwise unsuitable materials.
The solvated mesophase pitches of the present invention can vary in mesophase content. Normally the pitches will contain at least 40% by volume of OA in the solvated form. Preferably, artifacts are formed from solvated mesophase pitches containing at least 70% by volume OA. Solvated mesophase pitches usually contain from 5 to 40% solvent by weight based on the total weight of the solvated mesophase pitch.
When a mesophase pitch containing MSQI materials is solvated with an appropriate solvent it is meltable at temperatures below the carbonization temperature of the pitch, i.e. 400° C. or below, and can readily be spun or formed into fibers and other artifacts. After spinning or forming the pitch, the solvent solvating the mesophase pitch is driven off by such means as applying moderate heat while the formed pitch is subjected to a vacuum or the atmosphere is purged with an inert (non-oxidative) gas. The non-solvated pitch articles may then be converted to carbon by subjecting the articles to temperatures for a period of time and under conditions suitable for carbonization.
Optionally, the process of oxidative thermosetting may be applied prior to the carbonization of the pitch of the present invention. Because of the high-temperature stability of articles formed with the pitch of the invention the process step of oxidative thermosetting is often optional. When oxidative thermosetting is practiced it can be done at surprisingly high temperatures, well above the spinning temperature, on account of the high melting temperature of the solvent-free form of the pitch of the present invention. The oxygen uptake required to make the pitch unmeltable is correspondingly reduced.
In a concise statement, the present invention comprises solvated mesophase pitch wherein the non-solvent portion of the pitch is greater than 50% quinoline insoluble and the solvated pitch can be formed into artifacts, desolvated, and heated above the artifact-forming temperature without loss of artifact structure to melting.
During the carbonization process the articles formed from the mesophase pitch containing MSQI can remain structurally stable, as the non-solvated MSQI containing pitch can remain solid or unmelted at temperatures above the carbonization temperature of the pitch. Generally, carbonization occurs at a useful rate above 450° and especially above 500° C.
Often a carbonized artifact is the desired product. However, if higher performance is demanded of the formed artifacts, graphitization may then be carried out by heating the carbonized materials to even higher temperatures for a prolonged period of time.
The process of the invention comprises the steps of:
(a) forming a solvent-mesophase pitch mixture from a mesophase or mesophase-containing pitch having a MSQI content, and a solvent or combination of solvents suitable for solvating the mesophase pitch;
(b) heating the solvent-mesophase pitch mixture to a predetermined temperature while mixing for a time sufficient to form solvated mesophase pitch in a fluid state;
(c) phase separating the solvent-pitch mixture to obtain a solvent (extract) phase and a solvated mesophase pitch phase;
(d) recovering the solvated mesophase pitch phase;
(e) forming artifacts of a desired shape from the solvated mesophase pitch by shaping molten solvated mesophase pitch to the desired shape;
(f) de-solvating the mesophase pitch for a sufficient period of time by heating the pitch to a temperature below its solvated melting point and optionally, conducting the desolvating process under reduced pressure and/or sparging with inert gas to effect a partial or complete drying of the pitch artifacts;
(g) carbonizing the pitch artifacts by heating the artifacts to a temperature for a period of time and under conditions suitable for carbonization of the de-solvated mesophase pitch artifacts; and
(h) optionally, heating the carbonized mesophase pitch artifacts to a temperature and under conditions suitable for graphitization of the carbonized pitch artifacts.
Optionally, one can apply oxidative stabilization in conjunction with step (f), while volatiles are being removed, or as an alternative option, at the conclusion of step (f) after volatiles have been removed.
Suitable mesophase pitch starting materials are those mesophase pitches having an MSQI content up to 100 wt. % of the mesophase pitch. Such pitches include naphthalene derived mesophase pitch commercially available under the tradenames ARA 22 and ARA 24 from Mitsubishi Gas Chemical Company. Other suitable pitches include mesophase pitches such as described in U.S. Pat. Nos. 4,005,183 and 4,209,500, for example.
Although the process of this invention broadens the range of mesophase pitches which may be used to make carbon fibers and artifacts some pitches may still not be suitable for this application. For instance, unrefined mesophase pitch derived from coal tar pitch contains very large quantities of insoluble carbonaceous soot and soot-like materials which would clog spinnerettes and reduce the quality of carbon fibers and articles formed therefrom. Other unsuitable pitches include unrefined pitches derived from ethylene pyrolysis tars (pyro tars) and unrefined pitches derived from petroleum asphalts which contain large quantities of asphaltic materials. The bad QI content of the mesophase pitch must still be kept to a minimum in this invention.
Suitable solvents for use in forming the solvent-pitch mixture are one or more highly aromatic hydrocarbons wherein 40% or more (40-100%) of the carbons in the solvent are aromatic carbons. The solvents generally comprise one, two, and three ring aromatic solvents which may optionally have short alkyl sidechains of from C 1 -C 6 and hydroaromatic solvents which may optionally have short alkyl sidechains of from C 1 -C 6 . Solvent mixtures can contain some paraffinic components, such as heptane, to adjust solubility. Specific solvents which can be used in this invention include one or more of the solvents selected from the group consisting of tetralin, xylene, toluene, naphthalene, anthracene, and 9,10-dihydrophenanthrene.
The solvent pitch mixture is loaded into extraction equipment which for batch processing would be a suitable sealable container able to withstand the temperature and pressure generated by heating the contents to a range of 180°-400° C. for up to several hours. It is believed the pressure within the closed vessel helps to solvate the pitch. Also, the closed container prevents the solvent from escaping so pressure is essential to the process of the invention. An autoclave was used to prepare laboratory sized amounts of mesophase pitch for the Examples herein. It is envisioned that suitably sized and configured extraction equipment can be used to produce commercial quantities of pitch in either batch amounts or by a continuous process. It is also envisioned that the solvent separation can be accomplished by supercritical extraction wherein one or more solvent components is at supercritical conditions during the separation.
The solvent pitch mixture must be agitated or mixed during the heating process. Extraction equipment must therefore be equipped with stirring paddles, pump around loops, or other means for agitating and mixing together the pitch and solvent. In the case of a batch process, the container could be fitted with mixing paddles or blades as are well known in the art. In the case of continuous processing of the mesophase pitch, an in-line mixing device could provide adequate mixing.
The temperature to which the pitch and solvent mixture is heated and extraction is conducted is in the range of 180°-400° C. Preferably, the temperature is in the range of from 220°-350° C.
The pressure under which the heating is carried out is at or above the vapor pressure of the solvent or solvent mixture used in the extraction. Generally, this pressure would be the range of atmospheric to 5000 pounds per square inch gauge (psig), depending on the vapor pressure of the solvent. It is recognized that the vapor pressure of certain solvents suitable for use in this process may in fact be lower than atmospheric pressure. Although no experiments were conducted with solvents having a vapor pressure below atmospheric pressure it is believed that they would adequately solvate the pitch.
The amount of time required for mixing and phase separation ranges from about five minutes to several hours or longer. No specific amount of time is recited as the amount of time required for these steps will vary depending on the pitch, solvent, mixing, and the processing temperatures. As a general rule mixing should continue until the pitch is adequately solvated, and standing or separating should continue as long as necessary to obtain a solvent phase and a solvated pitch phase.
Separation of the solvent phase and the solvated pitch phase can be accomplished simply by allowing the mixture to stand without agitation. While this may be an adequate separation technique for batch processing techniques, it is envisioned that mechanical separators, such as centrifugal separators, may also be used to effect separation. In continuous process set-ups, separation may be accomplished in the line, or by passing the solvent-pitch mixture into a mechanical separator, or by passing the mix into suitable container or settling tank in which separation can occur.
Once the mixing of the extracted solvent-pitch mixture stops, the contents of the sealed container will phase separate into an upper solvent phase and a lower pitch phase. If permitted to cool sufficiently, the pitch phase will thicken and eventually harden. The thickening and solidifying temperatures can be determined by occasional movement of the paddles or other stirring means within the vessel. The pitch can be readily recovered after cooling to a solid. However, it is envisioned that the pitch could be recovered after phase separation has occurred, but while the pitch is still in a liquid form. It is further envisioned that if removed from the container while molten, the pitch could be formed into fibers and other artifacts directly, thus eliminating the need to remelt the pitch.
Melting behavior of the pitches described in this invention were observed while heating the pitches on a microscope hot stage under inert atmosphere at a heating rate of 5° C. per minute. Pitches were crushed to particle sizes from 10-200 microns before testing. Softening was said to occur at the first rounding of angular features of the pitch particles. Melting occurred when the first observable flow of the softened pitch was seen.
The invention will be further illustrated in the following examples.
EXAMPLES
Example 1
A batch of mesophase pitch was prepared from mid-continent refinery decant oil residue. The residue was an 850° F. (454° C.) and higher fraction which was found through NMR testing to be 92% carbon and 6.5% hydrogen. The residue was converted to mesophase pitch by heat soaking the oil residue at 386° C. for 28 hours while nitrogen was sparged through the oil residue at a rate of 0.08 standard cubic feet per hour per pound of oil residue.
After heat soaking, the residue was tested under plane polarized light and it was observed that the material had been converted to mesophase pitch. Further testing revealed the mesophase pitch melted at 329° C. and that the pitch yield was 15 wt. % of the starting residue. A portion of the mesophase pitch was tested for QI content by contacting 1 part of pitch with 20 parts of quinoline for a period of 2 hours at 70° C. The QI content was determined to be 81.1 wt. % of the mesophase pitch.
The mesophase pitch obtained by the process above was then combined with an equal weight amount of tetralin in an autoclave. The autoclave was then purged with nitrogen, evacuated and sealed. The contents of the autoclave were heated to 326° C. over 110 minutes while being stirred. The maximum pressure of the autoclave reached 120 psig.
Stirring was continued while the contents were allowed to cool to 294° C. over 30 minutes. Cooling of the contents was allowed to continue without stirring. Occasional movement of the stirrer revealed the contents thickened at about 290° C. and solidified at about 245° C.
On opening the cooled autoclave the contents were found to have separated into an upper liquid solvent extract phase, and a lower solid pitch phase. Plane polarized light microscopy of the solid pitch phase revealed that the material was a solvated mesophase pitch with 100% anisotropy. Analysis showed the pitch yield was 79% of the mesophase pitch charged in the autoclave.
The pitch was vacuum dried for 2 hours at 250° C. Analysis revealed that 21.4% volatile solvent had been removed from the pitch through this drying step. To determine the melting point of the dried pitch it was placed on a microscope hot stage under a nitrogen purge and heated at the rate of 5° C. per minute to 650° C. Although 650° C. is over 400° C. higher than the solidification point of the solvated mesophase pitch, the dried pitch showed no signs of melting.
Example 2
In this example an already prepared mesophase pitch was used which is available under the trade name ARA22 from Mitsubishi Gas Chemical Company, Inc., Tokyo, Japan. ARA 22 is a 100% mesophase pitch having a 220° C. softening temperature. ARA 22 is reported to be obtained by the HF--BF 3 catalyzed polymerization of naphthalene. A sample of ARA 22 was tested for QI content by the method described in Example 1 and found to be 55.7% QI.
7 parts of ARA 22 mesophase pitch were mixed in an autoclave with 2 parts tetralin solvent. The autoclave was purged with nitrogen, evacuated and then sealed. The contents of the autoclave were heated to 252° C. over 90 minutes while being stirred. Stirring was continued for 65 minutes while the contents of the autoclave were maintained at about 250° to 252° C. The maximum pressure of the autoclave reached 20 psig.
Stirring was discontinued and the contents were allowed to cool at the rate of about 1.5° C. per minute until reaching ambient temperature. Occasional movement of the stirrer revealed the contents thickened at about 177° C. and solidified at about 135° C. On opening the autoclave, the contents were found to be in two phases; a upper fluid (solvent) extract phase, and a lower solid pitch phase.
The pitch layer was found to be 100% anisotropic solvated mesophase pitch and the pitch yield was determined to be 81% based on the original weight of the ARA 22 mesophase. On vacuum drying followed by vacuum fusion at 360° C., 21.1% volatiles was removed from the pitch. The fused pitch softened at 309° C., melted at 320° C. and was 100% anisotropic. The softening point of the fused pitch was found to be higher than the softening point of the starting material mesophase pitch and much higher than the solidification temperature of the solvated mesophase pitch.
Example 3
7 parts of the ARA 22 mesophase pitch starting material described in Example 2 was mixed with 2 parts of xylene solvent. The pitch and solvent were loaded in a nitrogen purged and evacuated autoclave, which was subsequently sealed. The contents of the autoclave were stirred while being heated to 253° C., then stirred for 30 minutes at about 250° C., and subsequently cooled following the procedure in Example 2. Thickening of the contents was noted at about 173° C. and solidification at about 145° C.
On opening the autoclave the contents were separated into an upper extract (solvent) phase and a lower solid pitch phase. The pitch was analyzed under plane polarized light and found to comprise 99% anisotropic solvated mesophase. The pitch yield was determined to be 95%.
The pitch was vacuum dried and then vacuum fused at 360° C., thereby removing 180% volatiles The fused pitch was found to soften at 300° C., and to melt at 306° C. The fused pitch was determined to be 100% anisotropic mesophase pitch.
Example 4
1 part of ARA 22 mesophase pitch starting material and 1 part of tetralin solvent were mixed together and placed in an autoclave. The autoclave was nitrogen purged, evacuated, and sealed. The contents of the autoclave were stirred while heat was applied over two hours to bring their temperature to 315° C. Stirring was continued for an additional 30 minutes while the temperature was held at 315° C. The mixture was slowly cooled with only occasional movement of the stirrer to test for thickening of the pitch. Thickening was noted at about 217° C. and solidification at about 185° C. On opening the autoclave, it was observed that the contents had separated into an upper liquid extract (solvent) phase and a lower solid pitch phase. The pitch tested as 100% anisotropic solvated mesophase and the yield was calculated to be 55%.
The pitch was dried for 1.5 hours at 250° C. in a vacuum, wherein 17% volatile solvent was removed. On subjecting the dried pitch to heating on a hot stage of a microscope, with a 5° C. increase in temperature per minute up to 650° C., no melting was observed.
Some of the dried pitch was further treated by being heated in a vacuum at 360° C. for 30 minutes to cause fusing of the pitch. This additional treatment resulted in removal of 2.2% additional volatiles, comprising solvent and a small amount of volatile oils. Total volatiles removal for going from a solvated mesophase to a fused mesophase pitch was 19.2%. The fused mesophase pitch tested as being comprised of 95.2% QI. By comparison, a sample of the solvated mesophase product before drying or fusing tested as comprising 76.0% QI.
Example 5
Preparation of Feedstock for Examples 6 & 7
An isotropic petroleum pitch 850°+F. residue was obtained from a mid-continent refinery decant oil. The residue was heat soaked for 6.9 hours at 748° F. and then partly de-oiled by vacuum distillation. The resulting heat soaked pitch was determined to have an insolubles content of 20.0 wt % by combining a sample of the heat soaked pitch in ambient temperature tetrahydrofuran at a weight ratio of solvent to pitch of 20:1.
The heat soaked pitch was combined with xylene in a ratio of 1 gm pitch to 8 ml solvent. The mixture was loaded into an autoclave which was then evacuated and sealed. While being stirred, heat was applied to the mixture to bring it to a temperature of 235° C., at which temperature, the pressure within the autoclave was measured at about 95 psig. The mixture was maintained at a temperature of 235° C. and stirring was continued for 1 hour, then the mixture was allowed to settle at that temperature for 25 minutes. On cooling, a dense cake of solvated mesophase pitch was recovered from the bottom of the autoclave. The yield of solid product was calculated to be about 30%.
The solvated mesophase pitch was dried and then fused under vacuum at 360° C. to remove 17% volatiles. The fused pitch was determined to be 100% anisotropic and comprise 22.1% QI. The mesophase pitch prepared in this manner was used in Examples 6 and 7.
Example 6 (Comparative Example)
The fused mesophase pitch as prepared in Example 5 was mixed with tetralin in a weight ratio of 7 parts pitch to 2 parts solvent. The mixture was loaded into an autoclave which was then evacuated and sealed. While being stirred, heat was applied to the mixture to bring it to a temperature of 250° C. The mixture was maintained at a temperature of 250° C. and stirring was continued for 30 minutes. The maximum pressure within the autoclave was measured at about 20 psig. The contents of the autoclave were allowed to cool and it was noted that the pitch thickened near 159° C. and solidified near 125° C. Upon opening the autoclave the contents were in the form of a single phase of solid pitch, the yield of which was calculated at 129%. Polarized light microscopy revealed the pitch was comprised of 90% anisotropic solvated mesophase.
This comparative example shows that certain extracted mesophase pitches will resolvate rather than extract when combined with an amount of a solvent up to the amount of solvent which is soluble in the pitch. In Example 7, the same pitch was combined with an excess amount of solvent (i.e. an amount of solvent greater than that which is soluble in the pitch) which acts to solvate and extract the materials necessary in order to make a mesophase pitch according to the process of the invention.
Example 7
The same fused extracted mesophase pitch described in Example 5 was combined with tetralin in a weight ratio of 1 part pitch to 1 part solvent. The mixture was stirred 30 minutes at 307° C. and then slowly cooled. Thickening was noted at 210° C. and the pitch solidified near 175° C. The cooled autoclave contained a top tar-like extract phase and solid pitch bottom phase. The bottom mesophase portion of the pitch tested 100% anisotropic and was obtained in 90% yield. Vacuum drying followed by vacuum fusion at 360° C. removed 28.4% volatiles from the pitch. The fused mesophase partly softens at 373° C. and partly melts at 405° C. when heated at 5° C. per minute under nitrogen. QI of the fused pitch tested 85.6%.
Example 8 (Comparative)
Petroleum needle coke was selected as the mesophase feedstock for this example. As produced or "green" needle coke is a 100% anisotropic mesophase produced by thermal treatment of graphitizable carbonaceous feedstocks. Coking involves heat soaking the feeds to form mesophase and continuing the heat soak until the mesophase is completely unmeltable. The coke for this example tested 15.3% volatile matter when vigorously heated.
Green petroleum needle coke was combined with tetralin in a 7 to 2 weight ratio. Following the procedure of Example 5, the mix was stirred at 320° C. for 30 minutes. A pressure of 80 psig developed on account of the heating. On slow cooling the mixture became viscous at 156° C. but never became solid at or above room temperature. The cooled product consisted of a fluid tar phase and coke particles. While the solvent extracted some components from the coke, there was no evidence that the coke particles solvated. The particles remained angular indicating no softening at the process conditions.
This example shows that mesophase can be processed until it is sufficiently hard or high molecular weight so that it is no longer a suitable feed for making low melting solvated mesophase pitches.
Example 9
Mesophase pitch was obtained from Maruzen Petrochemical Company, Ltd., Japan, which was reportedly produced from coal derivative feeds. The pitch was 100% anisotropic and its quinoline insoluble content was determined to be 0.05%
The pitch was combined with tetralin in a weight ratio of 7 parts pitch to 2 parts solvent. The mixture was heated and stirred in an autoclave at 250°-252° C. for 30 minutes and then it was gradually cooled. All of the product was found to be solid, but separated into an upper isotropic phase and a lower anisotropic phase. The anisotropic phase was found to be 100% optically active (anisotropic) solvated mesophase, the yield of which was 32%. The thickening and solidification temperatures of this pitch were not observed because the level of pitch in the autoclave was not high enough to cover the stirrer blade. However, the solvated mesophase of this pitch was clearly fluid at 252° C., the process temperature of the solvation step in this Example. This is well below the 290° C. softening temperature of the Maruzen mesophase pitch.
The foregoing exemplification and description are provided to more fully explain the invention and provide information to those skilled in the art on how to carry it out. However, it is to be understood that such is not to function as limitation on the invention as described and claimed in the entirety of this application. | This application relates to a process for making carbon artifacts from solvated mesophase pitch comprising quinoline insoluble materials. The process has a significant advantage over the art as it permits the use of otherwise unusable pitch feedstocks and the artifacts formed according to the process retain their structural integrity during carbonization. This invention also relates to the pitch formed by this process and carbon artifacts formed by this process. | 3 |
BACKGROUND OF THE INVENTION
The invention is based on a fuel injection apparatus for internal combustion engines. In a fuel injection apparatus of this kind known from German Offenlegungsschrift 31 18 669, the fuel injection quantity that has been pre-stored in a pump work chamber is determined by the duration of the opening period of an electronically actuatable metering valve, and a shift in the instant of supply onset is attained, and controlled in accordance with operating characteristics, by means of a variation in the return-flow fuel quantity. This return-flow fuel quantity is adjustable by means of the controlled rotational position of the pump piston, which is provided with an oblique control edge, and in any event the pump work chamber is refilled prior to the next subsequent injection stroke. The refilling process is reinforced by a fuel reservoir that is connectable with the pump work chamber. Because of the variable volume of the fuel during its diversion and refilling, and because each operation takes place at a completely different pressure level, influences on the onset of injection and on the supply quality arise in the known fuel injection apparatus which must be compensated for in the electric control unit by mean of appropriate correction values. It is thus an object of the invention to improve the fuel injection apparatus such that the variable fuel volume during diversion and refilling does not have a disadvantageous effect on the accuracy of the controlled fuel injection quantity and the instant of supply onset. Further, the smallest possible idle volume in the vicinity of the inflow and return-flow conduit, additional errors that would be caused by escaping leaking fuel and impairments in fatigue strength that would be caused by cavitation and strains in the vicinity of the cylinder bore, the metering valve and the refill reservoir are prevented.
OBJECT AND SUMMARY OF THE INVENTION
In the fuel injection apparatus according to the invention, the return-flow fuel quantity diverted upon the end of supply is accurately refilled back into the pump work chamber, thereby precluding scattering in the supply quantity values and deviations in the instant of supply onset or at least reducing them to a value that is within the allowable tolerance. The metering pulse of the electric control unit that determines the opening duration of the metering valve thus results in an unequivocal supply quantity signal which is evaluatable in the regulating circuit of the control unit. A very substantial contribution to this improvement in function is made by the refill reservoir embodied as a piston reservoir and by the simplified conduit design, with the overflow conduit representing the sole and direct connection between the refill reservoir and the pump work chamber, which is opened by both control locations of the pump piston, so that at bottom dead center of the pump piston, whatever fuel quantity still remains in the refill reservoir after the closure of the overflow opening by the first control location is refilled back into the pump work chamber. By means of the incorporation of both the refill reservoir and the metering valve into the cylinder head of the two-part pump housing, this cylinder head also receives the pump cylinder and the pressure valve, the inevitable idle volumes and sealed locations can be reduced to a minimum. Furthermore, the lower part of the housing can be manufactured from lightweight metal to save weight and expense, while the cylinder head can be made from a high-grade material in terms of strain-, pressure- and wear-resistance, such as an appropriately selected steel. As a result, cavitation in the vicinity of the overflow conduit is avoided, and the structural length of series injection pumps can be reduced as a result of the shorter spacing between cylinders.
As a result of the provisions set forth herein, advantageous further embodiments and developments of the fuel injection apparatus are disclosed. In a fuel injection as embodied herein, the idle volumes in the vicinity of the overflow and inflow conduit can be kept very small, because for instance with horizontally disposed receiving bores for the refill reservoir and the metering valve, the bottom faces of these receiving bores can be brought very close to the pump cylinder. If the refill reservoir is parallel to the pump cylinder, then the cylinder head can be narrower in embodiment, and the diversion stream of the return-flow fuel diverted upon the end of supply does not strike the reservoir piston directly but is instead deflected, so that the energy of the emerging fuel is at least for the most part dissipated, and an overswing of the reservoir piston that could be caused by the diversion impact can be prevented. The impact sheath disclosed in claim 3 contains a substantial portion of the overflow conduit and prevents cavitation in the corresponding area of the area of the cylinder head that could be caused by the diversion stream.
In a fuel injection apparatus, in which the fuel injection pump is provided, as known from the patent cited above, with a cylinder liner containing the pump cylinder and fastened in the pump head and with an overflow bore in the wall of the cylinder liner that embodies at least a substantial portion of the overflow conduit, the design and disposition of the refill reservoir in the cylinder head as defined is capable of exerting a tensioning force upon the cylinder sheath of the refill reservoir that is sufficient to generate the required sealing force and yet precludes deformation of the cylinder liner, without putting the cylinder liner under strain.
In a fuel injection apparatus as embodied herein, any problems associated with sealing, leakage, wear and strain are eliminated by the integrated incorporation of the refill reservoir into the cylinder head that is manufactured from tempered steel.
Furthermore, with an appropriate matching of the cam drive of the fuel injection pump, embodied as a multi-cylinder pump, it is possible to use merely one metering valve for each two pump elements. The valve element required therefor, which blocks one of the pump work chambers at a time, may be embodied in accordance with claim 8 by a control face on the pump piston, so that in a particularly advantageous manner no additional structural parts are required.
The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of the preferred embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified illustration of the first exemplary embodiment of a fuel injection apparatus according to the invention, having a fuel injection pump embodied as a series injection pump and shown in cross section;
FIG. 2 is a partial cross section through the components of a fuel injection pump that are essential to the invention, in terms of a second exemplary embodiment;
FIG. 3 is a partial cross section taken along the line III--III in FIG. 4, similar to FIG. 2, but for the third exemplary embodiment, in which one metering valve is associated with two pump cylinders;
FIG. 4. is a plan view in the direction of the arrow D in FIG. 3 onto the cylinder head;
FIG. 5 is a cross section taken through a fourth exemplary embodiment, embodied as a plug-in pump; and
FIG. 6 is a function di for the piston stroke, with subdiagrams FIGS. 6a-6e showing the respective positions of the piston, refill reservoir, metering valve and pressure valve and the associated fill status in the pump work chamber and the refill reservoir.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows, as a first and preferred exemplary embodiment, a fuel injection pump 10 embodied as a series injection pump, which is shown in a cross-sectional view taken through a pumping element and has a pump piston 13 which is guided such as to be both axially and rotationally movable in a pump cylinder 11 and which defines a pump work chamber 12. The pump piston 13 is actuatable in the reciprocating direction by a cam drive 9; on its jacket face, the pump piston 13 has two control locations, of which one comprises an oblique control edge 14 cut into the jacket face of the pump piston 13 and the other of which comprises a horizontal control edge 15 embodied by the end face of the pump piston 13 toward the pump work chamber.
In the bottom dead center position (marked UT in the drawings) of the pump piston 13, an inflow conduit 16, which is closed by the jacket face of the pump piston 13 during pump supply, and a diametrically opposed overflow bore 17 of an overflow conduit 24 discharge into the pump work chamber 12, which is closable in the supply direction by a pressure valve 18 and is connectable via a pressure line 19, merely suggested in the drawing, with an injection nozzle, not shown.
The pump cylinder 11, in the exemplary embodiment shown in FIG. 1, is embodied as a cylinder bore of a cylinder liner 21 secured by means of a screw pipe joint 20 in a cylinder head 22a of a pump housing 22. The pump work chamber 12 defined inside the pump cylinder 11 by the pump piston 13 and the pressure valve 18 is connectable, in order to terminate the effective supply stroke that is controlled by the oblique control edge 14, via a stop groove 23 and the overflow conduit 24 with a refill reservoir 25 serving as a fuel reservoir.
Although a volume reservoir is also conceivable as a receptacle for the return-flow fuel quantity, a piston reservoir is used here in order to attain high accuracy in metering the quantity; this piston reservoir has a reservoir chamber 25a and a reservoir piston 26 acting as a movable wall, which is displaceable counter to the force of a compression spring 27 serving as a restoring means. A spring chamber 28 containing the spring 27 and disposed on the end of the reservoir piston 26 remote from the reservoir chamber 25a communicates via the relief line 29 in a manner not shown in detail with a fuel tank 31. The reservoir chamber 25a and a sliding guide for the reservoir piston 26 are embodied by a cylinder bore 32a of a cylinder sheath 32. This cylinder sheath 32 is firmly pressed by means of a hollow screw 34, which contains the spring chamber 28 of the restoring spring 27, against a contact shoulder 33a in the outer region of a bottom face 33b of a first receiving bore 33 inside the cylinder head 22a. The receiving bore 33 for the refill reservoir 25 is embodied as a blind bore extending toward the axial center of the pump cylinder 11 and extending from the outside into the cylinder head 22a; its bottom face 33b is divided from the pump cylinder 11 solely by a wall area 35 through which only the overflow conduit 24 passes. The components of this wall area 35 are a wall of the cylinder liner 21 that is penetrated by the overflow bore 17 and a wall in the cylinder head 22a that is penetrated by a connecting bore 37 and is defined toward the outside by the bottom face 33b. The overflow bore 17 and the connecting bore 37 together comprise the overflow conduit 24.
The pump housing 22 comprises two housing parts, threaded together in a plane of division 22c extending at right angles to the longitudinal axis of the pump piston 13, specifically the cylinder head 22a, which receives the cylinder liner 21, the pressure valve 18 and the refill reservoir 25, and a lower housing part 22b, which receives the cam drive 9 and an adjusting device 47 to be described in detail later herein; the lower housing part 22b is made of aluminum to save weight, while the cylinder head 22a is made of steel and is therefore capable of withstanding greater stresses in terms of wear, pressure and strain.
Diametrically opposite from the refill reservoir 25, a metering valve 38 which is electromechanically actuatable and is embodied as a magnetic valve is inserted in a pressure-tight manner into a second, multiple-step receiving bore 39 of the cylinder head 22a.
This receiving bore 39 for the metering valve 38 is, like the first receiving bore 33, embodied as a blind bore extending at least approximately toward the axial center of the pump cylinder 11 and extending from the outside into the cylinder head 22; its bottom face 39a is separated form the pump cylinder 11 by a wall area 44 located partly in the cylinder head 22a and partly in the cylinder liner 21.
The metering valve 38 supplies the pump work chamber 12 via the inflow conduit 16 with fuel pumped from a low-pressure source 41 and with its opening duration (b in FIG. 6) determines a fuel injection quantity that is pre-stored in the pump work chamber 12.
The low-pressure source 41 contains a feed pump 42, which aspirates the fuel out from the fuel tank 31 and pumps it via an inflow line 43 and inflow bores 45a and 45b, as well as via the metering valve 38 and the inflow conduit 16, into the pump work chamber 12 whenever the pump piston is in its bottom dead center position shown in FIG. 1.
In order to prevent the escape of leaking fuel at the point connecting the metering valve 38 and the inflow conduit 16, a mouthpiece 38a of the metering valve 38 is sealed off at the end face, in the vicinity of the bottom face 39a, by means of a sealing ring 46.
For correcting or adjusting the end of the effective supply stroke of the pump piston 13, the fuel injection pump 10 is equipped with an adjusting device 47, which in a known manner comprises a longitudinally displaceable regulating rod 48 and a steering sheath 49 for the pump piston 13 that is actuatable by the regulating rod 48. The regulating rod 48 is provided with couplers 48a secured by screws 50, which couplers 48a are adjustable and fixable in oblong slots 48b of the regulating rod 48 in order to synchronize the pump elements. Both parts 48 and 49 of the adjusting device 47 serve, upon a longitudinal movement of the regulating rod 48 effected by means of an adjusting member 51, to cause the rotation of the pump piston 13, as a result of which the relative position between the overflow bore 17 and the oblique control edge 14 on the pump piston 13 varies.
The adjusting member 51 actuating the regulating rod 48, as an electromechanical adjusting member, is embodied by an electromagnet, an electric servomotor or an electrohydraulic adjusting member, depending on the adjusting force required, and it receives its control pulse I FB , which is dependent on at least one operating characteristic, such as the load L or the rpm n, from an electric control unit 52. The change in the rotational position of the oblique control edge 14 attainable with the adjusting device 47, and thus the change in the end of supply, does not, however, in this case determine the fuel injection quantity Q E , but serves instead, in combination with the function of the refill reservoir described in detail above, to vary the instant of supply onset. The position of the adjusting member 51 at a given time is measured by an adjusting-path transducer 53 and fed to the control unit 52 in the form of an adjusting-path signal S S .
With its opening duration, the metering valve 38 embodied as a magnetic valve determines a fuel injection quantity pre-stored in the pump work chamber 12, which quantity corresponds exactly to the fuel quantity Q E that is to be injected. The magnetic valve 38, embodied in a known manner as a 2/2-way valve, receives a metering pulse I Z that determines its opening duration from the control unit 52, which contains an electronic regulating circuit, and into which in addition to an rpm signal n emitted by an rpm transducer 54, additional signals dependent on engine operating characteristics are also fed, such as a temperature signal T derived from a suitable location and further signals S. A load signal L to be fed in by a person operating the engine is generated by a set-point value feed means 55.
The fuel metering controlled by the magnetic valve 38 is effected at a constant fuel inflow pressure p Z via a constant inflow cross section, embodied for instance by the first cross section in the inflow conduit 16, at a variable opening duration of the magnetic valve 38 determined by the metering pulse I Z . The constant inflow cross section may also be embodied by the flowthrough cross section of the magnetic valve 38. The constant inflow pressure p Z is maintained by means of a pressure regulating valve 56 located in the low-pressure source 41. The metering pulse I Z determining the opening duration thus results in an accurate supply quantity signal.
In the second exemplary embodiment, shown in part in FIG. 2, of a fuel injection pump 10' of the fuel injection apparatus according to the invention, the sole difference from the fuel injection pump 10 shown in FIG. 1 is the differing manner in which the refill reservoir 25 and metering valve 38 are mounted. Identical elements are therefore identified by the same reference numerals, while differing elements have the same reference numeral with a prime, and new parts are identified by a new reference number. (In further exemplary embodiments, the reference numerals are correspondingly given double and triple primes.)
The first receiving bore, marked 33' in FIG. 2, for the refill reservoir 25 is embodied as a blind bore drilled from outside into the cylinder head 22a' parallel to the pump cylinder 11, into the bottom face 33b of which a connecting bore 37', serving as part of the overflow conduit 24', discharges. A substantial portion of the overflow conduit 24' is embodied by a longitudinal bore 61 and a transverse bore 62, directly adjoining the connecting bore 37', inside an impact sheath 63. This impact sheath 63 is made of wear-resistant material, such as tempered steel, and is inserted into the cylinder head 22a radially with respect to the pump cylinder 11. In this exemplary embodiment, the overflow conduit 24' thus comprises the overflow bore 17 in the cylinder liner 21, the longitudinal bore 61 and transverse bore 62 in the impact sheath 63, and the connecting bore 37' in the cylinder head 22a'. Both the longitudinal bore 61 in the impact sheath 63 and the transverse bore 62, diverging at right angles from the longitudinal bore 61, serve to dissipate the energy of the fuel stream emerging from the overflow bore 17 at the end of injection. The deflection toward the connecting bore 37' damps the diversion impact so greatly that even at very high rpm the reservoir piston 26 of the refill reservoir 25 does not start to oscillate. An end face 64 of the impact sheath 63 oriented toward the pump cylinder 11 is embodied as a sealing face resting in a positively-engaged manner on a cylindrical jacket face 21a of the cylinder liner 21 and being pressed against this jacket face 21a.
In the third exemplary embodiment of a fuel injection pump 10" shown in FIG. 3, the refill reservoir 25 is incorporated into the cylinder head 22a" parallel to the longitudinal axis of the pump piston, as in FIG. 2. In this fuel injection pump 10", which is also shown in plan view in FIG. 4, two pump work chambers 12 at a time are supplied with fuel by a single metering valve 38". The oblique mounting of the metering valve 38" makes possible a very narrow and compact structure on the part of the injection pump; furthermore, the refill reservoir 25 is also brought very close to the cylinder liner 21.
As shown in FIG. 4, two pump elements and two associated refill reservoirs 25 at a time are accommodated in one steel cylinder head 22a". In a four-cylinder series injection pump, two double cylinder heads 22a" are thus mounted onto a single lower housing part 22b" and connected therewith by fastening screws 66. The metering valve 38" that is common to two pump cylinders 11 at a time delivers the metered fuel injection quantity via a bore arrangement 67, shown in dashed lines in FIG. 4, in the respective cylinder head 22a" to the inflow conduits 16 of the respective pump cylinder 11. The inflow bores 45 of the two cylinder heads 22a" shown in FIG. 4 are, like the relief lines 29, connected with one another via appropriately sealed plug-in sleeves 68 and 69 at the resprective junctions of two cylinder heads 22a". The control effected by the associated cam drive (see 9 in FIG. 1) is designed such that only one of the two adjacent pump work chambers 12, for instance the one shown in FIG. 3, at a time is connected with the associated metering valve 38". At the same time the inflow conduit 16 to the other pump work chamber, that is, the one not shown in FIG. 3, is blocked by a control face 13a on the corresponding pump piston 13 acting as a valve element. The control face 13a on the pump piston 13 shown in Fig, 3, which is in its bottom dead center position, keeps the inflow conduit 16 from the metering valve 38" or from the bore arrangement 67 open to the pump work chamber 12 in this operating position.
Nevertheless, metering by one metering valve 38" to a plurality of pump work chambers 12 can also be realized without the valve elements (13a), if for instance all the associated pump pistons 13 are at bottom dead center and precisely matched throttling cross sections in the inflow conduits 16 assure uniform distribution of the metered fuel to the individual pump work chambers 12. The control described in the third exemplary embodiment (shown in FIGS. 3 and 4) does, however, advantageously guarantee a precise individual metering to each pump work chamber 12.
The fourth exemplary embodiment, shown in FIG. 5, has a fuel injection pump 10"' embodied as a plug-in pump and driven by a camshaft, not shown, located on the engine. The cylinder head 22a"' mounted onto the lower housing part 22b" assumes the function of the cylinder liner 21 used in the foregoing exemplary embodiments and is thus for reasons of wear and fracture resistance made of steel tempered at least at the points subject to heavy strain, such as is otherwise used for cylinder liners. The tempered receiving bore 33"' receiving the refill reservoir 25"' embodies both the reservoir chamber 25a"' and a sliding guide for the reservoir piston 26. Since no specialized cylinder liner is present in this embodiment, the reservoir chamber 25a"' can be brought very close to the pump work chamber 12 in the cylinder bore 11, in order to reduce the idle volume. The overflow bore, marked here as 17"', simultaneously acts as the overflow conduit. The wall area 35"' dividing the reservoir chamber 25a"' from the pump work chamber 12 is, like the corresponding wall area 44"' receiving the inflow conduit 16, located exclusively in the cylinder head 22a"'. Thus in order to avoid cavitation wear this wall area 35"' can be tempered in the vicinity of the conduits 17"' and 16 and has no additional sealing points. The lower housing part 22b"' of this injection pump 10"', which is embodied as a plug-in pump and is therefore provided with only one pump piston 13, contains an adjusting device 47"' known per se and differing in structure from the foregoing embodiments. Differing from the structure shown, however, it is also possible to embody double cylinder heads in the corresponding manner, which can then also be used in multi-cylinder series injection pumps.
The diagram shown in FIG. 6 shows a curve a representing the piston stroke H plotted over the cam angle α and includes sub-FIGS. 6a-6e in which the position at a given time of the pump piston 12, the reservoir piston 26, the metering valve 38 and the pressure valve 18, as well as the fill status at a given time in the pump work chamber 12 are all shown in simplified form. The piston stroke H is plotted to a double-size scale, while the cam angle α is plotted not to scale because of the associated FIGS. 6a-6e. A horizontal bar b shown in the vicinity of bottom dead center UT above the curve a represents the opening duration of the metering valve 38. The points for the supply onset FB and end of supply FE as well as the points US 1 and UO 2 , standing respectively for the instant when the overflow conduit 24 is closed by the oblique control edge 14 and for the instant when this overflow conduit 24 is opened by the horizontal control edge 15, are plotted on the curve a. The instant of closing of the overflow conduit 24 by the horizontal control edge 15 located after UT is represented by US 2 , while the instant when this conduit 24 is opened by the oblique control edge 14 occurs simultaneously with the end of supply at point FE. The associated positions of the pump piston 13 are again shown for FIGS. 6a, 6b, 6d and 6e below the piston 13. In FIG. 6c, the pump piston 13 assumes a position between the closing instant US 1 and the opening instant UO 2 , and the fill status shown in the pump work chamber 12 and the reservoir chamber 25a is already attained shortly after US 1 . The entire return-flow fuel quantity Q RF as well as a partial quantity Q F of Q RF and a remnant quantity Q R are shown by shading, and the fuel injection quantity Q E metered by the metering valve 38 is shown by double shading.
The mode of operation of the subject of the application will now be described with the aid of FIGS. 1 and 6 in terms of the first exemplary embodiment. The exemplary embodiments shown in FIGS. 2-5 function in the same manner and differ only in their structural details.
In FIG. 1, the pump piston 13 is shown in its bottom dead center position UT corresponding to FIG. 6d, and the entire return-flow fuel quantity Q RF and the fuel injection quantity Q E pre-stored by the metering valve 38 are contained in the partially evacuated pump work chamber 12. After the horizontal control edge 15a has closed the inflow opening 16 and, at US 2 , the overflow conduit 24 as well, the onset of supply is initiated at FB during the further upward stroke of the pump piston 13. The injection takes place until point FE, with the pressure valve 18 permitting the flow of fuel to the injection nozzle (see FIG. 6e). The end of supply FE is controlled by the opening of the overflow conduit 24 by the oblique control edge 14a (see FIG. 6a), and up to top dead center OT the pump piston 13 positively displaces the entire return-flow fuel quantity Q RF , the pressure valve 18 being closed, into the reservoir chamber 25a of the refill reservoir 25 (see FIG. 6b). During the return or aspiration stroke of the pump piston 13, until the closure of the overflow conduit 24 by the oblique control edge 14, a partial quantity Q F of the return-flow fuel quantity stroke of the pump piston 13, until the closure of the overflow conduit 24 by the oblique control edge 14, a partial quantity Q F of the return-flow fuel quantity Q RF is refilled or re-aspirated into the pump work chamber 12. Because of the differing compression volume at the end of supply and during the intake stroke, a remnant quantity Q R remains in the reservoir chamber 25a (see FIG. 6c). This remnant quantity Q R is refilled into the pump work chamber 12 after the opening instant UO 2 of the overflow conduit 24 and until bottom dead center UT of the pump piston 13, so that at UT the entire return-flow fuel quantity Q RF is again present and available in the pump work chamber 12. In the range between UO 2 and US 2 , and if possible at UT, the fuel injection quantity Q E is pre-stored into the pump work chamber 12 during the opening period of the metering valve 38 that is defined by the metering pulse I Z of the control unit 52 and indicated at b in FIG. 6. Between US and FB, a partial vacuum remaining in the pump work chamber 12 is compressed, and the subsequent fuel injection then begins at FB (see FIG. 6e).
The control of the end of supply FE by the corresponding rotational position of the oblique control edge 14 or by the change in rotational position of the pump piston 13 by means of the adjusting movement of the edge 14 or by the change in rotational position of the pump piston 13 by means of the adjusting movement of the regulating rod 48 effected by means of the electromechanical adjusting member 51 determines the instant of supply onset FB by means of the return-flow fuel quantity Q RF that is diverted and then refilled. If the opening duration of the metering valve 38 controlled by the metering pulse I Z of the control unit 52 is varied, then the adjusting member 51 is also followed up, by means of an appropriate correcting pulse of the control unit 52, at an appropriately adapted adjusting speed and the return-flow fuel quantity is corrected, so that the instant of supply onset FB remains constant. If however the instant of supply onset FB is to be varied in accordance with the rpm n or the load L or other operating characteristics, while the injection quantity Q E remains the same, then all that is done is that a different rotational position of the pump piston 13 is established by means of the adjusting device 47. For precise regulation of this rotational position, the adjusting member 51 is provided with the adjusting-path transducer 54, which emits an adjusting-path signal S S to the electrical control unit 52; this transducer 54 is merely suggested in FIG. 1 and may be disposed an any arbitrary location, for instance on the regulating rod 48 instead, and embodied by a known travel-path transducer operating capacitively, inductively or in some other manner.
The differing mode of operation of the third exemplary embodiment in terms of the metering, in which the fuel is metered to a plurality of pump work chambers 12 by means of a single metering valve 38", has already been explained in sufficient detail in the description of FIGS. 3 and 4.
The fuel injection apparatus described in terms of four exemplary embodiments and provided with a series injection pump may also contain, instead of the fuel injection pump 10, 10', 10" or 10"', pump/nozzles that have been combined into a modular unit with the injection nozzle. The operational principle of the fuel injection apparatus according to the invention can also be applied, being adapted accordingly, to distributor injection pumps.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other embodiments and variants thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | The fuel injection quantity of a fuel injection apparatus provided with a fuel injection pump is electrically regulated by means of the opening duration of a metering valve. Additionally, a shift in the instant of supply onset controlled in accordance with operating characteristics is attained by means of a change in the return-flow fuel quantity, which is diverted into a refill reservoir and then refilled completely into the pump work chamber by the beginning of the next subsequent injection stroke. Serving as the sole connection between the refill reservoir and a pump work chamber is an overflow conduit, which is opened by two control locations on the pump piston at the end of a supply and shortly prior to the bottom dead center. Both the pump cylinder with the pressure valve and the refill reservoir and the metering valve are inserted in a leak-fuel-proof manner in a cylinder head of the pump housing, which is embodied in two parts. The decreased idle volume, the reduction of possible leakage points, and the complete refilling of the return-flow fuel quantity assure that the fuel injection quantity is determined unequivocally by the opening duration of the metering valves. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/937,886, filed Jun. 29, 2007
FIELD OF INVENTION
[0002] The present invention is directed to a method of forecasting the volume impact of a target promotion.
BACKGROUND OF THE INVENTION
[0003] There is a continuing need for a reliable means for forecasting the product volume to be sold during a promotion in a retail store. Such forecasting will allow for better promotion design, resource allocation (e.g., return on investment), inventory planning, and product portfolio management, among other benefits.
[0004] See e.g., US 2003/0130883 A1; US 2005/0273380 A1; US 2005/0278218 A1; and US 2002/0169665 A1, and US 2003/0050828 A1; as well as U.S. Pat. Nos: 6,029,139; 6,151,582; 6,954,736; 7,039,606; 7,054,837; 7,072,843; 7,120,596; 7,155,402; and 7,171,379.
SUMMARY OF THE INVENTION
[0005] The present invention attempts to address these and other needs by providing, in a first aspect of the invention, a method for forecasting target volume of a product for a target promotion in a store comprising the steps: (a) assessing purchase data; (b) identifying the single highest selling historical promotion from the purchase data; and (c) forecasting the target volume of the product of the target promotion product based upon the highest selling historical promotion identified.
DETAILED DESCRIPTION OF THE INVENTION
Definitions:
[0006] “Product” is broadly defined as encompassing any product, service, communication, entertainment, environment, organization, system, tool, and the like, sold in a store. A product may be perishable or non-perishable, consumable or durable. Many products are coded (i.e., product codes) such as the use of UPC (universal product code) or SKU (stock keeping unit) of the product. Products can also be characterized by brand name, size, and flavor (e.g., fragrance or taste variety). Exemplary product forms and brands are described on The Procter & Gamble Company's website, www.pg.com, and the linked sites found thereon.
[0007] “Purchase data” is data that is a result, at least in part, of shoppers purchasing a product at a store. Purchase data may be household-based or transaction-based or a combination thereof. Examples of ways of obtaining purchase data may include those methods described in: U.S. Pat. No. 5,490,060 (entitled “Passive Data Collection System for Market Research Data”); or International Patent Publication WO 95/30201 (entitled “Method and Apparatus for Real-Time Tracking of Retail Sales of Selected Products”). Purchase data may come from point-of-sale terminals, or store processors, or communication networks, or combinations thereof. Purchase data may be obtained from a data supplier (such as ACNielsen or Information Resources, Inc.) or directly from a store or retailer.
[0008] Purchase data may comprise data about one or more historical promotions. Such data may include the number or volume of promotional products sold during the promotional time period. Purchase data can formatted, entered into, and assessed through programs known in the art such as ACCESS (MIRCOSOFT) or EXCEL (MICROSOFT) and by other methods known in the art.
[0009] “Promotion” is a special merchandizing event which seeks to draw the shopper's attention to a particular product or group of products in order to encourage sales, preferably comprising merchandizing product to shoppers in a shopping area of a store. A promotion comprises promotion attribute(s) that characterize the promotion.
[0010] “Promotion time period” is a finite period of time or duration that a promotion is made available to shoppers at the store (e.g., 1 day, 3 days, 1 week, and the like).
[0011] “Store” is a retail store, such as WAL-MART or TESCO. The term “store” may include many retail stores (associated with a chain, specific retailer, region, and the like), or a single, individual retail store.
[0012] “Target promotion” is a promotion that is planned, or being planned, comprising one or more target products. The target promotion may even be a hypothetical event with hypothetical data. The target product may comprise a pre-existing product (one currently being sold or one that has been sold in the market), or a prototypical product/hypothetical product, or the like.
[0013] “Historical promotion” is a promotion that took place in the past, relative to the target promotion, comprising one or more historical products. A historical promotion and a target promotion may have one or more promotion attributes that may be in common or substantially in common with each other.
[0014] “Volume” is used broadly to mean the number of products sold over a given period of time in a given store. Volume may be further defined as base volume, absolute volume, or promotion volume. “Base volume” is the number of products sold that is not generally influenced by a promotion. “Promotion volume” is the number of promotion products sold during and attributable to the promotion in question. “Absolute volume” is the total number product(s) sold irrespective of promotions that may or may not be occurring.
Forecasting Volume:
[0015] One aspect of the invention provides for a method of forecasting target volume of a target product of a target promotion in a store comprising the steps: (a) defining target promotion attributes of the target promotion, wherein the target promotion attributes comprise the target product, a target product promotion price, a target promotion time period, and combinations thereof; (b) assessing purchase data of a store, wherein the purchase data comprises data about a historical promotion, wherein the historical promotion comprises historical promotion attributes; wherein the historical promotion attributes comprise: a historical product, a historical product promotion price, a historical promotion time period, and combinations thereof; (c) identifying one or more historical promotion(s) (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or more historical promotions) from the assessed purchase data that matches the target promotion based on the respective target promotion attributes and historical promotion attributes; (d) identifying a single highest selling historical promotion from the one or more identified historical promotion(s); (e) determining a historical volume of the historical product of the identified single highest selling historical promotion; and (f) forecasting the target volume of the target product of the target promotion based upon the determined volume of the historical product.
[0016] The term “highest selling” means the most number of product(s) sold on an equivalent time basis (i.e., taking in to account any differences in the duration of the target promotion and the historical promotion).
[0017] The term “based upon” means using the determined volume of the historical product of the identified single highest selling historical promotion and optionally modifying the volume number taking into account any variables that may influence the accuracy of the forecasting.
[0018] Without wishing to be bound by theory, the impact of a promotion is not fully realized at a store because many promotions suffer from “out-of-stock” product inventory at the individual store level and the lost sales associated with being out of stock. A surprising discovery is that if a store forecasts the product volume of a target promotion based on the store's highest selling historical promotion and such product inventory is timely delivered to the store (to meet the increase in demand spurred by the target promotion), the store will typically meet that product volume forecasted. In other words, and again without wishing to be bound by theory, the impact of a promotion is often not fully realized since often the target product inventory is not available to meet demand. However, given the multitude of product promotions that may be happening concurrently in a given store, with the ever increasing competitive market place, inventory control and management for stores are important in efficiency and remaining competitive, and thus “over ordering” any specific product is not an attractive option. However, the present invention provides a simple means of accurately predicting the impact of a target promotion and places the resources behind a promotion (e.g., inventory management) to fully maximize the promotion impact—on the granular level (e.g., store-by-store basis) that is needed.
[0019] In one embodiment, the method of forecasting target product volume of a target promotion is conducted on a single, individual store basis (or “store-by-store basis”). Without wishing to be bound by theory, the simple manner of forecasting volume, as presented by the present invention, allows the forecaster to go into a deeper level of granularity (i.e., on an individual store basis) without the transaction costs and/or complexities associated with more complicated modeling approaches.
[0020] Given this simplicity, there is no need, in one aspect of the invention, to take into account “base volume.” That is, in one embodiment the method is one which is free or substantially free of calculating the base volume of a target product. In another embodiment, the method provides determining the “absolute volume” (e.g., base volume+promotion volume) of the historical product of the identified single highest selling historical promotion to which the forecasted volume of the target product is based upon. An example of ways to calculate base volume include those described in US 2005/0273380 A1, paragraphs 32-42.
[0021] The simplicity of the present invention also lends itself to adoption by speaking a “common language” between a retailer and manufacturer, and the use of relatively inexpensive and widely available computer programs (such as EXCEL) to execute the methods described herein.
Identifying Historical Promotion(s).
[0022] One aspect of the invention provides for identifying one or more historical promotion(s) from the assessed purchase data that matches the target promotion based on the respective target promotion attributes and historical promotion attributes. The term “matches” means comparing, analogizing, or the like, the various attributes between the historical promotion and the target promotion. For purposes of clarification, “matches” need not mean identifying those promotion attributes that exactly align with each other, but rather identifying those attributes that are likely most analogous and/or perhaps have the greatest influence to the accuracy/precision of the forecasting herein. There are various promotion attributes to consider including product, product price, promotion time period, and the like, and combinations thereof
[0023] Promotion attributes may include: (i) type of promotion; (ii) the product or products featured in the promotion; (iii) price of the product or products; (iv) in-store promotion location (i.e., where in the store was the promotion executed, preferably comprising the products in a promotion display (e.g., end cap, main aisle, promotional area)); (v) time relevancy of the promotion (i.e., how recently the historical promotion was executed relative to the target promotion (e.g., 1 month earlier, 6 months earlier, 1 year earlier, and the like); (vi) store compliance (i.e., asking whether the store complied with all the aspects of the program (e.g., ran circulars, posted advertising, and the like)); (vii) calendar timing (e.g., promoting coffee in the winter verses the spring; or 1-day promotion on the weekend verses the weekday) (viii) and the like; and (ix) combinations thereof.
[0024] The term “type of promotions” means a category of promotions. Examples of types of promotions include: a temporary price reduction, a distributed coupon campaign, an in-store coupon campaign, a loyalty card promotion, a rebate, an advertised price reduction, a sweepstakes, a free gift offered with purchase of the product, an attached coupon for reduced cost for another service or product, and the like, and combinations thereof. Types of promotions (or so-called “marketing components”) may include those described in US 2005/0278211 A1, paragraphs 11-14.
[0025] In one embodiment of the invention, the use of statistical analysis may help match those promotion attributes (between the historical promotion and the target promotion) that provide the greatest influence in forecasting (e.g., in the accuracy/precision of the forecasting), and optionally weigh those attributes/variables accordingly. For example, “regression analysis” is a well known statistical analysis technique by which the extent of each of a plurality of variables correlates with each of a plurality of outcomes is represented by a coefficient indicative of the strength of the correlation.
[0026] Examples of statistics and statistical techniques include: regression (e.g., Choosing and Using Statistics, Calvin Dytham, Blackwell Science, 2003, page 181 et seq.); pooled regression (e.g., Introducing Multilevel Modeling, Ita G. G. Kreft & Jan de Leeuw, Sage Publications Ltd, 2004, page 26 et seq.); ordinary least squares (OLS) regression (e.g., Applied Multiple Regression/Correlation Analysis for the Behavioral Sciences, Jacob Cohen et al., Lawrence Erlbaum Associates, 2003, page 124 et seq., ); mixed modeling (e.g., Mixed Models: Theory and Application, Eugene Demidenko, John Wiley & Sons, Inc., 2004); multivariate regression modeling ( Bayesian Data Analysis, Andrew Gelman & Hal S. Stem, CRC Press LLC, 2004, page 481 et seq.); and the like. Analysis programs executable on a computer to mathematically model and normalize data input into the model are also known in the art. Examples may include STATGRAPHICS from StatPoint, Inc., Herndon, Va. 20171; SAS® from SAS Institute, Inc., ( Step - By - Step Basics Statistics Using SAS, Larry Hatcher, SAS Institute, Inc, 2003) (see example of output as provided as FIGS. 1A, 1B, and 1C); SPSS® from SPSS Inc., ( Discovering Statistics Using SPSS, Andy Field, SAGE Publications Ltd., 2005); MATLAB® from MathWorks, Inc. ( MATLAWPrimer (7th edition), Timothy A Davis & Kermit Sigmon, CRC Press LLC, 2005; or Graphics and Guis with MATLAB, Patrick Marchand & O. Thomas Holland, 3 rd edition, CRC Press LLC, 2003); and the like.
Optimizing the Mix of Products
[0027] One aspect of the invention provides for a method of optimizing a mix of products, on an individual store basis, for a target promotion promoting products across a plurality of stores, wherein the optimized mix of products maximizes the overall number of products that are sold during the target promotion, wherein the method comprises the steps: (a) assessing historical purchase data on an individual store basis to identify the single highest selling historical promotion, wherein the historical promotion and the target promotion comprise substantially the same products on a Stock Keeping Unit (SKU) basis and substantially the same price for each SKU; (b) determining a historical volume of each product of the identified single highest selling historical promotion; (c) forecasting a target volume of each product of the target promotion based upon the determined volume for the respective product of the identified single highest selling historical promotion; (d) optimizing the mix of products for each store for the target promotion based on the forecasted volume of each product to maximize the number of stores that can sell through the products of the target promotion; (e) shipping the optimized mix of products for each store. Without wishing to be bound by theory, by optimizing the mix of products (i.e., the correct ratio/percentage and quantities of the products) offered during the promotion will strike the right balance of not being out-of-stock but also mitigating the effects of the accumulation of products that are not selling as fast (e.g., maintaining inventory, taking valuable shelf space with less shopper-desirable products, and the like).
Systems
[0028] Yet another aspect of the invention provides for systems and computer program products. The systems of the present invention include at least one computer-readable medium used for storing computer instructions, data, program products, and the like. A general example of a computer is described in US 2006/0010027 A1, paragraph 78. Examples of computer readable media are compact discs, hard disks, floppy disks, tape, magneto-optical disks, PROMs (EPROM, EEPROM, Flash EPROM, etc.), DRAM, SRAM, SDRAM, etc. Stored on any one or on a combination of computer readable media, the present invention includes software for controlling both the hardware of the computer and for enabling a user to interact with the computer to conduct the methods herein described. Such software may include, but is not limited to, device drivers, operating systems and user applications.
[0029] Examples of a retailer include WAL-MART, TARGET, KROGERS, CVS, WALGREENS, COSTCO, SAMS CLUB, and the like.
[0030] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
[0031] All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0032] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | Forecasting the volume of a product as part of a promotion provides for better resource allocation by the retailer and manufacturer to support the promotion. | 6 |
[0001] The present invention concerns a process to obtain a biological response modifier (BRM), particularly a medicament, as well as the medicament thus obtained and its use from highly diluted associations of vegetable, mineral and animal extracts, aiming to make use of its medicinal characteristics, internally and externally, in treatment, prevention, control and elimination of diseases, and therapeutic and aesthetic finalities, in human beings.
BACKGROUND OF THE INVENTION
[0002] The scientific advances in the last decade allowed an increase in the knowledge of physiopathology of several diseases, so that new modalities of immunotherapy are now used for several pathologies. The medicaments that modify the biological responses, stimulating the natural defense mechanisms of the host, are called “biological response modifiers”.
[0003] The efficacy of high dilutions of biologically active substances that alter immunologic response has been evaluated through different experimental and theoretical approaches. And the potentiated biological action of an association of vegetable and mineral extracts, even highly diluted, is justified by a synergistic action produced in multiple signaling biochemical routes.
[0004] Nowadays the attention of scientists and worldwide pharmaceutical industries aim to new forms of biological response modifying therapies with low toxicity for chronic diseases such as cancer, AIDS (Acquired Immunodeficiency Syndrome), hepatitis C, leukemias, etc. Those therapies are directed to specific cells or to cytokines that contribute to the immunoresponse. Thus, the production of a medicament obtained through the association of extracts of vegetal, mineral and animal origin, highly diluted, may denote a beneficial biological response, modulating the immunologic response, without citotoxicity, mutagenicity or mitogenicity.
[0005] Considering the immunologic system role in the tissue repair process (cicatrization), as well as in the homeostasis of oxygen reactive species, potentially involved in pathologic and cellular aging processes, the modulation of immunologic response promoted by the medicament of the invention is useful in the aesthetics area, both for promoting tissue repair and anti-aging action.
DESCRIPTION OF THE INVENTION
[0006] The present invention concerns in a first aspect the process to obtain a medicament through several steps of dilution and dynamization of several solutions, associated in different stages.
[0007] To facilitate the present process, prior to the several stages of association of the multiple components, one may prepare the dynamized decimal dilutions of the several vegetable and mineral mother tinctures, as well as the Lachesis animal dilution in its tenth dynamized decimal dilution.
[0008] Thus, besides the dilution of Lachesis , the following vegetable-origin solutions are previously prepared:
[0000] a) the fifth dynamized decimal solution from mother tinctures of the vegetables Conium maculatum, Bryonia alba, Pulsatilla, Ipecacuana and Riccinus;
b) the sixth dynamized decimal solution from the mother tincture of the vegetables Rhus toxicus and Thuya occidentalis ; and
c) the mother tinctures of the vegetables Asa foetida and Aconitum napellus.
[0009] The following solutions of mineral origin are also previously prepared:
[0000] a) the sixth dynamized decimal dilution from Arsenicum album;
b) the twelfth dynamized decimal solution of Phosphorus, Silicia and Sulphur;
c) the fifth dynamized centesimal dilution of calcium carbonate.
[0010] The process of the invention is characterized by the following steps:
[0000] a) associate 25 ml of the fifth dynamized centesimal dilution of calcium carbonate with 75 ml of 70% alcohol; succuss it;
b) add 10 ml Asa foetida mother tincture, 10 ml Aconitum mother tincture, 15 ml of the prior step (a) composition and 65 ml of 70% alcohol; succuss it;
c) to 10 ml of prior step (b) composition, add 25 ml of the fifth dynamized centesimal dilution of calcium carbonate and 65 ml of 70% alcohol; succuss it;
d) to 10 ml of the prior step (c) composition, add 25 ml of the fifth dynamized centesimal dilution of calcium carbonate and 65 ml of 70% alcohol; succuss it;
e) to 10 ml of the prior step (d) composition, add 25 ml of the fifth dynamized centesimal dilution of calcium carbonate and 65 ml of 70% alcohol; succuss it;
f) to 10 ml of the prior step (e) composition add 10 ml of the fifth dynamized centesimal dilution of calcium carbonate and 80 ml 70% alcohol; succuss it;
g) to 10 ml of the prior step (f) composition add 90 ml of 70% alcohol, obtaining a first composition; succuss it;
h) dilute 10 ml of the prior step (g) composition in 90 ml of 70% alcohol; succuss it;
i) in 10 ml of the prior step (h) composition add 10 ml of the twelfth dynamized decimal dilution of Sulphur and 80 ml of 70% alcohol, obtaining a second composition; succuss it;
j) add 10 ml of the sixth dynamized decimal dilution of Arsenicum album, 10 ml of the sixth dynamized decimal dilution of Rhus toxicus, 10 ml of the prior step (i) composition and 70 ml of 70% alcohol; succuss it;
k) associate 10 ml of the sixth dynamized decimal dilution of Thuya occidentalis, 10 ml of the fifth dynamized decimal dilution of Conium maculatum, 10 ml of the prior step (j) composition and 70 ml of 70% alcohol; succuss it;
l) associate 10 ml of the fifth dynamized decimal dilution of Bryonia alba, 10 ml of the fifth dynamized decimal dilution of Riccinus, 10 ml of the prior step (k) composition and 70 ml of 70% alcohol; succuss it;
m) associate 10 ml of the fifth dynamized decimal dilution of Pulsatilla, 10 ml of the prior step (l) composition, 10 ml of the fifth dynamized decimal dilution of Ipecacuana and 70 ml distilled water; succuss it;
n) associate 1 ml of the tenth dynamized decimal dilution of Lachesis, 10 ml of the twelfth dynamized decimal dilution of Phosphorus, 10 ml of the prior step (m) composition and 79 ml of 70% alcohol; succuss it;
o) associate 1 ml of the twelfth dynamized decimal dilution of Silicia, 10 ml of the prior step (n) composition and 89 ml of 70% alcohol; succuss it;
p) associate 5 ml of the prior step (o) composition, 5 ml of step (f) composition and 40 ml of 70% alcohol; succuss it;
q) dilute 5 ml of the prior step (p) composition in 10 ml of 96% alcohol and 35 ml distilled water; succuss it;
r) dilute 5 ml of the prior step (q) composition in 10 ml of 96% alcohol and 35 ml distilled water; succuss it; and
s) dilute the composition of step (r) another 3 times in the 1:10 proportion with distilled water, and succuss it every time.
[0011] Succussion, according the meaning employed herein, means vigorous agitation of the flask where dilution or mixture is performed, with 100 strokes against a semi-rigid shield. The succcussion may be manual or mechanized.
[0012] The alcohol used in the invention is neutral. All tinctures and dilutions employed are prepared according to the methodologies described in the German Homeopathic Pharmacopeia.
[0013] Another aspect of the invention relates to a medicament prepared according to the steps (a) to (s) above described, which may be considered a homeopathic medicament, due to the following characteristics:
[0014] a. the medicament is dynamized, that is, it is obtained by diluting its components in decimal scale and is succussioned, characterizing the hannemanian methodology;
[0015] b. it is prepared from animal, vegetal and mineral substances;
[0016] c. it does not present toxicity and side reactions, as all pharmacological actives are highly diluted;
[0017] d. the homeopathic medicament is complex, as it is comprises more than one single medicament, administrated simultaneously (complexist homeopathy practice);
[0018] Nevertheless, this medicament presents innovative characteristics:
[0019] a) Novel method of production in several specific steps of associations, and the originality of such associations in homeopathic matrices.
[0020] b) The first association is obtained in such a way that each dynamization (decimal dilution followed by succussion) the mixture receives a new addition of the fifth centesimal dilution of calcium carbonate. At this stage there are two great differentials:
a decimal dilution of a matrix in centesimal scale, not previewed by any pharmacopeia. considering that with each dynamization (dilution and succussion) energetic conditions of a medicament are modified, the progression of this dynamization scale always receiving a fifth centesimal dilution matrix will produce a growing dynamization scale of that matrix, so it can be inferred that such a substance (calcium carbonate) presents itself in this medicament as an “energetic chord”, that is, in various simultaneous stages of dynamization.
[0023] The present invention provides a new modifier of the biological response. Biologic assays, in vitro and in vivo, showed that this new formulation acts as a BRM—biological response modifier—as it can activate macrophages and after treatment reactive products of oxygen and nitrogen (ROS and RNS) can be detected and quantified. This formulation also induces increase of B cell precursors in bone marrow and increase of TCD8+ in lymph node when added in drinking water for seven days.
Example
[0024] Macrophages were washed from peritoneal cavities with 10 ml of cold Phosphate Buffer Solution (PBS), at pH 7.4. The macrophages were incubated at 37° C. under 5% CO 2 for 15 min. and the non-adherent cells were removed by washing with PBS. Dulbecco's Modified Eagle's Medium (DMEM) supplemented with 10% Fetal Bovine Serum (FBS), 50 μg/ml penicillin and 100 U/ml gentamicin were added to the culture. Cultured cells were treated with this formulation (200 μl/ml), and after 24 h a new dose of 20 μl/ml was given without replacing the medium. Treatment was carried out for 48 h in vitro. The formulation was always vigorously shaken, with the process named succussion, immediately before treatment.
[0025] Significant differences were observed in the treated group when compared to control groups (cells not treated with the formulation of the invention). Cells from the control groups were mainly resident macrophages, about 70%, and few activated macrophages were also present. Almost all cells from the treated group were activated, as defined by morphological alterations. About 86% of treated macrophages were activated when observed in light microscopy and transmission electron microscopy. The increased response capacity of activated macrophages is a result, in part, of the increase capacity of these cells to produce oxygen radicals; thus the oxidative metabolism of treated macrophages was evaluated, as described in the sequence.
[0026] Reduction of ferricytochrome c was used to measure rates of formation of O 2 − in culture supernatant. For measurement of O 2 − , cells (5×10 5 cells/well) were incubated in 80 μM HBSS containing ferricytochrome c (commercialized by Sigma Chemical Co.) in the presence or absence of 1 μg/ml phorbol miristate acetate (PMA). Since PMA is able to induce O 2 − production by macrophages it was used as positive control. Absorbance was measured at 550 nm in a microplate reader (commercialized by BIO-RAD Laboratories) and the extinction molar coefficient ε=2.1×10 4 M −1 Ca −1 was used to determine reduced ferricytochrome c. Results are expressed as nmol O 2 − /10 6 cells.
[0027] After 15 min a significant decreased liberation of O 2 − in the culture supernatant was found:
[0000]
Mean
Standard Deviation
Control
17.1
0.6
Control + PMA
17.7*
0.6
Med 8
16.2*
0.6
Med 8 + PMA
16.9
0.4
Med 8 is the code for this formulation and * shows when the difference is significant when compared with the respective control (*= P < 0.05).
[0028] Production of Hydrogen Peroxide (H 2 O 2 ) by macrophages after treatment was quantified based on the horseradish peroxidase-dependent oxidation of phenol red by H 2 O 2 5 . Macrophages (3.5×10 5 cells/well) were incubated in 15 U/ml, type IV-A horseradish peroxidase (commercialized by Sigma Chemical Co.) and 194 mg/ml phenol red solution dissolved in HBSS at 4° C., briefly before the start of the experiment. 1 μg/ml of PMA was added as a positive control of H 2 O 2 production 26 . The plates were incubated at 37° C. for the desired time interval (60 and 90 min) and the reaction stopped by adding 10 μl 1M NaOH aqueous solution per well. The absorbance of cell-free culture supernatant was read at 620 nm at a microplate reader (SLT Lab Instruments 340 ATC). The H 2 O 2 concentration was determined by reference to a standard curve using 1-50 nmol of H 2 O 2 in a solution containing 15 U/ml peroxidase, 194 mg/ml phenol red in HBSS. A significant decreased liberation of H 2 O 2 in the culture supernatant was found:
[0000]
Mean
Standard Deviation
Control
16.97
0.93
Control + PMA
17.28
2.75
Med 8
15.39*
0.81
Med 8 + PMA
16.31
0.39
Med 8 is the code for this formulation and * shows when the difference is significant when compared with the respective control (*= P < 0.05).
[0029] The NO generation was estimated by sampling culture supernatants for nitrite, which is a stable product of NO reaction. Macrophages treated in vivo and in vitro (5×10 5 cells/well) were plated into 96-well tissue culture plates. After 48 h, aliquots of 100 μl of cell-free supernatant were mixed with an equal volume of Griess-reagent (0.5% sulfanilamide and 0.05% N-1-naphtyl ethylenediamine dihydrochloride in 2.5% phosphoric acid) in 96-well tissue culture plates and incubated for 10 min at 25° C. 50 ng/ml LPS and 26 U/ml IFN-γ were added as a positive control for NO production. Optic density of the samples was subsequently measured at 550 nm at a microplate reader (commercialized by BIO-RAD Laboratories). The nitrite concentration was determined by reference to a standard curve using sodium nitrite (10-80 μM) diluted in culture medium. A significant increased liberation of NO in the culture supernatant was found:
[0000]
Mean
Standard Deviation
Control
28.4
1.4
Control + LPS/IFNy
35.0*
1.9
Med 8
31.9*
2.6
Med 8 + LPS/IFNγ
32.3*
2.0
Med 8 is the code for this formulation and * shows when the difference is significant when compared with the respective control (*= P < 0.05).
[0030] After 96 hours, the supernatant of plated culture was centrifuged and the quantification of cytokines measured by mouse Th1/Th2 cytokine CBA (Cytometric Bead Array) kit (commercialized by BD Pharmingen), according to the manufacturer instructions. This kit contains antibodies against IL-2, IL-4, IL-5, INF-γ and TNF-α cytokines. Cytokine concentration was obtained comparing data with a cytokine curve in the CBA program (commercialized by Becton Dickinson). Fluorescence was measured by a FACSCalibur flow cytometer (commercialized by Becton Dickinson), equipped with an argon ion laser (488 nm). Data was analyzed in a program commercialized by Cell Quest, according to manufacturer procedures. Data analysis was performed with ANOVA and Tukey test (P<0.05) to determine the statistical significance of the intergroup comparisons. So, if the cells are producing excess of TNFα, this formulation can reduce it.
[0000]
Group
Number
total
Mean
Control
4
408.35
102.09
Med 8
4
364.82
91.20*
Med 8 is the code for this formulation and * shows when the difference is significant when compared with the respective control (*= P < 0.05).
[0031] Nitric Oxide (NO) reacts very rapidly with oxygen radicals. The chemical and biological interaction of NO and ROS with various biological molecules has important consequences in the mechanisms of different immunological and pathological conditions. Macrophages have the opportunity to produce O 2 − and NO in nearly equimolar amounts. As NO migrates near to the source of O 2 − , it reacts to form peroxynitrite (ONOO − ). Thus the primary chemistry of ONOO − would be within close proximity of the O 2 − source. Without being bound by theory, as NO is small and uncharged, it can traverse the vesicle membrane and it can be assumed that in macrophages treated with this formulation ONOO − formation would be occurring within vesicles. It can be supported by the fact that O 2 − release from treated cells diminished considerably after 15 min.
[0032] Femurs from three-month old swiss mice were dissected and cleaned. Epiphyses were removed and the marrow was flushed with Dulbecco's Modified Eagle Medium (DMEM) containing 10% fetal bovine serum with 1 U/ml penicillin, 1 μg/ml streptomycin and 2.5 μg/ml amphoterycin. Cells were counted in a Neubauer chamber and adjusted depending of the experiments. They were seeded in 24- or 96-well culture plates or into culture flasks, and maintained at 37° C. in 5% CO 2 atmosphere for 24, 48, 72 and 96 hours.
[0033] Lymph nodes were removed from the mesentery. The tissue was dissociated using sterile Medicons (commercialized by Becton Dickinson) and the cell suspension was filtered with Filcons (commercialized by Becton Dickinson)/100 μm mesh to remove tissue fragments. After washing by centrifugations, the final suspension was incubated in a culture flask with PBS at 37° C. in a humidified atmosphere containing 5% CO 2 . After 40 min of incubation, the non-adherent cell suspension was transferred to sterile tubes, washed three times with PBS and the cell number was determined using an automated cell counter (commercialized by CELM-Brazil). These cells were plated and cultured for each experiment.
[0034] Surface markers were determined using a flow cytometer. Cells (10 6 ) were fixed with 1% paraformaldehyde, washed, counted and incubated with a biotinylated antibody (0.5 μg/ml) against CD45R (lymphocyte B marker), CD11b (Mac-1) (monocytes/macrophage marker), CD11c (dendritic cells marker), CD3 (lymphocyte T marker), Ly-6G (granulocyte marker) and TER-119 (erythrocyte marker) in PBS for 40 minutes. After that they were washed with PBS and incubated with 0.5 μg/ml phycoerythrin (PE) labeled secondary antibody in PBS for 30 minutes. Fluorescence was analyzed according to standard procedures on a FACSCalibur flow cytometer (commercialized by Becton Dickinson), equipped with an argon ion laser (488 nm). Data were analyzed in Cell Quest program (commercialized by Becton Dickinson).
[0035] Data was submitted to analysis of variance with factorial diagram (2×3) to determine the statistical significance. The Tukey test was performed when the effects of interaction were significant. The level of significance was taken at p<0.05. Data is representative of three independent experiments. Accordingly, this formulation induces an increase of B cell precursors in bone marrow and an increase of TCD8+ in lymph node.
[0036] So the use of the invention gently increases both the innate and acquired immune response, activating macrophages in a non-classic way.
[0037] A person skilled in the art may be able to reduce the invention to practice with the aid of the teachings contained herein, in ways not exactly as described, but it is understood that different embodiments that perform substantially the same function to reach substantially the same result of the invention are equivalent realizations also covered by the attached claims. | The present invention concerns a process to obtain a biological response modifier (BRM), particularly a medicament, as well as the medicament thus obtained and its use from highly diluted associations of vegetable, mineral and animal extracts, aiming to make use of its medicinal characteristics, internally and externally, in treatment, prevention, control and elimination of diseases, therapeutic and aesthetic finalities, in human beings. | 0 |
TECHNICAL FIELD
This invention relates to a cable winding drum and more particularly to a cable winding drum for closing a power sliding vehicular door.
BACKGROUND OF THE INVENTION
Power sliding doors for automotive vehicles such as minivans have seen recent popularity. The use of automatic doors is a great convenience for handicapped people, for young children and for other people who have their hands filled for example with groceries.
The use of pull cables have been found to be an expeditious mechanism to both open the door and close the door. When the cable is used to close the door, more torque is need for the cable to close the door against the resisting forces of the seals and door latch. Thus, it is greatly desired to increase the torque exerted by the cable winding drum to overcome the seals and latch mechanism without excessive forces exerted on the cable that may otherwise decrease the durability of the cable.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the invention, a cable winding drum for closing a vehicle power sliding door includes a first helical outer surface with a first radius about an axis of rotation for taking up cable at a first rate when closing the vehicle door. A second outer elliptically contoured helical surface is tangent with the first helical surface in proximity to a major axis of said second outer elliptically contoured helical surface. The take-up drum when in full closed position has the cable extended out on the second outer elliptically contoured helical surface in proximity to its minor axis at a point substantially closer to the axis of rotation than the first helical outer surface.
Preferably, the second outer elliptical contour has an eccentricity of at least 0.5.
It is also desired that the second outer elliptical contour has its minor axis intersect the axis of rotation with the axis of rotation interposed between the elliptical contour and the center point for the elliptical contour.
In accordance with another aspect of the invention, a first outer surface of the drum has a general first radius about the axis of rotation for taking up cable at a first rate. A second outer facing smoothly contoured surface has a greater bent section tangent to the first outer surface with a decreasing radius with respect to the the axis of rotation and a less bent section of the second outer facing smooth surface about the drum, the maximum tension force of the cable is misaligned and at a different point of the cable from the maximum bending force of the cable. It is preferred that the second outer facing smooth contoured surface has an elliptical contour.
In this fashion, the cable have its peak bending forces and peak tensile forces located at different locations along the cable thus lowering the peak combined force load on the cable which increases its durability.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference now is made to the accompanying drawings in which:
FIG. 1 is a perspective view of a cable drum assembly and a tool for installation;
FIG. 2 is an exploded perspective view of the cable drum assembly shown in FIG. 1;
FIG. 3 is front plan view of the drums illustrating the take up guide member in its initial position;
FIG. 4 is a view similar to FIG. 3 after the take up guide member has been moved to take up cable slack;
FIG. 5 is a partially segmented plan view of the drum illustrating its elliptical contour section; and
FIG. 6 is a side elevational view of the drum shown in FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, a cable tension assembly 10 includes housing 11 that is constructed to have a section 12 that rotatably houses a first drum 14 and second drum 16 that are connected to rotate together. A tool 15 can be operably mounted to the housing as shown in FIG. 1 . The housing 11 has a body section 18 and cover 20 that are fitted together to retain the two drums within. The two drums snap fit together via prongs 22 fitting into apertures 24 .
Both drums are rotatable via a motor not shown which rotates the drums about axis 26 . The motor and controls for the motor are conventional and form no part of this invention.
A cable 28 has one end secured 27 onto the second drum 16 at point 30 as shown in FIG. 5 and wraps about the outer surface 32 a plurality of times, extends about tension pulley 34 and out through an aperture 36 to exit the housing and be connected to the door (not shown).
Another cable 29 is then attached to the door and has its end 40 return back into the housing through aperture 38 and about a second tension pulley 42 and into the drum 14 through an aperture in the drum that communicates with an arcuate slot 48 within the drum. The end 40 then is connected to a tension take up member 46 that is mounted in the arcuate slot 48 within the drum 14 . The take up member 46 has resiliently mounted ratchet teeth 50 on a cantilevered section 49 that normally engage complementary ratchet teeth 52 about the outer wall 54 of the slot 48 . The cantilevered section 49 has some resilient flex.
The take up member 46 is initially positioned in proximity to one end 56 of slot 48 as shown in phantom in FIG. 3 . Furthermore there is sufficient length of cable 29 such that there is plenty of length of cable to easily reach end 40 of cable 29 into the slot 48 and be securely attached to tension take up member 46 without placing any tension onto cable 28 .
The take up member 46 is then free to slide in the direction shown by arrow 58 in slot 48 toward the position shown in FIG. 4 with the ratchet teeth 50 on cantilevered section 49 resiliently overriding ratchet teeth 52 in slot 48 until all slack is taken up in cable 29 to a set tension. The teeth 50 and 52 normally prevent the tension take up member from sliding back in a direction opposite arrow 58 toward end 56 . It is also noted that the ratchet teeth 52 progressively become larger away from end 56 and toward end 60 to help retain teeth 50 against larger tension forces placed on cable 29 .
A tool 15 and a gear wheel 62 expedite the take up of slack and the tensioning of the cable 28 . The gear wheel 62 is rotatably mounted adjacent the drum 16 and has gear teeth 64 that engage teeth 66 about the perimeter 68 of drum 16 . The gear wheel has an integral hex nut section 69 that can be engaged by tool 15 . The tool 15 socket engaging section 70 is mounted on a distal end of a shaft 72 that is moved by a lever handle 73 that is connected through a ratchet connection 74 . A knob 75 is also mounted on an opposing end of the shaft. A stop assembly 76 is rotatably mounted about the shaft and has one stop member 78 that protrudes through aperture 80 that limits the compression of the spring loaded pulley 34 to about one-half its travel capacity. Tool 15 also has a second stop member 82 that protrudes through aperture 84 and protrudes into slot 86 of take up guide member 46 .
In operation, after the cable 28 has been attached to the door, the door is positioned so that the slot 86 is visible through the aperture 84 . The installer then places tool 15 into position and cranks on lever handle 73 to rotate the shaft 72 which in turn rotates the nut 69 and gear wheel 62 . The gear then rotates the drum 14 and drum 16 . The tool simultaneously retains the take up member such that the take up member slides in slot 48 in the direction indicated by arrow 58 with the teeth 50 and 52 causing clicking indicating sounds. The excess cable is taken up onto the drum 16 as both drums rotate. Pulley 42 has its spring fully compressed and pulley 34 is limited by stop member 78 . When the tool is disengaged, the tension on both pulleys 42 and 54 re-balances to provide equal spring resiliency in both pulleys 34 and 42 . The take up guide member 46 remains positioned to be accessed through aperture 84 when the door is in the closed position.
If tension in the cable ever needs to be released, the drums 14 and 16 are positioned to align slot 86 with aperture 80 . A screw driver is then placed into slot 86 to flex the cantilevered section to disengage the teeth 50 from teeth 52 . Once the teeth are disengaged from each other the drums are free to rotate to release the tension of the cable system.
Drum 16 is used to pull cable 28 such that as the cable 28 wraps about its outer surface 90 , the door is moved to its closed position. As the door is moved to its fully closed position, the driving motor must overcome the higher torque forces cause by sealing members and the closure latch in the last few centimeters of travel. The extra torque is provided by decreasing the effective outer radius of the drum 16 for the last few centimeters of travel.
The drum 16 as more clearly shown in FIGS. 5 and 6 has a normal circular first outer surface section 92 normally referred to as a drum helix with a first radius indicated at 94 . A second outer surface helix section 96 has an elliptical contour that is tangent to the first outer surface section 92 at point 99 in proximity to the major axis 98 of the contour. The minor axis 100 of the elliptical contour intersects the axis of rotation 26 . The axis of rotation 26 is interposed between the defined center 102 of the elliptical contour and the elliptical contour surface 96 . The elliptical contour is positioned such that the effective radius continually decreases from the tangent point 99 to the minor axis 100 to it's minimum radius indicated at 104 .
It can be readily seen that the motor thus can provide for more torque to overcome the resisting forces of seals and latches by placing the cable along a smaller radius 104 .
In this fashion, when the door is closed and the most tension is placed on the cable, the highest bending stresses occur near the tangent point 99 near the major axis 98 and the highest tensile forces are in proximity of the minor axis 100 . However, the bending stress at the minor axis 100 is lowered due to its flattened elliptical contour. The most bending stress occurs along the major axis 98 where the tensile forces are lower. In this fashion, the location of the highest tensile force and the highest bending stress are displaced from each other along different sections of the cable 28 . By displacing the location of these two highest forces from each other, one lowers the peak stress along any given point along the cable and thus provides for a more durable cable.
Variations and modifications are possible without departing from the scope and spirit of the present invention as defined by the appended claims. | An automatic sliding door cable mechanism with a take up guide member ( 46 ) mounted in a drum ( 14 ) for taking up slack of a cable during installation of the cable. A second drum ( 16 ) has an elliptical profile drum helix ( 96 ) for increasing durability of the operating cable for the automatic door. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to a disengageable cylinder for an automobile lock mechanism.
The addition of a disengageable mechanism to a cylinder intended for an automobile lock makes it possible to prevent this cylinder from being forced. Specifically, if an improper key, or any other flat tool of suitable shape, is inserted into the rotor, and if an attempt is then made to rotate the rotor, the disengagement mechanism enables the rotor and an intermediate sleeve to pivot freely inside the stator without considerable stresses being exerted on the tumblers.
The fact is that, in the presence of excessive stresses, the tumblers are liable to be damaged or be retracted by force, thus allowing the cylinder to be unlocked without the appropriate key.
The invention is concerned more precisely with a disengageable cylinder, in particular for a motor vehicle lock mechanism, comprising a fixed stator, a tubular intermediate sleeve which is mounted in rotation about its axis in the stator and which is fixed axially with respect to the stator, a rotor which is mounted in rotation in the sleeve, which is fixed axially in the sleeve and which comprises tumblers which can move radially under the action of a key intended to be inserted axially into the rotor. Tumblers are fully retracted inside the rotor when the key is appropriate, so as to allow a free rotation of the rotor with respect to the sleeve and the stator and thus allow a lock operating lever, called a cam actuator, to be rotated, this lever being coupled to the rotor via a driver. The rotor and the intermediate sleeve are blocked against rotation with respect to one another by the tumblers when the key is not appropriate. The cylinder also comprises an indexer which can move axially between a rest position and a disengagement position, under the effect of a rotation of the sleeve with respect to the stator subsequent to the rotor being rotated by means of an inappropriate key, so as to move the driver axially toward a disengaged position.
Such a disengageable cylinder is described in patent document FR 2 748 513.
In this known cylinder, the indexer and the driver are in a configuration with a substantially end-to-end arrangement. These two parts are substantially arranged as a continuation of one another.
The indexer is coupled in rotation with the intermediate sleeve and is guided in translation therein. The driver for its part is guided in rotation on the rotor.
The indexer comprises a main ring and guide tabs which extend axially from the ring and which are intended to be accommodated in corresponding axial notches of the intermediate sleeve. It also comprises two lugs which extend axially in the opposite direction in the continuation of two diametrically opposed guide tabs.
This cylinder arrangement poses the following technical problems.
Due to its configuration with an end-to-end arrangement, the length of such a cylinder is relatively large.
Moreover, the indexer is a relatively fragile part due to its construction.
BRIEF SUMMARY OF THE INVENTION
The invention solves these problems by providing a disengageable cylinder which is particularly compact, that is to say one with a limited length and particularly robust construction.
Accordingly, the invention provides a disengageable cylinder, in particular for a motor vehicle lock mechanism, comprising a fixed stator, a tubular intermediate sleeve which is mounted in rotation about its axis in the stator and which is fixed axially with respect to the stator, a rotor which is mounted in rotation in the sleeve, which is fixed axially in the sleeve and which comprises tumblers which can move radially under the action of a key intended to be inserted axially into the rotor, the rotor and the intermediate sleeve being blocked against rotation with respect to one another by the tumblers when the key is not appropriate, a driver providing coupling between the rotor and an operating lever, called a cam actuator, when the key is appropriate, and an indexer which can move axially between a rest position and a disengagement position, under the effect of a rotation of the sleeve with respect to the stator subsequent to the rotor being rotated by means of an inappropriate key, so as to move the driver axially toward a disengaged position, characterized in that the indexer and the driver are cylindrical parts surrounding the rotor and can move while bearing on one another, in that the driver is connected in disengageable rotation on the rotor, and in that the indexer is connected in translation in the stator by means of ribs surrounding the intermediate sleeve.
According to a preferred embodiment, the driver is uncoupled from the rotor, in said disengaged position.
Preferably, the driver comprises internal ribs inserted in corresponding grooves of the rotor, in the engaged position, these grooves being open toward the rear of the rotor over a cylindrical portion whose diameter is less than the internal diameter of the driver.
Advantageously, the cylinder comprises a compression spring interposed between the cam actuator and the driver.
Preferably, the driver comprises, on its edge facing the cam actuator, at least one guide tab intended to cooperate with a corresponding notch belonging to the cam actuator, this notch allowing a translation of the driver toward the cam actuator against the force of the compression spring.
Said notch may be open on the rear end face of the cam actuator.
The driver may comprise a collar and two guide lugs which extend axially toward the cam actuator from the collar.
Preferably, the indexer is coupled in rotation with the cam actuator, in said disengaged position.
Advantageously, the indexer comprises, on its edge facing the cam actuator, at least one guide tab intended to cooperate with a corresponding notch belonging to the cam actuator.
Preferably, the indexer comprises, on its edge facing the key entry, at least one guide tab intended to cooperate with a corresponding notch belonging to the intermediate sleeve.
Advantageously, the indexer comprises a main ring, two first guide tabs of trapezoidal shape, as seen in cross section through a plane tangential to the ring, which extend axially toward the key entry from the ring, and two second guide tabs which extend axially toward the cam actuator from the ring.
The intermediate sleeve may comprise two notches corresponding to said first guide tabs, and the cam actuator comprises two notches corresponding to said second guide tabs.
The invention is described in more detail below with the aid of figures representing only one preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a disengageable cylinder according to the invention.
FIG. 2 is a view in longitudinal section of the disengageable cylinder according to the invention, in the initial position.
FIG. 3 is a view in cross section on G in FIG. 2 .
FIG. 4 is a view in cross section on I in FIG. 2 .
FIG. 5 is a view in longitudinal section on C in FIG. 2 .
FIG. 6 is a view in cross section on J in FIG. 2 .
FIG. 7 is a view in cross section on K in FIG. 2 .
FIG. 8 is a perspective view of a cylinder according to the invention, in the engaged position, the stator not being represented.
FIG. 9 is a view in longitudinal section of the disengageable cylinder according to the invention, in the disengaged position.
FIG. 10 is a view in cross section on P in FIG. 9 .
FIG. 11 is a view in longitudinal section on R in FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a rotary cylinder of longitudinal axis A 1 that comprises disengagement means according to the teachings of the invention. This cylinder is represented in FIGS. 2 to 7 in the initial position before insertion of a key.
The cylinder 10 essentially comprises a rotor 12 which is rotatably mounted, about the axis A 1 , inside a fixed stator 14 , with a tubular intermediate sleeve 16 being interposed between the two of them, this sleeve being mounted in rotation about its axis in the stator and being fixed axially with respect to the stator.
A ball 60 is mounted intermediately in a radial through orifice 16 A formed in the intermediate sleeve 16 . The rotor 12 , on the one hand, has an external cavity 12 R for accommodating this ball, and the stator 14 , on the other hand, has an internal cavity (not shown) for accommodating this ball. This orifice 16 A, this cavity 12 B in the rotor and this cavity 14 B in the stator are arranged such that in the rest position, before rotation of a key, the orifice 16 A, the cavity 12 B in the rotor and the internal cavity in the stator are aligned as represented in FIG. 2 .
The rotor 12 is intended to be rotated by means of a key (not shown) inserted axially inside the rotor 12 through a key entry 18 arranged in a front transverse face 20 of the rotor 12 , which face 20 is intended, for example, to be flush with the outside of a vehicle body panel (not shown).
The rear axial end 22 of the rotor 12 is intended to rotate a lever 24 which operates a lock mechanism (not shown) so as to allow the locking and unlocking of an opening leaf of the vehicle.
The rotor 12 is able to rotate the operating lever 24 , only in the presence of an appropriate key, via a driver 26 which can move axially in the cylinder 10 , under the action of an indexer 28 , between an engaged position in which it connects the rotor 12 and the operating lever 24 in rotation, and a disengaged position in which the rotor 12 is no longer able to rotate the lever 24 and in which the indexer 28 ensures that the lever 24 is blocked against rotation with respect to the stator 14 of the cylinder 10 .
The rotor 12 , the stator 14 and the intermediate sleeve 16 are not able to move in translation along the axis A 1 with respect to one another, and a helical compression spring 30 is interposed between the cam actuator 24 and the driver 26 so as to urge the latter axially rearward toward its engaged position.
The stator 14 has a cylindrical tubular general shape and it comprises means (not shown) which allow the cylinder 10 to be mounted and fastened on the vehicle.
In a known manner, the rotor 12 is intended to receive tumblers 32 arranged in transverse planes which follow one another at regular intervals in the direction of the axis A 1 of the cylinder 10 , these tumblers being received in corresponding housings of the rotor 12 .
The tumblers 32 can move radially in the rotor 12 and they are urged elastically toward a projecting position in which they partially protrude outside the housings of the rotor 12 .
However, when an appropriate key is inserted inside the rotor 12 , the tumblers 32 are fully retracted radially inward into the rotor 12 .
Thus, when the appropriate key is inserted into the rotor 12 , the latter can pivot freely with respect to the cylindrical intermediate sleeve 16 and with respect to the stator 14 .
However, if an inappropriate key, or any other tool, is inserted into the rotor 12 , the tumblers 34 are not fully retracted and are received inside corresponding apertures 36 arranged in the intermediate sleeve 16 . Thus, the tumblers 34 immobilize the rotor 12 in rotation with respect to the intermediate sleeve 16 which, for its part, remains free to rotate with respect to the stator 14 .
The indexer 28 , which can move axially between a rest position and a disengagement position, is connected in translation on the stator 14 via grooves arranged inside the stator and via ribs 38 A, 38 B which slide inside these grooves and surround the intermediate sleeve 16 . The ribs 38 A, 38 B and the grooves are two in number and are diametrically opposed.
The indexer 28 particularly comprises a main ring 38 and first guide tabs 40 of trapezoidal shape, as seen in cross section through a plane tangential to the ring 38 , which extend axially toward the front from the ring 38 . These first tabs 40 are intended to be received in corresponding axial notches 42 of the intermediate sleeve 16 . These first guide tabs 40 are two in number and are diametrically opposed on the ring 38 .
The notches 42 open out axially toward the rear in the rear axial end of the sleeve 16 such that, together with the guide tabs 40 , they make it possible to rotationally connect the indexer 28 with the intermediate sleeve 16 , while still allowing the possibility for the indexer 28 to move axially in the cylinder 10 .
The indexer also comprises second guide tabs 41 of rectangular shape, as seen in cross section through a plane tangential to the ring 38 , which extend axially toward the rear from the ring 38 . These second tabs 41 are intended to be received in corresponding axial notches 43 of the cam actuator 24 . These second guide tabs 41 are two in number, are diametrically opposed on the ring 38 and are arranged substantially opposite the first guide tabs 40 .
The driver 26 provides coupling between the rotor 12 and the cam actuator 24 when the key is appropriate. It is connected in translation on the rotor via internal ribs 26 A and via grooves 12 A belonging to the rotor 12 .
The internal ribs 26 A are inserted in the corresponding grooves 12 A of the rotor, in the engaged position, these grooves being open toward the rear of the rotor 12 over a cylindrical portion whose diameter is less than the internal diameter of the driver.
The driver 26 comprises a collar 39 whose outside or inside diameter is substantially equal to the outside or inside diameter of the ring 38 of the indexer 28 , the indexer and the driver being arranged end to end.
The driver 26 comprises guide lugs 45 of rectangular shape, as seen in cross section through a plane tangential to the collar 39 , which extend axially toward the rear from the collar 39 . These guide lugs 45 are intended to be received in corresponding axial notches 47 of the cam actuator 24 , these notches allowing a translation of the driver toward the cam actuator against the force of the compression spring 30 and advantageously being open on the rear end face of the cam actuator. These guide lugs 45 are two in number and are diametrically opposed on the collar 39 .
The cylinder 10 also comprises a return spring 50 which operates in torsion and which serves to return the cam actuator 24 to the initial position.
The operation of the cylinder according to the invention will now be described with reference to the other figures.
In FIG. 8 , an appropriate key has been inserted into the rotor 12 through the key entry 18 , and the cylinder is thus in the engaged position. The tumblers 32 are thus retracted inside the rotor 12 , which can turn in the intermediate sleeve 16 .
In this position, the rotor 12 can be turned with the key and drives the driver 26 along with it, this driver, by virtue of its lugs 45 fitting into the corresponding notches 47 of the cam actuator 24 , causing said actuator to rotate, releasing the lock.
The other parts remain immovable, more precisely the intermediate sleeve 16 , which is rotationally immovable and connected to the stator 14 by the ball 60 , and the indexer 28 fitted into said sleeve by its front guide tabs 40 .
The rotation of the cam actuator 24 is obtained by the rotation of the following parts: key/rotor/driver/cam actuator.
At the end of travel, when the key is released, the return spring 50 , whose one end is fixed and other end butts against a lug 24 A of the cam actuator 24 , returns the cam actuator to the initial position along with the driver and the rotor.
In FIGS. 9 to 11 , an inappropriate key has been inserted into the rotor 12 through the key entry 18 , and the cylinder is thus in the disengaged position. The tumblers 32 are thus not retracted inside the rotor 12 , which is consequently rotationally connected to the intermediate sleeve 16 as a result of the tumblers being inserted in the latter.
The rotation of the inappropriate key thus causes the rotor 12 and intermediate sleeve 16 , which are interconnected and take along the ball 60 in the orifice 16 A of the intermediate sleeve 16 and in the cavity 12 B in the rotor 12 , to be rotated. The rotation of the sleeve 16 results in the translation of the indexer 28 in the direction of the cam actuator 24 by virtue of the front guide tabs 40 of the indexer sliding out of the corresponding notches 42 of the sleeve 16 . In this translated position, the rear guide tabs 41 of the indexer 28 become inserted in the corresponding notches 43 of the cam actuator 24 . Since the indexer 28 is rotationally immovable as a result of its connection with the stator, the cam actuator cannot turn.
The driver 26 for its part is uncoupled from the rotor 12 , since it is pushed against the force of the compression spring 30 by the indexer 28 which bears on the front end face. Its ribs 26 A thus leave the corresponding notches 12 A of the rotor, and the rotational connection of the rotor and the driver is broken.
In this disengaged position, during the rotation of an inappropriate key, the ball rotationally connects the intermediate sleeve 16 and the rotor 12 , that is to say is inserted in the external cavity 12 B in the rotor.
The deliberate rotation of the key thus results in the movement of the following parts: rotation of the rotor/rotation of the intermediate sleeve/translation of the indexer and blocking of the cam actuator against rotation/rotation of the driver and uncoupling of the cam actuator.
During the subsequent insertion of an appropriate key, the rotor 12 is turned by virtue of the rotation of the key to the initial position represented in FIGS. 2 to 7 , the ball 60 being released from the rotor, and then the cylinder is engaged if the key is appropriate or is disengaged if the key is inappropriate. | A disengageable lock for a motor vehicle locking system includes a fixed stator, a sleeve, a rotor, a driver, and an indexer. The sleeve is mounted rotatably in the stator and is fixed axially relative to the stator. The rotor is mounted rotatably in the sleeve and is fixed axially in the sleeve. The driver is connected in disengageable rotation on the rotor. The indexer, which is axially mobile between rest and disengagement positions, is connected in translation in the stator by ribs surrounding the sleeve. When an appropriate key is inserted in the rotor, the driver couples the rotor and a cam actuator in rotation, releasing the lock. When an inappropriate key is inserted, the rotor and the sleeve rotate, causing the indexer to move toward the cam actuator. Because the indexer is rotationally immovable as a result of its connection with the stator, the cam actuator cannot rotate. | 4 |
FIELD OF INVENTION
[0001] The present invention relates to compounds of the general formula (I), their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts, pharmaceutical compositions containing them, methods for their preparation, use of these compounds in medicine and the intermediates involved in their preparation.
[0002] The present invention is directed towards compounds which can be used to treat diseases such as Hyperlipidemia and also have a beneficial effect on cholesterol.
[0000]
[0003] The compounds of the general formula (I) lower blood glucose, lower or modulate triglyceride levels and/or cholesterol levels and/or low-density lipoproteins (LDL) and raises the high-density lipoproteins (HDL) plasma levels and hence are useful in combating different medical conditions, where such lowering (and raising) is beneficial. Thus, it could be used in the treatment and/or prophylaxis of obesity, hyperlipidemia, hypercholesteremia, hypertension, atherosclerotic disease events, vascular restenosis, diabetes and many other related conditions.
[0004] The compounds of general formula (I) are useful to prevent or reduce the risk of developing atherosclerosis, which leads to diseases and conditions such as artereosclerotic cardiovascular diseases, stroke, coronary heart diseases, cerebrovascular diseases, peripheral vessel diseases and related disorders.
[0005] These compounds of general formula (I) are useful for the treatment and/or prophylaxis of metabolic disorders loosely defined as Syndrome X. The characteristic features of Syndrome X include initial insulin resistance followed by hyperinsulinemia, dyslipidemia and impaired glucose tolerance. The glucose intolerance can lead to non-insulin dependent diabetes mellitus (NIDDM, Type 2 diabetes), which is characterized by hyperglycemia, which if not controlled may lead to diabetic complications or metabolic disorders caused by insulin resistance. Diabetes is no longer considered to be associated only with glucose metabolism, but it affects anatomical and physiological parameters, the intensity of which vary depending upon stages/duration and severity of the diabetic state. The compounds of this invention are also useful in prevention, halting or slowing progression or reducing the risk of the above mentioned disorders along with the resulting secondary diseases such as cardiovascular diseases, like arteriosclerosis, atherosclerosis; diabetic retinopathy, diabetic neuropathy and renal disease including diabetic nephropathy, glomerulonephritis, glomerular sclerosis, nephrotic syndrome, hypertensive nephrosclerosis and end stage renal diseases, like microalbuminuria and albuminuria, which may be result of hyperglycemia or hyperinsulinemia.
[0006] The compounds of the present invention can be useful as aldose reductase inhibitors; for improving cognitive functions in dementia, and in the treatment and/or prophylaxis of disorders such as psoriasis, polycystic ovarian syndrome (PCOS), cancer, osteoporosis, leptin resistance, inflammation and inflammatory bowel diseases, wound healing, xanthoma, pancreatitis, myotonic dystrophy, endothelial cell dysfunction and hyperlipidemia.
BACKGROUND OF THE INVENTION
[0007] Higher LDL cholesterol levels in the plasma increase cardiovascular risk and reduction in the levels of LDL would decrease CVD risk by a comparable percentage (PNAS, 2009, 106, 9546-9547). Clearance of LDL cholesterol from plasma is through the action of LDL receptors in the liver and LDL receptors are cell surface glycoproteins that bind to apoliporpotein B100 (apoB 100) on LDL particles with high affinity and mediate their endocytic uptake (Journal of Biological Chemistry, 2009, 284, 10561-10570). Defect in hepatic cholesterol clearance and elevated levels of plasma LDL cholesterol that result from the mutations cause familial hypercholesterolemia. Such mutations are identified in the human LDL receptor and later in apolipoprotein-B (Nature Structural and Molecular Biology, 2007, 14, 413-419). Recently, mutations within certain subtypes of the pro-protein convertase subtilisin/gene such as the subtype nine (hereinafter “the gene”) were found to represent a third class of mutations associated with autosomal dominant hypercholesterolemia (ADH). The discovery, etiology and functions of this subtype gene is discussed in details in Nature Genetics, 2003, 34, 154-156, Trends in Biochemical Sciences, 2008, 33, 426-434 etc. Several missense mutations (S127R, D129G, F216L, D374H, D374Y) are associated with hypercholesterolemia and premature atherosclerosis (J Lipid Res. 2008, 49, 1333-1343). Loss-of-function mutations (R46L, L253F, A433T) lead to elevated receptor abundance, enhancing clearance of LDL cholesterol from the circulation and reducing cardiovascular risk (Nature Structural and Molecular Biology, 2007, 14, 413-419).
[0008] Detailed molecular mechanisms explaining the association of LDLR and the particular subtype gene and LDLR degradation is not very clear (Drug News Perspectives, 2008, 21, 323-330). Because of inhibition of LDLR recycling, number of LDL receptors on the cell surface are decreased and this increases plasma LDL levels (PNAS, 2009, 106, 9546-9547).
[0009] Various approaches for inhibiting this particular subtype gene are reported, including gene silencing by siRNA or antisense oligonucleotides, mAb disrupting protein-protein interactions or by peptides; all the above-mentioned strategies have shown lowering of LDL cholesterol which may be effective therapy for treating hypercholesterolemia (Biochemical Journal, 2009, 419, 577-584; PNAS, 2008, 105, 11915-11920; Journal of Lipid Research, 2007, 48, 763-767; PNAS, 2009, 106, 9820-9825). However, very little success has been reported in trying to inhibit this subtype gene by using small molecules. Such small molecule inhibitors has its obvious clinical and therapeutic benefit over the other approaches as discussed above. We herein disclose novel small molecules which have shown to inhibit this particular gene in in-vitro studies and therefore provides an alternate beneficial approach for treating patients in need of such therapy.
Preferred Embodiments of the Invention
[0010] An important object of the present invention is to provide novel substituted oximino derivatives represented by the general formula (I), their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts, and pharmaceutical compositions containing them or their mixtures thereof.
[0011] In an embodiment of the present invention is provided a process for the preparation of novel substituted oximino derivatives and their derivatives represented by the general formula (I), their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts.
[0012] In a further embodiment of the present invention is provided pharmaceutical compositions containing compounds of the general formula (I), their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts, or their mixtures in combination with suitable carriers, solvents, diluents and other media normally employed in preparing such compositions.
[0013] In a further embodiment of the present invention is provided process for treatment of diseases such as dyslipidemia, hyperlipidemia etc. by providing therapeutically effective amount of the compounds of formula (I) or their pharmaceutically acceptable salts or their suitable pharmaceutical compositions.
[0014] The above and other embodiments are described in details hereinafter.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Accordingly, the present invention relates to compounds of the general formula (I),
[0000]
[0000] their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts, and pharmaceutical compositions containing them wherein
[0016] ‘A’ represents an optionally substituted single or fused group selected from aryl, heterocyclyl or cycloalkyl groups;
[0017] In a preferred embodiment, ‘A’ is selected from optionally substituted aryl or heterocyclyl groups;
[0018] In a further preferred embodiment, the aryl group may be selected from substituted or unsubstituted monocyclic or bicyclic aromatic groups;
[0019] In a still further preferred embodiment, the aryl group is an optionally substituted phenyl group.
[0020] In an embodiment, when ‘A’ represents a heterocyclyl group, the heterocyclyl group may be selected from single or fused mono, bi or tricyclic aromatic or non-aromatic groups containing one or more hetero atoms selected from O, N or S;
[0021] In a preferred embodiment, the heterocyclyl group may be selected from pyridyl, thienyl, furyl, pyrrolyl, oxazolyl, thiazolyl, isothiazolyl, imidazolyl, isoxazolyl, oxadiazolyl, thiadiazolyl, triazolyl, tetrazolyl, benzofuranyl, benzothienyl, indolinyl, indolyl, azaindolyl, azaindolinyl, pyrazolopyrimidinyl, azaquinazolinyl, pyridofuranyl, pyridothienyl, thienopyrimidyl, quinolinyl, pyrimidinyl, pyrazolyl, quinazolinyl, pyridazinyl, triazinyl, benzimidazolyl, benzotriazolyl, phthalazynil, naphthyl idinyl, purinyl, carbazolyl, phenothiazinyl, phenoxazinyl, benzoxazolyl, benzothiazolyl, thiazepinyl, oxazolidinyl, thiazolidinyl, dihydrothiophene, dihydropyran, dihydrofuran, dihydrothiazole, benzopyranyl, benzopyranonyl, benzodihydrofuranyl, benzodihydrothienyl, pyrazolopyrimidonyl, azaquinazolinoyl, thienopyrimidonyl, quinazolonyl, pyrimidonyl, benzoxazinyl, benzoxazinonyl, benzothiazinyl, benzothiazinonyl, thieno piperidinyl and the like;
[0022] ‘Y’ represents either a bond or substituted or unsubstituted linear or branched (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl groups or the groups represented by ‘—U(CH 2 ) m —’ wherein U represents O, S(O) o , NR 4 ; ‘m’ represents integers from 2 to 4, ‘o’ represents integers from 0 to 2 and R 4 represents H, substituted or unsubstituted linear or branched (C 1 -C 6 )alkyl;
[0023] ‘Z’ represents an optionally substituted single or fused group selected from aryl, heterocyclyl or cycloalkyl groups;
[0024] In a preferred embodiment, ‘Z’ is selected from optionally substituted aryl or heterocyclyl groups;
[0025] In a further preferred embodiment, the aryl group may be selected from substituted or unsubstituted monocyclic or bicyclic aromatic groups;
[0026] In a still further preferred embodiment, the aryl group is an optionally substituted phenyl group.
[0027] When ‘Z’ represents a heterocyclyl group, the heterocyclyl group may be selected from single or fused mono or bi cyclic aromatic groups containing one or more hetero atoms selected from O, N or S;
[0028] In a still preferred embodiment, when ‘Z’ represents heteroaromatic group, the heteroaromatic group may be selected from pyridyl, thienyl, furyl, pyrrolyl, oxazolyl, thiazolyl, isothiazolyl, imidazolyl, isoxazolyl, oxadiazolyl, thiadiazolyl, triazolyl, tetrazolyl, benzofuranyl, benzothienyl, indolinyl, indolyl, azaindolyl, azaindolinyl, pyrazolopyrimidinyl, azaquinazolinyl, pyridofuranyl, pyridothienyl, thienopyrimidyl, quinolinyl, pyrimidinyl, pyrazolyl, quinazolinyl, pyridazinyl, triazinyl, benzimidazolyl, benzotriazolyl, phthalazynil, naphthylidinyl, purinyl, carbazolyl, phenothiazinyl, phenoxazinyl, benzoxazolyl, benzothiazolyl groups. ‘X’ represents either a bond, or may be selected from O, S(O) o or NR 4 ; wherein R 4 is as defined earlier;
[0029] ‘W’ represents substituted or unsubstituted linear or branched (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl groups;
[0030] R 1 represents hydrogen, optionally substituted, (C 1 -C 6 )alkyl, (C 3 -C 6 )cycloalkyl, alkoxyalkyl, hydroxyalkyl, aminoalkyl, aryl, heterocyclyl, aralkyl, heterocyclylalkyl groups;
[0031] R 2 represents hydrogen, or the groups selected from (C 1 -C 6 )alkyl, aryl, heterocyclyl, aralkyl, heterocyclylalkyl, (C 1 -C 6 )alkoxy, hydroxyalkyl, thio(C 1 -C 6 )alkyl, amino, aminoalkyl, alkylamino, each of which may be optionally substituted;
[0032] Alternatively R 1 and R 2 wherever possible, together may form 4 to 7 membered saturated or partially saturated ring containing from 0-2 additional heteroatoms selected from the group consisting of N, O, and S(O) o ;
[0033] R 3 at each occurrence independently represents hydrogen, halogen, (C 1 -C 3 )alkyl, halo(C 1 -C 3 )alkyl, (C 1 -C 3 )alkoxy, thio(C 1 -C 3 )alkyl, sulfenyl derivatives, sulfonyl derivatives;
[0034] ‘n’ represents integers from 0-3;
[0035] When A, R 1 , R 2 , R 3 or R 4 are substituted, the substituents at each occurrence may be independently selected from hydroxyl, oxo, halo, thiol, nitro, amino, cyano, formyl, or substituted or unsubstituted groups selected from amidino, alkyl, haloalkyl, perhaloalkyl, alkoxy, haloalkoxy, perhaloalkoxy, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, bicycloalkyl, bicycloalkenyl, alkoxy, alkenoxy, cycloalkoxy, aryl, aryloxy, aralkyl, aralkoxy, heterocylyl, heterocyclylalkyl, heterocycloxy, heterocyclylalkoxy, heterocyclylalkoxyacyl, acyl, acyloxy, acylamino, monosubstituted or disubstituted amino, arylamino, aralkylamino, carboxylic acid and its derivatives such as esters and amides, carbonylamino, hydroxyalkyl, aminoalkyl, alkoxyalkyl, aryloxyalkyl, aralkoxyalkyl, alkylthio, thioalkyl, cycloalkylthio, arylthio, heterocyclylthio, alkylsulfinyl, cycloalkylsulfinyl, arylsulfinyl, heterocyclylsulfinyl, alkylsulfonyl, cycloalkylsulfonyl, arylsulfonyl, heterocyclylsulfonyl, alkylsulfonylamino, cycloalkylsulfonylamino, arylsulfonylamino, heterocyclylsulfonylamino, alkylsulfonyloxy, cycloalkylsulfonyloxy, arylsulfonyloxy, heterocyclylsulfonyloxy, alkoxycarbonylamino, aryloxycarbonylamino, aralkyloxycarbonylamino, aminocarbonylamino, alkylaminocarbonylamino, alkoxyamino, hydroxylamino, sulfenyl derivatives, sulfonyl derivatives, sulfonic acid and its derivatives.
[0036] When the substituents on A, R 1 , R 2 , R 3 or R 4 are further substituted, the substituents may be selected from one or more groups described above.
[0000] The various groups, radicals and substituents used anywhere in the specification are described in the following paragraphs.
In a further preferred embodiment the groups, radicals described above may be selected from:
the “alkyl” group used either alone or in combination with other radicals, denotes a linear or branched radical containing one to six carbons, selected from methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, tert-butyl, amyl, t-amyl, n-pentyl, n-hexyl, and the like; the “alkenyl” group used either alone or in combination with other radicals, is selected from a radical containing from two to six carbons, more preferably groups selected from vinyl, allyl, 2-butenyl, 3-butenyl, 2-pentenyl, 3-pentenyl, 4-pentenyl, 2-hexenyl, 3-hexenyl, 4-hexenyl and the like; the “alkenyl” group includes dienes and trienes of straight and branched chains; the “cycloalkyl”, or “alicyclic” group used either alone or in combination with other radicals, is selected from a cyclic radical containing three to six carbons, more preferably cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the like; the “cycloalkenyl” group used either alone or in combination with other radicals, are preferably selected from cyclopropenyl, 1-cyclobutenyl, 2-cylobutenyl, 1-cyclopentenyl, 2-cyclopentenyl, 3-cyclopentenyl, 1-cyclohexenyl, 2-cyclohexenyl, 3-cyclohexenyl and the like; The terms “bicycloalkenyl” means more than one cycloalkenyl groups fused together; the “alkoxy” group used either alone or in combination with other radicals, is selected from groups containing an alkyl radical, as defined above, attached directly to an oxygen atom, more preferably groups selected from methoxy, ethoxy, n-propoxy, iso-propoxy, n-butoxy, t-butoxy, iso-butoxy, pentyloxy, hexyloxy, and the like; the “cycloalkoxy” group used either alone or in combination with other radicals, is selected from a cyclic radical containing three to seven carbons, more preferably cyclopropyloxy, cyclobutylxoy, cyclopentyloxy, cyclohexyloxy and the like; The terms “bicycloalkyloxy” means more than one cycloalkyl groups fused together; the “alkenoxy” group used either alone or in combination with other radicals, is selected from groups containing an alkenyl radical, as defined above, attached to an oxygen atom, more preferably selected from vinyloxy, allyloxy, butenoxy, pentenoxy, hexenoxy, and the like; the “haloalkyl” group is selected from an alkyl radical, as defined above, suitably substituted with one or more halogens; such as perhaloalkyl, more preferably, perfluoro(C 1 -C 6 )alkyl such as fluoromethyl, difluoromethyl, trifluoromethyl, fluoroethyl, difluoroethyl, trifluoroethyl, mono or polyhalo substituted methyl, ethyl, propyl, butyl, pentyl or hexyl groups; the “haloalkoxy” group is selected from suitable haloalkyl, as defined above, directly attached to an oxygen atom, more preferably groups selected from fluoromethoxy, chloromethoxy, fluoroethoxy, chloroethoxy and the like; the “aryl” or “aromatic” group used either alone or in combination with other radicals, is selected from a suitable aromatic system containing one, two or three rings wherein such rings may be attached together in a pendant manner or may be fused, more preferably the groups are selected from phenyl, naphthyl, tetrahydronaphthyl, indane, biphenyl, and the like; the “aryloxy” group used either alone or in combination with other radicals, is selected from groups containing an aryl radical, as defined above, attached directly to an oxygen atom, more preferably groups selected from phenoxy, naphthyloxy, tetrahydronaphthyloxy, biphenyloxy, and the like; the “heterocyclyl” or “heterocyclic” group used either alone or in combination with other radicals, is selected from suitable aromatic or non-aromatic radicals containing one or more hetero atoms selected from O, N or S. The non-aromatic radicals may be saturated, partially saturated or unsaturated mono, bi or tricyclic radicals, containing one or more heteroatoms selected from nitrogen, sulfur and oxygen, more preferably selected from aziridinyl, azetidinyl, pyrrolidinyl, imidazolidinyl, piperidinyl, piperazinyl, 2-oxopiperidinyl, 4-oxopiperidinyl, 2-oxopiperazinyl, 3-oxopiperazinyl, morpholinyl, thiomorpholinyl, 2-oxomorpholinyl, azepinyl, diazepinyl, oxapinyl, thiazepinyl, oxazolidinyl, thiazolidinyl, dihydrothiophene, dihydropyran, dihydrofuran, dihydrothiazole, benzopyranyl, benzopyranonyl, benzodihydrofuranyl, benzodihydrothienyl, pyrazolopyrimidonyl, azaquinazolinoyl, thienopyrimidonyl, quinazolonyl, pyrimidonyl, benzoxazinyl, benzoxazinonyl, benzothiazinyl, benzothiazinonyl, thieno piperidinyl, and the like; the aromatic radicals, may be selected from suitable single or fused mono, bi or tricyclic aromatic heterocyclic radicals containing one or more hetero atoms selected from O, N or S, more preferably the groups are selected from pyridyl, thienyl, furyl, pyrrolyl, oxazolyl, thiazolyl, isothiazolyl, imidazolyl, isoxazolyl, oxadiazolyl, thiadiazolyl, triazolyl, tetrazolyl, benzofuranyl, benzothienyl, indolinyl, indolyl, azaindolyl, azaindolinyl, pyrazolopyrimidinyl, azaquinazolinyl, pyridofuranyl, pyridothienyl, thienopyrimidyl, quinolinyl, pyrimidinyl, pyrazolyl, quinazolinyl, pyridazinyl, triazinyl, benzimidazolyl, benzotriazolyl, phthalazynil, naphthylidinyl, purinyl, carbazolyl, phenothiazinyl, phenoxazinyl, benzoxazolyl, benzothiazolyl and the like; the groups “heterocycloxy”, “heterocylylalkoxy” are selected from suitable heterocyclyl, heterocylylalkyl groups respectively, as defined above, attached to an oxygen atom; the “acyl” group used either alone or in combination with other radicals, is selected from a radical containing one to eight carbons, more preferably selected from formyl, acetyl, propanoyl, butanoyl, iso-butanoyl, pentanoyl, hexanoyl, heptanoyl, benzoyl and the like, which may be substituted; the “acyloxy” group used either alone or in combination with other radicals, is selected from a suitable acyl group, as defined above, directly attached to an oxygen atom, more preferably such groups are selected from acetyloxy, propionyloxy, butanoyloxy, iso-butanoyloxy, benzoyloxy and the like; the “acylamino” group used either alone or in combination with other radicals, is selected from a suitable acyl group as defined earlier, attached to an amino radical, more preferably such groups are selected from CH 3 CONH, C 2 H 5 CONH, C 3 H 7 CONH, C 4 H 9 CONH, C 6 H 5 CONH and the like, which may be substituted; the “mono-substituted amino” group used either alone or in combination with other radicals, represents an amino group substituted with one group selected from (C 1 -C 6 )alkyl, substituted alkyl, aryl, substituted aryl or arylalkyl groups as defined earlier, more preferably such groups are selected from methylamine, ethylamine, n-propylamine, n-butylamine, n-pentylamine and the like; the ‘disubstituted amino” group used either alone or in combination with other radicals, represents an amino group, substituted with two radicals that may be same or different selected from (C 1 -C 6 )alkyl, substituted alkyl, aryl, substituted aryl, or arylalkyl groups, as defined above, more preferably the groups are selected from dimethylamino, methylethylamino, diethylamino, phenylmethyl amino and the like; the “arylamine” used either alone or in combination with other radicals, represents an aryl group, as defined above, linked through amino having a free valence bond from the nitrogen atom, more preferably the groups are selected from phenylamino, naphthylamino, N-methyl anilino and the like; the “oxo” or “carbonyl” group used either alone (—C═O—) or in combination with other radicals such as alkyl described above, for e.g. “alkylcarbonyl”, denotes a carbonyl radical (—C═O—) substituted with an alkyl radical described above such as acyl or alkanoyl; the “carboxylic acid” group, used alone or in combination with other radicals, denotes a —COOH group, and includes derivatives of carboxylic acid such as esters and amides; the “ester” group used alone or in combination with other radicals, denotes —COO— group, and includes carboxylic acid derivatives, more preferably the ester moieties are selected from alkoxycarbonyl, such as methoxycarbonyl, ethoxycarbonyl, and the like, which may optionally be substituted; aryloxycarbonyl group such as phenoxycarbonyl, napthyloxycarbonyl, and the like, which may optionally be substituted; aralkoxycarbonyl group such as benzyloxycarbonyl, phenethyloxycarbonyl, napthylmethoxycarbonyl, and the like, which may optionally be substituted; heteroaryloxycarbonyl, heteroaralkoxycarbonyl, wherein the heteroaryl group, is as defined above, which may optionally be substituted; heterocyclyloxycarbonyl, where the heterocyclic group, as defined earlier, which may optionally be substituted; the “amide” group used alone or in combination with other radicals, represents an aminocarbonyl radical (H 2 N—C═O), wherein the amino group is mono- or di-substituted or unsubstituted, more preferably the groups are selected from methyl amide, dimethyl amide, ethyl amide, diethyl amide, and the like; the “aminocarbonyl” group used either alone or in combination with other radicals, may be selected from ‘aminocarbonyl’, ‘aminocarbonylalkyl”, “n-alkylaminocarbonyl”, “N-arylaminocarbonyl”, “N,N-dialkylaminocarbonyl”, “N-alkyl-N-arylaminocarbonyl”, “N-alkyl-N-hydroxyaminocarbonyl”, and “N-alkyl-N-hydroxyaminocarbonylalkyl”, each of them being optionally substituted. The terms “N-alkylaminocabonyl” and “N,N-dialkylaminocarbonyl” denotes aminocarbonyl radicals, as defined above, which have been substituted with one alkyl radical and with two alkyl radicals, respectively. Preferred are “lower alkylaminocarbonyl” having lower alkyl radicals as described above attached to aminocarbonyl radical. The terms “N-arylaminocarbonyl” and “N-alkyl-N-arylaminocarbonyl”denote amiocarbonyl radicals substituted, respectively, with one aryl radical, or one alkyl, and one aryl radical. The term “aminocarbonylalkyl” includes alkyl radicals substituted with aminocarbonyl radicals; the “hydroxyalkyl” group used either alone or in combination with other radicals, is selected from an alkyl group, as defined above, substituted with one or more hydroxy radicals, more preferably the groups are selected from hydroxymethyl, hydroxyethyl, hydroxypropyl, hydroxybutyl, hydroxypentyl, hydroxyhexyl and the like; the “aminoalkyl” group used alone or in combination with other radicals, denotes an amino (—NH 2 ) moiety attached to an alkyl radical, as defined above, which may be substituted, such as mono- and di-substituted aminoalkyl. The term “alkylamino” used herein, alone or in combination with other radicals, denotes an alkyl radical, as defined above, attached to an amino group, which may be substituted, such as mono- and di-substituted alkylamino; the “alkoxyalkyl” group used alone or in combination with other radicals, denotes an alkoxy group, as defined above, attached to an alkyl group as defined above, more preferably the groups may be selected from methoxymethyl, ethoxymethyl, methoxyethyl, ethoxyethyl and the like; the “alkylthio” group used either alone or in combination with other radicals, denotes a straight or branched or cyclic monovalent substituent comprising an alkyl group as defined above, linked through a divalent sulfur atom having a free valence bond from the sulfur atom, more preferably the groups may be selected from methylthio, ethylthio, propylthio, the “thioalkyl” group used either alone or in combination with other radicals, denotes an alkyl group, as defined above, attached to a group of formula —SR′, where R′ represents hydrogen, alkyl or aryl group, e.g. thiomethyl, methylthiomethyl, phenylthiomethyl and the like, which may be optionally substituted. the “alkoxycarbonylamino” group used alone or in combination with other radicals, is selected from a suitable alkoxycarbonyl group, as defined above, attached to an amino group, more preferably methoxycarbonylamino, ethoxycarbonylamino, and the like; the “arylthio” group used either alone or in combination with other radicals, denotes a comprising an aryl group as defined above, linked through a divalent sulfur atom having a free valence bond from the sulfur atom, more preferably the groups may be selected from phenylthio, naphthylthio, tetrahydronaphthylthio, indanethio, biphenylthio, and the like; the “heterocyclylthio” group used either alone or in combination with other radicals, denotes a comprising an heterocyclyl group as defined above, linked through a divalent sulfur atom having a free valence bond from the sulfur atom, more preferably the groups may be selected from aziridinylthio, azetidinylthio, pyrrolidinylthio, imidazolidinylthio, piperidinylthio, piperazinylthio, 2-oxopiperidinylthio, 4-oxopiperidinylthio, 2-oxopiperazinylthio, 3-oxopiperazinylthio, morpholinylthio, thiomorpholinylthio, 2-oxomorpholinylthio, azepinylthio, diazepinylthio, oxapinylthio, thiazepinylthio, oxazolidinylthio, thiazolidinylthio, dihydrothiophenethio, dihydropyranthio, dihydrofuranthio, dihydrothiazolethio, benzopyranylthio, benzopyranonylthio, benzodihydrofuranylthio, benzodihydrothienylthio, pyrazolopyrimidonylthio, azaquinazolinoylthio, thienopyrimidonylthio, quinazolonylthio, pyrimidonylthio, benzoxazinylthio, benzoxazinonylthio, benzothiazinylthio, benzothiazinonylthio, thieno piperidinylthio, pyridylthio, thienylthio, furylthio, pyrrolylthio, oxazolylthio, thiazolylthio, isothiazolylthio, imidazolylthio, isoxazolylthio, oxadiazolylthio, thiadiazolylthio, triazolylthio, tetrazolylthio, benzofuranylthio, benzothienylthio, indolinylthio, indolylthio, azaindolylthio, azaindolinylthio, pyrazolopyrimidinylthio, azaquinazolinylthio, pyridofuranylthio, pyridothienylthio, thienopyrimidylthio, quinolinylthio, pyrimidinylthio, pyrazolylthio, quinazolinylthio, pyridazinylthio, triazinylthio, benzimidazolylthio, benzotriazolylthio, phthalazynilthio, naphthylidinylthio, purinylthio, carbazolylthio, phenothiazinylthio, phenoxazinylthio, benzoxazolylthio, benzothiazolylthio and the like; the “alkoxycarbonylamino” group used alone or in combination with other radicals, is selected from a suitable alkoxycarbonyl group, as defined above, attached to an amino group, more preferably methoxycarbonylamino, ethoxycarbonylamino, and the like; the “aminocarbonylamino”, “alkylaminocarbonylamino”, “dialkylaminocarbonylamino” groups used alone or in combination with other radicals, is a carbonylamino (—CONH 2 ) group, attached to amino(NH 2 ), alkylamino group or dialkylamino group respectively, where alkyl group is as defined above; the “amidino” group used either alone or in combination with other radicals, represents a —C(═NH)—NH 2 radical; the “alkylamidino” group represents an alkyl radical, as described above, attached to an amidino group; the “alkoxyamino” group used either alone or in combination with other radicals, represents a suitable alkoxy group as defined above, attached to an amino group; the “hydroxyamino” group used either alone or in combination with other radicals, represents a —NHOH moiety, and may be optionally substituted with suitable groups selected from those described above; the “sulfenyl” group or “sulfenyl derivatives” used alone or in combination with other radicals, represents a bivalent group, —SO— or R x SO, where R x is an optionally substituted alkyl, aryl, heteroaryl, heterocyclyl, group selected from those described above; the “sulfonyl” group or “sulfones derivatives” used either alone or in combination with other radicals, with other terms such as alkylsulfonyl, represents a divalent radical —SO 2 —, or R x SO 2 —, where R x is as defined above. More preferably, the groups may be selected from “alkylsulfonyl” wherein suitable alkyl radicals, selected from those defined above, is attached to a sulfonyl radical, such as methylsulfonyl, ethylsulfonyl, propylsulfonyl and the like, “arylsulfonyl” wherein an aryl radical, as defined above, is attached to a sulfonyl radical, such as phenylsulfonyl and the like. The term “combination therapy” means the administration of two or more therapeutic agents to treat a therapeutic condition or disorder described in the present disclosure. Such administration encompasses co-administration of these therapeutic agents in a substantially simultaneous manner, such as in a single capsule having a fixed ratio of active ingredients or in multiple, separate capsules for each active ingredient. In addition, such administration also encompasses use of each type of therapeutic agent in a sequential manner. In either case, the treatment regimen will provide beneficial effects of the drug combination in treating the conditions or disorders described herein. The phrase “therapeutically effective” is intended to qualify the amount of active ingredients used in the treatment of a disease or disorder. This amount will achieve the goal of reducing or eliminating the said disease or disorder. The term “therapeutically acceptable” refers to those compounds (or salts, prodrugs, tautomers, zwitterionic forms, etc.) which are suitable for use in contact with the tissues of patients without undue toxicity, irritation, and allergic response, are commensurate with a reasonable benefit/risk ratio, and are effective for their intended use. As used herein, reference to “treatment” of a patient is intended to include prophylaxis. The term “patient” means all mammals including humans. Examples of patients include humans, cows, dogs, cats, goats, sheep, pigs, and rabbits.
[0079] Preferably, the patient is a human.
[0080] Suitable groups and substituents on the groups may be selected from those described anywhere in the specification.
[0081] Particularly useful compounds may be selected from
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenoxy)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl) benzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl) benzyl)oxy)imino)ethyl)pyridin-2-yl)amino)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenyl)amino)acetamide; 2,2′-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)oxazol-2-yl)azanediyl)bis(N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide); N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((1-(4-(trifluoromethyl)benzyl)-3-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)-1H-indol-5-yl)oxy)acetamide; 2-(2-methyl-4-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(2-phenyl-1-(((3-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(2-(pyridin-4-yl)-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(2-morpholino-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(2-thiomorpholino-1-(((4-(trifluoromethyl) benzyl)oxy)imino)ethyl)phenoxy)acetamide; 2-(2-methyl-4-(2-(thiophen-3-yl)-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-((((4-(trifluoromethyl) benzyl)oxy)imino)methyl)phenoxy)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-((((4-(trifluoromethyl) benzyl)oxy)imino)methyl)pyridin-2-yl)oxy)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((4-(1-(((4-(trifluoromethyl) benzyl)oxy)imino)ethyl)phenyl)amino)acetamide; 2-((5-(1-(((4-cyanobenzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyridin-2-yl)amino)acetamide; 2-((5-(1-((benzyloxy)imino)propyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-((5-(1-(((4-methylbenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-((5-(1-(((4-methoxybenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-((5-(1-(((4-fluorobenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-((5-(1-(((4-cyanobenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(2-methyl-4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)butyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(2-methoxy-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(2-hydroxy-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(2-methyl-4-(1-(((4-methylbenzyl)oxy)imino)-2-phenylethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide;
[0111] 2-(4-(1-(((4-methylbenzyl)oxy)imino)-2-phenylethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide;
2-(4-(1-(((4-fluorobenzyl)oxy)imino)-2-phenylethyl)-2-methylphenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-(((4-fluorobenzyl)oxy)imino)-2-phenylethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-(((4-chlorobenzyl)oxy)imino)-2-phenylethyl)-2-methylphenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-(((4-chlorobenzyl)oxy)imino)-2-phenylethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(2-methyl-4-(2-phenyl-1-(((4-(trifluoromethoxy)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(2-phenyl-1-(((4-(trifluoromethoxy)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-(((4-methoxybenzyl)oxy)imino)-2-phenylethyl)-2-methylphenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide. 2-(4-(1-(((4-methoxybenzyl)oxy)imino)-2-phenylethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-(((4-(methylsulfonyl)benzyl)oxy)imino)propyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(2-phenyl-1-((pyridin-2-ylmethoxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-((2-(1H-indol-1-yl)ethoxy)imino)propyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-(((5-ethylpyrimidin-2-yl)oxy)imino)propyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-(((5-methyl-2-phenyloxazol-4-yl)methoxy)imino)propyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-(((3-(tert-butyl)-1-(p-tolyl)-1H-pyrazol-5-yl)methoxy)imino)propyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(((4-(trifluoromethyl)benzyl)oxy)imino)-5,6,7,8-tetrahydronaphthalen-2-yl)oxy)acetamide; 2-((5-(((4-chlorobenzyl)oxy)imino)-5,6,7,8-tetrahydronaphthalen-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-((5-(((4-cyanobenzyl)oxy)imino)-5,6,7,8-tetrahydronaphthalen-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-((5-(((4-methoxybenzyl)oxy)imino)-5,6,7,8-tetrahydronaphthalen-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; Methyl 3-((((6-(2-oxo-2-(((tetrahydro-2H-pyran-4-yl)methyl)amino)ethoxy)-3,4-dihydronaphthalen-1(2H)-ylidene)amino)oxy)methyl)benzoate; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)quinolin-8-yl)oxy)acetamide; 2-methyl-N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenoxy)propanamide; 2-methyl-N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)propanamide; 2-(4-(1-(((tetrahydro-2H-pyran-4-yl)methoxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-((cyclohexylmethoxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-(4-(1-((naphthalen-2-ylmethoxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; 2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)amino)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((3-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)-1H-indol-5-yl)oxy)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((3-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)-1H-indol-5-yl)oxy)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((3-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)-1H-indol-5-yl)oxy)acetamide; 2-((3-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)-1H-indol-5-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-3-(5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyrimidin-2-yl)propanamide; N 4(tetrahydro-2H-pyran-4-yl)methyl)-3-(5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyrimidin-2-yl)propanamide; 3-(5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyrimidin-2-yl)-N-((tetrahydro-2H-pyran-4-yl)methyl)propanamide; N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)quinolin-8-yl)oxy)acetamide; 2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)quinolin-8-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide;
[0148] The present invention also discloses certain novel intermediates suitable for the preparation of compounds of formula (I). Specifically, the present invention discloses
2-((5-(14((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)acetic acid; 2,2′-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)oxazol-2-yl)azanediyl)diacetic acid; 2-((1-(4-(trifluoromethyl)benzyl)-3-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)-1H-indol-5-yl)oxy)acetic acid; 2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)quinolin-8-yl)oxy)acetic acid; 2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)amino)acetic acid; 2-((5-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)pyridin-2-yl)oxy)acetic acid; 2-((5-(1-(((4-cyanobenzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)acetic acid; 2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetic acid; 2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyridin-2-yl)amino)acetic acid; 2-((5-(1-((benzyloxy)imino)propyl)pyridin-2-yl)oxy)acetic acid; 2-((5-(1-(((4-methylbenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetic acid; 2-((5-(1-(((4-methoxybenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetic acid; 2-((5-(1-(((4-fluorobenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetic acid; 2-((5-(1-(((4-cyanobenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetic acid; 2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)acetic acid; 2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)amino)acetic acid; 2-((3-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)-1H-indol-5-yl)oxy)acetic acid; 2-((3-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)-1H-indol-5-yl)oxy)acetic acid; 2-((3-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)-1H-indol-5-yl)oxy)acetic acid; 2-((3-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)-1H-indol-5-yl)oxy)acetic acid; 3-(5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyrimidin-2-yl)propanoic acid; 3-(5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyrimidin-2-yl)propanoic acid; 3-(5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyrimidin-2-yl)propanoic acid; 2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)quinolin-8-yl)oxy)acetic acid; 2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)quinolin-8-yl)oxy)acetic acid.
[0174] The novel compounds of this invention may be prepared using the reactions and techniques as shown in scheme below and described in this section. The reactions are performed in solvents appropriate to the reagents and materials employed and are suitable for the transformations being affected. It is understood by those skilled in the art that the nature and order of the synthetic steps presented may be varied for the purpose of optimizing the formation of the compounds of the present invention. It will also be well appreciated that one or more of the reactants may be protected and deprotected for facile synthesis by techniques known to persons skilled in the art. It will also be appreciated that one or more of the compounds of the present invention may exist in stereoisomeric and/or diastereomeric forms. Such stereoisomers and/or diastereoisomers as well as their optical antipodes are to be construed to be within the scope of the present invention. It will also be well appreciated that one or more of these compounds may be converted to their salts and other derivatives based on the specific groups present on the compounds, which can be well comprehended by persons skilled in the art. Such salts and/or other derivatives, as the case may be should also be construed to be within the scope of the present invention.
[0000]
[0000]
Method A:
[0175] The compounds of formula VI, IX and (I) wherein all the symbols are as defined earlier may be prepared by appropriate starting materials as described in Scheme 1 and Scheme 2 using suitable inorganic base(s) such as NaOH, KOH, K 2 CO 3 , Cs 2 CO 3 and the like or organic base(s) such as pyridine, triethyl amine, diisopropyl ethylamine and the like. The reaction may be carried out neat or in presence of suitable protic solvent(s) such as methanol, ethanol, butanol and the like or suitable aprotic solvent(s) such as dimethyl formamide, tetrahydrofuran, dichloromethane and the like or suitable mixtures thereof. The reaction may be carried out at a temperature in the range 0° C. to reflux temperature of the solvent(s) used and the reaction time may range from 1 to 48 hours.
Method B:
[0176] The compounds of formula VI wherein all the symbols are as defined earlier may be prepared by using appropriate starting materials as described in Scheme 1 using suitable inorganic base(s) such as NaOH, KOH, K 2 CO 3 , Cs 2 CO 3 and the like or suitable organic base(s) such as pyridine, triethyl amine, diisopropyl ethylamine and the like. Alternatively the compounds of formula VI wherein all the symbols are as defined earlier may also be prepared by using suitable palladium based catalyst such as palladium acetate, Pd(Ph 3 P) 4 and the like and with or without organic ligand such as BINAP and the like. The reaction may be carried out neat or in presence of suitable protic solvent(s) such as methanol, ethanol, butanol and the like or suitable aprotic solvent(s) such as dimethyl formamide, toluene, tetrahydrofuran, dichloromethane and the like or mixtures thereof. The reaction may be carried out at a temperature in the range 0° C. to reflux temperature of the solvent(s) used and the reaction time may range from 1 to 48 hours.
Method C:
[0177] The compounds of the formula VII and XIV wherein all the symbols are as defined earlier may be prepared by reacting appropriate ketones as described in Scheme 1 and Scheme 2 with hydroxylamine hydrochloride in the presence of a base(s) like NaOH, NaOAc, pyridine and the like. The reaction may be carried out in presence of suitable solvent(s) such as methanol, ethanol, butanol, water and the like or suitable mixtures thereof. The reaction may be carried out at a temperature in the range 0° C. to reflux temperature of the solvent(s) used and the reaction time may range from 1 to 48 hours.
Method D:
[0178] The compounds of the formula X and XII wherein all the symbols are as defined earlier may be prepared by hydrolyzing appropriate esters as described in Scheme 1 and Scheme 2 using suitable base(s) e.g., NaOH, LiOH, KOH and the like. Reaction may be conducted in suitable solvent(s) such as methanol, ethanol, THF, water and the like or the mixtures thereof. The reaction may be carried out at a temperature in the range 20° C. to reflux temperature of the solvent(s) used and the reaction time may range from 1 to 48 hours.
[0179] Method E: The compounds of the formula (I) and XIII wherein all the symbols are as defined earlier may be prepared by coupling reaction of appropriate acid and appropriate amine as described in scheme 1 and scheme 2 under suitable conditions such as those described in Tetrahedron, 2005, 61(46), 10827-10852 with suitable modifications and alterations as are well known to a skilled person. The reaction may be carried out in presence of reagents(s) such as N-(3-dimethylaminopropyl)-N′-ethylcarbodimide hydrochloride (EDCl) & 1-Hydroxybenzotriazole (HOBT), and the like. The reaction may be carried in suitable solvent(s) such as dimethyl formamide, tetrahydrofuran, dichloromethane and the like or mixtures thereof.
[0180] The reaction may be carried out at a temperature in the range 0° C. to reflux temperature of the solvent(s) used and the reaction time may range from 1 to 48 hours.
[0181] The pharmaceutical composition is provided by employing conventional techniques. Preferably the composition is in unit dosage form containing an effective amount of the active component, that is, the compounds of formula (I) according to this invention.
[0182] The quantity of active component, that is, the compounds of formula (I) according to this invention, in the pharmaceutical composition and unit dosage form thereof may be varied or adjusted widely depending upon the particular application method, the potency of the particular compound and the desired concentration. Generally, the quantity of active component will range between 0.5% to 90% by weight of the composition.
[0183] The invention is explained in greater detail by the examples given below, which are provided by way of illustration only and therefore should not be construed to limit the scope of the invention.
[0184] 1H NMR spectral data given in the examples (vide infra) are recorded using a 400 MHz spectrometer (Bruker AVANCE-400) and reported in 5 scale. Until and otherwise mentioned the solvent used for NMR is CDCl 3 using tetramethyl silane as the internal standard.
Example 1
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenoxy)acetamide
Step 1: Ethyl 2-(4-propionylphenoxy)acetate
[0185] To a solution of 1-(4-hydroxyphenyl)propan-1-one (33 g, 0.2200 moles) in DMF (165 mL), potassium carbonate (60.7 gm, 0.4400 moles) and ethyl bromo acetate (40.6 gm, 0.2420 moles) were added and the reaction mixture was srirred at 50° C. for 3 hours. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure to yield 49 gm (94%) of product as thick liquid.
[0186] 1 H NMR: DMSO-d 6 δ 1.06 (t, J=7.2 Hz, 3H), 1.20 (t, J=4.8 Hz, 3H), 2.96 (q, J=7.4 Hz, 2H), 4.14 (q, J=3.6 Hz, 2H), 4.88 (s, 2H), 7.02 (dd, J=2.0 & 6.8 Hz, 2H), 7.92 (dd, J=2.0 & 6.8 Hz, 2H).
Step 2: Ethyl 2-(4-(1-(hydroxyimino)propyl)phenoxy)acetate
[0187] To a solution of the product of step 1 (49 g, 0.2076 moles) in methanol (343 ml), hydroxylamine hydrochloride (28.6 g, 0.4152 moles) and a solution of sodium acetate (34 g, 0.4152 moles) in water (147 ml) were added and the reaction mixture was refluxed for 1 hour. The solvents were evaporated under reduced pressure. The residue was dissolved in water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evapourated under reduced pressure to yield 40 gm (76%) of product as solid.
[0188] 1 H NMR: DMSO-d 6 δ 1.01 (t, J=7.4 Hz, 3H), 1.21 (t, J=7.0 Hz, 3H), 2.66 (q, J=7.6 Hz, 2H), 4.16 (q, J=7.2 Hz, 2H), 4.79 (s, 2H), 6.93 (dd, J=5.2 & 2.8 Hz, 2H), 7.56 (dd, J=6.8 & 2.0 Hz, 2H), 10.93 (s, 1H).
Step 3: Ethyl 2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenoxy)acetate
[0189] To a solution of the product of step 2 (18 g, 0.0723 moles) in DMF (54 mL), cesium carbonate (47 gm, 0.1446 moles) and 4-(trifluoromethyl)benzyl bromide (19 gm, 0.0795 moles) were added and the reaction mixture was srirred at 25° C. for 3 hours. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evapourated under reduced pressure to yield 28 gm (95%) of product as thick liquid.
[0190] 1 H NMR: DMSO-d 6 δ 1.05 (t, J=7.4 Hz, 3H), 1.19 (t, J=7.0 Hz, 3H), 2.73 (q, J=7.6 Hz, 2H), 4.16 (q, J=7.2 Hz, 2H), 4.80 (s, 2H), 5.26 (s, 2H), 6.93 (dd, J=7.2 & 2.4 Hz, 2H), 7.56 (dd, J=6.8 & 2.0 Hz, 2H), 7.59 (d, J=8.0 Hz, 2H), 7.72 (d, J=8.0 Hz, 2H)
Step 4: 2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenoxy)acetic acid
[0191] To a solution of the product of step 3 (28 g, 0.0683 moles) in THF (140 ml), a solution of lithium hydroxide (4.3 g, 0.1024 moles) in water (140 ml) was added and the reaction mixture was stirred at 25° C. for 3 hours. The solvents were evaporated under reduced pressure. The residue was dissolved in water, acidified with 1N HCl and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evapourated under reduced pressure to yield 23 gm (88%) of product as solid.
[0192] 1 H NMR: DMSO-d 6 δ 1.05 (t, J=7.4 Hz, 3H), 2.73 (q, J=7.4 Hz, 2H), 4.69 (s, 2H), 5.26 (s, 2H), 6.92 (dd, J=2 & 6.8 Hz, 2H), 7.55 (dd, J=2.4 & 7.2 Hz, 2H), 7.59 (d, J=8 Hz, 2H), 7.72 (d, J=8 Hz, 2H).
Step 5: N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenoxy)acetamide
[0193] To a solution of the product of step 4 (23 g, 0.0602 moles) in DMF (69 mL), (tetrahydro-2H-pyran-4-yl)methanamine (7.6 gm, 0.0662 moles), HOBT (50 mg, catalytic amount), EDC.HCl (17.5 g, 0.0903 moles) and DMAP (50 mg, catalytic amount) were added and reaction mixture was srirred at 25° C. for 16 hours. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evapourated under reduced pressure. The crude product was purified by coloumn chromatography using ethyl acetate:Hhexane (1:1) as eluent to yield 16.5 g (57%) of product as white solid. 1 H NMR: DMSO-d 6 δ 1.10 (t, J=6.6 Hz, 3H), 1.13-1.16 (m, 2H), 1.46-1.49 (m, 2H), 1.61-1.70 (m, 1H), 2.74 (q, J=7.6 Hz, 2H), 3.01 (t, J=6.6 Hz, 2H), 3.17-3.23 (m, 2H), 3.78-3.81 (dd, J=11.4 & 2.6 Hz, 2H), 4.51 (s, 2H), 5.26 (s, 2H), 6.96 (dd, J=6.8 & 2.0 Hz, 2H), 5.57-5.61 (m, 4H), 7.72 (d, J=8.0 Hz, 2H), 8.10 (t, J=6.0 Hz, NH).
Example 2
2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)acetic acid
Step 1: Ethyl 2-((5-acetylpyridin-2-yl)oxy)acetate
[0194] To a solution of 1-(6-chloropyridin-3-yl)ethanone (4.0 gm, 0.0257 mole) in DMF (15 mL), cesium carbonate (16.8 gm, 0.051 mole) was added followed by addition of methyl 2-hydroxyacetate (8.0 ml, 0.103 mmoles) at 25° C. under nitrogen atmosphere and the reaction mixture was stirred at 80-90° C. for 18 h. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evapourated under reduced pressure. The crude product was purified by column chromatography (Eluent: 16% ethyl acetate in hexane) to yield 1.25 gm (23%) of product as off white solid.
[0195] 1 H NMR: DMSO-d 6 , δ 2.55 (s, 3H), 3.67 (s, 3H), 5.02 (s, 2H), 7.04 (dd, J=8.8 & 0.4 Hz, 1H), 8.20 (dd, J=8.8 & 2.4 Hz, 1H), 8.78 (d, J=2.0 Hz, 1H).
Step 2: Methyl 2-((5-(1-(hydroxyimino)ethyl)pyridin-2-yl)oxy)acetate
[0196] To a solution of methyl 2-((5-acetylpyridin-2-yl)oxy)acetate (1.23 gm, 0.059 mole) in ethanol (10 mL), a solution of sodium acetate (0.942 gm, 0.0117 mole) and hydroxylammonium chloride (1.2 gm, 0.0117 mole) in water (5 ml) was added and the reaction mixture was refluxed for 1 h. The reaction mixture was coiled to room temperature and solvent was evapourated in vacuum. The residue was diluted with ice cold water and solid seperated was filtered, washed with water and dried over P 2 O 5 under vacuum to yield 1.15 gm (88%) of title product as off white solid.
[0197] 1 H NMR: DMSO-d 6 , δ 2.12 (s, 3H), 3.66 (s, 3H), 4.94 (s, 2H), 6.95 (d, J=8.8 Hz, 1H), 8.02 (dd, J=8.4 & 2.4 Hz, 1H), 8.34 (d, J=2.0 Hz, 1H).
Step 3: Methyl 2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)acetate
[0198] To a solution of 1-(bromomethyl)-4-(trifluoromethyl)benzene (0.87 ml, 5.6 mmoles) in DMF (10 mL), cesium carbonate (3.35 gm, 10.2 mmoles) was added followed by addition of methyl 2-((5-(1-(hydroxyimino)ethyl)pyridin-2-yl)oxy)acetate (1.15 gm, 5.1 mmoles) at 25° C. under nitrogen atmosphere and the reaction mixture was stirred at the same temperature for 12 h. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evapourated under reduced pressure to yield 2.0 gm (94%) of product as thick liquid.
[0199] 1 H NMR: DMSO-d 6 , δ 2.24 (s, 3H), 3.65 (s, 3H), 4.94 (s, 2H), 5.29 (s, 2H), 6.94 (d, J=8.8 Hz, 1H), 7.60 (d, J=8.0 Hz, 2H), 7.73 (d, J=8.0 Hz, 2H), 8.00 (dd, J=8.8 & 2.4 Hz, 1H), 8.36 (d, J=2.4 Hz, 1H).
Step 4: 2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)acetic acid
[0200] To a solution of the product of step 3 (2.0 gm, 5.2 mmoles) in a mixture of THF (12 mL), methanol (4 mL) and water (4 mL), lithium hydroxide (440 mg, 10.5 mmoles) was added and the reaction mixture was stirred at ambient temperature for 4 hours. The solvents were evaporated under reduced pressure. The residue was dissolved in water, acidified with 1N HCl and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evapourated under reduced pressure to yield 1.7 gm (88%) of title product as white solid.
[0201] 1 H NMR: DMSO-d 6 , δ 2.24 (s, 3H), 4.84 (s, 2H), 5.29 (s, 2H), 6.93 (d, J=8.8 Hz, 1H), 7.60 (d, J=8.0 Hz, 2H), 7.73 (d, J=8.0 Hz, 2H), 7.98 (dd, J=8.8 & 2.8 Hz, 1H), 8.36 (d, J=2.4 Hz, 1H).
Example 3
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl) benzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)acetamide
[0202] To a solution of compound prepared in example 3 (2.0 gm, 5.43 mmoles) in DMF (10 mL), (tetrahydro-2H-pyran-4-yl)methanamine (625 mg, 5.43 mmoles), HOBT (1.09 gm, 8.14 mmoles), EDC.HCl (1.25 gm, 6.52 mmoles) and N-ethyl morpholine (2.05 mL, 16.29 mmoles) were added and reaction mixture was srirred at 25° C. for 5 hours under nitrogen atmosphere. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure. The crude product was triturated with hexane to yield 2.8 gm (72%) of product as white solid.
[0203] 1 H NMR: DMSO-d 6 δ 1.07-1.11 (m, 2H), 1.45-1.49 (m, 2H), 1.58-1.64 (m, 1H), 2.24 (s, 3H), 2.96 (t, J=6.8 Hz, 2H), 3.17-3.23 (m, 2H), 3.22 (dd, J=11.4 & 2.6 Hz, 2H), 4.72 (s, 2H), 5.29 (s, 2H), 6.91 (d, J=8.8 Hz, 1H), 7.60 (d, J=8.0 Hz, 2H) 7.72 (d, J=8.0 Hz, 2H), 7.98-7.99 (m, 1H), 8.33 (d, J=2.0 Hz, 1H).
Example 4
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl) benzyl)oxy)imino)ethyl)pyridin-2-yl)amino)acetamide
Step 1: ethyl 2-((5-acetylpyridin-2-yl)amino)acetate
[0204] To a mixture of 1-(6-aminopyridin-3-yl)ethanone (700 mg, 5.15 mmoles) and perchloric acid (1.4 ml), a solution of glyoxal (0.24 ml, 5.15 mmoles) in methanol (14 ml) was added and reaction mixture was refluxed for 48 hrs. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evapourated under reduced pressure. The crude product was purified by column chromatography (Eluent: 1.5% methanol in chloroform) to yield 350 mg (33%) of product as off white solid.
[0205] 1 H NMR: DMSO-d 6 δ 2.43 (s, 3H), 3.63 (s, 3H), 4.12 (d, J=6.0 Hz, 2H), 6.62 (dd, J=8.8 Hz, 1H), 7.86 (dd, J=8.8 & 2.4 Hz, 1H), 8.34 (d, J=2.0 Hz, 1H).
Step 2: 2-((5-acetylpyridin-2-yl)amino)acetic acid
[0206] To a solution of the product of step 1 (1.1 gm, 5.3 mmoles) in a mixture of THF (12 ml), methanol (4 ml) and water (4 ml), lithium hydroxide (444 mg, 10.6 mmoles) was added and the reaction mixture was stirred at ambient temperature for 4 hours. The solvents were evaporated under reduced pressure. The residue was dissolved in water, acidified with 1N HCl and evaporated in vacuum. The residue was diluted with ethyl acetate, stirred for 30 min and filtered. The filtrate was concentrated in vacuum to yield 1.0 gm (98%) of title product as off white solid.
[0207] 1 H NMR: CD 3 OD: δ2.48 (s, 3H), 4.08 (s, 2H), 6.59 (dd, J=8.8 Hz, 1H), 7.86 (dd, J=8.8 & 2.0 Hz, 1H), 8.65 (d, J=2.4 Hz, 1H).
Step 3: N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl) benzyl)oxy)imino)ethyl)pyridin-2-yl)amino)acetamide
[0208] To a solution of the product of step 2 (1.4 gm, 7.2 mmoles) in DMF (10 mL), (tetrahydro-2H-pyran-4-yl)methanamine (1.2 gm, 7.94 mmoles), HOBT (1.48 gm, 10.8 mmoles), EDC.HCl (1.16 gm, 8.66 mmoles) and N-ethyl morpholine (2.75 mL, 21.6 mmoles) were added and reaction mixture was srirred at 25° C. for 2 hours under nitrogen atmosphere.
[0209] The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure to yield 1.0 gm of crude product as an oil.
[0210] The crude product was dissolved in ethanol (10 ml) and a solution of sodium acetate (0.564 gm, 6.8 mmoles) and hydroxylammonium chloride (0.615 gm, 6.8 mmoles) in water (5 ml) was added and the reaction mixture was refluxed for 1 h. The reaction mixture was cooled to room temperature and solvent was evapourated in vacuum. The residue was diluted with ice cold water and extarcted with ethyl acetate. The ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated in vacuum to yield 420 mg of product as an oil.
[0211] To a solution of product obtained above (450 mg, 1.47 mmoles) in DMF (5 mL), cesium carbonate (959 mg, 2.94 mmoles) was added followed by addition of 1-(bromomethyl)-4-(trifluoromethyl)benzene (350 mg, 1.47 mmoles) at 25° C. under nitrogen atmosphere and the reaction mixture was stirred at the same temperature for 12 h. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water and brine, dried over sodium sulphate and evapourated under reduced pressure to yield 135 mg (58%) product as off white solid.
[0212] 1 H NMR: DMSO-d 6 , δ 1.22-1.25 (m, 2H), 1.47-1.50 (m, 2H), 1.57-1.62 (m, 1H), 2.17 (s, 3H), 2.95 (t, J=6.4 Hz, 2H), 3.16-3.22 (m, 2H), 3.78-3.81 (dd, J=2.8 & 11.2 Hz, 2H), 3.85 (d, J=6.0 Hz, 2H), 5.23 (s, 2H), 6.55 (d, J=9.2 Hz, 1H), 7.11 (t, J=5.8 Hz, 1H), 7.59 (d, J=8.0 Hz, 2H), 7.65-7.68 (dd, J=2.4 & 8.8 Hz, 1H), 7.73 (d, J=8.4 Hz, 2H), 7.83 (t, J=6.0 Hz, —NH), 8.19 (s, 1H).
Example 5
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenyl)amino)acetamide
Step 1: N-(4-(1-(((4-(Trifluoromethyl)benzyl)oxy)imino)propyl)phenyl)acetamide
[0213] To a solution of N-(4-(1-(hydroxyimino)propyl)phenyl)acetamide (6 gm, 0.0291 moles) in DMF (60 mL), cesium carbonate (18.9 gm, 0.0582 moles) and 4-(trifluoromethyl)benzyl bromide (6.96 gm, 0.0291 moles) were added and the reaction mixture was srirred at 25° C. for 3 hours. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure to yield 10 gm (94%) of product as solid.
[0214] 1 H NMR: DMSO-d 6 δ 1.06 (t, J=7.4 Hz, 3H), 2.04 (s, 3H), 2.75 (q, J=7.6 Hz, 2H), 5.27 (s, 2H), 7.55-7.61 (m, 6H), 7.73 (d, J=8 Hz, 2H), 10.07 (s, 1H).
Step 2: 1-(4-Aminophenyl)propan-1-one O-(4-(trifluoromethyl)benzyl)oxime
[0215] To a solution of the product of step 1 (10 g, 0.0275 moles) in ethanol (70 ml), a solution of potassium hydroxide (6.15 g, 0.1098 moles) in water (30 ml) was added and the reaction mixture was stirred at 80-90° C. for 36 hours. The reaction mixture was poured into ice cold water and extracted by dichloromethane. The combined dichloromethane extract was washed with water and brine, dried over sodium sulphate and evapourated under reduced pressure to yield 7.5 gm (84%) of product as liquid.
[0216] 1 H NMR: DMSO-d 6 δ 1.03 (t, J=3.8 Hz, 3H), 2.66 (q, J=7.6 Hz, 2H), 5.21 (s, 2H), 5.42 (s, 2H), 6.51-6.56 (m, 2H), 7.30-7.35 (m, 2H), 7.57 (d, J=8 Hz, 2H), 7.72 (d, J=8.4 Hz, 2H).
Step 3: Ethyl 2-((4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenyl)amino)acetate
[0217] To a solution of the product of step 2 (3.5 g, 0.0097 moles) in DMF (35 mL), potassium carbonate (4 gm, 0.0291 moles) and Ethyl bromo acetate (1.8 gm, 0.0107 moles) were added and reaction mixture was srirred at 100° C. for over night. The reaction mixture was poured into ice cold water and extracted by ethyl acetate. The combined ethyl acetate extract was washed with water and brine, dried over sodium sulphate and evapourated under reduced pressure to yield 2.2 gm (55%) of product as solid.
[0218] 1 H NMR: DMSO-d 6 δ 1.04 (t, J=7.6 Hz, 3H), 1.19 (t, J=7.2 Hz, 3H), 2.67 (q, J=7.6 Hz, 2H), 3.90 (d, J=6.4 Hz, 2H), 4.10 (q, J=7.2 Hz, 2H), 5.22 (s, 2H), 6.37 (t, J=6.4 Hz, 1H), 6.52 (d, J=8.8 Hz, 2H), 7.37 (d, J=8.8 Hz, 2H), 7.58 (d, J=8.4 Hz, 2H), 7.72 (d, J=8.4 Hz, 2H).
Step 4: 2-((4-(1-(((4-(Trifluoromethyl)benzyl)oxy)imino)propyl)phenyl)amino)acetic acid
[0219] To a solution of the product of step 3 (2.2 g, 5.39 mmoles) in THF (10 ml), a solution of lithium hydroxide (0.45 g, 10.77 mmoles) in water (10 mL) was added and the reaction mixture was stirred at 25° C. for 3 hours. The solvents were evaporated under reduced pressure. The residue was dissolved in water and neutralized to pH 6 with 1N HCl. Solid seperated was filtered, washed with water and dried over CaCl 2 under vacuum to give 1.64 g (82%) of title product.
[0220] 1 H NMR: DMSO-d 6 , δ 1.04 (t, J=7.6 Hz, 3H), 2.66-2.71 (m, 2H), 3.80 (s, 2H), 5.21 (s, 2H), 6.52 (d, J=8.8 Hz, 2H), 7.37 (d, J=8.8 Hz, 2H), 7.58 (d, J=8 Hz, 2H), 7.72 (d, J=8.4 Hz, 2H).
Step 5: N-((Tetrahydro-2H-pyran-4-yl)methyl)-2-((4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenyl)amino)acetamide
[0221] To a solution of the product of step 4 (6.5 g, 0.0171 moles) in DMF (40 mL), (tetrahydro-2H-pyran-4-yl)methanamine hydrochloride (2.6 gm, 0.0171 moles), HOBT (2.31 gm, 0.0171 moles), EDC.HCl (4.24 gm, 0.0222 moles) and N-ethyl morpholine (5.9 gm, 0.0513 moles) were added and reaction mixture was srirred at 25° C. for 5 hours under nitrogen atmosphere. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evapourated under reduced pressure. The crude product was purified by coloumn chromatography using 1% MeOH in chloroform as eluent to yield 1.22 g (15%) of product as white solid.
[0222] 1 H NMR: DMSO-d 6 , δ 1.03 (t, J=7.6 Hz, 3H), 1.06-1.10 (m, 2H), 1.44 (d, J=12.8 Hz, 2H), 1.58-1.61 (m, 1H), 2.69 (q, J=7.6 Hz, 2H), 2.96 (t, J=6.4 Hz, 2H), 3.15-3.22 (m, 2H), 3.64 (d, J=6 Hz, 2H), 3.77 (dd, J=11.6 & 2.8 Hz, 2H), 5.21 (s, 2H), 6.25 (t, J=6 Hz, 1H), 6.51 (d, J=8.8 Hz, 2H), 7.37 (d, J=8.8 Hz, 2H), 7.57 (d, J=8.0 Hz, 2H), 7.72 (d, J=8.0 Hz, 2H), 7.89 (t, J=6.0 Hz, 1H).
Example 6
2,2′-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)oxazol-2-yl)azanediyl)diacetic acid
Step 1: Diethyl 2,2′-((5-acetyloxazol-2-yl)azanediyl)diacetate
[0223] To a solution of 1-(2-aminooxazol-5-yl)ethanone (300 mg, 2.38 mmoles) in DMF (2 mL), cesium carbonate (1.16 gm, 3.57 mmoles) was added followed by addition of ethyl bromoacetate (794 mg, 4.76 mmoles) at 25° C. under nitrogen atmosphere and the reaction mixture was stirred at the same temperature for 18 h. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure to yield 310 mg (44%) of product as thick liquid.
[0224] 1 H NMR: δ 1.27 (t, J=7.0 Hz, 6H), 2.33 (s, 3H), 4.20-4.27 (m, 4H), 4.37 (s, 4H), 7.57 (s, 1H).
Step 2: Diethyl 2,2′-((5-(1-(hydroxyimino)ethyl)oxazol-2-yl)azanediyl)diacetate
[0225] To a solution of diethyl 2,2′-((5-acetyloxazol-2-yl)azanediyl)diacetate (300 mg, 1.01 mmoles) in ethanol (6 mL), a solution of sodium acetate (165 mg, 2.01 mmoles) and hydroxylammonium chloride (139 mg gm, 2.01 mmoles) in water (2 ml) was added and the reaction mixture was refluxed for 1 h. The reaction mixture was cooled to room temperature and solvent was evapourated in vacuum. The residue was diluted with ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure to yield 252 mg (80%) of title product as thick liquid.
[0226] 1 H NMR: δ 1.25-1.37 (m, 6H), 2.45 (s, 3H), 4.18-4.29 (m, 4H), 4.37 (s, 4H), 7.57 (s, 1H).
Step 3: Diethyl 2,2′-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)oxazol-2-yl)azanediyl)diacetate
[0227] To a solution of 1-(bromomethyl)-4-(trifluoromethyl)benzene (200 mg, 0.84 mmoles) in DMF (2 mL), cesium carbonate (408 mg, 1.26 mmoles) was added followed by addition of diethyl 2,2′-((5-(1-(hydroxyimino)ethyl)oxazol-2-yl)azanediyl)diacetate (262 mg, 0.84 mmoles) at 25° C. under nitrogen atmosphere and the reaction mixture was stirred at the same temperature for 18 h. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure. The crude product was purified by column chromatography (Eluent: 15% ethyl acetate in hexane) to yield 295 mg (75%) product as thick liquid.
[0228] 1 H NMR: δ 1.25-1.36 (m, 6H), 2.04 (s, 3H), 4.19 (q, J=7.2 Hz, 4H), 4.32 (s, 4H), 5.22 (s, 2H), 6.99 (s, 1H), 7.47 (d, J=8.0 Hz, 2H), 7.60 (d, J=8.4 Hz, 2H).
Step 4: 2,2′-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)oxazol-2-yl)azanediyl)diacetic acid
[0229] To a solution of the product of step 3 (295 mg, 0.62 mmoles) in a mixture of THF (6 ml), methanol (2 ml) and water (2 ml), lithium hydroxide (105 mg, 1.25 mmoles) was added and the reaction mixture was stirred at ambient temperature for 4 hours. The solvents were evaporated under reduced pressure. The residue was dissolved in water and acidified with 1N HCl. White solid seperated was filtered and washed with water & dried over P 2 O 5 under vacuum to give 250 mg (82%) of title product as off white solid.
[0230] 1 H NMR: DMSO-d 6 δ 2.06 (s, 3H), 4.16 (s, 4H), 5.23 (s, 2H), 7.31 (s, 1H), 7.58 (d, J=8.0 Hz, 2H), 7.72 (d, J=8.4 Hz, 2H).
Example 7
2,2′-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)oxazol-2-yl)azanediyl)bis(N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide)
[0231] To a solution of compound prepared in example 6 (250 mg, 0.60 mmoles) in DMF (2 mL), (tetrahydro-2H-pyran-4-yl)methanamine (138 mg, 1.20 mmoles), HOBT (121 mg, 0.90 mmoles), EDC.HCl (138 mg, 0.72 mmoles) and N-ethyl morpholine (227 μL, 1.80 mmoles) were added and reaction mixture was srirred at 25° C. for 2-5 hours under nitrogen atmosphere. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure. The crude product was triturated with hexane to yield 180 mg (49%) of product as white solid.
[0232] 1 H NMR: DMSO-d 6 , δ 1.04-1.14 (m, 4H), 1.47-1.50 (m, 4H), 1.58-1.62 (m, 2H), 2.04 (s, 3H), 2.96 (t, J=6.2 Hz, 4H), 3.18 (t, J=10.8 Hz, 4H), 3.76 (dd, J=11.0 Hz & 3.0 Hz, 4H), 4.08 (s, 4H), 5.20 (s, 2H), 7.28 (s, 1H), 7.58 (d, J=8.0 Hz, 2H), 7.72 (d, J=8.4 Hz, 2H).
Example 8
2-((1-(4-(trifluoromethyl)benzyl)-3-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)-1H-indol-5-yl)oxy)acetic acid
Step 1: ethyl 2-((1H-indol-5-yl)oxy)acetate
[0233] To a solution of 5-hydroxy indole (4.56 gm, 0.034 moles) in DMF (20 ml), potassium carbonate (9.43 gm, 0.068 moles), ethyl bromoacetate (6.29 gm, 0.0377 moles) were added and the reaction mixture was stirred at ambient temperature for 12 hours. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evapourated under reduced pressure to yield 6.2 gm (82%) of product as solid.
[0234] 1 H NMR: DMSO-d 6 , δ 1.20 (t, J=3.6 Hz, 3H), 4.13 (q, J=8.6 Hz, 2H), 4.70 (s, 2H), 6.31 (d, J=2.0 Hz, 1H), 6.74 (dd, J=8.8 & 2.4 Hz, 1H), 6.99 (d, J=2.4 Hz, 1H), 7.27 (dd, J=5.6 & 2.8 Hz, 2H), 10.95 (bs, 1H).
Step 2: ethyl 2-((3-((hydroxyimino)methyl)-1H-indol-5-yl)oxy)acetate
[0235] To DMF (1.74 gm, 0.023 moles) cooled to 0° C. under nitrogen atmosphere, Phosphorous oxy chloride (3.5 gm, 0.022 moles) was added in portions and stireed for 15 mins. To this was added a solution of the product of step 1 (2.5 gm, 0.011 mole) in dichloro ethane (18 ml) at 0° C. and heated to 80° C. for 2 hrs. The solvents were evaporated under reduced pressure. The residue was dissolved in water, basified with NaOH and extracted with ethyl acetate. The ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure. The crude product was purified by column chromatography (eluent: 40% EtOAC in hexane) to yield 900 mg (31%) of product as solid.
[0236] 1 H NMR: DMSO-d 6 δ 1.22 (t, J=1.82 Hz, 3H), 4.15 (q, J=7.2 Hz, 2H), 4.77 (s, 2H), 6.91 (dd, J=8.8 & 2.8 Hz, 1H), 7.41 (d, J=8.8 Hz, 1H), 7.52 (d, J=2.4 Hz, 1H), 8.23 (d, J=2.8 Hz, 1H), 9.88 (d, J=4.4 Hz, 1H), 12.06 (bs, 1H).
Step 3: ethyl 2-((3-((hydroxyimino)methyl)-1H-indol-5-yl)oxy)acetate
[0237] To a solution of the product of step 2 (880 mg, 3.56 mmoles) in methanol (6 mL) and water (3 mL), hydroxylamine hydrochloride (491 mg, 7.12 mmoles), sodium acetate (584 mg, 7.12 moles were added and the reaction mixture was heated at 70° C. for 2 hours. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure, The crude product was purified by column chromatography using 40% EtOAC in hexane as eluent to yield 280 mg (27%) of product as solid.
[0238] 1 H NMR: δ 1.21 (t, J=4.0 Hz, 3H), 4.14 (q, J=7.0 Hz, 2H), 4.70 (s, 2H), 6.83 (dd, J=8.8 & 2.4 Hz, 1H), 7.31 (d, J=8.8 Hz, 1H), 7.43 (d, J=2.4 Hz, 1H), 7.58 (d, J=2.8 Hz, 1H), 8.22 (s, 1H), 10.46 (s, 1H), 11.30 (bs, 1H).
Step 4: ethyl 2-((1-(4-(trifluoromethyl)benzyl)-3-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)-1H-indol-5-yl)oxy)acetate
[0239] To a solution of the product of step 3 (280 mg, 1.068 mmoles) in DMF (2 ml), cesium carbonate (1.0 gm, 3.2 mmoles), 4-trifluoromethyl benzylbromide (510 mg, 2.13 mmoles were added and the reaction mixture was stirred at 25° C. for 2 hours. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure, The crude product was purified by column chromatography using 15% EtOAC in hexane as eluent to yield 350 mg (56%) of product as solid.
[0240] 1 H NMR: δ 1.16 (t, J=7.0 Hz, 3H), 4.11 (q, J=6.9 Hz, 2H), 4.69 (s, 2H), 5.23 (s, 2H), 5.54 (s, 2H), 6.85 (dd, J=8.8 & 2.4 Hz, 1H), 7.35-7.40 (m, 4H), 7.68 (d, J=2.4 Hz, 4H), 7.74 (d, J=8.0 Hz, 2H), 7.85 (s, 1H), 8.44 (s, 1H).
Step 5: 2-((1-(4-(trifluoromethyl)benzyl)-3-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)-1H-indol-5-yl)oxy)acetic acid
[0241] To a solution of the product of step 4 (350 mg, 0.605 mmoles) in THF (2 mL) Water: (2 ml), lithum hydroxide monohydrate (38 mg, 0.908 mmoles), was added and the reaction mixture was stirred at 25° C. for 3 hours. The reaction mixture was poured into ice cold water, acidified by dil.HCl and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure to yield 250 mg (77%) of product as solid.
[0242] 1 H NMR: δ 4.61 (s, 2H), 5.21 (s, 2H), 5.53 (s, 2H), 6.84 (dd, J=9.2 & 2.8 Hz, 1H), 7.36 (t, 3H), 7.42 (d, J=2.4 Hz, 1H), 7.67 (d, J=8.4 Hz, 4H), 7.74 (d, J=8.4 Hz, 2H), 7.84 (s, 1H), 8.42 (s, 1H), 12.98 (d, J=4.4 Hz, 1H)
Example 9
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((1-(4-(trifluoromethyl)benzyl)-3-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)-1H-indol-5-yl)oxy)acetamide
[0243] To a solution of compound prepared in example 8 (250 mg, 0.454 mmoles) in DMF (2 mL), (tetrahydro-2H-pyran-4-yl)methanamine hydrochloride (83 mg, 0.545 mmoles), HOBT (Catalyst), EDC.HCl (130 mg, 0.681 mmoles) and N-ethyl morpholine (0.173 ml, 1.362 mmoles) were added and the reaction mixture was srirred at 25° C. for 5 hours under nitrogen atmosphere. The reaction mixture was poured into ice cold water and extracted with ethyl acetate. The combined ethyl acetate extract was washed with water & brine, dried over sodium sulphate and evaporated under reduced pressure. The crude product was purified by column chromatography to yield 200 mg (68%) of product as white solid.
[0244] 1 H NMR: δ 1.01-1.11 (m, 2H), 1.42 (d, J=12.8 Hz, 2H), 1.61-1.67 (m, 1H), 2.67 (t, J=1.8 Hz, 2H), 2.98-3.15 (m, 2H), 3.71 (dd, J=14.0 & 2.8 Hz, 2H), 4.45 (s, 2H), 5.23 (s, 2H), 5.53 (s, 2H), 6.89 (dd, J=8.8 & 2.4 Hz, 1H), 7.34 (d, J=8.0 Hz, 2H), 7.38 (d, J=9.2 Hz, 1H), 7.46 (d, J=2.4 Hz, 1H), 7.68 (t, J=8.2 Hz, 4H), 7.75 (d, J=8.0 Hz, 2H), 7.84 (s, 1H), 8.08 (t, J=6.0 Hz, 1H), 8.42 (s, 1H).
Example 10
2-(2-methyl-4-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0245] 1 H NMR: δ 1.2 (m, 2H), 1.5 (m, 2H), 1.7 (m, 1H), 2.2 (s, 3H), 3.2 (t, J=6.4 Hz, 2H), 3.3 (t, J=11.4 Hz, 2H), 3.9 (dd, J=11.6 & 3.6 Hz, 2H), 4.1 (s, 2H), 4.6 (s, 2H), 5.2 (s, 2H), 6.6 (t, NH), 6.7 (d, J=8.4 Hz, 1H), 7.1-7.2 (m, 5H), 7.3 (m, 3H), 7.5 (s, 1H), 7.6 (d, J=8.0 Hz, 2H).
Example 11
2-(4-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0246] 1 H NMR: DMSO-d 6 , δ 1.02-1.13 (m, 2H), 1.43-1.46 (m, 2H), 1.58-1.65 (m, 1H), 2.97 (t, J=6.4 Hz, 2H), 3.15-3.20 (m, 2H), 3.75 (dd, J=11.4 & 2.6 Hz, 2H), 4.17 (s, 2H), 4.47 (s, 2H), 5.31 (s, 2H), 6.89 (d, J=9.2 Hz, 2H), 7.12-7.16 (m, 3H), 7.20-7.24 (m, 2H), 7.55-7.61 (m, 4H), 7.71 (d, J=8.0 Hz, 2H), 8.80 (t, NH).
Example 12
2-(4-(2-phenyl-1-(((3-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0247] 1 H NMR: DMSO-d 6 , δ, 1.11-1.06 (m, 2H) 1.46-1.43 (m, 2H), 1.64-1.59 (m, 1H), 2.99 (t, J=12.8 Hz, 2H), 3.19 (t, J=21.6 Hz, 2H), 3.78 (d, 2H), 4.16 (s, 2H), 4.47 (s, 2H), 5.31 (s, 2H), 6.91 (d, J=8.8 Hz, 2H), 7.15 (t, J=3.8 Hz, 3H), 7.22 (d, J=6 Hz, 2H), 7.60 (t, J=8.8 Hz, 3H), 7.67 (s, 1H), 7.70 (s, 2H), 8.10 (t, J=11.6 Hz, 1H).
Example 13
2-(4-(2-(pyridin-4-yl)-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0248] 1 H NMR: DMSO-d 6 , δ 1.05-1.10 (m, 2H), 1.45 (d, J=12.8 Hz, 2H), 1.65-1.71 (m, 1H), 2.98 (t, J=6.4 Hz, 2H), 3.14-3.20 (m, 2H), 3.75-3.78 (m, 2H), 4.20 (s, 2H), 4.47 (s, 2H), 5.30 (s, 2H), 6.92 (d, J=8.8 Hz, 2H), 7.14 (d, J=6.0 Hz, 2H), 7.55 (d, J=8.0 Hz, 2H), 7.61 (d, J=8.8 Hz, 2H), 7.71 (d, J=8.0 Hz, 2H), 8.07 (s, —NH), 8.40 (d, J=4.4 Hz, 2H).
Example 14
2-(4-(2-morpholino-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0249] 1 H NMR: DMSO-d 6 , δ 1.05-1.16 (m, 2H), 1.48 (d, J=13.2 Hz, 2H), 1.62-1.68 (m, 1H), 2.36 (br s, 4H), 3.01 (t, J=6.4 Hz, 2H), 3.20 (t, J=11.0 Hz, 2H), 3.46 (m, 4H), 3.64 (s, 2H), 3.78-3.81 (dd, J=11.6 & 2.4 Hz, 2H), 4.51 (s, 2H), 5.27 (s, 2H), 6.93 (d, J=8.8 Hz, 2H), 7.61 (d, J=8.0 Hz, 2H), 7.67 (d, J=8.8 Hz, 2H), 7.74 (d, J=8.4 Hz, 2H), 8.11 (t, NH).
Example 15
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(2-thiomorpholino-1-(((4-(trifluoromethyl) benzyl)oxy)imino)ethyl)phenoxy)acetamide
[0250] 1 H NMR: DMSO-d 6 , δ 1.09-1.18 (m, 2H), 1.46-1.49 (m, 2H), 1.60-1.65 (m, 1H), 2.47-2.49 (m, 4H), 2.61-2.63 (m, 4H), 2.99 (t, J=6.6 Hz, 2H), 3.17-3.23 (m, 2H), 3.67 (s, 2H), 3.78-3.81 (m, 2H), 4.50 (s, 2H), 5.26 (s, 2H), 6.92 (dd, J=7.0 & 1.8 Hz, 2H), 7.59-7.65 (m, 4H), 7.73 (d, J=8.0 Hz, 2H), 8.09 (t, NH).
Example 16
2-(2-methyl-4-(2-(thiophen-3-yl)-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0251] 1 H NMR: DMSO-d 6 , δ 1.04-1.14 (m, 2H), 1.44 (d, J=12.8 Hz, 2H), 1.58-1.67 (m, 1H), 2.19 (s, 3H), 2.98 (t, J=6.4 Hz, 2H), 3.15-3.21 (m, 2H), 3.76-3.79 (m, 2H), 4.11 (s, 2H), 4.50 (s, 2H), 5.31 (s, 2H), 6.77 (d, J=8.8 Hz, 1H), 6.89 (m, 1H), 7.11 (s, 1H), 7.38-7.40 (m, 1H), 7.43 (dd, J=8.6 & 1.8 Hz, 1H), 7.51 (s, 1H), 7.55 (d, J=8.0 Hz, 2H), 7.70 (d, J=8.4 Hz, 2H), 7.90 (t, NH).
Example 17
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-((((4-(trifluoromethyl) benzyl)oxy)imino)methyl)phenoxy)acetamide
[0252] 1 H NMR: DMSO-d 6 , δ 1.05-1.16 (m, 2H), 1.46-1.49 (m, 2H), 1.62-1.98 (m, 1H), 2.99 (t, J=6.4 Hz, 2H), 3.17-3.24 (m, 2H), 3.78-3.81 (m, 2H), 4.51 (s, 2H), 5.23 (s, 2H), 6.97-6.99 (dd. J=2.0 & 8.8 Hz, 2H), 7.54 (dd, J=2.0 & 8.8 Hz, 2H), 7.60 (d, J=8.0
[0253] Hz, 2H), 7.73 (d, J=8.0 Hz, 2H), 8.12 (t, NH), 8.29 (s, 1H).
Example 18
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)acetamide
[0254] 1 H NMR: DMSO-d 6 , δ 1.12-1.07 (m, 2H), 1.45-1.44 (m, 2H), 1.48 (m, 1H), 2.21 (s, 3H), 2.99 (t, J=6.4 Hz, 2H), 3.22-3.16 (m, 2H), 3.80-3.77 (m, 2H), 4.49 (s, 2H), 5.26 (s, 2H), 6.96-6.93 (dd, J=2.0 & 6.8 Hz, 2H), 7.60-7.56 (m, 4H), 7.71 (d, J=8.0 Hz, 2H), 8.10 (t, J=5.6 Hz, 1H).
Example 19
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-((((4-(trifluoromethyl) benzyl)oxy)imino)methyl)pyridin-2-yl)oxy)acetamide
[0255] 1 H NMR: δ 1.24-1.35 (m, 2H), 1.54-1.58 (m, 2H), 1.73-1.81 (m, 1H), 3.21 (t, J=6.6 Hz, 2H), 3.31-3.37 (m, 2H), 3.93-3.97 (m, 2H), 4.85 (s, 2H), 5.23 (s, 2H), 6.42 (bs, NH), 6.83 (d, J=8.4 Hz, 1H), 7.49 (d, J=8.0 Hz, 2H), 7.61 (d, J=8.0 Hz, 2H), 7.95 (dd, J=8.4 & 2.4 Hz, 1H), 8.12 (s, 1H), 8.20 (d, J=2.4 Hz, 1H).
Example 20
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((4-(1-(((4-(trifluoromethyl) benzyl)oxy)imino)ethyl)phenyl)amino)acetamide
[0256] 1 H NMR: DMSO-d 6 , δ 1.06-1.15 (m, 2H), 1.44 (d, J=12.8 Hz, 2H), 1.60 (m, 1H), 2.16 (s, 3H), 2.94 (t, J=6.4 Hz, 2H), 3.16-3.22 (m, 2H), 3.64 (d, J=6.0 Hz, 2H), 3.77-3.80 (m, 2H), 5.22 (s, 2H), 6.23 (t, J=6.0 Hz, 1H), 6.51 (d, J=8.4 Hz, 2H), 7.38 (d, J=8.4 Hz, 2H), 7.58 (d, J=8 Hz, 2H), 7.71 (d, J=8.0 Hz, 2H), 7.88 (t, J=5.8 Hz, 1H).
Example 21
2-((5-(1-(((4-cyanobenzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0257] 1 H NMR: DMSO-d 6 , δ 1.06-1.10 (m, 2H), 1.44-1.47 (m, 2H), 1.62-1.68 (m, 1H), 2.24 (s, 3H), 2.95 (t, J=6.4 Hz, 2H), 3.15-3.22 (m, 2H), 3.76-3.80 (dd, J=2.8 & 11.6 Hz, 2H), 4.71 (s, 2H), 5.27 (s, 2H), 6.91 (d, J=8.8 Hz, 1H), 7.57 (d, J=8.0 Hz, 2H), 7.83 (d, J=6.4 Hz, 2H), 7.95-8.01 (m. 2H), 8.32 (s, 1H).
Example 22
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetamide
[0258] 1 H NMR: δ 1.14 (t, J=7.6 Hz, 3H), 1.24-1.34 (m, 2H), 1.55-1.58 (m, 2H), 1.72-1.82 (m, 1H), 2.76 (q, J=7.6 Hz, 2H), 3.23 (t, J=6.4 Hz, 2H), 3.30-3.37 (m, 2H), 3.93-3.97 (m, 2H), 4.85 (s, 2H), 5.25 (s, 2H), 6.44 (bs, NH), 6.81 (d, J=8.8 Hz, 1H), 7.48 (d, J=8.0 Hz, 2H), 7.61 (d, J=8.0 Hz, 2H), 7.94 (dd, J=8.6 & 2.2 Hz, 1H), 8.35 (d, J=2.4 Hz, 1H).
Example 23
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyridin-2-yl)amino)acetamide
[0259] 1 H NMR: δ 1.03 (t, J=7.6 Hz, 3H), 1.07-1.11 (m, 2H), 1.47-1.51 (m, 2H), 1.57-1.63 (m, 1H), 2.68 (q, J=7.6 Hz, 2H), 2.94 (t, J=6.4 Hz, 2H), 3.16-3.23 (m, 2H), 3.78 (dd, J=11.2 & 2.4 Hz, 2H), 3.86 (d, J=6.0 Hz, 2H), 5.23 (s, 2H), 6.55 (d, J=8.8 Hz, 1H), 7.12 (t, J=6.0 Hz, NH), 7.58 (d, J=8.0 Hz, 2H) 7.64 (dd, J=9.0 & 2.6 Hz, 1H), 7.72 (d, J=8.0 Hz, 2H), 7.83 (t, J=6.0 Hz, NH), 8.18 (d, J=2.0 Hz, 1H).
Example 24
2-((5-(1-((benzyloxy)imino)propyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0260] 1 H NMR: δ 1.11 (t, J=7.6 Hz, 3H), 1.24-1.35 (m, 2H), 1.54-1.58 (m, 2H), 1.72-1.82 (m, 1H), 2.72 (q, J=7.6 Hz, 2H), 3.21 (t, J=6.6 Hz, 2H), 3.31-3.37 (m, 2H), 3.93-3.96 (m, 2H), 4.84 (s, 2H), 5.21 (s, 2H), 6.45 (bs, NH), 6.80 (dd, J=8.8 & 0.4 Hz, 1H), 7.29-7.41 (m, 5H), 7.96 (dd, J=8.8 & 2.4 Hz, 1H), 8.35 (d, J=2.0 Hz, 114).
Example 25
2-((5-(1-(((4-methylbenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0261] 1 H NMR: δ 1.10 (t, J=7.2 Hz, 3H), 1.25-1.36 (m, 2H), 1.56-1.59 (m, 2H), 1.73-1.84 (m, 1H), 2.36 (s, 3H), 2.72 (q, J=7.2 Hz, 2H), 3.22 (t, J=6.6 Hz, 2H), 3.32-3.38 (m, 2H), 3.94-3.98 (m, 2H), 4.85 (s, 2H), 5.27 (s, 2H), 6.47 (bs, NH), 6.82 (d, J=8.4 Hz, 1H), 7.17 (d, J=7.6 Hz, 2H), 7.29 (d, J=8.0 Hz, 2H), 7.98-8.00 (m, 1H), 8.35 (d, J=2.0 Hz, 1H).
Example 26
2-((5-(1-(((4-methoxybenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0262] 1 H NMR: δ 1.10 (t, J=7.6 Hz, 3H), 1.24-1.35 (m, 2H), 1.54-1.56 (m, 2H), 1.73-1.80 (m, 1H), 2.69 (q, J=7.6 Hz, 2H), 3.21 (t, J=6.6 Hz, 2H), 3.31-3.37 (m, 2H), 3.81 (s, 3H), 3.93-3.96 (m, 2H), 4.84 (s, 2H), 5.13 (s, 2H), 6.45 (bs, NH), 6.81 (d, J=8.8 Hz, 1H), 6.88-6.91 (m, 2H), 7.31-7.35 (m, 2H), 7.96 (dd, J=8.8 & 2.4 Hz, 1H), 8.34 (d, J=2.0 Hz, 1H).
Example 27
2-((5-(1-(((4-fluorobenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0263] 1 H NMR: δ 1.11 (t, J=7.6 Hz, 3H), 1.24-1.35 (m, 2H), 1.54-1.58 (m, 2H), 1.73-1.81 (m, 1H), 2.71 (q, J=7.6 Hz, 2H), 3.21 (t, J=6.6 Hz, 2H), 3.31-3.37 (m, 2H), 3.93-3.96 (m, 2H), 4.84 (s, 2H), 5.16 (s, 2H), 6.45 (bs, NH), 6.81 (dd, J=8.8 & 0.4 Hz, 1H), 7.01-7.07 (m, 2H), 7.34-7.39 (m, 2H), 7.95 (dd, J=8.8 & 2.4 Hz, 1H), 8.34 (d, J=2.0 Hz, 1H).
Example 28
2-((5-(1-(((4-cyanobenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0264] 1 H NMR: δ 1.16 (t, J=7.6 Hz, 3H), 1.25-1.35 (m, 2H), 1.55-1.59 (m, 2H), 1.72-1.81 (m, 1H), 2.75 (q, J=7.6 Hz, 2H), 3.21 (t, J=6.6 Hz, 2H), 3.31-3.38 (m, 2H), 3.93-3.97 (m, 2H), 4.85 (s, 2H), 5.26 (s, 2H), 6.44 (bs, NH), 6.82 (dd, J=8.8 Hz, 1H), 7.47 (d, J=8.0 Hz, 2H), 7.65 (d, J=8.4 Hz, 2H), 7.93 (dd, J=8.4 & 2.4 Hz, 1H), 8.35 (d, J=2.0 Hz, 1H).
Example 29
2-(2-methyl-4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)butyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0265] 1 H NMR: DMSO-d 6 , δ 0.87 (t, J=7.4 Hz, 3H), 1.07-1.15 (m, 2H), 1.41-1.48 (m, 4H), 1.60-1.67 (m, 1H), 2.21 (s, 3H), 2.72 (t, J=7.6 Hz, 2H), 3.00 (t, J=6.4 Hz, 2H), 3.16-3.22 (t, J=12.0 Hz, 2H), 3.77-3.80 (dd, J=11.2 &11.2 Hz, 2H), 4.51 (s, 2H), 5.24 (s, 2H), 6.80 (d, J=8.4 Hz, 1H), 7.36-7.38 (dd, J=8.8 & 8.4 Hz, 1H), 7.43 (d, J=1.6 Hz, 1H), 7.58 (d, J=8.0 Hz, 2H), 7.72 (d, J=8.0 Hz, 2H), 7.93 (t, J=5.8 Hz, 1H).
Example 30
2-(4-(2-methoxy-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0266] 1 H NMR: DMSO-d 6 , δ 1.07-1.04 (m, 2H), 1.15-1.13 (m, 2H), 1.66-1.62 (m, 1H), 3.00 (t, 2H), 3.16-3.17 (m, 2H), 3.19 (s, 3H), 3.80-3.77 (m, 2H), 4.49 (s, 2H), 4.58 (s, 2H), 5.27 (s, 2H), 6.95-6.93 (dd, J=2 & 7.2 Hz, 2H), 7.55-7.52 (m, 2H), 7.59 (d, J=8 Hz, 2H), 7.72 (d, J=8.0 Hz, 2H), 8.09 (t, J=5.9 Hz, 1H).
Example 31
2-(4-(2-hydroxy-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0267] 1 H NMR: DMSO-d 6 , δ 1.05-1.15 (m, 2H), 1.46 (d, J=12.8 Hz, 2H), 1.62-1.68 (m, 1H), 2.99 (t, J=6.4 Hz, 2H), 3.17 (t, J=10.8 Hz, 2H), 3.77-3.81 (m, 2H), 4.49 (s, 2H), 4.60 (d, J=5.6 Hz, 2H), 5.15 (t, J=5.6 Hz, 1H), 5.25 (s, 2H), 6.93 (d, J=8.8 Hz, 2H), 7.55 (d, J=8.8 Hz, 2H), 7.59 (d, J=8 Hz, 2H), 7.71 (d, J=8 Hz, 2H), 8.09 (t, J=5.6 Hz, 1H).
Example 32
2-(2-methyl-4-(1-(((4-methylbenzyl)oxy)imino)-2-phenylethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0268] 1 H NMR: DMSO-d 6 , δ 1.03-1.16 (m, 2H), 1.43 (m, 2H), 1.58-1.66 (m, 1H), 2.18 (s, 3H), 2.28 (s, 3H), 2.97 (t, J=6.6 Hz, 2H), 3.1-3.20 (m, 2H), 3.75-3.79 (m, 2H), 4.10 (s, 2H), 4.48 (s, 2H), 5.15 (s, 2H), 6.74 (d, J=8.8 Hz, 1H), 7.10-7.16 (m, 5H), 7.18-7.21 (m, 2H), 7.24 (d, J=8.0 Hz, 2H), 7.40 (dd, J=8.6 & 2.2 Hz, 1H), 7.50 (d, J=1.6 Hz, 1H), 7.91 (t, J=6.0 Hz, NH)
Example 33
2-(4-(1-(((4-methylbenzyl)oxy)imino)-2-phenylethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0269] 1 H NMR: DMSO-d 6 , δ 1.06-1.16 (m, 2H), 1.43 (d, J=12.8 Hz, 2H), 1.59-1.66 (m, 1H), 2.28 (s, 3H), 2.96 (t, J=6.4 Hz, 2H), 3.14 (m, 2H), 3.75-3.78 (m, 2H), 4.11 (s, 2H), 4.46 (s, 2H), 5.16 (s, 2H), 6.89 (d, J=8.8 Hz, 2H), 7.11-7.16 (m, 5H), 7.18-7.22 (m, 2H), 7.24 (d, J=8.0 Hz, 2H), 7.59 (d, J=8.8 Hz, 2H), 8.07 (t, J=5.8 Hz, NH).
Example 34
2-(4-(1-(((4-fluorobenzyl)oxy)imino)-2-phenylethyl)-2-methylphenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0270] 1 H NMR: DMSO-d 6 , 1.21-1.36 (m, 2H), 1.54-1.57 (m, 2H), 1.72-1.79 (m, 1H), 2.25 (s, 3H), 3.23 (t, J=6.4 Hz, 2H), 3.31-3.37 (m, 2H), 3.93 (dd, J=11.2 & 3.6 Hz, 2H), 4.11 (s, 2H), 4.48 (s, 2H), 5.20 (s, 2H), 6.68 (d, J=8.8 Hz, 2H), 6.98 (t, J=8.8 Hz, 2H), 7.13-7.32 (m, 7H), 7.39 (dd, J=8.8 & 2.0 Hz, 1H), 7.52 (s, 1H).
Example 35
2-(4-(1-(((4-fluorobenzyl)oxy)imino)-2-phenylethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0271] 1 H NMR: δ 1.24-1.35 (m, 2H), 1.54-1.57 (m, 2H), 1.71-1.80 (m, 1H), 3.23 (t, J=6.2 Hz, 2H), 3.29-3.36 (m, 2H), 3.92-3.96 (m, 2H), 4.12 (s, 2H), 4.47 (s, 2H), 5.20 (s, 2H), 6.58 (s, 1H), 6.85 (d, J=12 Hz, 2H), 6.98-7.03 (m, 2H), 7.13-7.24 (m, 5H), 7.29-7.32 (m, 2H), 7.58-7.61 (m, 2H).
Example 36
2-(4-(14((4-chlorobenzyl)oxy)imino)-2-phenylethyl)-2-methylphenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0272] 1 H NMR: DMSO-d 6 , δ 1.03-1.14 (m, 2H), 1.43 (d, J=12.8 Hz, 2H), 1.59-1.65 (m, 1H), 2.18 (s, 3H), 2.97 (t, J=6.4 Hz, 2H), 3.15-3.20 (m, 2H), 3.75-3.79 (m, 2H), 4.12 (s, 2H), 4.49 (s, 2H), 5.19 (s, 2H), 6.75 (d, J=8.8 Hz, 1H), 7.12-7.15 (m, 3H), 7.19-7.22 (m, 2H), 7.35-7.43 (m, 5H), 7.58 (d, J=1.2 Hz, 1H), 7.90 (t, J=5.8 Hz, NH).
Example 37
2-(4-(1-(((4-chlorobenzyl)oxy)imino)-2-phenylethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0273] 1 H NMR: DMSO-d 6 , δ 1.05-1.13 (m, 2H), 1.43 (d, J=11.6 Hz, 2H), 1.61-1.63 (m, 1H), 2.96 (t, J=6.4 Hz, 2H), 3.14 (t, J=10.8 Hz, 2H), 3.75-3.78 (m, 2H), 4.13 (s, 2H), 4.46 (s, 2H), 5.20 (s, 2H), 6.89 (d, J=8.8 Hz, 2H), 7.12-7.15 (m, 3H), 7.19-7.23 (m, 2H), 7.36-7.42 (m, 4H), 7.58 (d, J=8.8 Hz, 2H), 8.06 (t, J=5.8 Hz, NH).
Example 38
2-(2-methyl-4-(2-phenyl-1-(((4-(trifluoromethoxy)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0274] 1 H NMR: δ 1.25-1.37 (m, 2H), 1.57 (m, 2H), 1.71-1.80 (m, 1H), 2.25 (s, 3H), 3.25 (t, J=6.6 Hz, 2H), 3.31-3.37 (m, 2H), 3.93-3.97 (m, 2H), 4.13 (s, 2H), 4.48 (s, 2H), 5.23 (s, 2H), 6.58 (s, 1H), 6.70 (d, J=8.8 Hz, 1H), 7.14-7.24 (m, 7H), 7.33 (d, J=8.8 Hz, 2H), 7.39-7.42 (m, 1H), 7.51 (d, J=7.6 Hz, 1H).
Example 39
2-(4-(2-phenyl-1-(((4-(trifluoromethoxy)benzyl)oxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0275] 1 H NMR: DMSO-d 6 , δ 1.02-1.13 (m, 2H), 1.43 (d, J=12.8 Hz, 2H), 1.58-1.65 (m, 1H), 2.96 (t, J=6.4 Hz, 2H), 3.14-3.20 (m, 2H), 3.75-3.78 (m, 2H), 4.14 (s, 2H), 4.47 (s, 2H), 5.24 (s, 2H), 6.89 (d, J=8.8 Hz, 2H), 7.13-7.14 (m, 3H), 7.18-7.22 (m, 2H), 7.33 (d, J=8.4 Hz, 2H), 7.47 (d, J=8.8 Hz, 2H), 7.59 (d, J=8.8 Hz, 2H), 8.06 (t, J=5.8 Hz, NH).
Example 40
2-(4-(1-(((4-methoxybenzyl)oxy)imino)-2-phenylethyl)-2-methylphenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0276] 1 H NMR: DMSO-d 6 , δ 1.03-1.14 (m, 2H), 1.43-1.47 (m, 2H), 1.59-1.64 (m, 1H), 2.18 (s, 3H), 2.97 (t, J=6.4 Hz, 2H), 3.14-3.20 (m, 2H), 3.73 (s, 3H), 3.75-3.79 (m, 2H), 4.08 (s, 2H), 4.48 (s, 2H), 5.12 (s, 2H), 6.74 (d, J=8.8 Hz, 1H), 6.88-6.92 (m, 2H), 7.10-7.13 (m, 3H), 7.17-7.21 (m, 2H), 7.29-7.32 (m, 2H), 7.40 (dd, J=8.6 & 2.2 Hz, 1H), 7.50 (d, J=1.6 Hz, 1H), 7.91 (t, J=6.0 Hz, NH)
Example 41
2-(4-(1-(((4-methoxybenzyl)oxy)imino)-2-phenylethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0277] 1 H NMR: DMSO-d 6 , δ 1.03-1.13 (m, 2H), 1.43-1.46 (m, 2H), 1.59-1.65 (m, 1H), 2.96 (t, J=6.4 Hz, 2H), 3.14-3.20 (m, 2H), 3.73 (s, 3H), 3.75-3.78 (m, 2H), 4.10 (s, 2H), 4.46 (s, 2H), 5.13 (s, 2H), 6.89 (dd, J=8.8 & 2.0 Hz, 4H), 7.10-7.13 (m, 3H), 7.18-7.21 (m, 2H), 7.29 (dd, J=11.2 & 2.8 Hz, 2H), 7.58 (d, J=10.0 Hz, 2H), 8.06 (t, J=6.0 Hz, NH).
Example 42
2-(4-(1-(((4-(methylsulfonyl)benzyl)oxy)imino)propyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0278] 1 H NMR: δ 1.04-1.16 (m, 5H), 1.45-1.49 (m, 2H), 1.61-1.70 (m, 1H), 2.72 (q, J=7.6
[0279] Hz, 2H), 2.99 (t, J=6.4 Hz, 2H), 3.17-3.23 (m, 5H), 3.77-3.81 (dd, J=11.4 & 2.6 Hz, 2H), 4.51 (s, 2H), 5.28 (s, 2H), 6.95-6.98 (m, 2H), 7.55-7.59 (m, 2H), 7.62 (d, J=8.0 Hz, 2H), 7.91 (dd, J=6.8 & 1.6 Hz, 2H), 8.08 (t, J=5.8 Hz, NH).
Example 43
2-(4-(2-phenyl-1-((pyridin-2-ylmethoxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0280] 1 H NMR: δ 1.27-1.35 (m, 2H), 1.53-1.57 (m, 2H), 1.72-1.79 (m, 1H), 3.21 (t, J=6.6 Hz, 2H), 3.29-3.36 (m, 2H), 3.92 (dd, J=11.0 & 3.4 Hz, 2H), 4.21 (s, 2H), 4.47 (s, 2H), 5.39 (s, 2H), 6.58 (bs, NH), 6.82-6.86 (m, 2H), 7.16-7.28 (m, 7H), 7.60-7.64 (m, 3H), 8.56-8.58 (m, 1H).
Example 44
2-(4-(1-((2-(1H-indol-1-yl)ethoxy)imino)propyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0281] 1 H NMR: DMSO-d 6 , δ 0.83 (t, J=7.4 Hz, 3H), 1.08-1.12 (m, 2H), 1.45-1.49 (m, 2H), 1.60-1.68 (m, 1H), 2.49-2.53 (m, 2H), 3.00 (t, J=6.4 Hz, 2H), 3.20 (t, J=11.6 Hz, 2H), 3.78-3.81 (dd, J=11.4 & 2.6 Hz, 2H), 4.36-4.38 (t, J=5.0 Hz, 2H), 4.48-4.51 (m, 4H), 6.41 (d, J=3.2 Hz, 1H), 6.94 (d, J=8.8 Hz, 2H), 6.97-7.01 (m, 1H), 7.08 (t, J=7.0 Hz, 1H), 7.30 (d, J=2.8 Hz, 1H), 7.44 (d, J=8.0 Hz, 1H), 7.51-7.56 (m, 3H), 8.10 (t, NH).
Example 45
2-(4-(1-(((5-ethylpyrimidin-2-yl)oxy)imino)propyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0282] 1 H NMR: DMSO-d 6 , δ 1.07-1.20 (m, 8H), 1.47-1.50 (dd, J=12.8 & 12.8 Hz, 2H), 1.65-1.66 (m, 1H), 2.56-2.61 (q, 2H), 2.86-2.92 (q, 2H), 3.02 (t, J=6.4 Hz, 2H), 3.18-3.28 (m, 2H), 3.78-3.81 (dd, J=11.2 & 11.2 Hz, 2H), 4.55 (s, 2H), 7.03-7.06 (m, 2H), 7.73-7.76 (m, 2H), 8.13 (t, J=5.8 Hz, 1H), 8.54 (s, 2H).
Example 46
2-(4-(1-(((5-methyl-2-phenyloxazol-4-yl)methoxy)imino)propyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0283] 1 H NMR: δ 1.07 (t, J=7.6 Hz, 3H), 1.25-1.37 (m, 2H), 1.56-1.64 (m, 2H), 1.75-1.81 (m, 1H), 2.47 (s, 3H), 2.71 (q, J=7.6 Hz, 2H), 3.23 (t, J=6.6 Hz, 2H), 3.32 (t, J=11.8 Hz, 2H), 3.94 (dd, J=11.0 & 3.8 Hz, 2H), 4.51 (s, 2H), 5.12 (s, 2H), 6.62 (bs, NH), 6.88-6.92 (m, 2H), 7.40-7.45 (m, 3H), 7.59-7.63 (m, 2H), 7.99-8.02 (m, 2H).
Example 47
2-(4-(1-(((3-(tert-butyl)-1-(p-tolyl)-1H-pyrazol-5-yl)methoxy)imino)propyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0284] 1 H NMR: δ 1.06 (t, J=7.6 Hz, 3H), 1.27-1.34 (m, 2H), 1.36 (s, 9H), 1.58-1.60 (m, 2H), 1.78-1.80 (m, 1H), 2.37 (s, 3H), 2.69 (q, J=7.4 Hz, 2H), 3.24 (t, J=6.6 Hz, 2H), 3.32 (t, J=11.6 Hz, 2H), 3.94 (dd, J=11.0 & 3.4 Hz, 2H), 4.52 (s, 2H), 5.11 (s, 2H), 6.37 (s, 1H), 6.62 (s, NH), 6.90 (d, J=8.8 Hz, 2H), 7.21 (d, J=8.0 Hz, 2H), 7.44 (d, J=8.0 Hz, 2H), 7.58 (d, J=8.8 Hz, 2H).
Example 48
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(((4-(trifluoromethyl)benzyl)oxy)imino)-5,6,7,8-tetrahydronaphthalen-2-yl)oxy)acetamide
[0285] 1 H NMR: DMSO-d 6 , δ 1.08 (t, J=6.6 Hz, 2H), 1.44 (d, J=12.8 Hz, 2H), 1.48 (m, 1H), 1.75 (t, J=5.8 Hz, 2H), 2.66 (t, J=5.6 Hz, 2H), 2.98 (t, J=6.6 Hz, 2H), 3.01 (t, J=6.4 Hz, 2H), 3.16-3.21 (m, 2H), 3.80 (d, J=2.4 Hz, 2H), 4.47 (s, 2H), 5.24 (s, 2H), 6.74 (d, J=2.4 Hz, 1H), 6.77-6.80 (dd, J=2.8 & 8.8 Hz, 1H), 7.58 (d, J=8 Hz, 2H), 7.69-7.73 (dd, J=4 & 8 Hz, 3H), 8.09 (t, J=5.6 Hz, 1H).
Example 49
2-((5-(((4-chlorobenzyl)oxy)imino)-5,6,7,8-tetrahydronaphthalen-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0286] 1 H NMR: DMSO-d 6 , δ 1.09-1.15 (m, 2H), 1.45 (d, J=12.8 Hz, 2H), 1.61-1.69 (m, 1H), 1.69-7.75 (m, 2H), 2.63-2.68 (m, 4H), 2.99 (t, J=6.4 Hz, 2H), 3.15-3.22 (m, 2H), 4.47 (s, 2H), 5.12 (s, 2H), 6.73 (d, J=2.4 Hz, 1H), 6.78-6.81 (dd, J=2.8 & 8.8 Hz, 1H), 7.38 (d, J=8 Hz, 4H), 7.71 (d, J=8.8 Hz, 1H), 8.08 (t, J=6.0 Hz, 1H).
Example 50
2-((5-(((4-cyanobenzyl)oxy)imino)-5,6,7,8-tetrahydronaphthalen-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0287] 1 H NMR: DMSO-d 6 , δ 1.07-1.30 (m, 2H), 1.44-1.48 (m, 2H), 1.64 (m, 1H), 1.72-1.75 (m, 2H), 2.66 (t, J=6.0 Hz, 2H), 2.69-2.72 (m, 2H), 2.99 (t, J=6.4 Hz, 2H), 3.16-3.22 (m, 2H), 3.76-3.80 (q, J=2.6 Hz, 2H), 4.47 (s, 2H), 5.23 (s, 2H), 6.74 (d, J=2.8 Hz, 1H), 6.77-6.8 (dd, J=2.4 & 8.4 Hz, 1H), 7.54 (d, J=8.4 Hz, 2H), 7.68 (d, J=8.8 Hz, 1H), 7.81 (d, J=1.6 Hz, 2H), 8.08 (t, J=6.0 Hz, 1H).
Example 51
2-((5-(((4-methoxybenzyl)oxy)imino)-5,6,7,8-tetrahydronaphthalen-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0288] 1 H NMR: DMSO-d 6 , δ 1.09-1.16 (m, 2H), 1.46-1.49 (dd, J=1.6 & 12.8 Hz, 2H), 1.64-1.74 (m, 3H), 2.61-2.66 (m, 4H), 2.99 (t, J=6.4 Hz, 2H), 3.18-3.24 (m, 2H), 3.74 (s, 3H), 3.78-3.82 (dd, J=2.4 & 11.2 Hz, 2H), 4.48 (s, 2H), 5.06 (s, 2H), 6.75 (d, J=2.4
[0289] Hz, 1H), 6.80-6.83 (dd, J=2.8 & 8.8 Hz, 1H), 6.92 (d, J=8.4 Hz, 2H), 7.34 (d, J=8.4 Hz, 2H), 7.77 (d, J=8.8 Hz, 1H), 8.08 (t, J=6.0 Hz, 1H)
Example 52
Methyl 3-((((6-(2-oxo-2-(((tetrahydro-2H-pyran-4-yl)methyl)amino)ethoxy)-3,4-dihydronaphthalen-1(2H)-ylidene)amino)oxy)methyl)benzoate
[0290] 1 H NMR: DMSO-d 6 , δ 1.08-1.15 (m, 2H), 1.45-1.49 (dd, J=1.6 & 12.8 Hz, 2H), 1.64-1.66 (m, 1H), 1.72 (t, J=6.0 Hz, 2H), 2.65-2.71 (m, 4H), 2.99 (t, J=6.4 Hz, 2H), 3.17-3.20 (m, 2H), 3.78-3.81 (dd, J=2.4 & 11.2 Hz, 2H), 3.85 (s, 3H), 4.48 (s, 2H), 5.22 (s, 2H), 6.75 (d, J=2.8 Hz, 1H), 6.79-6.82 (dd, J=2.8 & 8.8 Hz, 1H), 7.50 (t, J=7.6 Hz, 1H), 7.68 (d, J=7.6 Hz, 1H), 7.74 (d, J=8.8 Hz, 1H), 7.88-7.91 (m, 1H), 7.98 (s, 1H), 8.06 (t, J=6.0 Hz, 1H).
Example 53
2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)quinolin-8-yl)oxy)acetic acid
[0291] 1 H NMR: DMSO-d 6 , δ 2.36 (s, 3H), 4.78 (s, 2H), 5.32 (s, 2H), 7.23 (d, J=7.6 Hz, 1H), 7.41-7.44 (m, 1H), 7.55-7.58 (m, 1H), 7.64-7.66 (m, 2H), 7.77 (d, J=8.4 Hz, 2H), 8.40 (d, J=8.8 Hz, 1H), 8.86 (d, J=2.8 Hz, 1H).
Example 54
N-((tetrahydro-2H-pyran-4-yl)methyl)-245-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)quinolin-8-yl)oxy)acetamide
[0292] 1 H NMR: DMSO-d 6 , δ 1.09-1.16 (m, 2H), 1.44 (d, J=12.8 Hz, 2H), 1.61-1.64 (m, 1H), 2.36 (s, 3H), 3.04 (t, J=6.4 Hz, 2H), 3.16-3.23 (m, 2H), 3.77 (dd, J=2.8 & 11.6 Hz, 2H), 4.77 (s, 2H), 5.33 (s, 2H), 7.24 (d, J=8.4 Hz, 1H), 7.43 (dd, J=4.4 & 8.8 Hz, 1H), 7.58 (d, J=8.4 Hz, 1H), 7.64 (d, J=8 Hz, 2H), 7.77 (d, J=8 Hz, 2H), 8.34 (t, J=5.8 Hz, 1H), 8.39 (dd, J=1.6 & 8.8 Hz, 1H), 8.89 (dd, J=1.6 & 4.0 Hz, 1H).
Example 55
2-methyl-N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)phenoxy)propanamide
[0293] 1 H NMR: δ 1.14 (t, J=7.6 Hz, 3H), 1.23-1.34 (m, 2H), 1.50-1.51 (m, 2H), 1.57 (s, 6H), 1.72-1.77 (m, 1H), 2.74 (q, J=7.6 Hz, 2H), 3.17 (t, J=6.6 Hz, 2H), 3.29-3.36 (m, 2H), 3.91-3.95 (m, 2H), 5.25 (s, 2H), 6.68 (t, J=5.8 Hz, NH), 6.86-6.90 (m, 2H), 7.49-7.55 (m, 4H), 7.60 (d, J=8.4 Hz, 2H).
Example 56
2-methyl-N-((tetrahydro-2H-pyran-4-yl)methyl)-2-(4-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)phenoxy)propanamide
[0294] 1 H NMR: δ 1.23-1.34 (m, 2H), 1.51-1.56 (comp, 8H), 1.71-1.77 (m, 1H), 2.26 (s, 3H), 3.17 (t, J=6.6 Hz, 2H), 3.29-3.36 (m, 2H), 3.92-3.95 (m, 2H), 5.26 (s, 2H), 6.71 (t, J=5.6 Hz, NH), 6.86-6.90 (m, 2H), 7.49-7.55 (m, 4H), 7.60 (d, J=8.0 Hz, 2H).
Example 57
2-(4-(1-(((tetrahydro-2H-pyran-4-yl)methoxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0295] 1 H NMR: DMSO, δ 1.09-1.16 (m, 2H), 1.23-1.31 (m, 2H), 1.50 (dd, J=12.8 & 1.6 Hz, 2H), 1.61 (dd, J=12.8 & 2 Hz, 2H), 1.62-1.66 (m, 1H), 1.67-1.96 (m, 1H), 2.15 (s, 3H), 3.01 (t, J=6.4 Hz, 2H), 3.18-3.24 (m, 2H), 3.26-3.29 (m, 2H), 3.78-3.86 (m, 4H), 3.97 (d, J=6.4 Hz, 2H), 4.51 (s, 2H), 6.97 (dd, J=7.2 & 2.4 Hz, 2H), 7.60 (dd, J=6.8 & 2.0 Hz, 2H), 8.12 (t, J=5.8 Hz, 1H)
Example 58
2-(4-(1-((cyclohexylmethoxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0296] 1 H NMR: DMSO-d 6 , δ 0.95-0.98 (m, 2H), 1.09-1.21 (m, 5H), 1.48 (dd, J=12.8 & 1.6 Hz, 2H), 1.64-1.74 (m, 7H), 2.14 (s, 3H), 3.01 (t, J=6.6 Hz, 2H), 3.18-3.24 (m, 2H), 3.82 (dd, J=11.2 & 2.4 Hz, 2H), 3.92 (d, J=6.4 Hz, 2H), 4.51 (s, 2H), 6.94-6.98 (m, 2H), 7.57-7.60 (m, 2H), 8.12 (t, J=6 Hz, 1H).
Example 59
2-(4-(1-((naphthalen-2-ylmethoxy)imino)ethyl)phenoxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
[0297] 1 H NMR: DMSO-d 6 , δ 1.05-1.16 (m, 2H), 1.46 (d, J=13.2 Hz, 2H), 1.63-1.68 (m, 1H), 2.22 (s, 3H), 3.01 (t, J=6.4 Hz, 2H), 3.16-3.23 (m, 2H), 3.78-3.82 (dd, J=11.2 & 2.4 Hz, 2H), 4.50 (s, 2H), 5.33 (s, 2H), 6.97 (d, J=7.2 Hz, 2H), 7.49-7.52 (m, 2H), 7.54-7.56 (dd, J=8.8 & 1.6 Hz, 1H), 7.59-7.61 (dd, J=6.8 & 1.6 Hz, 2H), 7.89-7.93 (m, 4H), 8.11 (t, J=5.8 Hz, 1H).
[0000] The following compounds can be prepared by procedure similar to those described above with appropriate variations of reactions, reaction conditions and quantities of reagents which are within the scope of persons skilled in the art.
Example 60
2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)amino)acetic acid
Example 61
2-((5-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)pyridin-2-yl)oxy)acetic acid
Example 62
2-((5-(1-(((4-cyanobenzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)acetic acid
Example 63
2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetic acid
Example 64
2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyridin-2-yl)amino)acetic acid
Example 65
2-((5-(1-((benzyloxy)imino)propyl)pyridin-2-yl)oxy)acetic acid
Example 66
2-((5-(1-(((4-methylbenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetic acid
Example 67
2-((5-(1-(((4-methoxybenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetic acid
Example 68
2-((5-(1-(((4-fluorobenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetic acid
Example 69
2-((5-(1-(((4-cyanobenzyl)oxy)imino)propyl)pyridin-2-yl)oxy)acetic acid
Example 70
[0298] 2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)acetic acid
Example 71
2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
Example 72
2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)amino)acetic acid
Example 73
2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyridin-2-yl)amino)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
Example 74
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((3-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)-1H-indol-5-yl)oxy)acetamide
Example 75
[0299] 2-((3-((((4-(trifluoromethyl)benzyl)oxy)imino)methyl)-1H-indol-5-yl)oxy)acetic acid
Example 76
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((3-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)-1H-indol-5-yl)oxy)acetamide
Example 77
[0300] 2-((3-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)-1H-indol-5-yl)oxy)acetic acid
Example 78
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((3-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)-1H-indol-5-yl)oxy)acetamide
Example 79
2-((3-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)-1H-indol-5-yl)oxy)acetic acid
Example 80
2-((3-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)-1H-indol-5-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
Example 81
2-((3-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)-1H-indol-5-yl)oxy)acetic acid
Example 82
N-((tetrahydro-2H-pyran-4-yl)methyl)-3-(5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyrimidin-2-yl)propanamide
Example 83
3-(5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyrimidin-2-yl)propanoic acid
Example 84
N-((tetrahydro-2H-pyran-4-yl)methyl)-3-(5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyrimidin-2-yl)propanamide
Example 85
3-(5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)pyrimidin-2-yl)propanoic acid
Example 86
3-(5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyrimidin-2-yl)-N-((tetrahydro-2H-pyran-4-yl)methyl)propanamide
Example 87
3-(5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)pyrimidin-2-yl)propanoic acid
Example 88
N-((tetrahydro-2H-pyran-4-yl)methyl)-2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)quinolin-8-yl)oxy)acetamide
Example 89
2-((5-(1-(((4-(trifluoromethyl)benzyl)oxy)imino)propyl)quinolin-8-yl)oxy)acetic acid
Example 90
2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)quinolin-8-yl)oxy)-N-((tetrahydro-2H-pyran-4-yl)methyl)acetamide
Example 91
2-((5-(2-phenyl-1-(((4-(trifluoromethyl)benzyl)oxy)imino)ethyl)quinolin-8-yl)oxy)acetic acid
[0301] The compounds of the present invention lowered LDL, triglyceride and total cholesterol. This was demonstrated by in vitro as well as in vivo animal experiments.
A) Demonstration of In Vitro Efficacy of Compounds
[0302] The in vitro binding assay described hereinafter is a quantitative solid phase binding assay for determining the efficacy of the compounds. Plates were pre-coated with a recombinant LDLR-AB domain, which binds to the gene pro-protein convertase of the subtype nine. Test compound at different concentrations was added to the subtype gene and added to LDLR immobilized on the wells. The amount of bound gene is measured by binding it with biotinylated anti-His-tag monoclonal antibody, followed by binding with horseradish peroxidase conjugated streptavidin substrate. The color was quantified by ELISA reader at 450 nM which reflects the relative amount of “the gene” that binds to LDLR in presence and absence of the inhibitor. EC 50 values were calculated by nonlinear regression analysis using graph pad prism software. Each concentration point represents values in duplicates.
[0000]
Example No
Concentration (μM)
% Inhibition
1
1
29
10
35
100
57
3
1
28
10
41
100
54
4
1
34
10
39
100
51
5
1
34
10
40
100
50
10
1
3
5
18
10
35
100
51
11
1
20
5
23
10
49
100
61
12
1
19
10
55
100
79
13
1
22
10
32
100
48
14
1
15
10
31
100
41
15
1
25
10
37
100
39
16
1
10
5
21
10
35
100
61
17
1
13
10
19
100
44
18
1
16
10
38
100
63
19
10
40
100
46
20
1
20
10
34
100
57
21
100
15
22
1
29
10
46
100
46
23
1
30
10
42
100
47
24
1
24
10
28
100
52
25
1
28
10
34
100
50
26
1
45
10
45
100
52
27
1
10
10
15
100
29
28
100
23
30
100
36
31
1
15
10
20
100
29
32
1
14
10
35
100
48
33
1
10
10
10
100
28
34
1
7
10
13
100
32
35
1
22
10
13
100
25
36
1
6
10
9
100
36
37
1
20
10
26
100
28
38
10
19
100
38
39
10
33
100
42
40
10
20
100
47
41
1
10
100
19
42
10
9
100
51
43
10
15
100
27
48
1
17
10
42
100
64
49
10
7
100
11
B) LDL-C Lowering Activity—In High Fat Diet C57 Mice
[0303] The in-vivo LDL-c lowering for test compound was tested in C57 mice which were kept on high fat diet for 4 weeks and the blood was collected by retro-orbital sinus puncture method under light ether anesthesia on day 0 (pretreatment). Animal are grouped based on LDL-C levels, after that 4-6 week treatment with vehicle or test compound orally at a dose of 30 mpk dose once a day was given. On completion of treatment on day 28 of the treatment the blood was collected for LDL-C levels measurement. The percent change in LDL-C in test compound group Vs Vehicle group was calculated.
[0000]
Example
% Change Vs Vehicle Control
No
Dose
LDL-C
TC
1
30 mg
−48.8 ± 4.2
−11.8 ± 2.7
3
30 mg
−74.6 ± 2.0
−33.6 ± 2.0
18
30 mg
−75.2 ± 3.5
−41.6 ± 1.9
22
30 mg
−64.6 ± 4.1
−21.5 ± 2.8
31
30 mg
−30.6 ± 3.6
−3.5 ± 3.4
[0304] In certain instances, it may be appropriate to administer at least one of the compounds described herein or a pharmaceutically acceptable salt, ester, or prodrug thereof in combination with another therapeutic agent. Several reasons can be attributed for using a combination therapy depending on the need of the patient. As an example, if one of the side effects experienced by a patient upon receiving one of the compounds herein is hypertension, then it may be appropriate to administer an anti-hypertensive agent in combination with the initial therapeutic agent. Or, by way of example only, the benefit experienced by a patient may be increased by administering one of the compounds described herein with another therapeutic agent (which also includes a therapeutic regimen) that also has therapeutic benefit. Several such instances are well known to a skilled person and the use of combination therapy may be envisaged for all such situations. In any case, regardless of the disease, disorder or condition being treated, the overall benefit experienced by the patient may simply be additive of the two therapeutic agents or the patient may experience a synergistic benefit.
[0305] Specific, non-limiting examples of possible combination therapies include use of certain compounds disclosed herein with agents found in the following pharmacotherapeutic classifications as indicated below. These lists should not be construed to be closed, but should instead serve as illustrative examples common to the relevant therapeutic area at present. Moreover, combination regimens may include a variety of routes of administration and should include oral, intravenous, intraocular, subcutaneous, dermal, and inhaled topical.
[0306] For the treatment of metabolic disorders, compounds disclosed herein may be administered with an agent selected from the group comprising: insulin, insulin derivatives and mimetics, insulin secretagogues, insulin sensitizers, biguanide agents, alpha-glucosidase inhibitors, insulinotropic sulfonylurea receptor ligands, meglitinides, GLP-1 (glucagon like peptide-1), GLP-1 analogs, DPPIV (dipeptidyl peptidase IV) inhibitors, GPR-119 inhibitors, sodium-dependent glucose co-transporter (SGLT2) inhibitors, PPAR modulators, non-glitazone type PPAR.delta. agonist, HMG-CoA reductase inhibitors, cholesterol-lowering drugs, rennin inhibitors, anti-thrombotic and anti-platelet agents and anti-obesity agents.
[0307] For the treatment of metabolic disorders, compounds disclosed herein may be administered with an agent selected from the group comprising: insulin, metformin, Glipizide, glyburide, Amaryl, gliclazide, meglitinides, nateglinide, repaglinide, amylin mimetics (for example, pramlintide), acarbose, miglitol, voglibose, Exendin-4, vildagliptin, Liraglutide, naliglutide, saxagliptin, pioglitazone, rosiglitazone, HMG-CoA reductase inhibitors (for example, rosuvastatin, atrovastatin, simvastatin, lovastatin, pravastatin, fluvastatin, cerivastatin, rosuvastatin, pitavastatin and like), cholesterol-lowering drugs (for example, fibrates which include: fenofibrate, benzafibrate, clofibrate, gemfibrozil and like; cholesterol absorption inhibitors such as Ezetimibe, eflucimibe etc.
[0308] From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. Such different embodiments are also to be considered to be within the scope of the present invention. | The present invention relates to compounds of the general formula (I), their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts, pharmaceutical compositions containing them, methods for their preparation, use of these compounds in medicine and the intermediates involved in their preparation.
The present invention is directed towards compounds which can be used to treat diseases such as Hyperlipidemia and also have a beneficial effect on cholesterol. | 2 |
FIELD OF THE INVENTION
The present invention relates in general to the purification of fluid streams and more particularly to the removal of mercury entrained in liquid streams or mercury vapor from gas streams, such as natural gas, by means of adsorbing the mercury using an integrated system of regenerated and non-regenerated fixed adsorbent beds. In the system the bulk of the mercury is removed from the feed stream by initial passage through the non-regenerated bed, the effluent from which is further treated by passage through a regenerated bed to obtain the desired degree of purity.
BACKGROUND OF THE INVENTION
Mercury is an undesirable constituent of a considerable number of fluid streams, and consequently a considerable number of methods have been devised to selectively remove the mercury. In the main the mercury impurity is in the form of elemental mercury, but in a few instances mercury compounds, including organic mercury compounds, are of concern. In the case of elemental mercury the purification processes are largely adsorption procedures, and in these the most common type of adsorbent is an activated carbon having supported thereon a mercury reactive material such as potassium triodide, sulfur, sulfuric acid, chlorine, silver, copper or various salts of silver or copper. Other supports for the mercury reactive materials include silicas, aluminas, silica-aluminas and zeolitic aluminosilicates. Ion-exchange resins, particularly the strongly basic anion-exchange types which have been reacted with a polysulfide, have also been reported. See U.S. Pat. No. 4,591,490 (Horton) in this latter regard. The disclosures of U.S. Pat. No. 4,500,327 (Nishino) and U.S. Pat. No. 4,196,173 (de Jong et al) are pertinent to the use of activated carbon supports.
Perhaps the two greatest problems involved in removing mercury from fluid streams are (a) achieving a sufficient reduction in the mercury concentration of the feed stream being treated, and (b) avoiding the reentry of the recovered mercury into some other environmental medium. Although permissible levels of mercury impurity vary considerably, depending upon the ultimate intended use of the purified product, for purified natural gas, mercury concentrations greater than about 0.01 microgram per normal cubic meter (μg/nm 3 ) is considered undesirable, particularly in those instances in which the natural gas is to be liquefied by cryogenic processing. In the cases where mercury is removed from process streams by use of non-regenerable adsorbents, very large adsorption beds are required. This is because sufficient adsorbent must be present not only for the long term equilibrium capacity, but also enough adsorbent to contain the mass transfer (reaction) zone. In the case where the mercury removal is done by regenerative means, less adsorbent is required since only the adsorbent for containing the mass transfer zone is required. If regenerable, the regeneration media requirements are not only large but result in a large mercury-laden bed effluent which must itself be disposed of in an environmentally safe manner. A means has now been devised to combine the favorable aspects of both regenerable and non-regenerable process systems. Such a combination allows for (a) attaining the lowest possible mercury levels in the process streams, (b) making full utilization of the non-regenerative mercury removal adsorbent, and (c) disposing of the mercury in an environmentally safe manner.
THE DRAWINGS
The sole figure of the drawings is a schematic flow diagram showing one embodiment of the process system used in the practice of this invention.
SUMMARY OF THE INVENTION
In accordance with the present invention the process comprises: (a) providing a fluid stream containing at least 0.02, and preferably at least 2.0, μg/nm 3 of elemental mercury; (b) passing said stream into a first and non-regenerable fixed adsorption bed containing an adsorbent on which said mercury is preferentially adsorbed whereby mercury is adsorbed and a mercury-depleted fluid stream is recovered as the effluent therefrom; (c) passing said effluent into a second and regenerable fixed adsorption bed containing an adsorbent for mercury whereby a mercury mass transfer front is established and a product effluent further depleted in mercury is recovered; (d) terminating the flow into said second adsorption bed prior to breakthrough of the mercury mass transfer front; (e) regenerating said second fixed bed by passing therethrough, preferably in a direction countercurrent to the direction of flow therethrough during step (c), a purge desorbent having essentially the same chemical composition as the effluent from said second bed during step (c) whereby mercury is desorbed and removed from said bed in the effluent; and (f) combining the effluent from said second fixed bed with the fluid stream provided in step (a).
DETAILED DESCRIPTION OF THE INVENTION
In carrying out the present process the adsorption system employed comprises a principal non-regenerable fixed adsorption bed and a secondary regenerable fixed adsorption bed. As used herein the term non-regenerable as applied to the principal bed is not used in the absolute sense to mean that regeneration of the adsorbent is impossible but rather that regeneration, if in fact feasible, is not cyclically carried out as an integral part of the process scheme. The function of the non-regenerable bed is to provide a long-term equilibrium capacity for adsorbed mercury. Since, however, it is necessary to remove the mercury content of the feed stream being treated to very low levels, it is found that following a relatively brief period of use after installation of fresh adsorbent in the bed, the bed effluent contains more than tolerable concentrations of mercury even though the bed retains a very large capacity to adsorb additional mercury. This circumstance is remedied in the present process by the use of a secondary regenerable adsorption bed which treats the effluent from the principal bed on a short-term basis, i.e., is employed to treat that effluent only for the period in which the effluent from the secondary bed contains tolerable concentrations of mercury. Thereafter the secondary bed is regenerated and the desorbed mercury is recycled through the principal bed thereby increasing the efficiency of the principal bed as a mercury absorber.
Accordingly the adsorbent contained in the principal bed is advantageously one which is relatively inexpensive yet has a capacity to accumulate a high loading of adsorbed mercury when contacted with fluid streams containing concentrations of mercury significantly higher than the feed stream introduced initially into the adsorption system. A preferred adsorbent for the principal bed is selected from the various activated carbon-supported compositions, particularly those containing sulfur or sulfur compounds reactive with mercury, or the copper or sulfur loaded aluminosilicate zeolites such as zeolite X and zeolite Y in the alkali metal and alkaline earth metal cation forms. The Hg ++ cation forms of zeolites X and Y are reported by Barrer et al [J. Chem. Soc. (1967) pp. 19-25] to also exhibit very large capacities for mercury adsorption due to the chemisorption of metallic mercury at the Hg ++ cation sites to form Hg 2 ++ cations initially and then to proceed further to create clusters of mercury within the zeolite in accordance with the proposed equation
Hg.sub.2.sup.++ +xHg→Hg.sub.x+2.sup.++
Copper sulfide carried on an alumina support has also been reported to be a satisfactory adsorbent for the bulk removal of mercury from gas streams. The specific mention of these materials is not intended to be limitative, the composition actually selected being a matter deemed most advantageous by the practitioner given the particular circumstances to which the process is applied.
As alluded to hereinbefore, the function of the secondary bed in the process is two-fold, namely to remove additional mercury from the effluent stream from the principal bed so that a product stream of desired purity is obtained, and to concentrate mercury not initially retained by the principal bed into a regeneration gas stream so as to provide a feed stream to the principal bed richer in mercury content and thus maximize the loading of adsorbed mercury on the principal bed prior to that adsorbent's periodic removal from the system. The relative importance of the second of the aforenamed functions will depend upon the initial concentration of mercury in the external feed stream being treated and the shape of the mercury adsorption isotherm of the adsorbent at the process temperature. Accordingly the adsorbent in the secondary bed is preferably chosen on the basis of the degree to which it can adsorb mercury from feedstreams relatively low in mercury concentrations. Since, moreover, the secondary bed is to be repeatedly regenerated in situ in the system, the initial cost of the adsorbent is less of a factor in its selection. An especially effective adsorbent for this purpose is one of the zeolite-based compositions containing cationic or finely dispersed elemental forms of silver, gold, platinum or palladium. A particularly preferred adsorbent of this type is disclosed in U.S. Pat. No. 4,874,525 (Markovs) wherein the silver is concentrated on the outermost portions of the zeolite crystallites. More specifically the adsorbent is formed of particles comprised of crystallites of a zeolitic molecular sieve having pore diameters of at least 3.0 Angstroms and in which the said zeolite crystallites forming the outer shell of the adsorbent particles to a depth of not greater than about 0.1 millimeter into the particles and constituting less than about 35 volume percent of said particles, contain ionic or elemental silver. The remainder of the overall adsorbent particles are preferably free of silver since this additional silver does not adsorb mercury as efficiently as the more exposed outer surface silver, and thus adds unduly to the cost of the adsorbent. Zeolite A containing elemental gold is disclosed as an adsorbent for mercury in the later issued U.S. Pat. No. 4,892,567 (Yan).
The mercury-containing fluid stream suitably treated by the present process can be either in the liquid or the vapor state. The constituents other than mercury are not critical except in those cases in which such constituents seriously attack the particular adsorbents involved in the process and render same incapable of functioning to selectively adsorb and retain mercury. Suitable streams include natural gas streams, which typically contain as high as 22 parts per billion (vol.) mercury vapor, but can contain much higher concentrations of mercury, along with carbon dioxide, water vapor, hydrogen and higher hydrocarbons as impurities, by-product hydrogen streams from the commercial production of chlorine by the electrolysis of sodium chloride using a mercury-containing electrode, helium and other inert gases, furnace stack gases, battery disposal incinerator gases, air, hydrocarbons such as ethylene (cracked gas), light and heavy naphtha fractions, liquefied petroleum gas, dripolene and the like. The feedstocks are suitably processed by the present process in the temperature range of 0° C. to 65° C. and using pressures of from atmospheric to 2500 psia.
In carrying out the present process it will be understood that for continuous operation over an appreciable period it is necessary that there be at least two trim beds capable of receiving partially purified effluent from a principal bed in order that one trim bed can be regenerated while another is engaged in purifying principal bed effluent. While highly desirable, continuous operation is not, however, essential in the practice of the present invention.
A typical process embodiment of the present invention is illustrated with reference to the flow diagram of the drawings. Principal bed 10 contains 49,000 pounds of 1/8" extruded zeolite X pellets loaded with 6 weight percent elemental sulfur. Natural gas, from which CO 2 has optionally been removed, saturated with water vapor and containing 14 parts per billion [ppb (v)] mercury vapor is passed into bed 10 through line 12 at a superficial velocity of 35.3 feet per minute and at a temperature of 21° C. The bulk of the mercury is adsorbed on the sulfur-loaded adsorbent and an effluent stream containing 0.35 ppb mercury passes through line 14, valve 16 and line 18 into secondary bed 20. Secondary beds 20 and 22 are compound beds having a discrete upper zone of a conventional desiccant, zeolite 4A, and a lower mercury-adsorbing zone of a silver-loaded zeolite 13X. Each secondary bed contains in the lower zone 3,985 pounds of 1/8" extruded zeolite X pellets having 13.6 weight percent silver as zeolitic cations, 95 percent of which are located within 0.1 millimeter of the external surface of the pellets. The upper desiccant zone contains 20,515 pounds of zeolite 4A. The natural gas effluent from bed 20 is substantially water-free and contains less than 10 parts per trillion (v) of mercury and the major portion is recovered as purified product through line 24. The remainder of the effluent from bed 20 is passed through line 26, valve 28, line 30, valve 32, compressor 34, line 36, heater 38, line 40, valve 42, and line 44 into the bottom of bed 22. Bed 22 has previously been in service in the same adsorption-purification mode as bed 20 is presently involved and contains about 0.47 pounds of adsorbed mercury. The purge desorption stream of purified natural gas entering the bottom of bed 22 has been heated in heater 38 to a temperature of about 290° C. In passing through bed 22, the purge gas desorbs mercury and the effluent stream leaving bed 22 through line 46 contains, on average, about 9.4 ppm mercury vapor and is saturated with water vapor. This stream passes through valve 48 and line 50 to chiller 52 and knock-out 54 wherein condensed liquid mercury is removed from the system through line 56 and water is removed through line 58. The effluent vapor from knock-out 54 is passed through line 60 to join the natural gas feed stream being fed to adsorbent bed 10. Operation is continued in this manner until the capability of bed 10 to effectively adsorb mercury is reached. Thereafter the adsorbent charge in bed 10 is replaced with fresh adsorbent and the process continued.
In view of the foregoing a number of obvious modifications within the proper scope of the invention will be apparent to those of skill in the art. For example, where leakage of mercury from the non-regenerated bed is relatively low resulting in relatively low adsorbed mercury loadings in the regenerated beds, it can be the case that no liquid mercury is recovered from the knock-out apparatus before the regeneration stream is recycled to the non-regenerated bed. It may also be the case that the feedstock being treated is substantially free of water vapor. In that event the knock-out apparatus is unnecessary, although means to reduce the temperature of the regeneration gas before it enters the non-regenerated bed is highly desirable.
The same process scheme as illustrated in the drawing is also suitable for recovering mercury from hydrocarbon streams such as naphtha. The feedstock is advantageously treated in the liquid phase in such a process and instead of regenerable compound beds, beds containing only adsorbents for mercury removal are employed. Regeneration of the regenerable beds can be in the vapor phase using a vaporized portion of the purified product. | Mercury is often removed as an impurity from process fluid streams by adsorption in fixed beds using any of several well-known adsorbents having the ability to selectively adsorb mercury. It is also common to reintroduce this sequestered mercury into the environment by means of the spent gas used to periodically regenerate the fixed beds. A solution to this problem is provided by the present invention in which the mercury is removed from the process stream using a large non-regenerated adsorption bed in combination with a periodically regenerated secondary adsorption bed, the mercury content of the latter being transferred to the former during the regeneration procedure. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to electromagnetic ballasts for gaseous discharge lamps and particularly to such ballasts for starting and operating serially connected fluorescent lamps.
[0003] 2. Description of Related Art
[0004] The voltages which a ballast must provide to start and operate serially connected gaseous discharge lamps, e.g. fluorescent lamps, are substantially larger than those needed for single or parallel connected lamps. These voltages become even larger for higher wattage lamps and/or for lamps which must start and operate at low ambient temperatures. As a consequence, the lamp voltages might exceed the voltage ratings of fixtures and/or hardware for holding the lamps.
SUMMARY OF THE INVENTION
[0005] It is an object of the invention to provide an electromagnetic ballast which is capable of starting and operating serially connected gaseous discharge lamps at open circuit lamp voltages which exceed the rated voltages of lamp holder apparatus, but without imposing such high voltages on the lamp holder apparatus itself.
[0006] In accordance with the invention an electromagnetic ballast for starting and operating a plurality of gaseous discharge lamps, which are serially connected between a first lamp holder connection and a second lamp holder connection, comprises a transformer including a primary winding for electrical connection to an AC power source and a secondary winding. The primary winding includes first and second subwindings. The first subwinding has a first end for electrical connection to the first lamp holder connection and to the AC power source and has a second end. The second subwinding has a first end electrically connected to the second end of the first subwinding and has a second end for electrical connection to the AC power source. The secondary winding has a first end electrically connected to the second end of the first subwinding and to the first end of the second subwinding and has a second end electrically connected to the second lamp holder connection. The windings are wound such that, in operation, voltages produced by the first subwinding and the secondary winding are additive, but voltages produced by the second subwinding and the secondary winding are subtractive, whereby the voltage at each of the lamp connections is substantially lower than the voltage across the serially connected lamps.
BRIEF DESCRIPTION OF THE DRAWING
[0007] [0007]FIG. 1 is a schematic illustration of a first embodiment of an electromagnetic ballast for powering serially connected fluorescent lamps.
[0008] [0008]FIG. 2 illustrates operating parameters of a specific ballast of the type shown in FIG. 1.
[0009] [0009]FIG. 3 is a schematic illustration of a second embodiment of an electromagnetic ballast for powering serially connected fluorescent lamps.
[0010] [0010]FIG. 4 illustrates operating parameters of a specific ballast of the type shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] [0011]FIG. 1 schematically illustrates an exemplary embodiment of an electromagnetic ballast for starting and operating serially connected fluorescent lamps L 1 and L 2 . Lamp L 1 includes filamentary electrodes E 1 A and E 1 B positioned within opposite ends of the lamp envelope. Two pairs of conductive pins, which are electrically connected to opposite ends of the electrodes E 1 A and E 1 B , extend through the envelope and are received within respective lamp holders H 1 A and H 1 B . Similarly, lamp L 2 includes filamentary electrodes E 2 A and E 2 B positioned within opposite ends of the lamp envelope and electrically connected to respective pairs of lamp pins which extend through the envelope and are received within respective lamp holders H 2 A and H 2 B . Each of the lamp holders is a conventional socket which includes a pair of electrical contacts for making electrical connections to the ends of a respective one of the filamentary electrodes via the conductive pins received in the lamp holder.
[0012] The lamps L 1 and L 2 are electrically connected in series combination by conductors W 1 and W 2 , each of which is connected to respective one end of each of the lamp electrodes E 1 B and E 2 A via the electrical contacts in lamp holders H 1 B and H 2 A . A capacitor C 1 is electrically connected in parallel with lamp L 1 for the purpose of shunting this lamp during starting, so that all of the available open circuit voltage is applied initially across lamp L 2 . Once L 2 starts its impedance drops and the available voltage is now applied across L 1 causing it to start.
[0013] The ballast includes a transformer having a primary winding and a plurality of secondary windings, all wound on a common magnetic core, as is well known in the art. The primary winding includes a first sub winding, P 1 A having ends 1 and 2 , and a second sub winding P 1 B , having ends 3 and 4 . The ends 2 and 3 are commonly electrically connected to form an intermediate tap of the primary winding. A principal secondary winding S 1 has one end 5 electrically connected to the tap of the primary winding. Secondary windings S 2 , S 3 and S 4 are provided for applying relatively low heating voltages to the filamentary electrodes. Winding S 2 is electrically connected to electrode E 1 A via lamp holder H 1 A , winding S 3 is electrically connected to electrodes E 1 B and E 2 A via wires W 1 , W 2 and lamp holders H 1 B , H 2 A , and winding S 4 is electrically connected to electrode E 2 B via lamp holder H 2 B .
[0014] Note that each of the windings has a dot symbol near one end to indicate the polarity of the voltage across the winding. Thus, for example, whenever the voltage at the dot end of any winding is positive with respect to the voltage at the other end, the same is true at all other windings.
[0015] In order to apply starting and operating power to the lamps, the primary winding and the principal secondary winding are electrically connected to a source of AC power PS and to the series combination of the lamps L 1 and L 2 . However, this is done in a manner which avoids applying the full open circuit starting or operating voltage (relative to ground) to any of the lamp connections. Specifically:
[0016] End 1 of the primary winding is electrically connected to the electrode E 1 A at one end of the series combination, via a power factor correction capacitor C 2 and the lamp holder H 1 A , and also to the power source PS, via a lead W BLK . This lead is electrically connected to a hot terminal T H of the power source and thus the voltage applied to lamp holder H 1 A never exceeds the supply voltage V AC .
[0017] End 4 of the primary sub winding P 1 B is electrically connected to a lead W WH . This lead is electrically connected to a neutral terminal T N of the power source and thus the voltage applied to end 4 always remains at or near ground potential.
[0018] End 6 of the secondary winding S 1 is electrically connected to the electrode E 2 B at the opposite end of the series combination, via lamp holder H 2 B .
[0019] Note that, as indicated by the dot symbols, secondary winding S 1 and the primary sub windings P 1 A and P 1 B are wound and connected such that the voltages across the series combination of windings P 1 A and S 1 are additive, but the voltages across the series combination of windings S 1 and P 1 B are subtractive. Thus, the voltage across primary sub winding P 1 A and a stepped up voltage across secondary winding S 1 add, resulting in an open circuit voltage across the series lamp combination sufficient to ensure starting under worst case conditions (e.g. operation at low ambient temperatures). However, the voltages across secondary winding S 1 and primary sub winding P 1 B subtract, resulting in a voltage at lamp holder H 2 B (referenced to ground) which is necessarily smaller than the voltage across the series lamp combination.
[0020] The actual voltages developed across the transformer windings and applied to the lamp holders are determined by the magnitude of the source voltage V AC and the relative numbers of turns in the windings. FIG. 2 indicates these voltages in an actual circuit, which has been built and tested, for starting and operating two serially connected, 86 watt, high output fluorescent lamps, requiring an open circuit AC voltage of approximately 820 volts to start and operate the lamps at an ambient temperature of −20° F. (Note that all voltage values are RMS.) However, the highest rated lamp holder voltage was only 600 volts. The available power source was an AC power line having a voltage of 277 volts. Note that the open circuit voltage applied across the serial lamp combination was 840 volts, but the highest magnitude voltage (relative to ground) at any lamp holder was a voltage of 710−147=563 volts at lamp holder H 2 B . The voltage at lamp holder H 1 A was 130+147=277 volts.
[0021] [0021]FIG. 3 schematically illustrates a second exemplary embodiment of an electromagnetic ballast in accordance with the invention. This embodiment is similar to that of FIGS. 1 and 2, but is particularly useful with lower supply voltages, e.g. 120 volts. The secondary winding is subdivided into two sections S 1 and S 2 connected at either end of a primary winding P 1 and the secondary windings for heating the filaments are now designated S 3 , S 4 and S 5 . Windings P 1 , S 1 and S 2 are all connected in series.
[0022] Note that, as indicated by the dot symbols, all three windings are wound and connected such that the voltages across them are additive. The resulting voltage across the lamps is sufficient to start them under worst case conditions. However, the voltages at each of the lamp holders H 1 A and H 2 B are well below the open-circuit starting voltage applied across the lamps. This results because the voltage at lamp holder H 1 A is referenced to ground through the windings S 1 and P 1 , while the voltage at lamp holder H 2 B is referenced to ground through the winding S 2 .
[0023] [0023]FIG. 4 illustrates the voltages in an actual circuit, which has been built and tested, for starting and operating the same two serially connected, 86 watt, high output fluorescent lamps as in the embodiment of FIG. 2. However, in this case, the supply voltage V AC is only 120 volts. This ballast still provides a starting voltage of 840 volts, but the highest magnitude voltage (relative to ground) at any of the lamp holders was a voltage of 345+120=465 volts at lamp holder H 1 A . The voltage at lamp holder H 2 B was 375 volts. | Apparatus for sequentially igniting and serially operating a pair of high output rapid start fluorescent lamps from a source of AC voltage. The apparatus includes a transformer with a primary winding that may be subdivided in two sections, a principal secondary winding connected in series aiding with one section of the primary and in opposition with the other primary section. This arrangement provides the advantage of developing a comparatively high open circuit voltage for starting the lamps without exceeding lamp holder voltage ratings. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an ink-jet printer and a control method thereof, and more particularly, to an ink-jet printer which can be operated by power supply from, e.g., either a rechargeable secondary battery or a power supply unit of converting a commercial power source into a DC power source, acting as an operation power source, and a power control method thereof.
[0003] 2. Related Background Art
[0004] In recent years, various electronic apparatuses such as a portable personal computer, a portable telephone, a video camera, a portable printer and the like have appeared on the market.
[0005] These electronic apparatuses are downsized in consideration of portability, and can be used in a state, i.e., a cordless state, being not connected to a household power source.
[0006] Therefore, each of these electronic apparatuses is constituted to be able to be used without connecting it to the household AC power source through a power cord, in such a way that a battery is built into the electronic apparatus or a unit such as a battery pack having a battery built-in is externally connected to the electronic apparatus.
[0007] As the power source to be used for these electronic apparatuses, a rechargeable battery, i.e., a so-called secondary battery, is frequently used. Here, as the secondary batteries, a nickel-cadmium battery, a nickel-hydrogen battery, a lithium-ion battery and the like are known.
[0008] On one hand, an external power supply unit (generally called an AC adapter) of converting the AC power source into a DC power source can be connected to the electronic apparatus so that it can be operated also based on the AC power source in a house, an office or the like. Also, a current to charge the secondary battery is supplied from the AC adapter.
[0009] The secondary battery is generally charged in a case where the AC power source connected to the electronic apparatus is turned on and the electronic apparatus has electric power in reserve because it does not perform high-current driving such as a mechanical operation or the like, or in a case where the electronic apparatus is in a power-off state.
[0010] Therefore, even while the electronic apparatus is not powered, if the AC adapter is being connected to the electronic apparatus, it is necessary to be able to automatically charge the secondary battery without any user's operation.
[0011] For this reason, in the case where the above electronic apparatus is not powered, the structure to shut off the power from the AC power source to the AC adapter by a mechanical switch is not adopted generally. Instead, even when the electronic apparatus is not powered, the power is supplied to the electronic apparatus to operate a built-in MPU (microprocessor unit), whereby on and off states of the power switch of the electronic apparatus are always detected.
[0012] In such a structure, to decrease power consumption while the power switch is turned off, generally, clock frequencies of the MPU and a control circuit for controlling the electronic apparatus are decreased as compared with the case where the power switch is turned on, or the clock frequencies are stopped.
[0013] However, in the above conventional case, although the lower consumption as above is achieved, it is still necessary to supply the power to a logic circuit including the MPU of the electronic apparatus, whereby it is not avoided that the electronic apparatus consumes the electric power more than a certain value.
[0014] Moreover, the AC adapter consumes the electric power of about 0.3 W to 0.5 W even in an unloaded state that the electronic apparatus is not powered, and the power consumption tends to increase with accelerating speed if the electronic apparatus performs some operation.
[0015] Therefore, in order to suppress the power consumption to about 0.5 W and below in the state that an overall system including the AC adapter and the electronic apparatus is not powered, it is necessary to set the power consumption of the electronic apparatus to substantially “0” while it is not powered. If it pays attention to the current state that reactive power while the electronic apparatus is not powered becomes a problem due to recent concern about energy saving and tighter regulations, it is demanded to further decrease the power consumption.
SUMMARY OF THE INVENTION
[0016] In order to solve the above problem, an ink-jet printer according to the present invention is the ink-jet printer including a control circuit for controlling a recording operation by receiving power supply from an AC adapter acting as a power supply means, and comprising: a voltage output circuit for outputting a voltage on the basis of a signal output by the power supply means; and a voltage output control circuit for turning on and off the voltage output circuit, wherein, in case of starting the power supply from the AC adapter, the voltage output control circuit sets the output of the voltage output circuit to an off state after setting the output to an on state for a certain period of time.
[0017] A control method for the ink-jet printer according to the present invention is the control method for the ink-jet printer which performs the recording operation by receiving the power supply from the AC adapter acting as the power supply means, comprising: a voltage output step of outputting a voltage by the voltage output circuit, on the basis of the signal from the power supply means; an output step of outputting a control signal to turn on and off the voltage output circuit; and a control step of controlling, in case of starting the power supply from the AC adapter, the output step to output the control signal to turn on the voltage output circuit for a certain period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a perspective view showing a printer;
[0019] [0019]FIG. 2 is a block diagram showing the structure of a control circuit of the printer;
[0020] [0020]FIG. 3 is a block diagram showing the structure of a power supply unit of the printer according to the first embodiment;
[0021] [0021]FIG. 4 is a timing chart showing main signals of the control circuit when an AC adapter is connected;
[0022] [0022]FIG. 5 is a timing chart showing the main signals of the control circuit when a power switch is turned on and off;
[0023] [0023]FIG. 6 is a flow chart showing a control procedure of an MPU according to the first embodiment;
[0024] [0024]FIG. 7 is a block diagram showing the structure of a power supply unit of the printer according to the second embodiment; and
[0025] [0025]FIG. 8 is a flow chart showing a control procedure of an MPU according to the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] [0026]FIG. 1 is an external perspective view showing a portable ink-jet printer (hereinafter called a printer) 1 according to the typical embodiment of the present invention. The printer is shown as having the structure capable of performing both color printing and black and white color (monochrome) printing. If the printer is considered as a black and white color (monochrome) printing dedicated device, it has the structure that only an ink cartridge containing black ink explained later is mounted on a recording head.
[0027] As shown in FIG. 1, a multi-nozzle recording head 102 having 128 nozzles and a cartridge guide 103 are mounted on a carriage 101 , and the recording head 102 discharges a black (K) ink, or cyan (C), magenta (M) and yellow (Y) inks respectively. When the printer performs a recording operation, an ink cartridge 110 containing the black ink and an ink cartridge 111 containing the other three kinds of color inks are being mounted on the recording head 102 , whereby the cyan (C), magenta (M), yellow (Y) and black (K) inks are supplied from the respective ink cartridges, and driving signals for the respective nozzles of the recording head 102 are supplied through a flexible cable (not shown) on which numerous conductive wires are arranged.
[0028] On one hand, the carriage 101 is mounted on two guide rails 104 and 105 , whereby the carriage 101 is reciprocated in the X direction (hereinafter called a main scan direction) according to that an endless belt 109 connected to the carriage 101 is driven by a carrier motor (later described). Moreover, a recording sheet 106 is stretched by auxiliary rollers 107 so that the recording sheet 106 can be smoothly conveyed, and a conveyance roller 108 is driven by a conveyance motor (later described) to feed the recording sheet 106 in the Y direction (hereinafter called a sub scan direction).
[0029] [0029]FIG. 2 is a block diagram showing the structure of a control circuit in the printer. In FIG. 2, numeral 170 denotes an interface through which data is input from an external device such as a host computer or the like, numeral 171 denotes an MPU (microprocessor unit), numeral 172 denotes a ROM which stores control programs (including character fonts, if necessary) to be executed by the MPU 171 , and numeral 173 denotes a DRAM which temporarily stores various data (control parameters, recording data, etc.).
[0030] Numeral 174 denotes a gate array (G.A.) which controls recording data supply to the recording head 102 and further controls the data transfer among the interface 170 , the MPU 171 and the DRAM 173 . Numeral 179 denotes a carrier motor which moves the recording head 102 in the main scan direction, numeral 178 denotes a conveyance motor which conveys the recording sheet, numeral 175 denotes a head driver which drives the recording head 102 , and numerals 176 and 177 denote motor drivers which respectively drive the conveyance motor 178 and the carrier motor 179 .
[0031] Next, the outline of the operation of the above control circuit will be explained. If a recording signal is input to the interface 170 , the input recording signal is converted into recording data for printing between the gate array 174 and the MPU 171 . Thus, the motor drivers 176 and 177 are respectively driven, and the recording head 102 is driven according to the recording data transferred to the head driver 175 , whereby a recording operation is performed.
[0032] Here, it should be noted that the portable ink-jet printer is explained as a typical example of the electronic apparatus. However, in addition to the ink-jet printer, the present invention is applicable to electronic apparatuses such as a laptop personal computer, a palmtop personal computer, a digital video camera, an Internet-accessible personal digital assistance and the like capable of operating by the secondary battery or the AC power source.
[0033] <First Embodiment>
[0034] [0034]FIG. 3 is a block diagram showing the detailed structure of a control unit 1 of the printer (also called the printer 1 hereinafter).
[0035] Numeral 2 denotes an AC adapter which converts an AC power source from a household outlet or the like into a DC power source and supplies power to the control unit 1 of the printer, and numeral 3 denotes a secondary battery which supplies power to the control unit 1 of the printer. When only the secondary battery 3 is connected to the printer, the power is supplied to the control unit 1 through a line 1 a , a charging control circuit 10 and a line 1 b in due order.
[0036] On one hand, when the AC adapter 2 is connected to the control unit 1 of the printer, the power is supplied from the AC adapter 2 irrespective of whether or not the secondary battery 3 is connected. That is, an AC voltage from an AC power source 1 c is converted into a DC voltage by the AC adapter 2 , and the converted DC voltage is input through a line 1 d . In the present embodiment, it is assumed that the DC voltage has the value of, e.g., 16V. The voltage supplied from the secondary battery 3 or the AC adapter 2 through the line 1 d is stepped down to a predetermined voltage (e.g., 5V) by a DC-DC converter 4 , and the stepped-down voltage is supplied as a logic operation voltage V CC of the control unit 1 of the printer.
[0037] The voltage supplied from the secondary battery 3 or the AC adapter 2 through the line 1 d is likewise input to a DC-DC converter 13 and stepped up to a predetermined voltage (e.g., 19V), and the stepped-up voltage is supplied as a driving voltage V H for the motor and the recording head of the printer.
[0038] In a case where the secondary battery 3 is connected and not in a full-charged state, and there is room in the power consumption of the printer, the battery is charged through the AC adapter 2 and the charging control circuit 10 .
[0039] Here, it should be noted that the secondary battery is a rechargeable battery of Ni—Cd system, lithium-hydrogen system of the like such as a nickel-cadmium battery, a nickel-hydrogen battery, a lithium-ion battery or the like.
[0040] Next, the structure of the printer 1 and an on/off sequence of the power source will be explained in detail with reference to FIGS. 4 and 5 being the timing charts of the main signals shown in FIG. 3.
[0041] As shown in FIG. 3, a power switch 17 for turning on/off the printer is provided in the control unit 1 of the printer, and an output signal if from the power switch 17 is read by the MPU 171 through an input port 18 , and it is controlled based on an output signal 1 g from an output port 19 to turn on/off a transistor 20 .
[0042] First, if the AC adapter 2 is connected to the printer 1 in the state that it is connected to the outlet of the AC power source, the input voltage rises on the line 1 d (of course, the input voltage rises on the line 1 d even if the AC adapter is connected to the outlet of the AC power source in the state it is connected to the control unit 1 of the printer). Here, since the power switch 17 is not depressed, the printer is in the state that the power source is not turned on based on the on state of the power switch.
[0043] The signal on the line 1 d is input to the DC-DC converter 4 , and the line 1 d is connected to one end of a resistor R 1 . The other end of the resistor R 1 is connected to an output control terminal 30 of the DC-DC converter 4 , and a capacitor C 1 is inserted between the resistor R 1 and the ground.
[0044] The output control terminal 30 of the DC-DC converter 4 comes to be in a state of capable of oscillating at “L” level, and the logic operation voltage V CC comes to be in an output state. On the other hand, the output control terminal 30 comes to be in a state of incapable of oscillating at “H” level, and the logic operation voltage V CC comes to be in an output-off state.
[0045] An integration circuit is composed by the resistor R 1 and the capacitor C 1 , and an input signal 1 h of the output control terminal 30 of the DC-DC converter 4 gradually rises from 0V at a time constant determined according to the resistor R 1 and the capacitor C 1 .
[0046] After the DC voltage on the line 1 d rose, the input signal 1 h of the output control terminal 30 is recognized as “L” level for a certain period of time, whereby the power is supplied from the DC-DC converter 4 to the logic circuit including the MPU while the signal is being “L” level.
[0047] After then, as shown in FIG. 4, since the input signal 1 h of the output control terminal 30 is recognized as “H” level when it comes to have a regulated voltage or more, the DC-DC converter 4 stops oscillating, whereby the output voltage V CC from the DC-DC converter 4 becomes 0V.
[0048] Therefore, before the output control terminal 30 is recognized as “H” level, the MPU 171 of which the reset state is released by receiving the power supply outputs the signal 1 g of “H” level from the output port 19 to turn on the transistor 20 , whereby the output control terminal is set as “L” level, and the operation state of the MPU 171 is maintained.
[0049] After then, the MPU 171 checks through the charging control circuit 10 whether or not it is necessary to charge the secondary battery 3 . This check is performed by flowing the charging current to the secondary battery and measuring the value of the flown current. If it is necessary to charge the secondary battery 3 , a current of predetermined magnitude flows, while if it is unnecessary to charge the battery, only a little current flows.
[0050] If it is unnecessary to charge the secondary battery 3 because it is in the full-charged state, the MPU 171 outputs the signal 1 g of “L” level from the output port 19 to turn off the transistor 20 . Then, if the transistor 20 is turned off, the potential 1 h increases according to a time constant of the integration circuit composed of the resistor R 1 and the capacitor C 1 , and the DC-DC converter 4 stops oscillating at the time when the output control terminal 30 comes to have the regulated voltage or more. As a result, the output voltage V CC becomes 0V, and the logic circuit stops operating, whereby the power consumption of the printer becomes approximately zero.
[0051] Incidentally, in FIG. 3, a diode D 2 and a resistor R 3 together function to discharge electrical charges on the capacitor C 1 through the line of the plus terminal of the capacitor C 1 →the diode D 2 →the resistor R 3 →the minus terminal of the capacitor C 1 , when the output connector of the external supply unit (AC adapter) 2 is pulled out.
[0052] Moreover, this discharge circuit can connect the cathode of the diode D 2 to the output V CC being the output line of the DC-DC converter 4 without using the resistor R 3 , and thus discharge the electrical charges by using an impedance of the device.
[0053] Next, the circuit operation that a user depresses the power switch 17 in this state to again supply the power to the printer and operate it will be explained with reference to the timing chart shown in FIG. 5.
[0054] Before the start (i.e., the depression of the power switch 17 ) of the timing chart shown in FIG. 5, although the power is supplied from the AC adapter up to the line 1 d , the DC-DC converter 4 stops oscillating, whereby the logic circuit does not operate because the output voltage V CC is 0V.
[0055] In this state, if the user depresses the power switch 17 to operate the printer, the potential on the signal line 1 h becomes about 0.6V through a diode D 1 because one end of the power switch 17 is grounded. Thus, the output control terminal 30 is recognized as “L” level, the DC-DC converter 4 starts oscillating, and the logic voltage V CC is supplied to the logic circuit including the MPU 171 .
[0056] Then, if the logic power source voltage V CC becomes a certain level or more, a reset circuit 21 outputs a rest signal 1 j of “L” level for a predetermined period of time T (about 100 msec) to reset the MPU 171 . After this reset operation ends and the reset is released, the MPU 171 executes the control program stored in the ROM 172 to control the printer 1 .
[0057] In the initial control according to the control program stored in the ROM 172 , the output port 19 outputs the signal 1 g of “H” level to turn on the transistor 20 . By this operation, since the potential of the signal 1 h is maintained as “L” level after the depression of the power switch 17 ends, the DC-DC converter 4 comes to be in the output state, and the state that the power is supplied is maintained, whereby the printer 1 comes to be in the operation state.
[0058] Next, a circuit operation from the operation state of the printer 1 , i.e., the state that the power is being supplied from the AC adapter 2 to the internal circuit of the printer 1 through the DC-DC converter 4 , to the state that the power supply to the printer 1 is interrupted by the depression of the power switch 17 and thus the printer 1 comes to be in the power off state will be explained.
[0059] First, in the state that the power is supplied from the power supply unit (AC adapter) 2 to the printer 1 , the potential of the signal 1 h is maintained as about 0.6V because the transistor 20 is kept on through the output port 19 as described above.
[0060] In this state, if the power switch 17 is depressed and subsequently released, a pulse P as shown in FIG. 5 is output to the power switch output signal if and then input to the input port 18 .
[0061] On one hand, if it is detected through the input port 18 that the power switch 17 is depressed, then the MPU 171 starts a power off sequence. In the power off sequence, the MPU 171 first changes the level of the output signal 1 g of the output port 19 to “L” level, whereby the transistor 20 comes to be in the off state. Thus, the potential of the signal line 1 h becomes “H” level, the DC-Dc converter 4 stops oscillating, and the logic power source voltage V CC decreases.
[0062] Then, if the logic power source voltage V CC becomes a certain level or less, the output of the reset circuit 21 , i.e., the signal 1 j , becomes “L” level. As a result, it is possible to prevent an erroneous operation of the transistor 20 due to that the output signal of the output port 19 becomes unstable.
[0063] Hereinafter, a control procedure to be performed by the MPU 171 when the power source of the printer 1 is turned on/off will be explained with reference to the flow chart shown in FIG. 6.
[0064] As described above, in the present embodiment, it is assumed that the power switch 17 is depressed by the user to operate the printer 1 , the logic voltage V CC is resultingly supplied to the logic circuit including the MPU 171 of the printer, the power source voltage is supplied to the printer 1 , and the reset is released after elapsing the regulated period of time T after the voltage is applied to the logic circuit including the MPU 171 . Thus, the MPU 171 starts the control according to the program stored in the ROM 172 .
[0065] After the reset is released, in a step S 101 , the signal of “H” level is first output to the output port 19 to turn on the transistor 20 , whereby the oscillation state of the DC-DC converter 4 is maintained, and the power is continuously supplied from the AC adapter 2 .
[0066] Next, in a step S 102 , the output signal 1 f to the input port 18 is read to check whether or not the power switch 17 of the printer 1 is depressed. If the power switch 17 is not depressed, it is considered that the AC adapter 2 is only connected to the printer 1 but the user does not wish to start the printer, whereby the step advances to a step S 106 .
[0067] Then, it is checked in the step S 106 whether or not the secondary battery is connected. It should be noted that this check can be performed by measuring the terminal voltage of the connection unit to the secondary battery. Then, it is checked in a step S 107 whether it is necessary to charge the secondary battery. If it is considered in the step S 106 that the secondary battery is not mounted or if it is checked in the step S 107 that it is unnecessary to charge the secondary battery even if it is mounted, the flow advances to a step S 110 .
[0068] On the other hand, if it is considered that the secondary battery is mounted and it is necessary to charge the secondary battery, the flow advances to a step S 108 to perform the charging until the battery comes to be in the full-charged state, as checking in a step S 109 whether the battery comes to be in the full-charged state.
[0069] In the step S 110 , the signal of “L” level is output to the output port 19 to turn off the transistor 20 , whereby the DC-DC converter 4 stops oscillating. As a result, the voltage V CC becomes 0V, and the MPU 171 stops operating.
[0070] On the other hand, if it is considered in the step S 102 that the power switch 17 is depressed, the printer is operated in a step S 103 . Here, the printer first performs an initialization operation when the power source is turned on. For example, the printer performs a recovery operation of the recording head to set the state that the recording head can satisfactorily discharge inks. Moreover, as the initialization operation, the printer starts communication with the host apparatus such as the personal computer or the like. Then, the printer receives and records the data sent from the personal computer, and performs the recovery operation of the recording head between the recording operations according to need.
[0071] While the printer is operating, the state of the power switch 17 is always checked by polling or interrupt in a step S 104 . If it is considered in the step S 104 that the power switch 17 is depressed during the operation of the printer, the flow advances to a step S 105 to end the currently performed operation of the printer, and the flow further advances to the step S 110 to interrupt the power supply from the AC adapter 2 .
[0072] As explained above, when the AC adapter is connected to the outlet of the AC power source, the DC-DC converter 4 is turned on for a certain period of time to supply the power to the printer even if the power switch is not turned on, whereby the MPU can operate. Thus, it is possible to check the state of the secondary battery and to charge the secondary battery if necessary. If the charging is unnecessary or completed, the MPU stops operating, the DC-DC converter 4 is turned off, and the printer is on standby until the power switch is turned on, whereby the power consumption of the printer system becomes zero.
[0073] <Second Embodiment>
[0074] [0074]FIG. 7 is a block diagram showing the detailed structure of a power supply unit of a printer 1 . The structure in the present embodiment differs from the structure of FIG. 3 explained in the first embodiment in the point that there is no secondary battery and no charging circuit for the secondary battery, that is, other portions in the present embodiment are the same as those in the first embodiment.
[0075] Therefore, since the sequence to turn on/off the power source in the present embodiment is the same as that in the first embodiment, the explanation of main signals will be omitted.
[0076] Then, a control procedure to be executed by an MPU 171 when the power source of the printer 1 is turned on/off will be explained with reference to a flow chart shown in FIG. 8.
[0077] After the reset is released, in a step S 201 , a signal of “H” level is first output to an output port 19 to turn on a transistor 20 , whereby the oscillation state of a DC-DC converter 4 is maintained, and the power is continuously supplied from an AC adapter 2 .
[0078] Next, in a step S 202 , an output signal 1 f to an input port 18 is read to check whether or not a power switch 17 of the printer 1 is depressed. If the power switch 17 is not depressed, it is considered that the AC adapter 2 is only connected to the printer 1 but a user does not wish to start the printer, whereby the step advances to a step S 206 .
[0079] Then, it is checked in the step S 206 whether or not a carriage is capped. It should be noted that this check is performed by a position sensor (not shown) on the carriage. Then, if the carriage is capped, the flow advances to a step S 208 , while if the carriage is not capped, a capping operation to move the carriage to a capping position is performed in a step S 207 . The capping is not only to protect the surface of the recording head but also to be able to prevent the ink from flowing out of a not-shown ink tank (including a waste ink tank) of the portable printer, whereby it is very effective.
[0080] Incidentally, when the capping operation is performed, recovery operations such as a preliminary discharging operation, a wiping operation and the like to protect the surface of the recording head are performed according to need.
[0081] In the step S 208 , the signal of “L” level is output to the output port 19 to turn off the transistor 20 , whereby the DC-DC converter 4 stops oscillating. As a result, a voltage V CC becomes 0V, and the MPU 171 stops operating.
[0082] On the other hand, if it is considered in the step S 202 that the power switch 17 is depressed, the printer is operated in a step S 203 . Here, the printer first performs an initialization operation when the power source is turned on. For example, the printer performs a recovery operation of the recording head to set the state that the recording head can satisfactorily discharge inks. Moreover, as the initialization operation, the printer starts communication with the host apparatus such as a personal computer or the like. Then, the printer receives and records the data sent from the personal computer, and performs the recovery operation of the recording head between the recording operations according to need.
[0083] While the printer is operating, the state of the power switch 17 is always checked by polling or interrupt in a step S 204 . If it is considered in the step S 204 that the power switch 17 is depressed during the operation of the printer, the flow advances to a step S 205 to end the currently performed operation of the printer, and the flow further advances to the step S 208 to interrupt the power supply from the AC adapter 2 .
[0084] As explained above, when the AC adapter is connected to the outlet of the AC power source, the DC-DC converter 4 is turned on for a certain period of time to supply the power to the printer, whereby the MPU can operate. Thus, it is checked whether or not the recording head is capped, and the capping operation is performed if necessary. If the capping operation is unnecessary, the MPU stops operating, and the DC-DC converter 4 is turned off, whereby the power consumption of the printer system becomes zero. As above, in the first and second embodiments, although the integration circuit composed by the resistor R 1 and the capacitor C 1 is described as the example of the way to turn on the step-down circuit for the certain period of time when the AC adapter is connected and when the printer is connected to the AC outlet, it is possible to achieve the same function by using a differentiating circuit.
[0085] Moreover, in the embodiments, the tact switch having the structure to be on in the case where the switch is being depressed is explained by way of example of the power switch for operating the printer. However, the present invention is not limited to this, that is, other type of switch such as a slide switch or the like is applicable.
[0086] Moreover, in the embodiments, the DC-DC converter is described by way of example of the step-down circuit for generating the logic voltage. However, it is apparent that a voltage regulator (often called a three-terminal regulator, in general) having output control terminals can be used.
[0087] Moreover, as the method of judging whether or not it is necessary to charge the secondary battery, the method of performing the judgment based on the value of the charging current is described, but other method is applicable. For example, if there is information concerning the charging to the secondary battery, a method of performing the judgment based on this information is applicable.
[0088] Moreover, the regulated period of time T of the reset signal in the reset circuit is 100 msec. However, other value is applicable if it satisfies the control according to the embodiments. Besides, the output value of the AC adapter is 16 V, other voltage value is applicable.
[0089] According to the present invention, it is possible to suppress the power consumption of the ink-jet printer to approximately zero when the printer is being turned off, whereby there is an effect of enabling to provide the apparatus that the power consumption of the overall ink-jet printer including the power supply unit is extremely small.
[0090] Moreover, even if the power source of the ink-jet printer is in the off state, it is possible, without user's operation, to perform the process only by connecting the AC adapter. | An ink-jet printer includes a control circuit for controlling a recording operation by receiving power supply from an AC adapter, a voltage output circuit for outputting a voltage on the basis of a signal output by the AC adapter, and a voltage output control circuit for turning on and off the voltage output circuit. In the printer, in case of starting the power supply from the AC adapter, the voltage output control circuit sets the output of the voltage output circuit to an off state after setting the output to an on state for a certain period of time, whereby it is possible to decrease reactive power while the electronic apparatus is not powered. | 8 |
BACKGROUND OF THE INVENTION
[0001] This application is a Continuation-in-Part of application Ser. No 11/613,463, filed Dec. 20, 2006.
FIELD OF THE INVENTION
[0002] This invention relates to methods of preparing alcohol, mainly referred to as a method of converting herbaceous plant fibers into fuel alcohol.
DESCRIPTION OF THE PRIOR ART
[0003] At present, foods such as sorghum and corn serve as the main raw materials for producing fuel alcohol. The technology of producing fuel alcohol from corn consist of grinding the corn, mixing it with water in the proportion of from 1:30 to 1:40 corn to water by weight, heating the mixture to between 70 and 80° C., precooking for 20 to 40 minutes, and then boiling for no less than 90 minutes using a boiling vessel under 141 to 145° C. and pressure of from 3.2 to 3.5 kg/cm 2. However, many problems arise in using foods for the production of alcohol including high cost, low output rate, and high energy consumption.
[0004] Besides using foods, trials also have been made to produce alcohol using straws. The technology of such a method may consist of the following steps: grinding-syrup discharge-saccharification-sugar liquor-alcoholic fermentation-yeast separation-distillation-fuel alcohol. However, this method also has limitations such as high energy consumption and low output rate. Due to technical reasons, producing alcohol with straws is still at the experimental stage, which makes it unable to realize industrial production. Therefore, large numbers of straws and herbaceous plants are used as fuels, forages, and fertilizers, leading to a waste of resources.
[0005] The present invention has arisen to mitigate and/or obviate the afore-described disadvantages.
SUMMARY OF THE INVENTION
[0006] The aim of this invention is to provide a method of converting herbaceous plant fibers into fuel alcohol. By adding cellulase and other materials, cellulose is hydrolyzed to reduce sugar, which then is fermented to produce fuel alcohol. This method improves the output and the speed of cellulose hydrolysis and overcomes the shortcomings of the present technology for fuel alcohol production.
[0007] The technical scheme of realizing this invention: this method comprises the following steps:
[0008] 1. Pretreatment
[0009] a. Grind the raw materials of herbaceous plants into 100 to 180 mesh, and load them in a reaction tank.
[0010] b. Loosen and separate the structures between the walls of raw fibers by adding CO 2 with supersonic waves.
[0011] c. Add a liquid mixture of alcohol, liquid ammonia, and water to the raw material in the proportion of between 1:1.5 and 1:3 (the weight ratio of the raw material to the liquid). The alcohol accounts for 30-40%, and liquid ammonia accounts for 6-10%; the rest is water.
[0012] d. Add dilute alkali NaOH with 3-12% of the weight ratio of the raw material and stir.
[0013] e. Boil for 20 minutes to 2 hours at between 100 and 250° C. and the pressure of 2-6 Mpa.
[0014] f. Reduce the pressure to normal and reduce the temperature to between 30 and 40° C.
[0015] 2. Recovery
[0016] a. Recover the organic liquids.
[0017] b. Wash them under high pressure and high temperature.
[0018] 3. Biological Enzyme Hydrolysis
[0019] a. At 40 to 60° C. and pH 3.0 to 6.0, add the cellulase comprising endo-β-glucanase, exo-β-glucanase and β-glucanase. This accounts for 0.5 to 3% of the liquid weight
[0020] b. The enzymolysis process takes about 8 to 12 hours.
[0021] 4. Fermentation
[0022] a. Under the temperature of 40-60° C. and pH 3.0-6.0, add liquid Candida mycoderma, Rhizopus oryzae, and dry yeast (compounded), which account for 3 to 8% of the liquid weight.
[0023] b. Ferment for 50-80 hours at the temperature of between 30 and 40° C.; and
[0024] c. Optionally, further add ammonium sulfate and phosphoric acid during this process to enhance fermentation.
[0025] 5. Refinement
[0026] a. When the detected alcohol concentration reaches between 18 and 25 degrees, it will come into the preliminary process of refining alcohol from distillate spirits.
[0027] b. When the alcohol concentration reaches between 35 and 50 degrees, it will be sent to the alcohol tower for further refinement until the concentration reaches 95 degrees.
[0028] The technical scheme further includes:
[0029] The said cellulase further comprises glucosiduronate enzyme, acetyl enzyme, xylanase, β-xylanase, galactomannoglycan enzyme, and glucomannan enzyme.
[0030] The pressure/temperature relief process comprises transient decompression and transient cooling as well as real-time water-adding temperature relief.
[0031] The recovery of organic liquids comprises pretreatment using different alcohol, liquid ammonia and dilute alkali NaOH.
[0032] The beneficial results of this invention are chracterized by such features as extensive sources of raw material, simple process, low cost, low energy consumption, high output rate, environment protection and partial replacement of oil, this invention can also convert herbaceous plant fibers into other chemical products and biochemical products.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The present invention will be clearer from the following description when viewed together with the accompanying drawings, which show, for purpose of illustrations only, the preferred embodiment in accordance with the present invention.
A. Pretreatment
[0034] a. Grind the raw materials of herbaceous plants into 100 to 180 mesh, and load them in a reaction tank.
[0035] This case technical feature is during carrying on the industrial production, when vegetable fiber raw material hydrolisis transfers the saccharification hydrolisis the effect, can enable in the saccharification hydrolisis fluid to have more glucose densities, as well as the less xylose density, is advantageous the efficiency which ferments in the enhancement, produces more ethanols. Simultaneously the equipment and the technology to create the output cost the influence, and the production technology's circulation again use influence output and the cost, and may recycle use again, and will not have the environmental pollution technical feature main point to take the patent research which will carry on to the overall technology's coordination.
[0036] 1. Grind the raw materials of herbaceous plants into 100 to 180 mesh, and load them in a reaction tank,—The related attrition part of this application document is completely different from the levigation type processing raw material and general dry-like attrition processing raw material; The levigation type and the dry-like attrition as following:
[0037] The Potency of the Dry-Like Attrition
(1) The dry-like attrition energy consumption breakage great cost is very high, is the levigation-like five to six time of energy consumption quantities, (2) The output by the dry-like attrition is very few, (3) The dry-like milling equipment components lose the quick cost to be very high, the replacement loss components cost is very high, (4) Dry-like grinds the complete set of equipment to be very expensive, (5) The dry-like attrition dust is very big, the easy environmental pollution to need to reduce the dust, (6) The dry-like attrition needs to increase pulls out vacuum cleaning, will otherwise have the environmental pollution cost to be very high, and will cause when the fermentation will have the fungus category pollution, will affect the production output, will make the cost to increase, (7) The dry-like attrition can produce the very massive hot air, to the low temperature factory, has the cost to be very high,
(1∘) the cost of The air conditioning increases, (2∘) the cost of Ferments Temperature controls increases
(8) When dry-like attrition production is limited to vegetable fiber chain's tearing, to reduces the following pretreatment the processing hydrolisis and the saccharification time has not helped,
[0048] The Potency of Water Type Attrition
(1) The water type attrition energy consumption quantity is low, compared to dry-like energy consumption quantity low five to six times, (2) The water type attrition output is very big, the production output may increase along with the output demand, the supplemental equipment, the cost is low, (3) The water type milling equipment components lose the few costs to be low, the replacement loss components few costs are low, (4) The water type grinds the complete set of equipment to be cheap, dry-like grinds the complete set of equipment cost to be low, the expansion development is quick, (5) Water type attrition dust if needs to reduce the dust very greatly, (6) When water type attrition production does not need to increase pulls out vacuum cleaning, belongs to dustlessness type production, will not have the environmental pollution to create this increases, to fermentation when will not have the fungus category pollution, will not affect the production output, will make the cost to increase, (7) The water type attrition cannot produce the massive hot air, will not produce to the low temperature factory controls the influence warm, will make the production cost to increase, (1∘) the cost of the air conditioning will not increase, (2∘) the cost of Ferments Temperature controls will not increase, (8) When water type attrition production the biggest merit is carries on tearing to the vegetable fiber chain, reduces the following pretreatment the processing hydrolisis and the saccharification time, when the production already produced the heat generation high temperature cellulose to decompose, appearance “preliminary” cellulose hydrolisis,
[0057] b. Loosen and separate the structures between the walls of raw fibers by adding CO 2 with supersonicwaves:
[0058] The influence to cellulose by the pretreatment with carbon dioxide & ultrasonic wave jointly
[0059] Joins the carbon dioxide belongs to when the fermentation produces the product, will not have the situation which the cost will increase, after vegetable fiber attrition, will need to further carry on tearing again to the textile fiber chain, will carry on the ultrasonic wave using the recycling carbon dioxide coordination application ultrasonic wave to add the carbon dioxide to the vegetable fiber “second step” the pretreatment hydrolisis, the carbon dioxide coordination supersonic wave energy force cellulose decomposition will release the more monosaccharide members and the return to original state sugar density in the research is high, maximizing. The cellulose material uses the carbon dioxide coordination ultrasonic wave to increase separately to the cellulose demolition responded, thus raised the disintegration rate and the cellulose hydrolisis degree. In this pretreatment process, if micrite cellulose, when the use carbon dioxide coordination ultrasonic wave carries on the compression response to occur. When an explosive carbon dioxide relief pressure, and increased the cellulose substrate contacted area to the cellulose disarrangement of the structure, will affect to the hydrolisis effect is very big. The result indicated that the carbon dioxide coordination ultrasonic wave to the cellulose pretreatment is quite effective. In the pressure will increase will be advantageous in the crystal structure the carbon dioxide member seepage speed, after the detonation will occur, will thus produce more glucose is from the cellulose material separation. This detonation pretreatment enhanced the cellulose raw material hydrolisis rate as well as reaches as high as 50% glucose output increase. Also indicated from the synchronization diastatic fermentation test result that the fermentation cellulose may make the ethanol productivity for the carbon source material to increase. As one new substitution method, the plant lignocellulose demolition which the carbon dioxide coordination ultrasonic wave produces explodes, pretreatment law and so on airing, high temperature high pressure, low temperature low pressure compared to the ammonia to be able to reduce more expenditures and the time.
[0060] In the pretreatment technology of plant lignocellulose, has (1) the acid (H2SO4) pretreatment law, (2) the alkali (NaOH) pretreatment law, (3) the acid-ultrasonic wave union pretreatment law, (4) the alkali-ultrasonic wave union pretreatment law four pretreatment methods, in the research discovered that the acid and alkali treatment and the acid-alkali-ultrasonic wave joint treatment law density is 2.0%, the time is 60 min, but adopts jointly using the carbon dioxide ultrasonic wave in the processing law technology the power is 125W, the time is 20 min. Then the pretreatment processing vegetable fiber main chemical composition which adopted jointly after these four pretreatment method and the carbon dioxide ultrasonic wave has carried on the analysis separately, discovered adopted the pretreatment vegetable fiber jointly after the carbon dioxide ultrasonic wave, after its processing chemical constituent and the pure acid and alkali and the acid-alkali-ultrasonic wave joint treatment law pretreatment's vegetable fiber processing chemical composition compared, discovered adopted the pretreatment vegetable fiber after the carbon dioxide ultrasonic wave to be able jointly to have more cellulose and the hemicellulose content as well as the lignin content are less. Simultaneously the carbon dioxide coordination supersonic wave energy force cellulose decomposition releases the more monosaccharide members and the return to original state sugar density is high, then to passed through the pretreatment later vegetable fiber which four method pretreatments and the carbon dioxide ultrasonic wave adopted jointly to carry on the saccharification hydrolisis condition orthogonal to optimize, has obtained the final best technological conditions is: pH value 4.8, temperature 45° C., enzyme density 20 mgg−1. Then carried on to under the best technological conditions' saccharification hydrolytic process observed and analyzes, discovered that after the acid-ultrasonic wave pretreatment as well as the alkali-ultrasonic wave pretreatment's vegetable fiber can later achieve the stable return to original state sugar density under the best technological conditions after 108 h, and the maximizing, respectively was 26.4 gL−1 and 33.0 gL−1, but after the pure acid pretreatment as well as the caustic pretreating vegetable fiber must be able to cause the return to original state sugar density after 120 h to stabilize and to reach the maximum value, respectively was 26.2 gL−1 and 32.7 gL−1. But the carbon dioxide ultrasonic wave adopts jointly the pretreatment later vegetable fiber can later namely achieve the stable return to original state sugar density under the best technological conditions after 87 h, and maximizing 56.2 gL−1, has carried on the analysis finally after several kind of pretreatment method processing vegetable fiber saccharification hydrolisis fluid's main chemical composition, generally speaking, the use carbon dioxide ultrasonic wave pretreatment's vegetable fiber's saccharification hydrolisis effect must surpass the traditional pure acid, the alkali and the acid-alkali-ultrasonic wave joint treatment method pretreatment law, the use carbon dioxide ultrasonic wave pretreatment vegetable fiber saccharification hydrolisis effect can enable in the saccharification hydrolisis fluid to have more glucose densities as well as the less xylose density, is advantageous the efficiency which ferments in the enhancement, produces more ethanols. (after the pretreatment carbon dioxide and the ultrasonic wave may use again repeatedly, save the cost.):
[0061] c. Add a liquid mixture of alcohol, liquid ammonia, and water to the raw material in the proportion of between 1:1.5 and 1:3 (the weight ratio of the raw material to the liquid). The alcohol accounts for 30-40%, and liquid ammonia accounts for 6-10%; the rest is water. Add dilute alkali NaOH with 3-12% of the weight ratio of the raw material and stir.
[0062] d. Boil for 20 minutes to 2 hours at between 100 and 250° C. and the pressure of 2-6 Mpa.
[0063] e. Reduce the pressure to normal and reduce the temperature to between 30 and 40° C.
[0064] B. Recover the Organic Liquids: Wash them Under High Pressure and High Temperature;
[0065] After Completing the Carbon Dioxide Coordination Ultrasonic Wave Pretreatment, Uses Chemistry to Pretreat Again
[0066] Put the 95% alcohols, the liquid ammonia, and the moisture content by 40%, 6%, 54% do join into the reactor; and will dilute the alkalinity sodium hydroxide dilutes and carries on the agitation by 3-12% percents by weight.
[0067] “third step” the hydrolisis use sodium hydroxide (NaOH) dissolves in the ethanol and in the water altogether resolver mixture.
[0068] The findings indicated that after NaOH pretreatment, the vegetable fiber obtains the Run bulge obviously, the cellulose crystalline indice reduces, the cellulose crystallizing field receives the destruction, passes through cellulase processing after again, the crystalline indice has the enhancement: The NaOH pretreatment is one effective vegetable fiber pretreatment method, after NaOH pretreatment vegetable fiber change in enzymolysis.
[0069] In the research only uses 2% NaOH in 85° C. to process 75 min to the vegetable fiber, lignin removing rate achieves 47.9%, after the processing textile fiber residual is degraded easy by the enzyme, the enzymolysis rate achieves 33.2%; After the liquid-solid separation's lye may the reuse 3-4 times, thus reduces the pretreatment cost; The sodium hydroxide pretreatment condition is temperate, the energy consumption is low, and might remove in raw material fermentation inhibitors effectively and so on ethanoic acid, was advantageous in the vegetable fiber hydrolisis fluid ethanol fermentation.
[0070] The alkali treatment can enhance the cellulase effectively the function substrate—cellulose proportion, thus raises the enzymolysis sugar yield. but in this application document, transforms the herb the fuel alcohol the method use ethanol, the liquid ammonia and the water removes by organic mellow method the lignin the effect is quickest. In the organic acid resolver escapes in the lignin process, the lignin macro-molecule after joining alkalinity Qingyanghuana catalyzes the hydrolisis, causes the cellulose many linear high polymer glucose glucoside key's connection to be able to have the break, causes on the cellulose member chain to form the carbonyl, had the carbonyl cellulose not to be unstable, promoted the glycosidic linkage in alkazid solution break, reduced the polymerization degree. Uses the hydroxidized sodium ion liquid union use ethanol, the liquid ammonia and the water and so on by organic makes the precipitating agent mellowly, can transfer the cellulose reducibility end terminal grouping the carboxyl group, can also transform the mellow hydroxyl the carbonyl, then has the sugar glucoside key's break in the hot alkaline solution.
[0071] The cellulose high polymer polymerization degree drops, the solubility enhances, finally obtains the low molecular compound, this process is called the cellulose the degradation reaction.
[0072] Cellulose 1 - 4 —The glucoside key is one kind of acetal key, the para acid is sensitive, under the suitable hydrogen ion concentration, the temperature and the time effect, the glucoside key break polymerization degree drops, this kind of response is called the cellulose the acidic hydrolysis, after the partial hydrolisis's cellulose product is called the hydrocellulose (hydrocellulose), time the complete hydrolisis's product produces the glucose.
[0073] Causes the lignin the soluble enhancement, uses the ethanol to take the precipitating agent, may promote the enzymolysis saccharification, the saccharification speed to compare the raw sewage cellulose not to enhance 80%.
[0074] The sodium hydroxide is the complete ion, includes the sodium ion and the hydroxide ion. The hydrogen ions way realizes the sodium hydroxide strong alkali and the acid response, dissolves in the sodium hydroxide this kind of ionic liquid the cellulose may through the make-up water, the ethanol and so on organic solvent separate out, because this is forms the hydrogen bond for this kind of resolver change and the hydroxidized sodium ion liquid, thus causes the cellulose instead to gather. May see when the findings, uses the ethanol makes the precipitating agent the obtained regenerated cellulose polymerization degree to be low, the saccharification speed is quick.
[0075] Meanwhile may see in the findings in 85° C. above the high temperature may destroy the cellulose intermolecular hydrogen bond, causes the dissolution; In 100° C. above insoluble cellulose; 1-butyl-3-methyl imidazole muriate ([BMIM]Cl) and 1-allyl-3-methyl imidazole muriate ([AMIM]Cl) the hydroxidized sodium ion liquid union use ethanol, the liquid ammonia and the water and so on by organic make the precipitating agent mellowly, including the strong hydrogen bond acceptor Cl-ion, causes the dissolution through them with the cellulose hydroxyl function. The carbaminate system is through with the cellulose in 100° C. above responded that transforms for the cellulose carbaminate, then dissolves again in the NaOH peroxide solution; The sodium hydroxide/water system, can only dissolve the crystallinity and the polymerization degree low cellulose; NaOH/liquid ammonia, peroxide solution they in precooling to −5—after 12° C., may dissolve the cellulose rapidly. Is mainly produces the small member through the low temperature and the greatly intermolecular new hydrogen bond network architecture, causes the cellulose intramolecular and the intermolecular hydrogen bond destruction dissolves, simultaneously the liquid ammonia the object impediment cellulose member causes the cellulose solution as Bao Hewu from the accumulation to be stable.
[0076] The findings indicated that uses the hydroxidized sodium ion liquid union use ethanol, the liquid ammonia and the water and so on by organic makes the precipitating agent mellowly, in 85° C. processes 35 min to the vegetable fiber, lignin removing rate achieves 87.2%, after the processing textile fiber residual is degraded easy by the enzyme, the enzymolysis rate achieves 93.7%; Because the sodium hydroxide this kind of ionic liquid union use ethanol, the liquid ammonia and the water and so on by organic make the precipitating agent mellowly, is the cellulose direct resolver, the fast precipitation may prevent dissolved the cellulose to restore to the original crystalline state. With the aqueous phase compared to, takes when the precipitating agent by the ethanol the cellulose separates out is more rapid. Moreover, the ethanol boiling point is low, may make the sodium hydroxide this kind of ionic liquid to be easier to recycle.
[0077] The findings indicated that in the cellulose enzyme hydrolysis vegetable fiber, has carried on the analysis to the cellulose saccharification advancement and the cellulase function mechanism. The result indicated that substrate enzymolysis in rate and pretreatment process lignin removing rate performance forward relevance, but the hemicellulose removing degree relations are not big; In the cellulose hydrolytic process at the same time the substrate hemicellulose becomes by the enzyme preparation in xylanase hydrolisis monosaccharides and so on xylose; In view of the textile fiber substrate specific volume major characteristic, uses makes up the material enzymolysis craft to enhance the substrate concentration in turn, thus enhanced in the enzymolysis fluid return to original state sugar density effectively, and has maintained the very high enzymolysis rate, caused the following fermentation the ethanol density to lay a better foundation.
[0078] C. Biological enzyme hydrolysis: At 40 to 60° C. and pH 3.0 to 6.0, add the cellulase comprising endo-β-glucanase, exo-β-glucanase and β-glucanase. This accounts for 0.5 to 3%o of the liquid weight The enzymolysis process takes about 8 to 12 hours.
[0079] The Biological Enzyme Raise and the Hydrolisis Transform Alcohol
[0080] First, we choose the fine mold mushroom spawn—mold mushroom spawn to have reproduce, the culture medium ingredient economy, to produce the enzyme stable property, the enzyme quickly thickly easy to separate characteristics and so on purification.
[0081] The next culture medium's configuration has the importance, the culture medium is provides the microorganism to grow the nutrients which, the reproduction and metabolism as well as the synzyme need. Therefore, culture medium pH, conditions and so on nutrients' ingredient and proportion must be advantageous to the protein synthesis. How to adjust the mold mushroom spawn reproduction condition introduction to be as follows:
[0082] Carbon source The carbon source is the microorganism cell structure as well as the vital activity material base, is one of synzyme primary data. Often uses each kind of starch and the hydrolysate like dextrin, the glucose and so on takes the carbon source.
[0083] Nitrogen source The nitrogen source is composes the protein and the nucleic acid principal element, is microorganism essential important raw material. The organic nitrogenous mainly has agricultural by-products as well as the protein peptone and so on bean cake, peanut cake material and so on. The inorganic nitrogen mainly has the ammonium sulfate, the ammonium chloride, the ammonium nitrate, the urea and so on.
[0084] Inorganic salts The inorganic salts constitute the microorganism cell's important ingredient, plays is adjusting the microorganism vital activity the role, mainly has the phosphorus, the sulfur, the magnesium, the potassium, the calcium, the copper, the iron, the manganese and so on.
[0085] Growth factor The growth factor is refers to the adjustment microorganism metabolic activity the micro organic matter, like Vitamin, amino acid, purine alkali, pyrimidine base and so on. In the enzyme production, the right amount increase growth factor may obviously raise the output.
[0086] PH The suitable potential of hydrogen is the microorganism normal growth as well as produces the enzyme the essential condition. Generally speaking, the most bacteria, the ray fungi grow most suitable pH is the neutrality to the alkalescency, but mold, yeast by chance slight acidity.
[0087] By liquid zymotechnics liquid in-depth zymotechnics. The enzyme preparation separation is refers to the enzyme withdraws from organism, causes it to separate with the impurity achieves the purity which the use goal adapts; Prevents the enzyme denatured deactivation. In obtains in enzyme extracting, the existence includes: Enzyme, mixed protein basis enzyme and mixed protein nature difference, purification method: 1, the centrifugal separation 2, filtrations and the membrane separation 3, precipitations separate 4, chromatographic analyses to separate.
[0088] β-glucosan Enzyme and β-grape glycosidase Assistance Hydrolisis Plant Cellose Rate Enhancement
[0089] In cellulose enzyme hydrolysis vegetable fiber process, biological enzyme hydrolysis processing: The temperature for 40-60° C., PH is 3.0-6.0, the increase β-glucosan enzyme and β-grape glycosidase may cause the fermentable monosaccharide rate enhancement, is one effective method of reducing the enzyme using amount. The reuse β-glucosan enzyme and β-grape glycosidase and optimized β-glucosan enzyme and β-grape glycosidase high production fungus raise condition and to produces the enzyme process to carry on the pH value and to make up the material regulation; The separation has purified outside two kind of butchers β-glucosan enzyme and β-grape glycosidase enzyme and one kind of butcher β-glucosan enzyme and β-grape glycosidase, matches the synthase the characteristic; Has established by the ultrafiltration, the acetone precipitation method, the fossilization enzyme law recycling use β-glucosan enzyme and β-grape glycosidase; And Beta-grape glycosidase carries on screening to β-glucosan enzyme, obtains β-glucosan enzyme and β-grape glycosidase high production strain, the maximum value achieves each strain 5.7 U/ml. In the secretion β-glucosan enzyme and β-grape glycosidase's process, the strain can produce the superelevation vigor interior contact β-glucosan enzyme and β-grape glycosidase and circumscribes β-glucosan enzyme and β-grape glycosidase, the filter paper enzyme achieves 0.75 IU/ml exactly. And, in the thick enzyme fluid β-grape glycosidase and the interior contact glucosan enzyme have strongly bear the ethanol characteristic. Produces when the enzyme controls the initial pH value is 5.0. Will produce the enzyme time the pH value control to be advantageous about 4.0 to β-glucosan enzyme and β-grape glycosidase secretion, when 100 h the enzyme vigor achieves each strain 6.15 U/ml. In produces in the enzyme process to pass through five supplement brans, the enzyme vigor enhanced nearly 4 times. Makes up in the material fermentation process, the suitable bran initial density is 2.8%, when makes up the material total quantity is certain, uses decreasing progressively to make up the material way effect to be best, its enzyme vigor achieves 7.35 U/ml. Makes up the material raise is in turn one kind very good raises the enzyme output the method. Uses steps and so on salting out, sparse water chromatographic analysis, anionic exchange chromatographic analysis, gel filtration, outside two kind of butchers who the purification obtains Beta-grape glycosidase, its molecular weight respectively is 122.3 KD and 80.7 KD. The macromolecular weight enzyme has bears the high sugar characteristic, take causes two kind of enzymes to the nitrophenol-β-D-glucose glucoside as the substrate not to need to rely on the metallic ion to maintain its activeness, can by certain density ethanol, the methanol, the normal butyl alcohol, the ethyl acetate activation. After the purification, in the butcher Beta-grape glycosidase, its molecular weight size is 135.2 KD. The methanol, the ethanol, the normal butyl alcohol, the acetone and the ethyl acetate and so on organic solvent has the remarkable activation function to this enzyme. Precipitates 2 h with −20° C. the acetone, the enzyme returns-ratio is 95.7%. When successive sedimentation cellobiose enzymolysis fluid, the 15th time enzyme returns-ratio still could about 46%, be possible to save needs the enzyme quantity 82.35%. When take the input speed as 1.5 ml/min, 1.0 the ml/min continual enzymolysis, the enzymolysis rate respectively achieves 96.65% and 99%. With uses the cellulase to compare alone, in β-glucosan enzyme and β-grape glycosidase total activity and the filter paper enzyme lives the ratio is 0.5 (FPA=2.0 IU/ml) under the condition, the fossilization β-glucosan enzyme and β-grape glycosidase and the cellulase synergism degeneration filter paper cellulose and micrite cellulose 60 h, their hydrolisis rate increased 28.4% separately and 33.1%.
[0090] β-glucosan Enzyme and β-grape glycosidase and xylanase Strengthening Cellulase—the Hydrolitic Reaction, the Sugar Rate Enhances Effect More Obvious
[0091] Uses the cellulose enzyme hydrolysis vegetable fiber in the research, discovered that spikes the xylanase to be able to strengthen the cellulase hydrolisis vegetable fiber the situation. In the research the cellulose enzyme hydrolysis responded that the sugar rate and the enzyme amount used, the sugar rate and reaction time's relations and join the xylanase strengthening cellulase hydrolisis, in the response the sugar rate and the xylanase recruitment, the sugar under rate and the reaction time reciprocity. Discovered that the cellulose enzyme hydrolysis response increase ration the xylanase, β-glucosan enzyme and β-grape glycosidase and under the cellulase synergism degeneration, may be clear about the affirmation hydrolisis plant cellose rate relative enhancement. Will surpass filters the technology to apply in the enzymolysis process, uses half batch operation. Inspected in half batch operation, the cellulase vigor respectively is under 50, 100 FPIU/g conditions, the sugar rate and reaction time's relations, as well as compare the sugar rate change situation with the batch operation. Uses half batch operation the enzymolysis-ultra to filter the coupled system to produce the sugar regarding the enhancement rate to have the effect. Uses half batch operation, β-glucosan enzyme and β-grape glycosidase and the xylanase strengthening cellulase hydrolitic reaction, the sugar rate enhances the effect to be more obvious. In the cellulase vigor is 50 FPIU/g, the increase β-glucosan enzyme and β-grape glycosidase and the xylanase sum total quantity, when respectively is 25, 50, 80 IU/g, the sugar rate enhances 33.38 separately, 41.80, 23.27%. The cellulase vigor is when 100 FPIU/g enhances 41.88 separately, 52.86, 39.96%. In half batch operation, the xylanase strengthening cellulase hydrolitic reaction, the unit mass zymoprotein produces the sugar quantity distinct enhancement. When the cellulase vigor is 50 FPIU/g, the increase β-glucosan enzyme and β-grape glycosidase and the xylanase quantity respectively is 25, 50, 80 IU/g, the unit mass zymoprotein produces the glucose quantity to enhance 12.93 separately, 15.16, 21.83%; The unit mass zymoprotein produces the cellobiose slightly to have the enhancement. When the cellulase vigor is 100 FPIU/g, the unit mass zymoprotein produces the glucose quantity to enhance 18.36 separately, 22.93, 18.08%; The unit mass zymoprotein produces the cellobiose quantity to enhance 17.66 separately, 18.38, 19.42%.
[0092] Research hydrolyze function. In the cellulase component circumscribes β-glucosan enzyme (the C1 enzyme), the interior contact β-glucosan enzyme (the CMC enzyme) and the interior contact β-grape glycosidase has the different adsorption nature on the identical cellulose substrate, in substrate granularity factors and so on size, pretreatment condition, pH value and temperature has the different influence to the cellulase adsorption. Under specific enzymolysis condition (substrate quality score 10%, pH value 4.8,50 ° C.), C1 enzyme, CMC enzyme component main adsorption on vegetable fiber textile fiber substrate, but interior contact β-grape glycosidase component majority of dissociations in liquid phase. Using the cellulase adsorption characteristic, has realized the cellulase recycling multiplying in the vegetable fiber enzymolysis craft. When the vegetable fiber textile fiber substrate quality score is 10%, cellulase initial amount used for each gram substrate 15 FPIU, after enzymolysis 48 h, filters out the hydrolisis fluid, the retention cellulose residual and joins the fresh substrate, simultaneously supplements the interior contact β-grape glycosidase (each gram substrate 4 IU) and the few cellulases (each gram substrate 7.5 FPIU), continues enzymolysis 48 h, is so redundant carries on. Indicated in the tandem duplication 5 batch of test results: This enzymolysis craft is easy to do, the cellulase amount used may save 50%.
[0093] In enzyme hydrolysis period, the cellulose is degraded into by the cellulase can by the yeast or the bacterial fermentation ethanol return to original state sugar.
[0094] With the cellulose enzyme hydrolysis herb textile fiber's in cellulose production ethanol, the cellulase is the function relatively slow enzyme, materially is because they use the substrate are complex, is insoluble, with half crystal structure. The cellulase also needs to have the quite high vigor as well as the correlation in β-glucosan enzyme, outside β-glucosan enzyme and β-grape glycosidase's synergism can transform completely the cellulose the glucose.
[0095] Biological enzyme hydrolysis processing: The temperature for 40-60° C., PH is 3.0-6.0, joins the cellulase including in β-glucosan enzyme, outside β-glucosan enzyme, in β-grape glycosidase, outside β-grape glycosidase, joins the quantity to account for the liquid weight 0.5-3%o, the enzymolysis process is 8-12 hours; Fermentation: In the temperature for 35-50° C., PH is 3.0-6.0 simultaneously joins the liquid rayon yeast and the Meegan mildew yeast and the dry yeast, joins the quantity to account for the liquid weight 3-8%o, the fermentation, temperature for 30-40° C., the fermentation time is 50-80 hours, in the fermentative process joins the ammonium sulfate and the phosphoric acid;
[0096] D. Fermentation: Under the temperature of 40-60° C. and pH 3.0-6.0, add liquid Candida mycoderma, Rhizopus oryzae, and dry yeast (compounded), which account for 3 to 8%o of the liquid weight. Ferment for 50-80 hours at the temperature of between 30 and 40° C.; and, further add ammonium sulfate and phosphoric acid during this process to enhance fermentation.
[0097] Candida mycoderma, Rhizopus oryzae, and Dry Yeast can Simultaneously Pentose Sugar and Six Carbon Sugars in the Hemicellulose Ferment to Ethanol
[0098] When the yeast cell density is higher than 8 g/L and the xylose content is higher than the total sugar 20%, the easy metabolism's hexose the inhibitory action which produces to the xylose to be possible to eliminate. In 30° C.˜40° C. and under the limit ventilation's condition, 90% above monosaccharides obtained the use, the ethanol rate are the 0.63˜0.78 g/g consumption sugars. The anaerobic fermentation causes the xylose to use and the xylitol accumulation not completely, but the ventilation excessive causes the yeast cell to multiply and to reduce the ethanol rate. This mold mushroom spawn to the cellulose, the hemicellulose hydrolisis fluid (textile fiber hydrolisis fluid) the fermentation inhibitor has high endures patiently ability. The fermenting property research, discovers Candida mycoderma, Rhizopus oryzae, and dry yeast, no matter bears the ethanol heat-resisting performance aspect in the fermenting power to be superior and other mold mushroom spawns. Embarks the strain take Candida mycoderma, Rhizopus oryzae as the mutagenesis, through EMS, LiCI and the ultraviolet ray three factor compound mutageneses, as well as 60Co-γ the exposure induces mutation or chromosomal change repeatedly, unifies the TTC plate, the Du acorn tube fermentation and the liquid state rocker ferments third-level screening, obtains two superiority mutagenesis strain finally, the two ethanol production rate achieves 0.383±0.015 g/g and 0.377±0.017 g/g, approximately for theoretical value 77.16% and 78.33%. The confirmation experimental result indicated that the fermentation vegetable fiber saccharification fluid produced the ethanol ability original mold mushroom spawn Candida mycoderma, Rhizopus oryzae enhanced approximately 2 times, after simultaneously cellulose enzymolysis saccharification, carried on when the fermentation transformation ethanol to the enzymolysis saccharification fluid its ethanol rate may reach above equally 87-93% by Candida mycoderma, Rhizopus oryzae, and dry yeast.
[0099] E. Refinement: When the detected alcohol concentration reaches between 18 and 25 degrees, it will come into the preliminary process of refining alcohol from distillate spirits. When the alcohol concentration reaches between 35 and 50 degrees, it will be sent to the alcohol tower for further refinement until the concentration reaches 95 degrees.
[0100] Absolute Ethanol Purification
[0101] The ethanol structural formula is CH3CH2OH, is the alcohol type one kind, is the liquor essential component, therefore is called the ethanol, popular name ethanol. The chemical formula may also write is C2HSO11 or EtOH, Et represents the ethyl. The ethanol is the commonly used fuel, the resolver and the disinfectant, also uses in the chemical industry.
[0102] The ethanol physical property mainly concerns with its low-carbon linear chain mellow nature. In the molecular hydroxyl may form the hydrogen bond, therefore the ethanol viscosity is very big, is also inferior to the close relative molecular mass the organic compound polarity to be big. Under the room temperature, the ethanol is colorless flammable, and has the special fragrance volatile liquid.
[0103] λ=589.3 nm and 18.35° C., the ethanol refractive index is 1.36242, compared to Shui Shaogao.
[0104] The ethanol (ethanol) under standard state's density is 0.79 absolute ethanol (dehydrated alcohol) under the standard state density is 0.7893.
[0105] Alcohol-water blend 20° C. time dense:
[0106] The ethanol solution density (g/cm3) (20° C.)−every (g/cm3) includes the ethanol weight (%) the g-density (volume to compare %)=(1 degree=1% volume)
[0107] 0.791-99.5-99.7
[0108] May calculate: Every (g/cm3) includes the ethanol weight (%) g
[0109] The density (volume compares %)=(1 degree=1% volume)
[0110] For example: The density is 0.791 g/cm3
[0111] Every (g/cm3) includes the ethanol weight: 0.791×99.5%=0.787045 g
[0112] Density: 99.7%=99.7
[0113] Density (gram/centimeter 3) Ethanol density (%)
[0114] Alcohol Proof
[0115] When the Proof of an alcohol solution is used, one is dealing with a solution of mainly ethanol: CH3CH2OH and some water.
[0116] The value of the Proof is exactly twice the percentage of alcohol in the solution.
[0117] Pure alcohol is 200 Proof.
[0118] A solution that is 50% alcohol would be 100 Proof.
[0119] 2. The said cellulase further comprises glucosiduronate enzyme, acetyl enzyme, xylanase, β-xylanase, gal actomannoglycan enzyme, and glucomannan enzyme.
[0120] 3. The pressure/temperature relief process comprises transient decompression and transient cooling as well as real-time water-adding temperature relief.
[0121] 4. The recovery of organic liquids comprises pretreatment using different alcohol, liquid ammonia and dilute alkali NaOH.
[0122] While we have shown and described various embodiments in accordance with the present invention, it is clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention. | This disclosure teaches a method of converting herbaceous plant fibers into fuel alcohol comprising the following steps: The pre-treatment stage consists of grinding; using ultrasonic waves; adding the liquids mixed with alcohol, liquid ammonia, and water; adding NaOH; and then stirring and cooking. The second stage involves the recovery of organic liquids as well as high-pressure and high-temperature washing. Next, biological enzyme hydrolysis is conducted by adding endo-β-glucanase, exo-β-glucanase, and β-glucanase. Candida mycoderma, Rhizopus oryzae, ammonium sulfate, and phosphoric acid are added during the fermentation process. Finally, the alcohol is refined from distillate spirits, with further refinement in an alcohol tower. | 2 |
RELATED APPLICATIONS
This is a divisional of U.S. patent application Ser. No. 102,241 filed Dec. 10, 1979 now U.S. Pat. No. 4,275,596.
BACKGROUND OF THE INVENTION
This application pertains to a device for determining the lateral location of an object with respect to a two-dimensional surface. More particularly, it pertains to a device for determining positions by measuring various optical characteristics of the two-dimensional surface.
In some industrial processes it is necessary to monitor the exact position of one object (normally a scanning sensor) with respect to another (normally an object being scanned). One example of such a process is inspecting a weldment by ultrasonically scanning the volume containing it. In such a process, an ultrasonic source is moved from one position to another adjacent one surface of the volume containing the weldment to be inspected. At each position, ultrasonic waves are emitted and the reflections from the workpiece are analyzed and interpreted to provide the desired information as to the quality of the weldment. Various examples of such a method are given in detail in McMasters, Non-Destructive Testing Handbook, Library of Congress No. 59-14660 (1959), especially pages 43-33 through 43-37 and 46-1 through 46-25, the disclosure of which is incorporated herein by reference. The use of the locating device of the present invention will be described herein with reference to such an ultrasonic scanning system. It should be recognized, however, that the use of the invention is not so limited and the invention may be used in connection with any system which requires information concerning the location of one object (normally a scanning sensor) with respect to a second scanning object (normally an object being scanned).
Ultrasonic techniques in use at present commonly require manual positioning of an ultrasonic source at each of many points with respect to the volume to be inspected, interpretation of the results obtained at each location, and documentation of the results. Only an extremely skilled operator can successfully obtain an accurate depiction of an internal defect in a workpiece being examined. Results are nearly always uncertain, since there is no guarantee that all of a weld has been explored. For these reasons, presently available field-operated ultrasonics equipment is not adequate for evaluating a new surface comprehensively and can only be used to monitor in-service deterioration.
Radioscopic examination, the common alternative to ultrasonics testing, has its own severe disadvantages. X-ray testing is very time consuming, requiring set up time for each exposure, time to clear the area of personnel before making the exposure, and time for developing and interpreting the exposure. In order to minimize radiation danger to personnel, X-ray inspection is generally carried out at night, requiring higher pay for the operator; in addition, night-time operation requires the operators to work in pairs for safety and results in less supervisory control of the inspection process. Moreover, X-ray films are bulky, hard to store, and costly and deteriorate relatively rapidly. In addition, an extremely high level of skill is required to interpret the exposures. For all of these reasons, radioscopic inspection is extremely expensive.
SUMMARY OF THE INVENTION
It is accordingly one object of the present invention to provide means for determining the location of an object with respect to a two-dimensional surface.
It is another object to provide means for monitoring not only the location but also the angular orientation of an object with respect to a two-dimensional surface.
It is still another object to provide such means that can be used in conjunction with a microprocessor or otherwise to make an ultrasonic scan and a permanent record of a weldment or other internal structure of a solid body.
It is yet a further object to attain these ends cheaply, simply and efficiently.
According to one preferred embodiment of the present invention, a two-dimensional screen is printed with each of two colors, preferably complimentary colors. The intensity of one color varies uniformly from a minimum to a maximum along one direction on the screen, while the intensity of the other color varies uniformly from a minimum to a maximum along a second direction oblique to the first direction. An object to be moved over the surface of the screen and whose position with respect to the screen is to be monitored, is provided with color intensity measuring units, each of which measures the color intensity of one of the two colors in the region of the screen nearest the object. Each of the color intensity measurement units is provided with an appropriate filter so that it measures the intensity of only one of the two colors with which the screen is printed. Since the combination of the respective values of the intensities of the two colors is unique for each point of the screen, measurement of the intensities permits exact determination of the location of the object.
Other features and advantages of the present invention will become clearer upon consideration of the following detailed description taken in conjunction with the accompanying Figures.
In the following description, reference is made to an ultrasonic scanning system. While this represents the presently preferred use of the position locating system of the present invention, it should be recognized that the invention is not so limited and that any use of the position locating system falls within the broad scope of the invention.
BRIEF DESCRIPTION OF THE FIGURES
For the purpose of illustrating the invention, there are shown in the drawings several embodiments which are presently preferred; it is to be understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a schematic front view of a bichromatic screen according to the present invention.
FIG. 2 is a schematic diagram of an ultrasonic scanning system utilizing the location determining apparatus of the present invention.
FIG. 3 is a bottom view of the ultrasonic sensor unit having two light transmission paths, which system forms part of the system shown schematically in FIG. 2.
FIG. 4 is a cross-sectional view of the ultrasonic sensor unit of FIG. 3 taken along section line 4--4 of FIG. 3.
FIG. 5 is a schematic view of a color detector which is used in conjunction with the system of FIG. 2.
FIG. 6 is a view similar to FIG. 3 of an ultrasonic sensor unit having three light transmission paths to permit determination of the angular orientation of the unit.
FIG. 7 is a schematic view of a screen of the present invention showing the manner in which a threechannel device of the type shown in FIG. 5 can be used to determine angular orientation.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like numerals indicate like elements, FIG. 1 shows a bichromatic screen 10 according to the present invention, which provides a system of coordinates by means of which the exact location of any point on the surface of the screen 10 can be exactly specified. One color, color A, is printed on the surface of the screen with an intensity which preferably, but not necessarily, varies uniformly from a maximum to a minimum along the X direction. The pigmentation of color A is represented by the cross-hatched vertical bars 12 whose horizontal spacing increases from the right-hand to the left-hand end of the screen. A second color B, preferably complementary to color A, is also printed on the screen surface, its intensity varying uniformly from a maximum to a minimum along a direction Y oblique to direction X. This is shown schematically by the cross-hatched horizontal bars 14. In the illustrated embodiment, directions X and Y are perpendicular, and each corresponds to a major axis of the rectangular screen. It should be recognized, however, that directions X and Y may have any relation as long as they are not parallel, that neither direction needs to correspond to a principal axis of the screen, and that the screen can have any convenient shape. It should also be noted that although the varying intensity of color A is represented by bars 12 of color A lying perpendicular to the X direction and being disposed with a linear density in the X direction that varies from one end of the screen to the other, the varying intensity of color B being similarly indicated, in actual practice the manner of obtaining the required variable densities is not critical. The particular colors used are also not critical. Black, while technically not a color, can also be used.
As noted above, the primary object of the present invention is to make it possible to determine the location of a portable sensor 16 with respect to the bichromatic screen 10. By locating the screen 10 at a predetermined disposition with respect to an object to be ultrasonically scanned, it is possible to move the sensor 16 across the screen 10 and at all times determine the location of the sensor 16 with respect to the object being scanned. This relationship is illustrated in FIG. 2. As shown therein, the screen 10 is located between the volume 18 whose internal structure is to be scanned and the ultrasonic sensor 16. The spacing between the sensor 16, bichromatic screen 10 and volume 18 has been exaggerated in order to separately illustrate the three elements. In practice, the bichromatic screen 10 will normally be placed in contact with the outer surface of volume 18 and the sensor 16 will be moved across the face of screen 10 in contact therewith.
The preferred structure of portable sensor 16 is illustrated in FIGS. 3 and 4. FIG. 3 is a bottom view of portable sensor 16 while FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3. As best viewed in FIG. 4, sensor 16 includes an ultrasonic transducer 20 and a pair of light transmission paths 22, 24. Transducer 20 is coupled to a sonic control circuit 26 via a pair of conductive leads 28, 30. The sonic control circuit generates impulse signals which are applied to transducer 20 and which cause transducer 20 to establish shear mode or suitable mode sonic waves in the volume 18. Sonic control circuit 26 also receives echo information from transducer 20 and converts this information into a sonic echo signal indicative of the internal structure of volume 18. By way of example, sonic control circuit 26 will measure the time interval between the instant in which it applies a drive pulse to transducer 20 (which drive pulse sets up a shear mode wave form in volume 18) and the time it takes for transducer 20 to generate an electrical signal indicating that the shear mode wave form has reflected off of a boundary condition in volume 18 (either the external boundary of volume 18 or an internal defect in volume 18) and returned to the transducer 20. The sonic echo signal generated by control-circuit 26 is indicative of this time differential and therefore indicative of the internal condition of the volume 18 at the point where the sonic wave form enter the volume. Sonic control circuits of this general type are well known in the prior art and will not be described herein.
As seen in FIGS. 3 and 4, the light transmission paths 22, 24 are located on either side of transducer 20. Each light transmission path 20, 22, includes a pair of optical fibers 32, 34 which form part of respective color intensity detectors 36, 38. The structure of color intensity detector 36 is illustrated in FIG. 5. As shown therein, color intensity detector 36 detects the intensity of color A on bichromatic screen 30 and therefore detects the position of portable sensor 16 along the X direction of screen 10 (see FIG. 1).
White light generated by a light source 40 is transmitted by optical fiber 32 onto bichromatic screen 10 at a location adjacent the remaining optical fiber 34. The ends of each optical fiber 32, 34 are preferably cut at an angle to ensure that a large percentage of the light emitted by optical fiber 32 will be received by optical fiber 34. The light received by optical fiber 34 is transmitted through a color filter 42 to a photodetector 44. Filter 42 filters out B color light. As such, the intensity of the light applied to photodetector 44 will vary as a function of the intensity of color A on the screen 10 in the area adjacent the ends of optical fibers 32, 34. As such, the intensity of the light appearing at the output of filter 42 is indicative of the position of a light transmission path 22, and therefore the position of portable sensor 16 along the X direction of screen 10.
Photodetector 44, which may be a photocell or other light sensitive device, generates an output signal indicative of the magnitude of the light appearing at the output side of filter 42. The signal is applied to an amplifier 46 which generates an X output signal indicative of the location of light transmission path 22 along the X axis of screen 10.
The structure and operation of color intensity detector 38 is identical to that of detector 36 with the exception that the filter 42 will filter out all A color light. As a result, color detector 38 generates a Y output signal which is indicative of the position of sensor 16 along the Y axis of screen 10. The X and Y output signals generated by color detectors 36, 38 together define the location of portable sensor 16 with respect to bichromatic screen 10, and therefore with respect to volume 18.
Reviewing the foregoing, color intensity detectors 36 and 38 generate output signals X and Y which are indicative of the position of sensor 16 with respect to screen 10 along the X and Y directions, respectively, and sonic control circuit 26 generates ultrasonic echo data signals indicative of the condition of volume 18 at the location indicated by the X and Y outputs of detectors 36 and 38, respectively. In the preferred embodiment, these three signals are applied to a microcomputer 42 which analyzes the signals and stores them in a memory 44. In a simple application, microcomputer 42 will convert the X and Y outputs of color intensity detectors 36 and 38, respectively, into an address signal unique to the position of portable sensor 16 with respect to screen 10. In this regard, microcomputer 42 divides screen 10 up into a plurality of discrete locations, each of which has a unique X and Y coordinate. Microcomputer 42 examines the X and Y outputs of detectors 36 and 38 and determines which discrete location on screen 10 these outputs correspond to. Microcomputer 42 then generates an address signal which is unique to this location and applies it to memory 44 via line 46. Microcomputer 42 also applies a digital signal to memory 44 on line 48 which signal is indicative of the information contained in the ultrasonic echo data signal generated by sonic control circuit 26. As such, microcomputer 42 will store the ultrasonic echo data signal appearing in the output of sonic control circuit 26 in that memory location of memory 44 which corresponds to the position of portable sensor 16 with respect to screen 10. If portable sensor 16 is moved across the entire face of screen 10, memory 44 will contain information regarding the internal structure of the entire volume 18 (assuming that screen 10 is at least relatively as big as the volume 18).
In addition to storing the information concerning the internal structure of volume 18 in memory 44, microcomputer 42 preferably displays this information on an output device 50. Output device 50 may be a simple printer which merely reads out a number corresponding to the echo time required for the sonic pulse generated by transducer 20 to reach the boundary condition in volume 18 and return to transducer 20 for each discrete position on screen 10. In a more sophisticated embodiment of the invention, output device 50 can be a CRT display which displays a pictorial representation of the internal structure of volume 18. The input information to the CRT display would be generated by microcomputer 42 as a function of the information contained in memory 44 in accordance with well known microcomputer techniques. Similarly, output device 50 can be a plotting device which produces a graphical representation of the internal structure of volume 18.
In the foregoing embodiment, only two color sensors 36 and 38 are used. Since the two light transmission paths 22, 24 of the sensors must be spaced apart from each other and from ultrasonic transducer 24, their outputs will positively locate the position of the transmitted ultrasonic beam only when the angular orientation of sensor 16 is at a preset orientation with reespect to the X-Y axis. This orientation may be referred to as the "perfect square". When moving the transducer across the two color screen, it may be angularly rotated with respect to the X-Y axis. Such an orientation is illustrated in FIG. 7. In order to compensate for this rotation, a third color intensity detector 52 may be used. Such a detector is illustrated in phantom in FIG. 2. The structure of this detector will be identical to that of detector 36 and will include a filter 42 which does not pass color B. As shown in FIG. 6, detector 52 will include a light transmission path 54 which is located to the right of light transmission path 22 as illustrated in FIG. 6. When sensor 16 is oriented at the "perfect square" with respect to screen 10, the output of detector 52 will be identical to the output of detector 36 (these two detectors dictating color A). Whenever the sensor 16 is off the "perfect square", the output of detectors 36, 52 will be different and, in fact, will indicate the angular orientation of sensor 16 with respect to screen 10.
As shown in FIG. 2, the output of color A detector 52 is applied to microcomputer 42 along with the output of detectors 36 and 38. Microcomputer 42 uses these three inputs to determine the exact orientation of sensor 16 with respect to screen 10 and adjusts the address signals applied to memory 44 accordingly.
As should be clear from the foregoing, it is necessary to scan the portable sensor 16 across the entire face of screen 10 in order to ensure that information containing the entire internal structure of volume 18 is stored in memory 44. Accordingly, microcomputer 42 preferably includes circuitry which indicates when the entire memory 44 is filled. This condition will only occur when the entire surface of screen 10 has been scanned. Alternatively, microcomputer 42 can control the operation of a CRT display which is initially all one color (i.e. black) and which is changed to a second color (i.e. white) at each location on a CRT screen corresponding to a location on screen 10 over which portable sensor 16 has been scanned. The operator of sensor 16 can ensure that he has scanned the entire screen 10 by continuing to move the sensor 16 until the entire face of the CRT tube has changed to the second color.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification as indicating the scope of the invention. | A method and apparatus for determining the position of a sensor with respect to a color screen are disclosed. The screen is colored with first and second colors in such a way that the intensity of each color varies from a minimum to maximum along a respective direction lying in the plane of the screen, the two respective directions being oblique to each other. As a result, each point on the screen is characterized by a unique pair of color intensities. The sensor is provided with means for measuring the intensity of each color at the point on the colored surface corresponding to the location of the sensor. In one advantageous application of the invention, one surface of a screen is colored as described above, and the screen is placed over an object to be ultrasonically inspected. The ultrasonic scanner is provided with color intensity measurement means and can be made to automatically scan the entire object being tested without intervention by the operator, the resulting data being stored and processed by a microprocessor or other suitable means. | 6 |
[0001] This application is a continuation of U.S. patent application Ser. No. 13/120,441, filed Mar. 23, 2011, which is a 371 of PCT/US2009/058614, filed Sep. 28, 2009, which claims priority to U.S. Provisional Application No. 61/100,318 filed on Sep. 26, 2008, the contents of all of which are hereby incorporated by reference in their entirety.
BACKGROUND
[0002] Currently, the only batteries (rechargeable or non-rechargeable) commercially available with ZnMn chemistries are round bobbin cells. ZnMn chemistries are low cost and lightweight, are environmentally benign, and have a very long charge retention. Round bobbin cells have a positive electrode that is stamped or pressed into a cylindrical hollow pellet and seated into a can, and the negative electrode is a gel that is filled into the center void of the positive electrode.
[0003] The high internal resistance of low capacity round bobbin cells limits the currents (i.e., power) that they can deliver. In contrast, flat plate (electrode) cells can be scaled up to large sizes providing high currents and storage capacities.
[0004] CA 2 389 907 A1 relates to a method of producing flat plate electrodes in a small format that exhibit high current densities, higher utilization of the active materials, and better rechargeability. The method of forming the electrodes requires the active materials, binders, thickening agents, additives, and an alkaline electrolyte to form a paste that is applied to a current collector. CA 2 389 907 A1 provides is a flat plate rechargeable alkaline manganese dioxide-zinc cell.
[0005] What is needed are low cost, lightweight, environmentally friendly batteries that can be used, for example, for large power back-up systems, which are primarily currently served by lead acid and NiCd chemistries. Such batteries should exhibit improvements in, for example, current density, memory effect (i.e., capacity fade), shelf life, charge retention (e.g., at higher operation temperatures), and voltage level of discharge curve over known round bobbin and flat plate cells.
SUMMARY
[0006] Provided is a flat plate electrode cell. The flat plate electrode cell comprises positive electrode plates and negative electrode plates. The positive electrode plates each comprise manganese and compressed metal foam. The negative electrode plates each comprise zinc and compressed metal foam. The positive electrode plates can have aligned tabs and the negative electrode plates can have aligned tabs, and the flat plate electrode cell can further comprise a positive terminal formed from the aligned tabs of the positive electrode plates and a negative terminal formed from the aligned tabs of the negative electrode plates.
[0007] The rechargeable flat plate electrode cell of the present disclosure provides improvements in, for example, current density, memory effect (i.e., capacity fade), shelf life, charge retention (e.g., at higher operation temperatures), and voltage level of discharge curve over known round bobbin and flat plate cells. In particular, the rechargeable flat plate electrode cell of the present disclosure provides longer cycle life with reduced capacity fade as compared with known round bobbin and flat plate cells.
[0008] The rechargeable flat plate electrode cell of the present disclosure achieves such benefits primarily through unique electrode formation. In particular, both the positive and negative electrode of the rechargeable flat plate electrode cell of the present disclosure are formed from compressed metal foam, which provides both low resistance and high rate performance to the electrodes and the cell.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWING
[0009] FIG. 1 depicts an embodiment of the assembly of positive (cathode) electrode plates and negative (negative) electrode plates.
[0010] FIG. 2 shows the improvements of the rechargeable flat plate electrode cell of the present disclosure over commercially available ZnMn round bobbin consumer cells in terms of Cell Capacity Versus Discharge Rate.
[0011] FIG. 3 shows the improvements of the rechargeable flat plate electrode cell of the present disclosure over commercially available ZnMn round bobbin consumer cells in terms of Cell Capacity versus Cycles/Life.
DETAILED DESCRIPTION
[0012] The rechargeable flat plate electrode cell of the present disclosure reduces the material costs, weight, toxicity (regulated limitations), volume, and maintenance of known batteries (e.g., batteries used for stationary power back-up applications), while increasing charge retention and reliability. The rechargeable flat plate electrode cell of the present disclosure can be used wherever high capacity DC power storage is required, can replace lead acid or NiCd large format batteries or other high power electric back-up systems, and can be used directly in applications that can accept a wide voltage range and in conjunction with a voltage stabilizing system when the application requires a narrower voltage range.
[0013] The rechargeable flat plate electrode cell of the present disclosure comprises one or more anode plates comprising anode paste and one or more cathode plates comprising cathode paste. The anode and cathode pastes each comprises active material metal powders (e.g., zinc and manganese, respectively) mixed with aqueous or organic binder to create a paste that can be consistently coated on one or both sides of a substrate. The substrate holds the active material (i.e., the paste) and acts as a current collector. In an embodiment, the substrate is made of a conductive material such as steel, Ni, or Cu, and may be plated with indium or Ni (i.e., a material that is non-active relative to MnO 2 ) for the cathode and Cu (i.e., a non-active material relative to zinc) for the anode. In an embodiment, the substrate comprises a porous conductive substrate such as, for example, perforated metal, metal foam, metal felt, expanded metal, or carbon foam. More specifically, the substrate comprises nickel foam and/or copper plated nickel foam. Accordingly, the anode or cathode paste is coated on and throughout the foam mesh.
[0014] The coated substrate is dried and sized (i.e., compressed) to create a highly conductive, dense, porous flat plate electrode. The flat plate electrodes are wrapped and sealed in a layer of barrier and separator material to prevent short circuits and dendrite growth. The wrapped and sealed flat plate electrodes are stacked in an alternating cathode and anode pattern that is repeated until a desired capacity of the cell is reached. Tabs (collectors) of the flat plate cathode electrodes are connected together and tabs of the flat plate anode electrodes are connected together. In an embodiment, the rechargeable flat plate electrode cell of the present disclosure is bi-polar. Such bipolar batteries use a substrate to hold the positive active materials on one side and negative active materials on the other and the substrate acts as a cell wall. The cell walls are sealed either peripherally or tangentially to hold internal pressure and electrolyte.
[0015] In metal foams, typically 75-95% of the volume consists of void spaces. As such, the use of metal foams allows for thicker electrode substrates without increasing the resistance of the electrode substrates. Target compression from sizing for this embodiment is between about 42% and 45%, which gives desirable porosity, required for low resistance/high rate performance of the rechargeable flat plate electrode cell.
[0016] Without wishing to be bound by any theories, it is believed that the high density of compression reduces the resistance within the paste by reducing the distance between active particles in the active material and reduces the resistance to the substrate by bringing the active particles closer to it. The high density reduces the volume so the energy density is increased. The high density also reduces the void volume in the active material which reduces the amount of electrolyte required to fill the electrode which in turn reduces the rate at which dendrites are formed which protects the cell from shorting and increases cycle life. The density level is critical since over-compression will cause dry spots in the active material where electrolyte cannot get to. These dry spots are very high resistance which reduces performance and can create gassing areas which cause cell failure.
[0017] Without sizing, desired energy density and high power capability are not achieved. The target coated sized thickness for the cathode is less than about 0.0300 inches. Coated sized thickness for the cathode greater than about 0.0300 inches results in rate capability (power) losses, while coated sized thickness for the cathode less than about 0.0200 inches results in energy density losses, due to excess inter electrode spacing and substrate relative to active material.
[0018] The anode paste comprises about 75-98 weight %, for example, about 83.1 weight %, zinc active material; about 0.01-1.0 weight %, for example, about 0.27 weight %, polymeric binder; and about 0-20 weight %, for example, about 16.6 weight %, solid zinc oxide. Exemplary zinc active materials include lead-free zinc and zinc alloy, such as, for example, in metallic, powder, granular, particulate, fibrous, or flake form.
[0019] The cathode paste comprises about 70-90 weight % electrolytic manganese dioxide; about 2-15 weight %, for example, about 7.5 weight %, graphite and/or carbon black; about 3-10 weight %, for example, about 6 weight %, polymeric binder; about 1-15 weight %, for example, about 5 weight %, barium compound; and about 0.01-10 weight %, for example, about 5 weight %, hydrogen recombination catalyst. Exemplary barium compounds include barium oxide, barium hydroxide, and barium sulfate. Exemplary hydrogen recombination catalysts include silver, silver oxides, and hydrogen absorbing alloys. The cathode paste may further comprise indium.
[0020] Exemplary polymeric binders of either the cathode paste or anode paste include carboxymethyl cellulose (CMC), polyacrylic acid, starch, starch derivatives, polyisobutylene, polytetrafluoroethylene, polyamide, polyethylene, and a metal stearate. The polymeric binder of either the cathode paste or anode paste can include conductive graphite, for example, conductive graphite having an average particle size between 2 and 6 microns.
[0021] The rechargeable flat plate electrode cell of the present disclosure differs from currently commercially available rechargeable ZnMn batteries in that the flat plate electrodes of the cell:
are flat; have an internal carrier (substrate); have a current collector attached to the internal carrier; and have the anode's active material completely sealed in a barrier to stop dendrite failures.
[0026] The rechargeable flat plate electrode cell of the present disclosure further differs from currently commercially available batteries in that:
flat plate cathode electrodes are produced by use of aqueous or organic binder and metal powder which is coated, dried and sized, instead of a glycol gel that is injected into a barrier wrapped pocket, which allows for the production of high volume flat plate electrodes required for economical power back-up batteries; flat plate anode electrodes are produced by use of an aqueous or organic binder and metal powder which is coated, dried, and sized, instead of mixing and then high pressure stamp forming into a ridged pellet, which allows for the production of high volume flat plate electrodes required for economical power back-up batteries; multiple flat plate cathode electrodes and flat plate anode electrodes can be connected in parallel then placed in a container, filled with electrolyte, and then sealed, instead of a cathode pellet wedged into a metal can, a barrier separator inserted into the cathode pellet cavity, and then anode gel injected into the cavity with a metal pin inserted into the center of the gel, and closed using a seal ring and crimping, which allows for the high capacity required for stationary power back-up batteries.
[0030] Advantages of the rechargeable flat plate electrode cell of the present disclosure include:
reducing battery cost through lower material costs, lower production costs, and using fewer components; reducing battery weight through higher energy dense chemistry, and using fewer components; reducing battery volume through higher energy dense chemistry, and using fewer components; reducing environmental and regulated (storage, disposal, shipping) issues by using environmentally friendly chemistry; improving reliability by using batteries with higher capacities and internal series collectors so fewer batteries/connections are used; reducing continuous energy losses by using a chemistry with higher charge retention; and reduces energy losses in the system by improving performance (charge efficiency, rate capability) through battery design that reduces losses from internal resistance in the battery.
[0038] FIG. 1 depicts an embodiment of the assembly of positive (cathode) electrode plates and negative (anode) electrode plates. In particular, cathode plate C 1 is stacked atop anode plate A 1 , which is stacked atop cathode plate C 2 , which is stacked atop anode plate A 2 . While not shown in FIG. 1 , in the electrode stack, the alternating positive and negative electrode plates can be separated by separator layers, which insulate the electrode plates from one another. Alternatively, the flat plate electrodes can be wrapped and sealed in a layer of barrier and separator material to prevent short circuits and dendrite growth, as explained above. The lightly shaded section of each of the electrode plates represents the portion thereof upon which cathode paste or anode paste, respectively, has been applied. The darkly shaded section of each of the electrode plates represents the portion thereof which has been pressed (i.e., “coined”) to create a thin, flat, high density area (e.g., about 0.15 inch wide), to which a tab can be welded. Accordingly, the unshaded section of each of the electrode plates represents the tab (e.g., 1 inch wide) welded to the electrode plate. The tab can be, for example, copper or copper plated nickel. A positive terminal is formed from aligned tabs of the positive electrode plates and a negative terminal is formed from aligned tabs of the negative electrode plates.
[0039] As illustrated in FIGS. 2 and 3 , the rechargeable flat plate electrode cell of the present disclosure exhibits improved performance over commercially available ZnMn round bobbin consumer cells. In particular, FIG. 2 shows the improvements of the rechargeable flat plate electrode cell of the present disclosure over commercially available ZnMn round bobbin consumer cells (i.e., “Baseline Round Bobbin” and “Improved Round Bobbin”) as well as a cell as disclosed in CA 2 389 907 A1 in terms of Cell Capacity (expressed as a percentage of initial capacity) Versus Discharge Rate (expressed as a percentage of one hour capacity), while FIG. 3 shows the improvements of the rechargeable flat plate electrode cell of the present disclosure over commercially available ZnMn round bobbin consumer cells (i.e., “Baseline Round Bobbin” and “Improved Round Bobbin”) as well as a cell as disclosed in CA 2 389 907 A1 in terms of Cell Capacity (expressed as a percentage of initial capacity) versus Cycles/Life (expressed as full charge/discharge at C/16 and Room Temperature). As can be seen from FIG. 2 , the rechargeable flat plate electrode cell of the present disclosure has a capacity of greater than 50% of initial capacity, and in particular, a capacity of greater than 80% of initial capacity, at a discharge rate of greater than or equal to 50% of one hour capacity. As can be seen from FIG. 3 , the rechargeable flat plate electrode cell of the present disclosure has a capacity of greater than or equal to 60% of initial capacity at greater than or equal to 25 cycles at room temperature.
[0040] With further reference to FIG. 3 , the Baseline Round Bobbin was tested for seven cycles, the Improved Round Bobbin was tested for sixty-five cycles, and a cell as disclosed in CA 2 389 907 A1 was tested for one hundred cycles. The rechargeable flat plate electrode cell of the present disclosure was tested for twenty-five cycles, with predicted results shown for up to 200 cycles.
[0041] Additionally performance characteristics of the rechargeable flat plate electrode cell of the present disclosure can include capacity of greater than 5 Ahr, cycle life exceeding 200 cycles at 80% DOD above 50% initial capacity, power exceeding C/2 rate to 1 V at 50% initial capacity and 2C rate to 1V at 25% initial capacity, energy density exceeding 90 Whr/kg, and power density exceeding 180 W/kg. DOD, or depth of discharge, is a measure of how much energy has been withdrawn from a battery, expressed as a percentage of full capacity. C/2 rate refers to a discharge rate of 50% of one hour capacity.
[0042] The rechargeable flat plate electrode cell of the present disclosure can be utilized in a vehicle for starting a internal combustion engine, or in a more portable format can be used in power tools, cell phones, computers, and portable electronic devices.
[0043] The following illustrative examples are intended to be non-limiting.
EXAMPLES
[0044] With regard to formation of the flat plate anode electrodes, 360 grams of Zn, 72 grams of ZnO, and 59.88 grams of 2% CMC gel were mixed to form a paste comprising 83.1 weight % zinc active material (i.e., Zn), 16.6 weight % solid zinc oxide, and 0.27 weight % polymeric binder. The paste was applied to one side of copper plated nickel foam and pressed/worked in. The copper was plated on the nickel foam via copper plating 1A for 30 minutes. Water was evaporated from the paste, and the dried pasted foam was pressed to approximately 50% of its original thickness. A 0.15 inch strip at the top of each flat plate anode electrode was coined for attachment of a tab. Further details of formed flat plate anode electrodes can be found in Table 1, below. With regard to the capacity calculations in Table 1, the capacity of 0.625 g Zn is 512 mAh.
[0045] With regard to formation of the flat plate cathode electrodes, 41.90 grams of 2% CMC gel and 100 grams of cathode powder ground down to 1/10 th of the initial particle size were mixed to form a paste. The cathode powder comprised electrolytic manganese dioxide, 7.5 weight % graphite/carbon black, 5 weight % polymeric binding agent, 5 weight % barium compound, and 5 weight % hydrogen recombination catalyst, and is pressed to form high density initial particles. The 2% CMC gel provided an additional 1 weight % polymeric binding agent to provide a paste with a total of 6 weight % polymeric binding agent. The paste was applied to one side of nickel foam having a weight basis of 0.255 g/in 2 . Water was evaporated from the paste, and the dried pasted foam was pressed to approximately 50% of its original thickness. A 0.15 inch strip at the top of each flat plate cathode electrode was coined for attachment of a tab. Further details of formed flat plate cathode electrodes can be found in Table 2, below.
[0000]
TABLE 1
Anode Design
Sized
Thickness
(Substrate
Paste
Sized
Sized
and
Paste Weight/
Weight
Width
Length
Weight
Width
Length
Paste)
Sized Area
Substrate
(g)
(in)
(in)
(g)
(in)
(in)
(in)
(g/in 2 )
A · h/in 2
A · h/in 3
1
2.669
2.52
2.37
13.098
2.54
2.50
0.0370
2.063
1.406
37.988
2
2.697
2.52
2.37
13.258
2.54
2.52
0.0370
2.071
1.411
38.147
3
2.634
2.53
2.38
15.061
2.54
2.53
0.0380
2.344
1.597
42.027
4
2.679
2.52
2.35
13.833
2.53
2.47
0.0370
2.214
1.508
40.767
5
2.631
2.53
2.38
15.144
2.55
2.55
0.0380
2.329
1.587
41.763
6
2.699
2.50
2.39
14.534
2.53
2.50
0.0370
2.298
1.566
42.319
7
2.375
2.54
2.36
15.238
2.56
2.49
0.0380
2.390
1.629
42.867
8
2.360
2.54
2.36
14.495
2.55
2.48
0.0370
2.292
1.562
42.212
9
2.339
2.52
2.38
15.492
2.55
2.48
0.0380
2.450
1.669
43.929
10
2.308
2.53
2.38
16.602
2.55
2.50
0.0390
2.604
1.775
45.502
11
2.618
2.53
2.37
14.380
2.54
2.51
0.0360
2.256
1.537
42.694
[0000]
TABLE 2
Cathode Design
Paste
Sized
Weight/
Sized
Thickness
Sized
Coated
Paste
Sized
Sized
Coated
(Substrate
Coated
Weight
Width
Length
Thickness
Length
Weight
Width
Length
Length
and Paste)
Area
Substrate
(g)
(in)
(in)
(in)
(in)
(g)
(in)
(in)
(in)
(in)
(g/in 2 )
mAh/in 2
1
1.168
2.53
1.81
0.058
1.54
4.492
2.57
2.02
1.77
0.0250
0.988
216
2
1.170
2.52
1.82
0.054
1.56
4.129
2.57
1.97
1.72
0.0235
0.934
205
3
1.141
2.50
1.79
0.050
1.56
3.555
2.52
1.90
1.66
0.0225
0.850
186
4
1.149
2.49
1.81
0.049
1.57
3.577
2.54
1.94
1.69
0.0230
0.833
182
5
1.143
2.49
1.80
0.048
1.58
3.756
2.54
1.94
1.72
0.0230
0.860
188
6
1.138
2.48
1.80
0.050
1.58
3.815
2.53
1.94
1.72
0.0235
0.877
192
7
1.139
2.51
1.78
0.052
1.55
4.328
2.56
1.96
1.75
0.0235
0.966
212
8
1.154
2.50
1.81
0.050
1.56
4.067
2.56
1.96
1.69
0.0235
0.940
206
9
1.152
2.51
1.80
0.050
1.58
4.041
2.56
1.94
1.74
0.0230
0.907
199
[0046] Many modifications of the exemplary embodiments disclosed herein will readily occur to those of skill in the art. Accordingly, the rechargeable flat plate electrode cell of the present disclosure is to be construed as including all structure and methods that fall within the scope of the appended claims. | Provided is a flat plate electrode cell, comprises positive electrode plates and negative electrode plates. The positive electrode plates each comprise manganese and compressed metal foam. The negative electrode plates each comprise zinc and compressed metal foam. Both the positive and negative electrodes can have alignment tabs, wherein the flat plate electrode cell can further comprise electrical terminals tanned from the aligned tabs. The rechargeable flat plate electrode cell of the present disclosure, formed from compressed metal foam, provides both low resistance and high rate performance to the electrodes and the cell. Examples of improvements over round bobbin and flat plate cells are current density, memory effect, shelf life, charge retention, and voltage level of discharge curve. In particular, the rechargeable flat plate electrode cell of the present disclosure provides longer cycle life with reduced capacity fade as compared with known round bobbin and flat plate cells. | 8 |
PRIORITY
[0001] This application claims priority to U.S. Provisional Application No. 61/468,672, filed Mar. 29, 2011, which is hereby incorporated in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to mounting brackets. More specifically, the present invention relates to mounting brackets for mounting “wet” location lighting fixtures.
BACKGROUND OF THE INVENTION
[0003] Several applications, including food processing facilities, commercial kitchens, industrial facilities, pedestrian and road tunnels, laundries, saunas, elevator shafts, storage buildings, car washes, refrigerators and freezer, among others, utilize a UL Listed “wet” location lighting fixture.
[0004] Wet locations require that lighting and the corresponding mounting mechanisms that are placed within such locations to be suitably water resistant and bug resistant. Water resistant and bug resistant lighting fixtures and mounting mechanisms provide for a safe and controlled environment in which there is minimized danger of electrical shorts or bug infestation, for example, which is critical in the aforementioned applications.
[0005] Typically, traditional surface-mounted brackets do not provide water resistant and bug resistant seals between fixture boxes and lighting fixture housings. Those that do provide some sort of water-resistant or bug-resistant properties are often bulky and project the fixture far from the mounting surface. As a result, traditional methods using conduit and wire-pulling via a fixture whip and junction box cover plate are often used to mount lighting fixtures in wet locations. Such traditional methods require costly superfluous materials, such as metallic straight connectors, 90 degree connectors, liquid tight conduits, GFF series fixture mounting hardware, conduit hangers, 14 AWG THHN—Black wiring, 14 AWG THHN—White wiring, and 14 AWG THHN—Green wiring, for example.
[0006] Not only is the pure cost of materials expensive, but superfluous cost is incurred in traditional installation methods in moving all of these materials to the job site, preparing the materials for installation, and working with the materials to install lighting fixtures. The actual installation process in traditional mounting methods therefore also requires time-consuming and expensive labor costs.
[0007] Also, the look and appearance of traditional fixture whip installation methods is often unsightly and obtrusive, a consideration that should not be minimized. In lighting fixture installations using a fixture whip, the conduit or whip often runs from one end of the lighting fixture housing for a length along the ceiling or wall and finally terminating at a junction box. A junction box cover is typically used to cover the junction box and wiring within. Often, these conduits or whips and junction box covers are in a color in complete contrast to the color of the ceiling or wall (typically being available in either black or white). Alternatively, additional cost can be incurred in trying to match the color of the whip to the color of the ceiling or wall material. Additionally, whip or conduit brackets are often required to affix the whip or conduit to the ceiling or wall. Therefore, traditional installation methods provide a very cluttered and unsightly appearance proximate the installed fixture.
[0008] Further, the National Electrical Code (NEC), a United States standard for the safe installation of electrical wiring and equipment, stipulates the connection of an electric-discharge luminaire as it relates to access to boxes. Referring to §410.24(B), “Electric-discharge luminaires surface mounted over concealed outlet, pull, or junction boxes and designed not to be supported solely by the outlet box shall be provided with suitable openings in the back of the luminaire to provide access to the wiring in the box.”
[0009] Therefore, there is a need for an easily-installed and effective surface-mounting bracket for installing lighting fixtures in wet locations that is cost effective, easy to install, and in compliance with UL and National Electrical Code regulations.
SUMMARY OF THE INVENTION
[0010] A mounting bracket according to embodiments of the present application substantially meets the aforementioned needs of the industry. The mounting bracket, according to embodiments of the invention, provides a mounting means for mounting a light fixture to a support surface in wet locations. Specifically, in embodiments, a 4-foot or 8-foot GFF series light fixture can be installed over a new or existing junction box.
[0011] In a feature and advantage of embodiments of the invention, the bracket complies with UL Listing requirements. Gasketing and a plurality of bumpers provide a waterproof fit between the fixture and the junction box. In an embodiment, neoprene closed cell foam gaskets provide water and bug resistance, thereby creating a closed environment between the fixture and the junction box. Thus, the critical area between the supply connectors and the lighting fixture is protected and power is able to pass efficiently and safely to the fixture from the junction box in wet locations. In embodiments, wet location applications therefore provide a UL listing, NEMA 4× rating, and IP67 rating that are protected against dust and the ingress of water; for example, against strong jets of directed water, and against the entry of water during prolonged submersion at a limited depth. Embodiments further protect against corrosion and against damage by the external formation of ice on any piece of the lighting system.
[0012] In another feature and advantage of embodiments of the invention, the bracket provides for an opening in the fixture and the bracket to access wiring in the junction box, in compliance with NEC §410.24(B). Therefore, embodiments are NEC compliant.
[0013] In another feature and advantage of embodiments of the invention, a simple mounting bracket eliminates the need for superfluous installation materials such as, for example, metallic straight connectors, 90 degree connectors, liquid tight conduits, GFF series fixture mounting hardware, conduit hangers, 14 AWG THHN—Black wiring, 14 AWG THHN—White wiring, and 14 AWG THHN—Green wiring of traditional fixture whip-mounted lighting fixtures. In an embodiment, 95% of the materials required in installation can be eliminated compared to traditional conduit and wire-pulling methods. Time and cost is likewise saved in not transporting the aforementioned materials to the job site, preparing the materials for installation, and working with the materials during actual installation.
[0014] Embodiments allow for much faster installation than traditional mounting means, as no fixture whips are needed to wire to the junction box from the fixture—the electrician is able to wire directly to the junction box through the fixture hole, as the fixture is positioned directly over an existing or new recessed junction box on a ceiling or wall. Additionally, the bracket provides a “snap” fit onto the fixture housing and fixture lens, further easing installation. In embodiments, no adhesive sealant or gasket is required during installation and coupling of the fixture to the mounting surface. In embodiments, a 41% material and labor savings can be realized using embodiments when compared to traditional conduit and wire method (for a 4-foot GFF series lighting fixture). An efficiently-installed and labor-saving mounting bracket is therefore provided in embodiments.
[0015] In another feature and advantage of embodiments of the invention, a clean and pleasing look is provided. Embodiments make certain types of light fixture installations much cleaner than traditional mounting means by hiding the junction box beneath the light fixture. In embodiments, no unsightly fixture whip runs from one end of the lighting fixture housing for a length along the ceiling or wall to a junction box. A pleasing look is further provided because no junction box cover plate is necessary when compared to traditional fixture whip installations. Further, there is no need to match whip colors to wall or ceiling material colors in attempt to mask the exposed whip. Likewise, no superfluous whip brackets are exposed. Therefore, only the sleek fixture lens is exposed.
[0016] Additionally, the fixture housing is mounted flush against the mounting surface, with only the thin width of the bracket material between the fixture housing between and the mounting surface, in embodiments. Therefore, embodiments of the lighting fixture only project from the mounting surface at a height of roughly the fixture height itself. The obtrusion into the area surrounding the installation location is therefore minimized. Bulky mounting brackets are therefore avoided in embodiments.
[0017] The above summary of the invention is not intended to describe each illustrated embodiment or every implementation of the present invention. The figures and the detailed description that follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
[0019] FIG. 1 is an exploded perspective view of a lighting system depicted in conjunction with a mounting surface, according to an embodiment.
[0020] FIG. 2 is an exploded, partial sectional, side view of the lighting system of FIG. 1 , depicted in conjunction with a mounting surface presented in cross section.
[0021] FIG. 3A is a perspective view of a surface mount bracket, according to an embodiment, depicted in conjunction with a mounting surface.
[0022] FIG. 3B is a perspective view of a supplemental surface mount bracket, according to an embodiment, depicted in conjunction with a mounting surface.
[0023] FIG. 4 is an exploded perspective view of a lighting system utilizing a supplemental surface mount bracket, according to an embodiment, depicted in conjunction with a mounting surface.
[0024] FIG. 5 is a sectional side view of the surface mount bracket of FIG. 3A operably coupled to a mounting surface.
[0025] FIG. 6 is a sectional side view of the supplemental surface mount bracket of FIG. 3B operably coupled to a mounting surface.
[0026] FIG. 7 is a partial sectional side view of a lighting system installed to a mounting surface, according to an embodiment.
[0027] FIG. 8 is a flow chart depicting a sequence of events for installing a fluorescent lamp with an embodiment of a mounting bracket hereof.
[0028] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0029] Referring generally to FIGS. 1-2 , a lighting system 100 is depicted, according to an embodiment. Lighting system 100 generally includes lighting fixture 102 , mounting bracket 104 , and junction box 106 .
[0030] Lighting fixture 102 comprises housing 108 , geartray 110 , lens 112 , and one or more lamps 113 . In an embodiment, lighting fixture 102 and its components are configured in a direction relatively orthogonal to a mounting surface, for example, along axis A of FIG. 1
[0031] Housing 108 is configured as a base to which other components of lighting fixture 102 can be coupled. Housing 108 comprises an elongated body 114 , a first elongated sidewall 116 a , a second elongated sidewall 116 b , a first abbreviated sidewall 118 a , a second abbreviated sidewall 118 b , a lip 120 , and one or more retaining clips 122 . Elongated body 114 is substantially flat and substantially rectangular, having a length greater than a width, in an embodiment. In an embodiment, then, elongated body 114 comprises two elongated sides and two abbreviated sides and presents a longitudinal axis. Other embodiments of elongated body 114 can be more or less elongated, depending on the application and desired lighting effect. Further, the width or abbreviated side of elongated body 114 can be more or less wide, depending on the application and desired lighting effect.
[0032] One or more access apertures 124 can be configured along elongated body 114 and configured to allow access to junction box 106 . As depicted in FIG. 1 , access aperture 124 is circular and positioned roughly in the center of elongated body 114 and therefore, housing 108 . In another embodiment, access aperture 124 can comprise a square or any other shaped void. In embodiments, access aperture 124 is not centered within elongated body 114 , and is instead offset along one of the elongated sides or offset along the width elongated body 114 . In embodiments, elongated body 114 can comprise a plurality of access apertures 124 . In an embodiment of a 4-foot lighting fixture 102 , for example, elongated body 114 comprises two access apertures 124 . In an embodiment of an 8-foot lighting fixture 102 , for example, elongated body 114 comprises three access apertures 124
[0033] First elongated sidewall 116 a extends at an angle from elongated body 114 along one of the elongated edges of elongated body 114 for the length of elongated body 114 . As depicted in FIG. 1 , first elongated sidewall 116 a extends at an angle greater than 90 degrees with respect to the surface of elongated body 114 . However, in embodiments, first elongated sidewall 116 a can extend from elongated body 114 at an angle of 90 degrees or less, depending on the application. First elongated sidewall 116 a extends for a length shorter than the width of elongated body 114 , although lengths of first elongated sidewall 116 a that are shorter or longer than the depiction in FIG. 1 are also possible. As such, first elongated sidewall 116 a is substantially rectangular. In other embodiments, first elongated sidewall 116 a can be substantially trapezoidal, with non-parallel sides having the same base angles, thus creating a shape that is substantially isosceles-trapezoidal. Other differently-shaped embodiments are also considered.
[0034] Second elongated sidewall 116 b extends at an angle from elongated body 114 along the elongated edge of elongated body 114 opposite first elongated sidewall 116 a for the length of elongated body 114 . As depicted in FIG. 1 , second elongated sidewall 116 b extends at an angle greater than 90 degrees with respect to the surface of elongated body 114 . However, in embodiments, second elongated sidewall 116 b can extend from elongated body 114 at an angle of 90 degrees or less, depending on the application. Second elongated sidewall 116 b extends for a length shorter than the width of elongated body 114 , although lengths of second elongated sidewall 116 b that are shorter or longer than the depiction in FIG. 1 are also possible. In embodiments, as depicted, first elongated sidewall 116 a and second elongated sidewall 116 b extend at similar angles from their respective edges along elongated body 114 and to similar lengths, thus aiding in manufacturing. Similar to first elongated sidewall 116 a , second elongated sidewall 116 b can comprise substantially rectangular, trapezoidal, or isosceles-trapezoidal shapes, among others, in embodiments.
[0035] First abbreviated sidewall 118 a extends at an angle from elongated body 114 along the abbreviated edge of elongated body 114 for the width of elongated body 114 to couple first elongated sidewall 116 a and second elongated sidewall 116 b . As depicted in FIG. 1 , first abbreviated sidewall 118 a extends at an angle greater than 90 degrees with respect to the surface of elongated body 114 . However, in embodiments, first abbreviated sidewall 118 a can extend from elongated body 114 at an angle of 90 degrees or less, depending on the application. First abbreviated sidewall 118 a extends for a length shorter than the width of elongated body 114 , although lengths of first abbreviated sidewall 118 a that are shorter or longer than the depiction in FIG. 1 are also possible. First abbreviated sidewall 118 a comprises a shape suitable to couple the interfacing edges of first elongated sidewall 116 a and second elongated sidewall 116 b . As such, first abbreviated sidewall 118 a can comprise substantially rectangular, trapezoidal, or isosceles-trapezoidal shapes, among others, in embodiments, depending on the respective shapes of first elongated sidewall 116 a and second elongated sidewall 116 b.
[0036] Second abbreviated sidewall 118 b extends at an angle from elongated body 114 along the abbreviated edge of elongated body 114 opposite first abbreviated sidewall 118 a for the width of elongated body 114 to couple first elongated sidewall 116 a and second elongated sidewall 116 b at the end opposite first abbreviated sidewall 118 a . As depicted in FIG. 1 , second abbreviated sidewall 118 b extends at an angle greater than 90 degrees with respect to the surface of elongated body 114 . However, in embodiments, second abbreviated sidewall 118 b can extend from elongated body 114 at an angle of 90 degrees or less, depending on the application. Second abbreviated sidewall 118 b extends for a length shorter than the width of elongated body 114 , although lengths of second abbreviated sidewall 118 b that are shorter or longer than the depiction in FIG. 1 are also possible. In embodiments, as depicted, first abbreviated sidewall 118 a and second abbreviated sidewall 118 b extend at similar angles from their respective edges along elongated body 114 and to similar lengths. Likewise, second abbreviated sidewall 118 b comprises a shape suitable to couple the interfacing edges of first elongated sidewall 116 a and second elongated sidewall 116 b at the edge of elongated body 114 opposite first abbreviated sidewall 118 a . As such, second abbreviated sidewall 118 b can comprise substantially rectangular, trapezoidal, or isosceles-trapezoidal shapes, among others, in embodiments, depending on the respective shapes of first elongated sidewall 116 a and second elongated sidewall 116 b.
[0037] The angles presented by the operable coupling of sidewalls 116 a , 116 b , 118 a , and 118 b to elongated body 114 , as well as the angles presented by the coupling of first elongated sidewall 116 a to first abbreviated sidewall 118 a and first elongated sidewall 116 a to second abbreviated sidewall 118 b , and likewise the angles coupling second elongated sidewall 116 b to first abbreviated sidewall 118 a and second elongated sidewall 116 b to second abbreviated sidewall 118 b can be rounded or otherwise sloped, and need not be at discrete angles.
[0038] In an embodiment, sidewalls 116 a , 116 b , 118 a , and 118 b themselves can be angled. For example, a portion of sidewalls 116 a , 116 b , 118 a , and 118 b distal elongated body 114 can diverge from the plane of the projection from elongated body 114 . In an embodiment, a portion of sidewalls 116 a , 116 b , 118 a , and 118 b extends generally orthogonal to elongated body 114 . In embodiments, this can be defined as a sidewall angle.
[0039] Lip 120 comprises a projection from each of first elongated sidewall 116 a , second elongated sidewall 116 b , first abbreviated sidewall 118 a , and second abbreviated sidewall 118 b that runs along each of these aforementioned components at their respective ends distal elongated body 114 . Lip 120 therefore forms a shape substantially similar to elongated body 114 , but smaller or larger depending on the angle of extension of first elongated sidewall 116 a , second elongated sidewall 116 b , first abbreviated sidewall 118 a , and second abbreviated sidewall 118 b from elongated body 114 . For example, if the respective angle of extension is greater than 90 degrees, the shape formed by lip 120 will be larger than the shape of elongated body 114 . Conversely, if the respective angle of extension is less than 90 degrees, the shape formed by lip 120 will be smaller than the shape of elongated body 114 . In an embodiment, for example as depicted in FIG. 2 , lip 120 is substantially L-shaped. In embodiments therefore, lip 120 initially projects orthogonally from sidewalls 116 a , 116 b , 118 a , and 118 b , then relatively parallel to sidewalls 116 a , 116 b , 118 a , and 118 b along the angled portion of lip 120 . Other shapes of lip 120 are considered, depending on the application. For example, the angle of lip 120 need not be exactly orthogonal. Further, lip 120 can comprise rounded or otherwise curved projections, or comprise a single projection that has no angle or curve whatsoever. In embodiments, lip 120 is configured to receive a corresponding lip of lens 112 .
[0040] One or more retaining clips 122 are configured to operably engage housing 108 . In an embodiment, a set of retaining clips 122 comprise a pair of opposing metal projections configured to hold geartray 110 in place when so engaged. As shown in FIG. 1 , a first set of retaining clips 122 are positioned intermediate the length of housing 108 , roughly one-third of the length of housing 108 distal first abbreviated sidewall 118 a , and a second set of retaining clips 122 are positioned intermediate the length of housing 108 , roughly one-third of the length of housing 108 distal second abbreviated sidewall 118 b . While two pairs of retaining clips 122 are depicted at roughly one-third the length of housing 108 , any number of possible pluralities or configurations of retaining clips 122 are possible. In another embodiment, one or more retaining clips 122 are not operably coupled to housing 108 , but are formed as a discrete structure within housing 108 during manufacture. An individual set of retaining clips 122 , comprising a pair, are configured to be squeezed or otherwise receive pressure such that each retaining clip 122 in the pair moves parallel to geartray 110 towards the other retaining clip 122 in the pair. Upon release of such pressure, the retaining clips 122 in the pair are configured to move in a direction parallel to geartray 110 away from the other retaining clip 122 in the pair.
[0041] In embodiments, housing 108 therefore comprises roughly half of an enclosed lighting fixture 102 , with lens 112 providing the opposing half.
[0042] Optionally, housing 108 can comprise one or more alignment tabs 126 or 128 , one or more latch-mounting members 130 , and one or more latches.
[0043] Alignment tabs 126 comprise projections that extend from within the inner surface or surfaces of housing 108 , for example, on elongated body 114 , sidewalls 116 a , 116 b , 118 a , or 118 b , or any combination thereof. Referring to FIG. 1 , for example, a series of alignment tabs 126 are configured at the angle of interface at elongated body 114 and second elongated sidewall 116 b . A corresponding series of alignment tabs 126 are configured at the same relative positions along housing 108 , but at the interface between second elongated sidewall 116 b and lip 120 . Another set of alignment tabs 126 are configured at the angle of interface at elongated body 114 and first elongated sidewall 116 a , similarly with corresponding alignment tabs 126 positioned at the interface between first elongated sidewall 116 a and lip 120 . Such alignment tabs 126 are configured to guide geartray 110 along its edges or optionally, corresponding notches reflective of alignment tab 126 positions.
[0044] Other types of alignment tabs 128 are also considered. For example, referring again to FIG. 1 , an alignment tab 128 projects directly from elongated body 114 along the width of elongated body 114 , between first elongated sidewall 116 a and second elongated sidewall 116 b . Such alignment tabs 128 are configured to allow clearance for the various electrical and wiring components of geartray 110 . Specifically, alignment tabs 128 inhibits geartray 110 from being positioned flush or too proximate elongated body 114 such that the various electrical and wiring components of geartray 110 are overly compressed or contacted. In another embodiment, alignment tabs 128 inhibits geartray 110 or any of its components from contacting housing 108 at all. In an embodiment, one or more alignment tabs 128 serve a secondary purpose as a tether cable interface point. The tether cable interface is operably couplable to one or more alignment tabs 128 . For example, a clip is operably coupleable to an alignment tab 128 to subsequently be coupled to a geartray 110 tether. Other types or configurations of alignment tabs 126 or 128 are also considered, but not necessarily shown in the figures.
[0045] Latch-mounting members 130 comprise projections that extend from the outer surface or surfaces of housing 108 , for example, sidewalls 116 a , 116 b , 118 a , 118 b , or lip 120 . In an embodiment, a pair of proximately-positioned mounting members 130 comprise the structure for mounting a single latch. In an embodiment, referring to FIG. 1 , latch-mounting members 130 are positioned along lip 120 from the edge distal elongated body 114 to, for example, first elongated sidewall 116 a . A plurality of latch-mounting members 130 can be positioned along housing 108 , depending on the number of latches. In FIG. 1 , four sets of latch-mounting members 130 are positioned per elongated side of housing 108 , for example as shown along first elongated sidewall 116 a . In another embodiment, latch-mounting members 130 do not comprise projections, but a single latch-mountable structure.
[0046] One or more latches (not shown) comprise cam-type latches configured to interface and lock to lens 112 . Each latch is mountable within two opposing, projecting, latch-mounting members 130 . In an embodiment, latches can be made of polycarbonate that resists airborne particles. In another embodiment, latches can be made of steel or stainless steel, making such embodiments ideal for food processing facilities, freezer applications having extreme temperatures, and livestock containment buildings having acidic conditions.
[0047] In an embodiment, housing 108 and its subcomponents can be made of stainless steel. In another embodiment, housing 108 can be made of reinforced polyester. In another embodiment, housing 108 can be made of plastic. In embodiments, solid housing 108 provides strong rigidity with no or limited deflection.
[0048] Geartray 110 comprises a body 134 , first lip 136 a , second lip 136 b , one or more lampholder projections 138 , one or more ballasts 140 , and fixture wiring 142 .
[0049] Body 134 is substantially flat and substantially rectangular, having a length greater than a width, in an embodiment. Other embodiments of body 134 can be more or less elongated, depending on the application and desired lighting effect. Further, the width of body 134 can be more or less wide, depending on the application and desired lighting effect. In embodiments, body 134 of geartray 110 is slightly smaller than the side of housing 108 in order to accommodate geartray 110 into housing 108 . Likewise, the shape of body 134 is dictated by the shape of housing 108 , and specifically, elongated body 114 . In an embodiment, body 134 can be made of corrosion-protected metal or other suitable materials.
[0050] One or more retaining clip apertures 144 are configured along body 134 . An individual retaining clip aperture 144 is of a size such that retaining clip 122 is designed to fit within an individual retaining clip aperture 144 when lighting fixture 102 is assembled, yet keeping the continuity of body 134 as contiguous as possible. For example, retaining clip aperture 144 can comprise a slit or slot slightly larger than the size of retaining clip 122 . Retaining clip apertures 144 , in an embodiment, are positioned as pairs of apertures along body 134 at the relative location along lighting fixture 102 as retaining clips 122 are along housing 108 . For example, referring to the depiction of an embodiment in FIG. 1 , a first set of retaining clip apertures 144 are positioned intermediate the length of body 134 , roughly one-third of the length of body 134 distal a first end corresponding to that proximate first abbreviated sidewall 118 a when assembled, and a second set of retaining clip apertures 144 are positioned intermediate the length of body 134 , roughly one-third of the length of body 134 distal a second end corresponding to that proximate second abbreviated sidewall 118 b when assembled. One or more retaining clip apertures 144 therefore allow one or more retaining clips 122 to project through body 134 to be accessible to a user.
[0051] First lip 136 a comprises, in an embodiment, a substantially V-shaped projection that extends along one of the elongated edges of body 134 for the length of body 134 . In an embodiment, first lip 136 a extends from body 134 such that the arc created by the two rays of first lip 136 a , as connected by a vertex, is substantially in the same plane as body 134 . Other shapes of first lip 136 a are considered, depending on the application. For example, the angle of first lip 136 a need not be V-shaped. Further, first lip 136 a can comprise rounded or otherwise curved projections, or comprise a single projection that has no angle or curve whatsoever. First lip 136 a is configured to interface with lip 120 of housing 108 , as well as lens 112 .
[0052] Second lip 136 b comprises, in an embodiment, a substantially V-shaped projection that extends along the elongated edge of body 134 opposite first lip 136 a for the length of body 134 . Similar to first lip 136 a , in an embodiment, second lip 136 b extends from body 134 such that the arc created by the two rays of second lip 136 b , as connected by a vertex, is substantially in the same plane as body 134 . Other shapes of second lip 136 b are considered, depending on the application and likewise, the shape of first lip 136 a . First and second lips 136 a and 136 b can comprise the same shape, or shapes different than the other, in embodiments.
[0053] Body 134 , first lip 136 a , and second lip 136 b can be made of, for example, stainless steel, or reinforced polyester, in embodiments. Other non-conductive, insulative, or semi-conductive materials can comprise body 134 , first lip 136 a , and second lip 136 b.
[0054] Lampholder projection 138 comprises a semicircle or semi-ovular projection from body 134 configured to apply electrical current to lamp 113 . In an embodiment, a first lampholder projection 138 is positioned at a first end of body 134 , and a second lampholder projection 138 is positioned at a second end opposite the first end at the length of body 134 to comprise a set or pair. The set or pair of lampholder projections 138 is thus configured to operably couple to and power a single lamp 113 . In the embodiment depicted in FIG. 1 , a first set of lampholder projections 138 is positioned proximate first lip 136 a , and a second set of lampholder projections 138 is positioned proximate second lip 136 b . Myriad different positionings and pluralities of sets are considered. Further, in an embodiment, lampholder projections 138 need not be in pairs, but comprise a single projection configured to hold lamp 113 in a cantilevering manner.
[0055] Ballast 140 limits the amount of current in the circuit created by the lighting system 100 . In an embodiment, ballast 140 comprises an inductive ballast that limits the current through the lamps 113 , which can otherwise rise to harmful levels. As such, ballast 140 is operably coupled to fixture wiring 142 and through to one or more lamps 113 . In an embodiment, ballast 140 is operably coupled to body 134 . As depicted in FIG. 2 , ballast 140 is positioned on body 134 on the side opposite lampholder projections 138 . In other embodiments, ballast 140 can be positioned and affixed on the side of lampholder projections 138 , or can be free from body 134 .
[0056] Fixture wiring 142 comprises the wiring adapted to couple the supply conductors from junction box 106 to ballast 140 and lamps 113 . Fixture wiring 142 therefore comprises wiring coupling ballast 140 to one or more lamps 113 , and through the electrical contacts of lampholder projections 138 , in an embodiment. In an embodiment, fixture wiring 142 comprises a luminaire disconnect configured to couple junction box 106 supply connectors to ballast 140 . In an embodiment, the luminaire disconnect is yellow and color coded for circuit wiring. In an embodiment, the termination of hot supply line conductors are connected to a black port and a neutral conductor is connected to white, while a green ground is connected to a green bonding pigtail to the underside of geartray 110 . Such a configuration maintains correct polarity from junction box 106 to lamps 113 .
[0057] Optionally, geartray 110 comprises a tether (not shown) that is operably coupled to body 134 , first lip 136 a , or second lip 136 b , or some combination thereof. The tether can comprise an extension of wiring, string, or other material that can be coupled to housing 108 to retain geartray 110 near housing 108 . Such a configuration simplifies installation and allows for easy ballast 140 replacement.
[0058] Lens 112 comprises a lens elongated body 144 , a lens first elongated sidewall 146 a , a lens second elongated sidewall 146 b , a lens first abbreviated sidewall 148 a , a lens second abbreviated sidewall 148 b , and a lens lip 150 .
[0059] Lens elongated body 144 is substantially flat and substantially rectangular, having a length greater than a width, in an embodiment. Other embodiments of lens elongated body 144 can be more or less elongated, depending on the application and desired lighting effect. Further, the width of lens elongated body 144 can be more or less wide, depending on the application and desired lighting effect.
[0060] Lens first elongated sidewall 146 a extends at a rounded angle from lens elongated body 144 along one of the elongated edges of lens elongated body 144 for the length of lens elongated body 144 . As depicted in FIG. 1 , lens first elongated sidewall 146 a extends at a rounded angle greater than 90 degrees with respect to the surface of lens elongated body 144 . However, in embodiments, lens first elongated sidewall 146 a can extend from lens elongated body 144 at an angle of 90 degrees or less, depending on the application. Lens first elongated sidewall 146 a extends for a length shorter than the width of lens elongated body 144 , although lengths of lens first elongated sidewall 146 a that are shorter or longer than the depiction in FIG. 1 are also possible. As such, first elongated sidewall 116 a is substantially rectangular. In other embodiments, lens first elongated sidewall 146 a can be substantially trapezoidal, with non-parallel sides having the same base angles, thus creating a shape that is substantially isosceles-trapezoidal. Other differently-shaped embodiments are also considered. Additionally, the outer surface of lens first elongated sidewall 146 a can be ridged or otherwise stepped to create a different diffusion appearance.
[0061] Lens second elongated sidewall 146 b extends at a rounded angle from lens elongated body 144 along the elongated edge of lens elongated body 144 opposite lens first elongated sidewall 146 a for the length of lens elongated body 144 . As depicted in FIG. 1 , lens second elongated sidewall 146 b extends at a rounded angle greater than 90 degrees with respect to the surface of lens elongated body 144 . However, in embodiments, lens second elongated sidewall 146 b can extend from lens elongated body 144 at an angle of 90 degrees or less, depending on the application. Lens second elongated sidewall 146 b extends for a length shorter than the width of lens elongated body 144 , although lengths of lens second elongated sidewall 146 b that are shorter or longer than the depiction in FIG. 1 are also possible. In embodiments, as depicted, lens first elongated sidewall 146 a and lens second elongated sidewall 146 b extend at similar angles from their respective edges along lens elongated body 144 and to similar lengths, thus aiding in manufacturing. Similar to lens first elongated sidewall 146 a , lens second elongated sidewall 146 b can comprise substantially rectangular, trapezoidal, or isosceles-trapezoidal shapes, among others, in embodiments. Further, the outer surface of lens second elongated sidewall 146 b can be ridged or otherwise stepped, as in lens first elongated sidewall 146 a.
[0062] Lens first abbreviated sidewall 148 a extends at a rounded angle from lens elongated body 144 along the abbreviated edge of lens elongated body 144 for the width of lens elongated body 144 to couple lens first elongated sidewall 146 a and lens second elongated sidewall 146 b . As depicted in FIG. 1 , lens first abbreviated sidewall 148 a extends at a rounded angle greater than 90 degrees with respect to the surface of lens elongated body 144 . However, in embodiments, lens first abbreviated sidewall 148 a can extend from lens elongated body 144 at an angle of 90 degrees or less, depending on the application. Lens first abbreviated sidewall 148 a extends for a length shorter than the width of lens elongated body 144 , although lengths of lens first abbreviated sidewall 148 a that are shorter or longer than the depiction in FIG. 1 are also possible. Lens first abbreviated sidewall 148 a comprises a shape suitable to couple the interfacing edges of lens first elongated sidewall 146 a and lens second elongated sidewall 146 b . As such, lens first abbreviated sidewall 148 a can comprise substantially rectangular, trapezoidal, or isosceles-trapezoidal shapes, among others, in embodiments, depending on the respective shapes of lens first elongated sidewall 146 a and lens second elongated sidewall 146 b . The outer surface of lens first abbreviated sidewall 148 a can be ridged or otherwise stepped.
[0063] Lens second abbreviated sidewall 148 b extends at a rounded angle from lens elongated body 144 along the abbreviated edge of lens elongated body 144 opposite lens first abbreviated sidewall 148 a for the width of lens elongated body 144 to couple lens first elongated sidewall 146 a and lens second elongated sidewall 146 b at the end opposite lens first abbreviated sidewall 148 a . As depicted in FIG. 1 , lens second abbreviated sidewall 148 b extends at an angle greater than 90 degrees with respect to the surface of lens elongated body 144 . However, in embodiments, lens second abbreviated sidewall 148 b can extend from lens elongated body 144 at an angle of 90 degrees or less, depending on the application. Lens second abbreviated sidewall 148 b extends for a length shorter than the width of lens elongated body 144 , although lengths of lens second abbreviated sidewall 148 b that are shorter or longer than the depiction in FIG. 1 are also possible. In embodiments, as depicted, lens first abbreviated sidewall 148 a and lens second abbreviated sidewall 148 b extend at similar angles from their respective edges along lens elongated body 144 and to similar lengths. Likewise, lens second abbreviated sidewall 148 b comprises a shape suitable to couple the interfacing edges of lens first elongated sidewall 146 a and lens second elongated sidewall 146 b at the edge of lens elongated body 144 opposite lens first abbreviated sidewall 148 a . As such, lens second abbreviated sidewall 148 b can comprise substantially rectangular, trapezoidal, or isosceles-trapezoidal shapes, among others, in embodiments, depending on the respective shapes of lens first elongated sidewall 146 a and lens second elongated sidewall 146 b . The outer surface of lens second abbreviated sidewall 148 b can be ridged or otherwise stepped.
[0064] Lens lip 150 comprises a projection from each of lens first elongated sidewall 146 a , lens second elongated sidewall 146 b , lens first abbreviated sidewall 148 a , and lens second abbreviated sidewall 148 b that runs along each of these aforementioned components at their respective ends distal lens elongated body 144 . Lens lip 150 therefore forms a shape substantially similar to lens elongated body 144 , but smaller or larger depending on the angle of extension of lens first elongated sidewall 146 a , lens second elongated sidewall 146 b , lens first abbreviated sidewall 148 a , and lens second abbreviated sidewall 148 b from lens elongated body 144 . For example, if the respective angle of extension is greater than 90 degrees, the shape formed by lens lip 150 will be larger than the shape of lens elongated body 144 . Conversely, if the respective angle of extension is less than 90 degrees, the shape formed by lens lip 150 will be smaller than the shape of lens elongated body 144 . In an embodiment, for example as depicted in FIG. 2 , lens lip 150 is rounded. In embodiments therefore, lens lip 150 projects from sidewalls 116 a , 116 b , 118 a , and 118 b , outward and sloping back towards lens elongated body 144 , then parallel with sidewalls 116 a , 116 b , 118 a , and 118 b . Other shapes of lens lip 150 are considered, depending on the application. For example, lens lip 150 need not rounded or curved; orthogonal configurations are also considered. Lens lip 150 can also comprise a single projection that has no angle or curve whatsoever. In embodiments, lens lip 150 is configured to interface with lip 120 of housing 108 .
[0065] Lens 112 and its components can be made of acrylic to form an acrylic ribbed diffuser, in an embodiment. In another embodiment, lens 112 can be made of acrylic to form an acrylic clear diffuser, in both a basic and a wide specular reflector option.
[0066] One or more lamps 113 can comprise fluorescent bulbs, in an embodiment. In embodiments, lamps 113 T 5 and T 8 bulbs having long life and energy efficiency with uniform lumen distribution. Lamps 113 are configured to be operably coupled to opposing one or more lampholder projections 138 . In embodiments, lamps 113 can number one, two, three, four, or more in an individual housing (and corresponding geartray 110 ). Lamps 113 can be, for example, 4-feet in embodiments. In another embodiment, lamps 113 can be 8-feet in embodiments.
[0067] Referring to FIG. 3A , Mounting bracket 104 generally comprises a mounting plate 151 having a main surface 152 , a plurality of mounting bracket clips 154 , and one or more gaskets 156 . Mounting bracket 104 is configured to engage housing 108 and/or lens 112 , or any combination thereof, to provide positive, resilient engagement of light fixture 102 .
[0068] Main surface 152 is substantially flat and substantially rectangular, having a length greater than a width, in an embodiment. Main surface 152 is configured to mirror the relative shape of housing 108 , and specifically, elongated body 114 . In an embodiment, then, main surface 152 comprises two elongated sides and two abbreviated sides and is configured to abut the longitudinal axis of elongated body 114 . Other embodiments of main surface 152 can be more or less elongated, depending on the shape of elongated body 114 . Further, the width or abbreviated sides of main surface 152 can be more or less wide, depending on the shape of elongated body 114 . Of course, main surface 152 can comprise any number of shapes and sizes, and need not exactly mirror the shape of elongated body 114 . As depicted in FIG. 1 , main surface 152 is of a length much less than the length of housing 108 . However, main surface 152 can comprise a longer relative portion of housing 108 , in embodiments.
[0069] Main surface 152 comprises one or more wiring apertures 158 . As depicted in FIG. 3A , wiring aperture 158 is circular and positioned roughly in the center of main surface 152 along, for example, along an axis B through main surface 152 . Wiring aperture 158 is configured to mirror the relative shape of access aperture 124 . Therefore, in another embodiment, wiring aperture 158 can comprise a square or any other shaped void. In embodiments, wiring aperture 158 is not centered within main surface 152 , and is instead offset along one of the elongated sides or offset along the width of main surface 152 . Similarly, in embodiments, main surface 152 can comprise a plurality of wiring apertures 158 .
[0070] Main surface 152 further comprises a plurality of coupling apertures 160 . Coupling apertures 160 are configured to receive a fastener for securing mounting bracket 104 . In an embodiment, for example, that depicted in FIG. 3A , coupling apertures 160 are of a type of slotted aperture. In embodiments, coupling apertures 160 can be of a shape other than a slot, for example, a circular void or any other suitable shape.
[0071] Coupling apertures 160 can be configured in myriad positions relative to main surface 152 . In an embodiment, coupling apertures 160 can be positioned with the lengthwise opening of the slot parallel with an elongated side of main surface 152 . In another embodiment, coupling apertures 160 can be orthogonal to an elongated side of main surface 152 . In another embodiment, main surface 152 can comprise some coupling apertures 160 running parallel to an elongated side of main surface 152 , and others running orthogonal to an elongated side of main surface 152 . Of course, in embodiments, coupling apertures 160 need not be perfectly parallel or orthogonal to an elongated side of main surface 152 . In another embodiment, two coupling apertures 160 intersect to form an X or cross shape. In other embodiments, two or more coupling apertures 160 intersect to form other aperture shapes.
[0072] In an embodiment, a plurality of coupling apertures 160 are configured on a single main surface 152 , having for example, eight coupling apertures 160 . As depicted in FIG. 3A , on one side of main surface 152 , three coupling apertures 160 are configured parallel to an elongated side of main surface 152 , and one coupling apertures 160 is configured orthogonal to an elongated side of main surface 152 . That configuration is mirrored on the opposing side of main surface 152 . In embodiments, there can be more or less coupling apertures 160 per main surface 152 , depending on the application of lighting system 100 and the mounting surface.
[0073] In an embodiment, referring to FIG. 3A , each elongated side of main surface 152 comprises two mounting bracket clips 154 . A first mounting bracket clip 154 is positioned along the first elongated side at a location proximate the first abbreviated side, for example, proximate an axis C through main surface 152 . A second mounting bracket clip 154 is positioned along the first elongated side at a location proximate the second abbreviated side, therefore distal the first mounting bracket clip 154 along the main surface 152 first elongated side. Similarly, a third mounting bracket clip 154 is positioned along the second elongated side at a location proximate the first abbreviated side, for example, along an axis C through main surface 152 . A fourth mounting bracket clip 154 is positioned along the second elongated side at a location proximate the second abbreviated side, therefore distal the third mounting bracket clip 154 along the main surface 152 second elongated side.
[0074] Each of a plurality of mounting bracket clips 154 generally comprises a leg 162 and a hook 164 . Leg 162 , in an embodiment, comprises a first portion 166 and a second portion 168 , with an angle of projection 170 presented at the junction between first portion 166 and main body 152 , and an angle of extension 172 presented at the junction of first portion 166 and second portion 168 .
[0075] First portion 166 is operably coupled to main surface 152 and projects at an angle of projection 170 from main surface 152 . Similar to the angle of attachment of first and second elongated sidewalls 116 a and 116 b to elongated body 114 , the angle of projection 170 of first portion 166 can be greater than 90 degrees with respect to the main surface 152 . However, in embodiments, angle of projection 170 from main surface 152 can be at an angle of 90 degrees or less, depending on the application. Angle of projection 170 generally mirrors the angle of attachment of first elongated sidewall 116 a to elongated body 114 and second elongated sidewall 116 b to elongated body 114 . Angle of projection 170 need not perfectly mirror the angle of attachment of first and second elongated sidewalls 116 a and 116 b , in embodiments, but, as depicted for example, in FIG. 6 , can be such that the respective first portions 166 of each leg 162 are flush with first and second elongated sidewalls 116 a and 116 b.
[0076] First portion 166 extends for a length similar to that of the projection of first or second elongated sidewalls 116 a and 116 b from elongated body 114 , in an embodiment. The length of first portion 166 is configured to interface with first or second elongated sidewalls 116 a and 116 b . As such, first portion 166 can be elongated or shortened, depending on the relative projection of first or second elongated sidewalls 116 a and 116 b from elongated body 114 . As described above with respect to first and second elongated sidewalls 116 a and 116 b , first portion 166 can extend for a length shorter than the width of main surface 152 , although lengths of first portion 166 that are shorter or longer than the depiction in FIGS. 1-3A are also possible. First portion 166 can be substantially rectangular, in embodiments.
[0077] Second portion 168 extends from first portion 166 . The junction between first portion 166 and second portion 168 creates an angle of extension 172 that mirrors the extension of lip 120 from housing 108 , and specifically, the extension of lip 120 from first elongated sidewall 116 a and second elongated sidewall 116 b . In an embodiment, angle of extension 172 can be greater than 90 degrees with respect to first portion 166 . However, in embodiments, angle of extension 172 from first portion 166 can be at an angle of 90 degrees or less, depending on the application. As depicted in FIG. 2 , second portion 168 is orthogonal to main surface 152 , thus creating an angle of extension 172 that is greater than 90 degrees relative to first portion 166 .
[0078] Second portion 168 extends for a length similar to that of the length of lip 120 , in an embodiment. Second portion 168 is therefore configured to interface with any extension of housing 108 beyond first or second elongated sidewalls 116 a and 116 b . As such, second portion 168 can be elongated or shortened, depending on the relative projection of housing 108 past the termination of sidewalls 116 a and 116 b . First portion 166 can be substantially rectangular, in embodiments.
[0079] In an embodiment, individual legs 162 , and specifically, individual first portions 166 can be connected by supporting member 174 as depicted in FIG. 3A , but can also be directly coupled to main surface 152 in other embodiments. Supporting member 174 can span the relative length of an elongated side of main surface 152 that is not spanned by each leg 162 and specifically, each first portion 166 so as to couple individual legs 162 on the same side, together. Supporting member 174 can have a similar or identical angle of projection 170 as that of first portion 166 with main surface 152 . Supporting member 174 can likewise extend from main surface 152 up to or longer than the extension of first portion 166 from main surface 152 .
[0080] In an embodiment, an angle of connection 176 is created between first portion 166 and supporting member 174 . Angle of connection 176 can provide additional stability to individual legs 162 , depending on its measure. Angle of connection 176 between first portion 166 and supporting member 174 can be relatively rounded, as depicted in FIG. 3A , but can be at sharp angles, in embodiments. The greater the relative angle of angle of connection 176 , the more support to individual legs 162 is provided, until reaching a maximum point of a straight connection between, for example, the junction of angle of extension 172 , and the relative intermediate point of supporting member 174 along an elongated side of main surface 152 . Angle of connection 176 can therefore be varied, depending on the embodiment.
[0081] Hook 164 is located at a distal end of leg 162 , and specifically, the end of second portion 168 distal the end of second portion 168 that extends from first portion 166 . Hook 164 extends back toward main surface 152 , in an embodiment. As such, hook 164 is configured to interface with lip 120 . In an embodiment, a portion of housing 108 , and likely lip 120 can be encompassed on two sides by hook 164 when so interfaced. In another embodiment, hook 164 extends back towards main surface 152 , and then orthogonal to the extension towards main surface 152 , such that a portion of hook 164 extends relatively parallel to second portion 168 . In an embodiment, a portion of housing 108 , and likely lip 120 , can be encompassed on three sides by hook 164 when so interfaced.
[0082] Mounting bracket 104 and its components can be made of can be made of, for example, stainless steel, reinforced polyester, or any non-conductive, insulative, or semi-conductive material or combination of materials. In embodiments, mounting bracket 104 is made of corrosion-protected metal.
[0083] Gasket 156 comprises a ring gasket operably coupled to main surface 152 in a ring surrounding wiring aperture 158 . Gasket 156 can span any length of main surface 152 surrounding wiring aperture 158 , as appropriate. Gasket 156 has a depth that is compressible and configured to interface to the surface of housing 108 , and specifically elongated body 114 . Gasket 156 is therefore configured to provide a seal between the mounting surface, the surface of main surface 152 , and the surface of housing 108 , and specifically elongated body 114 . Such a seal protects wiring aperture 158 and the wiring passing therethrough. In an embodiment, as depicted in FIG. 3A , gasket 156 comprises a substantially rectangular gasket. In embodiments of main surface 152 having multiple wiring apertures 158 , multiple gaskets 156 can likewise be operably coupled to main surface 152 . Gasket 156 can be made of, for example, neoprene closed cell foam, or any other water-repelling foam, sponge, rubber, or other suitable material. In embodiments, gasket 156 can be made of any other suitable UL approved or tested material.
[0084] Optionally, one or more bumpers 178 can be positioned along main surface 152 . In an embodiment, bumpers 178 are circular, as depicted in FIG. 3A . In other embodiments, bumpers 178 can be any other shape suitable for the relative main surface 152 to which they are mounted, and for the relative application in which mounting bracket 104 is placed. Each bumper 178 has a depth similar to that of gasket 156 that is compressible and configured to interface to the surface of housing 108 , and specifically elongated body 114 . Because, in embodiments, bumpers 178 are spread along the length of main surface 152 , a relatively uniform compression is achieved when main surface 152 is interfaced with elongated body 114 . Bumpers 178 can be made of, for example, neoprene closed cell foam, or any other water-repelling foam, sponge, rubber, or other suitable material. Bumpers 178 can also be identified as supporting gaskets.
[0085] Optionally, mounting bracket 104 can further comprise one or more fasteners 180 and related mounting hardware. Fasteners 180 and mounting hardware are configured to be received by coupling apertures 160 through main surface 152 and into a mounting surface to secure mounting bracket 104 to the mounting surface. For example, referring to FIG. 1 , fastener 180 can comprise a screw. Other fasteners are also considered. In embodiments, mounting hardware can further comprise a washer to interface with a portion of main surface 152 , and specifically, the portion proximate an individual coupling aperture 160 to which fastener 180 is positioned through.
[0086] Junction box 106 comprises a frame 182 and a plurality of supply conductors 184 . Frame 182 comprises a box or walled container configured to contain supply conductors 184 and other electrical connections. Frame 182 can therefore comprise any number of shapes. For example, as depicted in FIGS. 2 , 5 , and 6 , junction box 106 comprises a square or rectangular container. In another embodiment, junction box 106 can comprise a circularly-walled container. In embodiments, junction box 106 can be made of metal or plastic. In an embodiment, junction box 106 can be recessed in a ceiling or wall, or other mounting surface, such that the mounting surface substantially covers the walls of junction box 106 , but is open or apertured where supply conductors 184 are positioned within. Supply conductors 184 comprise wiring that is configured to carry electric charges. As such, supply conductors 184 are operably coupled to a power supply configured with appropriate power to light one or more lamps 113 .
[0087] In another embodiment, referring to FIGS. 3B and 4 , a lighting system 200 generally includes mounting bracket 104 , lighting fixture 202 , supplemental mounting bracket 204 , and junction box 206 .
[0088] Lighting fixture 202 comprises housing 208 , geartray 110 , lens 112 , and one or more lamps 113 . Lighting fixture 202 is substantially the same as lighting fixture 102 , with differences described herein. Specifically, lighting fixture 202 comprises an offset access aperture 224 within elongated body 214 of housing 208 , as described above with respect to housing 108 .
[0089] Supplemental mounting bracket 204 can provide additional support for certain lighting fixtures 202 and lighting systems 200 when used alone or in combination with mounting bracket 104 . Supplemental mounting bracket 204 generally comprises a mounting plate 251 having a main surface 252 , mounting bracket clip 254 , and one or more optional bumpers 278 . Additionally, supplemental mounting bracket 204 can optionally comprise one or more fasteners 280 .
[0090] Main surface 252 is substantially the same as main surface 152 , but adapted to be of a size appropriate for supplemental mounting bracket 204 . Main surface 252 is substantially flat and substantially rectangular. In an embodiment, as depicted in FIG. 3B , main surface has a having a width greater than a length, according to the same measuring style of main surface 152 , in an embodiment. Main surface 252 is configured to mirror the relative shape of housing 208 , and specifically elongated body 214 . Other embodiments of main surface 252 can be more or less elongated, depending on the shape of elongated body 214 . Further, the width sides of main surface 252 can be more or less wide, depending on the shape of elongated body 214 . Of course, main surface 252 can comprise any number of shapes and sizes, and need not exactly mirror the shape of elongated body 214 . As depicted in FIG. 3B , main surface 252 is of a length much less than the length of housing 208 . However, main surface 252 can comprise a longer relative portion of housing 208 , in embodiments.
[0091] Main surface 252 further comprises a plurality of coupling apertures 260 . Coupling apertures 260 are substantially the same as coupling apertures 260 , but are configured to receive a fastener for securing supplemental mounting bracket 204 . In an embodiment, for example, that depicted in FIG. 3B and in the center of main surface 252 , coupling apertures 260 are of a type of slotted aperture. In embodiments, coupling apertures 260 can be of a shape other than a slot, for example, a circular void or any other suitable shape, such as those in the relative corners of main surface 252 .
[0092] Coupling apertures 260 can be configured in myriad positions relative to main surface 252 . In an embodiment, coupling apertures 260 can be positioned in the center of main surface 252 . In another embodiment, coupling apertures 260 can be positioned in the relative corners of main surface 252 . In other embodiments, coupling apertures 260 can slotted apertures parallel or orthogonal to a side of main surface 252 , or comprise X or cross shaped apertures, as described above with respect to main surface 152 .
[0093] In an embodiment, a plurality of coupling apertures 260 are configured on a single main surface 252 , having for example, five coupling apertures 260 , as depicted in FIG. 3B . In embodiments, there can be more or less coupling apertures 260 per main surface 252 , depending on the application of lighting system 200 and the mounting surface.
[0094] Mounting bracket clip 254 is substantially the same as mounting bracket clip 154 . Supplemental mounting bracket 204 therefore comprises two mounting bracket clips 254 . A first mounting bracket clip 254 is positioned along a side corresponding to an elongated side of housing 208 , and a second mounting bracket clip 254 is positioned along the opposing elongated side of housing 208 .
[0095] Mounting bracket clip 254 generally comprises a leg 262 substantially the same leg 162 and a hook 264 substantially the same as hook 164 . Leg 262 , in an embodiment, comprises a first portion 266 substantially the same as first portion 166 and a second portion 268 substantially the same as second portion 168 , with an angle of projection 270 at the junction between first portion 266 and main body 252 substantially the same as angle of projection 170 , and an angle of extension 272 at the junction of first portion 266 and second portion 268 substantially the same as angle of extension 172 .
[0096] One or more bumpers 278 substantially the same as bumpers 178 can be positioned along main surface 252 . Just as with bumpers 178 , bumpers 278 can be circular, in an embodiment, as depicted in FIG. 3B .
[0097] Each bumper 278 has a depth similar to that of gasket 156 and bumper 178 that is compressible and configured to interface to the surface of housing 208 , and specifically elongated body 214 . Bumpers 278 therefore allow supplemental mounting bracket 204 to be coupled at the same distance relative to housing 208 as mounting bracket 104 , because the same depth of material is interfaced between main surface 152 and housing 208 as is main surface 252 with housing 208 . Bumpers 278 can be made of, for example, neoprene closed cell foam, or any other water-repelling foam, sponge, rubber, or other suitable material.
[0098] Optionally, supplemental mounting bracket 204 can further comprise one or more fasteners 280 and related mounting hardware. Fasteners 280 and related mounting hardware are substantially the same as fasteners 180 , and are configured to be received by coupling apertures 260 through main surface 252 and into a mounting surface to secure supplemental mounting bracket 204 to the mounting surface. For example, referring to FIG. 5 , fastener 280 can comprise a screw. Other fasteners are also considered. In embodiments, mounting hardware can further comprise a washer to interface with a portion of main surface 252 , and specifically, the portion proximate an individual coupling aperture 260 to which fastener 280 is positioned through.
[0099] Junction box 206 is substantially the same as junction box 106 , with differences described herein. Specifically, junction box 106 is positioned at a location within the mounting surface such that it is near a wall or other obstruction, for example. In such an embodiment, lighting fixture 202 may not be able to be centered on mounting bracket 104 , and instead is mounted to one side of lighting fixture 202 .
[0100] In operation, referring generally to FIGS. 1 and 5 - 8 , the lighting system installation is done in a direction relatively orthogonal to the mounting surface, for example, along axis A of FIG. 1
[0101] At a step 302 , mounting bracket 104 is affixed to the mounting surface. Mounting bracket 104 is positioned directly under recessed junction box 106 where lighting fixture 102 is to be installed. Using coupling apertures 160 as a template, one or more fasteners 180 are secured through coupling apertures 160 to secure mounting bracket 104 to the mounting surface. In an embodiment, at least two fasteners 180 are used, with one fastener 180 positioned through main surface 152 at an area proximate a first set of mounting bracket clips 154 , and a second fastener 180 positioned through main surface 152 at an area proximate a second set of mounting bracket clips 154 . In an embodiment, washers contact main surface 152 to provide more coverage area to each fastener 180 than the fastener head. In another embodiment, three or more fasteners 180 are utilized. Mounting bracket 104 is thus operably coupled to the mounting surface, for example, as depicted in FIG. 5 .
[0102] At a step 304 , lens 112 is then removed from housing 108 by unsnapping lens 112 from housing 108 . In another embodiment, lens 112 is removed from housing 108 by opening or unsnapping latches located on the side of housing 108 .
[0103] At a step 306 , geartray 110 is removed from housing 108 by operation of retaining clips 122 . Specifically, in an embodiment, retaining clips 122 are squeezed together on the top of geartray 110 to free geartray 110 from housing 108 . In an embodiment, a first set of retaining clips 122 are squeezed together to free one side of geartray 110 , then a second set of retaining clips 122 are squeezed together to free the opposite side of geartray 110 . Geartray 110 can then be rotated backwards to expose ballast 140 and fixture wiring 142
[0104] At a step 308 , housing 108 is coupled to mounting bracket 104 . Housing 108 is positioned such that it is centered on mounting bracket 104 . In an embodiment, housing 108 is centered such that mounting bracket clips 154 are positioned just inside latch-mounting members 130 located on the sides of housing 108 . Housing 108 is pushed into mounting bracket 104 , and specifically, main surface 152 . In an embodiment, housing 108 can be secured in mounting bracket 104 by pushing first elongated sidewall 116 a and elongated body 114 into a pair of mounting bracket clips 154 —a first mounting bracket clip 154 positioned along the first elongated side at a location proximate the first abbreviated side and second mounting bracket clip 154 positioned along the first elongated side at a location proximate the second abbreviated side. Specifically, the angle created by first elongated sidewall 116 a and elongated body 114 is aligned to angle of projection 170 . Correspondingly, first portion 166 of leg 162 is aligned to first elongated sidewall 116 a and second portion 168 is aligned to lip 120 . Hook 164 secures the portion of lip 120 coupled to first elongated sidewall 116 a . Angle of projection 170 and angle of extension 172 , combined with hook 164 and the extension of first portion 166 , and the extension of second portion 168 of leg 162 provide resilient engagement of housing 108 .
[0105] Housing 108 can be slightly rotated to push second elongated sidewall 116 b and elongated body 114 toward main surface 152 until second elongated sidewall 116 b and the portion of lip 120 coupled to second elongated sidewall 116 b snaps into a second pair of mounting bracket clips 154 . As the respective hooks 164 of the second set of mounting bracket clips 154 secures second elongated sidewall 116 b , the angle created by second elongated sidewall 116 b and elongated body 114 is aligned to the respective angle of projection 170 of the second set of mounting bracket clips 154 . Likewise, first portion 166 of leg 162 is aligned to second elongated sidewall 116 b and second portion 168 is aligned to lip 120 . Gasket 156 and bumpers 178 are compressed and provide a sealed interface to housing 108 .
[0106] Geartray 110 can then be operably coupled to housing 108 via optional tether on geartray 110 , and alignment tab 128 , in an embodiment.
[0107] At a step 310 , supply conductors 184 are connected to fixture wiring 142 . Supply conductors 184 are fed from junction box 106 through mounting bracket 104 via wiring aperture 158 and through housing 108 via access aperture 124 . Supply conductors 184 can then be operably coupled to fixture wiring 142 . In an embodiment, supply conductors 184 are connected directly to fixture wiring 142 comprising a luminaire disconnect. In embodiments, the optional tether holds geartray 110 near housing 108 so as to not overextend fixture wiring 110 , ballast 140 , or junction box supply conductors 184 .
[0108] At a step 312 , geartray 110 is reinstalled into housing 108 . Geartray 110 is repositioned to align with retaining clips 122 . Once so positioned, geartray 110 can be pushed towards housing 108 until it snaps into a locked position.
[0109] At a step 314 , one or more lamps 113 can then be operably coupled to one or more lampholder projections 138 into a final lighting configuration within lighting fixture 102 .
[0110] At a step 316 , lens 112 can be snapped back into housing 108 . In another embodiment, latches can be re-snapped or re-secured to reinstall lens 112 .
[0111] Finally, at step 318 , power can be applied to one or more lamps 113 via supply conductors 184 , ballast 140 , and fixture wiring 140 to illuminate lighting fixture 102 .
[0112] Referring to the embodiment of FIG. 4 and lighting system 200 , mounting bracket 104 is installed as described above, but lighting fixture 202 is positioned such that housing 208 , and specifically, wiring aperture 258 is aligned with junction box 206 .
[0113] Further, supplemental mounting bracket 204 is positioned in line with mounting bracket 104 , as shown in FIG. 4 to provide support for the end of lighting fixture 202 distal the end coupled to mounting bracket 104 . As such, subsequent to step 302 , supplemental mounting bracket 204 is affixed to the mounting surface. Referring to FIG. 6 , using coupling apertures 260 as a template, one or more fasteners 280 are secured through coupling apertures 260 to secure mounting bracket 204 , and specifically, main surface 252 to the mounting surface. In an embodiment, one fastener 280 is utilized, although main surface 252 provides for additional fasteners 280 . Installation can then proceed as described above, with the installer aligning housing 208 into both mounting bracket 104 and supplemental mounting bracket 204 .
[0114] Various embodiments of systems, devices and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the invention. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the invention.
[0115] Persons of ordinary skill in the relevant arts will recognize that the invention may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the invention may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the invention may comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art.
[0116] Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein. | A mounting bracket for mounting “wet” location lighting fixtures. In embodiments, a mounting bracket allows a light fixture to be installed over a new or existing junction box. Gasketing and a plurality of bumpers provide a waterproof fit between the fixture and the junction box. In an embodiment, a lighting fixture system comprising a junction box, a lighting fixture, and a mounting bracket is presented. In another embodiment, a method of installing a lighting system to a mounting surface is presented. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an electrostatic discharge (ESD) protection device.
2. Description of the Prior Art
With the continued miniaturization of integrated circuit (IC) devices, the current trend in the sub-quarter-micron complementary metal-oxide semiconductor (CMOS) industry is to produce integrated circuits having shallower junction depths, thinner gate oxides, lightly-doped drain (LDD) structures, shallow trench isolation (STI) structures, and self-aligned silicide (salicide) processes. Nevertheless, all of these processes cause the related CMOS IC products to become more susceptible to electrostatic discharge (ESD) damage. Therefore, ESD protection circuits are built onto the chip to protect the devices and circuits of the IC against ESD damage. It is generally desired that the ESD robustness for commercial IC products be higher than 2 kV in human-body-model (HBM) ESD stress, and in order to sustain ESD overstress, devices with large dimensions need to be designed into the on-chip ESD protection circuit, and require a large total layout area on the silicon substrate.
Typically, the NMOS of an I/O ESD protection circuit has a total channel width of greater than 300 μm. With such large device dimensions, the NMOS is often realized with multiple fingers in the layout. However, under ESD stress, the multiple fingers of ESD protection NMOS do not uniformly turn on to bypass the ESD current. Only a portion of the fingers of the NMOS may be turned on, and consequently lead to damage from the ESD pulse. In this case, although the ESD protection NMOS has a very large device dimension, the ESD protection level is low.
In order to improve the turn-on uniformity among the multiple fingers, a gate-driven design has been commonly used to increase the protection level of the ESD protection device within large scale NMOS devices. However, it has been found that the ESD protection level of the gate-driven NMOS decreases dramatically when the gate voltage is somewhat increased. As it turns out, the gate-driven design pulls ESD current flowing through the channel surface of the NMOS. The NMOS is thus more easily burnt-out by the ESD energy.
Please refer to FIG. 1 . FIG. 1 is a schematic circuit diagram of a conventional ESD protection design by utilizing a gate-driven technique. Since all ESD protection designs using the gate-driven technique have the same basic idea, they may be generally illustrated as disclosed in FIG. 1 . As shown in FIG. 1 , the ESD protection circuit design 10 includes an ESD protection NMOS 12 . The NMOS 12 includes a source 13 , a drain 14 and a gate 16 . The drain 14 of the NMOS 12 is electrically connected to a pad 18 and the gate 16 is biased by a gate-biasing circuit 20 . The gate-biasing circuit 20 is typically designed with a coupled capacitor (not shown) electrically connected from the pad 18 to the gate and a resistor (not shown) electrically connected from the gate 16 to a V SS power terminal. Additionally, an internal circuit 22 is electrically connected to the pad 18 through a conductor 23 .
When a positive ESD voltage zaps the pad 18 , a sharp-rising ESD voltage pulse is coupled to the gate 16 of the ESD protection NMOS 12 . The ESD protection NMOS 12 is thus turned on to discharge the ESD current from the pad 18 to the V SS power terminal. This is the so-called gate-coupled design or gate-driven design. The gate bias improves the turn-on uniformity of the multiple fingers of the ESD protection NMOS, but an excessive gate bias also causes the ESD current to flow through the inversion layer of the surface channel of the ESD protection NMOS 12 , which can burn out the channel of the NMOS 12 .
Please refer to FIG. 2 . FIG. 2 is a schematic diagram of an ESD current path flowing through a gate-driven NMOS device. As shown in FIG. 2 , an ESD protection NMOS device 30 includes a P substrate 31 , a P-well 32 in the P substrate 31 , and an NMOS transistor 34 in the P-well 32 . The NMOS transistor 34 includes a source 35 , a drain 36 and a doped polysilicon gate 37 , and two lightly doped drains (LDD) 38 adjacent to the source 35 and drain 36 respectively. The source 35 region is electrically connected to a V SS power terminal, the drain 36 region is electrically connected to a pad 40 , and the gate 37 region is electrically connected to a gate-biasing circuit 42 . In FIG. 2 , ESD damage is often located at the surface channel close to the LDD 38 edge of the drain 36 .
The gate-biasing circuit 42 generates a high voltage (V G ) to bias the gate 37 of the NMOS transistor 34 during positive ESD zapping events. The generated V G gate voltage turns on the surface channel of the NMOS. Unfortunately, the surface channel of the NMOS 34 having a structure with a much shallower junction depth and smaller volume is more susceptible to ESD damage. As a result, the overheating caused by the damage may also damage the NMOS 34 itself. The ESD damage is often located at the surface channel close to the LDD 38 corner of the drain 36 . In general, a large ESD current (typically 1.33 Amp, for a 2 kV HMB ESD event) flowing through the very shallow surface channel of the NMOS transistor 34 often burns out the NMOS transistor 34 even if the NMOS 34 has large device dimensions.
Please refer to FIG. 3 . FIG. 3 is a perspective diagram showing the means of forming a diffusion region below the well of a conventional ESD protection device. As shown in FIG. 3 , in order to reduce the burnout of the surface channel of the NMOS 34 , a P+ diffusion region 33 is often formed below the drain 36 of the conventional ESD protection device 30 to lower the breakdown voltage of the PN junction formed between the drain 36 and the P-well 32 . Since the P+ diffusion region 33 is formed below the drain 36 , processes including a deep well fabrication process, a salicide block (SAB) mask, and an ion implantation have to be performed or utilized to lower the breakdown voltage between junctions to improve the efficiency of the ESD protection device, and thereby increase the complexity of the fabrication processes and cause misalignment problems.
SUMMARY OF THE INVENTION
It is therefore an objective of the present invention to provide an ESD protection device for solving the above-mentioned problems.
According to the present invention, an electrostatic discharge (ESD) protection device, wherein the ESD protection device is disposed on a substrate, the ESD protection device comprises: at least a first conductive type metal-oxide semiconductor (MOS), in which the drain and source of the first conductive type MOS are electrically connected to a first power terminal and a second power terminal separately; at least a second conductive type diffusion region; and at least a dummy gate disposed between the first conductive type MOS and the second conductive type diffusion region, in which the gate length of the dummy gate is less than the gate length of the first conductive type MOS gate, such that the junction between the second conductive type diffusion region and the drain of the first conductive type MOS have a low breakdown voltage.
Additionally, the present invention discloses another electrostatic discharge (ESD) protection device, in which the ESD protection device is disposed on a substrate, and the ESD protection device further includes: at least a first conductive type metal-oxide semiconductor (MOS), in which the drain and source of the first conductive type MOS are electrically connected to a first power terminal and a second power terminal separately; at least a second conductive type diffusion region; and at least a first conductive type lightly doped drain (LDD) disposed adjacent to the first conductive type MOS and the second conductive type diffusion region, such that the junction between the second conductive type diffusion region and the drain of the first conductive type MOS have a low breakdown voltage.
In contrast to the conventional ESD protection device, the present invention discloses an ESD protection device structure by forming an N+ diffusion region and a P+ diffusion region separately on each end of the dummy gate for decreasing the breakdown voltage of the PN junction. Consequently, when the length of the dummy gate is decreased to a certain degree, the concentration of the PN junction created by the N+ diffusion region and the P+ diffusion region will be increased thereby greatly reducing the junction breakdown voltage and improving the overall efficiency of the ESD protection device.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic circuit diagram of a conventional ESD protection design by utilizing a gate-driven technique.
FIG. 2 is a schematic diagram of an ESD current path flowing through a gate-driven NMOS device.
FIG. 3 is a perspective diagram showing the means of forming a diffusion region below the well of a conventional ESD protection device.
FIG. 4 is a perspective diagram showing the ESD protection device according to the first embodiment of the present invention.
FIG. 5 is a perspective diagram showing the ESD protection device according to the second embodiment of the present invention.
FIG. 6 is a perspective diagram showing the ESD protection device according to the third embodiment of the present invention.
FIG. 7 is a perspective diagram showing the ESD protection device according to the fourth embodiment of the present invention.
DETAILED DESCRIPTION
Please refer to FIG. 4 . FIG. 4 is a perspective diagram showing an ESD protection device 90 according to the first embodiment of the present invention. As shown in FIG. 4 , the ESD protection device 90 is formed on the P-well 92 of a substrate 91 , in which the ESD protection device 90 includes two NMOS devices 93 , an I/O buffering pad (not shown) and a V SS power terminal (not shown) electrically connected to the NMOS device 93 , a P+ diffusion region 100 , two P+ diffusion regions 99 , and two dummy gates 98 disposed between the NMOS device 93 and P+ diffusion region 100 . Preferably, the substrate 91 can be a P-type substrate or an N-type substrate and each of the NMOS devices 93 also includes a drain 96 electrically connected to the I/O buffering pad, a source 95 electrically connected to the V SS power terminal, and a doped polysilicon gate 94 . As shown in FIG. 4 , the P+ diffusion region 100 is in the same side as the drain 96 with respect to the source 95 , and the gate length of the dummy gates 98 is less than the gate length of the doped polysilicon gate of the NMOS device 93 . Additionally, the ESD protection device 90 further includes a plurality of shallow trench isolations (STI) 97 for separating the source 95 of the NMOS device 93 from the P+ diffusion region 99 , which has been serving as a pickup end of the P-type well 92 .
Ideally, the present invention is able to utilize the same P-type ion implantation process and mask patterns of other PMOS devices on the substrate 91 and the dummy gates 98 to form and self align the P+ diffusion region 100 and increase the concentration of the PN junction created between the N+ diffusion region (i.e. the drain 96 ) and the P+ diffusion region 100 , thereby decreasing the breakdown voltage of the PN junction and improving the efficiency of the ESD protection device 90 . By eliminating the utilization of an extra salicide block mask and an ion implantation process for forming the P+ diffusion region 100 , the present invention is able to effectively reduce the complexity and misalignment problem of the conventional ESD protection device. Moreover, the efficiency will be even greater if the length of the dummy gates 98 is further decreased.
In general, after an ESD voltage pulse is applied to the I/O buffering pad, the drain 96 of the NMOS device 93 and the P-well 92 will form a PN junction with a low breakdown voltage. Since the drain 96 and the source 95 of the NMOS device 93 and the P-well 92 form a parasitic lateral NPN bipolar junction transistor (BJT), the ESD voltage pulse will be directed from the drain 96 to the P+ diffusion region 100 , from the P+ diffusion region 100 to the P-well 92 below the dummy gate 98 , from the dummy gate 98 to the source 95 , and will finally exit via the V SS power terminal.
Please refer to FIG. 5 . FIG. 5 is a perspective diagram showing the ESD protection device 110 according to the second embodiment of the present invention. As shown in FIG. 5 , an ESD protection device 110 is formed on the N-well 112 of a substrate 111 , in which the ESD protecting device 110 includes two PMOS devices 113 , an I/O buffering pad (not shown) and a V SS power terminal (not shown) electrically connected to the PMOS device 113 , an N+ diffusion region 120 , two N+ diffusion regions 119 , and two dummy gates 118 disposed between the PMOS device 113 and N+ diffusion region 120 . Preferably, the substrate 111 can be a P-type substrate or an N-type substrate and each of the PMOS devices 113 also includes a drain 116 electrically connected to the I/O buffering pad, a source 115 electrically connected to the V SS power terminal, and a doped polysilicon gate 114 . As shown in FIG. 5 , the N+ diffusion region 120 is in the same side as the drain 116 with respect to the source 115 , and the gate length of the dummy gates 118 is less than the gate length of the doped polysilicon gate of the PMOS device 113 . Additionally, the ESD protection device 110 further includes a plurality of shallow trench isolations (STI) 117 for separating the source 115 of the PMOS device 113 from the N+ diffusion region 119 , which has been serving as a pickup end of the N-type well 112 .
Similarly, after an ESD voltage pulse is applied to the I/O buffering pad, the drain 116 of the PMOS device 113 and the N-well 112 will form a PN junction with a low breakdown voltage. Since the drain 116 and the source 115 of the PMOS device 113 and the N-well 112 form a parasitic lateral PNP bipolar junction transistor (BJT), the ESD voltage pulse will be directed from the drain 116 to the P+ diffusion region 120 via the PN junction, from the P+ diffusion region 120 to the N-well 112 below the dummy gate 118 , from the N-well 112 to the source 115 , and will finally exit via the V SS power terminal.
Please refer to FIG. 6 . FIG. 6 is a perspective diagram showing the ESD protection device 130 according to the third embodiment of the present invention. As shown in FIG. 6 , an ESD protection device 130 is formed on the P-well 132 of a substrate 131 , in which the ESD protection device 130 includes two NMOS devices 133 , an I/O buffering pad (not shown) and a V SS power terminal (not shown) electrically connected to the NMOS device 133 , a P+ diffusion region 140 , two P+ diffusion regions 139 , and two N+ lightly doped drains (NLDD) 138 disposed between the NMOS device 133 and P+ diffusion region 140 . Preferably, the substrate 131 can be a P-type substrate or an N-type substrate and each of the NMOS devices 133 also includes a drain 136 electrically connected to the I/O buffering pad, a source 135 electrically connected to the V SS power terminal, and a doped polysilicon gate 134 . Additionally, the ESD protection device 130 further includes a plurality of shallow trench isolations (STI) 137 for separating the source 135 of the NMOS device 133 from the P+ diffusion region 139 .
In contrast to the previous embodiments, the two NLDDs 138 formed between the NMOS device 133 and the P+ diffusion region 140 are utilized for replacing the two dummy gates 98 and 118 from the previous embodiments, such that the distance between the P+ diffusion region 140 and the adjacent NLDDs 138 will become smaller, thereby facilitating the ESD protection device to be utilized in sub 90 nm fabrication processes. Additionally, the present embodiment is able to utilize the same P-type ion implantation process and mask patterns from other PMOS devices on the substrate 131 and the same ion implantation process and mask patterns required for the lightly doped drains of other NMOS devices on the substrate 131 to form the P+ diffusion region 140 and the two NLDDs 138 for increasing the concentration of the PN junction created between the N+ diffusion region (i.e. the drain 136 ) and the P+ diffusion region 140 , decreasing the breakdown voltage of the PN junction, and improving the efficiency of the ESD protection device 130 . By eliminating the utilization of an extra salicide block mask and an ion implantation process for forming the P+ diffusion region 140 , the present embodiment is able to effectively reduce the complexity and misalignment problem of the conventional ESD protection device.
Similar to the previous embodiments, after an ESD voltage pulse is applied to the I/O buffering pad, the voltage pulse will be directed from the drain 136 to the P+ diffusion region 140 via the NLDD 138 , from the P+ diffusion region 140 to the P-well 132 below the NLDD 138 , from the P-well 132 to the source 135 , and will finally exit via the V SS power terminal.
Please refer to FIG. 7 . FIG. 7 is a perspective diagram showing the ESD protection device 150 according to the fourth embodiment of the present invention. As shown in FIG. 7 , an ESD protection device 150 is formed on the N-well 152 of a substrate 151 , in which the ESD protecting device 150 includes two PMOS devices 153 , an I/O buffering pad (not shown) and a V SS power terminal (not shown) electrically connected to the PMOS device 153 , an N+ diffusion region 160 , two N+ diffusion regions 159 , and two P+ lightly doped drains (PLDD) 158 disposed between the PMOS device 153 and N+ diffusion region 160 . Preferably, the substrate 151 can be a P-type substrate or an N-type substrate and each of the PMOS devices 153 also includes a drain 156 electrically connected to the I/O buffering pad, a source 155 electrically connected to the V SS power terminal, and a doped polysilicon gate 154 . Additionally, the ESD protection device 150 further includes a plurality of shallow trench isolations (STI) 157 for separating the source 155 of the PMOS device 153 from the N+ diffusion region 159 .
Similar to the third embodiment of the present invention, the two PLDDs 138 formed between the NMOS device 133 and the P+ diffusion region 140 are utilized for replacing the two dummy gates 98 and 118 from the previous embodiments. Hence after an ESD voltage pulse is applied to the I/O buffering pad, the voltage pulse will be directed from the drain 156 to the N+ diffusion region 160 via the PLDD 158 , from the N+ diffusion region 160 to the N-well 152 below the PLDD 158 , from the N-well 152 to the source 155 , and will finally exit via the V SS power terminal.
In contrast to the conventional ESD protection device, the present invention discloses an ESD protection device structure by forming an N+ diffusion region and a P+ diffusion region separately on each end of the dummy gate for decreasing the breakdown voltage of the PN junction. As a result, when the length of the dummy gate is decreased to a certain degree, the concentration of the PN junction created by the N+ diffusion region and the P+ diffusion region will be increased respectively, thereby greatly reducing the junction breakdown voltage and improving the overall efficiency of the ESD protection device. For instance, the breakdown voltage of a normal PN junction usually lies around 9V and when the length of the dummy gate of the present invention decreases to approximately 0.15 μm, the junction breakdown voltage is able to be reduced to 6V. Eventually, users are able to selectively manipulate the length of the dummy gate such that the junction breakdown voltage is around 7V to control the common working voltage of the ESD protection device to be under 3.3V for achieving optimal performance and stability. Additionally, the present invention also discloses a structure of forming two N+ lightly doped drains between each NMOS and the P+ diffusion region, or alternatively, forming two P+ lightly doped drains between each PMOS and the N+ diffusion region for replacing the two dummy gates and serving as a bridge between the diffusion regions and other devices, thereby reducing the complexity of fabrication processes, decreasing the PN junction breakdown voltage, and improving the overall effectiveness of the ESD protection device.
Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | An electrostatic discharge (ESD) protective device structure. The ESD protection device includes: at least a first conductive type metal-oxide semiconductor (MOS), in which the drain and source of the first conductive type MOS are electrically connected to a first power terminal and a second power terminal separately; at least a second conductive type diffusion region; and at least a dummy gate disposed between the first conductive type MOS and the second conductive type diffusion region, wherein the gate length of the dummy gate is less than the gate length of the first conductive type MOS gate, such that the junction between the second conductive type diffusion region and the drain of the first conductive type MOS have a low breakdown voltage. | 7 |
This application is a continuation of application Ser. No. 08/541,041, filed Oct. 11, 1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to conversion of film to video, post-production of video, conversion of video to film, and conversion between different video formats.
2. Description of the Prior Art
A vast amount of film masters are in a 24 frame/s or 25 frame/s format, and often it is required to convert the film to video for distribution, post-production and broadcast transmission, and to convert the video back to film as a sub-master. One standard format for video employs interlaced fields at 60 field/s. For example, the SMPTE 240M high definition format employs 1125 line/frame, 2:1 interlace, 60 field/s. Because of the difference in frame rate between the film and video, there is no one-to-one correspondence between the film frames and the video frames, and this presents a problem.
A partial solution to this problem in the case of 24 frame/s film (and also 25 frame/s film if a slightly incorrect speed is not unacceptable) is to use a 3232 format for the video. With 3232, there is a correspondence between a series of four film frames and ten video fields as follows:
Film
Video
Frame 1
Frame 1 odd field
Frame 1
Frame 1 even field
Frame 1
Frame 2 odd field (additional)
Frame 2
Frame 2 even field
Frame 2
Frame 3 odd field
Frame 3
Frame 3 even field
Frame 3
Frame 4 odd field
Frame 3
Frame 4 even field (additional)
Frame 4
Frame 5 odd field
Frame 4
Frame 5 even field
It will therefore be appreciated that the real-time relationship between 24 frame/s film and 60 field/s video is maintained (at least when averaged over a four film frame period), but that two of the video fields, frame 2 odd and frame 4 even, are duplicated, and so the fields of video frame 2 do not correspond to a single film frame and likewise with the fields of video frame 3 . During post-production of 3232 video, for example combining two 3232 video signals, there is the problem of synchronising the additional fields of the signals, so that if the video is later converted back to film the additional fields can be dropped and the other fields can all be maintained. Subsequent conversion to 50 field/s video compounds the problem, because every sixth field needs to be dropped. Sometimes the dropped field will be an additional field, and sometimes it will not.
SUMMARY OF THE INVENTION
The video signal according to the invention
In accordance with one aspect of the present invention, there is provided a video signal, such as a 1125 lines/frame high definition video signal, representing material which is acquired or generated at a real-time rate, wherein the video signal is in a 60 field/s format at 1.25 or 1.2 times the real-time rate. Such a video signal will hereinafter be referred to as a “gateway” video signal.
The gateway video signal provides a number of advantageous possibilities, including:
frame-locked transfer of material from real-time 24 frame/s and 25 frame/s film to the gateway format;
frame-accurate post-production editing not requiring a 3232 relationship and retaining the gateway format;
real-time post-production editing with a synchronised 3232 relationship between different sources and the product; and
frame-locked transfer of material from the gateway format to real-time 24 frame/s or 25 frame/s film and 50 field/s video.
In the case where source material is 24 frame/s film, the gateway video signal is at 1.25 times the real-time rate, hereinafter referred to as a “125% gateway” signal. In the case where the source material is 25 frame/s film, the gateway video signal is at 1.2 times the real-time rate, hereinafter referred to as a “120% gateway” signal.
Conversion of film to Gateway video
Very conveniently, a 30 frame/s telecine may be used to produce a 125% gateway signal from 24 frame/s film, and to produce a 120% gateway signal from 25 frame/s film.
Conversion of conventional 60 Hz video to Gateway video
The invention also provides a (first) method of converting a source 60 field/s video signal to a gateway video signal, comprising the step of dropping every fifth field from the source signal for 125% gateway video or dropping every sixth field from the source signal for 120% gateway video.
The invention furthermore provides a (first) apparatus for reproducing a gateway video signal from a source 60 field/s video signal recording, the apparatus including means for reproducing and outputting four out of every five fields of the recorded video signal for a 125% gateway signal, or five out of every six fields of the recorded video signal for a 120% gateway signal. Preferably, said reproducing and outputting means comprises means for reproducing the recording at 75 field/s for 125% gateway or 72 field/s for 120% gateway, and means for outputting four out of every five, or five out of every six, as the case may be, of the reproduced fields at 60 field/s.
Conversion of Gateway video to film.
Very conveniently, a 30 frame/s electron beam recorder (“EBR”) may be used to produce a film from a gateway signal. In the case of 125% gateway video, this will produce film whose proper speed is 24 frame/s, but for which viewing at 25 frame/s may be acceptable in many cases. In the case of 120% gateway video, this will produce film whose proper speed is 25 frame/s, but for which viewing at 24 frame/s may be acceptable in many cases.
Conversion of Gateway video to normal speed 60 field/s video
The invention provides a (second) method of converting a gateway video signal to a second real-time, or nearly real-time, 60 field/s video signal, comprising the step of duplicating every fourth field of the gateway signal to produce the second signal. This produces a real-time signal from a 125% gateway video signal, and a signal which is 0.96 of real-time from a 120% gateway signal. This method preferably further comprises the step of keeping track of the duplicated fields.
The invention also provides a (second) apparatus for reproducing a 60 field/s video signal from a recording of a gateway signal, the apparatus including means for reproducing the fields of the recorded video signal and duplicating every fourth reproduced field. In this case, the reproducing and duplicating means preferably comprises means for reproducing the recorded signal at 48 field/s and means for duplicating every fourth field to provide a field rate of 60 field/s. Preferably, means is provided for keeping track of the duplicated fields.
The invention also provides a (third) method of converting a gateway video signal to a second real-time, or nearly real-time, 60 field/s video signal, comprising the step of duplicating every fifth field of the gateway signal to produce the second signal. This produces a real-time signal from a 120% gateway video signal, and signal which is 1.042 of real-time from a 125% gateway signal. The method preferably further comprises the step of keeping track of the duplicated fields.
The invention also provides a (third) apparatus for reproducing a 60 field/s video signal from a recording of a gateway signal, the apparatus including means for reproducing the fields of the recorded video signal and duplicating every fifth reproduced field. In this case, the reproducing and duplicating means preferably comprises means for reproducing the recorded signal at 50 field/s and means for duplicating every fifth field to provide a field rate of 60 field/s. Preferably, means is included for keeping track of the duplicated fields.
Conversion of Gateway video to normal speed 50 field/s video
Optionally, the third method further comprises the step of conversion from the second signal to a 50 field/s video signal by dropping one in every six fields of the second signal. Preferably, the dropped fields are the fields which were duplicated when producing the second signal from the gateway signal.
Optionally, the third apparatus further comprises means, such as a 1125 lines, 60 field/s to 1250 lines, 50 field/s standards converter, or a 1125 lines, 60 field/s to 625 lines, 50 field/s standards converter, for dropping one in every six fields of the 60 field/s signal, preferably the duplicated fields.
It will therefore be appreciated that there is a one-to-one correspondence between the field pairs of the 50 field/s video signal and any film frames which were used in producing the signal. This makes the 50 field/s signal particularly valuable for further post-production in the 50 field/s domain, for example in a 625 lines, 50 field/s format.
Post-production of Gateway video
Post-production editing may be carried out directly on one or more gateway video signals, thus at 1.25 or 1.2 times the real-time rate, which in many cases may be advantageous. However, for previewing, the edited signal may be converted by the second or third method mentioned above, or by the second or third apparatus mentioned above, so that previewing may be carried out at, or at about, the real-time rate.
Alternatively, post-production editing may be carried out at, or at about, the real-time rate by firstly converting one or more gateway video signals using the second method or second apparatus mentioned above, and then carrying out editing. In this case, when two or more of the converted signals are to be combined, the duplicated fields are synchronised, and preferably a track is still kept of the duplicated fields. This provides the advantage that if the edited signal is subsequently down-converted to 525 lines, 60 field/s, further post-production can be carried out on the down-converted signal as if it had been directly produced from film in 3232 format.
Recordings of Gateway signals
The invention furthermore provides a recording of a gateway video signal. It will be appreciated that, compared with a conventional 60 field/s 3232 recording, 20% less recording medium is required.
Gateway video tape reproducing machine
The invention also provides an apparatus (such as a video tape recorder (“VTR”) or video disk player) for reproducing a video signal recorded on a medium in a 60 field/s format, comprising:
means for controlling a play speed of the recording medium;
means for reproducing fields of the video signal recorded on the medium; and
means for buffering and outputting at 60 field/s fields of the reproduced signal;
wherein the speed controlling means and field buffering means are operable in at least one of the following modes, including at least one of modes (A), (B), (D) and (E):
(A) the play speed is 75 field/s and four out of every five reproduced fields are output;
(B) the play speed is 72 field/s and five out of every six reproduced fields are output;
(C) the play speed is 60 field/s and all of the reproduced fields are output;
(D) the play speed is 50 field/s and all of the reproduced fields are output together with one out of every five reproduced fields which is duplicated; and
(E) the play speed is 48 field/s and all of the reproduced fields are output together with one out of every four reproduced fields which is duplicated.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the invention will be apparent from the following detailed description of illustrative embodiments which is to be read in connection with the accompanying drawings, in which:
FIGS. 1 and 2 illustrate conversion of 24 frame/s and 25 frame/s film to gateway video signals;
FIGS. 3 and 4 illustrate conversion of 125% and 120% gateway video signals to film;
FIG. 5 shows a VTR for converting a 60 field/s video recording to a gateway signal;
FIG. 6 shows a post-production facility for gateway video signals;
FIGS. 7 and 8 show two arrangements for previewing and converting gateway video signals; and
FIG. 9 shows a real-time post-production facility for gateway video signals.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a 125% gateway recording can be produced from 24 frame/s film 10 by running the film through a conventional telecine 12 which is conventionally used for producing 60 field/s 2:1 high definition video from 30 frame/s film. Motion in the picture represented by the output signal 14 from the telecine 12 is at 1.25 times the real-time rate, and the signal 14 is recorded by a conventional 60 Hz 2:1 high definition VTR 16 , so that the recorded signal is 1.25 times the real-time rate with a one-to-one correspondence between the 1/24s frames of the film 10 and the 1/30s field pairs of the video signal.
Referring to FIG. 2, a 120% gateway recording can be produced from 25 frame/s film 18 using the same equipment as shown in FIG. 1 . In this case, motion in the picture represented by the output signal 20 from the telecine 12 is at 1.2 times the real-time rate, and there is a one-to-one correspondence between the 1/25s frames of the film 18 and the 1/30s field pairs of the video signal.
Referring to FIG. 3, a film 22 can be produced from a 125% gateway video recording, by outputting the video from a VTR to a conventional EBR 24 which is conventionally used for producing 30 frame/s film from 60 field/s 2:1 high definition video, so as to produce a film 26 . If the film 26 is used as a 24 frame/s film, then motion will appear at the real-time rate, but if the film 26 is used as a 25 frame/s film, motion will appear at 1.042 times the real-time rate, which is acceptable in many cases. It will be appreciated that there is a one-to-one correspondence between the field pairs of the video signal and the frames of the film 26 .
Referring to FIG. 4, a film 30 can be produced from a 120% gateway video recording using the same equipment as shown in FIG. 3 . In this case, if the film 30 is used as 25 frame/s film, motion will appear at the real-time rate, but if used as 24 frame/s film motion will appear at 0.96 times the real-time rate, which again is acceptable in many cases. Again, there is a one-to-one correspondence between the field pairs of the video signal 32 and the frames of the film 30 .
Referring to FIG. 5, a 120% gateway video signal 34 can be produced from a conventional 60 field/s video recording using a modified VTR 36 . In the modified VTR 36 , a tape speed control circuit 38 is set so that the tape speed is 72 field/s, rather than 60 field/s, and the control 40 of the framestores of the VTR 36 is set so that every sixth field reproduced from the tape is dropped, the polarities of some of the fields are reversed, and the fields are output at 60 field/s, as follows:
Reproduced Field
Polarity
Output Field
Number and Polarity
Dropped
Reversal
Number and Polarity
1 odd
No
No
1 odd
2 even
No
No
2 even
3 odd
No
No
3 odd
4 even
No
No
4 even
5 odd
No
No
5 odd
6 even
Yes
—
—
7 odd
No
Yes
6 even
8 even
No
Yes
7 odd
9 odd
No
Yes
8 even
10 even
No
Yes
9 odd
11 odd
No
Yes
10 even
12 even
Yes
—
—
It will therefore be appreciated that motion in the picture represented by the output signal 34 will appear at 1.2 times the real-time rate. The output signal 34 may also be treated as a 125% gateway signal, but in this case it will be at 0.96 times the proper speed for a 125% gateway signal, but in many cases this may be acceptable.
The arrangement of FIG. 5 may also be modified to produce a 125% gateway video signal at the proper speed for such a signal by altering the setting of the tape speed control circuit to 75 field/s and by altering the control 40 of the framestores so that every fifth field reproduced from the tape is dropped, the polarities of some of the fields are reversed, and the fields are output at 60 field/s, as follows:
Reproduced Field
Polarity
Output Field
Number and Polarity
Dropped
Reversal
Number and Polarity
1 odd
No
No
1 odd
2 even
No
No
2 even
3 odd
No
No
3 odd
4 even
No
No
4 even
5 odd
Yes
—
—
6 even
No
Yes
5 odd
7 odd
No
Yes
6 even
8 even
No
Yes
7 odd
9 odd
No
Yes
8 even
10 even
Yes
—
—
It will therefore be appreciated that motion in the picture represented by the output signal will appear at 1.25 times the real-time rate. The output signal may also be treated as a 120% gateway signal, but in this case it will be at 1.047 times the proper speed for a 120% gateway signal, but in many cases this may be acceptable.
FIG. 6 shows a post-production facility for gateway video signals. There are one or more sources of gateway video signals. These may include conventional 60 field/s VTRs 22 which are reproducing gateway recordings or a modified VTR 36 as described above with reference to FIG. 5 which is reproducing a conventional recording in a special manner. The post-production facility also includes a post-production desk 42 for performing various operations on the source video signals such as combining, fading, zooming, shifting, colouring and other editing. The post-production desk provides an output gateway signal 44 to a conventional 60 field/s VTR 16 which records the signal 44 and also to a 60 field/s monitor 46 . It will be appreciated that the recording of the gateway signal 44 is at 1.2 or 1.25 times the real-time rate, and that the picture displayed by the monitor 46 is also at 1.2 or 1.25 times the real-time rate. It will also be appreciated that there is still a one-to-one correspondence between field pairs of the output signal 44 and any film frames which are used in producing the output signal 44 .
In order to preview the results of a 125% gateway post-production operation, an arrangement as shown in FIG. 7 may be used. The recorded gateway signal is reproduced by a modified VTR 48 . In the modified VTR 48 , the speed control circuit 38 is set so that the tape speed is 48 field/s, rather than 60 field/s, and the control 40 of the framestores of the VTR 48 is set so that one in every four reproduced fields is duplicated and the polarities of some of the fields are reversed as follows so that the fields are output in a 3232 format at 60 field/s as an output signal 58 . Also, the first output field in each series of ten fields is flagged for a purpose to be described later.
Reproduced
Output Field
Field Number
Polarity
Number and
and Polarity
Duplicated
Reversal
Polarity
Flagged
1 odd
No
No
1 odd
Yes
No
2 even
No
2 even
Yes
Yes
3 odd
No
3 odd
No
Yes
4 even
No
4 even
No
Yes
5 odd
No
5 odd
No
Yes
6 even
No
Yes
7 odd
No
6 even
Yes
No
8 even
No
7 odd
No
No
9 odd
No
8 even
No
No
10 even
No
The output signal 50 is then displayed on a 60 Hz 2:1 monitor 46 . It will therefore be appreciated that motion in the picture displayed by the monitor will be at the real-time rate, and although motion artifacts may be introduced by the 3232 format, these will be no worse than would be the case if the video signal had originally been acquired from source film using a 3232 format.
The arrangement of FIG. 7 may also be used to preview a 120% gateway signal, but in this case the displayed picture will be at 0.96 the real-time rate, but in many cases this will be acceptable.
The signal 50 produced by the arrangement of FIG. 7 may also be transmitted as an 1125 lines 60 field/s 2:1 interlace high definition video signal, or may be supplied to an 1125 lines to 525 lines down-converter 51 and then transmitted as a 525 lines 60 field/s 2:1 interlace conventional definition video signal.
In order to preview the results of a 120% gateway post-production operation, an arrangement as shown in FIG. 8 may be used. The recorded gateway signal is reproduced by a modified VTR 52 . In the modified VTR 52 , the speed control circuit 38 is set so that the tape speed is 50 field/s, and the control 40 of the framestores of the VTR is set so that one in every five reproduced fields is duplicated and the polarities of some of the fields are reversed as follows so that the fields are output at 60 field/s as an output signal 54 . Also each of the duplicated fields is flagged.
Reproduced
Output Field
Field Number
Polarity
Number and
and Polarity
Duplicated
Reversal
Polarity
Flagged
1 odd
No
No
1 odd
No
2 even
No
No
2 even
No
3 odd
No
No
3 odd
No
4 even
No
No
4 even
No
No
5 odd
No
5 odd
Yes
Yes
6 even
Yes
6 even
No
Yes
7 odd
No
7 odd
No
Yes
8 even
No
8 even
No
Yes
9 odd
No
9 odd
No
Yes
10 even
No
Yes
11 odd
No
10 even
Yes
No
12 even
Yes
The output signal 54 is then displayed on a 60 Hz 2:1 monitor 46 . It will therefore be appreciated that motion in the picture displayed by the monitor will be at the real-time rate, and although motion artifacts may be introduced by the duplicated fields, these are likely to prove acceptable in many cases.
The arrangement of FIG. 8 may also be used for 125% gateway signals, but in this case the output video signal will be at 1.042 times the real-time rate, but in many cases this may be acceptable.
The video signal 54 produced by the arrangement of FIG. 8 may also be transmitted as an 1125 lines 60 field/s 2:1 interlace high definition video signal, or may be supplied to an 1125 lines to 525 lines down-converter 51 and then transmitted as a 525 lines 60 field/s 2:1 interlace conventional definition video signal.
Additionally, the signal 54 produced by the arrangement of FIG. 8 may be supplied to a 1125 lines, 60 field/s to 1250 lines, 50 field/s up-converter or 1125 lines, 60 field/s to 625 lines, 50 field/s down-converter 56 which drops the flagged fields and reverses the polarity of some of the fields as follows so that the fields are output a 50 field/s signal 58 .
60 field/s Field
50 Field/s Field
Number and
Polarity
Number and
Polarity
Flagged
Dropped
Reversal
Polarity
1 odd
No
No
No
1 odd
2 even
No
No
No
2 even
3 odd
No
No
No
3 odd
4 even
No
No
No
4 even
5 odd
No
No
No
5 odd
6 even
Yes
Yes
—
—
7 odd
No
No
Yes
6 even
8 even
No
No
Yes
7 odd
9 odd
No
No
Yes
8 even
10 even
No
No
Yes
9 odd
11 odd
No
No
Yes
10 even
12 even
Yes
Yes
—
—
Importantly, by dropping the flagged fields which we previously added, there is a one-to-one correspondence between the originating film frames and the field pairs of the 50 field/s signal 58 . Therefore, not only is the 50 field/s signal 58 suitable for transmission, but it is also suitable for further post-production using a 50 field/s post-production facility.
Instead of direct post-production of the gateway signals as described with reference to FIG. 6, post-production of 125% gateway signals may be carried out at real-time using a facility as shown in FIG. 9 . One or more gateway recordings are reproduced by VTRs 48 which are modified in the manner described with reference to FIG. 7 so as to produce a 60 field/s 3232 format signal at the real-time rate, with the first field in each ten field sequence flagged. When combining two or more of the signals 50 , the VTRs 48 are controlled so that the flags of the signals 50 are synchronised, and the corresponding field of the output signal 60 is also flagged. The output signal 60 can then be recorded in its 3232 format by a conventional VTR 16 , and/or transmitted, and/or supplied to a 1125 lines to 525 lines down-converter 51 . Although the signal 62 output from the down-converter 51 is not in the gateway format but is in a real-time 3232 format, if it has been post-produced at 1125 lines from more than one film source, the 3232 relationships will be synchronised, and so the signal 62 is suitable for further post-production in the 525 lines format using a post-production facility which takes account of the 3232 format.
The arrangement of FIG. 9 may also be used for 120% gateway signals, but in this case the output video signal will be at 0.96 times the real-time rate, but in many cases this may be acceptable.
Whilst VTRs 16 , 22 , 36 , 48 have been described above having different reproduction modes, it will be appreciated that a single VTR may be provided with the facility to operate selectably in any two or more of those modes.
Although illustrative embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope and spirit of the invention as defined by the appended claims. | The gateway video signal is generated from inputted frames which represent a motion picture when reproduced at a real-time rate. The inputted frames are sped up to 1.2 or 1.25 times the real-time rate. The sped up frames are, then, converted to 60 field/second, thereby generating the gateway video signal. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 10/117,783 filed Apr 4, 2002, which issued as U.S. Pat. No. 7,103,838 on Sep. 5, 2006, which is a continuation-in-part of U.S. application Ser. No. 09/997,208 filed November 28, 2001, now abandoned, and U.S. application Ser. No. 10/045,620, filed Jan. 15, 2002 , now abandoned, which is a continuation-in-part of and claims the benefit of U.S. application Ser. No. 09/933,885, filed Aug. 20, 2001, now abandoned; U.S. application Ser. No. 09/935,782, filed Aug. 22, 2001, which issued as U.S. Pat. No. 6,915,294 on Jul. 5, 2005; U.S. application Ser. No. 09/940,188, filed Aug. 27, 2001, now abandoned; U.S. application Ser. No. 09/935,783, filed Aug. 22, 2001, now abandoned; and U.S. application Ser. No. 09/933,888, filed Aug . 20, 2001, now abandoned, which claim the benefit of one or more of U.S. Provisional Application No. 60/226,479, filed Aug. 18, 2000; U.S. Provisional Application No. 60/227,125, filed Aug. 22, 2000; and U.S. Provisional Application No. 60/227,875, filed Aug. 25, 2000. These applications are herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to the field of computer software. More specifically, the present invention relates to one or more of the definition, extraction, delivery, and hyper-linking of clips, for example web clips.
2. Description of Related Art
In this section, we first describe what clips are. We then briefly survey the state-of-art of web clip extraction. We then show why these techniques are inadequate in the face of the wide variety and dynamic nature of web pages.
Web Clips
A clip is simply a portion or selection of data of an existing document or set of data. The content of a clip may be contiguous or noncontiguous in the source representation of the document or in a visually or otherwise rendered representation. The particular example that we will use in this application is that of web clips, which are portions of existing web pages, though the methods described are application to many other types of documents or sets of data as well. (A document may be thought to contain a set of data, and a clip is a selection or subset of the data.)
FIG. 1 shows an example web clip. Henceforth, we shall refer to web clips for concreteness, rather than to clips in general. A web clip may consist of information or of interfaces to underlying applications or to any other document content.
FIG. 1 defining a web clip. The user uses a drag-and-drop graphical user interface to define a “CNN cover story web clip”.
Web clips have many uses. One important use is delivering content to the emerging internet-enabled wireless devices. Most existing web pages are authored for consumption on desktop computers where users typically enjoy generous display and networking capabilities. Most wireless devices, on the other hand, are characterized by limitations of small screen real estate and poor network connectivity. Browsing an existing web page as a whole on such a device is both cumbersome (in terms of navigating through the page) and wasteful (in terms of demand on network connectivity). Web clipping can eliminate these inconveniences enabling easy access to any desired content.
We note that web clipping is a complementary but orthogonal technique to other wireless web solutions such as transcoding. In its simplest form, the fundamental problem addressed by web clipping is information granularity. The default information granularity on the web is in units of pages. “Transcoders”, which are programs that automatically transform existing web pages for consumption on wireless devices using techniques such as reducing the resolution of images, address the information format but they do not alter the granularity. As a result, end devices are still flooded with information that overwhelms their capabilities. In practice, one should combine these techniques so that end devices receive content in both the right granularity and the right format.
Web clips are also useful for delivery to portals on personal computers or handheld or mobile devices. Even on personal or desktop computers, portals usually aggregate content and application interfaces from a multiple sources. Web clips, with or without transcoding, can be delivered to portals or portal software as well. Other example of the use of web clips is in exposing them to users, whether human users or applications, in a remotely or programmatically accessible manner, delivering them to databases or other channels or repositories, converting them to a representation with explicitly identified fine-grained structure even within a clip (such as the Extensible Markup Language or XML) and making them available to devices, transformation systems, applications (that can interact with these structured representations), databases and other channels. Many of these scenarios may require syntactic or semantic transformations to be performed on the web clips—for example, conversion from one description or markup language to another, or format and semantic alterations—but are orthogonal to the extraction of clips from the underlying documents.
Existing Web Clip Extraction Techniques and their Inadequacies
Recognizing the important uses of web clipping, several techniques to extract web clips from pages have been developed, including in a commercial context. In this section, we briefly survey these attempts and their limitations.
Static Clips vs. Dynamic Clips
When a user or another entity such as a computer program defines a web clip, which we also refer to as selecting a web clip, the definition is based on a particular version of the underlying page. For example, in FIG. 1 , the cover story clip definition is based on the CNN page as of Jun. 8 th , 2000 at 2:40 am. Pages, however, can evolve, in at least three dimensions: content, structure, and name (e.g. URL). In this simple example, the cover story of the CNN home page updates often, and this is the simplest form of page evolution: content change. In other examples, some aspects of the structure of the page (as encoded in its structural and formatting markup language tags and the relative placement of the pieces of data in the page, and to an extent reflected in its layout as viewed for example through a browser that renders the content based on the markup language) may change. Or pages with new names but similar structure to existing pages may be added all the time, e.g. new pages in a content catalog or new news stories (how to deal with changes in name or with pages with new names will be discussed in elsewhere; in particular, the question of which view to use as the original view when a page with a new name is encountered for extraction; for now, we assume that view to be is to be used and/or the page(s) on which it is defined is known). A challenging question that any web clip extraction technique must address is how to respond to these changes.
A simple solution to deal with changes is not to deal with them at all: the clip “freezes” at the time of clip definition. We call such clips static clips.
A different approach is to produce or extract clips that evolve along with the underlying pages. We call such clips dynamic clips. In this case, a clip definition or selection specifies which portion of the underlying page is to be clipped. We call such a definition a view. The example in FIG. 1 , defines a “CNN cover story view”, and FIG. 2 continues the example as we extract different cover stories from the evolving underlying page. The challenge now is to identify which portion of a current page best corresponds to (or has the greatest strength of correspondence with) the portion (or selected set of data) specified in the original view. Determining or identifying this corresponding set of data (or desired clip), is the central problem solved by the technologies described in this document, together with the problem of selecting the most appropriate original view in some cases as discussed later. We refer to the set of technologies as addressing the web clip extraction problem.
Clip Extraction Based on Characteristic Features
One approach to the problem of dynamic clip extraction is to identify relatively stable characteristic features either in the clip itself or in the surrounding area of the desired clip. These characteristic features, along with the positional relationship between these features and the desired clip, are stored. Given a new page, the system searches for these characteristic features and use the positional hints to locate the desired clip in the new page. This is often referred to as a rule-based approach.
The disadvantages of this approach are 1) it is labor-intensive, and 2) it is not robust. This is not a general solution that can be automated for any web page; instead, ad hoc solutions must be tailor made for different pages, as different characteristic features must be identified with human aid. It is also an iterative process based on trial and error, as multiple features may need to be tried out before a usable one is identified. It is a fragile solution, as the characteristic features and the positional information may evolve over time as well. Indeed, due to these disadvantages, it is necessary to have a human “expert” involved in the clip definition process, an expensive and slow proposition that precludes simple do-it-yourself deployment over the Internet.
Clip Extraction Based on Syntax Tree Traversal
Instead of relying exclusively on the use of characteristic features, an alternative solution is to exploit the fact that even though the content of an underlying page evolves, its syntactic structure may remain the same. Under this approach, an abstract syntax tree (AST) is built for the original underlying page (for example, based on the structure expressed by the markup language contained in the page), the tree nodes corresponding to the desired clip are identified, and the path(s) leading to a selected node(s) in the original page is recorded. Given a new page that shares the same syntax tree structure, one simply traverses the AST of the new page by following the recorded path and locates the nodes that represent the desired clip.
This solution does not require ad hoc heuristics for different pages. The amount of user involvement required is minimal, so this solution is suitable for do-it-yourself deployment over the Internet. The main disadvantage of this approach is that it relies on the stability of the syntactic structure of underlying page; as the AST of a page evolves, the traversal path leading to the desired nodes changes as well and locating the desired nodes becomes non-trivial.
Tracking page evolution by computing page differences is not a new idea. One example of earlier attempts is the “HtmlDiff” system explained in F. Douglis and T. Ball, Tracking and Viewing Changes on the Web, USENIX 1996 Technical Conference, 1996), hereby incorporated by reference. The focus of these systems is to allow users to easily identify the changes without having to resort to cumbersome visual inspection, or to reduce the consumption of network bandwidth by only transmitting the page difference to reconstruct the new page on a bandwidth-starved client.
One example of an existing edit sequence computation algorithm is explained in E. Myers, An O(ND) Difference Algorithm and Its Variations, Algorithmica , 1(2), 251-266, 1986, hereby incorporated by reference.
One example of an edit sequence distance algorithm for unordered trees is explained in K. Zhang, R. Statman, and D. Shasha, On the Editing Distance Between Unordered Labeled Trees, Information Processing Letters 42, 133-139, 1992, hereby incorporated by reference.
SUMMARY OF THE INVENTION
Some embodiments include methods of extracting relevant data. A first and a second set of data are accessed. The first set includes selected data. An edit sequence is determined between the first and the second sets, including considering at least repetitions for inclusion in the edit sequence. Corresponding data of the second set have a correspondence to the selected data are found at least partly by determining the edit sequence.
Some embodiments include methods of extracting relevant data. A first and a second tree of data are accessed. The first tree includes selected data. An edit sequence is determined between the first and the second trees, including considering at least repetitions for inclusion in the edit sequence. Corresponding data of the second tree have a correspondence to the selected data are found at least partly by determining the edit sequence.
In some embodiments, the edit sequence is tree-based.
In some embodiments, a set of data is from a document including markup language.
Some embodiments include methods of extracting relevant data. A first and a second representation of data are accessed. A representation includes a tree. The first tree includes selected data. A first path is from a root of the first tree to the selected data. A second path from a root of the second tree that corresponds to the first path is determined. Corresponding data of the second tree have a correspondence to the selected data are found at least partly by determining the second path.
In some embodiments, a third set of data are accessed.
In some embodiments, if two or more sets of corresponding data are found, then 1) if one of the corresponding sets of data has a substantially higher strength of correspondence than strengths of correspondence of the other corresponding sets of data, a high measure of quality is assigned to the selection of the selected data, and 2) a low measure of quality is assigned to the selection of the selected data, if at least one of: 2a) none of the corresponding sets of data has a substantially higher strength of correspondence than strengths of correspondence of the other corresponding sets of data, and 2b) if strengths of correspondence of all corresponding sets of data are low.
In some embodiments, a second edit sequence is determined.
In some embodiments, at least a plurality of first sets of data of a plurality of first documents is accessed. The correspondence is determined by comparing partial representations of the plurality of first sets of data with a partial representation of the second set of data.
In some embodiments, at least one of 1(1a and 1b) and 2 (2a and 2b) is performed: 1a) pruning a relevant subtree from at least part of the first tree, the relevant subtree at least partly determined from the forward and backward edit sequences; 1b) determining a pruned edit sequence between the pruned relevant subtree and at least part of the second tree; 2a) pruning a relevant subtree from at least part of the second tree, the relevant subtree at least partly determined from the forward and backward edit sequences; 2b) determining a pruned edit sequence between at least part of the first tree and the pruned relevant subtree.
In some embodiments, tree traversal is performed on at least part of the second tree, the tree traversal at least partly guided by the selected data and by at least part of the first tree. If tree traversal fails due to one or more differences between at least part of the second tree and at least part of the selected data, then an edit sequence is determined between at least part of the second tree and at least part of the first tree, the first tree including at least part of the selected data; corresponding data are found for at least part of the second tree, the corresponding data having a correspondence to at least part of the selected data, the correspondence at least partly found by determining the edit sequence; and tree traversal continued to be performed on at least part of the second tree, the tree traversal at least partly guided by the corresponding data.
In some embodiments, if the edit sequence fails a test, a tree-based edit sequence is determined between the first set of data and the second set of data, the edit sequence including any of insertions, deletions, substitutions, matches, and repetitions.
In some embodiments, a third set of data of third document including markup language is accessed.
Various embodiments use web-clipping approaches using algorithms such as PageDiff algorithms. PageDiff algorithms are based on the computation of the shortest edit sequence distance. They can take both content and structural information into account. They provide the foundation of a powerful content transformation infrastructure that can support many applications and services.
INCORPORATION BY REFERENCE
All publications and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:
FIG. 1 illustrates one embodiment of a web clip by using a drag and drop graphical user interface.
FIG. 2 illustrates one embodiment of extracting web clips by applying a view to a sequence of evolving pages.
FIG. 3A illustrates one embodiment of a view definition.
FIG. 3B illustrates one embodiment of a clip extraction.
FIG. 4 illustrates one embodiment of extracting a clip by computing a page difference.
FIG. 5 illustrates one embodiment of extracting a clip by applying FlatDiff.
FIG. 6 illustrates one embodiment of permutation of page elements.
FIG. 7 illustrates one embodiment of extracting a clip by applying TreeDiff.
FIG. 8 illustrates one embodiment of a subtree pruning using FlatDiff to improve TreeDiff performance.
FIG. 9 illustrates one embodiment of structural changes that may defeat tree traversal-based extraction.
FIG. 10 illustrates components of the “meta-web” graph.
FIG. 11 illustrates a TreeDiff using backing-up.
In particular, some of the detailed characteristics of the algorithms we describe are tailored to documents containing a markup language, which means that in addition to content (typically text-based content), they also have tags (typically text-based) associated with the content. Examples of markup languages include flavors of HTML (HyperText Markup Language), WML (Wireless Markup Language), various subsets or flavors of SGML (Standard Generalized Markup Language) and various subsets of XML (Extended Markup Language). The tags may specify structural, semantic, or formatting characteristics associated with the document or with specific pieces of content in it. For example, a tag may specify the beginning of a paragraph or table (structure), it may specify that a given number in the document is a product price (semantics), or it may specify that a given text string is to be rendered in bold font and red color (formatting).
The content and markup languages that our methods are specialized toward are typically text-based, e.g. the content and tags are represented in textual form, though the text includes numbers, foreign languages, special characters (e.g. new lines, tabs, other control characters) and the like. The term text-based also includes documents that embed images, video or audio, since the embedding is often specified in text form in the source document (e.g. how a video clip or image is included in an HTML document is specified in text in the source HTML document).
However, the methods described here can also be used for other applications. One example is extracting clips from plain-text documents, i.e. documents that do not have any markup language or tags (the methods are also highly applicable to documents that have only markup language tags and no content). Another is extracting clips from computer programs, which usually have a hierarchical structure just like documents that contain a markup language often do. The methods described here are applicable to extracting clips from computer programs (for example) as well, though the specifics or the weights given to different entities within the document (e.g. within the source code or some other representation of the computer program) may vary. The methods can also be used for extracting clips (nodes or subtrees) from any tree data structures or information that can be represented as a tree data structure, whether or not those trees represent documents that include a markup language or are derived from documents that include a markup language.
Desirable Features of a Good Clip Extraction Algorithm
In this section, we have briefly surveyed the related efforts in web clip extraction. As a result of analyzing their weaknesses, we can identify a list of desirable features of a good extraction algorithm:
Ease of use. Algorithms should allow views to be specified in very simple ways, e.g. simply pointing and clicking on the desired clips (in the original page) themselves, rather than requiring the specification of complex rules or heuristics by the user. Lack of restrictions in clipping. Techniques should allow as broad a set of data as possible to be included in a clip, instead of limiting the types of data that can be included in a clip definition or view to, for example, just images, hyper-links, or tables. Freshness of content. Techniques should be able to extract dynamic clips rather than only static clips. Graceful toleration of changes in page structure. The need for users to have to redefine view as a page changes in structure or content should be minimized. Graceful handling of URL changes. When the URL of the underlying page changes, users should not have to be required to explicitly name the view that is to be applied to this URL. Rather, the method should automatically select the most appropriate view as far as possible. Robustness. Since the underlying page can experience an arbitrary degree of change, we recognize that no clip extraction algorithm can boast 100% success. The goal is to be able to tolerate the greatest amount of content, structural, and naming (i.e., the name of the document or set of data from which the clip is extracted or on which it is defined) changes. Extensibility. While the system should be easy to use, even by casual users, it may also provide clip-processing infrastructure that can accommodate the more sophisticated transformation needs of power users.
DETAILED DESCRIPTION OF THE INVENTION
In this section, we first give an overview of the web-clipping process and infrastructure. We then describe in detail a number of web-clipping algorithms and how they can be integrated to provide good performance and robustness. We close by enumerating a number of extensions and applications of the basic web-clipping concept.
Overview: View Definition and Clip Extraction
FIG. 3 gives an overview of the components and data flow channels involved in clip extraction. FIG. 3( a ) illustrates how clips are defined. A clip definition is called a view. A proxy (named the view repository in the figure) retrieves a conventional web page (named page 1 ). The proxy then augments this page with some graphical user interface (GUI) code and sends the augmented page (named page 1 ′) to the user (named view client). The view client runs the GUI code to specify the data to be included in the selected clip (which selection of data will later be used for finding the best corresponding data such as a clip in another page). For example, the user may simply visually point to and select the data that are to be included in the selected clip, and might not specify anything else. The result (named view) is stored in the view repository for later use. It is not necessary that a human user perform the selection of the view; a program or any software can do it as well, in which case GUI code may or may not be needed.
FIG. 3( b ) illustrates how clips are extracted. The extraction engine accesses (obtains proactively or receives) a conventional web page (named page 2 ). It then accesses (obtains proactively or receives) an applicable view from the view repository. It calculates which portion of page 2 corresponds to the clip specified in the view based on page 1 . The result (clip) is sent to the display device (named display client). The figure shows the source of the web page, the machine (computer) that runs the extraction engine, the view repository and the display client being different machines connected by a network. However, it is possible that two or more of these entities (the source of the web page, the machine that runs the extraction engine, the view repository and the display client) be the same machine or run on the same machine. For example, the extraction engine can run on the web server that provides page 2 above. Or the extraction engine can run on the client (for example, when the client is a PC and the clips are being served up into a portal environment). Or all four (the extraction engine, the web server that serves up page 2 , the view repository and the client) can run on the same machine. Any combinations of the different pieces of software and storage running on the same machine or on network-connected machines is possible, though scenarios in which some of the processes run on different network-connected machines are most likely.
The algorithm(s) employed in the extraction engine is one of the key technologies, and it is this component that we describe in detail in the next few subsections. The choice of an applicable view from a view repository is another key technology that is described elsewhere. Other sections describe material supporting three other key technologies related to extraction: namely the adaptation of the view definition itself over time, the repeated application of the extraction algorithm(s) at successively smaller granularities to extract very small clips, and the use of the extraction algorithm to compute a quality measure for the view definition itself in order to give feedback about the quality of definition to the view definer.
PageDiff: Calculating Page Difference for Clip Extraction
Although pages evolve, in the vast majority of the cases, the changes are gradual and there is a great deal of commonality in terms of both content and structure between the new page and the old page, upon which the view was originally defined. A successful clip extraction algorithm must be able to exploit commonality as well as tolerate differences as pages evolve.
A key insight behind our technology is the realization that the problem of clip extraction is an extension of the more general problem of finding the shortest edit sequence between two documents. An edit sequence is a sequence of insert, delete, and replace operations that can transform a source document into a target document. The shortest edit sequence is usually called the difference between these two documents. For example, the “diff” utility on the Unix operating system uses the shortest edit sequence to compute the difference between two text files. Our approach is to use edit sequences not to find all differences between two files or documents, but rather to find the clip in the new document that best corresponds to the selected portion(s) in the first document. We call this approach of using difference computation to extract web clips PageDiff.
FIG. 4 illustrates the PageDiff insight. In this figure, two documents are the inputs to the system; one is the web page upon which the view is originally defined; and the other is the new version of the page (or a related or similar page). In one approach to PageDiff, by calculating the difference between these two pages, PageDiff attempts to “match” each piece of one document with a piece in the second document. In this example, the edit sequence contains replacing section B of the first page with section XY in the new page. Since section B is the clip in the old page, the algorithm is in effect declaring section XY to be the clip in the new page because it is the best match for B.
As another example, consider an HTML document containing the following set of data items: <BR><H4>, “War on Terrorism”, </H4>, <H1>, “Cover Story”, and </H1>. Let <H4>, “War on Terrorism”, and </H4> constitute the selection. Consider a second document with the following set of data items: <H4>, “Tax Cuts”, </H4>, <H2>, “Cover Story”, </H2>, and <p>. An implementation of PageDiff might declare that the following edit sequence transforms the first document to the second document: Delete <BR>, Substitute “Tax Cuts” for “War on Terrorism”, Substitute <H2> for <H1>, Substitute </H2> for <H1>, and Insert <p>. The above edit sequence therefore implies that:
The second document does not have any data item that corresponds to <BR> from the first document. The first data item from the second document, which is <H4>, corresponds to the second data item from the first document, which is also <H4>. The second data item from the second document, which is “Tax Cuts”, corresponds to the third data item from the first document, which is “War on Terrorism”. The third data item from the second document, which is </H4>, corresponds to the fourth data item from the first document, which is also </H4>.
It follows therefore that the data in the second document that corresponds to the selected data from the first document is the following: <H4>, “Tax Cuts”, and </H4>. We note that the edit sequence uniquely determines what data in the second document corresponds to the selected data in the first document. Therefore, the crux of the problem is in determining the edit sequence between the two documents.
PageDiff is a much more general, elegant, powerful, robust, and flexible approach to the web clip extraction problem than existing approaches. It is general and elegant in that it does not require ad hoc customized solutions for different pages. It is powerful and robust in that it takes all commonality between two pages into consideration, in terms of both content and structure; and it can tolerate both content and structural evolutions. Edit sequence computation is a well-defined and well-studied problem and the theoretical foundation of the solutions further lends a degree of confidence in the robustness of this approach. It is flexible in that depending on the amount of the difference between the two documents, one can choose implementation options of varying computation cost; and there are numerous ways of extending the base implementations.
Tracking changes in pages by computing page differences is not a new idea. The focus of these systems is to allow users to easily identify the changes without having to resort to cumbersome visual inspection, or to reduce the consumption of network bandwidth by only transmitting the page difference to reconstruct the new page on a bandwidth-starved client. However, the insight that one can also adapt page difference computation for the purpose of web clip extraction, and the specific algorithms and improvements for correctness and performance, are the key contributions of this work.
We next describe three implementations of PageDiff: FlatDiff, Enhanced Tree Walk, and TreeDiff. In each implementation, the algorithm accepts two sets of elements as input. Some of the elements in the first set are marked as selected. The algorithm then identifies what elements in the second set are corresponding elements of the selection made from the first set. We assume that there is an ordering of elements in each set, and the selected elements are contiguous within that ordering. In the cases where the defined clip is composed of non-contiguous portions of the first document, the extraction algorithm can be run once to extract all sub-clips or can be run once per sub-clip.
We also describe variants of the three implementations that either result in better performance or provide greater functionality in terms of what kinds of changes could be tracked. To attain better performance, we use approximation techniques (see, for example, the descriptions on approximating TreeDiff). To provide greater functionality, we use enhanced dynamic programming algorithms that are able to recognize repetitions of certain patterns in the input sets (see, for example, the description on enhancing FlatDiff to accommodate repeatable patterns).
We also describe how to combine these implementations and existing approaches to achieve good performance, correctness and robustness.
FlatDiff: Computing Page Difference between Unstructured Documents
Algorithms for computing edit sequence to determine the differences between documents are well known. The first approach we present is to treat a web page as a sequence of unstructured tokens and to compute page difference by extending an existing well-known edit sequence computation algorithm. FIG. 5 illustrates the process. Some of our extensions to the algorithm are discussed.
A parser first transforms a web page into an abstract syntax tree (AST). The tree is then linearized into a sequence of tokens, which consist of markup elements (defined by the markup language syntax and denoting structure, semantics, formatting or other information as discussed earlier) and text strings that represent the content. The token sequences corresponding to the view and the new page are then fed into the FlatDiff stage, which computes a shortest edit sequence using our extensions to a well-known flat edit sequence calculation algorithm. By locating the matching tokens in the original ASTs, the extraction stage outputs the desired clip.
Defining FlatDiff
The key component in FIG. 5 is the FlatDiff stage. It attempts to minimize the following edit sequence distance function:
C ( i,j )=min[ C ( i− 1, j )+ C d ( i ), C ( i,j− 1)+ C i ( i ), C ( i− 1, j− 1)+ C r ( i,j )]
where C(i,j) is the edit sequence distance of transforming the first i tokens of document one into the first j tokens of document two, C d (i) is the cost of deleting the i th token from document one, C i (i) is the cost of inserting the ith token into document one, and C r (i,j) is the cost of replacing the i th token of document one with the j th token of document two. C r (i,j)=0 if the i th token of document one and the j th token of document two are identical.
Tuning Cost Functions of FlatDiff
As mentioned earlier, the use of edit sequence to compute all the differences between documents is well known; however, in the context of using FlatDiff itself for our purpose of identifying corresponding clips, there are some enhancements we make to the basic edit sequence calculation algorithm. For example, how to define the cost functions (C d , C i , and C r ) is a key question that we must address in order to make FlatDiff work well for the purpose of matching web page elements rather than simply for identifying all differences between pages. One useful observation is that the cost functions can be dependent on the level in the syntax trees (of the document) where the tokens reside: for example, token matches at higher levels of the syntax tree may be deemed to be more significant. This is because these high level matches tend to correspond to matches of high level skeletal page structures. By favoring these matches, we can avoid ‘false’ matches either across different levels or at lower levels.
We can also manipulate cost functions to deal with more challenging page change scenarios. FIG. 6 shows an example involving permutation of page elements: the block denoted by B 1 is the desired clip in the old page; its content is changed to B 2 in the new page; and its position is changed as well. Since the remainder block, block A, has more tokens in it, a straightforward difference computation algorithm may correctly match block A and produce an edit sequence of [delete B 1 , insert B 2 ]. In general, however, such an edit sequence is unsuitable for clip extraction because it is not obvious to the extraction stage that B 1 and B 2 correspond to each other. Since the goal here is to identify a clip in the new page corresponding to a selected clip in the old page, a solution to this problem is to attach more significance to matches of tokens that are present in the selected clip than to tokens that are not present in the selected clip. In this example, even though blocks B 1 and B 2 have fewer token in them, their internal matches are given more importance so that the FlatDiff stage will match B 1 and B 2 and produce an edit sequence of [delete A, insert A]. The extraction stage can readily use this result to produce the correct result clip B 2 .
Enhanced FlatDiff with Support for Repeatable Patterns
We next describe a method that we have developed that allows for certain elements of the selected piece of the source sequence to be designated as repeatable patterns (or, more accurately, patterns that may repeat, with edits). These repeatable patterns may repeat in the source sequence as well, and can repeat an arbitrary number of times in the target sequence. In each case, the repetition may be exact (e.g. the pattern abcd repeating several times) or it may be inexact (abcd repeating as ab′cd, abc′d, ab′cd′, etc., i.e. an edit sequence is needed to converts the source pattern to each instance of the repeated patterns). We refer to these ‘repeatable’ subsequences as repeatable patterns.
Therefore, in addition to selecting a subsequence in the source tree, certain parts of the selected subsequence are also designated as repeatable patterns. The task of finding a corresponding subsequence in the target tree now should consider the possibility of these repeatable patterns appearing (potentially with edits) an arbitrary number of times in the target subsequence. Conceptually, there is a new class of edit operation called “repetition,” which is used to indicate a repetition of a sequence of nodes in exact or inexact form.
To solve this problem, we have developed a dynamic programming approach that is driven by the following set of equations.
dist ( A [ 0 … j ] , B [ 0 … j ] ) = { 0 , if i = 0 and j = 0 del ( A [ i ] ) + dist ( A [ 0 … i - 1 ] , B [ 0 … j ] ) , if i > 0 ins ( B [ j ] ) + dist ( A [ 0 … i ] , B [ 0 … j - 1 ] ) , if i > 0 repl ( A [ i ] , B [ j ] ) + dist ( A [ 0 … i - 1 ] , B [ 0 … j - 1 ] ) , if i > 0 and j > 0 repl ( A [ i ] , B [ j ] ) + ∑ k = SegStart ( i ) i - 1 + dist ( A [ 0 … SegEnd ( i ) ] , B [ 0 … j - 1 ] ) , if i > 0 and j > 0
where the various terms have the following semantics:
dist(A[i1 . . . i2], B[j1 . . . j2] denotes the cost of the edit sequence required to transform the sequence of elements numbered i1 through i2 in the list of tokens A to the sequence of elements numbered j1 through j2 in the target list of tokens B. SegStart(i) and SegEnd(i) denote the beginning and end of a repeatable pattern in A that includes the element numbered i. ins(B[j]) denotes the edit cost of inserting the element B[j], del(A[j]) denotes the edit cost of removing the element A[i], and repl(A[i], B[j]) denotes the cost of replacing element A[i] by element B[j].
This set of equations is used in a dynamic programming algorithm that computes the entries corresponding to the matrix dist. The order of evaluation of the various entries is determined by the dependencies implicit in the equations. A column order evaluation is one evaluation order that satisfies the dependencies. Recall that the repetitions might not be exact. For example, a pattern comprising a sequence of three tokens [A B C] might appear as [A B′C], resulting in an additional cost for considering [A B′C] as a repetition of the original pattern [A B C]. This additional cost would be the same as the substitution or replacement cost associated with matching B and B′. The algorithm as stated is capable of recognizing such inexact repetitions and for computing their associated costs.
FlatDiff Summary
In addition to the general benefits of PageDiff, FlatDiff can be implemented efficiently: its complexity is 0(N 2 ) where N is the number of tokens. One of its disadvantages is that it is not always easy to infer the desired clip simply from the edit sequence result. This is because FlatDiff works on unstructured token sequences and the resulting edit sequence also consists of a set of unstructured tokens. It may sometimes be difficult to identify syntactically coherent clips using the unstructured FlatDiff output.
Enhanced TreeWalk: Extraction from Tree Structured Documents
We begin by describing an algorithm that addresses some of the problems associated with extraction algorithms that use syntax tree traversal techniques (discussed earlier). As we had pointed out earlier, syntax tree traversal algorithms fail when there are changes in the path from the root to the tree to the selected subtree. As discussed earlier, the syntax tree traversal algorithms store the path from the root to the selected subtree by keeping track of which branches the path took (such as the k th child at the second level) and the nodes encountered in the path (such as a node with label “A”). If, for instance, a node or a subtree is inserted such that there is a change in any one of these two pieces of information at any level in the subtree, the extraction algorithm would fail.
The extraction algorithm can however be enhanced to tolerate some of these changes in the tree. The algorithm may tolerate certain changes by using analysis that is more global than the traditional syntax tree traversal technique. For instance, during traversal of the target tree, we may encounter a node n 1 , and let us assume that following the path to the selected subsequence in the original tree would require us to consider the k th child of n 1 as the next element on the path to the desired subtree, and, furthermore, would require the k th child to have an associated label n 2 . Now, if the target tree had an insertion or deletion of subtrees (relative to the source tree) that resulted in a change in the position of n 2 , a simple syntax tree traversal algorithm would fail. Syntax tree traversal algorithms can be extended and enhanced in various ways. For example, a more intelligent algorithm might scan all the children of n 1 to identify a node with the matching label n 2 . However, even that algorithm would fail if node labels can repeat, for example. In such scenarios, the question becomes what is the corresponding node with a label n 2 whose position is least displaced from the original position k. Even such an algorithm could potentially result in erroneous decisions, and we therefore rephrase the question in the following manner: Which node in the target tree corresponds to the source tree node with label n 2 , which is the k th child of the source node with label n 1 , such that there is minimum displacement (by some measure) amongst the nodes considered.
The minimum displacement may, for example and as in our Enhanced Treewalk algorithms, be computed at least in part from the edit sequence between a neighborhood of nodes around the node sought to be matched in the source tree and a neighborhood of the target tree around the current location and level in the target tree. The neighborhoods may be chosen based on connectivity in the tree (e.g. choose only the children nodes of the node under consideration, or choose some representation of the entire subtrees of the children of the node under consideration, or choose ancestors as well, or choose ancestors and/or descendents up to a certain number of levels up and down in the tree or by some other criteria) or based on number of levels (e.g. choose all nodes within k levels in the tree of the node under consideration) or by some combination of these criteria. Whatever the neighborhood chosen, the goal is to use an edit sequence algorithm that considers the two neighborhoods (from the source and target trees) to determine which node from within the target tree neighborhood best corresponds to the desired node in the source tree.
One example, using only children in each tree as the neighborhoods is as follows. Here, the minimum displacement metric may, for example, capture the edit sequence required to transform the child list (s 1 , s 2 , . . . s n ) from the source tree to the child list (d 1 , d 2 , . . . d m ) in the target tree, and the desired node is the node d 1 that is considered as a replaced to the source node s k by the edit sequence.
More formally, it attempts to minimize the following edit sequence distance function:
C ( i,j )=min[ C ( i− 1, j )+ C d ( i ), C ( i,j− 1)+ C i ( i ), C ( i− 1, j− 1)+ C r ( i,j )]
where C(i,j) is the edit sequence distance of transforming the first i children of the source child list into the first j tokens of the destination child list, C d (i) is the cost of deleting s i , C i (i) is the cost of inserting d i , and C r (i,j) is the cost of replacing s i with d j , where the replacement cost may be computed both based on the labels associated with the source and target tokens as well as the size of the subtree associated with the two tokens. In the ideal case, where the labels match and the size of the two subtrees match, the replacement cost is zero, while if there is a label mismatch or if the sizes of the two subtrees are substantially different, then a penalty is associated to replacing s i with d j . This method may, of course, be extended to more levels, and to ancestors or to level-based neighborhoods as well. And the edit sequence may be computed either using a FlatDiff, as discussed here, or by using a TreeDiff (described later).
This process is repeated for every level in the path that leads to the desired piece.
The process terminates when one of the following two conditions occur:
The edit sequence algorithm fails to identify a good enough corresponding node at some step in the traversal, and therefore terminates, or The algorithm does identify a corresponding subtree(s) as being a good match(es) to the original selected piece, but the identified subtree(s) does not satisfy certain thresholds in the following respects:
The number of (node) matches between the selected subtree in the source tree and the identified subtree in the target tree falls below a certain threshold, or There is a large discrepancy between the sizes of the selected subtree from the source tree and the identified subtree in the target tree, or The edit sequence between the selected subtree in the source tree and the identified subtree in the target tree is too large or costly. There is a large discrepancy in the position of the selected subtree in the source tree and the identified subtree in the target tree based on the postorder numberings of the two trees. There is a large discrepancy in the constitutions of the contexts or neighborhoods around the selected subtree in the source tree and the identified subtree in the target tree.
If a chosen subset of these failure conditions is encountered, the enhanced tree traversal algorithm may be deemed to have produced an erroneous result, and the more accurate but more expensive algorithms listed below may be used instead (of course, those more expensive algorithms may be used independently and from the start too, if desired). Other failure conditions or metrics may, of course, be easily constructed.
TreeDiff: Computing Page Difference between Structured Documents
Unlike FlatDiff, which largely discards structural information in the difference computation step, our second approach, TreeDiff, maintains the structural information throughout the entire process. TreeDiff is a tree-based edit sequence calculation approach, and is directly applicable to documents whose structure can be represented as a tree (examples include web pages, documents containing other formatting or markup languages, computer programs, and many other types of documents), i.e. where a tree representation of the data exists or can be created. It is also applicable to many tree-based data structures in general. Algorithms to compute the edit sequence distances between trees are known. In developing TreeDiff for the purpose of identifying and extracting corresponding clips rather than simply for computing differences between trees, we substantially extend—and combine with new techniques described later—a known edit sequence distance algorithm for unordered trees. FIG. 7 illustrates the process with a TreeDiff algorithm, with or without the extensions and modifications. The extensions and modifications we make are discussed in later subsections.
A parser first transforms a web page (or other applicable document) into an abstract syntax tree. The trees corresponding to the view and the new page are then fed into the TreeDiff stage, which computes a shortest edit sequence. By locating the matching subtrees in the original trees, the extraction stage outputs a subtree(s) that corresponds to the desired clip. When subtrees correspond to structural units in the page or its markup language, as they are expected to do, structural integrity of clips is maintained.
Defining TreeDiff
The key component in FIG. 7 is the TreeDiff stage. It attempts to minimize the edit sequence distance between two trees, where an edit sequence consists of a number of deletions, insertions, and replacements of tree nodes, and these operations are defined as the following:
Deletion: all children of the deleted node become children of its parent. Insertion: the children of the inserted node consist of its own children as well as children of its new parent. Replacement: The children of the replaced node become children of the replacing node. For nodes that are not deleted, inserted, or replaced, TreeDiff preserves the ancestor-descendent relationship.
Similar to FlatDiff, TreeDiff also associates costs to each of these operations. A simple metric that suffices for many extraction scenarios is outlined below:
Deletion costs 2 units per instance. Insertion costs 2 units per instance. Replacement costs 3 units per instance (so that replacement is less expensive than a deletion followed by an insertion).
Other metrics or costs for specific operations, specific types of nodes, or specific nodes may be appropriate for specific applications. As with FlatDiff, the specific costs assigned to operations may vary with the application of the method (for example, the document types or specific circumstances), and in some cases new operations may be defined as well. Also, as with FlatDiff, greater weight may be given to operations on or matches in some nodes or tokens (or types of nodes or tokens) than others, for example to nodes that are higher in the tree and to matches of nodes that are present in the selected clip from the old page.
Additionally, to improve the accuracy of our difference algorithm (TreeDiff or FlatDiff) for the specific case of web pages written in HTML (HyperText Markup Language), we may use some or all of the following cost metrics or rules that exploit the semantics of HTML components. HTML nodes are broadly classified into two categories: text-based content nodes, which represent the page content to be displayed, and tag nodes, which contain structural, semantic or formatting information associated with the content or text nodes. In addition, tag nodes might have optional attributes associated with them. Given these two categories, our cost metric could be enhanced to express which edit operations are likely to occur in practice. In particular,
If a text node from the old page is faithfully preserved in the new page, we may associate a negative cost to including such a match in the edit sequence. The negative cost provides an incentive to our algorithm to identify more of those exact matches.
If a text node from the old page does not appear in the new page, but there exists a string of approximately the same length, we may associate a small positive cost with the operation of replacing the old string with the new string. If the string is to be matched with another string of a substantially different length, a large positive cost may be associated with such a replacement.
A high positive cost may be associated with the edit operation of replacing a text node by a tag node or vice versa.
If a tag node from the old page is preserved in the new page with all its attributes intact, we may associate a negative cost with including such a match in the edit sequence.
If a tag node from the old page appears in the new page, but if the attributes associated with the node have changed, a small positive cost may be associated with the act of matching these two nodes.
These cost metrics and rules or relationships are applicable to FlatDiff as well as to Treediff. These cost metrics were derived after extensive experimentation and an in-depth study of the nature of changes that are made to web pages. Our algorithms, when deployed with these cost metrics, reliably identify the correspondence between nodes in dynamically changing HTML trees. Similar approaches, with similar or different specific scenarios and cost assignment considerations, will be appropriate for documents containing other markup languages, such as the Wireless Markup Language or WML, various flavors of Extensible Markup Language or XML, or various programming languages or program intermediate form representations. The specific cost assignments and rules may be altered for HTML documents as well.
Improving TreeDiff Performance by Pruning Subtrees Using FlatDiff
TreeDiff can be computationally expensive as it computes the edit sequence distance between all possible subtrees of the first tree and all possible subtrees of the second tree. Such an implementation may be too slow to be used for real time clip extraction from documents of significant size. We now describe a key optimization to reduce cost (illustrated by the example in FIG. 8 . Another key optimization is described in a following section.
In this example, to compute the edit sequence between two subtrees (or trees) we first linearize the two subtrees into two token sequences. We then perform on these two token sequences a 2-way FlatDiff: computing the difference in the forward direction and then computing the difference again in the backward direction. The 2-way FlatDiff, which is generally more effective than a one-way Flatdiff, prunes one of the subtrees to isolate a “relevant” sub-subtree. We identify this sub-token sequence by locating the boundary point in each direction beyond which the FlatDiff edit sequence distance starts to increase monotonically. We then feed this pruned sub-subtree into the vanilla TreeDiff in place of the un-pruned subtree. We combine the result of the vanilla TreeDiff with the result of the FlatDiff to form the final answer. As a result of this optimization, the size of the subtrees participating in most invocations of the vanilla TreeDiff method is significantly smaller.
Improving TreeDiff Performance: Subtree Matching
In the algorithms presented so far, the input includes the AST corresponding to the old HTML page (T 1 ), a distinguished node(s) n 1 inside T 1 , and a new tree, T 2 , corresponding to the new HTML page. The difference algorithms compute the mapping from the nodes in T 1 to the nodes in T 2 . Given such a mapping, we can identify whether the distinguished node(s) from the old page is preserved in some form inside the new page, and if so, the subtree rooted at that node in T 2 is the clip to be extracted. A significant modification of this algorithm is obtained by rephrasing the mapping problem in the following manner: given the subtree rooted at n 1 , what is the subtree in T 2 that has the smallest edit distance to the given subtree? At first sight, since rephrasing the question in this form requires the algorithm to consider every subtree in T 2 and compute the edit distance of that subtree from the subtree rooted at n 1 , it would appear that answering this question would require a substantial amount of computation. However, an integral part of the TreeDiff algorithm is to compute the edit distances between every pair of subtrees in the old and new ASTs. In fact, given a subtree S 1 from T 1 and a subtree S 2 from T 2 , the edit distances between these two subtrees is computed by extending the partial results obtained from computing the edit distances for every pair of subtrees inside S 1 and S 2 . Given such an algorithmic behavior, the reformulation does not require further computational enhancements to our original TreeDiff algorithm. In fact, since nodes in T 1 that are not descendents of n 1 need not be considered to answer the posed question, the input to the algorithm may be pruned substantially, resulting in a more efficient algorithm.
However, such pruning results in the loss of contextual information regarding the structure and content of the tree around n 1 . This loss of information could result in scenarios where our algorithm would identify matches that are “spurious” when the trees are considered in their entirety. To overcome this problem, we introduce the strategy of “back-off”, where progressively larger trees inside T 1 are considered if the node(s) inside T 2 that matches n 1 is ambiguous or if a good enough match is not found. Whether or not a good enough match is found can be determined using criteria like the ones described for determining the success/failure of the extended treewalk algorithm once the ‘best corresponding match’ is found.] Similarly, whether a match is ambiguous when the top two (or more) candidates for the best corresponding match are close enough to each other by those criteria; for example, when there are two or more subtrees inside T 2 that have similar edit distances from the subtree rooted at n 1 , we could declare that the algorithm couldn't identify a strong enough or unique enough correspondence or match. When such a situation arises, we consider the subtree rooted at the parent of n 1 , and identify what subtrees in T 2 are similar to this subtree. By including the parent of n 1 and the subtrees rooted at the siblings of n 1 , we are increasing the contextual information used for identifying matches. If this too is inadequate, we back-off one level higher in T 1 . Once the best larger matching subtree is found, the best clip corresponding to the view can be obtained from within it. Thus, if unambiguous matches are indeed available in T 2 , this strategy should eventually result in finding them. In fact, we can choose to perform some amount of back-off even at the very beginning in order to use a larger (effectively) selected subset from the source tree, if we believe that the originally selected subset is not large or uniquely defined enough. While back-off strategies are well suited to tree-based algorithms due to the inherent hierarchy in the representation, they can be used with flat diff approaches as well, by backing off to subsequently higher-level structural elements each time (e.g. paragraphs, sections, etc.) and performing flat diffs with those larger sub-documents.
The techniques used by the algorithm to determine the need for backoff may also be useful in informing the user doing the selection process whether their selection is not likely to result in good enough or unambiguous enough matches (for example, by doing the extraction from the source tree itself, or from a different target tree if available). This provides a user making selections with a useful ‘wizard’ that gives valuable feedback to enable the later success of extraction algorithms.
Enhanced TreeDiff with Support for Repeatable Patterns
We next describe a method that we have developed that allows for certain elements of the selected piece of the source tree to be designated as sequence of elements that can repeat an arbitrary number of times in the target tree. In addition to selecting a subtree in the source tree, certain parts of the selected subtree are also designated as patterns that are likely to repeat in the corresponding subtree in the target tree. The task of finding a corresponding subtree in the target tree now should consider the possibility of these repeatable patterns appearing an arbitrary number of times in the target subtree.
To solve this problem, we have developed a dynamic programming approach that is driven by the following set of equations:
forestdist ( A [ l ( i ι ) … i ] , B [ l ( j 1 ) … j ] ) = { 0 , if i = 0 and j = 0 del ( A [ i ] ) + forestdist ( A [ l ( i 1 ) … i - 1 ] , B [ l ( j 1 ) … j ] ) , if i > 0 ins ( B [ j ] ) + forestdist ( A [ l ( i 1 ) … i ] , B [ l ( j 1 ) … j - 1 ] ) , if j > 0 treedist ( A [ i ] , B [ j ] ) + forestdist ( A [ l ( i 1 ) … l ( i ) - 1 ] , B [ l ( j 1 ) … l ( j ) - 1 ] ) , if i > 0 and j > 0 treedist ( A [ i ] , B [ j ] ) + ∑ k = l ( SegStart ( i ) ) l ( i ) - 1 + forest dist ( A [ l ( i 1 ) … SegEnd ( i ) ] , B [ l ( j 1 ) - 1 ] ) , if i > 0 and j > 0
where the various terms have the following semantics:
forestdist(A[i1 . . . i2], B[j1 . . . j2] denotes the cost of the edit sequence required to transform the subtrees corresponding to the sequence of elements numbered i1 through i2 in the tree A to the subtrees corresponding to the sequence of elements numbered j1 through j2 in the tree B (where the numbering could be obtained through either post-order or pre-order traversal of the trees). l(k) denotes the leftmost-child of node k in a given tree. treedist(A[i], B[j]) is a special instance of forestdist and is exactly equal to forestdist(A[1(i) . . . i], B[1 . . . j]). SegStart(i) and SegEnd(i) denote the beginning and end of a repeatable pattern in A that includes the element numbered i. ins(B[j]) denotes the edit cost of inserting the element B[j], while del(A[j]) denotes the edit cost of removing the element A[i].
These set of equations is used in a dynamic programming algorithm that computes the entries corresponding to the matrices forestdist and treedist. The order of evaluation of the various entries is determined by the dependencies implicit in the equations. A column order evaluation is one evaluation order that satisfies the dependencies.
Approximating TreeDiff through Tree-Sized Edit Operations
We now consider another optimization that produces an approximate algorithm for computing TreeDiff in order to address the high computational cost of TreeDiff. The primary insight behind this new algorithm is that by allowing only those edit operations that operate on entire subtrees to be considered in edit sequences, the algorithm can reduce the solution space and find an approximate edit sequence with substantially fewer operations. We will illustrate the approximation made by this algorithm with the following simple example.
Consider a subtree comprising of just three nodes, n 1 , n 2 , and n 3 , where node n 1 is the parent of nodes n 2 and n 3 . The TreeDiff algorithm would consider the possibility of using the following operations in the edit sequence that transforms the source tree into the target tree: delete n 1 , retain nodes n 2 and n 3 . Such an edit sequence would have the effect of removing the node n 1 , and attaching nodes n 2 and n 3 to the node that is the parent of n 1 . In our approximate version of TreeDiff, we do not consider the possibility of such an edit sequence occurring. Instead, when a node is deleted, the entire subtree rooted at the node needs to be removed from the target tree. A similar logic applies to tree-sized insertions as well.
The following set of equations are used in a dynamic programming algorithm:
treedist ( A [ l ( i 1 ) … i ] , B [ l ( j 1 ) … j 1 ] ) = min { deltree ( A [ i 1 ] ) + intree ( B [ j 1 ] ) repl ( A [ i 1 ] , B [ j 1 ] ) + forestdist ( A [ l ( i 1 ) … i - 1 ] , B [ l ( j 1 ) … j - 1 ] )
forestdist ( A [ l ( i 1 ) … i ] , B [ l ( j 1 ) … j ] ) = min { 0 , if i = l ( i 1 ) - 1 and j = l ( j 1 ) - 1 deltree ( A [ i ] ) + forestdist ( A [ l ( i 1 ) … l ( i ) - 1 ] , B [ l ( j i ) … j ] ) , if i ≥ l ( i 1 ) instree ( B [ j ] ) + forestdist ( A [ l ( i 1 ) … i ] , B [ l ( j i ) … l ( j ) - 1 ] ) , if j ≥ l ( j 1 ) treedist ( A [ i ] , B [ j ] ) + forestdist ( A [ l ( i 1 ) … l ( i ) - 1 ] , B [ l ( j i ) … l ( j ) - 1 ] ) , if i ≥ l ( i 1 ) and j ≥ l ( j 1 )
where the terms forestdist and treedist are used as defined in earlier sections. In addition, we use deltree(A[i]) and instree(B[j]) to denote the cost of deleting a subtree rooted at A[i] and inserting a subtree rooted at B[j] respectively. The resulting dynamic programming algorithm requires a quadratic number of operations to identify an edit sequence, while the full-blown node-level TreeDiff algorithm requires a substantially greater number of calculations.
TreeDiff Summary
TreeDiff preserves the structural information throughout the entire process. One of the consequences is that the matches found by the algorithm are always structurally coherent. This makes the extraction stage simple to implement. The disadvantage of TreeDiff is its relatively high computational cost: TreeDiff has a complexity of O(N 2 ·D 2 ) where N is the number of tree nodes and D is the depth of the tree.
Integrating Clip Extraction Technologies
So far, we have described three clip extraction technologies that all take advantage of the syntactic structure of the web page at some stage of the algorithm:
Tree traversal: it has a complexity of O(D); but it cannot tolerate structural changes.
FlatDiff: it has a complexity of O(N 2 ); it addresses both content and structural changes; but the structural integrity is not maintained. We also described a variant of FlatDiff that recognizes repetitions of subsequences from the source sequence within the target sequence.
Enhanced Tree Walk: it has a complexity that is greater than that of tree traversal, but less than that of FlatDiff. It utilizes contextual information to find the desired target subtree. It is less fragile than Tree traversal in the sense that it can tolerate substantially more changes in the tree structure and still identify the correct target piece.
TreeDiff: it has a complexity of O(N 2 ·D 2 ); it addresses both content and structural changes; and it maintains structural integrity. We also described a variant of TreeDiff that recognizes repetitions of subtrees from the source tree within the target tree. We also described a variant of TreeDiff that allows only subtree-sized insert and delete operations, which results in improved running times.
In this section, we describe various ways of combining these algorithms.
Hybrid Integration
Hybrid integration refers to modifying one of these algorithms by incorporating elements of other algorithms. The optimization technique of augmenting TreeDiff with FlatDiff is an example of hybrid integration. In fact, the Enhanced TreeWalk algorithm may be seen as a hybrid of syntax tree traversal and a diff-based algorithm. This can be generalized to augment syntax tree traversal to use FlatDiff or TreeDiff in various ways, as discussed briefly below.
A vanilla tree traversal approach cannot tolerate structural changes that affect the traversal path to the desired node. FIG. 9 shows an example: the addition of node I in Page 2 interferes with locating the next node on the path, namely node C. It is possible to augment tree traversal with localized FlatDiff or TreeDiff. As we traverse down a path, if we detect structural changes that are likely to defeat tree traversal by, for example, noticing changes in the number or nature of children at the current tree level, we may invoke difference computation of the two subtrees rooted at the current node (or of broader connectivity-based or level-based neighborhoods of the trees around the nodes being considered, as desired). In the example of FIG. 9 , we compute the difference between the two shaded subtrees (rooted at node D). The difference computation matches the components of the subtrees and allows the tree traversal to recover (at Node C).
The potential advantage of the hybrid integration is as follows: for components of the path that have not changed, tree traversal progresses rapidly; and the more computationally intensive algorithm is only invoked on localized subtrees that hopefully contain a much smaller number of nodes.
Another approach to integrate the various strategies is to reformulate the clip extraction problem to develop a metric that considers structural similarity between the source and target clips as well as the similarity of the paths used to traverse the trees in reaching the clips. We use a cost metric, which given a source clip and a potential target clip, associates a value that is the weighted sum of the TreeDiff edit distance between the two clips and the FlatDiff edit distance between the traversal paths to the clips from the roots of the corresponding trees. This hybrid strategy helps the extraction algorithm identifies a target clip such that neither the structural nature of the clip nor its position has changed significantly.
Sequential Integration
Suppose we notice a structural change that demands difference computation. The choice that we face now is between FlatDiff and TreeDiff. Unlike hybrid integration, which modifies one algorithm by incorporating elements of other algorithms, sequential integration employs multiple algorithms in succession if necessary. Under sequential integration, we will attempt FlatDiff first, examine the result, and if the result fails a correctness test (based on edit sequence or other criteria, as discussed in the context of determining success or failure of the extended treewalk algorithm), we will resort to TreeDiff.
Another example of sequential integration is to have the following chain of algorithms employed in succession: Enhanced TreeWalk, Approximated TreeDiff with tree-sized edit operations, and TreeDiff. The result obtained from Enhanced TreeWalk is compares to the source subtree in terms of the set of metrics described earlier (number of matches, position within the tree, contextual information, etc.) with very high thresholds of acceptance. If the high thresholds are not met, the next algorithm in the chain of algorithms, which is Approximated TreeDiff with tree-sized edit operations, is invoked. This algorithm, unlike Enhanced TreeWalk, is capable of generating more than one potential candidate for the desired target piece. If the best candidate determined by Approximated TreeDiff satisfies the strict thresholds of acceptance in terms of the match metrics, it is declared as the desired target piece. Otherwise, the potential candidates are considered along with the solution returned earlier by Enhanced TreeWalk. If the candidate returned by Enhanced TreeWalk belongs to the set of candidates returned by Approximated TreeDiff and does not differ substantially (in terms of the metrics described earlier) from the best solution obtained from Approximated TreeDiff, then the solution returned by Enhanced TreeWalk is declared as the desired target piece. Otherwise, we lower the strict thresholds on the match metrics, and check whether any of the candidates satisfy the lowered standards, and if there are any, the best amongst them is chosen as the final result of the computation. If the lowered threshold are not met, then we would invoke the full-blown TreeDiff algorithm to identify the desired target piece. This particular chaining of algorithms illustrates one possible example of sequential integration. There are many such ways to integrate the various algorithms.
This approach is based on the simple observation that verifying the validity of the result can be far more efficient than computing the exact result directly: it is possible to verify in linear time that the result produced by FlatDiff should match that of a full-blown TreeDiff, thus avoiding the latter.
Integration Summary
In this section, we have seen that it is possible to combine the various syntax tree-based algorithms, either in a hybrid fashion, or sequentially. The goal is to rely on the faster algorithms most of the time on a majority number of the nodes and only resort to slower algorithms less frequently on a smaller number of nodes. As a result, we can harvest the best performance and robustness that the various algorithms have to offer.
Adaptation over Time and Periodic Extraction
A long time gap between the definition of a view and its application may allow the target page to experience several generations of structural change, the cumulative effect of which may become too complex for the simpler algorithms to succeed. To cope with this challenge, as our system polls the target page of a view periodically, it may refresh the view definition by applying the clip extraction mechanism and storing the fresher version of the page and its clip in place of the old view, allowing the system to adapt to incremental changes smoothly instead of allowing gradual changes to accumulate beyond the system's ability to recognize them using simpler means. The polling of the target page and the updating of the view definition can be done either on-demand, as the view is accessed, or on a scheduled basis (e.g. every 15 minutes).
The idea here is the following. When a target page P 2 is accessed for extraction of a clip, it uses a view definition, which includes a page P 1 on which a view is defined. Using the algorithms described above, a clip corresponding to the view (defined on P 1 ) is extracted from the target page P 2 . Let us assume now that P 2 is stored, along with the extracted clip being identified within it somehow, just as the original clip was marked in P 1 as part of the view definition. The next time a new target page P 3 is accessed in order to extract the corresponding clip (i.e. a clip corresponding to that defined on P 1 ), there are choices regarding which page to use as the view definition. One choice is to use the original page P 1 on which the user originally defined the view. Another choice is to use the most recently accessed target page corresponding to this view together with the clip that was extracted from it (i.e. P 2 , which was stored the previous time). Our system enables P 2 and its clip or view definition to be used, thus allowing the definition of a view to evolve over time. The fact that the view definition evolves with changes to the page or document ensures that the view definition that is used for a clip extraction is not very old but rather is based on a page that is recent and therefore likely to be more similar to the target page. This is likely to help the correctness of the extraction algorithm, as mentioned earlier, and also likely its performance, as the differences among the pages being compared are likely to be smaller than if the original user-defined view were used.
While simply refreshing the view definition as described above is sufficient for some pages, for others, this technique needs to be extended to maintaining a certain amount of page format history. For example, for a site that regularly cycles through several page formats or switches back and forth among them from time to time, keeping a history of view definitions based on these different formats allows the system to perform object extraction efficiently and accurately using the most appropriate definition at a given time.
The updating of the view definition can be done either each time a view is accessed by a user or application for its particular purpose, or on a scheduled basis (e.g. every 15 minutes or in a manner based on the frequency of changes to the page or other environmental factors).
Periodic scheduled extraction has other benefits. First, the fact that recent pages and their recently extracted clips are stored in or near the machine that performs extraction enables them to be reused like a cache. That is, if the page has not changed since the last time it was accessed and extracted from, there may not be a need to fetch the target page from its original server or to perform the extraction process. If it can be easily detected that the clip has not changed, the extraction may not have to be performed again either.
Second, periodic or schedule extraction can be used to support monitoring of the extraction or clip delivery system, whether or not the view definition is updated with successive extractions. At each periodic extraction, a determination can be made whether the extracted clip has enough of a ‘match’ with the defined clip or view that the system is working correctly and delivering the desired clip. If not—for example if the desired clip is no longer in the page at all or if the algorithm is not succeeding in identifying the desired clip or a clip with a strong enough match—based on edit sequence or other criteria—a user or administrator can be notified so that they can take corrective action (such as modifying the view definition appropriately).
Repeated Invocation to Extract Successively Smaller Clips
So far we have been discussing the extraction of a clip from a page. It is possible to invoke the extraction algorithm(s) repeatedly to extract successively smaller sub-clips from successively smaller clips. The user may define a view, and then within that view define a sub-view or sub-views, and within those define sub-sub-views, and so on. When a new page is obtained, the extraction algorithm can be run once to extract the highest-level clip from the new page; then again to extract the next-level sub-clip(s)—corresponding to the sub-view(s)—from the extracted clip (treating the clip as the whole document for this second invocation); then again to extract the next-level sub-sub-clip(s)—corresponding to the sub-sub-view(s)—from the extracted sub-clip(s) (treating the sub-clip(s) as the whole document(s) for this third invocation); and so on.
There may be several reasons to do. For one thing, the user may want a very small clip from a page, and the extraction algorithm may not be able to extract the corresponding small clip very reliably from a new page since there not be a strong enough unique match (e.g. the ‘wizard’ may tell the user this). One choice would be for the user to define a larger view, that contains the desired data within it but is more uniquely identifiable within the page. But the user may not want the corresponding larger clip to be extracted and delivered. The desired view is too small to lead to unique or reliable enough extraction uniquely, and the larger view that is reliable enough is undesirable. In such a situation, the user may define the larger view, which leads to reliable extraction of a clip, and then within it define the smaller view—which leads to reliable extraction from within the larger view (not from within the whole document at once). This two-step (possibly extended to multi-step) extraction process may well lead to the small clip being extracted reliably in situations where a one-step extraction does not lead to a strong or unique enough result.
Another important and related use of sub-clip extraction is to give fine-grained structure to the content of clips. For example, if a clip contains stock quotes for a particular stock ticker symbol, the clip is extracted as an undifferentiated ‘blob’ of content in a markup language (e.g. HTML). The clip does not provide any structured information about the meaning of its content. It may be desirable to give structure to at least some of the content in the clip. For instance, if the different pieces of the content are tagged as ‘stock ticker symbol,’ ‘stock price,’ ‘percentage change,’ ‘volume,’ ‘exchange,’ ‘input box for ticker entry.’ etc., then the tagged fields that result from extraction can be used in various ways. The user may define formatting or semantic transformations on the extracted data, such as computing how close the stock is to it's 52-week high price, or the user may define alerts on specific numerical data (e.g. alert me when the stock of company X falls below $70, or other applications or systems may use the structured data for programmatic access and manipulation. That is, just like internally undifferentiated clips of content in a markup language can be used effectively for display on mobile devices or in portals, internally structured clips can be used effectively for access and manipulation by other applications. The clip may be an interface to an application, and if its internal structure is exposed in sufficient detail, it may be easy for other applications to interact with that application (e.g. invoke operations on it) via the clip.
Sub-clip extraction may be specified and performed as follows. The user may first define a view. Within the view, the user may select certain sub-views or sub-snippets and give them tags as illustrated above. When a new page is to be extracted from, first the clip corresponding to the view is extracted. Then, the clip is treated as the new document and the defined view as the old document, and sub-clips are extracted from it using the sub-view definitions. This leads to reliably extracted and appropriately tagged structured sub-clips which are available for manipulation, transformation, and reformatting, and/or structured programmatic access by other applications.
Choosing an Appropriate View to Apply to a Page
So far, we have defined views that can only apply to fixed pages that are identified by fixed URLs. The second generalization allows for a wild-card view, a view definition that can apply to multiple pages with different URLs but similar page formats. For example, the URLs embedded in the CNN home page change constantly. A wild-card view defined for the page pointed to by one of these changing URLs is also applicable to all other “similar” pages that exist then or will exist in the future. Given an arbitrary page, the challenge is to identify the wild-card view(s) that may be applicable to it.
Another way to look at this problem is that often a page may be accessed and may have a URL or name on which no view is defined (e.g. every new detailed news story page that appears on CNN has a different URL and likely will not have had a view defined on it). When such a page is accessed, the problem arises to find a page that is similar enough to the page that is being accessed and that has a view defined on it, so that the view may be used. The candidate pages or views for a page or type of page may be identified, or all views defined on pages from that site or domain, or all views (and hence pages) in the view repository may have to be examined. The problem is to find the “most similar page” to the page being accessed.
Our system uses a combination of three approaches to solve this problem:
The URL-based approach compares the URL of the original page that defines the view to the URL of the arbitrary new page. If the two URLs “match”, for some definition of a “match”, such as a longest prefix match or a regular-expression based match, we declare the view to be applicable to this new page. The AST-based approach names pages not by their URLs, but by a concatenation of the AST paths, each of which identifies a tree node within a page encountered during a hypothetical navigation session. So even when URLs change, constant AST navigational paths can be used to identify the applicable view(s). The structure-based approach examines the syntactic structure of an arbitrary page and calculates a checksum that is used as an identifier for an applicable view.
When we encounter a page on which there have been no clips defined, a structure-based approach would require identifying whether the user has defined views on a page that is structurally similar to the current page. A faithful implementation of this approach would require measuring the edit distance between the structure of the current page with all other pages stored in the view repository and choosing a page that has the minimum edit distance. However, this approach is expensive and unlikely to scale. Hence, the need for a fast algorithm that approximates this computation without significant loss in accuracy.
We may therefore use optimizations that result in more approximate algorithms but that increase efficiency. First, the structure of every subtree in the AST is mapped to a single checksum value by combining the hashed values of the individual tag-nodes contained in the AST. Second, instead of considering checksums for whole trees, we consider the checksums only for those subtrees that are within a certain distance from the root of the AST or that lead to a small enough checksum value (measure in number of bits used). Using this pruned list of checksum values for two ASTs, we can use the FlatDiff algorithm to compute an approximate measure of how much the two ASTs differ in their structural representation. Observe that the performance optimizations are derived from the use of a computationally less expensive FlatDiff algorithm and from the pruning of the set of subtrees that are considered for structural comparison. These algorithmic design choices result in a system that is efficient without sacrificing on accuracy.
Using the Quality of the Results of Extraction to Provide User Feedback
The goal of the extraction algorithm is to find the clip (or sub-clip) with the strongest match to or greatest strength of correspondence with the view (or sub-view). As was discussed earlier, it is possible that multiple clips within a page match the view to some extent. The hope is that one match dominates the others, so a unique clip can be extracted with high confidence. For example, achieving a more unambiguous match is part of the goal of the backup method discussed earlier.
However, it is possible that multiple clips provide matches that are close to one another in the strength of correspondence match, as computed by overall edit distance or some other metric. In this case, not enough certainty is achieved by the algorithm regarding the best match to the selected clip(s) in the view. The extent to which a single clip dominates other possible clips in its strength of correspondence to a selected clip in the view, and it has a high enough strength of correspondence itself, may be used to assign a measure of quality to the view definition (or the definition of that clip in the view). If this measure of quality is high enough, for example if it is above a threshold value, that means that a match that is both unambiguous enough and good enough match has been found. If it is not high enough, feedback may be given to the user that this situation has occurred, so that the user may alter the definition of the view such that the data selected within the view are more unique within the page, and hence to hopefully lead to more unique and strong matches in the future. For example, in an extreme case if a user defines as a view only a single number or word within a page, it is likely that the algorithm will not find a unique enough match or a strong enough match based on content and structure or context.
The quality measure associated with the view definition is impacted negatively if the back-off method does not lead to an unambiguous best match, or even if the back-off method is invoked to being with (even if it ultimately leads to an unambiguous best match), and if the strength of the correspondence (match) of the best matching view is low. The reason that the invocation of the back-off method lowers the quality measure is that the need to invoke the back-off method implies that initially (by examining only the selected portion in the first document) a strong enough or unique enough match could not be found, and the back-off method had to be used to find a more unique match. Thus, the extent to which back-off is used, together the final relative strengths of correspondence of clips to the selected data, can be used to determine the quality measure ascribed to the view definition.
In fact, this approach of giving feedback in the case of ambiguous matches may be used to provide a user feedback at view-definition time. As soon as a user defines a view and saves the definition, the extraction algorithm can be run. This extraction may be done from the latest version of the page (which is in many cases likely to not have changed at all from the page on which the view was defined) or from an earlier version that has been stored before view definition time. If the quality measure ascribed to the view definition, as described above, is not high enough, the user is given feedback that the view is not defined well enough. The user may then alter the definition of the view, for example by including more data around the selected data, in order to make the view definition more unique within the page.
Thus, this method can be used to create a view definition ‘wizard’ or software assistant that helps the view-defining user (human or software) define better views by providing feedback about this measure of quality of the view definition to the user. The wizard may be run immediately upon view definition, as described above, or it may be scheduled to run one or more times after some periods of time, so that it is likely that the page will have changed and the extraction to test view definition quality will be done from changed pages rather than the very page on which the view was defined, resulting in more realistic and potentially more informative tests.
Generalizing the Definitions of Views, Clips, and Hyper-Links
So far, we have presented the concept of view definition and clip extraction in the context of extracting a single clip from its enclosing page. The definitions of views and clips, of course, can be much broader.
First, a view can be a composite view that contains a number of sub views, each of which specifies a clip from a page in the manner described above. In fact, these sub views need not even belong to the same enclosing page. As a result of applying these composite views, the clip extraction process can build composite clips that are made of smaller clips. Indeed, this process is not only useful for delivering finer-grained information to wireless devices, it is also useful for purposes such as aggregating content from different sources and delivering larger grained clips to large displays that, for example, can be as large as wall-sized.
The second generalization of the definition of a view allows it to be an arbitrary piece of code that performs some computation and transformation on source pages (or clips) and produces derived clips.
So far, our description is based on user-defined views of various kinds. A third generalization addresses pages that do not have views associated with them. For such pages, our system can break them down into smaller objects solely based on their syntactic structure. For example, lists, tables, and images are obvious candidates. Or it can break them down based on structure, physical proximity in a rendered version, and/or the use of keywords or “headers” and a knowledge base. Compared to clips generated by applying user-defined views, one disadvantage of these automatically generated objects is that they do not necessarily possess user-friendly look and meaning.
The fourth generalization extends the definition of hyper-links and introduces the concept of a meta-web. The key is to recognize that as a result of introducing views and clips onto the web, we now have a much richer link graph. FIG. 10 illustrates the components. A graph consists of nodes and edges. There are three types of nodes in our system: web pages, views, and web clips. There are two types of edges: a definition edge between node A and node B denotes that component A is defined in terms of component B, and a reference edge between node A and node B denotes that there is a hyper-link to component B within component A.
More specifically, FIG. 10 shows that there are many circumstances under which such edges can occur. The numbers in the following list correspond to the number labels in FIG. 10 . A view is defined in terms of an enclosing web page.
1. A clip is defined by a view. 2. A composite view can be defined in terms of other views. 3. Web pages reference views. 4. Clips references web pages. 5. Web pages reference clips. 6. Clips reference each other. 7. Clips reference views.
In particular, note that our system has given rise to two new types of hyper-links. One new type is hyper-links to views (items 4 and 8 above). For example, a web page can link to the “current CNN cover story view”. The second new type is hyper-links to clips. For example, a web page can link to the “CNN midnight cover story on Jul. 9, 2000”. We call this rich graph centered around views the meta-web. In this sense, a view-based clipping architecture may be viewed as a step towards our goal of providing an infrastructure that “liberates” data from the confines of pre-defined pages and places the most relevant information at users' finger tips. Some more information on Tree-based Extraction
The TreeDiff algorithms that we have described in the earlier sections perform a computation that unfolds in the following manner. In order to compute the edit distance between two trees: a “source tree” and a “destination tree”, it requires the edit distance values for every pair of subtrees enclosed within the two trees. These edit distance values are considered partial solutions and are extended using a dynamic programming algorithm to find the edit distance between progressively larger subtrees. The “edit script” for each intermediate step consists of three kinds of edit operations that operate on entire subtrees (instead of operating on individual nodes): deletion, insertion, and replacement of subtrees. This increase in the granularity of the edit operations (from individual nodes to subtrees) is a direct result of expressing the algorithm as a dynamic programming computation. While operating with tree-sized edit operations does speed up the computation of each intermediate step, it has the unfortunate consequence of having to decompose the tree-sized edit operations into smaller node-level edit operations once the entire difference computation comes to a halt.
In order to perform this decomposition, there are two alternatives that expose a time-space trade-off. One approach is to store the edit script for every sub-tree comparison performed during the entire algorithm. At the end of the process, one just needs to unfold a tree-sized edit script into a corresponding node-sized edit script by recursively incorporating the previously stored edit scripts between progressively smaller subtrees. The other approach is to discard the edit scripts, but store just the numeric edit distance values, which are the only pieces of information required by further steps of the dynamic programming algorithm. During extraction, when a tree-sized edit operation needs to be decomposed, we could recomputer the edit script resulting in an algorithm that performs more computation but uses substantially less space. However, the amount of redundant computation is a small fraction of the overall computational cost due to the following reason. Since we are interested in finding the replacement for a single target node in the source tree, the algorithm needs to decompose only the tree edit scripts that involve replacements of subtrees that enclose the target node in the source tree. Consequently, the number of recalculations that we must perform is at most equal to the depth of the tree.
We now illustrate this process using an example. In FIG. 11( a ), we show the source tree S, the destination tree T, and the target node in the source tree E 1. Our task is to find the corresponding node in tree T. FIG. 11( b ) shows the result of the first step of a TreeDiff algorithm: node E 1 is compared against all possible subtrees of T. Both E 2 and E 3 are determined to be close enough to E 1 so the TreeDiff result so far is inconclusive and we must continue. FIG. 11( c ) shows the result of the second step of the TreeDiff algorithm: after we “back up” one level, the subtree rooted at C is compared against all possible subtrees of T. The two subtrees rooted at C in the destination tree T are both determined to be close enough to the corresponding subtree in S so the TreeDiff result so far is inconclusive and we must continue. FIG. 11( d ) shows the result of the third step of the TreeDiff algorithm: after we “back up” one more level, the entire source tree S is compared against all possible subtrees of T. S is deemed to match T and since the match is unique, the TreeDiff algorithm halts.
Now we must extract the target node from the destination tree by taking advantage of the TreeDiff result, which is expressed as the edit script shown in FIG. 11( d ). Note the operations numbered 3 and 5 are edit operations on entire subtrees instead of individual nodes. From this edit script, we see that the desired target node E 1 is part of edit operation 5 . To identify the corresponding target node in T, we must decompose this operation into node-sized operations. We perform a redundant computation to find the edit distance to accomplish this decomposition and this decomposition is shown in FIG. 11( f ). Since this last edit script involves only node-sized edit operations, no further decomposition is necessary and we have concluded finally that E 2 is the node that we seek.
In this example, we have used one flavor of a TreeDiff algorithm that uses “backing-up”. We note that the extraction algorithm is not dependent on the particular flavor of the TreeDiff algorithm and the extraction algorithm is applicable to all flavors of TreeDiff.
FIG. 11 TreeDiff with backing up (a-d) and subsequent extraction (d-e). Subtrees that are deemed to match each other are marked. (a) The source tree S, the destination tree T, and the source target E 1 . (b) First step of TreeDiff. (c) Second step of TreeDiff after backing up once. (d) Third step of TreeDiff after backing up again. (e) The edit script that transforms S to T. (f) The edit script that transforms the subtree containing the target.
Note:
When a claim or a claim limitation or part of a claim limitation “comprises A and B” or “includes A and B”, the claim or the claim limitation or the part of a claim limitation is open ended, allowing further inclusion of, for example, C, or C and D, etc. | The present invention pertains to the field of computer software. More specifically, the present invention relates to one or more of the definition, extraction, delivery, and hyper-linking of clips, for example web clips. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to closure means for well conduits. More particularly, it relates to temporary plugs that are removable without mechanical intervention from the surface above the well.
2. Description of the Related Art
In conventional practice, when a well conduit is desired to be temporarily closed off, it is common to set a plug within the conduit to preclude the flow of fluids at the preferred location. Regarding oil and gas wells, there are may types of plugs that are used for different applications. As an example, there are known removable plugs typically used during cementing procedures that are made of soft metals that may be drilled out of the conduit after use. Plugs that may be removed from a well intact are referred to as "retrievable" plugs. Removal, however, requires mechanical intervention from the surface of the well. Common intervention techniques include re-entry into the well with wireline, coiled tubing, or tubing string.
After a conventional type plug has been set and it subsequently becomes necessary to reestablish flow, any tools that have been associated with the plug during its use must be removed or "pulled" from the well to provide access to the plug for the removal process. The pulling of tools and removal of the plug to reestablish flow within a downhole conduit often entails significant cost and rig downtime. It is, therefore, desirable to develop a plug which may be readily removed or destroyed without either significant expense or rig downtime.
Known conduit plugs incorporating frangible elements that must be broken from their plugging positions include frangible disks that are stationarily located within tubular housings and flapper type elements. Breakage may be initiated by piercing the plug to cause destructive stresses within the plug's body, mechanically impacting and shattering the plug, or increasing the pressure differential across the plug until the plug is "blown" from its seat. After breakage has occurred, the resulting shards or pieces must be washed out of the well bore with completion fluid or the like in many situations. Because most known designs call for a relatively flat plug to be supported about its periphery, the plug commonly breaks from the interior outwardly and into relatively large pieces.
In some cases, operations within a well will require that a temporary plug be set within a conduit, usually the tubing string or well casing, but it may also be tubular components associated with downhole tools being used in the well. An example of such a downhole tool is a pressure set packer. In a typical configuration, the packer assembly will have a tail-pipe extending below the pack off elements. A temporary plug will have been installed in the tail-pipe before the packer is placed within the well or will be installed during the setting process. Frangible plugs described hereinabove may be used to plug the tail-pipe. Alternative plug means may include a wireline disposed plug, a wireline disposed dart, or a seated ball. In any event, after the packer has been set, it is desirable that the plugging structure be removed in order to establish a passage way through the packer assembly. As previously described, a frangible plug in the packer must be mechanically broken from its seat. In the case of a ball seated in a collet catcher sub, sufficient pressure must be applied above the packer to expel the ball into the well beyond the packer assembly.
A common detriment of either the destroyed frangible member or the expelled ball is that potentially fouling debris remains in the well. The debris' significance increases in non-vertical wells because it may remain relatively localized at the location of dislodgment where continuing well activity and operations may take place, or at least pass in the future. The debris may also be carried upward in the well fouling equipment along the way or surface equipment at the top of the well. This should be contrasted to vertical wells where the debris is more likely to fall clear of working mechanisms, but may also create fouling problems.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for establishing a temporary fluid-type plug within well conduits that can be removed upon demand to permit fluid flow past the plugged point within a short period of time. It is anticipated that the plug apparatus and methods disclosed herein will be applicable in any size conduit. The dimensions of the plug will be dependent upon the area to be plug and the service conditions into which it will be placed. Degradation and removal of the plug is accomplished without mechanical intervention from the well's surface. Furthermore, the resulting debris or "fall out" from the removed plug comprises sufficiently small particles that are easily transported by the fluids of the well without blocking or fouling other aspects and equipment of the well. These benefits, as well as others that will become apparent from the disclosure made herein, provide time and cost savings to a well operator.
In one or more of the embodiments described herein, the plug has a radial edge which is vulnerable to the application of non-uniform shearing forces. The plug may be destroyed through application of increased pressure upon the housing carrying the plug that actuates a plug rupture mechanism which in turn destroys the integrity of the plug proximate its radial edge. This allows the plug to be substantially eliminated from the blocked conduit within a short period of time thereafter.
The plug is comprised of a salt and sand mixture which is highly resistant to fluid compressive forces but is subject to destruction under non-uniform shear forces proximate the radial edge and tensile forces at any location. The plug is encased within a plug sleeve. The sleeve is encased within a plug housing which may be disposed within the well bore. In an exemplary embodiment, the sleeve is associated with the housing so that fluid may be displaced about the plug sleeve as the housing is disposed into the well bore. In this capacity, the plug allows the well fluids to pass therethrough and fill the tubing above the plug during disposal into the well. This prevents the tubing from having to be filled from the surface to balance the hydrostatic pressures inside and outside the tubing. When the plug has reached the desired location within the wellbore, the plug sleeve is positioned within the housing so that fluid flow is blocked. This is considered to be a "check" position because the plug is blocking fluid flow in one direction (downward) in this position while it would permit flow in the other direction (upward).
An annular shear member presenting a point stress portion is contained within the plug sleeve and detachably connected thereto. When required, the shear member is released from the surrounding plug sleeve and the point stress portion forced against the radial edge plug to substantially destroy the plug structure. The plug material is substantially dissolvable within the well bore fluids to permit reestablishment of fluid flow therethrough and operations within the well bore shortly thereafter.
An apparatus commonly referred to as a plug assembly for temporarily closing a subterranean fluid conducting conduit which may include well casing, tubing string, or conduits within downhole equipment is illustrated, disclosed and claimed herein. The plug assembly includes a tubular housing disposed within the fluid of a subterranean well. There is a temporary plug positioned within the housing for blocking fluid passage through that housing. Also positioned within the housing is a mechanical fracturing means for breaking the temporary plug so that fluid flow through the housing is permitted. The temporary plug is constructed at least partially from material that is dissolvable in the well fluid. The dissolvable portion of the temporary plug includes an aggregate and binder that are solidified into a substantially rigid frangible member that is the plug body. Because the binder dissolves in the well fluid, the individual pieces of aggregate are released one from the other. By including the aggregate, the time required to dissolve the binding material is hastened because the aggregate falls away from the binder thereby exposing increased amounts of surface area of the binder to the dissolving well fluids. The size of the aggregate is such that each particle is sufficiently small so that it will not impede other operations performed within the well after the plug deteriorates. It is contemplated that the aggregate may also be dissolvable in the well fluids. The speed with which the aggregate dissolves in the well fluid would, however, differ from the time it take the binder to dissolve.
In an exemplary embodiment, the aggregate is sand particles and the binder is salt. To assure that the sand particles do not foul other operations, it has been found to be advantageous, but not critical, to employ sand particles having a diameter of about 1 millimeter.
In one preferred embodiment, the temporary plug is at least partially contained within a dissolving resistant encasement composed of substantially pure binder. A means for piercing the encasement to allow the well fluid access to the interior of said temporary plug may be provided.
A method for utilizing the above described temporary plug will include installing a temporary frangible plug within a housing located within a fluid conducting conduit and then disposing that housing into a well so that the plug is submerged in well fluid. The temporary plug is then fractured so that it breaks into pieces that are unsupportable within the housing and subsequently permits fluid flow through the housing. The plug is then dissolved into particles small enough that will not foul future operations within the well.
In another preferred embodiment, the temporary plug has an interior core of unbound aggregate contained within a flexible membrane. The aggregate is vacuum packed within the membrane so that the temporary plug is substantially rigid while the vacuum is maintained within the membrane. To remove the temporary plug, a means for piercing said membrane is provided that opens an avenue for allowing the well fluid access to the interior of the temporary plug. A corresponding method of utilizing this embodiment includes installing the temporary plug within the housing that is located within a fluid conducting conduit. The housing is then disposed into a fluid filled well so that the plug is submerged. The membrane is then pierced so that the vacuum pressure (differential across the membrane) is balanced to allow the previously substantially rigid plug to collapse and become unsupportable within the housing. As a result, fluid flow is similarly permitted through the housing. After collapse, the loose aggregate is released from the membrane and removed away from the housing by the well fluid.
Still another embodiment has a temporary plug supported within a housing at a periphery of the plug. The plug is substantially spherically dome shaped. Due to this shape, the forces experienced in the plug are almost exclusively compressive in nature. This may be contrasted with known frangible disks which are flat and vulnerable to breakage because of the tensile and shear stresses induced during operation. In a flat frangible disk, great tensile forces may be experienced on the lower face of the plug body that is away from the applied pressure while great shear forces are experienced about the periphery of the disk at the points where the edge of the disk bears upon the support structure. In combination, these stresses compromise the integrity of the flat disk's operation.
It may be similarly stated that the invention disclosed herein includes a frangible plug for disposal in a well bore to block fluid flow therethrough. The plug has a radial edge and is substantially rupturable upon the application of non-uniform shear forces proximate the edge of the plug. After rupture, the plug is substantially eliminated from the well bore by dissolving the resultant pieces in the well fluids. A method for employing the plug will include disposing the frangible plug within a well bore to block fluid flow therethrough. After use, the plug is then disposed of by using a plug rupture mechanism proximate the plug which is actuatable by the introduction of increased pressure within the plugged conduit. In one embodiment, the plug rupture mechanism comprises a pair of nested radial support members which are selectively separable to alter radial support of the plug thereby rendering the plug vulnerable to substantial destruction by well bore pressure.
Alternative embodiments are described wherein the plug is comprised of vacuum packed aggregate within a flexible encasement or made of a ceramic or glass material or of liquid soluble metals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A through 1C depict alternative embodiments of an exemplary plug constructed in accordance with the present invention.
FIG. 2A depicts a plug assembly constructed in accordance with the present invention during disposal within a well bore.
FIG. 2B depicts a plug assembly constructed in accordance with the present invention with the plug set against fluid flow.
FIG. 2C depicts destruction of the plug by the shear member.
FIG. 3 depicts an alternative plug assembly wherein the plug is comprised of a domed glass or ceramic material.
FIG. 4 and 5 depict an embodiment in which selective well fluid access is provided by breaking the sleeve in which the plug body is carried.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1A, there is shown an exemplary, temporary plug 10 having a convex upper side 11 and concave lower side 12, as well as an upwardly, outwardly angled vertical, conical surface 13. The interior portion of the plug 10 may be comprised of any material, or combinations of materials, that will either dissolve into the well fluids or break down into particles sufficiently small that those particles do not foul other components of the well or services performed therein. It is anticipated that the plug 10 will typically be comprised of a small aggregate and a binder material. The binder will usually be dissolvable in the well fluids and the aggregate will be small enough that it becomes suspended in the well fluids for transport therewith. In the event that the well fluids are too thin to support the aggregate, then the individual particles will be small enough that their presence does not interfere with other operations within the well. An example of an acceptable binder is salt and an example of an acceptable aggregate is sand. The use of sand in the plug's 10 composition assists the breakdown of the plug material in the well fluid after the initial integrity of the plug 10 is mechanically destroyed. The sand increases the porosity and permeability of the plug 10, thereby providing greater surface area upon which the dissolving forces of the fluid can act.
As shown, plug 10 is comprised of a salt and sand mixture. In a preferred embodiment, the sand is very fine and has substantially no particles larger than 1 millimeter in diameter. The salt may be of the granulated "table salt" variety. The exact proportions of sand to salt are not critical; a mixture of approximately 50% of each by weight has been found to be acceptable. A small amount of liquid is added to the mixture so that a plug 10 may be formed by densifying and solidifying the constituent materials under pressure and heat.
The plug 10 is formed in an. appropriately shaped mold to which the pressure and heat are applied. The temperature must be sufficient to drive off the moisture in the sand and salt mixture. In typical downhole applications in oil and gas wells, the resulting molded plug 10 should be capable of enduring compressive forces on the order of 3000 pounds per square inch (psi) and temperatures of 100° C. The plug should also have been sufficiently compressed so that it resists vibrations experienced within the well environment.
In one embodiment, the surface areas of the plug 10 that are exposed to well fluid are sealed. At the same time, the plug 10 should be sufficiently brittle to be vulnerable to shear destructive forces such as upon the application of a point stress of a selected magnitude.
It is supposed that the pressures to be contained by the plug 10 will be from above. Therefore, the plug 10 is oriented to contain those pressures while minimizing the amount of tensile stress experienced within the body of the plug 10. It is anticipated, however, that the plug 10 could be oriented to contain pressures from below, or any other direction. Therefore, in the exemplary illustrations the plug is upwardly arced shaped to provide optimum resistance against downwardly acting fluid compressive forces in a well bore. It is noted that in the preferred embodiment of FIG. 1A, the arc of concave surface 12 would correspond roughly to a segment of a smaller sphere than that to which the arc of convex surface 11 corresponds. Surface 13 is preferably angled outwardly in a conical shape. It should be appreciated, however, that the dimensions of the plug 10 are governed by the distance it must span to plug a particular conduit, and therefore are variable.
The integrity of the salt and sand plug 10 just described may be improved by the application of a thin protective fluid impermeable coating 15, such as epoxy, upon surfaces 11 and 12 to seal the plug surface against the well fluid. In addition, portions of the exterior of the plug 10 may be encased in a flexible sheath or encasement 17 for protection against the well bore fluids. Neoprene rubber or other soft rubbers are suitable for constructing the encasement 17.
Alternatively, the plug material within the encasement 17 may be only sand which is vacuum packed therein. The vacuum pressure within the encasement 17, having a magnitude of approximately one atmosphere, will maintain the sand grains in dense engagement with each other to prevent relative motion therebetween. It should be understood that the relative pressure upon the encased material will increase as the plug 10 is disposed further into the well due to hydrostatic pressure. Therefore, during operation, the vacuum pressure applied to the aggregate will be equal to the hydrostatic pressure, plus one atmosphere. When it is desired to remove such a vacuum packed plug 10 from a conduit, the encasement 17 is punctured or otherwise ruptured causing the contained sand to be liberated and the encasement to collapse. It is also possible that the sheath or encasement 17 will break into several pieces. Therefore, the sheath 17 should be thin enough so that resulting pieces do not present impedances to tools disposed within the well bore following destruction of the plug. Still further, the encasement 17 may be constructed from a material that will eventually dissolve in the well fluids, but not within the expected service time of the plug 10.
Referring now to FIG. 1B, an alternative embodiment of a plug 20 is shown which is shaped substantially the same as plug 10. Plug 20 contains a central portion 21 which may be comprised of a sand/salt mixture as previously described. An outer crust 22 is formed around the central portion 21. FIG. 1C illustrates a variation on plug 20 in which caps 27 and 28 are constructed similarly to the crust 22. The crust 22 may be comprised of substantially 100% binder which is compressed and heated to be formed integrally with the central portion 21 of the plug 20. In an exemplary embodiment, salt has been utilized as the crust 22 Testing has shown that plug material formed substantially of all salt is more resistant to compressive forces and degradation from well bore fluids than plug material of a salt/sand mixture. Therefore, a crusted combination as illustrated provides a stronger plug that initially retains its rigid form but subsequently breaks down quickly once the crust erodes allowing well fluid into the central portion. During construction of the plug 20, the thickness of the crust 22 will be governed by the desired time period before the soluble crust is sufficiently dissolved to expose a portion of the central portion 21, following which destruction of the plug occurs rapidly.
Turning now to FIG. 2A, an exemplary plug assembly 50 is shown which includes an outer plug housing 52 which is substantially tubular in shape and adapted to be connected in a tubing string (conduit) disposed within a well bore in which a temporary plug is desired. The housing 52 includes an upper section 53 threadedly connected at joint 57 to a lower section 55. Upper section 53 has a radially enlarged bore section 54 having a downwardly facing, inward frusto-conical shoulder 56 and the upper terminal end of lower section 55 forms an upwardly facing, frusto-conical sealing shoulder 58. Upwardly facing sealing shoulder 58 is preferably angled inwardly at an approximate angle of 45°.
Within the radially enlarged bore section 54 is slidably disposed a plug sleeve 60 having an upper longitudinal end 62 adapted to contact the upper inwardly disposed annular shoulder 56 of the housing 52. Fluid flow ports 64 are disposed about the circumference of the sleeve 60 proximate upper end 62. Sleeve 60 also forms a tapered conical section 66 which is downwardly, inwardly tapered and disposed below the flow ports 64. A radially expanded section 68 is disposed below the conical section 66 and forms an annular bearing portion 69 between sections 66, 68. Downward shoulder 75 is disposed about the interior circumference of sleeve 60.
Within the tapered section 66 of sleeve 60 is disposed a frangible plug 70 which may be of any one of the types described or depicted with respect to FIG. 1A-1C. The plug 70 is preferably tightly received within the conical section 66. In one preferred embodiment, the plug 70 may be formed and prestressed within the tapered section to afford it greater strength against liquid compression forces while disposed within a well bore. Alternatively, the plug may be formed separately and pressed and bonded into the sleeve with a suitable sealing glue compound, such as rubber cement or the like. In any event, the interior central portion of the plug will be shielded from the well fluid.
An annular shear member 72 is disposed within the sleeve 60 and features an upper reduced diameter portion 61 forming an outwardly facing annular shoulder 74 which is received within the radially expanded section 68 of the sleeve 60. The upper terminal end of member 72 is supported by bearing portion 69. One or more elastomeric seals 76 may be used to seal the connection between shear member 72 and the sleeve 60. A shear ring 78 detachably connects the sleeve 60 to the shear member 72. Shear member 72 presents a point stress portion 80 directed toward the plug 70. Preferably, the point stress portion comprises an arcuate support shoulder 81 located proximate a portion of the bottom radial edge of plug 70 and an arcuate tapering non-supporting shoulder 83 which tapers downwardly from support shoulder 81 and away from the bottom of plug 70. Shear member 72 presents a lower annular frusto-conical shoulder 82 adapted to sealingly engage shoulder 58. In operation, the shear ring 78 will preferably require a preselected shear force to shear and release shear member 72 from sleeve 60. A lock wire 84 is disposed about the inner circumference of the enlarged bore section 54.
The plug assembly 50 is assembled substantially as shown in FIG. 2A during running of the plug assembly 50 into a well bore. Fluid is displaced around the plug 70 as the plug assembly 50 is disposed into the well bore. The resistance presented by the fluid in the well causes plug 70, shear member 72 and sleeve 60 to be carried in an upper most position during downward travel through the fluid. In the upper position, fluid from below flows between shoulders 82 and shoulder 58, into the annular area 89 formed by sleeve 60 and housing 52, and ultimately through flow ports 64 upwardly into flow bore 91.
When the plug assembly 50 has been disposed to the proper depth within the well bore, fluid pressure is applied to the top of the plug 70 causing the plug 70, shear member 72 and sleeve 60 to shift downwardly, as illustrated in FIG. 2B such that sleeve 60 moves downwardly within housing 52 until shoulder 82 meets and seals against shoulder 58, thereby establishing a metal-to-metal seal against fluid flow. In this position, the plug assembly 50 seals against fluid transfer across the plug 70.
When it is desired to break down the plug 70, sufficient fluid pressure is applied to plug 70 to force the downward movement of sleeve 60 within housing 52. Downward movement of sleeve 60 will result from pressurizing the interior of housing 52 to a degree sufficient to cause shear ring 78 to shear. FIG. 2C illustrates this operation. Once shear ring 78 is sheared, the fluid pressure on top of the plug 70 and sleeve 60 causes plug 70 and sleeve 60 to snap downward within housing 52 since sleeve 60 is no longer supported by shear ring 78. The plug 70 is then forced downwardly against the arcuate support shoulder 81 of point stress portion 80 of shear member 72 that acts as a plug rupture mechanism. Point stress portion 80 applies non-uniform shearing forces proximate the radial edge of plug 70. The non-uniform shear forces applied by the shear member 72 are sufficient to pierce any protective coating or encasement that may be present and then break the frangible plug 70 into pieces. Downward movement of the sleeve 60 with respect to shear member 72 will ultimately be limited by the engagement of opposing shoulders. Lock wire 84 maintains housing 52 and sleeve 60 in non-sliding engagement after the sleeve 60 has moved downward.
Once the plug 70 has been broken into smaller pieces or the interior exposed to the well fluids, complete break down follows soon thereafter. The salt in the plug 70 is dissolved by the well bore fluid, leaving the sand to unconsolidate and either innocuously settle in the well or blend with the well fluids.
FIG. 3 depicts an alternative embodiment of the present invention featuring a plug assembly 100 having a plug 102 made of rigid and brittle material such as glass or ceramics. The ceramic or glass plug 102 may take a form different from that of the plugs previously described, but have similar effectiveness as a fluid barrier. Plug 102 may be considerably thinner than the sand and salt type plugs described earlier and be substantially dome shaped with the radii of curvature of upper and lower surfaces 104 and 105 being roughly the same.
Plug assembly 100 includes an upper housing 106 and lower housing 108 which form a flow bore 109 therethrough. The upper and lower housing 106 and 108 are threadedly connected at 110 to form a radially enlarged bore section 112. Plug 102 is disposed in a fixed relation within upper housing section 106 so as to block fluid flow through fluid flow bore 109; by orienting the plug 102 so that the convex portion of the dome is upwardly facing, a greater fluid force may be resisted for above the plug 102. Fluid flow will, however, be blocked in both directions. An upper piston 114 radially surrounds and contacts the outer edges of upper surface 104 of plug 102. O-rings 116 and 118 ensure a fluid tight seal between the plug 102 and the piston 114. Plug 102 is supported radially by outer support member 120 and inner support member 122 which is nested therewithin. Inner support member 122 is an annularly shaped ring-type member having a number of slots 124 cut into its upper portion. It also presents inwardly facing upper arcuate shoulders 126 upon which the radial edges of plug 102 are seated. Outer support member 120 is also an annularly shaped, ring-type structure which surrounds inner support member 122 and presents inwardly projecting protuberances which reside within slots 124 when inner support member 122 is nested within outer support member 120. Sleeve 130 supports the outer and inner support members 120 and 122. Sleeve 130 is detachably connected to ring 132 by means of a shear wire or other shear mechanism 134. Ring 132 is seated on shear member 136 which abuts the lower housing 108.
In operation, the plug 102 will resist downward compression through flow bore 109 as the glass or ceramic structure of plug 102 will be predominantly stressed by relatively uniform compressive forces since the edges of the plug 102 are firmly supported between the piston 114 above and the inner and outer support members 120 and 122 below.
If it is desired to destroy plug 102, a pressure must be applied into flow bore 109 which exceeds the shear value of the shear wire 134. For this reason, the value of the shear wire or other shear mechanism must be set in excess of those operating pressures under which plug 102 is designed to resist. Increased pressure downward through flow bore 109 will act across the surfaces of plug 102 and piston 114, urging them downwardly along with outer and inner support members 120 and 122 and sleeve 130. When shear wire 134 is sheared, inner sleeve 130 will move downward with respect to ring 132 and shear member 136. As this occurs, ring 132 blocks downward movement of outer support member 120 but not inner support member 122. The radial support of the edges of plug 102 at shoulders 126 will now be removed and plug 102 will be supported solely by the protuberances 128 of the outer support member 120. This creates non-uniform shear forces proximate the edges of the plug 102. The lack of uniform support for the plug 102 will allow the pressure within the flow bore 109 to destroy plug 102 thereby acting as the plug rupture mechanism. Ideally, the plug 102 breaks into a number of small pieces as a result of the stress patterns. Once ruptured, the pieces of plug 102 should be sufficiently small so as not to foul other operations subsequently performed within the well. As a result, the plug 102 is substantially eliminated from the wellbore.
In a variation of this embodiment, it is contemplated that a water soluble metal may be used to construct the plug 102. After physical destruction of the metal plug, the well bore fluids dissolve the plug fragments within a short time thereafter.
A further exemplary embodiment of the present invention is shown in FIGS. 4 and 5. In this embodiment, the plug rupture mechanism provides selective well fluid access to portions of the radial edge of the plug 70 which are readily degradable by fluid contact. It is noted that plugs which are suitable for use in plug assemblies of this type are those constructed similar to or shown in FIG. 1A-C.
FIGS. 4 and 5 illustrate cross-sectional views of an exemplary plug assembly 150. To aid in illustrating the operation of the plug assembly 150, the figures present juxtaposed halves of the tool in different stages of operation. The right half of FIG. 4 illustrates the assembly 150 as it would appear while being disposed downwardly within the well bore and permitting fluid flow upwardly around the plug 70. The left half of FIG. 4 shows the plug assembly 150 set for fluid flow blockage. The right half of FIG. 5 shows the plug assembly 150 after initial plug rupture. The left half of FIG. 5 illustrates the configuration of the assembly 150 following substantial destruction of the plug 70.
The assembly 150 includes an upper adaptor 152 with upper threads or other connector means 154 which permit the assembly 150 to be incorporated within a conduit. Upper adaptor 152 is connected at thread 156 to plug housing 158. Plug housing 158 includes lower adaptor threads 160 for connection with other portions of a conduit. A central portion of housing 158 includes sleeve bore 162 having inner upward facing shoulders 164, 166 and 167.
Above sleeve bore 162 is radially expanded fluid flow bore 168 which presents an annular upward facing shoulder 170. Annular ring 172 is disposed proximate fluid flow bore 168 within the housing 158 and features an annular lower shoulder 174 which is adapted to be generally complimentary to shoulder 170. It is preferred that shoulders 170 and 174 do not form a seal, but, when engaged, will permit fluid flow therebetween. Ring 172 features a number of lateral ports 176 about its periphery.
Sleeve bore 162 contains a sleeve 178 which is slideably received therein. Sleeve 178 presents an outwardly tapered plug support section 180 with an upper ring contacting portion 182. The outer radial surface of sleeve 178 presents a downwardly facing shoulder 184. The sleeve also presents a lower edge 186 which is complimentary to seat 188 of sleeve support member 190. Sleeve support member 190 is shear pinned at 192 to plug housing 158 and features lower edge 191.
During disposal within a well bore, assembly 150 permits fluid flow around the plug sleeve 178 in a manner similar to that described with respect to previous embodiments and as shown in the right side of FIG. 4.
When disposed within a well bore for blockage of fluid flow therethrough as illustrated in the left half of FIG. 4, plug sleeve 178 is moved downwardly within bore 162 until lower edge 186 contacts seat 188 to form a seal against fluid flow therethrough. In this portion, little or no fluid flow is permitted between shoulder 174 and ring contacting portion 182 toward portions of plug 70.
Upon application of increased pressure within the well bore 151, sleeve 178 is shifted downward as shown in the right half of FIG. 5 until downward facing shoulder 184 of the sleeve 178 contacts shoulder 164. Upward facing shoulder 166 may also act to limit downward movement of sleeve support member 190 and edge 191 will ultimately be limited from excessive downward movement by shoulder 167. In this downward position, pressurized fluid within well bore 151 passes through ports 176 outward into radially enlarged fluid flow bore 168 and between shoulders 170 and 174. Due to the separation of ring contacting portion 182 and shoulder 174, fluid is permitted to contact plug 70 proximate its upper radial edge to begin dissolution of the plug 70 as previously described. After a period of time, plug 70 dissolves as shown in the left half of the FIG. 5.
While the invention has been described with respect to preferred embodiments, modifications thereof can be made by one skilled in the art without departing from the spirit of the invention. | A method and apparatus for establishing a fluid plug within a well bore which can then be substantially destroyed upon demand to permit reestablishment of the well within a short period of time thereafter. Increased pressure actuates a plug rupture mechanism which destroys the integrity of the plug and allows the plug to be substantially eliminated from the wellbore within a short period of time thereafter. In described preferred embodiments, the plug is comprised of a salt and sand mixture which is highly resistant to fluid compressive forces but is subject to destruction under shear tension forces. The plug may be encased within a plug sleeve which is, in turn, encased within a plug housing which may be disposed within the well bore. The sleeve is associated within the housing so that fluid may be displaced about the plug sleeve as the housing is disposed into the well bore. When the plug has reached the proper position within the well bore, the plug sleeve may be set within the housing such that fluid flow is stopped. A shear member is contained within the plug sleeve and detachably connected thereto. When required, the shear member may be released from the surrounding plug sleeve and forced against the plug to substantially destroy the integrity of the plug through introduction of shear tension forces within the plug structure and reestablish fluid flow through the housing. The plug is further dissolved into well bore fluids to substantially destroy it. | 4 |
[0001] The invention relates to a method for impregnating a rope with a liquid material. The invention further relates to a device for carrying out the same.
BACKGROUND OF THE INVENTION
[0002] It has been the universal commercial practice to pass a rope slowly through a bath of liquid material to permit the material to penetrate the voids or interstices of the rope. Such a method and a device for carrying out the method are known from U.S. Pat. No. 3,960,050 wherein the rope is placed in a basket which is immersed in an impregnation tank containing the liquid material to be impregnated in the rope. Alternatively, the rope may be passed through an impregnation bath containing said liquid. U.S. Pat. No. 3,960,050 also describes a device for carrying out the method disclosed therein. Further methods for impregnating a rope and devices for carrying out said methods are known from U.S. Pat. No. 4,197,695 wherein an impregnation bath or an impregnation closing die are used; U.S. Pat. No. 4,490,969 wherein an impregnation bath or a spraying device are used; U.S. Pat. No. 5,098,493 wherein injection needles are used; and U.S. Pat. No. 4,635,432 wherein an injection die is used.
[0003] Another device for impregnation is disclosed for example in U.S. Pat. No. 1,587,652 which is used to saturate a fibrous material in particular a felt sheet with e.g. asphalt. The device disclosed therein contains a pressure saturating chamber which uses high pressure, i.e. pressure higher than the atmospheric pressure, to cause the asphalt to penetrate the sheet. After saturating or impregnating the sheet using high pressure, the device may subsequently use vacuum to extract any moisture or air trapped therein; and then the sheet may be again subjected to saturation under great pressure. Vacuum however is not used during the saturation step.
[0004] CA 768356 also discloses a device for impregnating a textile, the device comprising an impregnation bath containing an impregnant and a vacuumed column located within the impregnant such that the impregnant acts as a seal for the bottom of the column. Just as in U.S. Pat. No. 1,587,652, vacuum is used to extract any air which may be retained within the impregnated textile. A device similar to the one of CA 768356 is disclosed by JP 48-41094.
[0005] Another disclosure of a device for impregnating a wire rope is given by JP 2005 264358. The device disclosed therein operates in a batch-like fashion wherein a portion of a length of the wire rope is placed in a vacuumed tube and a molten resin is injected under pressure in said tube, to impregnate said portion. After impregnation, the vacuum is released, the impregnated portion of the rope is removed from the tube and a portion of the adjacent non-impregnated part of the rope is placed in the tube. The operation is repeated to impregnate the complete length of the rope.
[0006] Moreover, although impregnating a rope and coating a rope are in principle two different processes with different characteristics, in some instances is arguable that the methods for coating a rope may also achieve some low degree of impregnation. A method for coating a rope is described for example in JP 5 510 2457, wherein the rope is coated with grease by injecting the grease into a chamber while the chamber moves along the length of the rope. The thickness of coated grease is controlled by the size of the gap between the outer periphery of the rope and the internal periphery of the outlet of the chamber which discharges the rope. Further methods for coating ropes wherein some degree of impregnation may be achieved are known from U.S. Pat. No. 4,067,211 wherein a spraying method is used for coating the rope; and U.S. Pat. No. 8,105,657 wherein a coating chamber is used.
[0007] It was however noticed that the results obtained with the known impregnation or coating methods may depend on the modus operandi, or in other words, to the skills of the operator, i.e. the person carrying out the method. The rather poor reproducibility of such methods typically implies that the quality of the impregnation may vary with the skills of the operator and in turn, impregnated ropes forming for example a rope batch may have inconsistent properties. Also due to the employment of complicated machinery and/or heavy hardware, the known methods may be cumbersome to use and even pose safety risks.
[0008] It was also noticed that the above mentioned methods have difficulties in achieving an optimum degree of impregnation; in particular since the liquid material does not always optimally penetrate inside the rope. Moreover, achieving sizeable rope lengths which are optimally impregnated with the liquid material along a significant, preferably entire, length thereof is hardly possible. Especially for thick ropes, e.g. ropes having an effective diameter of more than 10 mm and even more than 20 mm, it was observed that the liquid material hardly penetrates fully the rope reaching the core of the rope also. Such an uneven distribution of the liquid material inside the rope may in turn cause a reduced life time thereof and even variations in rope strength along its length during its use.
[0009] To partly solve the above drawbacks and in particular the inhomogeneous penetration, methods were devised where ropes were assembled from previously coated fibers or coated strands containing fibers. Such a method is for example disclosed in DE 749 220. Therein, before constructing a rope, the individual elements of the rope, e.g. fibers, yarns of strands, are coated or impregnated by passing several filaments through an impregnation bath and thereafter combining them in an elongated nozzle tube. However, processes such as the one of DE 749 220 are very complicated and extremely polluting. Also, it came as a surprise for such methods that in spite of distributing a liquid material on each fiber or strand of the rope, the exterior of the rope assembled from said fibers and/or strands contained less liquid material than the core of the rope. Hence, even for such methods the degree of rope impregnation can be optimized.
[0010] Accordingly, the object of the present invention may be to provide a method for coating a rope which shows the above mentioned disadvantages to a lesser extent. In particular, the present invention aims to provide a method for more uniformly impregnating a rope with a liquid material and a device for carrying out said method.
SUMMARY OF THE INVENTION
[0011] The invention proposes a method for impregnating a liquid material into a rope comprising a plurality of fibers and interstices between said fibers, said method comprising the steps of:
a. Providing a liquid material in a tank, said liquid material defining a level of liquid in said tank; b. Providing an impregnation unit containing a chamber at least partially immersed in said liquid material, said chamber comprising:
i. a rope-inlet for tightly receiving the rope, wherein said rope-inlet is positioned below the level of liquid; ii. a rope-outlet for tightly discharging said rope; iii. a vacuum-outlet; and
c. Providing a vacuum-device operatively connected to said vacuum-outlet for lowering the pressure in said chamber below the atmospheric pressure; d. Passing the rope through the liquid material in the tank and then inside and outside said chamber via the rope-inlet and rope-outlet, while maintaining the pressure inside said chamber below the atmospheric pressure to force the liquid material to fill at least part of said interstices between the fibers of the rope by penetrating between said fibers.
[0019] It was observed that the method of the invention has an increased safety factor and offers good reproducibility as well as a high level of ergonomics. Ropes with a uniform distribution of the liquid material, as observed on a cross-section of the rope, may be produced. The method of the invention also seems less sensitive to the type of the liquid material used for impregnation or to the characteristics of the rope to be impregnated, e.g. the construction, diameter or material thereof. In particular it was observed that with the method of the invention the efficiency of the impregnation was optimized, e.g. the liquid material reached the core of the rope, which in turn led to a larger quantity of liquid material present inside said rope than it was obtained heretofore. Another important advantage of the method of the invention is that said method can be applied continuously.
[0020] The invention also relates to a device for carrying out the method of the invention, which comprises:
a. A tank comprising a liquid material, said liquid material defining a level of liquid in said tank; b. An impregnation unit containing a chamber at least partially immersed in said liquid material, said chamber comprising:
i. a rope-inlet for tightly receiving the rope, wherein said rope-inlet is positioned below the level of the liquid material in the tank; ii. a rope-outlet for tightly discharging said rope; iii. a vacuum-outlet; and
c. A vacuum-device operationally connected to said vacuum-outlet for lowering the pressure in said chamber below the atmospheric pressure.
[0027] The device of the present invention makes use of vacuum to force the liquid material from the tank inside the rope, between the fibers forming the rope, such that said liquid material fills voids, pores and interstices present in the rope and effectively coats the individual fibers of which the rope is composed. In other words, in order to force the liquid material to penetrate inside the rope and in-between the fibers of the rope to fill out said voids, pores and interstices, a pressure difference is created in respect with the atmospheric pressure with the lower pressure being in the chamber. This pressure difference forces the liquid material to flow inside the chamber between the fibers of the rope and thus filling out said voids, pores and interstices. Therewith in order for the device to operate properly, a pressure difference Δ, wherein Δ=P atm −P chamber , needs to be maintained throughout the impregnation process, with a pressure in the chamber (P chamber ) that is lower than the pressure outside the chamber. Typically, the pressure outside the chamber is the atmospheric pressure, hereinafter denoted as P atm . Preferably Δ is maintained at a constant level to ensure for a uniform impregnation of the rope. Δ can vary widely depending on e.g. the rope characteristics, e.g. rope tightness, diameter and materials used; but also time needed for impregnation and characteristics of the liquid material, e.g. viscosity. For example, the higher the diameter of the rope or the tightness of the rope, applying a higher Δ can be considered. On the other hand when dealing with a rope having a specific construction, applying a higher Δ may imply that more liquid material impregnates the rope. In one embodiment, it is preferred that Δ is at least 0.05 bar, more preferably at least 0.1 bar, most preferably at least 0.5 bar. For example, a Δ of 0.05 bar when the P atm is 1 bar would correspond to a P chamber of 0.95 bar. Although not limited for upper values, for practical reasons, preferably Δ is at most 10 bar, most preferably at most 5 bar, most preferably at most 3 bar.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The invention is further illustrated by the following drawings:
[0029] FIG. 1 is a schematic representation of the device for carrying out the method of the invention.
[0030] FIG. 2 is a picture showing the difference between a rope impregnated with known methods and a rope impregnated using the device of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The invention proposes a method for impregnating a liquid material into a rope comprising a plurality of fibers and interstices between said fibers. With reference to FIG. 1-1 , the device ( 100 ) for carrying out the method of the invention comprises a supplying device (not shown) such as a bobbin or an unwinder from which the rope ( 101 ) to be impregnated is supplied through rollers ( 102 ) to the impregnation unit ( 103 ). The impregnation unit ( 103 ) is immersed into a tank ( 104 ) comprising a liquid material ( 105 ) to be impregnated into the rope ( 101 ).
[0032] The impregnation unit ( 103 ) comprises chamber ( 106 ), the chamber having preferably an inversed T shape and containing a rope-inlet ( 107 ) for receiving rope ( 101 ); a rope-outlet for discharging rope ( 101 ) and a vacuum-outlet ( 109 ). A vacuum device (not shown) such as for example a vacuum pump is operatively connected to the vacuum-outlet ( 109 ) via a system of pipes for example and is used to reduce the pressure inside the chamber ( 106 ) below the atmospheric pressure. The reduced pressure inside the chamber ( 106 ) will cause a flow of the liquid material ( 105 ) from the tank ( 104 ) into the chamber ( 106 ) between the fibers of the rope ( 101 ). During the method of the invention, the liquid material ( 105 ) is continuously transported from the tank ( 104 ) into the chamber ( 106 ) and may also accidentally enter the vacuum outlet causing a pollution of the vacuum device. To prevent such pollution, a buffer vessel (not shown) may be provided preferably between the vacuum outlet and the vacuum device. Also a feedback system (not shown) may be utilized where the liquid material from the buffer vessel is fed back to the tank ( 104 ) to replenish the amount of the liquid material ( 105 ).
[0033] The liquid material ( 105 ) has a defined liquid level ( 105 - 1 ) inside the tank ( 104 ) which is preferably maintained constant during the impregnation process. This can be carried out by using for example the feedback mechanism described hereinabove provided with a liquid-feeding system (not shown) and a liquid level detector which triggers a replenishing mechanism when the level ( 105 - 1 ) drops below a set point.
[0034] The rope-inlet ( 107 ) and the rope-outlet ( 108 ) tightly receive and discharge the rope ( 101 ), respectively. This may be carried out by using sealing means ( 110 ) or any other type of valves (not shown in figures), e.g. pneumatic diaphragm valves, of suitable character so that the pressure in the chamber ( 106 ) may be lowered and maintained at the desired level.
[0035] As shown in FIG. 1-1 , the rope ( 101 ) having an outer-surface ( 101 - 1 ) is received by the rope-inlet ( 107 ) of the chamber ( 106 ), said rope-inlet having an inner wall ( 107 - 1 ). The sealing means ( 110 ) is positioned between the rope outer-surface ( 101 - 1 ) and the inner wall ( 107 - 1 ) of the rope-inlet ( 107 ) to provide a tightly sealing thereof.
[0036] A preferred sealing means is a tapered sealing device having for example a shape of a frustum of a cone ( FIG. 1-2A ). Such a shape of the tapered sealing device may ease its installment while being less sensitive to the size of the rope used or to the dimensions of the rope-inlet or of the rope-outlet contained by the impregnation unit. Moreover, such a device usually has good sealing properties. With reference to FIG. 1-2A , the tapered sealing device contains an admission inlet ( 110 - 1 ) with lateral dimensions, e.g. diameter, adjusted to accommodate the rope such that a tight fit between said device and the rope is achieved. The tapered region ( 110 - 2 ) also has dimensions adjusted to accommodate the rope-inlet ( 107 ) or the rope-outlet ( 108 ), respectively, such that a tight fit between said device and the respective inlet or outlet is achieved. The skilled person can routinely determine the necessary dimensions of said admission inlet ( 110 - 1 ) and of said tapered region ( 110 - 2 ) with due regard to the size of the rope to be impregnates as well as of the rope-inlet and of the rope-outlet of the impregnation unit such that an optimum tight fit is achieved.
[0037] A second preferred embodiment of a sealing means is a sealing device having essentially a cylindrical shape ( FIGS. 1-2B ) and containing an admission inlet ( 110 - 1 ) for receiving the rope, wherein said device has an inner surface ( 110 - 11 ) and a outer surface ( 110 - 2 ) wherein said inner surface and/or said outer surface are provided with a plurality of protrusions ( 110 - 12 ) and ( 110 - 21 ), respectively, said protrusions preferably having a cross-section defined by a height ( 110 - 6 ) and a width ( 110 - 7 ). Although referred to as essentially cylindrical shape, is it understood that the shape of the sealing device may vary in order to tightly engage the rope and the inner wall of the rope-inlet and of the rope-outlet, e.g. said sealing device may have two, preferably parallel, bases connected to each other by at least one lateral face, wherein said parallel bases may be polygons or may have a rounded shape, e.g. elliptic or circular. The protrusions of the inner surface, hereinafter referred to as the inner protrusions, define an effective inner diameter ( 110 - 3 ) which is the smallest distance between the tips of two opposite inner protrusions. The protrusions of the outer surface, hereinafter referred to as the outer protrusions, define an effective outer diameter ( 110 - 4 ) which is the largest distance between the tips of two opposite outer protrusions. The sizes of the inner and/or outer protrusions are adjusted to provide a tight fit with the outer surface of the rope and with the inner wall of the rope-inlet and/or of the rope-outlet.
[0038] Is to be understood that the above-mentioned embodiments of the sealing means are only representative, without imposing any limitation on the shape or size of the sealing means. Any sealing means, such as gaskets, rubber sealing and the like, which ensures for a tight fitting between the rope outer surface and the inner wall of the rope-inlet and of the rope-outlet may be used. Moreover, the described embodiments should not be understood as being limited to the shapes and the sizes mentioned thereto. It is to be understood that the profiles of the rope-inlet and of the rope-outlet, as well as when applicable the profiles of the admission inlets of the sealing means, are determined by the profile of the rope to be impregnated. The skilled person can routinely determine such profiles.
[0039] By tightly receiving or discharging the rope it here understood that the liquid material ( 105 ) for impregnating the rope ( 101 ) which is stored in the tank ( 104 ) mainly flows from said tank ( 104 ) into the chamber ( 106 ) through the rope ( 101 ) between the fibers of said rope. The sealing means ( 110 ) preferably prevent the liquid material ( 105 ) to flow into the chamber ( 106 ) through an eventual opening between the sealing means and the inner wall of the rope-inlet or rope-outlet, respectively. By the term “mainly flows” is herein understood that leakages are acceptable wherein the liquid material can flow, percolate or exude through an eventual space between the sealing means and the surface of the rope. It was observed that such embodiment may enable the manufacturing of a rope which not only is well impregnated but also optimally coated.
[0040] In one embodiment, the sealing means are adapted such that the rope-inlet and the rope-outlet are hermetically receiving and hermetically discharging, respectively, the rope. By hermetically receiving or discharging the rope is herein understood that the flow of liquid material between the sealing means and the surface of the rope is prevented in order to force most of the liquid material to penetrate the rope. The advantage of such an embodiment is that an optimally impregnated rope may be obtained.
[0041] The skilled person knows how to obtain a tighter, e.g. hermetical, fitting or a looser fitting between the sealing means and the rope surface by for example utilizing various known embodiments of valves or sealing means but preferably those disclosed hereinabove.
[0042] It is further preferred that the sealing means does not deform the rope ( 101 ) to be impregnated, by for example exerting a compressing action on said rope ( 101 ), since such deformation may minimize or even close the interstices between the fibers forming the rope, impeding therefore the flow of the liquid material ( 105 ) inside the chamber ( 106 ) between the fibers of said rope. To avoid such deformation, the sealing means may be constructed out of a resilient material, however, flexible enough to ensure for a minimized deformation of the rope passing thereto. Example of suitable materials for constructing said sealing means include widely known thermoplastic and thermosetting materials, most preferred being ones manufactured from rubber-based materials, i.e. having elastic properties. It was also observed that a suitable construction of the sealing means, such as the one of the second preferred embodiment presented hereinbefore, may minimize the deformation of the rope ( 101 ) passing through the sealing means. Avoidance of rope deformations may be achieved for example by adjusting the height ( 110 - 6 ) of the inner protrusions ( 110 - 12 ) and/or their width ( 110 - 7 ) to ensure for enough flexibility thereof.
[0043] Preferably, the sealing means are halved, i.e. they contain two, preferably symmetrical, parts ( 110 - 51 ) and ( 110 - 52 ) which engage each other in a tight fit such that an eventual gap ( 110 - 5 ) between the parts is minimized. Such a construction allows for an optimum installation thereof.
[0044] According to the invention, the rope-inlet is positioned below the level ( 105 - 1 ) of the liquid material ( 105 ). Although this ensures an optimum flow of the liquid material ( 105 ) between the fibers of the rope ( 101 ), it is also envisaged that in case the rope ( 101 ) needs to be impregnated only partially, the rope-inlet may be at least partially immersed in said liquid material. Furthermore, although the rope-outlet is shown in FIG. 1-1 as positioned below the level ( 105 - 1 ) of the liquid material ( 105 ), it is to be understood that said rope-outlet may be also positioned above said level of the liquid material. Such an embodiment offers several advantages, such as a cleaner impregnation process for example.
[0045] The rope ( 101 ) is passed through the liquid material ( 105 ), through the impregnation unit ( 103 ) and then out of the tank ( 104 ) via a system of driven and/or idle belts, e.g. caterpillars, rollers and/or winches. It is preferred that during the impregnation process, the rope ( 101 ) is kept under a tension Σ, wherein the tension Σ is sufficient enough to at least keep said rope taut. When the rope ( 101 ) is passed continuously through the liquid material and impregnation unit, the tension Σ should be high enough to ensure a preferably constant haul of said rope during the impregnation process. Preferably, said tension Σ is low enough not to deform the rope to the extent that the flow of liquid material ( 105 ) from the tank ( 104 ) into the chamber ( 106 ) between the fibers of the rope ( 101 ) is impeded.
[0046] Any liquid material suitable for rope impregnation can be used in accordance with the present invention. For example melts of polymeric materials such as those used typically in injection molding processes can be used for impregnation; suitable examples thermoplastics, thermosets and elastomers, more in particular polyolefins and polyolefin copolymers such as polypropylenes and polyethylenes, e.g. low density polyethylene (LDPE); liquid crystal polymers; acrylonitrile butadiene styrene copolymers (ABS); styrene-acrylonitrile copolymers (SAN); polyvinyl acetate (PVA) and ethyl-vinylk acetate (EVA) polyacrylates; polyamides; polybutadienes; epoxies; polyimides; silicon- and fluorosilicone-based rubbers and the like. Also materials such as pitch, tar, asphalt, or other hydrocarbon or bituminous compounds may be used. Also liquid formulation such as suspensions of various solids into a liquid medium may be used. Preferably the liquid medium is water. Suitable examples of solid materials suitable for manufacturing said suspensions, and in particular water based suspensions, include polyurethanes, epoxies, waxes, rubbers and silicone based materials.
[0047] The liquid material needs also to be able to flow under the pressure difference Δ between two locations, e.g. from the tank inside the rope, through a narrow passage, e.g. the passage dictated by the voids, pores and interstices of the rope. It is known that the extent to which a rope is impregnated depends upon at least three factors, namely the porosity of the rope, i.e. the amount and size of voids, pores and interstices thereof; the flow behavior of the liquid material; and the time allowed for impregnation, i.e. the speed with which the rope passes through the impregnation device. The flow behavior of a liquid material depends on its viscosity or in other words, the less viscous the liquid material is the easier it flows. The viscosity of the liquid materials used in accordance with the invention can vary between wide ranges, e.g. between water-like viscosities for diluted water based suspensions to melt-like viscosities for melts of polymeric materials. It is to be understood that the viscosity is not the limiting factor for carrying out the present invention as even higher viscosity liquid materials can be forced between the fibers of a rope by applying a larger pressure difference Δ between the atmospheric pressure and the pressure of chamber ( 106 ) and/or by using ropes having larges interstices between the fibers thereof.
[0048] By rope it is understood an elongated body having a length much larger than its lateral dimensions of for example width and thickness or diameter. The rope to be used in accordance with the invention may have a cross-section which is rounded or polygonal or combination thereof. Preferably, ropes having an oblong cross-section or a circular cross-section are used in the present invention as it is easier to provide a tight fitting into the impregnation unit for such ropes. By diameter of the rope is herein understood the largest distance between two opposite locations on the periphery of a cross-section of the rope. The diameter of the rope used in accordance with the invention can vary between large limits, e.g. from diameters specific to fishing lines of less than 1 mm, to diameters specific to off-shore mooring lines of more than 200 mm and even more than 500 mm. Although not a limiting factor, it was observed that good results were obtained when said diameter of said rope is at least 10 mm, more preferably at least 20 mm, most preferably at least 30 mm. Also good impregnation was achieved for larger diameter ropes, i.e. ropes having a diameter of at least 80 mm, preferably at least 100 mm which otherwise are difficult to be impregnated with the known methods or even manually.
[0049] The rope is preferably passed through the impregnating unit ( 103 ) with a speed that is adjusted with due regard to the diameter and construction of the rope, the pressure difference applied and the characteristic of the liquid material. The skilled person can easily adjust said speed to achieve an optimum impregnation.
[0050] Preferably, the rope used in accordance with the invention is a non-impregnated rope, i.e. a rope which has not yet been subjected to an impregnation step or steps; or a rope which was subjected to a light impregnation. In other words, the preferred rope utilized herein is a rope which contains less than 10 wt % based on the total weight of the rope of components other than the fibres, more preferably less than 5 wt %, most preferably less than 1 wt %. It was observed that using such a rope may lead to better impregnation.
[0051] The rope used in accordance with the invention comprises a plurality of fibers and interstices between said fibers. Preferably the fibers are grouped or bundled into yarns which preferably are subsequently grouped or bundled into strands. Preferably the ropes used in accordance with the present invention comprise a plurality of strands, said strands comprising a plurality of yarns containing said fibers. Preferred constructions of ropes which entail the presence of interstices between the fibers of the rope include braided ropes and laid ropes. The tightness of the rope also determines the size of the interstices between the fibers forming thereof; the tighter the rope is the smaller the interstices may be. The tightness of the rope may be related for a braided rope to the braiding period and for a laid rope to the twist factor; whereas the smaller said braiding period or the larger said twist factor, the tighter the rope.
[0052] The fibers contained by the rope used in the present invention may be natural or synthetic fibers, i.e. fibers produced out of a natural or a synthetic material. Natural materials may include metals but also cotton, hemp, abaca, bamboo, coir, flax (linen), jute, kapok, kenaf, pina, raffia, ramie, sisal, wood. Also animal fibers may be used to produce the rope to be impregnated in accordance with the present invention such as alpaca, angora, byssus, camel hair, cashmere, catgut, silk, wool, yak and the like.
[0053] Preferably, the ropes used in the present invention are synthetic ropes, i.e. ropes containing synthetic fibers. Said synthetic ropes preferably contain at least 50 wt %, based on the total weight of the rope, synthetic fibers, more preferably at least 70 wt %, even more preferably at least 90 wt %, most preferably all fibers contained by said synthetic ropes are synthetic fibers. It was observed that by using such rope, the best impregnation results were achieved. By synthetic fibers are herein understood fibers manufactured out of a synthetic material such as cellulose, e.g. acetate, triacetate, rayon, but also polymeric materials. Preferably the synthetic fibers are manufactured from a polymer chosen from the group consisting of polyamides and polyaramides, e.g. poly(p-phenylene terephthalamide) (known as Kevlar®); poly(tetrafluoroethylene) (PTFE); poly{2,6-diimidazo-[4,5b-4′,5′e]pyridinylene-1,4(2,5-dihydroxy)phenylene} (known as M5); poly(p-phenylene-2, 6-benzobisoxazole) (PBO) (known as Zylon®); liquid crystal polymers (LCP); poly(hexamethyleneadipamide) (known as nylon 6,6), poly(4-aminobutyric acid) (known as nylon 6); polyesters, e.g. poly(ethylene terephthalate), poly(butylene terephthalate), and poly(1,4 cyclohexylidene dimethylene terephthalate); polyvinyl alcohols; and also polyolefins e.g. homopolymers and copolymers of polyethylene and/or polypropylene. The preferred synthetic fibers are polyaramide fibers and high or ultra high molecular weight polyethylene (HMWPE or UHMWPE) fibers. Preferably the HMWPE fibers are melt spun and the UHMWPE are gel spun, e.g. fibers manufactured by DSM Dyneema, NL. An example of a melt spinning process for producing melt spun HMWPE fibers is disclosed in EP 1,350,868
[0054] In a preferred embodiment, the rope used in the present invention contains UHMWPE fibers, more preferably gel spun UHMWPE fibers. Preferably the UHMWPE used to manufacture the UHMWPE fibers has an intrinsic viscosity (IV) of at least 3 dl/g, more preferably at least 4 dl/g, most preferably at least 5 dl/g. Preferably said IV is at most 40 dl/g, more preferably at most 25 dl/g, more preferably at most 15 dl/g. The IV may be determined according to ASTM D1601(2004) at 135° C. in decalin, the dissolution time being 16 hours, with BHT (Butylated Hydroxy Toluene) as anti-oxidant in an amount of 2 g/l solution, by extrapolating the viscosity as measured at different concentrations to zero concentration. Examples of gel spinning processes for the manufacturing of UHMWPE fibers are described in numerous publications, including EP 0205960 A, EP 0213208 A1, U.S. Pat. No. 4,413,110, GB 2042414 A, GB-A-2051667, EP 0200547 B1, EP 0472114 B1, WO 01/73173 A1, EP 1,699,954 and in “ Advanced Fibre Spinning Technology ”, Ed. T. Nakajima, Woodhead Publ. Ltd (1994), ISBN 185573 182 7.
[0055] The fibers contained by the rope used in the present invention may be continuous fibers, also referred to in the art as filaments, or discontinuous fibers, also referred to in the art as staple fibers.
[0056] The method of the invention may also contain a drying step when a liquid material containing volatile mediums is used, or a solidifying step when a liquid material which is a melt is used. It was observed that the rope coated with the method of the invention contained an optimum distribution of solids, i.e. the materials left in the rope after drying or solidifying, and/or may even contain a higher amount of solids.
[0057] Furthermore, the present invention allows for a simplification of the entire method and of the device for impregnation as well as simplified technical service thereof.
[0058] The invention also relates to a 1-step impregnated rope obtainable by the method of the invention.
[0059] By 1-step impregnated rope is herein understood a rope which is impregnated as produced, i.e. directly after being constructed. For example a process wherein a rope containing a plurality of strands is firstly open, i.e. the individual strands are spread apart, then immersed or dipped into a liquid material for impregnation and then reassembled into its initial form, is not a 1-step process but at least a 2-steps process wherein the rope first is opened and subsequently impregnated. In contradistinction with such a process, the method of the invention allows for a 1-step impregnation process since the rope is not firstly opened but used as produced.
[0060] The rope of the invention can be utilized in a variety of applications such as tugging, mooring, hoisting/lifting, installation, offshore, commercial fishing, sayling and yachting, forestry, arborists, diving, rescue and safety, station keeping, dredging, climbing/rappelling and sailing.
[0061] The invention will be further explained with the help of the following example and comparative experiment.
EXAMPLE
[0062] A rope having an essentially circular cross-section with an effective diameter of about 21 mm was braided from 12 principal strands, each principal strand containing 7 laid secondary strands, each secondary strand containing a bundle of 15 yarns having 1760 dtex and comprising UHMWPE fibers. The yarns were sold by DSM Dyneema, NL, under the name of Dyneema® SK75. The primary strands were braided with a braiding period of 150 mm. The secondary strands were twisted to form a primary strand with a twist factor of 15 twists per m. The yarns were twisted to form a secondary strand with a twist factor of 13 twists per m.
[0063] The rope was unwound from a coil and pulled through a tank containing a liquid material. The liquid material was a water dispersion and contained a liquid phase and a solid phase and had a viscosity of about 90 mPa*s (Brookfield viscosity, cup 1, 50 rpm, 25° C.). The solid phase amounted to about 50 wt % of the total weight of said liquid material.
[0064] From the tank, the rope entered an impregnation unit, which was completely submerged into the liquid material, through a rope-inlet and then it exited said impregnation unit through a rope-outlet. A hermetical seal was ensured between the rope and the impregnation unit by sealing means such as the ones depicted in FIG. 1-2B . The height and the width of the inner protrusions was adjusted to ensure for enough flexibility of said protrusions in order to avoid the rope being compressed, though to ensure a hermetical fitting with the rope and prevent the liquid material from oozing between the sealing means and the surface of the rope.
[0065] The rope was pulled through the impregnation unit with a linear speed of about 3 m/min while a vacuum pump connected to the vacuum outlet reduced the pressure inside the chamber of the impregnation unit to between −0.1 bar and −0.7 bar.
[0066] To avoid potential damages to the vacuum pump due to the excess of the liquid material in the chamber of the impregnation unit a buffer vessel was used. About 60 cm of rope was impregnated with the liquid material and after impregnation the rope was dried by allowing the liquid phase contained by the liquid material to evaporate.
[0000] The results are presented in Table.
Comparative Experiment
[0067] The rope of example 1 was coated dipping the rope into the liquid material and allowing said liquid material to diffuse into the rope. The results are presented in Table.
[0000]
TABLE
Weight of the solid material in
Weight impregnated
the impregnated rope after
Pressure
sample after drying
drying
Sample
(bar)
(g)
(g/m)
(wt %)
Ex. 1
−0.5
157
265
52
−0.68
161
271
56
C. Ex.
N/A
125
231
33 | A method for impregnating a liquid material ( 105 ) into a rope ( 101 ) comprising a plurality of fibers and interstices between said fibers, said method comprising the steps of: (a) Providing a liquid material in a tank, ( 104 ) said liquid material defining a level of liquid ( 105 - 1 ) in said tank ( 104 ); (b) Providing an impregnation unit ( 103 ) containing a chamber ( 106 ) at least partially immersed in said liquid material ( 105 ), said chamber ( 106 ) comprising: (i.) a rope-inlet ( 107 ) for at least partially tightly receiving the rope ( 101 ), wherein said rope-inlet ( 107 ) is positioned below the level of liquid ( 105 - 1 ); (ii) a rope-outlet ( 108 ) for at least partially tightly discharging said rope ( 101 ); iii) a vacuum-outlet ( 109 ); and (c) Providing a vacuum-device operatively connected to said vacuum-outlet ( 109 ) for lowering the pressure in said chamber ( 106 ) below the atmospheric pressure; (d) Passing the rope ( 101 ) through the liquid material ( 105 ) in the tank ( 104 ) and then inside and outside said chamber ( 106 ) via the rope-inlet ( 107 ) and rope-outlet ( 108 ), while maintaining the pressure inside said chamber ( 106 ) below the atmospheric pressure to force the liquid material ( 105 ) to fill at least part of said interstices between the fibers of the rope ( 101 ) by penetrating between said fibers. A corresponding device, rope an use of the rope is also disclosed. | 3 |
BACKGROUND OF THE INVENTION
[0001] Polyester, nylon, fleece and other fabrics have been around for quite some time. The dyeing of these fabrics has also taken place so that various colors, routine patterns and the like are available for use to form a number of objects such as pillows, jackets, shirts, pants and the like. However, because polyester, nylon or fleece material is formed of a man-made fiber, the material is typically non-absorbent of liquids, and is therefore difficult to print on with any great accuracy and detail. While the use of standard dyes and printing in a repeating pattern or single color may be sufficient because great detail is not required, the printing of more precise and detail-oriented images such as photographs has proven difficult.
SUMMARY OF THE INVENTION
[0002] In accordance with the invention, a desired colorful design, such as a photographic image, is first printed on a sheet of transfer paper. This image is printed on the transfer paper using a dispersion, scattering of dissipation of oil dye onto a pretreated paper to form the transfer image paper. Thus, the image is not printed directly onto the fabric, thereby allowing for additional detail to be shown as will be discussed below. While this type of transfer paper is used for printing many types of products, it is the method for transfer of this transfer paper image to the polyester-type fabric and the makeup of the inks, dyes and additives adhered to the transfer paper that comprises the core of the invention.
[0003] The dyes or inks utilized in accordance with the invention have “sublime” characteristics. Thus, these inks or dyes would sublime directly from solid state to gaseous state upon the application of heat, and condense from gas back to solid state upon removal of the heat source, bypassing the liquid state in both directions. Therefore, when heated under pressure, the solid dye from the transfer paper is vaporized, and spreads through the polyester fibers to create a depth of overlapping or overlaying colors that adhere directly to the polyester fleece. Thus, rather than simply printing with ink on a surface of the polyester fabric, the dye is infused into the fabric, condensing back to a solid form and binding with the fibers on multiple layers, thereby ensuring a vivid depth of color and resiliency. This process is termed a heat-transfer printing.
[0004] Therefore, this invention addresses the problem of fleece or other polyester fabrics that are not very absorbent and have a high-fiber density. Commonly used screen-printing would not be able to show the detailed design of an image. Furthermore, this screen-printing process would not provide a three-dimensional expression with various color depth as is shown and desirable in the reprinting of a photograph.
[0005] Therefore, in accordance with the invention, a detailed image or photograph may be transferred to a polyester fleece-type material, providing three-dimensional depth of color such as in a photograph in a manner and with a result not previously obtainable.
[0006] Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification and the drawings.
[0007] The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others, and the apparatus embodying features of construction, combinations of elements and arrangement of parts that are adapted to effect such steps, all as exemplified in the following detailed disclosure, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a more complete understanding of the invention, reference is made to the following description and accompanying drawings, in which:
[0009] [0009]FIG. 1 is a flow chart diagram depicting the steps for heat transfer printing to a polyester or fleece fabric in accordance with the invention;
[0010] [0010]FIG. 2 is a chart depicting the solvent composition for solvents employed in accordance with the invention; and
[0011] [0011]FIG. 3 is a further chart depicting the features of the solvents in accordance with the invention.
[0012] These and other embodiments will be described and/or will be obvious from the following detailed description.
DETAILED DESCRIPTION
[0013] The following detailed description, given by way of example, is not intended to limit the invention to any specific embodiments described. The detailed description may be understood in conjunction with the accompanying figures, incorporated herein by reference. Without wishing to unnecessarily limit the foregoing, the following shall disclose the present invention with respect to certain preferred embodiments.
[0014] As is shown in FIG. 1, a flow chart for depicting a procedure in accordance with the invention is disclosed for printing an image to a generally non-absorbent fabric. While this fabric may be used to produce a pillow or the like, and use for the fabric, such as jackets, clothing household goods, or any other fabric product may be produced. As is shown in FIG. 1, first an image is designed at step 102 . Thereafter, a color separation process as is well known in the art is performed at step 104 . Once the color separation process at step 104 has been completed, the inks or dyes are sprayed and mixed at step 106 , and the various colors are set at step 108 . Thus, in accordance with the mixing, the colors that are required for the proper printing have been determined in the color separation process of step 104 , and these colors are generated at steps 106 and 108 .
[0015] Thereafter, at step 110 , the colors are confirmed, and at step 112 , the actual printing boards are produced. These boards will receive the inks, and will print the transfer paper as is noted below. Thus, at step 112 , after production of the board, the inks are transferred to the board, and the image from the boards are printed to the transfer paper at step 114 . After including the image on transfer paper at step 114 , the image is printed to fabric, at step 116 (as will be described in greater detail below) and the final product is produced at step 118 .
[0016] When producing the various products in the production procedure, the following raw materials and equipment may be employed. First, the dyes in accordance with the invention comprise dispersed dye material, adhesive powder and various solvents. The proper mixture of these three products will allow for the appropriate printing procedure, employing sublimation, as well as appropriate other characteristics for a printing process. The transfer paper that is to receive the image and then transfer the image to a fabric may include a typical tracing or transfer paper, or other waxed paper as appropriate. This paper may also include newspaper, copper-plated paper or the like. Additionally, in order to receive the ink printed onto it, and to appropriately transfer the image under pressure, the paper must be resilient enough to receive heat and a predetermined pressure thereon so that the dyes may be transferred, while the paper will remain intact and not melt into the fleece fabric, or otherwise affect the transfer of ink.
[0017] As noted above, the boards that are used for printing are typical offset lithographical printing boards, or other printing boards that are appropriate for printing ink images to a transfer paper. These boards may be generated using electrical engraving, laser engraving or various etching (erosion) and engraving.
[0018] The equipment required for the printing procedure may include the following: a printing machine for printing on paper, such as a concave board printing machine, a printing machine for printing on fabrics such as a heat-transfer printing machine, an electronic board machine, an automatic conveyor machine to supply materials, a rowing machine for paper, a rowing machine for fabric, a multi-rowing machine, a machine to prepare the design and drawings, and also specific for colors to perform the color separation process, a mixing machine for mixing of adhesives, and an infiltration apparatus. In accordance with the invention, the step of transferring the printing image to the fabric is a critical step. The sublimation of the inks and dyes is required so that a three-dimensional effect such as in a picture image may be provided, to ensure that a proper depth of color is produced, and to ensure that inks will properly bond to, and not be washed off of, the polyester fleece fabric. This process allows for the printing to take place through the image, and not simply on the surface thereof.
[0019] While this sublimation process is well understood by the inventor, the control of the precise transfer of ink from the transfer paper to the polyester fleece fabric is difficult. It requires precise application of heat and for specific periods of time in order to achieve appropriate and/or optimal transfer. Therefore, in accordance with the invention, when transferring the images from the transfer paper to the fabric, such as a polyester fleece, the temperature for transferring the image is in the range of from about 180° C. to 280° C., preferably from 200° C. to 240° C. applied for the range of between 10 to 30 seconds and preferably between 15 and 20 seconds. This application will cause the dye to separate, vaporize, adhere to the fleece and thereafter, upon removal of the heat, condense and transform back into a solid, properly bonded with the fleece. Preferably, the procedure for this printing is performed in a very high volume printing environment, for example, about 20,000 meters of fabric per day, and therefore can be performed on a roll such as printing on a roll-fed stock so that the fleece is pulled through a machine, and appropriate heat and pressure are applied for precise periods of time to insure proper transfer of the image. However, the process is equally applicable to sheet fed, low volume applications.
[0020] Through the proper application of these inks to the fabric, the dye imported to the fabric in accordance with the invention does not fade after repeated washing because the inks have been bonded to the fibers throughout the entire depth of the fabric, and are not merely placed on the surface thereof. Rather they have infused in a three-dimensional effect into various levels of the fabric. While certain fading may appear, such as with the blue dye, generally, the colors are quite colorfast and uneven discoloration is not a problem.
[0021] In the heat transfer process, dyes are first transferred from transfer paper and vaporized by the application of heat as noted above. Thereafter, the fiber surface and various fibers in the three-dimensional layers absorb the gaseous dyes. The gaseous dyes infiltrate into the core of the fibers at all levels of the fabric, thereby bonding therewith. Thus, the gaseous dyes are permanently adhered to the internal portion of the fiber, and upon removal of the heat source, these colors condense are bonded and set in their location. While printing on fleece has taken place in the past, the procedure has been less than satisfactory, and indeed has been more complicated, requiring more machinery and manpower than the present invention. Indeed, the apparatus in accordance with the present invention is easier to operate, requires less machinery, thus saving space, requires less steps and therefore less labor. Furthermore, electricity and heat treatment are utilized without boiling pots, washing machines, steam machines, dryers and therefore does not create harmful chemicals and/or gasses to pollute the environment. The product can be produced in a shorter amount of time, and can be printed on any wrinkle-free or waterproof material. Finally, the transfer paper that the original design has been placed upon can be recycled.
[0022] As is noted above, the composition of the inks, dyes and solvents is of utmost importance in order to generate proper sublimation. The dyes are generated by placing an appropriate solvent in a container and slowly adding in adhesive materials while stirring. Once all the adhesive materials have been added to the solvent, a high-speed mixer is employed to mix the solvent and adhesive materials for three to four hours. The solution then preferably sits for at least 8 hours or until it reaches a desired saturation. The solvents are preferably non-toxic, do not have an unpleasant odor or fragrance, and must contain less than about 3% of water to guarantee appropriate purity. Finally, the solvents, after mixing, must be filtered to make sure there are no contaminations in the chemicals. As is shown in FIG. 2, the combination of solvents may be adjusted based upon ambient temperature and humidity in the air. Therefore, an IBA solvent is utilized more in the summer and less in the winter, while an MeOH solvent is utilized more in the winter and less in the summer.
[0023] [0023]FIG. 3 shows the specific gravity and boiling temperature of various chemicals that may be employed for solvents, such as methyl alcohol or methanol, ethanol, and isobutyl alcohol or isopropylcarbinol. The specific characteristics of each of these solvents will determine the precise combination and percentages of uses for the appropriate desired results and appropriate ambient conditions.
[0024] Therefore, in accordance with the invention, by the appropriate application of heat for a particular period of time, a proper and desirable sublimation of inks, solvents and adhesive material can be obtained. Therefore, in accordance with the invention, the sublimated inks are transferred to a thick layer of fleece or other polyester material, and saturates into the fibers on all of the various interweaved layers of material. This insures a deep, rich color and allows for a more precise transfer of an image to a polyester, fleece or other generally non-absorbent fabric.
[0025] In accordance with the invention, a more detailed image can be transferred, reducing bleeding, and improving durability, as opposed to the transfer methods previously employed.
[0026] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, because certain changes may be made in carrying out the above method and in the construction(s) set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0027] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | The present invention claims and discloses a method of transferring an image to a generally non-absorbent fabric having at least one fiber. The method comprises the steps of providing an image on a transfer sheet or a medium, placing the transfer sheet or the medium against the generally non-absorbent fabric, applying a predetermined amount of heat in a predetermined amount of time to the transfer sheet or the medium, subliming the solid state ink or dye on the transfer sheet or the medium from a solid state to a gaseous state, binding the gaseous ink or dye with the fiber of the generally non-absorbent fabric and condensing the gaseous ink or dye to a sold state, thereby binding the dyes or ink into the fiber of the generally non-absorbent fabric. The fabric may be in the form of a pillow or a clothing article or any item of desire. | 1 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61,384,883 entitled “Non-Precious Metal Catalysts” filed Sep. 21, 2010 and U.S. Provisional Application No. 61/408,129 entitled “Non-Precious Metal Catalysts” filed Oct. 29, 2010, both incorporated by reference herein.
STATEMENT OF FEDERAL RIGHTS
The United States government has rights in this invention pursuant to Contract No. DE-AC52-06NA25396 between the United States Department of Energy and Los Alamos National Security, LLC for the operation of Los Alamos National Laboratory.
FIELD OF THE INVENTION
The present invention relates to novel catalysts suitable for use in fuel cells and in particular, in alkaline fuel cells, comprising a metal, a nitrogen source such as cyanamide (CM), a sulfur source and a carbon source.
BACKGROUND OF THE INVENTION
Among several types of fuel cells, polymer electrolyte fuel cells (PEFCs) are the best suited for transportation vehicles because of fast startup time, low sensitivity to orientation, and favorable power-to-weight ratio. Though relatively low temperature operation at around 80° C. makes fast startup possible, it also requires the use of scarce, expensive platinum-based catalysts especially for the oxygen reduction reaction (ORR) at the cathode. A need exists, therefore, for non-precious metal catalysts suitable for use in fuel cells, which exhibit a catalytic activity similar to precious metal catalysts.
The potential use of non-precious materials instead of Pt in the PEFC cathode has recently received increased attention due to cost analyses that have demonstrated a pressing need. Transition metal-nitrogen-carbon (M-N—C) type catalysts have been studied for almost 50 years since the discovery of their ORR activity in macrocycles bound with transition metals, and considered as the best non-precious metal catalyst to substitute for platinum in PEFCs.
According to previous reports, the most important element of active site(s) in M-N—C catalysts is the nitrogen. Nitrogen in the carbon can exist as pyridinic type (contributing one p-electron to p band), and pyrrole type (contributing two p-electrons to p band). Pyridinic nitrogen can exist only on the edge of the graphene layer, while pyrrolic nitrogen can exist both on the edge of and within the graphene layer. Experimental and quantum mechanical calculation results strongly show that pyridinic and pyrrolic nitrogen are closely related with the activities of M-N—C catalysts.
The effect of sulfur on the ORR catalytic activity has been rarely studied. However, sulfur has a high potential to enhance the activity of ORR in a manner similar to both pyridinic and pyrrolic nitrogen because sulfur resembles the pyridinic nitrogen in that sulfur also has a lone pair of electrons, and sulfur also resembles the pyrrolic nitrogen in that both contribute two p electrons to the pi band of graphene layer.
SUMMARY OF THE INVENTION
The present invention meets the aforementioned need by providing novel non-precious metal catalysts suitable for use in fuel cells, which comprise a sulfur-containing moiety (i.e. metal-nitrogen-sulfur-carbon, or “MNSC” catalysts). Embodiment catalysts of the present invention were produced using a cyanamide precursor.
Sulfur evaporates during pyrolysis, and is therefore difficult to stabilize into the carbon. However, cyanamide is capable of stabilizing the sulfur into the carbon during pyrolysis, resulting in increased ORR activity of the catalyst. In proton exchange membrane fuel cells (PEMFCs), platinum-based catalysts are currently used for both anode and cathode catalysts. Expensive platinum is currently needed for oxygen reduction in the cathode side due to the high overpotential. Replacing an expensive platinum based catalyst with an inexpensive carbon based catalyst would have a tremendous impact on one of the main obstacles to commercializing PEMFCs, namely the high cost of precious metals. In addition, the embodiment catalysts of the present invention function well in alkaline fuel cells, and further may have a number of applications in the chlor-alkali industry and in metal-air batteries.
The following describe some non-limiting embodiments of the present invention.
An embodiment catalyst prepared by a process comprising heating a mixture of cyanamide, carbon black, and a salt selected from an iron sulfate salt and an iron acetate salt at a temperature of from about 700° C. to about 1100° C. under an inert atmosphere, and thereafter removing acid soluble components from the mixture, and thereafter heating the mixture at a temperature of from about 700° C. to about 1100° C. under an inert atmosphere to form the catalyst.
An embodiment membrane electrode assembly prepared by a process comprising:
preparing a catalyst by heating a mixture of cyanamide, carbon black, and a salt selected from an iron sulfate salt and an iron acetate salt at a temperature of from about 700° C. to about 1100° C. under an inert atmosphere and thereafter removing acid soluble components from the mixture, and thereafter heating the mixture at a temperature of from about 700° C. to about 1100° C. under an inert atmosphere to form the catalyst.
mixing the catalyst with water and with an ionomer suspension to form a catalyst composition;
applying the catalyst composition onto a first side of a membrane;
applying the catalyst composition onto a first side of a gas diffusion layer;
forming a membrane electrode assembly by placing the first side of the membrane in direct contact with the first side of the gas diffusion layer; and
applying heat and pressure to the membrane electrode assembly.
According to another embodiment of the present invention, a catalyst comprising graphitic carbon is provided, said graphitic carbon comprising a metal species, a nitrogen-containing species and a sulfur-containing species.
According to another embodiment of the present invention, a method of forming a catalyst is provided, comprising mixing a cyanamide precursor material, a metal-sulfate precursor material and carbon black to form a graphitic C 3 N 4 compound; heating the mixture at a temperature of from about 800° C. to about 1100° C. in an inert atmosphere; and removing acid-soluble components from the mixture.
According to another embodiment of the present invention, a method of forming a membrane electrode assembly is provided, comprising providing a catalyst having graphitic carbon, said graphitic carbon including a metal species, a nitrogen-containing species, and a sulfur-containing species; mixing the catalyst with water; mixing the catalyst and the water with an ionomer suspension to form a catalyst composition; applying the catalyst composition onto a first side of a membrane; applying the catalyst composition onto a first side of a gas diffusion layer; forming a membrane electrode assembly by placing the first side of the membrane in direct contact with the first side of the gas diffusion layer; applying heat and pressure to the membrane electrode assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : ( a ) Fuel cell polarization plots recorded with FeSO 4 .7H 2 O—CM-Ketjenblack ORR catalysts obtained at different heat-treatment temperatures. ( b ) Fuel cell polarization plots recorded with Fe(CH 3 COO) 2 —CM-Ketjenblack ORR catalysts obtained at different heat-treatment temperatures. ( c ) Fuel cell polarization plots comparison with FeSO 4 .7H 2 O—CM-Ketjenblack heat-treated at 1050° C. and Fe(CH 3 COO) 2 —CM-Ketjenblack heat-treated at 1000° C. Nafion® 117 membrane; anode—30 psig H 2 , 0.25 mg cm −2 Pt (catalyzed-cloth GDL, E-TEK); cathode—30 psig O 2 , non-precious catalyst loading 4.0 mg cm −2 (double-sided cloth GDL, E-TEK); humidification for H 2 and O 2 was 100% RH; constant 300/500 standard mL per minute anode/cathode flow rates for H 2 and O 2 respectively; MEA surface area 5 cm 2 .
FIG. 2 : ( a ) A schematic diagram of pyridinic, pyrrolic, graphitic, and authentic pyrrole nitrogen and thiophene sulfur incorporated into the graphene carbon layer. ( b ) one electron (e − ) donor-type and two e − donor-type and total nitrogen content variation with heat-treatment temperatures determined by N 1s XPS. One e − donor-type nitrogen content was determined from B.E. 398.8 eV, and two e − donor-type nitrogen content from B.E. 400.2 and 401.4 eV. Total nitrogen content was obtained from the sum of pyridine-type and pyrrole-type nitrogen content.
FIG. 3 : ( a ) XPS S 2p spectra of the pyrolyzed cyanamide-derived catalyst at 1050° C. and ( b ) Total, thiophene-like and thiolate (or thiocyanide)-like sulfur content variation with temperatures determined by XPS. ( c ) Ionic current of the mass spectroscopy of SO 2 of FeSO 4 .7H 2 O-Ketjenblack samples obtained with and without the addition of cyanamide; (m/e=64 SO 2 ).
FIG. 4 shows the effect of S on the catalytic activity, in particular, how activity is enhanced with increasing S content in the catalyst.
FIG. 5 shows S—Fe—C catalytic activity, in particular, that even S—Fe—C can show catalytic activity for Oxygen Reduction Reaction (ORR).
FIG. 6 shows ORR activity of carbon-based NPM catalyst in alkaline solution, in particular, that the carbon-based catalyst, when compared to platinum-based catalysts, shows comparable catalytic activity and better durability in an alkaline solution (pH 13).
FIG. 7 summarizes data that show a higher activity of an embodiment N—S—Fe—C catalyst compared to the state-of-the-art N—Fe—C catalyst.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, cyanamide was selected as the nitrogen precursor, capable of forming graphitic-C 3 N 4 under certain pyrolysis conditions. Graphitic-C 3 N 4 (g-C 3 N 4 ) has a high nitrogen content, which is often associated with ORR activity in non-precious metal catalysts. Cyanamide was found to aid the incorporation of sulfur from the iron sulfate precursor into the carbon.
Embodiment non-precious ORR catalysts were synthesized by mixing 2.0 g cyanamide (CM) and 1.5 g FeSO 4 .7H 2 O (or 1.1 g Fe(CH 3 COO) 2 ) with 1.0 g oxidized carbon (Ketjenblack EC-300J), pretreated in 70% nitric acid at 80° C. for 8 hours. After mixing, two heat-treatment steps followed at 700-1100° C. in nitrogen atmosphere. The temperature of both heat-treatment steps was kept the same, and so a single heat-treatment temperature is referred to for each sample. Between heat-treatments, the catalyst was leached in 0.5 M H 2 SO 4 at 80° C. for 8 hours in order to remove acid-soluble components.
A cathode catalyst ink for the membrane-electrode assembly (MEA) was prepared by thoroughly blending an embodiment catalyst prepared as described above with de-ionized water and recast Nafion® ionomer (5% Nafion® suspension in alcohols; SOLUTION TECHNOLOGY, INC). The catalyst:water:ionomer weight ratios were about 1:20:0.6. The catalyst ink was dispersed ultrasonically for 90 seconds(s) and then hand-brushed onto the membrane and gas diffusion layer (GDL). 0.25 mg cm −2 Pt (catalyzed cloth GDL, E-TEK) was used as the anode. The membranes used in this experiment were Nafion®117. MEA was hot-pressed at 120° C. for 90 s. A 5-cm 2 cell was used for fuel cell testing.
X-ray photoelectron spectroscopy (XPS) measurements were performed on a KRATOS Axis Ultra spectrometer using an Mg Kα X-ray source. A DYCOR DYMAXION quadrupole mass spectrometer was used for the mass analyses. The product gas concentration of the samples heated from room temperature to 1050° C. at a rate of 5° C./min in Ar at a flow rate of 25 mL/min was analyzed for masses up to 100.
The data obtained for the embodiment catalysts indicate that as much as about 70% of platinum activity at 0.8 V is approached, which is currently the highest activity reported. The data are summarized in the Figures, which are described in further detail below.
FIGS. 1( a, b and c ) displays the results of H 2 —O 2 fuel cell tests of the CM-derived (i.e. cyanamide-derived) catalysts with different iron sources (FeSO 4 .7H 2 O and Fe(CH 3 COO) 2 ). For CM-FeSO 4 .7H 2 O-KB (KB=Ketjenblack) 900° C. and 1050° C. heat-treated catalysts, the OCV is about 1.0 V in both cases and the current densities are 70 mA and 83 mA (105 mA for iR-corrected) at 0.80 V, respectively. Based on these values, the CM-derived catalysts compare favorably to the top five most active non-precious metal catalysts recently reviewed. One property of the CM-FeSO 4 .7H 2 O-KB derived catalyst is an unusual dependence of activity on the synthesis temperature, observed in both RDE and fuel cells tests. Improvement in catalyst performance is observed up to a heat-treatment temperature of 900° C., but the performance decreases when the catalyst is pyrolyzed at 1000° C. Interestingly, the highest performance is attained when the heat-treatment temperature is further increased to 1050° C. (This activity dependence on temperature is also observed with Black Pearls 2000™ as a carbon support; data not shown). This is an unusual phenomenon compared to other reports that show a volcano-type plot of activity versus pyrolysis temperature, and CM-Fe(CH 3 COO) 2 -KB catalysts ( FIG. 1 b ). Such behavior is believed to be related to the identity of the active site(s). The two most notable characteristics of CM-derived catalysts can be summarized as (i) high. ORR activity, and (ii) unusual activity dependence on temperature.
According to previous reports, the nitrogen content and type present in M-N—C catalysts is important for ORR activity. As depicted in FIG. 2( a ), there are several types of nitrogen species that can be largely classified as “two p electrons donor” (to the pi-band of carbon) and “one p electron donor” (to the pi-band of carbon). The two p electrons donor species (especially graphitic and pyrrolic-N) are expected to lower the carbon band gap energy and possibly promote catalytic activity. The one p electron donor (pyridinic-N) specie also has a lone pair of electrons available for binding with metal atoms (see FIG. 2( a )); indeed, this pyridinic nitrogen content has been the most closely correlated to the activities of M-N—C catalysts.
Using these categories to label the nitrogen, the XPS peak at 398.8 eV (pyridinic-N) was assigned as “one e − donor”, and the XPS peaks appearing at 400.2 eV (pyrrolic-N) and 401.4 eV (graphitic-N) were labeled as “two e − donor” to construct the plot in FIG. 2( b ). Clearly, the total nitrogen content (from 1.5 to 1.0%), the “one e − donor”, and the “two e − donor” nitrogen content all decrease monotonically with increasing pyrolysis temperature. The decrease in nitrogen content of all types does not match the unusual pattern of the ORR activity results discussed above. (Note that using other definitions of nitrogen type does not reveal any correlating pattern.) Therefore, other factors must be considered to explain the relatively high activities of CM-FeSO 4 .7H 2 O-KB based catalysts and unusual activity increase at 1050° C.
The CM-FeSO 4 .7H 2 O-KB-based catalyst discussed herein contains sulfur due to the iron source, ferrous sulfate 7-hydrate (FeSO 4 .7H 2 O). FIG. 3( a ) shows S 2p spectra of 1050° C. heat-treated catalysts; the other catalysts show the similar pattern. The first two peaks (162.3 eV and 163.4 eV) and second two peaks (164.4 eV and 165.7 eV) are doublet structures due to spin-orbit coupling (S 2p3/2 and S 2p1/2 ). The peak at 164.4 eV has been attributed previously to S 2p3/2 of thiophene, and the peak at 162.3 eV has been assigned before to S 2p3/2 of thiolate or thiocyanate. Comparing the intensities of both peaks, sulfur is found to exist mainly as thiophene, as depicted in FIG. 3 ( a ). The total and thiophene-type sulfur content in the catalyst increases with temperature, as shown in FIG. 3( b ). In a previous report, sulfur in sulfate form did not react with carbon to form C-heteroatoms, in contrast to these results. FIG. 3 ( c ) shows the evolution of SO 2 (mass 64), as detected by mass spectrometry during the first heat treatment of samples composed of FeSO 4 .7H 2 O mixed with Ketjenblack. EC-300J™, both with and without the addition of cyanamide. With cyanamide, the decomposition of the sulfate and evolution of SO 2 is greatly depressed, indicating that an interaction between cyanamide and sulfate (or sulfate-derived species) stabilizes sulfur in the sample perhaps through the formation of C—S bonds.
To further investigate whether sulfur enhances the ORR activity of the CM-based catalyst, samples were prepared using iron(II) acetate as the iron source rather than iron sulfate, thus avoiding any sulfur addition. The performance of these catalysts at high voltage/low current density (under kinetic rather than mass-transport control) was half that of the catalyst prepared from the iron sulfate precursor, as shown in FIG. 1( c ). This difference strongly indicates that sulfur is responsible for the improved activity of CM-based catalysts.
The effect of sulfur on the ORR catalytic activity has been rarely studied. As shown in FIG. 2( a ), however, sulfur has the potential to enhance ORR activity in the same manner as “one e − donor” and “two e − donor” nitrogens. Sulfur resembles the “one e − donor” nitrogen in having a lone pair of electrons, which can possibly interact with metal atoms. It also resembles “two e − donor” nitrogen by having two p electrons that can interact with the π band of graphene layer. Consequently, the high ORR activity in spite of a decreasing amount of nitrogen of all types and unusual activity dependence on temperature in CM-FeSO 4 .7H 2 O-KB derived catalyst could possibly be explained by the beneficial effect of sulfur incorporated into the graphene carbon.
FIG. 4 shows a plot of cell voltage (in volts) versus current density in amperes per square centimeter) for two catalysts prepared using iron sulfate (top two graphs) and a catalyst prepared using ferric nitrate. The graphs show the effect of S on the catalytic activity, in particular, how activity is enhanced with increasing S content in the catalyst.
FIG. 5 ( a ) shows x-ray photoelectron spectra for thiophene p electrons plotted as intensity versus binding energy (in electron volts) at 5 different temperatures. This plot shows that the S present in the embodiment catalysts is similar to the S present in thiophene, which is believed to be a new catalytic active site for ORR. FIG. 5( b ) The plot at the left is current density versus potential. The topmost graph corresponds to heat treatment at 700° C. during the synthesis of the catalyst. The next plot directly below corresponds to heat treatment at 800° C., the next to 900° C., the next to 1000° C., and the bottom plot to 1100° C. The catalyst loading was 600 micrograms per square centimeter. The electrolyte was 0.1 molar HClO 4 . The graph shows that S—Fe—C can show catalytic activity for Oxygen Reduction Reaction (ORR).
FIG. 6 ( a ) shows a plot of current density versus potential for a PVC catalyst and an embodiment cyanamide-derived catalyst for the initial cycle. The E1/2 for the Pt-based catalyst is 0.91 volts while that for the embodiment catalyst is 0.93 volts. FIG. 6 ( b ) shows a plot similar to that of FIG. 6( a ) but after 5000 cycles in O2. As the plot shows, the E1/2 for the Pt-based catalyst is equal to 0.90 volts while that for the embodiment catalyst is 0.95 volts. Thus, the ORR activity of an embodiment carbon-based NPM catalyst in alkaline solution is comparable to platinum-based catalysts, and with better durability in an alkaline solution (pH 13) compared to the Pt-based catalyst.
FIG. 7 compares the activities of a state-of-the-art N—Fe—C catalyst taken from M, Lefevre et al., Science, vol. 324, p. 71 (2009) with the activity of an embodiment N—S—Fe—C. As FIG. 7 shows, the embodiment N—S—Fe—C catalyst shows a higher activity compared to the activity of the state-of-the-art N—Fe—C catalyst.
In all embodiments of the present invention, all percentages are by weight of the total composition, unless specifically stated otherwise. All ratios are weight ratios, unless specifically stated otherwise. All ranges are inclusive and combinable. All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
Whereas particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | Catalyst comprising graphitic carbon and methods of making thereof; said graphitic carbon comprising a metal species, a nitrogen-containing species and a sulfur containing species. A catalyst for oxygen reduction reaction for an alkaline fuel cell was prepared by heating a mixture of cyanamide, carbon black, and a salt selected from an iron sulfate salt and an iron acetate salt at a temperature of from about 700° C. to about 1100° C. under an inert atmosphere. Afterward, the mixture was treated with sulfuric acid at elevated temperature to remove acid soluble components, and the resultant mixture was heated again under an inert atmosphere at the same temperature as the first heat treatment step. | 2 |
RELATED APPLICATION(S)
This application claims the benefit of U.S. Provisional Application No. 60/387,295, filed on Jun. 7, 2002.
The entire teachings of the above application are incorporated herein by reference.
BACKGROUND
Business directory services provide users with lists or names of businesses in a specified category or location. A user can request a business of a particular type in a particular city and receive a listing of all available businesses of that type. Such services are sometimes referred to as Yellow Page services. Existing directory services have different interfaces and functionality: some allow searching by partial or exact business name, within a city, or by category, or a combination of the three. A smaller set of service providers allow searching by name and category within a specified distance from an addressable location. An addressable location is a uniquely identified geographical point such as, for example, a street address or a uniquely identified point of interest, or named administrative areas such as cities or postal codes.
There are several standard nomenclatures for categorization and classification of businesses. Examples of such standards are the Standard Industrial Classification (SIC) codes, the North American Industrial Classification System (NAICS), which replaces the SIC system, and Universal Standard Products and Services Classification created by the Electronic Commerce Code Management Association (ECCMA). In addition, some directory service providers create custom nomenclatures and protocols.
Business directory services are accessed by users from computers or other electronic access devices, such as, for example, cellular phones enabled for web browsing. If not satisfied with results of the first query, a user can submit another query, supplying original parameters as well as additional restrictions. This narrowing of search, referred to as “drilling down,” is typically limited to the original category or subcategory. For example, if the user is looking for a car dealership within a certain distance of a given location, in a process of drilling down, the user may be able to narrow the allowed distance but not add additional markers or specifications for the search.
SUMMARY
Particular embodiments of the invention can include business directory services that allow definitions of custom category hierarchies and different search methods, such as, for example, search by location, distance from an addressable location, partial or complete business name, and category. A stepwise refinement search interface can provide a capability for searching within search results using different search methods or categories. Thus, a user does not have to refine and re-enter search criteria in order to get a progressively selective search. This is particularly useful for users of wireless devices, such as mobile phone or hand-held devices, when users may prefer not to have to re-enter the criteria on each search, but rather incrementally refine the search criteria.
Additional functionality can allow customers to browse business categories and drill down a search from a simple cell phone interface, where entering a lot of text at the same time is not practical. A context object can be used to represent search criteria at any given time. The context object can meet the requirements listed above by, for example, allowing users to specify partial search criteria at any given time. With the narrowed result set returned, the user can continue to specify more criteria and search within the results until the final page entry is located.
Aspects of the invention include methods for providing business directory services to users. A user can enter query parameters into a client. The search parameters can be stored in a context object and passed to the business directory server, which process the requests and returns search results to the client. Once the search results are presented to the user, the user can decide to revise the query by drilling down into particular listings or categories. Additional search parameters can then be added to the context object and can be passed back to the business directory server for processing. Searching can proceed in such iterations until the desired level of result granularity is achieved.
Search parameters can include type of the search to be performed: whether it is to find a listing, browse listings, or browse by category. Within each type, there may be additional limitations. In addition, user can specify search parameters based on a particular geographic object (for example, an address, or a uniquely defined geographic location).
If the user is accessing the business directory services from a wireless device, the results can be presented in such a way as to make it easy for the user to browse them and to enter additional search parameters.
The business directory services system can consist of a dispatcher module, which receives requests from the client, a business directory server module, which processes the requests and sends database queries to a database. The business directory server module also processes database results, converts them to a pre-defined XML schema and sends them back to the client through the dispatcher module.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the contextual search interface for business directory services will be apparent from the following more particular description of particular embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 is a schematic diagram of the business directory service architecture according to one embodiment of the invention;
FIG. 2 is a schematic diagram illustrating processing of a request;
FIG. 3 is a schematic diagram of the business services server;
FIG. 4 is a flow chart illustrating operation of the business directory services request client;
FIGS. 5 a–c illustrate XML schema for requests and responses between clients and the business directory server;
FIGS. 6 a–c illustrate database schema for a business directory database;
FIG. 7 is a flow chart illustrating operation of the business directory server module.
DETAILED DESCRIPTION
The use of business directory services is greatly improved with additional functionality that allows users to refine and improve search criteria based on the received search results and additional categories. For example, if a user wants to find a Mercedes-Benz dealer around the Boston area, the user can specify “automobile dealers” as a high level category. The business directory service engine might then return a list of several categories, from which the user can select “new car dealers.” A list of car brands will be presented next, with the context “automobile/new car dealers” as a business category. Then the user can select “Mercedes-Benz” followed by the location, for example, Boston, Mass., as the location criteria. During each query step, an object containing context, that is, the business category hierarchy and the location hierarchy (or simply location information) is recorded and passed on to the following inquiries.
Implemented in a particular embodiment of the invention are various search features, such as looking up a business listing by a combination of name, category and location. For example, one may look at a listing of a business names “Pizzico” in the category “restaurants” (or eating and drinking places) and in Nashua, N.H. In addition specific business or home locations can be looked up or browsed by the category hierarchy. Additional search features can be supported such as, for example, searching by names of individuals (instead of businesses) or searching using custom hierarchies.
Various string match modes and a business or category name look-ups can be supported. The modes are: “exact,” “starts with,” “contains,” and “sounds like.” In addition, searches like “nearest neighbor” and “within distance” are supported when a location is specified. That is, the user can run a search for a business within a specified category or a specific business that is within a specified distance from or nearest to a given location. The location can be described as a place name, street address, postal code or geographic objects.
Data for the business directory service can be provided by multiple providers, each using its own data format. Different data formats can be accommodated as described below in connection with FIG. 6 , and multiple data providers' classification schemes or category hierarchies can be supported within one business directory service implementation.
As used herein, “business directory service” refers not only to services allowing users to search for various businesses, but also to a more generalized search service, allowing users to search for addresses, locations defined by description, businesses or any other geographical object. A particular business directory service is implemented using Standard Industrial Classification (SIC) codes, however, an alternative embodiment of the invention can use any other standard or custom categorization nomenclature.
Referring now to FIG. 1 , there is shown a schematic representation of a general architecture of the business directory service according to one embodiment of the invention. The business directory service 100 is implemented as a multi-tier system. Clients 10 a–x access the system 100 using networked clients using communication protocols such as known in the art. Networked clients 10 a–x can be running on personal computers, mobile phones, hand-held devices, or any other devices capable of being connected to a network.
The system 100 consists of a dispatcher module 110 , which receives requests from clients and performs initial processing. The dispatcher module 110 is connected to a business directory server 112 . The business directory server 112 , in turn, interacts with a database server 114 in order to fulfill clients' requests. The database server 114 can contain business data and user-defined category hierarchies. The data contained in the database server 114 can come from different data providers, and be formatted in different ways, depending on the type of information contained in a particular subset of data.
The operation of the system 100 is described in further detail in FIG. 2 . The clients 10 a–x send requests do the dispatcher module 110 , which forwards those requests to the business directory server 112 . The business directory server parses the request and creates database queries. In response to a database query sent by the business directory server 112 , the database server 114 returns appropriate database results. The business directory server 112 then formats the received results and forwards them back to the dispatcher module 110 , which, in turn, communicates with the requesting client. In a particular embodiment of the invention, the business directory server 112 communicates with the database server 114 using SQL queries. In an alternative embodiment of the invention, server/database communications can be implemented in any appropriate way, as determined by one skilled in the art. The database server 114 can include additional servers or multiple databases, all referred herein to as a single database.
The dispatcher module 110 and the business directory server 112 can be separate programs running on different computers, or they can be located on a single computer, with only logical separation in their function. In addition, the database 114 can also be located on the same physical hardware, or, alternatively, be spread out over several physical servers.
Operation of the business directory server 112 is further described in connection with FIG. 3 . The business directory server module 112 consists of two subroutines: an initialization subroutine (not shown) and a find subroutine 310 . Initialization subroutine is used to load data vendor information from the database 114 during the initialization time. Loading the database vendor information ensures that the business directory server 112 can issue SQL queries to the right tables by looking up in memory the appropriate vendor information tables.
After initialization, the business directory server 112 is ready to process the client requests. When the system 100 receives a business directory request, it forwards it to the business directory server 112 . A request is received at the find subroutine 310 . In one embodiment of the invention, the business response module is implemented in Java, although a different programming language can be used, as determined by one skilled in the art. The business directory server 112 runs on a web application server (for example, Oracle 9i Internet Application Server). The dispatcher module 110 runs as a separate servlet (for example, as a J2EE component) and receives all the requests. In an alternative embodiment of the invention, both the business directory server 112 and the dispatcher module 110 can be implemented as separated servers running on separate hardware.
The business directory find subroutine 310 determines whether a particular request is for looking up a listing by business name, or looking by category name, or by browsing by category hierarchy. It then passes the request on to the proper function, such as a find listing function 312 , a find category function 314 , or a browse category function 316 , respectively. In an alternative embodiment of the invention, additional find or browsing capabilities may be provided, such that the user can, for example, browse individual listings or be able to select from different data vendors. Once the results are returned from the database 114 , the find subroutine 310 sends results to the dispatcher module 110 to be returned to the client 10 .
The clients 10 a–x can be implemented using software appropriate for the particular client type. For example, client software for the client 10 x , a cellular phone, can be implemented to have minimum display requirements and be able to fit as much information on a small display, as possible. Regardless of the type of client used, client software on all clients can take similar steps in sending and receiving requests. Operation of client software modules is generally illustrated in FIG. 4 .
After initializing the business directory request module in the step 410 , the user can enter request parameters in the step 412 . These request parameters can include, for example, business location, business category, or any other search parameters. In an alternative embodiment of the invention, initial request parameters can be retrieved from a user settings store 408 , such that the user does not have to define initial parameters. This can be used for, for example, initiating a query from a particular geographic location or limit to this location. In addition, the user settings 408 can contain the parameters of the last search performed by this client.
In another embodiment of the invention, some of the initial search parameters can be supplied from external modules—for example, in a client equipped with GPS capabilities, the initial search parameters can automatically include location within a certain distance from the present location of the client. In yet another embodiment of the invention, similar location capabilities of the cellular phones may be used to supply geographic restrictions for initial search parameters. Obtaining geocode parameters is described, for example, in U.S. patent application Ser. No. 10/165,811, filed on Jun. 7, 2002, the entire teachings of which are incorporated herein by reference.
After the search parameters are received in step 412 , the client formats the proper request using those parameters in step 414 . The request is sent to the dispatcher module 110 in step 416 . The client then awaits receipt of the response from the dispatcher module 112 . Received results are displayed in step 418 . Based on the results received from the initial query, the user may decide to drill down in to the categories or to add additional search parameters. If the decision to drill down is made in step 420 , the module returns to the step 412 where new parameters now include those that the user chooses to enter in addition to the original query. The client module can proceed in such iterations until the user receives the desired results.
A context object is used within the client to store information about the current query—when the user enters the search parameters for drilling down, they are added to the context object. In such a way, additional information is maintained from one query to another, and the user does not need to re-enter all the original parameters. Information from the context object can then be sent to the business directory service 100 in order to obtain appropriate results.
In a particular embodiment of the invention, all the query parameters get sent from the clients 10 a–x to system 100 in all queries. In an alternative embodiment of the invention, some customization or cashing can be done within system 100 . For example, business directory server 112 can store information about previous queries from particular clients. In this case, the client 10 would need to only supply additional search parameters, without having to send all the query parameters. For example, if the user is searching for a Mercedes-Benz dealership, the request can include only indication of narrowed up categories while the business directory server 112 will store the general categories in which the search will be performed. In yet another embodiment of the invention, the parameters can be cashed or stored within the dispatcher module 112 , or even within the database 116 .
Information from the context object is transmitted to and from the business directory service 100 using data packets. In a particular embodiment of the invention, the format of the data packets is that of XML packets. Illustrated in FIGS. 5 a–c are sample XML definitions, which can be used to transfer responses and requests. Using XML allows for easy storing of context object information and translation of information for displaying in whichever format appropriate for the particular client.
Three query types can be provided: listing looking, category look up, and category browsing. Query type is specified by the “type” attribute 512 of <request> node 510 . The query conditions of the three query types are specified in corresponding node, <listing_lookup> 514 , <category_lookup>, and <category_browse> (not shown). The “result_type” attribute 516 allows users to specify how detailed listing results should be. Three results types are defined: Basic, Detail1 and Detail2. The “number_to_return” attribute 518 can be used to limit the maximum number of listing records to be returned.
A search condition can be combination of the following query criteria: listing name, category name/code and search region. A <listing_name> node can be used to search for listings whose names satisfy requirements such as being equal to, containing, starting with or containing keyword sound like some given keyword. The following example is used to search for listings with name starting with “iron gate”:
<listing_name search_string=“iron gate” search_mode=“start_with”/>
A <category> node can be used to search for listings in some specific categories, whose category codes are in the given list or whose names satisfy such requirement as being equal to, containing, starting with, ending with, or sounding like some given string. Either category code or category name can be used to search for categories.
A <search_region> node can be used to search for listings within some geographic region, which is specified by administration area, such as city, state and postal code, or by distance from some given location.
In addition to looking up objects, users can browse categories using <category_browse> node. Altogether, there is a wide range of possibilities for types and kinds of searching presented in a general XML schema. The input document schema of a particular embodiment is shown in FIG. 5 b.
Results returned from the database are formatted by the business directory server 112 in a pre-defined output XML schema ( FIG. 5 c ). For a listing lookup query, the business directory server 112 returns a list of matched listing, along with the list of categories that the listing belongs to. For a category lookup query, the business directory server 112 returns a list of matched categories, and for a category browsing query, a listing of the requested category hierarchy is returned.
In an alternative embodiment of the invention, different XML schemas may be used, as defined by one skilled in the art. In yet another embodiment of the invention, a context object may be passed from the clients to the business directory service 100 in an object state, without converting it to XML definitions. In yet another embodiment of the invention, cashing and storing of the information may be used, such that only additional components of the new queries may need to be transferred.
As discussed above, data from multiple vendors may be used to provide business directory services. The database 114 can contain a wide range of data formats and types. Illustrated in FIGS. 6 a – 6 c are database schema for the business directory service according to one embodiment of the invention. There are three types of tables in the database schema: vendor profile table ( FIG. 6 a ), category table ( FIG. 6 b ), and business listing table ( FIG. 6 c ). Vendor profile table stores the data vendor dependent information. Category tables store the category hierarchy information, while the business listing tables store the actual business directory listing information. There can be multiple category tables and listing tables for multiple data vendors. Typically, each data vendor will have one category table and one listing table to store its own category and business listing information.
The vendor profile table ( FIG. 6 a ) describes how the actual category and listing data are stored for different vendors. Each row contains information about the category and listing table names for a data vendor and the country to which the data belongs. If a vendor providers data for multiple countries, it can have multiple rows in this table. Thus if INFOUSA is the data supplier for U.S. business directory information, then in the vendor table there will be an entry with the following values: [“INFOUSA”, “US”, “CATEGORY_INFOUSA”, “LISTING_INFOUSA”].
The listing table stores information of the business listings. Table structure for different data suppliers can be different, and illustrated in FIG. 6 b is one way of structuring table columns. The category table ( FIG. 6 c ) stores category names, SIC codes (or codes for any other nomenclature), and the category hierarchy. In an alternative embodiment of the invention, different database schema can be used. In yet another embodiment of the invention, data from different vendors can be filtered and combined into one coherent set of tables.
Referring now to FIG. 7 , illustrated there is a flow chart illustrating operation of the business directory server module 112 . As discussed above, the business directory server module receives client requests (step 710 ), parses them from the XML format (step 712 ), finds proper data vendors for the request (step 714 ), creates an appropriate SQL database query (step 716 ), which is sent to the database 114 in step 718 . After results are returned from the database 114 , business directory server module 112 formats the results and returns them to dispatcher module 110 (step 720 ). The business directory server module can be threaded, such that a separate thread is spawned for each request. In another embodiment of the invention, several business directory server modules can be available at once, listening on the communication ports for receiving the client requests.
Those of ordinary skill in the art should recognize that methods for the business directory service may be embodied in a computer program product that includes a computer usable medium. For example, such a computer usable medium can include a readable memory device, such as a solid state memory device, a hard drive device, a CD-ROM, a DVD-ROM, or a computer diskette, having stored computer-readable program code segments. The computer readable medium can also include a communications or transmission medium, such as a bus or a communications link, either optical, wired, or wireless, carrying program code segments as digital or analog data signals.
While the system has been particularly shown and described with references to particular embodiments, it will be understood by those of ordinary skill in the art that various changes in form and details may be made without departing from the scope of the invention encompassed by the appended claims. For example, the methods of the invention can be applied to various environments, and are not limited to the described environment. | Business directory services allow definitions of custom category hierarchies and different search methods, such as, for example, search by location, distance from an addressable location, partial or complete business name, and category. A stepwise refinement search interface provides capability for searching within search results using different search methods or categories. Thus, a user does not have to refine and re-enter search criteria in order to get a progressively selective search. This is particularly useful for mobile phone or hand-held device users who would prefer not to have to re-enter the criteria on each search but rather incrementally refine the search criteria. | 8 |
FIELD OF THE INVENTION
This invention relates to a tamper evident locking device including a cable which passes through two aligned holes in two relatively movable pieces of apparatus. The cable forms a loop with each end secured to a seal. Thus, relative movement between the pieces of apparatus having the aligned holes requires a severing of the cable or a disengagement of the cable from the seal. Either alternative alerts the next user of the apparatus to possible tampering.
BACKGROUND OF THE INVENTION
It is important in various industries for a customer receiving a shipment of goods on a railroad car or a trailer to expect the shipper to mechanically lock the door of the car or trailer by a tamper proof device to provide evidence to the customer that the contents of the car or trailer have not been changed since the time they were dispatched by the shipper. Similar devices are used at a part separation line in gas meters, electric meters, etc. to make sure there has been no tampering by vandals or the like.
The most well known seal device for this purpose involves a pre-formed lead seal having one end of a flexible cable secured therein. The free end of the cable projects through aligned holes in the handle, door or frame of the railroad car or trailer or between two separable housing parts of the meter. The free end of the cable then passes through an opening in the lead seal and the lead seal is deformed to frictionally lock the two ends of the cable therein. In order to move the two relatively movable pieces of the apparatus to be sealed, a person is required to sever the cable or disengage one end of the cable from the deformed lead seal. Thereby, any person observing the severed locking device is alerted to a prior opening.
U.S. Pat. No. 2,809,065 discloses two plastic parts having unique wedge-shaped configurations and a strip intermediate the two having flanged, serrated and wedge-shaped surfaces to lock the strip to the two plastic parts forming the seal. The strip passes through holes in apparatus to be secured. After the strip is secured to the two plastic parts and they are secured together, the strip must be severed or the plastic parts destroyed to open the secured apparatus.
U.S. Pat. No. 3,770,307 discloses a cable lock and seal device which comprises a flexible cable and an enclosure fixedly secured to one end of the cable. A passage extends through the enclosure and is proportioned slidably to receive the distal end portion of the cable therethrough. A wedge element and a disk-shaped jam element are sealed within the enclosure, the wedge element including a ramp surface disposed at a small angle with respect to the passage and laterally spaced apart therefrom. The jam element is frictionally engaged between the ramp surface and cable portion whereby, movement of the cable through the passage in one direction causes movement of the jam element laterally away therefrom and movement of the cable in a direction opposite the aforementioned direction causes movement of the jam element laterally toward the cable to thereby jam the cable between the passage walls and the jam element so as to prevent further movement thereof in that direction.
U.S. Pat. No. 4,674,778 discloses a locking ring formed of a plurality of curved clamp portions connecting in an end-to-end relationship for securing an electrical power measuring device with a mounting base. The semi-circular clamp portions are molded from a single piece of plastic, are identical in construction and are fully interchangeable. Each clamp is preferably formed with a semi-circular curved arc body having a male connection at one end and a female connection at the other end. The male end is formed with a pair of projections of which the first male projection serves as an alignment guide during make-up and use while the second male projection carries a movable latch shoulder for effecting the end-to-end connection with the adjacent mating clamp portion. The female end includes a housing having a central opening with separated first and second entrances formed by a roof mounted lug. The lug also forms a locking surface for engaging with the latch surface of the second male projection of the adjacent clamp portion to operably connect the clamp portions. A tampering indicating locking block is forced into the second entrance after the clamp portions are connected to block movement of the second male projection that would disengage the latch shoulder.
U.S. Pat. No. 4,883,295 discloses a tamper deterrent assembly which is molded of plastic material and includes a body member with an enclosed locking space having an open end. The open end is closed by a closure member mounted on the body member and movable toward a closed end of the locking space. The closure member is normally retained on the body member in a first position and may be moved to a locking position where a strip engaging unit carried by the closure member is received and locking by a locking unit. The locking unit may be carried by an elongated locking strip which is inserted into the locking chamber through a strip receiving slot in the body, or the strip engaging unit may pass through the locking strip and engage a locking unit carried on an end wall of the body.
What is needed in the industry is a simpler locking device to serve the desired purpose and this invention fills that need.
SUMMARY OF THE INVENTION
A flexible cable has one end secured to a plastic female member by an over-sized bead and the other end is configured to be frictionally locked in the female member in an aperture substantially filled by a male member.
The cable projects through an opening in the female member, which opening is smaller than the over-sized bead. Thereby, the cable passes through the opening but the bead cannot. The secured cable is designed to have its distal end slip through aligned holes in two relatively movable parts of an apparatus to be secured by the tamper deterrent locking device.
The female member has an aperture with an internally and transversely extending ridge therein.
The cable projects from the female member through the two holes in the relatively movable pieces of apparatus, and doubles back through the aperture or a second opening in the female member where it is frictionally locked in place by the insertion of a male member of about the same configuration of the aperture. After it is completely inserted in the aperture, the male member is locked in place in the female member by an integral groove designed to receive the transversely extending ridge.
The male and female members are of solid but resilient plastic material and when the male member is inserted it frictionally engages the cable between the facing surfaces of the male member and the walls of the aperture. The male member is wedge-shaped at its forward end so that it cams the sides of the female member outwardly as it slips past the transversely extending ridge. The ridge ultimately snaps into place in the groove intermediate the innermost and outermost ends of the male member. That locks the male and female members together with the cable frictionally held between the two.
Objects of the invention and the scope of applicability of the present invention will become apparent from the detailed description to follow taken in conjunction with the accompanying drawings in which like parts are designated by like reference characters.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings wherein:
FIG. 1 is a perspective view of an injection molded preform for both male and female members of the locking device of invention; the cable is shown separately adjacent the pre-form;
FIG. 2 is a perspective view of the locking device of this invention shown in locked operative position;
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is sectional view taken along line 4--4 of FIG. 3; and
FIG. 5 is a fragmentary view, partially in section, taken along line 5--5 of FIG. 4.
In describing the preferred embodiments of the invention which are illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the words connected, secured or terms similar thereto are often used. They are not limited to direct connection but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a pre-form 10 of the two injection molded male and female members of the locking device of this invention. The male member 12 is secured to the female member 14 by a bridge member 16 which will be broken off and discarded upon the locking device being used for its intended purpose. The bridge member serves a useful purpose because it holds the two parts together as a unit until the time they are to be used. Thereby, the purchaser of the product is required to carry only one bag of plastic parts and one bag of flexible metal cables, but the worker does not have to fish around in a bag of plastic pieces trying to find two separate plastic parts at the time he wants to use them. In actual practice the cables and pre-forms may be in the same bag or box but that is immaterial to this invention.
A flexible metal cable 18 has a bead 20 on one end. The purpose of the bead 20 is to secure the cable 18 to the female member 14 when the cable is inserted through a first opening 22. It will be observed that the cable 18 is smaller in diameter than first opening 22, but the bead 20 is larger, thereby, the cable may pass through opening 22 but the bead cannot. A countersink 21 facilitates insertion of the cable and allows bead 20 to sit in the countersink below the top surface 23 of female member 14. An oversized bead is not the only means for preventing cable 18 from passing through opening 22. A crimp in the cable may serve the same purpose. Any other means to accomplish the same result is within the inventive concept.
The female member has a generally rectangular aperture 24 having inwardly bulging corners 25 (best seen in FIG. 5). Corners 25 provide slots 26 therebetween at each end of aperture 24 to accommodate the wire cable 18 passing therethrough. Toward the lower surface 27 of the female member the aperture 24 opens into a cavity 28.
Note should be taken of the symmetry of the female member 14 which includes a second opening 29 being generally parallel with, and similarly shaped, to first opening 22. Thereby, the operator may use either of the two openings as the "first opening" without having to analyze the configuration thereof. A similar countersink 30 appears in surface 23 around opening 29.
Within aperture 24 are a pair of ridges 31 projecting inwardly from the surface of the aperture. Each ridge 31 has a slopping cam surface 32 facing toward cavity 28. The purpose of cam surfaces 32 is to cooperate with a wedge-shaped surface 34 on the male member 12.
Male member 12 has its forward end 36 with the two tapered surfaces 34 immediately downstream of a pair of grooves 38. The forward end of each groove includes a shoulder 40 which is generally perpendicular to the axis of the male member 12. Shoulders 40 are designed to snap into place behind flange surfaces 42 on the downstream side of aperture 24. Flange surfaces 42 extend generally perpendicular to the axis of aperture 24.
The cavity 28 in the upstream side of the female member 14 is of greater cross-sectional area than the aperture 24. The sidewalls of cavity 28 converge toward aperture 24 at an angle of about 91/4° and the mating surfaces of the male member are similarly sloped.
It will be observed that transversely projecting arms 44 on the generally T-shaped male member are configured to fit into the cavity 28 in close fitting relationship whereby when the two plastic members are conjoined in operative relationship, the periphery of the male member does not extend beyond the periphery of the female member except for the non-functional molding knob 45.
In operation, the cable 18 is inserted through the first opening 22 until the bead 20 engages the 45° angled countersink surface 21 of the female member with the distal end of the cable extending well beyond the cavity 28. Next the cable is bent to extend back through the female member a second time (best seen in FIG. 4), passing through the slot 26. For best performance, the cable is pulled tight such that the bead fits tightly in countersink 21 of first opening 22 and the cable fits against the bottom 46 of the cavity 28 or nearly so.
The end of the cable projecting outwardly from slot 26 is inserted through aligned holes 48 and 50 in two relatively movable parts 52 and 54 of the apparatus to be secured by the tamper deterrent locking device.
After extending through holes 48 and 50 the free end of the cable is inserted through the female member a third time to provide a closed loop 56. After the loop 56 is pulled to a suitably tight position, the free end of the cable is inserted through the female member for a fourth time, whereby the free end of the cable extends from the periphery of the female member at the same surface as engages bead 20. In the illustrated embodiment the third pass through the female member is through second opening 29. Countersink 30 serves the same insertion facilitating purpose as disclosed for countersink 21. However, the third pass may be through aperture 24 and the fourth pass through opening 29 if desired.
At this point the male member is inserted into the female member with the forward end 36 moving past the 45° angled cam surfaces 32 as the 45° angled wedge-shaped surfaces 34 resiliently deform the sidewalls of the aperture 24 in a radially outward direction until the wedge-shaped surfaces 34 move past flange surfaces 42, and at that point, the ridges 31 snap back into place in grooves 38 where shoulders 40 engage flange surfaces 42 to prevent disengagement of the male and female members without destruction of the same. The knob 45 is the only part of the male member which extends beyond the periphery at this point. Knob 45 is a non-functional element in the operative combination and for all practical purpose is non-existent.
By appropriate dimensional relationships the transversely extending arms 44 fit snugly into cavity 28 and thereby prevent access by vandals or the like who might try to disengage the two parts.
With the male member in place the cable 18 is frictionally engaged by the surfaces of the slots 26 of aperture 24 and the male member 12, and in addition, the several looped configurations of the cable within the cavity 28 combine to minimize the possibility of the cable being pulled from its frictionally locked position.
Having thus described the apparatus and procedural steps for carrying out the invention, it will be clear to those having ordinary skill in the art, that various modifications may be made in the apparatus and the procedural steps without departing from the inventive concept. It is not intended that the words used in the specification to describe the invention, nor the drawings illustrating the same, be limiting on the invention. Rather it is intended that the invention be limited only by the scope of the appended claims. | A tamper deterrent locking device includes a cable secured to a female member, the cable forming a loop projecting from the female member with the free end thereof projecting through an aperture in the female member. The male member fits into the aperture to frictionally lock the cable between the male and female members. The loop is passed through two aligned holes in two pieces of relatively movable apparatus whereby one who moves said relatively movable pieces is required to sever the cable or disengage it from the frictional engagement. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vibration isolation system, vibration isolation method, a lithographic apparatus and a device manufacturing method. The present invention also relates to vibration isolation using modal decoupling.
2. Description of the Related Art
A lithographic apparatus is a machine that applies a desired pattern onto a target portion of a substrate. Lithographic apparatus can be used, for example, in the manufacture of integrated circuits (ICs). In that circumstance, a patterning device, such as a mask, may be used to generate a circuit pattern corresponding to an individual layer of the IC, and this pattern can be imaged onto a target portion (e.g. including part of one, or several, dies) on a substrate (e.g. a silicon wafer) that has a layer of radiation-sensitive material (resist). In general, a single substrate will contain a network of adjacent target portions that are successively exposed. Known lithographic apparatus include so-called steppers, in which each target portion is irradiated by exposing an entire pattern onto the target portion at once, and so-called scanners, in which each target portion is irradiated by scanning the pattern through the projection beam in a given direction (the “scanning”-direction) while synchronously scanning the substrate parallel or anti-parallel to this direction.
In a prior art lithographic apparatus, a projection system for projecting a patterned beam onto a target portion of the substrate is supported by and positioned relative to a metrology frame. The metrology frame is supported by and positioned relative to a base frame.
Vibrations of the projection system may cause incorrect projections on the substrate rendering the substrate unusable. Therefore, any vibration of the projection system is to be prevented. The base frame however is coupled to the environment of the lithographic apparatus, such as a factory floor. The base frame passes any vibration of the environment on to any body rigidly coupled to the base frame. The metrology frame is not rigidly coupled to the base frame, but is coupled and supported using springs, preferably air springs, which isolate and damp certain vibrations. Other vibrations need to be isolated and damped by active isolator devices.
In the prior art lithographic apparatus, active devices are used in combination with the air springs, which are passive devices, although it is also known to use pneumatically controlled air springs, in which case the air springs are active devices for low frequencies, but may be regarded as passive devices for higher frequencies. Essentially, the active isolator devices may be regarded as active for frequencies where the air springs are or may be regarded as passive.
In the prior art lithographic apparatus, sensors detect any vibration of the metrology frame and the detected vibration is fed to a control system. In response to the detected vibrations, the control system determines a compensation to be performed by the active isolator devices. The compensation is intended to isolate and damp the detected vibration. The compensation also be employed to position the metrology frame with respect to the base frame.
The metrology frame has six degrees of freedom: translations in three directions and rotations in three directions. This implies that a vibration may be decomposed in those six (Cartesian or other orthogonal) directions and a vibration may be isolated and damped by compensations in those six directions. However, a compensation force in one direction may result in a movement not only in the one direction, but also in one or more of the other five directions. Thus, the control system needs to be a multiple-input multiple-output (MIMO) system. Such a system is a complex system, in particular if the system is unstable in at least one direction.
If the system is unstable in one direction, it needs to be stabilized by the control system, since a force exerted on the system in such an unstable direction may lead to an uncontrollable movement in the unstable direction, and may even lead to damage to the system. Generally, in a MIMO system, such instability and corresponding stabilization in one direction results in forces and vibrations in other directions, since the directions are coupled. Thus, an isolation and damping performance in a coupled other direction is compromised when the unstable direction is stabilized.
SUMMARY OF THE INVENTION
It is an aspect of the present invention to provide a vibration isolation system, wherein an unstable natural mode is stabilized without compromising isolation and damping performance in another direction.
The above aspect is achieved according to the present invention in a vibration isolation system for at least partially isolating and damping vibrations of a body, the system including a number of active isolator devices mechanically coupled to the body; and a control system for controlling the active isolator devices, wherein the control system is configured to: decouple vibrations in modal directions; determine a modal compensation signal for each modal direction; recouple each modal compensation signal into an active isolator control signal for each active isolator device; and stabilize at least one unstable natural mode of the body.
Modal decoupling decomposes movements, e.g. vibrations, in directions that correspond to directions of natural vibrations of the body (natural modes). Natural vibrations are a physical characteristic of a body and its coupling to its environment. The directions of the natural vibrations depend, for example, on the shape, the coupling with the environment, stiffness, material and other characteristics of the body.
An important feature of the natural vibrations is the fact that they are independent. That means that applying a force in a direction of a natural vibration results in a movement only in the direction of the respective natural vibration. Thus, a vibration in a modal direction may be isolated and damped by a modal compensation force in the same modal direction without causing movements or vibrations in other modal directions.
A control system in a vibration isolation system according to the present invention decouples any movement or vibration in modal directions resulting in one or more modal vibrations. Then, for each modal vibration, the control system determines a modal compensation signal. The modal compensation signal represents a force in the respective modal direction of the corresponding modal vibration, which force is to isolate and/or damp the modal vibration. Since the modal directions are independent, each single modal vibration may be isolated and/or damped by a single modal compensation signal. Thus, the control system may be a single-input single-output (SISO) system.
As the active isolator devices do not usually act in the modal directions, the modal compensation signals, one signal for each modal direction, are recoupled to the directions wherein the active isolator devices act.
The body, including the way it is supported, may have an unstable natural mode, i.e. natural vibration. Since an uncontrollable movement can occur in an unstable direction, there is no vibration isolation possible in the unstable direction. To stabilize such an unstable natural mode additional forces need to be introduced. With a modal control system, it is possible to generate such an additional force in the modal direction of the unstable natural mode without introducing forces in any other modal direction. Thus, the system characteristics may be shaped, and stabilized, in each modal direction, independently from any other modal direction.
To detect vibrations in the body, a number of sensors may be provided. The sensors detect vibrations in a number of arbitrary directions, for example the above mentioned Cartesian directions (translations in three perpendicular directions and three corresponding rotational directions). Otherwise, a mathematical transformation may be applied to these detected vibrations to obtain the vibrations in desired directions, for example the Cartesian directions. Also, a mathematical transformation may be applied to directly obtain the vibrations in the modal directions.
According to an aspect of the present invention, there is provided a lithographic apparatus including an illumination system configured to provide a beam of radiation; a support configured to support a patterning device, the patterning device configured to impart the beam with a pattern in its cross-section; a substrate table configured to hold a substrate; and a projection system configured to project the patterned beam onto a target portion of the substrate, wherein the projection system is supported by and positioned relative to a metrology frame, vibrations of the metrology frame being at least partially isolated and damped by a plurality of active isolator devices which are controllable by a control system, the control system being configured to: decouple vibrations in modal directions; determine a modal compensation signal for each modal direction; recouple each modal compensation signal in an active isolator control signal for each active isolator device; and stabilize at least one unstable natural mode of the metrology frame.
According to a further aspect of the present invention, there is provided a vibration isolation method for at least partially isolating and damping vibrations of a body, the method including detecting vibrations in the body; decoupling the detected vibrations in modal directions of the body; determining a modal compensation signal in each modal direction; transforming the modal compensation signal into an active isolator control signal for each of a number of active isolator devices which are mechanically coupled to the body; and feeding the active isolator control signals to the respective active isolator devices, wherein at least one unstable natural mode of the body is stabilized.
According to another aspect of the present invention, there is provided a device manufacturing method including projecting a patterned beam of radiation onto a target portion of a substrate, wherein disturbing vibrations in a projection system performing the projecting of the patterned beam of radiation are prevented by: detecting vibrations in the projecting system; decoupling the detected vibrations in modal directions of the projecting system; determining a modal compensation signal in each modal direction; recoupling the modal compensation signal into an active isolator control signal for each of a number of active isolator devices which are mechanically coupled to the projecting system; and feeding the active isolator control signals to the respective active isolator devices; wherein at least one unstable natural mode of the projecting system is stabilized.
Although specific reference may be made in this text to the use of lithographic apparatus in the manufacture of ICs, it should be understood that the lithographic apparatus described herein may have other applications, such as the manufacture of integrated optical systems, guidance and detection patterns for magnetic domain memories, liquid-crystal displays (LCDs), thin-film magnetic heads, etc. It should be appreciated that, in the context of such alternative applications, any use of the terms “wafer” or “die” herein may be considered as synonymous with the more general terms “substrate” or “target portion”, respectively. The substrate referred to herein may be processed, before or after exposure, in for example a track (a tool that typically applies a layer of resist to a substrate and develops the exposed resist) or a metrology or inspection tool. Where applicable, the disclosure herein may be applied to such and other substrate processing tools. Further, the substrate may be processed more than once, for example in order to create a multi-layer IC, so that the term substrate used herein may also refer to a substrate that already contains multiple processed layers.
The terms “radiation” and “beam” used herein encompass all types of electromagnetic radiation, including ultraviolet (UV) radiation (e.g. having a wavelength of 365, 248, 193, 157 or 126 nm) and extreme ultra-violet (EUV) radiation (e.g. having a wavelength in the range of 5-20 nm), as well as particle beams, such as ion beams or electron beams.
The term “patterning device” used herein should be broadly interpreted as referring to a device that can be used to impart a beam with a pattern in its cross-section such as to create a pattern in a target portion of the substrate. It should be noted that the pattern imparted to the beam may not exactly correspond to the desired pattern in the target portion of the substrate. Generally, the pattern imparted to the beam will correspond to a particular functional layer in a device being created in the target portion, such as an integrated circuit.
Patterning devices may be transmissive or reflective. Examples of patterning devices include masks, programmable mirror arrays, and programmable LCD panels. Masks are well known in lithography, and include mask types such as binary, alternating phase-shift, and attenuated phase-shift, as well as various hybrid mask types. An example of a programmable mirror array employs a matrix arrangement of small mirrors, each of which can be individually tilted so as to reflect an incoming radiation beam in different directions. In this manner, the reflected beam is patterned. In each example of patterning devices, the support may be a frame or table, for example, which may be fixed or movable as required and which may ensure that the patterning device is at a desired position, for example with respect to the projection system. Any use of the terms “reticle” or “mask” herein may be considered synonymous with the more general term “device means”.
The term “projection system” used herein should be broadly interpreted as encompassing various types of projection system, including refractive optical systems, reflective optical systems, and catadioptric optical systems, as appropriate for example for the exposure radiation being used, or for other factors such as the use of an immersion fluid or the use of a vacuum. Any use of the term “lens” herein may be considered as synonymous with the more general term “projection system”.
The illumination system may also encompass various types of optical components, including refractive, reflective, and catadioptric optical components for directing, shaping, or controlling the projection beam of radiation, and such components may also be referred to below, collectively or singularly, as a “lens”.
The lithographic apparatus may be of a type having two (dual stage) or more substrate tables (and/or two or more mask tables). In such “multiple stage” machines the additional tables may be used in parallel, or preparatory steps may be carried out on one or more tables while one or more other tables are being used for exposure.
The lithographic apparatus may also be of a type wherein the substrate is immersed in a liquid having a relatively high refractive index, e.g. water, so as to fill a space between the final element of the projection system and the substrate. Immersion liquids may also be applied to other spaces in the lithographic apparatus, for example, between the mask and the first element of the projection system. Immersion techniques are well known in the art for increasing the numerical aperture of projection systems.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:
FIG. 1 depicts a lithographic apparatus according to an embodiment of the present invention;
FIG. 2 schematically illustrates a lithographic apparatus having a base frame, a metrology frame and a projection system;
FIG. 3 schematically illustrates a control scheme of a prior art vibration isolation system;
FIG. 4 schematically illustrates a control scheme of a vibration isolation system
FIG. 5 depicts numerical results.
DETAILED DESCRIPTION
FIG. 1 schematically depicts a lithographic apparatus according to exemplary embodiment of the present invention. The apparatus includes an illumination system (illuminator) IL configured to provide a beam of radiation PB (e.g. UV radiation or EUV radiation). A first support (e.g. a mask table) MT supports a patterning device (e.g. a mask) MA and is connected to a first positioning device PM that accurately positions the patterning device with respect to a projection system (“lens”) PL. A substrate table (e.g. a wafer table) WT holds a substrate (e.g. a resist-coated wafer) W and is connected to a second positioning device PW that accurately positions the substrate with respect to the projection system. The projection system (e.g. a refractive projection lens) PL images a pattern imparted to the beam PB by the patterning device MA onto a target portion C (e.g. including one or more dies) of the substrate W.
As depicted here, the apparatus is of a transmissive type (e.g. employing a transmissive mask). Alternatively, the apparatus may be of a reflective type (e.g. employing a programmable mirror array of a type as referred to above).
The illuminator IL receives radiation from a radiation source SO. The source and the lithographic apparatus may be separate entities, for example when the source is an excimer laser. In such cases, the source is not considered to form part of the lithographic apparatus and the radiation beam is passed from the source SO to the illuminator IL with the aid of a beam delivery system BD comprising for example suitable directing mirrors and/or a beam expander. In other cases the source may be integral part of the apparatus, for example when the source is a mercury lamp. The source SO and the illuminator IL, together with the beam delivery system BD if required, may be referred to as a radiation system.
The illuminator IL may comprise an adjusting device AM configured to adjust the angular intensity distribution of the beam. Generally, at least the outer and/or inner radial extent (commonly referred to as σ-outer and σ-inner, respectively) of the intensity distribution in a pupil plane of the illuminator can be adjusted. In addition, the illuminator IL generally includes various other components, such as an integrator IN and a condenser CO. The illuminator provides a conditioned beam of radiation PB having a desired uniformity and intensity distribution in its cross-section.
The beam PB is incident on the mask MA, which is held on the mask table MT. Having traversed the mask MA, the beam PB passes through the lens PL, which focuses the beam onto a target portion C of the substrate W. With the aid of the second positioning device PW and position sensor IF (e.g., an interferometric device), the substrate table WT can be moved accurately, e.g. so as to position different target portions C in the path of the beam PB. Similarly, the first positioning device PM and another position sensor (e.g., an interferometric device) (which is not explicitly depicted in FIG. 1 ) can be used to accurately position the mask MA with respect to the path of the beam PB, e.g. after mechanical retrieval from a mask library, or during a scan. In general, movement of the object tables MT and WT will be realized with the aid of a long-stroke module (coarse positioning) and a short-stroke module (fine positioning), which form part of the positioning devices PM and PW. However, in the case of a stepper (as opposed to a scanner) the mask table MT may be connected to a short stroke actuator only, or may be fixed. Mask MA and substrate W may be aligned using mask alignment marks M 1 , M 2 and substrate alignment marks P 1 , P 2 .
The depicted apparatus can be used in the following preferred modes:
1. In step mode, the mask table MT and the substrate table WT are kept essentially stationary, while an entire pattern imparted to the projection beam is projected onto a target portion C at once (i.e., a single static exposure). The substrate table WT is then shifted in the X and/or Y direction so that a different target portion C can be exposed. In step mode, the maximum size of the exposure field limits the size of the target portion C imaged in a single static exposure.
2. In scan mode, the mask table MT and the substrate table WT are scanned synchronously while a pattern imparted to the projection beam is projected onto a target portion C (i.e., a single dynamic exposure). The velocity and direction of the substrate table WT relative to the mask table MT is determined by the (de-)magnification and image reversal characteristics of the projection system PL. In scan mode, the maximum size of the exposure field limits the width (in the non-scanning direction) of the target portion in a single dynamic exposure, whereas the length of the scanning motion determines the height (in the scanning direction) of the target portion.
3. In another mode, the mask table MT is kept essentially stationary holding a programmable patterning device, and the substrate table WT is moved or scanned while a pattern imparted to the projection beam is projected onto a target portion C. In this mode, generally a pulsed radiation source is employed and the programmable patterning device is updated as required after each movement of the substrate table WT or in between successive radiation pulses during a scan. This mode of operation can be readily applied to maskless lithography that utilizes programmable patterning device, such as a programmable mirror array of a type as referred to above.
Combinations and/or variations on the above-described modes of use or entirely different modes of use may also be employed.
In FIG. 2 it is illustrated how a base frame BF, a metrology frame MF and a projection system PL of a lithographic apparatus are supported and positioned relative to each other. The base frame is coupled to the environment of the lithographic apparatus, which is, for example, positioned on a factory floor. All other elements of the lithographic apparatus are positioned relative to the base frame BF. For example, a reticle handling system RH receives a reticle, i.e. a lithographic mask, from the outside having the base frame BF as a reference point, and positions the received reticle relative to the projection system PL. Similarly, a wafer handling system WH receives a wafer, i.e. a substrate, from the outside and positions the wafer relative to the projection system PS.
Projection of a pattern from the reticle on the wafer is very sensitive to vibrations. Therefore, parts of the reticle handling system RH, a reticle support structure for example, parts of the wafer handling system WH, a wafer support structure for example, and the projection system PL are not rigidly mechanically coupled to the base frame BF, since the base frame BF may receive vibrations from the outside. If the base frame BF and the handling systems WH and RH and/or the projection system PL would be rigidly mechanically coupled, these vibrations from the outside would be transferred to the systems resulting in incorrect projections. Therefore, these systems may be supported by the base frame BF via a vibration isolation and damping system.
A known device to support a body and to isolate and damp vibrations from the outside is a spring or an air mount having spring-like characteristics. A mass-spring system including the body and the spring has a resonance frequency. A passive damping and isolation device only isolates and damps above the resonance frequency. Moreover, vibrations having a frequency, at least approximately, equal to the resonance frequency will not be damped, instead they will be amplified.
Active vibration isolation devices may compensate any undesirable characteristics of the passive isolation devices. A known active vibration isolation system comprises active isolation devices and a control system to control the active isolation devices. Such an active isolation system, in particular the control system thereof, may be configured to employ a modal decoupling technique. Modal decoupling is a coordinate transformation, usually from a Cartesian coordinate system, to a modal coordinate system. The modal coordinate system comprises coordinate axes that are orientated in the directions of the natural vibrations of the body concerned. The modal coordinate system is unique for each body and the way the body is coupled to the outside.
Referring again to FIG. 2 , the metrology frame MF and the projection system PL are mechanically coupled to each other and to the base frame BF via vibration isolation devices ID. However, the coupling between the metrology frame MF and the projection system PL may also be stiff. The vibration isolation devices ID may include both passive and active devices, the active device compensating for any undesirable characteristics of the passive devices. Further a number of sensors S detect the relative positions and, if present, any vibrations of the separate bodies. A suitable vibration isolation device ID possibly also includes one or more sensors. An example of a suitable vibration isolation device ID is disclosed in Subrahmanyan et al., Active Vibration Isolation Design for a Photolithographic Stepper, In Proc. 6th International Symposium on Magnetic Bearings, pp. 10-21, 1998.
As may be seen in FIG. 2 , a common center of gravity of the metrology frame MF and the projection system PL generally does not lie in a center of stiffness of the metrology frame MF or of the projection system PL. This may result in an unstable natural mode of the system. In particular, the common center of gravity may be translated vertically with respect to the geometric centers of the aforementioned frame MF and system PL. Thus, in particular, a natural mode in a substantially vertical or a rotational direction, in which direction a movement may bring the center of gravity downward with respect to the coupling points to the environment, may be unstable.
A control system, not shown in FIG. 2 , receives sensor signals from sensors S indicating relative positions and vibrations and determines, in response, a control signal for each active isolation device in each isolation device ID. The control signals are subsequently fed to the respective active vibration isolation devices.
How the vibration isolation system functions is explained in relation to FIG. 3 and FIG. 4 . In FIG. 3 , a control diagram of a prior art active vibration isolation system is shown, wherein a rigid body is represented by a mass M and a stiffness K, being modeled as a feedback circuit. This circuit model of a rigid body comprising a mass M and a stiffness K in a feedback circuit is deduced from the equations of motion which may be readily derived by a person skilled in the art.
The body may move in a number of degrees of freedom, e.g. translations and rotations in a number of directions. Sensors S detect any vibration in the rigid body. Since the sensors may detect vibrations in directions that are not identical to the directions of the degrees of freedom of the rigid body, sensor decoupling SD is performed to obtain vibrations in each degree of freedom. As known to a person skilled in the art, a body such as a metrology frame and projection system PS has six degrees of freedom: translations in three Cartesian directions (x, y and z-directions), and rotations in three Cartesian directions (Rx, Ry, and Rz-directions).
The detected and decoupled vibrations are input to a controller C. The controller C determines in response to the detected vibrations a force in each degree of freedom needed to compensate those vibrations. Next, by actuator decoupling AD, the forces are decoupled to forces that may be exerted by the active isolation devices included in the isolation devices ID. The actuator decoupled forces, represented by corresponding signals, are fed to the respective actuators AID, i.e. active isolation devices. In response to the signals the active isolation devices AID exert corresponding forces on the rigid body.
The circuit model of FIG. 4 represents a control diagram of a vibration isolation system according to the present invention including modal decoupling. It is noted that decoupling means a transformation of coordinate system such that the coordinate system includes independent axes. For example, sensor decoupling results in detected vibrations independent from the sensor positioning and detection. Modal decoupling is a transformation to a coordinate system having axes in the directions of the natural modes or eigenmodes of the corresponding body. Thus, vibrations of the body may be represented in the modal coordinate system by independent vibrations in the modal directions.
After sensor decoupling SD, modal decoupling MD is performed. However, both decoupling steps, SD and MD, may also be performed in one step, directly transforming from a sensor coordinate system to the modal coordinate system, omitting a transformation to a Cartesian coordinate system.
In FIG. 4 , the controller C is configured to determine respective accelerations, to be enforced by the actuators, in the modal coordinate system in response to the modal vibrations determined by the modal decoupling. The control technique, and thus the configuration of the controller C, is simpler than in FIG. 3 . Since the vibrations are independent in the modal directions, the controller C may regard the input vibrations as independent and may compensate (or correct) the vibrations independently. Thus, a vibration in one modal direction requires only one compensating acceleration in the same modal direction, as opposed to the control diagram of FIG. 3 , wherein such a vibration may require a number of compensating accelerations in a respective number of (Cartesian) directions. Thus, the modal decoupling control strategy is very suitable to stabilize an unstable direction or natural mode of a body without compromising vibration isolation in other directions.
The compensation accelerations determined by the controller C and to be enforced by forces exerted by the actuators then need to be transformed to the actuator coordinate system. Again, this may be performed as indicated in FIG. 4 by two steps: modal recoupling MR and thereafter actuator decoupling AD, or in one step performing both actions, i.e. modal recoupling MR and actuator decoupling AD.
Modelling of the mechanical system, determining the corresponding equations of motion and modal decoupling are described in Subrahmanyan et al., Active Vibration Isolation Design for a Photolithographic Stepper, In Proc. 6th International Symposium on Magnetic Bearings, pp. 10-21, 1998, which is incorporated herein by reference.
The mass array M and the stiffness array K, or at least a fair estimate of the arrays M and K, are needed in the control method according to the present invention to obtain the required or desired amount of decoupling and damping. Such an estimate may be derived from a model, possibly refined using an iterative method. Also, the arrays M and K may be determined from measurements. However, if the natural modes of a body are known or determined directly, the mass array M and the stiffness array K are not required.
FIG. 5 shows numerical results obtained for a prior art vibration isolation system and a vibration isolation system according to the present invention. The results are organized in four rows and six columns. The first and second rows are obtained from the prior art system; the third and fourth rows are obtained from the system according to the present invention.
The upper row and the lower row represent each six degrees of freedom of an active vibration isolated system. The first row shows six orthogonal, in particular Cartesian, directions (X, Y, Rz, Z, Rx, Ry) for the degrees of freedom of the prior art system. The fourth row shows the modal directions for the subject body of the system according to the present invention.
The second and third rows show the corresponding sensitivities to vibrations in the Cartesian and modal directions, respectively. In the diagrams in the second and third row, the horizontal axis represents a frequency in Hz on a logarithmic scale. The vertical axis represents the amplification in dB, a negative value thus representing an attenuation. In each diagram six curves are shown indicating the sensitivity of a vibration in one direction corresponding to the corresponding upper or lower row in each of the six degrees of freedom.
The diagrams in the second row represent the sensitivities in the Cartesian directions. Most curves show at least two peaks indicating a coupling with at least one other direction. In the Z and the Rz directions however, one curve lies higher than other curves and shows only one peak, indicating that these directions have only a weak coupling with other directions.
Note that two of the modal directions, shown in the third and sixth column (third and fourth row), approach the Cartesian Rz-direction and Z-direction, respectively, closely. This implies that these Cartesian directions are close to modal directions and therefore are decoupled from other directions, which explains the above-mentioned and in the first and second row of FIG. 5 shown weak coupling of the Cartesian Rz-direction and Z-direction with other Cartesian directions.
In the third row, each diagram shows one curve lying substantially higher (50-100 dB) than the other five curves. Further, these curves show only one peak and thus it is concluded that the sensitivity in the direction indicated in the respective columns of the fourth row is not practically coupled with other directions. A vibration in one of the modal directions as indicated in the fourth row does not initiate a substantial vibration in another (modal) direction. In a system according to the present invention, this modal decoupling is employed to stabilize the unstable vertical natural mode without compromising the isolation and damping performance in any other direction.
While specific embodiments of the present invention have been described above, it will be appreciated that the invention may be practiced otherwise than as described. The description is not intended to limit the invention. | A vibration isolation system isolates a body from its surroundings with respect to vibrations. The vibration isolation system includes active isolator devices that isolate and damp the body in unstable directions. However, such active isolators may exert damping forces not only in the unstable direction, but simultaneously in other stable directions due to mechanical coupling of the stable and unstable directions. As a result the damping and isolation in the other stable directions may be deteriorated due to the active isolation and damping. Employing modal decoupling, i.e. decomposing any vibration into independent directions, and isolating and damping in the independent directions, enables compensation of any vibration in an unstable direction without influencing the isolation and damping performance in any other, possibly stable, direction. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to German patent application numbers DE 10 2005 050 426.4, filed Oct. 21, 2005, DE 10 2005 051 042.6, filed Oct. 25, 2005, and PCT/EP2006/009843, filed Oct. 12, 2006.
FIELD OF THE INVENTION
[0002] The invention relates to a retention system for a motor vehicle with a seat belt retractor accommodating one end of a seatbelt component which has a belt shaft and a pretensioner device having a drive connection with the belt shaft.
BACKGROUND OF THE INVENTION
[0003] A restraining system of the aforementioned type is described, for example, in DE 103 04 943 B3. With the known restraining system, the associated seat belt retractor is part of an end fitting pretensioner in which the end of the seat belt to be fixed on the motor vehicle structure is fixed on the retractor shaft, so that this end of the seatbelt is wound up on the shaft upon actuation of the pretensioner drive and is tightened in this way. The locking of the shaft element with the seat belt retractor housing is undertaken in such a way that the locking element is arranged in the radial interior of the shaft element, which has a hollow configuration, and is pretensioned by means of a passage opening configured in the shaft element by spring action over the outer circumference of the shaft element until it engages in the associated gearing of the housing leg that supports the belt shaft. Consequently, the locking element is in a permanent locking with the seat belt retractor housing so that the end of the seat belt is correspondingly fixed and therewith fixedly mounted on the motor vehicle. When the pretensioner drive is activated, the locking element ratchets away through the gearing of the housing leg in the corresponding direction of the belt shaft, while in the event of a rotation of the belt shaft in the belt withdrawal direction after completing the pretensioning rotation, the immediate locking of the belt shaft takes place.
[0004] It is an object of the invention to increase the pretensioning force of a restraining system of the type described above.
[0005] This object, including the advantageous embodiments and further developments of the invention, is attained with the features of the present invention described herein.
SUMMARY OF THE INVENTION
[0006] The invention provides in its basic conception to slide a sleeve, which enlarges the outer circumference of the shaft element in this area and is immovably axially and radially connected to the shaft element, on one end of the shaft element, in which the thickness of the wall of the sleeve is dimensioned in such a way that the drive radius of the shaft element is enlarged and a reduction in speed of the pretensioner drive is established as compared with wrapping the pretensioner cable directly onto the shaft element. Due to the arrangement of the sleeve, the tightening radius and therewith the tightening force are enlarged when the diameter of the shaft element, and therefore the winding radius of the wound-up belt webbing, remain constant because the drive cable is wound around the sleeve at a greater radial distance with respect to the central axis of the shaft element.
[0007] According to an exemplary embodiment of the invention, the belt shaft is configured as a hollow shaft with a locking element arranged in the interior of the shaft element, as is known from the prior technology as described by DE 103 04 943 B3, in which the sleeve is slid on the end that accommodates the locking element and is mounted in the housing leg, and has an opening that is flush with the passage opening of the shaft element for the locking element.
[0008] According to exemplary embodiments of the invention, it can be provided with respect to mounting of the drive cable on the belt shaft, that the drive cable extends through the sleeve and is mounted on the shaft element, or that the drive cable is mounted directly on the sleeve. It can also be provided that the drive cable is mounted both on the shaft element and the sleeve.
[0009] To the extent that a supporting of the locking element on the shaft element is to be ensured for transferring load from the belt shaft to the seat belt retractor housing, the locking element can be supported in the engaged state with the gearing of the housing leg on an edge region of the passage opening of the shaft element, which is configured as a nose.
[0010] As an alternative, the locking element can be braced in the engaged state with the gearing of the housing leg at an edge region of the opening configured in the sleeve, which is configured as a nose.
[0011] An especially secure force transmission results according to one embodiment of the invention when the locking element is braced in the engaged state with the gearing of the housing leg on the edge of the passage opening of the shaft element as well as the opening configured in the sleeve, which is configured as a joint nose.
[0012] With regard to the radial and axial fixation of the sleeve on the shaft element, it can be provided according to an exemplary embodiment of the invention that the connection of the sleeve and the shaft element is created by means of projections stamped out of the sleeve radially inward extending into associated recesses of the shaft element.
[0013] As long as the projections of the sleeve are inclined in axial direction of the shaft element, it is practical to arrange two projections with an opposite oriented inclination.
[0014] The force transmission is improved overall as long as, according to an exemplary embodiment of the invention, a multitude of recesses and projections are distributed over the circumference of the shaft element and the sleeve.
[0015] In a further embodiment of the invention, it is provided that two annular closed retaining elements with a smooth internal circumference enclosing the housing leg as well as the deflected locking element between them are slid on the shaft element for axial position securing of the belt shaft on the housing leg lockingly interacting with the locking element, in which the shaft element has a stop for the axial fixation of the internal retaining element, which comes to lie between the stop and the housing leg, and the outer sleeve lying outwardly against the housing leg as a further retaining element is fixed using an anti-sliding safety on the shaft element. The advantage that due to the axial shaft fixing device, an axial displacement of the belt shaft relative to the retractor housing is ruled out, especially due to the action of the tightening device coupled to the belt shaft. An axial shaft fixing device such as this is basically known from the generic restraining system disclosed in DE 103 48 461 A1.
[0016] As long as according to an exemplary embodiment of the invention it is provided that the stop provided on the shaft body is formed by stamping the shaft element as a radial elevation of the circumference of the shaft element, the advantage that the stop can be economically manufactured without an additional component is provided.
[0017] In accordance with a further exemplary embodiment of the invention, it is provided that the inner retaining element is configured as a retaining ring which can be slid on the shaft element, and the outer retaining element is configured as a sleeve which can be slid against the housing leg on the retaining element, while the drive cable is wound on the outer circumference of the sleeve. In this case, it can be provided that the anti-sliding safety for the sleeve consists of a cable suspension configured at the end of the drive cable, which passes through the sleeve as well as the shaft element of one opening in each case. The advantage that the anti-sliding safety is likewise realized without an additional component is associated with this.
[0018] According to an exemplary embodiment of the invention, it is provided that the retaining elements are provided in each case at their front end that faces the housing leg with an axial facet, in such a way that a linear installation of the retaining element on the housing leg results. In this way, friction losses due to the rotation of the belt shaft are minimized. It can moreover be provided that the facet of the retaining elements in each case bridges the opening configured in the shaft element for penetration of the toothed lock washer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In the drawings are depicted exemplary embodiments of the invention, which will be described in the following, and wherein;
[0020] FIG. 1 illustrates an overall view of a seat belt retractor and pretensioning device in accordance with the present invention,
[0021] FIG. 2 illustrates the device shown in FIG. 1 in a side view,
[0022] FIG. 3 illustrates the latching element of the seat belt retractor shown in FIG. 1 ,
[0023] FIG. 4 illustrates the latching plane of the seat belt retractor in accordance with this invention shown in section, and
[0024] FIG. 5 illustrates an exemplary embodiment of the belt shaft with an axial locking device in section view.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The seat belt retractor and a pretensioning device 10 in accordance with this invention, which can be seen in FIG. 1 , the seat belt retractor consists of a U-shaped seat belt retractor housing 11 , in whose housing legs 12 a belt spool or shaft 13 is mounted, on which a belt webbing 14 is wound. A belt buckle 15 is mounted on the free end of the belt webbing 14 , into which or from which a locking tongue 16 can be inserted or detached, wherein the locking latch plate tongue 16 is mounted on a seat belt 17 . Seat belt arrangements such as that described above are known. In order to be able to subject the belt buckle 15 to a tightening by winding up the belt webbing 14 on the belt shaft 13 , a pretensioning device 18 is fastened on a housing leg 12 consisting of a pretensioner tube 19 and a gas generator receptacle 20 . The connection between the pretensioning device 18 and the belt shaft 13 is carried out by means of a drive wire or cable 22 , which is wound on a shaft extension 24 of the belt shaft 13 and its end is affixed to the shaft.
[0026] As can also be seen in FIG. 2 , the end of the drive cable 22 attached to the pretensioning device 18 is guided into the pretensioner tube 19 and is connected herein to a piston 21 , which can move within the tightening tube 19 . A gas generator 23 is arranged in the gas generator receptacle 20 of the pretensioner tube 19 , which upon activation releases gas, which drives the piston 21 in the pretensioner tube 19 , so that the drive cable 22 is unwound from the shaft extension 24 of the belt shaft 13 and consequently causes the belt shaft 13 to rotate which tightens or pretensions webbing 14 .
[0027] The belt shaft 13 has a shaft element 25 , which has a hollow configuration, on which the belt webbing 14 is wound. A locking element 27 , which passes with at least one tooth through a passage opening 28 arranged in the shaft element 25 , is arranged within the plane of the housing leg 12 in the shaft element 25 , through which passes the shaft extension 24 . A sleeve 26 on whose outer circumference the drive cable 22 is wound, is slid on the shaft extension 24 , which overlaps the shaft extension 24 in order to enlarge the tightening radius. The sleeve 26 has an opening 29 for the passage of the locking element 27 , which is flush with the passage opening 28 of the shaft element 25 , so that the locking element engages with the allocated gearing of the housing leg 12 when it is pivoted out into its locking position. As is not shown in detail, the locking element 27 , according to the description of DE 103 04 943 B3, which is herewith also being made into an object of the present disclosure, is pretensioned by a spring element into its pivoted out locking position, so that the locking element 27 ratchets away over the gearing of the housing leg 12 when the belt shaft 13 is rotated, and brings about the immediate locking of the belt shaft 13 in the belt withdrawal direction when the belt shaft 13 is rotated after the pretensioning rotation has ended.
[0028] As can be inferred in more detail from FIG. 3 , the sleeve 26 is axially and radially fixedly mounted on the shaft element 25 , in that projections 30 are stamped in the plane of the shaft element 25 , which project from the sleeve 26 radially inwardly, which in turn engage into recesses 31 formed in the sleeve 26 . Two diametrically opposite projections 30 engaging with recesses 31 are represented in the shown exemplary embodiment, in which the projections 30 are aligned inclined in the axial direction of the shaft element 25 in such a way that their longitudinal axis intersects the longitudinal axis of the shaft element 25 . The mutually opposite projections 30 are preferably arranged therein with an opposite oriented inclination, so that the sleeve 26 is axially and radially immovably fixed on the shaft element 25 . In FIG. 3 can furthermore be seen a cable end fitting or bushing 32 for the drive cable 22 , which in the shown exemplary embodiment is positioned in the interior of the shaft element 25 , so that the drive cable 22 runs toward its outer circumference through a corresponding clearance in the sleeve 26 .
[0029] In FIG. 4 can finally be seen the arrangement and mounting of the locking element 27 in the hollow shaft element 25 , which corresponds to the description in the representative DE 103 04 943 B3. Here, the locking element 27 , which is mounted with a bearing arrangement 35 in a perforation 36 formed in the shaft element 25 as well as in the sleeve 26 , respectively, is supported when engaged with the gearing 37 of the allocated housing leg 12 , on an edge region of the opening 29 of the sleeve 26 , which is configured as an inwardly curved nose 33 that engages in a pocket 34 formed in the locking element 27 . Consequently, the introduction of the bracing force is carried out, on the one hand, into the sleeve 26 , and on the other hand, via the bearing attachment 35 into the sleeve 26 as well as into the shaft element 25 .
[0030] As can be seen in FIG. 5 , the axial locking device of the belt shaft 13 is positioned on the housing leg 12 that interacts with the locking element 27 , and namely through an internal retaining element 41 slid on the shaft element 25 , which is configured, with the exception of the passage opening 28 , with a closed circumference. The internal retaining element 41 is located in the interior of the housing frame 11 between the housing legs 12 and is configured as a closed retaining ring, which is supported on a stop 42 configured by stamping or forming of the shaft element 25 . The sleeve 26 , on whose outer circumference the drive cable 22 is wound, is slid on the outside of the shaft extension 24 , which projects beyond the housing leg 12 . The drive element, which is provided at its end with a cable fitting 44 , is guided into the interior of the shaft element through an opening 43 formed in the sleeve 26 as well as in the shaft element 25 and is fixed by means of the cable fitting 44 . Due to this configuration, the cable fitting 44 together with the drive cable 22 extending from it acts at the same time as an anti-sliding safety for the external sleeve 26 , so that after the installation is complete, the sleeve is immovably fixed on the shaft element 25 .
[0031] In order to reduce friction losses during the rotation of the belt shaft 13 , the internal retaining element 41 as well as the external sleeve 26 are provided with a radial facet 45 which respectively face the housing leg 12 , so that a basically linear installation of the two retaining elements 41 or 26 on the housing leg 12 is achieved. Here, the facet 45 is formed in such a way that the passage opening 28 , which is configured in the shaft element 25 to allow the passage of the locking element 27 , is bridged in each case.
[0032] The features of object of these documents, which are disclosed in the previous description, the patent claims, the abstract, and the drawings, can be essential individually and also in any desired combinations for the realization of the invention in its various embodiments. | A restraining system for a motor vehicle with a seat belt retractor that accommodates the one end of a seatbelt component, which has a tightening device having a belt shaft and a drive cable connected to the belt shaft, in which a sleeve ( 26 ) that enlarges the outer circumference of the shaft element ( 25 ) is slid onto one end of the shaft element ( 25 ) and is axially and radially fixed to the shaft element ( 25 ), while the wall thickness of the sleeve ( 26 ) is dimensioned in such a way that the drive radius of the shaft element ( 25 ) and a reduction in speed of the tightening drive is provided as compared with a cable wrapped onto the belt shaft. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an implantable medical device in general and to an implantable heart stimulator in particular.
The implantable heart stimulator preferably is an implantable pacemaker or an implantable cardioverter/defibrillator (ICD), or a device for cardiac resynchronization (CRT-D).
2. Description of the Related Art
Heart stimulators such as cardiac pacemakers are medical devices, usually implantable, that can be connected to or that are permanently connected to electrode leads for delivery of electrical stimulations pulses to the tissue (myocardium) of a human heart. Dual chamber pacemakers are capable of generating stimulation pulses for the atrium and the ventricle of a human heart. Biventricular pacemakers usually are capable to stimulate at least three chambers of a human heart that is the right atrium, the right ventricle and the left ventricle.
In a dual chamber pacemaker, this is usually realized by placing electrodes in both the right atrium and right ventricle of the heart.
In a demand-type pacemaker these electrodes are coupled through intravenous and/or epicardial leads to sense amplifiers housed in an implanted pacemaker. Electrical activity occurring in these chambers can thus be sensed. When electrical activity is sensed, the pacemaker assumes that a depolarization following a contraction of the indicated chamber has occurred. If no electrical activity is sensed within a prescribed time interval, typically referred to as an atrial or ventricular escape interval, then a pulse generator, also housed within the pacemaker housing, generates a stimulation pulse that is delivered to the indicated chamber, usually via the same lead as is used for sensing.
Separate stimulation pulse generators are usually provided for each heart chamber (atrium or ventricle) to be stimulated.
A control unit triggers the generation of a respective atrial or ventricular stimulation pulse according to a pre-programmed, variable timing regime in order to provide for adequate timing of the stimulation pulses.
A stimulation pulse to the myocardium may cause a contraction of a respective heart chamber, if the myocardium of that chamber is not in a refractory state and if the stimulation pulse intensity is above the stimulation threshold of said myocardium. A sub-threshold stimulation pulse will not cause a cardiac contraction even if delivered to the myocardium in its non-refractory state.
Depending on the mode of operation, a pacemaker only delivers a stimulation pulse (pacing pulse) to a heart chamber (atrium or ventricle) if needed, that is, if no natural excitation of that chamber occurs. Such mode of operation is called an inhibited or demand mode of operation since the delivery of a stimulation pulse is inhibited if a natural excitation of the heart chamber is sensed within a predetermined time interval (usually called escape interval) so the heart chamber is only stimulated if demanded.
In a demand mode, the pacemaker monitors the heart chamber to be stimulated in order to determine if a cardiac excitation (heartbeat) has naturally occurred, such natural (non-stimulated) excitation, also referred to as “intrinsic” or “signs” cardiac activity, are manifested by the occurrence of recognizable electrical signals that accompany the depolarization or excitation of a cardiac muscle tissue (myocardium). The depolarization of the myocardium is usually immediately followed by a cardiac contraction. For the purpose of the present application, depolarization and contraction may be considered as simultaneous events and the terms “depolarization” and “contraction” are used herein as synonyms.
In order to monitor the heart chamber and thus to determine whether or not a natural contraction of a heart chamber has occurred a pacemaker has a sensing stage which during operation of the pacemaker is connected to an electrode placed in a respective heart chamber. A natural contraction of a heart chamber can be detected by evaluating electrical potentials sensed by such sensing electrode. In the sensed electrical signal the depolarization of an atrium muscle tissue is manifested by occurrence of a signal known as “P-wave”. Similarly, the depolarization of ventricular muscle tissue is manifested by the occurrence of a signal known as “R-wave”. A P-wave or an R-wave represents an atrial event or a ventricular event, respectively, in the further course of this application.
In a demand mode of operation, the pacemaker monitors the heart for the occurrence of P-waves and/or R-waves. If such signals are sensed within a prescribed time period or time window, which is called atrial or ventricular escape interval, respectively, then the escape interval is reset (i.e., restarted) and generation of a stimulation pulse is inhibited and no unnecessary stimulation pulse is triggered. The escape interval is measured from the last heartbeat, i.e., from the last occurrence of an intrinsic (sensed) atrial event (P-wave, A-sense, AS) if the atrium is monitored, or an intrinsic (sensed) ventricular event (R-wave, V-sense, VS) if the ventricle is monitored, or the generation of a stimulation pulse (V-pace, VP; A-pace, AP) if no respective intrinsic event has occurred. If the escape interval “times-out”, i.e., if a time period equal to the escape interval has elapsed without the sensing of a P-wave and/or R-wave (depending upon which chamber of the heart is being monitored), then a stimulation pulse is generated at the conclusion of the escape interval, and the escape interval is reset, i.e., restarted. In this way, the pacemaker provides stimulation pulses “on demand,” i.e., only as needed, when intrinsic cardiac activity does not occur within the prescribed escape interval.
Several modes of operation are available in a state of the art multi mode pacemaker. The pacing modes of a pacemaker, both single and dual or more chamber pacemakers, are classified by type according to a three letter code. In such code, the first letter identifies the chamber of the heart that is paced (i.e., that chamber where a stimulation pulse is delivered), with a “V” indicating the ventricle, an “A” indicating the atrium, and a “D” indicating both the atrium and ventricle. The second letter of the code identifies the chamber wherein cardiac activity is sensed, using the same letters, and wherein an “O” indicates no sensing occurs. The third letter of the code identifies the action or response that is taken by the pacemaker. In general, three types of action or responses are recognized: (1) an Inhibiting (“I”) response wherein a stimulation pulse is delivered to the designated chamber at the conclusion of the appropriate escape interval unless cardiac activity is sensed during the escape interval, in which case the stimulation pulse is inhibited; (2) a Trigger (“T”) response wherein a stimulation pulse is delivered to a prescribed chamber of the heart a prescribed period of time after a sensed event; or (3) a Dual (“D”) response wherein both the Inhibiting mode and Trigger mode may be evoked, e.g., with the “inhibiting” occurring in one chamber of the heart and the “triggering” in the other.
To such three letter code, a fourth letter “R” may be added to designate a rate-responsive pacemaker and/or whether the rate-responsive features of such a rate-responsive pacemaker are enabled (“O” typically being used to designate that rate-responsive operation has been disabled). A rate-responsive pacemaker is one wherein a specified parameter or combination of parameters, such as physical activity, the amount of oxygen in the blood, the temperature of the blood, etc., is sensed with an appropriate sensor and is used as a physiological indicator of what the pacing rate should be. When enabled, such rate-responsive pacemaker thus provides stimulation pulses that best meet the physiological demands of the patient.
Multiple-mode, demand-type, cardiac pacemakers shall allow a sequence of contractions of the heart's chamber which equals as far as possible a natural behavior of the healthy heart for damaged or diseased hearts that are unable to do so on their own.
In a healthy heart, initiation of the cardiac cycle normally begins with depolarization of the sinoatrial (SA) node. This specialized structure is located in the upper portion of the right atrium wall and acts as a natural “pacemaker” of the heart. In a normal cardiac cycle and in response to the initiating SA depolarization, the atrium contracts and forces the blood that has accumulated therein into the ventricle. The natural stimulus causing the atrium to contract is conducted to ventricle via the atrioventricular node (AV node) with a short, natural delay, the atrioventricular delay (AV-delay). Thus a short time after an atrial contraction (a time sufficient to allow the bulk of the blood in the atrium to flow through the one-way valve into the ventricle), the ventricle contracts, forcing the blood out of the ventricle to body tissue. A typical time interval between contraction of the atrium and contraction of the ventricle might be 180 ms; a typical time interval between contraction of the ventricle and the next contraction of the atrium might be 800 ms.
Thus, in a healthy heart providing proper AV-synchrony an atrial contraction (A) is followed a relatively short time thereafter by a ventricle contraction (V), that in turn is followed a relatively long time thereafter by the next atrial contraction and so on. Where AV synchrony exists, the heart functions very efficiently as a pump in delivering life-sustaining blood to body tissue; where AV synchrony is absent, the heart functions as an inefficient pump.
To mimic the natural behavior of a heart, a dual-chamber pacemaker, in conventional manner, defines a basic atrial escape interval (AEI) that sets the time interval for scheduling an atrial stimulation pulse. The atrial escape interval can be started by a ventricular event and end with an atrial event. A basic AV delay (AVD) or ventricular escape interval (VEI) sets the time interval or delay between an atrial event and a ventricular event. In such embodiment, AEI and AVD (or VEI) thus together define a length of a heart cycle which is reciprocal to the pacing rate at which stimulation pulses are generated and delivered to a patient's heart in the absence of sensed natural cardiac activity.
For the purpose of this application, a “ventricular event” may refer either a natural ventricular excitation (intrinsic ventricular event) which is sensed as an R-wave or a ventricular stimulation pulse (V-pulse, VP). Similarly, an atrial event shall refer to both, a P-wave or an atrial stimulation pulse (A-pulse, AP).
Since the atrial escape interval usually defines the time of delivery of a next scheduled atrial stimulation pulse, and since an atrial stimulation pulse may be timed from the latest ventricular event as well as from the latest atrial event, in some cases the atrial escape interval is an A-A interval.
One basic parameter of a heart stimulator's operation is stimulation rate. The stimulation rate is the V-V interval or the A-A interval the heart stimulator is applying. In modern heart stimulators the stimulation rate is often time variable in order to meet a hemodynamic demand of a patient that depends on the patient's physical activity. A hemodynamic sensor or activity sensor can be provided to adapt the actual stimulation rate to an actual hemodynamic demand. A heart stimulator allowing such rate adaption is called rate adaptive. Usually the actual stimulation rate is elevated compared to a base (minimum) stimulation rate. The base stimulation rate is applied whenever a patient is at rest. In order to mimic a natural circadian rhythm different base stimulation rates are provided for daytime (daytime base stimulation rate) when the patient is expected to be awake and night time when the patient is expected to sleep (nighttime stimulation rate).
Some parameters of an implantable medical device impact the lifestyle of a patient. An example is the time at which an implantable pulse generator (IPG) transitions from nighttime stimulation rate to daytime base stimulation rate. The former is generally lower than the later and thus provides less hemodynamic support. A pacemaker dependent person may thus feel less energetic if he or she wakes up before the programmed transition time.
All parameters may be programmed by the physician at follow-up using a device known as “physician programmer”. The follow-ups typically occur every three to six months. The physician may not have the time to discuss all the lifestyle impacting parameters with the patient. Even if time is allocated to this task during the follow-up, adapting the parameters to the lifestyle of the patient only two to four times a year may not provide sufficient granularity to react to changes that can potentially occur daily.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention to provide a heart stimulator that best fits the need of a patient.
The fundamental idea to achieve the object of the invention consists in allowing the patient to modify a subset of implantable medical devices parameters.
According to the invention the patient can modify selected parameters of its implantable medical device that impact his or her lifestyle more often, thereby improving quality of life.
This is achieved by an implantable medical device (IMD) that can be wirelessly connected to a user interface by which a patient can enter values of selected control parameters for controlling the IMD whereas other control parameters are not accessible via said user interface and can only be modified by a physician or other authorized personnel.
The term selected parameter or selected control parameter shall apply to those parameters that a patient can change. Non-selected parameters thus are parameters that only can be changed by authorized personnel such as a physician.
The selected subset of implantable medical devices parameters that a patient can modify comprises only parameters, with associated tuning ranges, that may safely be changed by someone without medical training. For example, an average patient can be trusted to adapt the transition time of an IPG from nighttime rate to daytime rate to its lifestyle, much like he or she would program an alarm clock. On the other hand, changing the atrioventricular delay interval (AV delay interval) requires knowledge not found outside the expert community and this parameter should therefore not be available for the patient to modify.
According to the invention, the implantable medical device comprises a telemetry unit connected to a memory and a control unit that control the implantable medical device's operation according to parameters stored in the memory.
The telemetry unit is adapted to wirelessly receive parameters for controlling the implantable medical device.
It is part of the invention to define a subset of implantable medical devices parameters that can be changed and the ranges within these selected parameters that can be changed, and to define other parameters that only can be amended by a physician.
In addition to adapt the heart stimulator so as to allow some selected parameters to be manipulated by a patient, a user interface is provided allowing the patient to modify the selected subset of the implantable medical device's parameters that can be patient modified.
According to alternative preferred embodiments of the invention two options are provided.
According to a first embodiment, the external device is provided with an interface that allows the patient to only modify the selected parameters. This external device can connect wirelessly to the implantable medical device. Optionally, the external device may be connected to a network where patient changes can be logged and analyzed. Optionally, the network may be connected to a physician network access so that the physician can receive notices of the patient changes to the parameters and review change history.
According to an alternative embodiment it is suggested to allow the patient to program selected parameters through a network access, for example a PC connected to the internet. The network access may be provided by a central service center that can connect to the implantable medical device via the external device. The central service center may thus provide a remotely accessible user interface that allows a user to only amend selected parameters. The central service center may further provide a second user interface with restricted access so only authorized personnel can access the second user interface. Via the second user interface a physician can amend other, non-selected parameters. The access to the first user interface (the patient interface) may be restricted so as to only allow a particular patient to access this interface in order to amend selected parameters of his own implantable medical device.
According to a particularly preferred embodiment according to the first alternative, the external device provides a wireless link to the implantable medical device and provides a user interface corresponding to a user interface of an alarm clock. In a particularly preferred embodiment, the external device is adapted to allow the patient to set the current time, program the wake-up alarm time and arm the wake-up alarm.
It is further preferred, that the external device is adapted to telemetrically instruct the implantable medical device to start the transition to nighttime rate when the patient arms the wake-up alarm. In addition, the external device may be adapted to telemetrically instruct the implantable medical device to program the wake-up alarm time that the patient entered as the transition time from nighttime rate to daytime rate.
Optionally, the external device may be connected to a central service center via a network where patient changes can be logged and analyzed. Optionally, the central service center provides a physician network access so that a physician can receive notices of the patient changes to the selected parameters and review change history.
Optionally, the external device may provide other features found in alarm clocks, such as a radio tuner and/or a CD player.
According to the invention this objective is achieved by a heart stimulation system comprising an implantable heart stimulator and an external transceiver device for wireless communication with said implantable heart stimulator.
BRIEF DESCRIPTION OF THE DRAWINGS
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. 1 is a schematic overview over a implantable device system comprising an implantable medical device, an external transceiver device and a service center.
FIG. 2 shows a three chamber bi-ventricular implantable cardioverter/defibrillator (ICD).
FIG. 3 is a schematic diagram of the device modules of the ICD of FIG. 2 .
FIG. 4 is a schematic diagram of the external transceiver device.
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.
FIG. 1 shows an implantable device system comprising an implantable medical device 10 , an external transceiver device 80 and a central service center 90 . The implantable medical device 10 is for example an implantable pacemaker or an implantable cardioverter/defibrillator or device for cardiac resynchronization. The implantable medical device 10 comprises an implant transceiver (not shown) for wireless communication with the external transceiver device 80 . The external transceiver device 80 comprises an external transceiver unit (not shown) for wireless communication with the implant transceiver unit and a data communication interface (also not shown) adapted to allow a data communication with the service center 90 . The data communication interface preferably is adapted to use a public data communication line as a telephone landline connection or wireless connection via GPRS/UMTS or SMS.
The central service center 90 comprises or is connected to a user interface allowing a physician or a team of physicians to interact with the central service center. The user interface may comprise a display for displaying data to the physician 100 and some input device allowing the physician 95 to enter instructions or data into the central service center 90 . The central service center 90 further comprises a central data base that is connected to said data communication interface (see FIG. 4 ) and a data evaluation module that is connected to the data base that is adapted to evaluate data stored in said data base.
A patient having the medical device 10 implanted may communicate with the implantable medical device 10 , the central service center 90 or both by means of the external transceiver device 80 . For this purpose, the external transceiver device 80 may feature a user interface 108 as is illustrated in FIG. 4 . The patient may also directly connect with the central service center 90 without using the external device but via the internet, for example.
In FIG. 2 the implantable medical device is a three chamber biventricular pacemaker and cardioverter/defibrillator 10 that is connected to pacing/sensing leads placed in a heart 12 is illustrated.
Pacemaker 10 comprises a gas proof housing (case) 42 made from a biocompatible metal such as titanium. Pacemaker 10 comprises a transparent header 11 that is made from electrically insulating plastic and that encloses terminals to which electrode leads 16 , 18 and 30 are connected detachably. Electrode leads 16 , 18 and 30 each comprise a proximal connector (not shown) that is plugged into the connectors of header 13 .
The implantable medical device 10 is electrically coupled to heart 12 by way of leads 14 , 16 and 30 .
Lead 14 is a right atrial electrode lead that has a pair of right atrial electrodes 22 and 24 that are in contact with the right atria 26 of the heart 12 .
Lead 16 is a right ventricular electrode lead that has a pair of ventricular stimulation and sensing electrodes 18 and 20 that are in contact with the right ventricle 28 of heart 12 . Further, a ventricular defibrillation shock coil 38 and an atrial defibrillation shock coil 40 are arranged on lead 16 .
Electrodes 22 and 18 are tip electrodes at the very distal end of leads 14 and 16 , respectively. Electrode 22 is a right atrial tip electrode RA Tip and electrode 18 is a right ventricular tip electrode. Electrodes 24 and 20 are ring electrodes in close proximity but electrically isolated from the respective tip electrodes 22 and 18 . Electrode 24 forms a right atrial ring electrode RA Ring and electrode 20 forms a right ventricular ring electrode RV Ring. Atrial cardioversion shock coil 40 is a coil electrode providing a relatively large geometric area when compared to the stimulation electrodes 18 , 20 , 22 and 24 .
Lead 30 is a left ventricular electrode lead passing through the coronary sinus of heart 12 and having a left ventricular ring electrode LV RING 32 a left ventricular tip electrode LV TIP 34 . Further, a left ventricular defibrillation shock coil 36 is arranged on lead 30 .
Implantable medical device 10 has a case 42 made from electrically conductive material such as titanium that can serve as a large surface electrode IMD CASE.
The plurality of electrodes 18 , 20 , 22 , 24 , 32 , 34 , 36 , 38 and 40 connected to implantable medical device 10 together with case 42 allow for a number of different electrode configurations for measuring intrathoracic and intracardiac impedance.
Referring to FIG. 3 a simplified block diagram of an implantable medical device 10 is illustrated. During operation of the pacemaker leads 14 , 16 and 30 are connected to respective output/input terminals of pacemaker 10 as indicated in FIG. 2 and carry stimulating pulses to the tip electrodes 18 , 22 and 34 from a right ventricular pulse generator RV-STIM, a right atrial stimulation pulse generator RA-STIM and a left ventricular pulse generator LV-STIM, respectively. Further, electrical signals from the right ventricle are carried from the electrode pair 18 and 20 , through the lead 16 , to the input terminal of a right ventricular sensing stage RV-SENS; and electrical signals. from the right atrium are carried from the electrode pair 22 and 24 , through the lead 14 , to the input terminal of a right atrial channel sensing stage RA-SENS. Electrical signals from the left ventricle are carried from the electrode pair 32 and 34 , through the lead 30 , to the input terminal of a right ventricular sensing stage RV-SENS
The atrial channel sensing stage A-SENS and ventricular sensing stages RV-SENS and LV-SENS comprise analog to digital converter (ADC; not shown) that generate a digital signal from electric signals picked up in the atrium or the ventricle, respectively.
Controlling the implantable medical device 10 is a control unit CTRL 54 that is connected to sensing stages A-SENS and V-SENS, to stimulation pulse generators A-STIM and V-STIM and to an impedance determination unit 70 . Control unit CTRL 54 comprises a digital microprocessor forming a central processing unit (CPU; not shown) and is—at least in part—controlled by a program stored in a memory circuit MEM 56 that is coupled to the control unit CTRL 54 over a suitable data/address bus ADR.
Control unit CTRL 54 receives the output signals from the atrial sensing stage RA-SENS and from the ventricular sensing stages RV-SENS and LV-SENS. The output signals of sensing stages RA-SENS and RV-SENS are generated each time that a P-wave representing an intrinsic atrial event or an R-wave representing an intrinsic ventricular event, respectively, is sensed within the heart 12 . An As-signal is generated, when the atrial sensing stage RA-SENS detects a P-wave and a Vs-signal is generated, when the ventricular sensing stage RV-SENS detects an R-wave.
Control unit CTRL 54 also generates trigger signals that are sent to the atrial stimulation pulse generator RA-STIM and the ventricular stimulation pulse generators RV-STIM and LV-STIM, respectively. These trigger signals are generated each time that a stimulation pulse is to be generated by the respective pulse generator RA-STIM, RV-STIM or LV-STIM. The atrial trigger signal is referred to simply as the “A-pulse”, and the ventricular trigger signal is referred to as the “V-pulse”. During the time that either an atrial stimulation pulse or ventricular stimulation pulse is being delivered to the heart, the corresponding sensing stage, RA-SENS, RV-SENS and/or LV-SENS, is typically disabled by way of a blanking signal presented to these amplifiers from the control unit CTRL 54 , respectively. This blanking action prevents the sensing stages RA-SENS, RV-SENS and LV-SENS from becoming saturated from the relatively large stimulation pulses that are present at their input terminals during this time. This blanking action also helps prevent residual electrical signals present in the muscle tissue as a result of the pacer stimulation from being interpreted as P-waves or R-waves.
Furthermore, atrial sense events As recorded shortly after delivery of a ventricular stimulation pulses during a preset time interval called post ventricular atrial refractory period (PVARP) are generally recorded as atrial refractory sense event Ars but ignored.
Control unit CTRL 54 comprises circuitry for timing ventricular and/or atrial stimulation pulses according to an adequate stimulation rate that can be adapted to a patient's hemodynamic need as pointed out below.
Control unit CTRL 54 is connected to a memory circuit MEM 56 that allows certain control parameters, used by the control unit CTRL 54 in controlling the operation of the implantable medical device 10 , to be programmably stored and modified, as required, in order to customize the implantable medical device's operation to suit the needs of a particular patient. Such data includes the basic timing intervals used during operation of the pacemaker 10 and AV delay values and hysteresis AV delay values in particular. The stored control parameters in particular include an AV delay interval, a daytime base stimulation rate, a nighttime base stimulation rate and a night-to-day transition time and a day-to-night transition time.
Further, data sensed during the operation of the implantable medical device 10 may be stored in the memory MEM 56 for later retrieval and analysis.
A telemetry circuit TEL 58 is further included in the implantable medical device 10 . This telemetry circuit TEL 58 is connected to the control unit CTRL 54 by way of a suitable command/data bus. Telemetry circuit TEL 58 allows for wireless data exchange between the implantable medical device 10 and some remote programming or analyzing device which can be part of a centralized service center serving multiple pacemakers. Telemetry circuit 56 serves as a data interface for wireless data communication with external device 80 and for receiving values for selected control parameters to be stored in memory circuit MEM 56 , in particular. The selected control parameters include the night-to-day transition time and a day-to-night transition time.
The implantable medical device 10 in FIG. 3 is referred to as a three chamber pacemaker/cardioverter/defibrillator because it interfaces with the right atrium 26 , the right ventricle 28 and the left ventricle of the heart 12 . Those portions of the pacemaker 10 that interface with the right atrium, e.g., the lead 14 , the P-wave sensing stage A-SENSE, the atrial stimulation pulse generator A-STIM and corresponding portions of the control unit CTRL 54 , are commonly referred to as the atrial channel. Similarly, those portions of the pacemaker 10 that interface with the right ventricle 28 , e.g., the lead 16 , the R-wave sensing stage V-SENSE, the ventricular stimulation pulse generator V-STIM, and corresponding portions of the control unit CTRL 54 , are commonly referred to as the ventricular channel.
In order to be able to detect periods of physical activity of a patient indicating that the patient is awake and in order to allow rate adaptive pacing in a DDDR or a DDIR mode, the pacemaker 10 further includes a physiological sensor ACT 60 that is connected to the control unit CTRL 54 of the pacemaker 10 . While this sensor ACT 60 is illustrated in FIG. 2 as being included within the pacemaker 10 , it is to be understood that the sensor may also be external to the implantable medical device 10 , yet still be implanted within or carried by the patient.
The control unit CTRL 54 is adapted to determine an adequate heart rate or stimulation rate in any manner known as such. This includes application of a base application when a patient is at rest and applying an elevated stimulation rate, when the activity sensor 60 senses physical activity of a patient. Depending on the daytime, either a daytime base stimulation rate is applied or a nighttime base stimulation rate.
For impedance measurement, impedance determination unit 70 is provided. Impedance determination unit 70 comprises a constant current source 72 that is connected or can be connected to electrodes for intracorporeal placement as shown in FIG. 2 . In order to allow for a plurality of impedance measurement electrode configurations, preferably some means of switching is provided between the constant current source 72 and the electrode terminals of the implantable medical device 10 . The switch is not shown in FIG. 3 . Rather, particular impedance measurement configurations are shown as examples.
Similarly, a impedance measuring unit 74 for measuring a voltage corresponding to a current fed through a body by said constant current source is provided and can be connected to a number of electrodes although a switch for switching between these configurations is not shown in FIG. 3 .
As an alternative to constant current source 72 a constant voltage source can be provided. Then, the measuring unit will be adapted to measure a current strength of a current fed through a body by said constant voltage source.
Both, constant current source 72 and impedance measurement unit 74 , are connected to an impedance value determination unit 76 that is adapted to determine an impedance value for each measuring current pulse delivered by the constant current source 72 .
The impedance value determination unit 76 comprises another analog to digital converter ADC in order to generate a digital impedance signal that is fed to the control unit CTRL 54 .
Further, a clock 78 is connected to control unit CTRL 54 in order to allow control unit 54 to control a base stimulation depending on the daytime. Depending on the output signal of clock 78 and the night-to-day transition time and a day-to-night transition time stored in Memory circuit 56 , control unit CTRL 54 either applies the daytime base stimulation rate or the nighttime base stimulation rate as stored in memory circuit MEM 56 .
Control unit CTRL 54 further comprises watchdog and reset units to provide safety when the CPU should fail. The watchdog units therefore are designed to operate independently from the CPU of the control unit CTRL 54 . In FIG. 3 , the watchdog and reset units are not shown.
FIG. 4 is a more detailed representation of the external transceiver device 80 . The external device 80 comprises a telemetry circuit 100 adapted for wireless data transmission to the implantable medical device 10 and a data exchange interface 102 adapted to allow a data communication with service center 90 . Both, the telemetry circuit 100 and the data exchange interface 102 are connected to an external device control unit 104 . The external device control unit 104 is connected to an external device memory 106 . The external device memory 106 is adapted to store data received from or to be transmitted to either the central service center 90 or to the implant 10 . Further, the external device memory circuit 106 comprises data that can be entered via an external device user interface 108 . The external device user interface 108 is connected to the external device control unit 104 and comprises an input and display panel 110 and an interface circuit 112 . The input display panel 110 comprises a display 114 and two input buttons 116 and 118 .
The user interface 108 is adapted to display an actual day time on the display 114 . Further, an alarm time can be set via buttons 116 and 118 . Button 116 serves for entering the hour of alarm and button 118 serves for entering the minute of alarm. The alarm time thus set is displayed in display 114 . In order to enable or disable the alarm a toggle-button 120 is provided. The state of the alarm—enabled or disabled—is indicated on display 114 by an according icon.
Control unit 104 of the external device 80 is adapted to generate a data package to be sent to implant 10 , whenever an alarm is activated via user interface 108 . The data package comprises a night to day transition time corresponding to the alarm time set via user interface 108 and a day to night transition time corresponding to the actual day time when the alarm was activated.
This data package is received by telemetry circuit 58 of the implantable medical device 10 and the night to day transition time and the day to night transition time contained in the data package is stored in memory circuit MEM 56 of the implantable medical device 10 . The selected parameters thus generated, transmitted and stored in the implantable medical device 10 are used as control parameters for controlling the implantable medical device via the implantable medical device control unit CTRL 54 .
Although an exemplary embodiment of the present invention has been shown and described, it should be apparent to those of ordinary skill that a number of changes and modifications to the invention may be made without departing from the spirit and scope of the invention. This invention can readily be adapted to a number of different kinds of implantable medical devices by following the present teachings. All such changes, modifications and alterations should therefore be recognized as falling within the scope of the present invention. | An implantable medical device (IMD) that can be wirelessly connected to user interface by which a patient can enter values of selected control parameters for controlling the IMD whereas other control parameters are not accessible via said user interface and can only be modified by a physician or other authorized personnel. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to the field of wood burning furnaces and comprises a high efficiency furnace having an aperture for the removal of accumulated creosote from the heat exchanger.
With the rising cost of operating electric and gas fired furnaces has come an increased interest in wood burning furnaces and an effort to utilize firewood when such wood is inexpensive and available. Rising demand for wood burning furnaces has encouraged efforts to make the wood furnace more energy efficient and also more adaptable to existing buildings having already installed gas fired or electric heating systems. In addition, there are a growing number of mobile homes and trailers, particularly in outlying areas, which would utilize wood burning furnaces if the furnaces could be safely and effectively combined with the existing gas fire furnaces typically used with such trailers and mobile homes. In situations where the wood furnace is to be used in combination with an existing home heating system, it is helpful to be able to position the wood furnace outside the home or trailer. Such external positioning eliminates indoor smoke odors as well as eliminating the need to move sometimes dirty firewood into the home and to carry the ashes outdoors. In some geographic areas, building code restrictions can also be less demanding for an externally positioned wood furnace.
In order to reduce the amount of wood consumed by such a furnace and to prolong the burning time with a given quantity of wood, more efficient furnaces with improved heat exchangers are desirable. Typically such efficiency is gained by constructing the heat exchanger to extract more heat from the hot air and smoke passing through the exchanger before exhausting the air and smoke from the furnace chimney. Efficiency can be noticably increased by having the heat exchanger be a tightly closed doorless chamber with minimal external openings through which heat loss can occur. It has been found, however, that as the heat exchanger successfully removes more and more heat from the smoke within it, that the amount of creosote deposited from the smoke onto the heat exchanger increases. Such deposits of creosote can be undesirable because they tend to insulate the heat exchanger walls from the smoke and thereby progressively reduce later heat transfer, and additionally, such creosote can eventually create a fire hazard, producing secondary fires in the exchanger and chimney. Accordingly, it is desirable to not only increase the efficiency of the heat exchanger but to also provide a means to intermittently purge the interior of the closed heat exchanger of such creosote deposits and to dispose of the creosote. The present invention provides an improved heat exchanger of high efficiency and a means for effectively removing the creosote from the heat exchanger.
SUMMARY OF THE INVENTION
The invention comprises an improved wood furnace designed to be positioned external to a home or trailer and provided with an improved, highly efficient heat exchanger which can be easily purged of accumulated creosote.
The wood furnace is provided with an upright frame which carries a conventional fire box on top of which a heat exchanger is mounted. The heat exchanger is connected with the fire box by a pair of upright columns which supply smoke from fire box to heat exchanger.
The heat exchanger has a generally flat top and bottom interconnected by vertical and angled side walls so that creosote scraped from the side walls will slide downwardly and inwardly to the bottom of the heat exchanger.
A scraper blade having an outer periphery generally similar to the cross section of the heat exchanger chamber is slidably mounted for movement from the rear wall to the front wall of the chamber and is provided with a pair of parallel rods which extend forwardly through the front wall of the heat exchanger and are accessible to an operator so as to permit scraping movement of the blade within the heat exchanger to remove the creosote deposits. Such deposits drop downwardly to the bottom of the heat exchanger and are forced into the upright columns for subsequent movement into and burning within the fire box.
The lower end of the chimney stock extends downwardly into the heat exchanger to delay the escape of hot air and smoke from the exchanger and to thereby increase the heat transferred to the exchanger.
These and other objects and advantages of the invention will appear more fully from the following description made in conjunction with the accompanying drawings wherein like reference characters refer to the same or similar parts throughout the several views.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front perspective partially exploded and cut-away view of a wood burning furnace embodying the invention.
FIG. 2 is a cross sectional side elevation view of the furnace of FIG. 1 and showing the creosote removal blade in alternative positions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, an improved hot air wood burning furnace 10, embodying the invention, has an upright frame 12 which surrounds internal fire box 14 and heat exchanger 16. The frame 12 utilizes four generally upright, rectangular cross section, tubular metal posts 18, 20, 22 and 24 which are interconnected by upper side rails 26, intermediate side rails 28, and lower side rails 30, the side rails being rigidly welded between posts 20 and 22 and between posts 18 and 24. Similarly, upper rail 32, middle rail 34 and lower rail 36 are welded between posts 22 and 24 at the rear of the furnace. Front horizontal support rails 38, 40, 42 and 44 extend between upright posts 18 and 20 at the front of the furnace. Horizontal base rails 47 and 49 extend transversely between lower side rails 30. The collective posts 18, 20, 22 and 24 and the interconnecting rails 26-49 collectively comprise an upright frame for supporting the furnace described herein.
The fire box 14 is formed of sheet steel, is generally octagonal in cross section and is provided with a conventional, hinged fire box door 46 and a combustion air inlet 48. The interior of the fire box is provided with a floor of commercially available fire brick 50 on which the wood fire 52 is laid. The fire box 14 is supported on four upright tubular metal studs 54 which are rigidly welded to rails 47 and 49 and to the base of the fire box 14. The fire box is positioned within the frame 12 so as to be spaced inwardly from all of the side walls and upwardly from the rails 47 and 49 to permit free air circulation about the fire box, as will be described further hereafter. A rectangular extender 54 is welded to the front of the fire box and extends outwardly to the outer surface of the furnace housing 114. The extender is also welded to the horizontal rails 40 and 42 and provides a means of offsetting the fire box door from the outer surface of the furnace to decrease the likelihood of accidental contact with the hot fire box door.
The heat exchanger 16 is preferably hexagonal in cross section and is provided with an internal chamber 56. The exchanger has a generally flat top 58 and bottom 60 which are interconnected by generally vertical side walls 62 and 64 and downwardly, inwardly angled side walls 66 and 68. The side walls 62-68 are rigidly welded to one another as shown in FIG. 1 and are welded to front end wall 70 and rear end wall 72.
The bottom 60 of the heat exchanger 16 is provided with circular apertures 74 and 76 which communicate with upright columns 78 and 80, respectively. The columns 78 and 80 are formed of rigid sheet steel and are of generally round cross section with their upper and lower ends being welded to the heat exchanger and the fire box, respectively. These columns 78 and 80 provide a means for connecting the fire box and the heat exchanger and directing smoke from the fire box upwardly into the heat exchanger chamber, as will be described further hereafter.
A chimney stack 82 extends downwardly through an aperture in the top 58 of the exchanger and is rigidly welded to the top. The stack 82 extends downwardly within the heat exchanger chamber 56 substantially halfway between the top and bottom of the chamber so that heated air and smoke within the chamber 56 must linger adjacent the top of the chamber before eventually entering the lower, open end of the chimney stack 82 and being exhausted from the furnace 10. This increased time delay, during which the heated smoke is retained within the exchanger, allows additional heat transfer to occur from the smoke to the exchanger.
Positioned wholly within the closed exchanger chamber 56 is a rigid, metal scraper blade 84 which is slidable between the rear wall 72 and the front wall 70 of the exchanger. The blade 84 is shaped to be closely similar to the inner periphery of the heat exchanger and has a lower edge 86 which is arranged to scrape the bottom 60 of the exchanger and, similarly, has lateral edges 88 and 90 which scrape side walls 68 and 64, respectively. Similarly, edges 92 and 94 are closely adjacent side walls 66 and 62, respectively, to scrape against those side walls during movement of the blade 84. Upper edge 96 is positioned closely adjacent the top 58 to remove creosote deposits from the top of the exchanger. A rectangular groove 98 is cut in the blade 84 and is sized to accommodate the cross section of chimney stack 82 to allow the scraper to pass by the chimney 82 without contacting or damaging the chimney.
First and second, generally parallel, spaced apart rigid metal rods 100 and 102 have one end of each rod rigidly fixed to the scraper blade 84 with the remaining end of each rod being passed slidably outwardly through apertures 104 and 106 in end wall 70 and through communicating apertures in housing 114. A handle 108 interconnects the ends of rods 100 and 102. Accordingly, the rods 100 and 102, and handle 108, define a means for mounting the blade 84 for movement between a forward position 110 adjacent front end wall 70 and a rearward position 112 adjacent rear wall 72 to allow an operator to slide the blade along the inner periphery of the chamber 56 to thereby rub off and dislodge accumulated creosote deposits which would otherwise insulate the interior of the heat exchanger from the heat from fire box 14 and eventually pose a potential fire hazard.
After installation of the fire box and the heat exchanger within the framework as shown, an insulative housing 114 is attached to the framework and defines an interior air plenum 116 within the insulative housing and surrounding the fire box and heat exchanger. Apertures are provided in the insulative housing to permit the upward passage of chimney stack 82 and sliding motion of rods 100 and 102 through the housing. It has been found desirable to form the housing of inner and outer layers 120 and 118, respectively, of sheet steel with an intermediate layer of insulation 122 positioned therebetween. Preferably, a layer of pyrex paper is positioned between the insulation 122 and inner layer 120.
A chimney extension 124 is attached to the upwardly extending chimney stack 82 and is surrounded by an outer chimney housing 126 which is fixed to the top of the stove housing 114.
Positioned outside the rear insulative wall of the furnace is a blower housing 128 which contains air blower 130 which is mechanically coupled to electric motor 132 for rotation of the blower. A cold air inlet duct 134 extends upwardly from the blower housing to a cold air inlet 136 which interconnects the ducts with plenum 116 to deliver cold air from the blower 130 to the plenum for heating.
A hot air outlet 138 is located in the rear wall of the furnace adjacent the bottom of the plenum and communicates with hot air duct 140 which is connected with the house or trailer to be heated, or to the duct system in such house or trailer, for delivery of the hot air to the house. Similarly, the cold air duct 142 connects with the cold air return in the house or trailer.
A thermostat 144 is positioned on the rear wall of the furnace and has a sensing element 146 which extends inwardly toward the heat exchanger to sense the temperature level in the plenum 116. The thermostat is electrically connected between the blower motor 132 and a source of electrical energy to actuate the blower motor when the temperature within the plenum reaches an appropriate operating temperature, such as approximately 140° F. and to turn off the electric current to the motor when the temperature drops to approximately 90° F.
In operation, an operator builds a fire 52 within the fire box 14, permitting the hot smoke 159 to rise upwardly through columns 78 and 80 and into the heat exchanger 14. Hot air entering the heat exchanger moves upwardly adjacent the top 58 of the heat exchanger and is prevented from immediate exhausting into the chimney stack 82 by the chimney stack having its lower end extending downwardly within the chamber 56. Accordingly, additional heat transfer occurs within the heat exchanger 16 thereby providing better utilization of the hot smoke. Eventually, the hot smoke drops downwardly as it cools and exhausts through the chimney stack as shown by the arrows 150 in FIG. 2.
As the smoke within heat exchanger 16 cools, creosote is deposited on the side walls, end walls and top and bottom of the heat exchanger chamber and eventually would build up to levels which would require purging. To eliminate such depositing on the top, bottom and side walls, the operator slides the scraper blade 84 between front and rear positions 110 and 112 by manipulating handle 108 in directions 148 and 149 thereby causing the creosote to be scraped from the described surfaces and to drop downwardly within the heat exchanger. The vertical side walls 62 and 64 and the angled side walls 66 and 68 collectively direct the creosote downwardly to the bottom 60 of the heat exchanger when the movement of blade 84 causes the deposits to drop downwardly through columns 78 and 80 for re-burning within the fire box 14.
As the temperature within the plenum 116 reaches the predetermined minimum temperature, the thermostat 144 turns to an "on" condition and energizes the blower motor 132 to cause cold air to be delivered through cold air inlet 136 to the plenum. Air circulates through the plenum and around and between the fire box and heat exchanger to become warmed, after which the heated air is withdrawn through hot air outlet 138 and conducted to the house for utilization along hot air duct 140.
Accordingly, the invention provides a wood burning furnace which has high efficiency, is easily cleaned, and is inexpensively constructed to thereby provide better heating and utilize available supplies of firewood.
While the preferred embodiment of the present invention has been described, it should be understood that various changes, adaptions and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. | A wood burning furnace, positionable exterior to a home or trailer utilizes an improved heat exchanger with a chimney stack extending downwardly into the heat exchanger chamber to prolong the time interval in which smoke stays in the heat exchanger. A creosote removal blade is slidably mounted within the chamber to scrape creosote deposits from the inner periphery of the chamber and to direct it downwardly into the fire box for subsequent burning. | 5 |
This is a divisional application of Ser. No. 09/012,827, filed Jan. 23, 1998.
BACKGROUND OF THE INVENTION
The present invention relates to a novel chemical-sensitization photoresist composition or, more particularly, to a positive-working chemical-sensitization photoresist composition used in the photolithographic patterning in the manufacture of various kinds of electronic devices.
Chemical-sensitization photoresist compositions in the prior art usually contain a resinous ingredient having high transparency to the KrF excimer laser beams of 248 nm wavelength which is mainly a polyhydroxystyrene resin, optionally, substituted for the hydroxyl groups therein by acid-dissociable solubility-reducing groups. It is a trend in recent years, however, that the KrF excimer laser beam as the exposure light is increasingly under replacement with an ArF excimer laser beam having a shorter wavelength of 193 nm in order to comply with the requirements toward finer and finer patterning in the manufacture of modern semiconductor devices.
When the photolithographic patterning process is conducted with the ArF excimer laser beams as the exposure light source, the polyhydroxystyrene-based resinous ingredient is no longer suitable as the resinous ingredient of the photoresist compositions because of the low transparency of the resin to the light of 193 nm wavelength due to the aromatic ring structure contained in the resin. In this regard, acrylic resins having no aromatic structure are highlighted as a substitute for the polyhydroxystyrene resins while acrylic resins in general have a disadvantage of low resistance against dry etching.
It is known that an acrylic resin can be imparted with increased resistance against dry etching when monomeric units derived from an alicyclic alkyl ester of acrylic acid are introduced into the molecular structure of the acrylic resin. For example, proposals have been made, in Japanese Patent Kokai 4-39665, for a polymer of an acrylic ester having a skeleton of adamantane in the ester-forming group and, in Japanese Patent Kokai 5-265212, for a copolymer of an acrylic ester having a skeleton of adamantane in the ester-forming group and tetrahydropyranyl acrylate.
Although improvements in the transparency and resistance against dry etching can be accomplished to some extent for an acrylic resin by the introduction of the monomeric units derived from an acrylic ester having a skeleton of adamantane, the improvements obtained thereby are still not quite satisfactory if not to mention the low availability and hence expensiveness of such an acrylic ester having a skeleton of adamantane along with a disadvantage of low photosensitivity of the photoresist composition formulated with such an acrylic resin not to give an excellent result of patterning.
While the photolithographic patterning process by using ArF excimer laser beams as the exposure light has an important target to form a very finely patterned resist layer with extremely fine pattern resolution of 0.2 μm or even finer, such extremely fine patterning is sometimes accompanied by a defect of pattern falling due to deficiency in the adhesion between the substrate surface and the resist layer formed thereon. As a remedy for this drawback, proposals have been made for an acrylic resin containing monomeric units derived from an acrylic ester having an oxygen-containing heterocyclic group such as 3-oxocyclohexyl acrylate (Japanese Patent Kokai 5-346668) and γ-butyrolactone (Japanese Patent Kokai 7-181677).
When such an acrylic resin, into which the monomeric units of an acrylic acid ester having an oxygen-containing heterocyclic group are introduced, is used as a resinous ingredient of a photoresist composition to be used for patterning exposure with ArF excimer laser beams, however, a patterned resist layer having high fidelity cannot be obtained in the puddle development treatment as a major current in the manufacture of semiconductor devices due to insufficient affinity of the photoresist composition with the aqueous alkaline solution as the developer solution, even though an improvement to some extent can be obtained in the adhesion of the photoresist layer to the substrate surface. Therefore, one of the important subject matters in the technological field of photoresist compositions is to develop a photoresist composition for patterning exposure to light such as the ArF excimer laser beams exhibiting excellent adhesion between the resist layer and the substrate surface and having high affinity with an aqueous alkaline developer solution suitable for a puddle development treatment.
SUMMARY OF THE INVENTION
The present invention accordingly has an object to provide, in view of the above described situations in the prior art, a chemical-sensitization photoresist composition having high transparency to the ArF excimer laser beams and suitable for a puddle development treatment with high affinity to an aqueous alkaline developer solution to give a patterned resist layer with high photosensitivity having an excellently orthogonal cross sectional profile and exhibiting excellent adhesion to the substrate surface and resistance against dry etching.
Thus, the present invention provides a chemical-sensitization positive-working photoresist composition which comprises, as a uniform solution in an organic solvent:
(A) 100 parts by weight of an acrylic resin of which the solubility in an aqueous alkaline solution is subject to an increase in the presence of an acid; and
(B) from 0.5 to 30 parts by weight of a radiation-sensitive acid-generating agent capable of releasing an acid when irradiated with actinic rays,
the acrylic resin as the component (A) being a copolymer consisting of monomeric units derived from (meth)acrylic acid esters, of which from 20% to 80% by moles are the monomeric units having an oxygen-containing heterocyclic group represented by the general formula
in which R 1 is a hydrogen atom or methyl group, R 2 , R 3 and R 4 are each, independently from the others, a hydrogen atom, lower alkyl group having 1 to 4 carbon atoms or lower alkoxy group having 1 to 4 carbon atoms and n is 0 or 1.
The (meth)acrylic acid ester compounds, from which the the monomeric units represented by the general formula (I) given above are derived, are each a novel compound not known in the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The component (A) in the inventive photoresist composition defined above is a specific acrylic resin of which the solubility in an aqueous alkaline solution is increased in the presence of an acid. Such an acrylic resin in general is a copolymer of monomeric compounds including (a) a derivative of (meth)acrylic acid substituted by a group capable of increasing the resistance of the resin against dry etching or an acid-dissociable protective group, (b) an ethylenically unsaturated carboxylic acid and, optionally, (c) at least one kind of other copolymerizable monomers.
Of the above mentioned three classes of the monomeric compounds, the monomeric compound of the first class (a) is a derivative of (meth)acrylic acid which can be selected from the (meth)acrylic acid derivatives conventionally used in the prior art chemical-sensitization photoresist compositions with an object to enhance the resistance of the resist layer against dry etching or to introduce acid-dissociable protective groups to the resin.
Examples of such a (meth)acrylic acid derivative belonging to the class (a) include:
(a1) acrylic or methacrylic acid substituted for the carboxylic hydrogen atom by an acid-dissociable protective group such as tert-butyl group, 2-tetrahydropyranyl group, 2-tetrahydrofuranyl group, 1-methylcyclohexyl group, 1-methyladamantyl group, 1-ethoxyethyl group and 1-methoxypropyl group as well as an ester of acrylic or methacrylic acid with 2-hydroxy-3-pinanone; and
(a2) acrylic or methacrylic acid substituted for the carboxylic hydrogen atom by an acid-undissociable group such as adamantyl group, cyclohexyl group, naphthyl group, benzyl group, 3-oxocyclohexyl group, bicyclo [2.2.1] heptyl group, tricyclodecanyl group and acetonyl group as well as an ester of acrylic or methacrylic acid with terpinol.
The monomeric compound of the second class (b) is an unsaturated carboxylic acid having an ethylenic double bond and is used with an object to impart the resin with alkali solubility. Examples of such a monomeric compound include acrylic acid, methacrylic acid, maleic acid and fumaric acid, of which acrylic acid and methacrylic acid are preferred.
The monomeric compound of the third class (c) is an ethylenically unsaturated monomer having copolymerizability with the monomer of the class (a) or monomers of the classes (a) and (b). Examples of such a monomeric compound include alkyl (meth)acrylates such as methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, isopropyl (meth)-acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, n-hexyl (meth)acrylate, octyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, lauryl (meth)acrylate, 2-hydroxyethyl (meth)acrylate and 2-hydroxypropyl (meth)acrylate, amides of (meth)acrylic acid such as (meth)acrylamide, N-methylol (meth)acrylamide and diacetone (meth)acrylamide, (meth)acrylonitrile, vinyl chloride and ethyl vinyl ether.
In addition to the monomeric units represented by the above given general formula (I), the acrylic resin as the component (A) in the inventive photoresist composition optionally contains the monomeric units derived from other acrylic monomers having a different oxygen-containing heterocyclic group, however, not used in the prior art for the preparation of an acrylic resin capable of being imparted with increased solubility in an aqueous alkaline solution in the presence of an acid. Examples of such acrylic monomers include the (meth)acrylic ester compounds represented by the general formulas
in which R 1 is a hydrogen atom or a methyl group and X is an alkyl-substituted or unsubstituted methylene group, and
in which R 1 is a hydrogen atom or a methyl group, R 5 is a hydrogen atom or a lower alkyl group, Y is an oxygen atom or an acyl-substituted or unsubstituted methylene group and Z is an alkyl-substituted or unsubstituted methylene group or a carbonyl group.
Examples of the (meth)acrylic ester compounds represented by the above given general formula (II) include (meth)acrylic acid esters with an ester-forming group such as 2-oxacyclopentan-4-on-1-yl, 3-methyl-2-oxacyclopentan-4-on-1-yl and 3,3-dimethyl-2-oxacyclopentan-4-on-1-yl.
Examples of the (meth)acrylic acid ester compounds represented by the above given general formula (III) include (meth)acrylic acid esters with an ester-forming group such as 2,4-dioxacyclohexan-5-on-1-yl, 3-methyl-2,4-dioxacyclohexan-5-on-1-yl, 3,3-dimethyl-2,4-dioxacyclohexan-5-on-1-yl, 1-methyl-2-oxacyclohexan-3,5-dion-1-yl and 1-methyl-4-acetyl-2-oxacyclohexan-3,5-dion-1-yl.
The acrylic resin as the component (A) in the inventive photoresist composition is preferably a copolymer of a monomer mixture consisting of a monomeric compound of the class (a) with one or more of the monomeric compounds belonging to the classes (b) and (c). More preferably, the monomer mixture contains a (meth)acrylic acid substituted for the carboxylic hydroxyl group by an acid-dissociable acetal group such as 2-tetrahydropyranyl (meth)acrylate, 2-tetrahydrofuranyl (meth)acrylate, 1-ethoxyethyl (meth)acrylate and 1-methoxypropyl (meth)acrylate or, most preferably, 2-tetrahydropyranyl (meth)acrylate in respect of the high acid-dissociability and low dependency on the conditions of the post-exposure baking treatment.
It is essential that the acrylic resin as the component (A) contains the monomeric units represented by the general formula (I) in a molar fraction of 20% to 80% or, preferably 50% to 80%, the balance being the other types of the monomeric units, from the standpoint of obtaining excellent properties of the photoresist composition such as resistance against dry etching and adhesion of the resist layer to the substrate surface and contrast of patterning.
The monomeric compound, from which the monomeric units represented by the general formula (I) in the acrylic resin as the component (A), can be readily synthesized by the esterification reaction of acrylic or methacrylic acid with a hydroxyl compound having a structure of the oxygen-containing heterocyclic ring represented by the general formula
in which each symbol has the same meaning as defined before, or an oxygen-containing heterocyclic compound represented by the general formula
in which R 2 has the same meaning as defined before, according to a conventional method of esterification.
Examples of the compounds used in the above mentioned reactions include 3-hydroxy-1-oxacyclopentan-2-one, 4-methyl-3-hydroxy-1-oxacyclopentan-2-one, 4,4-dimethyl-3-hydroxy-1-oxacyclopentan-2-one, 3-methyl-3-hydroxy-1-oxacyclopentan-2-one and 4-methoxy-1-oxacyclopentan-3-en-2-one. Preferable compounds of the general formula (IV) are those having a hydrogen atom or methyl group as each of the groups R 2 , R 3 and R 4 , of which 4,4-dimethyl-3-hydroxy-1-oxacyclopentan-2-one is more preferable, and a preferable compound of the general formula (V) is that having a methoxy group as R 2 .
The radiation-sensitive acid-generating agent as the component (B) in the inventive chemical-sensitization photoresist composition can be selected from those used as the acid-generating compound in chemical-sensitization photoresist compositions of the prior art without particular limitations. Examples of suitable acid-generating compounds includes the following compounds classified into classes (1) to (7):
(1) bissulfonyl diazomethane compounds such as bis(p-toluenesulfonyl) diazomethane, bis(1,1-dimethylethylsulfonyl) diazomethane, bis(cyclohexylsulfonyl)diazomethane and bis(2,4-dimethylphenylsulfonyl)diazomethane;
(2) nitrobenzyl compounds such as 2-nitrobenzyl p-toluenesulfonate and 2,6-dinitrobenzyl p-toluenesulfonate;
(3) sulfonic acid esters such as pyrogallol trimesylate and pyrogallol tritosylate;
(4) onium salt compounds such as diphenyliodonium hexafluorophosphate, (4-methoxyphenyl)phenyliodonium trifluoromethane sulfonate, bis(p-tert-butylphenyl)iodonium trifluoromethane sulfonate, triphenylphosphonium hexafluorophosphate, (4-methoxyphenyl)diphenylsulfonium trifluoromethane sulfonate and (p-tert-butylphenyl)diphenylsulfonium trifluoromethane sulfonate;
(5) alkyl-substituted or unsubstituted benzoin tosylate compounds such as benzoin tosylate and α-methylbenzoin tosylate;
(6) halogen-containing triazine compounds such as 2-(4-methoxyphenyl)-4,6-bis(trichloromethyl)-1,3,5-triazine, 2-(4-methoxynaphthyl)-4,6-bis(trichloromethyl)-1,3,5-triazine, 2[2-(2-furyl)ethenyl]-4,6-bis(trichloromethyl)-1,3,5-triazine, 2-[2-(5-methyl-2-furyl)ethenyl]-4,6-bis(trichloromethyl)-1,3,5-triazine, 2-[2-(3,5-dimethoxyphenyl)ethenyl]-4,6-bis(trichloromethyl)-1,3,5-triazine, 2-[2-(3,4-dimethoxyphenyl)ethenyl]-4,6-bis(trichloromethyl)-1,3,5-triazine, 2-(3,4-methylenedioxyphenyl)-4,6-bis(trichloromethyl)-1,3,5-triazine, 2,4,6-tris(2,3-dibromopropyl)-1,3,5-triazine and tris(2,3-dibromopropyl) isocyanurate; and
(7) cyano group-containing oximesulfonate compounds such as
α-(methylsulfonyloxyimino)phenyl acetonitrile,
α-(methylsulfonyloxyimino)-4-methoxyphenyl acetonitrile,
α-(trifluoromethylsulfonyloxyimino)phenyl acetonitrile,
α-(trifluoromethylsulfonyloxyimino)-4-methoxyphenyl acetonitrile,
α-(ethylsulfonyloxyimino)-4-methoxyphenyl acetonitrile,
α-(propylsulfonyloxyimino)-4-methylphenyl acetonitrile,
α-(methylsulfonyloxyimino)-4-bromophenyl acetonitrile,
α-(methylsulfonyloxyimino)-1-cyclopentenyl acetonitrile,
α-(1- or 2-naphthylsulfonyloxyimino)-4-methoxybenzyl cyanide and α-(10-canphorsulfonyloxyimino)-4-methoxybenzyl cyanide; of which the onium salt compounds and the cyano group-containing oximesulfonate compounds are particularly preferable.
The amount of the acid-generating agent as the component (B) in the inventive photoresist composition is in the range from 0.5 to 30 parts by weight or, preferably, from 1 to 10 parts by weight per 100 parts by weight of the acrylic resin as the component (A). When the amount of the component (B) is too small, no practical patterning of the resist layer can be accomplished while, when the amount of the component (B) is increased to exceed the upper limit, a photoresist composition in the form of a uniform solution cannot be obtained or the storage stability of the photoresist solution is decreased.
It is of course optional according to need that the chemical-sensitization photoresist composition of the present invention is admixed with various kinds of additives used in the conventional chemical-sensitization photoresist compositions in the prior art including halation inhibitors, antioxidants, heat stabilizers, adhesion improvers, plasticizers, coloring agents, surface active agents, auxiliary resins, carboxylic acids and amine compounds each in a limited amount.
The photoresist composition of the present invention is used usually in the form of a uniform solution prepared by dissolving the above described essential and optional ingredients in an organic solvent. Examples of suitable organic solvents include ketone solvents such as acetone, methyl ethyl ketone, cyclohexanone, methyl isoamyl ketone and 2-heptanone, polyhydric alcohols and derivatives thereof such as ethyleneglycol, ethyleneglycol monoacetate, propyleneglycol, propyleneglycol monoacetate, dipropyleneglycol and dipropyleneglycol monoacetate as well as monomethyl, monoethyl, monopropyl, monobutyl and monophenyl ethers thereof, cyclic ethers such as dioxane, and ester solvents such as methyl acetate, ethyl acetate, butyl acetate, methyl pyruvate, ethyl pyruvate, methyl methoxypropionate and ethyl ethoxypropionate. These organic solvents can be used either singly or as a mixture of two kinds or more according to need.
Following is a typical procedure for the photlithographic patterning by using the chemical-sensitization photoresist composition of the present invention. Thus, a substrate such as a semiconductor silicon wafer is uniformly coated with the photoresist composition in the form of a uniform solution and the coating layer is subjected to a pre-baking treatment at a temperature of 70 to 150° C. for 30 to 150 seconds to form a photoresist layer on the substrate surface, which is pattern-wise exposure to actinic rays such as ArF excimer laser beams through a pattern-bearing photomask to form a latent image of the pattern in the resist layer followed by a post-exposure baking treatment at a temperature of 70 to 150° C. for 30 to 150 seconds. Thereafter, the latent image formed in the resist layer is developed by using an aqueous alkaline solution, such as an aqueous solution of tetramethylammonium hydroxide and choline, as the developer so as to dissolve away the resist layer in the pattern-wise exposed areas leaving the resist layer in the unexposed areas.
In the following, the present invention is described in more detail by way of Examples as preceded by the description of the procedure for the preparation of the specific acrylic resin used as the component (A) of the photoresist composition. In the Examples given below, the term of “parts” always refers to “parts by weight”.
Preparation 1.
A mixture was prepared by dissolving 70.2 g (0.54 mole) of 4,4-dimethyl-3-hydroxy-1-oxacyclopentan-2-one and 60 g (0.60 mole) of triethylamine in 200 ml of tetrahydrofuran and, then, 62.4 g (0.60 mole) of methacryloyl chloride were added dropwise to the mixture at 25° C. under agitation over a period of 1 hour to give a reaction mixture.
After further continued agitation for 24 hours at 25° C., the reaction mixture was filtered and the filtrate was distilled to remove the solvent. The residue was dissolved in 300 ml of diethyl ether and the solution was repeatedly washed 10 times with a 10% by weight aqueous solution of sodium hydroxide. The reaction product contained in this solution was purified by column chromatography with n-heptane as the eluant to give a colorless liquid which could be identified by analysis to be a methacrylic acid ester of the compound expressed by the structural formula
The 1 H-NMR spectrum of this compound taken with acetone d 6 as the solvent had peaks corresponding to the δ values of 1.15 ppm, 1.25 ppm, 1.92 ppm, 4.10 ppm, 5.50 ppm, 5.62 ppm and 6.12 ppm.
A polymerization mixture was prepared by dissolving 20.0 g (0.094 mole) of the thus prepared methacrylic acid ester and 5.3 g (0.031 mole) of 2-tetrahydropyranyl methacrylate in 150 g of tetrahydrofuran with addition of 0.82 g of azobisisobutyronitrile as a polymerization initiator and the polymerization mixture was heated at 75° C. for 3 hours under agitation to effect polymerization of the monomers. After completion of the polymerization reaction, the polymerization mixture was poured into 5 liters of n-heptane to precipitate the polymer, referred to as the copolymer A1 hereinafter, which was taken by filtration and dried at room temperature under reduced pressure. The yield of the copolymer A1 was 15.0 g. The copolymer A1 had a weight-average molecular weight of 14000 with a dispersion of the molecular weight distribution of 1.90.
Preparation 2.
A mixture was prepared by dissolving 55.1 g (0.54 mole) of 3-hydroxy-1-oxacyclopentan-2-one and 60 g (0.60 mole) of triethylamine in 200 ml of tetrahydrofuran and, then, 62.4 g (0.60 mole) of methacryloyl chloride were added dropwise to the mixture at 25° C. under agitation over a period of 1 hour to give a reaction mixture.
After further continued agitation for 24 hours at 25° C. the reaction mixture was filtered and the filtrate was distilled to remove the solvent. The residue was dissolved in 300 ml of diethyl ether and the solution was repeatedly washed 10 times with a 10% by weight aqueous solution of sodium hydroxide. The reaction product contained in this solution was purified by column chromatography with n-heptane as the eluant to give a colorless liquid which could be identified by analysis to be a methacrylic acid ester of the compound expressed by the structural formula
The 1 H-NMR spectrum of this compound taken with acetone d 6 as the solvent had peaks corresponding to the δ values of 1.92 ppm, 2.30 to 2.50 ppm, 3.90 to 4.10 ppm, 5.20 ppm, 5.60 ppm and 6.12 ppm.
A polymerization mixture was prepared by dissolving 17.4 g (0.094 mole) of the thus prepared methacrylic acid ester and 5.3 g (0.031 mole) of 2-tetrahydropyranyl methacrylate in 560 g of tetrahydrofuran with addition of 0.81 g of azobisisobutyronitrile as a polymerization initiator and the polymerization mixture was heated at 75° C. for 3 hours under agitation to effect polymerization of the monomers. After completion of the polymerization reaction, the polymerization mixture was poured into 5 liters of n-heptane to precipitate the polymer, referred to as the copolymer A2 hereinafter, which was taken by filtration and dried at room temperature under reduced pressure. The yield of the copolymer A2 was 14.9 g. The copolymer A2 had a weight-average molecular weight of 13500 with a dispersion of the molecular weight distribution of 2.01.
Preparation 3.
A mixture was prepared by dissolving 62.6 g (0.54 mole) of 4-methoxy-1-oxacyclopent-3-en-2-one in 200 ml of tetrahydrofuran and, then, 112 g (1.08 mole) of methacryloyl chloride were added thereto under agitation to give a reaction mixture.
Thereafter, 0.3 g of para-toluene sulfonic acid was added to the reaction mixture which was further agitated for 4 hours at 25° C. The reaction mixture was dissolved in 300 ml of diethyl ether and repeatedly washed 10 times with a 10% by weight aqueous solution of sodium hydroxide. The reaction product contained in this solution was purified by column chromatography with n-heptane as the eluant to give a colorless liquid which could be identified by analysis to be a methacrylic acid ester of the compound expressed by the structural formula
The 1 H-NMR spectrum of this compound taken with acetone d 6 as the solvent had peaks corresponding to the δ values of 1.92 ppm, 2.30 to 2.80 ppm, 3.80 ppm, 5.65 ppm and 6.12 ppm.
A polymerization mixture was prepared by dissolving 20.2 g (0.094 mole) of the thus prepared methacrylic acid ester and 5.3 g (0.031 mole) of 2-tetrahydropyranyl methacrylate in 560 g of tetrahydrofuran with addition of 0.81 g of azobisisobutyronitrile as a polymerization initiator and the polymerization mixture was heated at 75° C. for 3 hours under agitation to effect polymerization of the monomers. After completion of the polymerization reaction, the polymerization mixture was poured into 5 liters of n-heptane to precipitate the polymer, referred to as the copolymer A3 hereinafter, which was taken by filtration and dried at room temperature under reduced pressure. The yield of the copolymer A3 was 15.5 g. The copolymer A3 had a weight-average molecular weight of 14000 with a dispersion of the molecular weight distribution of 2.10.
Preparation 4.
A mixture was prepared by dissolving 62.6 g (0.54 mole) of 3-hydroxy-3-methyl-1-oxacyclopentan-2-one and 60 g (0.60 mole) of triethylamine in 200 ml of tetrahydrofuran and, then, 62.4 g (0.60 mole) of methacryloyl chloride were added dropwise to the mixture at 25° C. under agitation over a period of 1 hour to give a reaction mixture.
After further continued agitation for 24 hours at 25° C. the reaction mixture was filtered and the filtrate was distilled to remove the solvent. The residue was dissolved in 300 ml of diethyl ether and the solution was repeatedly washed 10 times with a 10% by weight aqueous solution of sodium hydroxide. The reaction product contained in this solution was purified by column chromatography with n-heptane as the eluant to give a colorless liquid which could be identified by analysis to be a methacrylic acid ester of the compound expressed by the structural formula
The 1 H-NMR spectrum of this compound taken with acetone d 6 as the solvent had peaks corresponding to the δ values of 1.80 ppm, 1.92 ppm, 2.30 to 2.50 ppm, 3.90 to 4.10 ppm, 5.65 ppm and 6.12 ppm.
A polymerization mixture was prepared by dissolving 18.7 g (0.094 mole) of the thus prepared methacrylic acid ester and 5.3 g (0.031 mole) of 2-tetrahydropyranyl methacrylate in 560 g of tetrahydrofuran with addition of 0.81 g of azobisisobutyronitrile as a polymerization initiator and the polymerization mixture was heated at 75° C. for 3 hours under agitation to effect polymerization of the monomers. After completion of the polymerization reaction, the polymerization mixture was poured into 5 liters of n-heptane to precipitate the polymer, referred to as the copolymer A4 hereinafter, which was taken by filtration and dried at room temperature under reduced pressure. The yield of the copolymer A4 was 15.0 g. The copolymer A4 had a weight-average molecular weight of 12000 with a dispersion of the molecular weight distribution of 1.85.
Preparation 5.
A copolymer of adamantyl methacrylate expressed by the structural formula
2-tetrahydropyranyl methacrylate and methacrylic acid, referred to as the copolymer A5 hereinafter, was prepared by conducting, in the same manner as in Preparation 1 described above, the polymerization reaction of a monomer mixture of these three kinds of monomeric compounds of which the molar fractions of adamantyl methacrylate, 2-tetrahydropyranyl methacrylate and methacrylic acid were 50%, 45% and 5%, respectively. The yield of the copolymer A5 was 16.0 g. The copolymer A5 had a weight-average molecular weight of 16500 with a dispersion of the molecular weight distribution of 2.20.
Preparation 6.
A copolymer of a methacrylic acid ester compound expressed by the structural formula
and 2-tetrahydropyranyl methacrylate, referred to as the copolymer A6 hereinafter, was prepared by conducting, in the same manner as in Preparation 1 described above, the polymerization reaction of a monomer mixture consisting of 17.2.g (0.094 mole) of the monomeric compound of the above given structural formula and 5.3 g (0.031 mole) of 2-tetra-hydropyranyl methacrylate. The yield of the copolymer A 6 was 14.7 g. The copolymer A6 had a weight-average molecular weight of 14500 with a dispersion of the molecular weight distribution of 1.98.
Example 1.
A chemical-sensitization positive-working photoresist solution was prepared by dissolving 100 parts of the copolymer A1 prepared in Preparation 1 and 2 parts of bis(4-tert-butylphenyl) iodonium trifluoromethane sulfonate in 680 parts of propyleneglycol monomethyl ether acetate.
This photoresist solution was uniformly applied onto a semiconductor silicon wafer by using a spinner and dried by heating for 90 seconds on a hot plate at 100° C. to form a photoresist layer having a thickness of 0.5 μm.
The photoresist layer was pattern-wise exposed to ArF excimer laser beams of 193 nm wavelength on an ArF excimer laser exposure machine (manufactured by Nikon Co.) followed by a post-exposure baking treatment at 110° C. for 90 seconds and then subjected to a puddle development treatment in a 2.38% by weight aqueous solution of tetramethylammonium hydroxide taking 65 second at 23° C.
The minimum exposure dose required for obtaining a line-and-space patterned resist layer with a line:space width ratio of 1:1 by using a line-and-space photomask pattern of 0.25 μm line width was 5.0 mJ/cm 2 as a measure of the photosensitivity of the photoresist composition.
Further, the cross sectional profile of the thus formed line-patterned resist layer of 0.25 μm line width was excellently orthogonal standing upright on the substrate surface as examined on a scanning electron microscopic photograph.
The resist layer on the substrate surface was subjected to a dry etching treatment with tetrafluoromethane as the etching gas on a dry-etching instrument (Model OAPM-406, manufactured by Tokyo Ohka Kogyo Co.) to find that the rate of film thickness decrease per unit time, as a measure of the resistance against dry etching, was 1.1 relative to the rate of film thickness decrease of a polyhydroxystyrene layer taken as 1.0. Patterning resolution was so high that a line pattern of 0.20 μm line width could be fully reproduced without pattern falling.
Example 2.
The experimental procedure was substantially the same as in Example 1 excepting for the replacement of the copolymer A1 with the same amount of the copolymer A2 prepared in Preparation 2. The results of the evaluation tests were that the minimum exposure dose representing the photosensitivity was 6.0 mJ/cm 2 , the cross sectional profile of the line-patterned resist layer of 0.25 μm width was excellently orthogonal standing upright on the substrate surface and the relative resistance against dry etching was 1.1. Patterning resolution was so high that a line pattern of 0.20 μm line width could be fully reproduced without pattern falling.
Example 3.
The experimental procedure was substantially the same as in Example 1 excepting for the replacement of the copolymer A1 with the same amount of the copolymer A3 prepared in Preparation 3. The results of the evaluation tests were that the minimum exposure dose representing the photosensitivity was 5.5 mJ/cm 2 , the cross sectional profile of the line-patterned resist layer of 0.25 μm width was excellently orthogonal standing upright on the substrate surface and the relative resistance against dry etching was 1.1. Patterning resolution was so high that a line pattern of 0.20 μm line width could be fully reproduced without pattern falling.
Example 4.
The experimental procedure was substantially the same as in Example 1 excepting for the replacement of the copolymer A1 with the same amount of the copolymer A4 prepared in Preparation 4. The results of the evaluation tests were that the minimum exposure dose representing the photosensitivity was 5.0 mJ/cm 2 , the cross sectional profile of the line-patterned resist layer of 0.25 μm width was excellently orthogonal standing upright on the substrate surface and the relative resistance against dry etching was 1.2. Patterning resolution was so high that a line pattern of 0.20 μm line width could be fully reproduced without pattern falling.
Comparative Example 1.
The experimental procedure was substantially the same as in Example 1 excepting for the replacement of the copolymer A1 with the same amount of the copolymer A5 prepared in Preparation 5. The results of the evaluation tests were that the minimum exposure dose representing the photosensitivity was 15 mJ/cm 2 and the relative resistance against dry etching was 1.0. Patterning resolution was not so high that a line pattern of 0.30 μm or finer line width could not be completely reproduced.
Comparative Example 2.
The experimental procedure was substantially the same as in Example 1 excepting for the replacement of the copolymer A1 with the same amount of the copolymer A6 prepared in Preparation 6. The results of the evaluation tests were that the minimum exposure dose representing the photosensitivity was 5.0 mJ/cm 2 and patterning resolution was so high that a line pattern of 0.25 μm line width could be fully reproduced without pattern falling. However, the cross sectional profile of the line-patterned resist layer of 0.30 μm width was not orthogonal but trapezoidal. The relative resistance against dry etching was 1.5. | Proposed is a chemical-sensitization positive-working photoresist composition for photolithographic patterning in the manufacture of semiconductor devices having high transparency even to ultraviolet light of very short wavelength such as ArF excimer laser beams of 193 nm wavelength to exhibit high photosensitivity and capable of giving a patterned resist layer with high pattern resolution. The composition comprises (A) a resinous ingredient which is subject to an increase of the solubility in an aqueous alkaline developer solution in the presence of an acid and (B) a radiation-sensitive acid-generating compound. Characteristically, the resinous ingredient as the component (A) is a (meth)acrylic copolymer of which from 20% to 80% by moles of the monomeric units are derived from a (meth)acrylic acid ester of which the ester-forming group has a specific oxygen-containing heterocyclic ring structure. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority benefit under 35 U.S.C. Section 119(e) to U.S. Provisional Patent Ser. No. 61/121,789 filed on Dec. 11, 2008, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
Embodiments of the present invention relate to a process and a system for drilling sidetrack wells. Specifically, the present invention relates to the drilling of sidetrack wells in existing casing strings which are in close proximity to the packer assembly and/or contain a large constriction ratio.
BACKGROUND OF THE INVENTION
It is well known that hydrocarbons may be produced from subterranean formations through a well that has been drilled into a hydrocarbon bearing formation. Drilling is accomplished by utilizing a drill bit mounted to the end of a drill support member, i.e., a drill string. The drill string is rotated by a top drive, i.e., rotary table, on a surface platform or by a down hole motor mounted towards the lower end of the drill string to facilitate drilling to a desired depth. After reaching the desired depth, the drill string and drill bit are removed, and the wellbore is lined with a string of pipe, i.e., casing. The casing typically extends down the wellbore from the surface of the well to a designated depth. An annular space or annulus, i.e., space between two concentric objects, is formed between the string of casing and the wellbore. The casing string is temporarily fixed or “hung” from the surface of the well. A cementing operation is then conducted in order to fill the annular space with cement. The combination of cement and casing strengthens the wellbore and facilitates the isolation of certain areas of the formation behind the casing for the production of hydrocarbons.
It is common to employ more than one string of casing in a wellbore. In this respect, the well is drilled to a first designated depth with the drill bit on the drill string. The drill string is removed. A first string of casing is run into the wellbore and set in the drilled out portion of the wellbore, and cement is circulated into the annulus behind the casing string. The well is drilled to a second designated depth, and a second string of casing is run into the drilled out portion of the wellbore. The second string is set at a depth such that the upper portion of the second string of casing overlaps the lower portion of the first string of casing. This second casing string is then hung off of the existing casing by slip members and cones to wedgingly fix the second string of casing in the wellbore. The second casing string is then cemented. The process is typically repeated, as necessary with additional casing strings until the well is drilled to the desired depth. As more casing strings are set in the wellbore, the casing strings become progressively smaller in diameter in order to fit within the previous casing string. In this manner, wells are typically formed with two or more strings of casing of an ever-decreasing diameter.
In many circumstances, it is desirable to alter the direction of the wellbore by drilling one or more additional wellbores (often referred to as “laterals” or “sidetracks”) outward from the primary wellbore in an effort to increase the productivity of the well or to access additional hydrocarbons in adjacent formations. This can be an effective and economical way to substantially increase the profitability of a well and to increase the overall recovery of fluids from a single, primary well site and surface installation. These lateral wells may extend outwardly from the primary wellbore for substantial distances (e.g., 2000 feet or more) or may be relatively short “drainholes” which extend only a few feet (e.g., 100 feet or less) into the formation. However, the ability to drill precisely on target is a significant challenge when drilling laterals. Drill rigs are expensive and several extra days of rig time may substantially reduce the profitability of drilling additional laterals. Efficiently drilling laterals, which directly and precisely exit the primary wellbore at the desired location within the wellbore first, requires cutting an opening or a window through heavy casing or liner.
A conventional technique for drilling laterals may involve the setting of a kickoff plug, or the like, in a primary wellbore. A kickoff plug may have a length ranging from about 50 to about 500 feet, and may comprise a cement composition. The kickoff plug is typically set in the wellbore by lowering a drill string or open-ended tubing string to the desired depth and pumping a cement composition into the wellbore. The cement composition is allowed to cure and form a plug. After the cement plug has formed, a drill string may be used to reinitiate drilling operations. The drill string and drill bit use the plug to drill in a new direction, so as to thereby deflect the drill string and change the direction in which the drilling proceeds. However, the use of kickoff plugs may be problematic due to the fact that the plug prevents access to further production fluids from lower portions of the original wellbore because the cement seals the well at the deviation.
Another conventional method of forming a lateral wellbore employs a whipstock which is inserted into the main wellbore and fixed therein. The whipstock is typically a steel structure that includes a concave, slanted surface along its upper portion arranged to direct drilling tools coming down the wellbore toward one side thereof. In particular, the whipstock forms a guide for gradually directing a cutting device from the main wellbore of the well into and through the wall of the existing wellbore where the new lateral wellbore will be formed or cut. However, similar to the kickoff plug method, whipstocks are typically permanently installed. A conventional permanently installed whipstock may prevent further access to lower formations below the installed whipstock. Furthermore, wells require some amount of work over to remain productive, which may be prevented to some degree by the installation of a permanent whipstock.
When altering the direction of drilling operations, use of small diameter tailpipes may be desired. It is common practice to mill “dual string” window exits through both the tailpipe and the liner in a single milling operation. However, when the clearance between the tailpipe and the liner approach the diameter of the mill, the mill cannot cut through the liner but rather mills down the annulus potentially trapping the mill. Thus, when the inner diameters of the liner and tailpipe have a “high ratio” approaching 2:1, dual string window exits require separate assemblies and at least two oriented milling runs to mill through the tailpipe and liner even though the inner pipe is well anchored by cement. Additionally, cementing operations utilized in current methods of high ratio window exits severely restrict access to lower formations, requiring expensive and risky operations to gain access to these lower formations.
Therefore, a need exits for a process and a system for completing a well to facilitate a sidetrack operation through a liner.
SUMMARY OF THE INVENTION
In an embodiment of the present invention, a process for drilling a sidetrack wellbore into a desired formation, wherein the process includes: (a) installing a liner within the formation, wherein the liner includes an outer diameter and an inner diameter; (b) installing a tubing string within the formation, wherein the tubing string includes an inner diameter and an outer diameter; (c) installing a tailpipe releasably attached to the tubing string, wherein the tailpipe includes an inner diameter and an outer diameter, wherein the tailpipe is positioned within the liner with the use of millable stabilizing bands, wherein the millable stabilizing bands are connected to the outer diameter of the tailpipe, wherein the outer diameter of the tailpipe is increased until the clearance between the tailpipe and the liner can be safely run into the formation, wherein a diametrical clearance between the tailpipe and the liner is between about ⅛ inch to about ¼ inch, wherein the inner diameter of the tailpipe is larger than the inner diameter of the liner, wherein the tailpipe is fabricated from a durable material capable of being milled; (d) installing a packer assembly, wherein the packer assembly is located along the tubing string and above the tailpipe; (e) installing a whipstock assembly, wherein the whipstock assembly includes an inclined guide surface, wherein the whipstock assembly includes a heel, wherein the tailpipe positions the whipstock assembly near a centerline within the liner, wherein the difference between the inner diameter of the liner and the maximum deviation of the whipstock from the centerline in the formation is minimized to about ½ the value of the diametrical clearance, thereby reducing the distance between the heel of the whipstock to the inner wall of the liner, wherein the whipstock assembly is guided into the formation to a desired location within the tailpipe, wherein the whipstock assembly is then set in place at the desired location within the tailpipe; (f) guiding a milling assembly into the formation through the tailpipe and onto the inclined guide surface of the whipstock assembly, wherein the milling assembly is a straight motor mill; and (g) milling through the tailpipe and the liner in a single milling operation.
In a further embodiment of the present invention, a process for drilling a sidetrack wellbore into a desired formation, wherein the process includes: (a) installing a liner within the formation, wherein the liner includes an outer diameter and an inner diameter; (b) installing a tubing string within the formation, wherein the tubing string includes an inner diameter and an outer diameter; (c) installing a tailpipe releasably attached to the tubing string, wherein the tailpipe includes an inner diameter and an outer diameter, wherein the outer diameter of the tailpipe is increased until the clearance between the tailpipe and the liner can be safely run into the formation; (d) installing a whipstock assembly, wherein the whipstock assembly includes an inclined guide surface, wherein the whipstock assembly includes a heel, wherein the tailpipe positions the whipstock assembly near a centerline within the liner, wherein the difference between the inner diameter of the liner and the maximum deviation of the whipstock from the centerline in the formation is minimized to less than the value of the diametrical clearance, thereby reducing the distance between the heel of the whipstock to the inner wall of the liner, wherein the whipstock assembly is guided into the formation to a desired location within the tailpipe, wherein the whipstock assembly is then set in place at the desired location within the tailpipe; (e) guiding a milling assembly into the formation through the tailpipe and onto the inclined guide surface of the whipstock assembly; and (f) milling through the tailpipe and the liner.
In another embodiment of the present invention, a system for drilling a sidetrack wellbore into a desired formation, wherein the system includes: (a) a liner within the formation, wherein the liner includes an outer diameter and an inner diameter; (b) a tubing string within the formation, wherein the tubing string includes an inner diameter and an outer diameter; (c) a tailpipe releasably attached to the tubing string, wherein the tailpipe includes an inner diameter and an outer diameter, wherein the outer diameter of the tailpipe is increased until the clearance between the tailpipe and the liner can be safely run into the formation; (d) a whipstock assembly, wherein the whipstock assembly includes an inclined guide surface, wherein the whipstock assembly includes a heel, wherein the tailpipe positions the whipstock assembly near a centerline within the liner, wherein the difference between the inner diameter of the liner and the maximum deviation of the whipstock from the centerline is minimized to about ½ the value of the diametrical clearance, thereby reducing the distance between the heel of the whipstock to the inner wall of the liner; and (e) a milling assembly into the formation through the tailpipe and onto the inclined guide surface of the whipstock assembly, wherein the milling assembly mills through the tailpipe and the liner.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is shown by way of example and not by way of limitation in the accompanying figures, in which:
FIG. 1 illustrates a mill through tailpipe liner exit in accord with an embodiment of the present invention.
FIG. 2 illustrates a mill through tailpipe liner exit in accord with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not as a limitation of the invention. 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 instances, features illustrated or described as part of one embodiment can be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations that come within the scope of the appended claims and their equivalents.
In the description which follows, like parts are marked throughout the specification and drawing with the same reference numerals. The drawing figures are not necessarily to scale and certain features are shown in schematic form or are exaggerated in scale in the interest of clarity and conciseness.
In a conventional drilling operation, a primary wellbore extends into an earth formation for the production of oil and gas. The primary wellbore includes a casing string which is inserted into the wellbore after the wellbore has been drilled. The casing string is generally installed in a wellbore when the well is drilled to target depth or when the sidewalls of the wellbore are in danger of collapsing. If the sidewalls of the wellbore collapse, the wellbore is cased and drilling continues with a smaller drill bit. Once the target is reached, a smaller diameter casing or liner is installed to prevent the sidewalls from collapsing. Typically, once the casing string is installed, cement is forced down the inside of the casing string and up the annulus to seal the casing to the wellbore and prevent fluids from transiting along the wellbore outside of the casing from one formation to another.
A liner 10 is installed within the casing within the primary wellbore. Once a production zone has been reached, a tubing string 12 is installed within the liner 10 to carry hydrocarbons to the surface where such hydrocarbons are recovered and transported to market. Near the down hole end of the tubing string 12 , a packer assembly 24 is installed to seal a annular space 13 between the liner 10 and the tubing string 12 in order to prevent fluids from escaping into other parts of the wellbore or formation and to direct the produced fluids into the tubing string 12 . Additionally, the packer assembly 24 ensures the fluids do not flow to lower portions of the wellbore.
The packer assembly 24 , in the collapsed state, can be inserted into the annulus 13 to a desired location along the length of the tubing string 12 . As depicted in FIG. 1 , the packer assembly 24 is inserted into the annulus 13 between the tubing string 12 and the liner 10 above the tailpipe 26 . In an embodiment, the packer assembly 24 is an inflation type packer assembly and hence uses inflation means for positioning. In another embodiment, the packer assembly 24 is an expansion type packer assembly and hence uses expansion means for positioning.
As depicted in FIG.1 , the tubing string 12 is divided into a first section and a second section thus allowing the production tubing string 12 to be interrupted by the installation of a tailpipe 26 . At the downhole end of the tailpipe 26 , the remaining portion of the tubing string 12 , i.e., the second portion of the tubing string, picks back up and continues through the wellbore. FIG. 1 depicts a second packer assembly 36 , which is again utilized to ensure fluids do not flow down the liner to lower portions of the wellbore. Likewise, the second packer assembly 36 is inserted, in its collapsed form, into the annulus 35 between the tubing string 12 and the liner 10 at the downhole end of the tailpipe 26 . A nipple 38 can be utilized at the end of the second section of the tubing string below the tailpipe.
As previously mentioned, it is sometimes desirable to drill a sidetrack well from within a wellbore. For clarity, it should be understood that conventional wells are drilled substantially vertically from the surface downward to or through the producing formation. However, wellbores may be drilled at a slanted or inclined orientation from the vertical axis. Likewise, deviation may produce a horizontal orientation. Sidetrack wells may extend in any direction from the original well and, in the case of a horizontal wellbore, may extend upward or downward.
The tailpipe 26 assists in formation of a sidetrack wellbore 34 . Upon being inserted into the wellbore, below the first section of the tubing string 12 and above the second section of the tubing string 12 , the tailpipe 26 is positioned as close to center as practical within the liner 10 . In an embodiment, the tailpipe 26 is positioned near center within the liner with the use of millable stabilizing bands 40 , which are connected to the outer diameter of the tailpipe. In another embodiment, the tailpipe is positioned within the liner with the use of cement. In another embodiment, the tailpipe is wedgingly positioned in place.
The tailpipe 26 includes an inner diameter and an outer diameter. The tailpipe 26 guides the whipstock assembly 30 in the liner and minimizes any void space encountered during the drilling operation. Specifically, the outer diameter of the tailpipe is increased until the clearance between the tailpipe and the liner can be safely run into the formation. The diametrical clearance between the tailpipe and the liner is between about ⅛ inch to about ¼ inch. In an embodiment, the inner diameter of the tailpipe 26 is the same as the inner diameter of the tubing string 12 . When the inner diameter of the tailpipe 26 is substantially similar to the inner diameter of the tubing string 12 , the tailpipe must compensate by either utilizing stabilizing bands or thick walls. A thick wall tailpipe may be utilized to ensure a clearance 25 between the tailpipe and the liner can safely be run into the formation. The thickness of the thick wall tailpipe is determined by the desired inner diameter of the tailpipe and the minimum clearance 25 required to insert the tailpipe into the liner. In another embodiment, the inner diameter of the tailpipe is larger than the inner diameter of the production tubing string 12 , as shown in FIG. 2 . In yet another embodiment, the inner diameter of the tailpipe 26 is smaller than the inner diameter of the production tubing string 12 .
With the tailpipe 26 being in close proximity with the liner wall 10 , there is enhanced support for the milling assembly 42 in the annulus 13 . Furthermore, the close proximity between the tailpipe 26 and the liner 10 can also potentially eliminate the need for cement thereby allowing the original production below the tailpipe 26 . In an embodiment, the tailpipe is fabricated with an easily millable, long-lasting and durable material. In a further embodiment, the tailpipe is made of aluminum, brass, bronze, tin, or lead, or any combinations thereof.
FIG. 1 further depicts a whipstock assembly 30 utilized to assist in the efficient and economical formation of a sidetrack or lateral well. The whipstock assembly includes an inclined surface and a “heel.” The whipstock is positioned as close to center as practical within the tailpipe. Specifically, the difference between the inner diameter of the liner and the maximum deviation of the whipstock from a centerline in the formation is minimized to about ½ the value of the diametrical clearance, thereby reducing the distance between the heel of the whipstock to the inner wall of the liner. The positioning of the whipstock within the tailpipe thus minimizes the maximum annular space the mill will encounter, allowing the exit to be cut in a single run with a straight milling assembly requiring no orientation. However, in certain operations it may be desirable to use a bent-motor milling assembly perhaps requiring additional runs.
For demonstrative purposes, and not by way of limitation, the present illustrated embodiments provide a sidetrack well which exits liner 10 to the right. As depicted in FIG. 1 , the whipstock assembly 30 includes an inclined whipstock guide surface 32 for positioning the mill in a predetermined location for creating sidetrack wellbore 34 . In an embodiment, the whipstock is permanent. In a preferred embodiment, the whipstock assembly is retrievable to allow access to further formations and/or production below the whipstock assembly.
In operation, a mill is guided down the tubing string and through the tailpipe until it reaches the whipstock assembly. Upon contacting the whipstock assembly, the mill is guided via the inclined surface of the whipstock and ultimately forms the sidetrack wellbore. In an embodiment, the mill is a straight motor mill. In another embodiment, the mill is a bent motor mill.
The preferred embodiment of the present invention has been disclosed and illustrated. However, the invention is intended to be as broad as defined in the claims below. Those skilled in the art may be able to study the preferred embodiments and identify other ways to practice the invention that are not exactly as described in the present invention. It is the intent of the inventors that variations and equivalents of the invention are within the scope of the claims below and the description, abstract and drawings not to be used to limit the scope of the invention. | A method and apparatus for forming a window in the wall of a tubular wellbore. In one embodiment described herein, a down hole apparatus for forming a window in the wall of a wellbore utilizing a plurality of tubing string sections and a thick tailpipe positioned at the down hole end of a tubing section. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the manufacturing of integrated circuits.
2. Discussion of the Related Art
Technology, as it advances, provides more and more complex integrated circuits integrating a great number of components of different types, particularly, CMOS transistors and bipolar transistors. The conventional forming of such structures necessitates a large number of manufacturing steps due to the fact that steps specific to the manufacturing of bipolar transistors must be added to the manufacturing steps of a CMOS circuit.
It is thus a constant object of research in the field of integrated circuit manufacturing to search for manufacturing methods enabling simultaneous optimization of components of different types while minimizing the number of manufacturing steps. In particular, it is desired to make the largest possible number of steps common when manufacturing bipolar transistors and MOS transistors on an integrated circuit.
SUMMARY OF THE INVENTION
The present invention aims at the simultaneous manufacturing of bipolar and MOS transistors on an integrated circuit in which a large number of manufacturing steps of the bipolar transistors remain common with the MOS transistor manufacturing steps.
More specifically, the present invention aims at the manufacturing of an emitter of a bipolar transistor similarly to the manufacturing of the gate of a MOS transistor.
More generally, the present invention aims at forming a contact between a doped polysilicon layer and an underlying substrate, despite the presence of a thin insulating layer between them.
To achieve these and other objects, the present invention provides a method for manufacturing a contact between a semiconductor substrate and a doped polysilicon layer deposited on the substrate with an interposed insulating layer, in which elements adapted to making the insulating layer permeable to the migration of dopants from the polysilicon layer to the substrate are implanted through the polysilicon layer.
According to an embodiment of the present invention, the insulating layer is a silicon oxide layer.
According to an embodiment of the present invention, said elements are formed of hydrogen.
According to an embodiment of the present invention, said elements are formed of silicon or germanium.
The present invention also provides a method for manufacturing the emitter area of a bipolar transistor in a CMOS-type integrated circuit wafer, including the steps of forming, on the wafer, an insulating layer topped with a polysilicon layer over the entire integrated circuit; in the bipolar transistor area, implanting through the polysilicon layer elements adapted to making the insulating layer permeable to the migrating of dopants from the polysilicon layer; and removing the polysilicon layer and the insulating layer outside of locations where the emitter of the bipolar transistor and the gates of the MOS transistors are desired to be formed.
According to an embodiment of the present invention, the insulating layer is a silicon oxide layer.
According to an embodiment of the present invention, the implantation step includes the implantation of silicon or germanium.
According to an embodiment of the present invention, the implantation step includes the implantation of hydrogen.
The present invention also aims at a method for manufacturing a bipolar transistor in an integrated circuit of CMOS type, including the steps of forming, in the integrated circuit substrate, a region adapted to forming the collector area of the bipolar transistor; implanting in the region a doped region adapted to forming the base of the bipolar transistor; and forming the emitter of the bipolar transistor by the previously mentioned method.
The present invention also aims at a method for manufacturing the emitter area of a bipolar transistor in a CMOS-type integrated circuit, including the steps of implanting, in the bipolar transistor area, an element able to prevent formation of an electrically insulating zone on the said bipolar transistor area; forming an insulating area over the entire integrated circuit; and removing the polysilicon layer and the insulating area outside of the locations where the bipolar transistor emitter and the MOS transistor gates are desired to be formed.
The foregoing objects, features and advantages of the present invention will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 6 are simplified cross-section views illustrating successive steps of simultaneous manufacturing of a MOS transistor and of a bipolar transistor; and
FIGS. 7 to 9 are simplified cross-section views illustrating a third embodiment of the steps of FIGS. 3 to 6 .
DETAILED DESCRIPTION
It should be noted that in these different drawings, as usual in the representation of integrated circuits, the thicknesses and lateral dimensions of the various layers are drawn to scale neither within a same drawing, nor from one drawing to the other, to improve the readability of these drawings. Further, the same references will designate the same elements or layers, possibly at successive manufacturing stages. Finally, only those steps necessary to understanding the method according to the present invention will be described in detail hereafter, and the intermediary steps, well known by those skilled in the art, will not be described in detail.
The forming on an integrated circuit of a P-channel MOS transistor in the right-hand portion and the manufacturing of an NPN-type bipolar transistor in the left-hand portion of FIGS. 1 to 6 will be described hereafter as an example. Of course, parallel to the forming of NPN-type transistors and of P-channel MOS transistors, N-channel MOS transistors which are not shown in the drawings for clarity are also formed on the integrated circuit.
FIG. 1 shows an integrated circuit wafer including a P-type semiconductor substrate 10 . On the bipolar transistor side, an N-type region 11 is topped with a more lightly-doped N-type region 12 . On the side of the P-channel MOS transistor, an N-type region 13 is formed at the same time as region 12 . A main trench 14 filled with an insulator, for example, silicon oxide, separates the bipolar transistor area from that of the P-channel MOS transistor. On the bipolar transistor side, an auxiliary trench 15 filled with an insulator delimits with main trench 14 an N-type well 16 connecting the wafer surface to N-type region 11 , located under N-type region 12 .
On FIG. 2, a mask 17 covers the P-channel MOS transistor area. A P-type dopant is implanted, to form a P-type region 18 at the surface of N-type region 12 of the bipolar transistor area. Region 18 is intended to form the base of the bipolar transistor.
At the step shown on FIG. 3, a gate oxide layer 19 , for example, silicon oxide, for example having a 1.5-nm thickness, is grown over the entire outer surface of the wafer.
On FIG. 4 is shown a polysilicon layer 20 , for example having a 0.2-μm thickness, deposited over gate oxide layer 19 , and covered, at the level of the P-channel MOS transistor area, with a mask 21 .
According to a first embodiment of the present invention, a hydrogen implantation is then performed in oxide layer 19 through polysilicon layer 20 unprotected by mask 21 , that is, at the level of the bipolar transistor area. The implantation is, for example, performed under a 10-keV energy, and with a dose from 10 15 atom/cm 2 to 10 17 atom/cm 2 . Polysilicon layer 20 is N-type doped at the level of the bipolar transistor and of the N-channel MOS transistor (not shown) and is P-type doped at the level of the P-channel MOS transistor.
FIG. 5 illustrates the structure obtained after removal of polysilicon layer 20 and of gate oxide 19 except on the location where the emitter of the bipolar transistor and the gate of the P-channel MOS transistor are desired to be formed. On the bipolar transistor side, a first multiple-layer 25 formed of a portion 27 of gate oxide layer 19 in which a hydrogen implantation has been performed, topped with a portion 28 of polysilicon layer 20 , is obtained. On the P-channel MOS transistor side, a second multiple-layer 26 intended to form the gate of the P-channel MOS transistor also includes an unmodified portion 29 of gate oxide layer 19 topped with a portion 30 of polysilicon layer 20 .
FIG. 6 schematically shows subsequent manufacturing steps of the transistors. An implantation of P-type dopants is performed to form, on either side of second multiple-layer 26 , regions designated with reference 33 . After the implantation, spacers designated with reference 31 at the level of first multiple-layer 25 on the bipolar transistor side and spacers designated with reference 32 at the level of second multiple-layer 26 on the P-channel MOS transistor side are formed. Then, a second implantation of P-type dopants is performed, to form heavily-doped regions on either side of the first and second multiple-layers. The extrinsic base regions 36 of the bipolar transistor and drain and source regions 35 of the P-channel transistor are thus formed.
An activation anneal is generally performed at this step, for example, at a 1,000° C. temperature and for a duration of 10 seconds. During this anneal, the hydrogen implanted in gate oxide portion 27 on the bipolar transistor side combines, according to a conventional oxidation-reduction reaction, with the SiO 2 molecules.
The reduction of gate oxide portion 27 by hydrogen modifies its properties. In particular, this oxide portion 27 no longer opposes the migration of the N-type dopants present in polysilicon portion 28 to P-type region 18 , to form an emitter area 37 . An NPN-type transistor having its emitter corresponding to region 37 in contact with polysilicon portion 28 is thus obtained, its base corresponding to the P-type doped region 18 extending to reach extrinsic base regions 36 , and its collector corresponding to the N-type region 12 extending in region 11 and well 16 . Further, upon operation of the NPN-type transistor, oxide portion 27 no longer opposes the passing of the charge carriers, that is, oxide portion 27 becomes conductive.
According to a second embodiment of the present invention, instead of implanting hydrogen in gate oxide layer 19 , silicon or germanium is implanted. The implantation is performed, for example, with a dose from 10 15 to 10 17 atoms/cm 2 . A significant factor at this step is the current with which silicon or germanium are implanted. Indeed, the silicon or germanium ions alter the structure of gate oxide layer 19 . This alteration of the oxide essentially occurs during the silicon or germanium ion implantation and not during the activation anneal as was the case for the first embodiment. The silicon or germanium current will for example be from 10 to 100 μA.
The silicon or germanium implantation risks damaging the underlying layers, that is, P-type base region 18 . However, during one of the anneal steps, a reconstruction of the crystalline material will occur.
A third embodiment of the present invention is shown in FIGS. 7 to 9 . A nitrogen implantation on the bipolar transistor area is performed before the forming of gate oxide layer 19 , in P-type region 18 intended to form the base of the bipolar transistor. The nitrogen implantation is performed, for example, at a dose from 10 14 to 10 16 atom/cm 2 .
As shown on FIG. 7, when gate oxide layer 19 is grown over the entire integrated circuit wafer, the presence of the nitrogen implants reduces the oxide growth at the level of P-type region 18 . Thus, when gate oxide layer 19 is grown to obtain an average 1.2-nm thickness at the level of the P-channel MOS transistor, a gate oxide layer 19 exhibiting an average 0.8-nm thickness is obtained at the level of the bipolar transistor. A polysilicon layer 20 is then grown as in the previously described embodiments.
FIG. 8 shows two multiple-layers 25 , 26 remaining in place after removal of polysilicon layer 20 and of gate oxide 19 . Multiple-layer 25 , located on the bipolar transistor side, exhibits a gate oxide portion 27 modified with respect to that of multiple-layer 26 located on the P-channel MOS transistor side.
FIG. 9 shows the final steps of this third embodiment which are identical to those of the preceding embodiment. The presence of very thin oxide layer 27 allows diffusion of the dopants present in polysilicon portion 28 during the activation anneal, to form an emitter area 37 .
According to an alteration of the third embodiment of the invention, instead of nitrogen, any element can be used to prohibit the growth, on the bipolar transistor side, of an oxide layer or, at least, to limit the depth of such an oxide layer on the bipolar transistor side so that the oxide layer is locally thin and allows, on the bipolar transistor side, the diffusion of the dopants present in polysilicon portion 28 .
Thus, according to the embodiment of the present invention, it becomes possible to manufacture on an integrated circuit MOS-type transistors and bipolar transistors with a minimum number of steps specific to the bipolar transistor. The essential differences include, on the one hand, the implantation of a P-type doped region, for example corresponding to the implantation of the sources and drains of the P-channel MOS transistor, to form the intrinsic base of the NPN transistor, and on the other hand, the step of modifying the gate oxide layer so that it does not oppose the passing of the dopants, during the activation anneal, to form the emitter area.
In the foregoing, specific embodiments of the present invention have been described. Clearly, these embodiments are likely to have alterations and modifications which will readily occur to those skilled in the art. In particular, all conductivity types may be inverted to simultaneously form an N-channel MOS transistor and a PNP bipolar transistor.
Further, although the present invention has been described in the context of the manufacturing, on an integrated circuit, MOS-type transistors and bipolar transistors, it may apply to the simultaneous manufacturing on an integrated circuit of MOS-type transistors and of junction field-effect transistors JFET, the control junction of the JFET field effect transistor being then obtained similarly to the emitter region of the bipolar transistor according to the method of the present invention.
Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and the scope of the present invention. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. The present invention is limited only as defined in the following claims and the equivalents thereto. | A method for manufacturing a contact between a semiconductor substrate and a doped polysilicon layer deposited on the substrate with an interposed insulating layer, wherein elements adapted to making the insulating layer permeable to the migration of dopants from the polysilicon layer to the substrate are implanted. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electroconductive polypyrrole which is superior in solubility and thus able to be cast into films and solution-sprayed into coatings. Also, the present invention is concerned with a process for preparing soluble, electroconductive polypyrrole by polymerizing pyrrole monomers in an aqueous solution in the presence of dodecylbenzene sulfonic acid (DBSA).
2. Description of the Prior Art
Since polypyrrole is high in electroconductivity and stable in the air, it is useful for a plurality of purposes including electroconductive coating materials and paints, electrode materials for batteries, semiconductor parts, electrolytes for solid electrolytic capacitors, solar cells utilizing solar energy into electricity and so on. Accordingly, extensive research has recently been directed to the synthesis and applications of polypyrrole.
However, there are many limitations in its practical processing and application since the strong intermolecular interaction of the heterocyclic planar structure of polypyrrole makes it virtually impossible not only to dissolve polypyrrole in any solvent, but also to melt it.
Polypyrrole can be easily synthesized by electrochemical or chemical polymerization techniques.
Films of polypyrrole uniform and superior in mechanical properties can be obtained by electrochemical polymerization techniques. In these techniques, correspondingly large electrodes are necessary to obtain a polypyrrole film with a large area. In addition, it is difficult to synthesize uniformly thick films by electrochemical polymerization techniques. Further, electrochemically synthesized polypyrrole films always have bumpy (shaped like bunches of grapes) surfaces (FIG. 1A), making it difficult to control electric and electronic functions when the polypyrrole films are used as electrode materials of micro-electric devices because the distances between the electrodes are different and thus, an oversupply of current passes in certain portions.
For chemical polymerization techniques the polypyrrole is obtained as powder which is insoluble so that it alone cannot be formed into films. Polymerization of pyrrole monomer through chemical oxidation is generally accomplished by the addition of a persulfate oxidant and an acid serving as a dopant, resulting in a polypyrrole doped with the acid anion. It is also reported that a powder of polypyrrole is obtained by using FeCl 3 as an oxidant and 2-naphthalene sulfonic acid or p-toluene sulfonic acid as a dopant. However, the powder obtained was not dissolved in any organic solvent.
Extensive studies were made to allow processability to polypyrrole. Most of them proceed toward weakening intermolecular interaction through modifications of pyrrole monomer, so as to give the resulting polypyrrole solubility. For example, a successful example of the solubility of polypyrrole is reported in J. Chem. Soc., Chem. Commun, 11, 725, 1989), which is accomplished by attaching an alkyl group with a long chain, such as octyl, to pyrrole monomer. However, the pyrrole derivative is difficult to synthesize and costs too much compared with non-substituted pyrrole. Besides, the modified polypyrrole is very poor in electroconductivity and examples of its actual applications are indeed rare.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a soluble, electroconductive polypyrrole.
It is a further object of the present invention to provide a soluble polypyrrole which is capable of being cast into films having a very smooth surface.
It is a further object of the present invention to provide a method for preparing polypyrrole.
In accordance with one aspect of the present invention, there is provided a soluble, electroconductive polypyrrole represented as the following structural formula II: ##STR3## wherein A - = ##STR4##
In accordance with another aspect of the present invention, there is provided a method for preparing soluble, electroconductive polypyrrole represented as the structural formula II, comprising the step of polymerizing pyrrole monomer represented as the following structural formula I: ##STR5## using an aqueous solution containing dodecylbenzene sulfonic acid as a dopant, in the presence of an oxidant.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A is an atomic force micrograph (AFM) of a film made of electrochemically synthesized polypyrrole showing a rough surface:
FIG. 1B is an atomic force micrograph (AFM) of a film made by casting the polypyrrole according to the production method of the present invention, showing a smooth surface;
FIG. 2 shows two FT-Raman spectra for electrochemically synthesized polypyrrole (A) and the soluble polypyrrole synthesized according to the method of the present invention (B);
FIG. 3 is a plot of the electroconductivity of the present polypyrrole with respect to weight fractions of poly(methylmetacrylate)(PMMA) in PMMA/polypyrrole blends.
DETAILED DESCRIPTION OF THE INVENTION
The polypyrrole according to the present invention is soluble in an organic solvent, and thus it is capable of being spray-coated by virtue of its superior solubility, and is capable of being processed into conductive composites.
The soluble polypyrrole according to the present invention is capable of being cast into films having a smooth surface. Herein, the term "soluble polypyrrole" means that it can be formed into films which can have any desirable thickness and size.
The present invention provides polypyrrole represented as the following structural formula II: ##STR6##
In the present polypyrrole, an anion, denoted by A - , which results from the dissociation of dodecylbenzene sulfonic acid, acts as a dopant which is doped in the polymer, rendering electroconductivity to it. Since this dopant is located between the molecules of polypyrrole and has a molecular weight of about 5 times as large as a pyrrole monomer, it prevents the polypyrrole molecules from coming into direct contact with each other. Thus, the dopant greatly reduces the intermolecular interaction of polypyrrole, resulting in large improvements in the solubility of the polypyrrole. It is known to those knowledgeable in the art that one anion is doped per 3 or 4 pyrrole repeating units.
Powders of the polypyrrole according to the present invention are dissolved in weakly polar organic solvents such as dichloromethane and m-cresol and polar organic solvents such as tetrahydrofuran (THF) and dimethylformamide (DMF). Also, they could be dissolved even in chloroform provided that dodecylbenzene sulfonic acid is added at an amount of 100 to 200 weight % based on the total weight of the polypyrrole.
Gel permeation chromatography (GPC), which is generally used to measure molecular weights of polymers, is not effective for doped conductive polymers which are in an oxidation state. Further, because K and a values, necessary for the Mark-Houwink equation, are not known for polypyrrole, its molecular weight cannot be determined by measurement of inherent viscosity.
But, the intrinsic viscosity of a m-cresol solution dissolving the polypyrrole according to the present invention is about from 0.07 dl/g to 0.3 dl/g at 30° C. which is lower than that of soluble polyaniline, 0.18-2.62 dl/g as reported in Polymer 34, 3139 (1993) by Y. Cao and P. Smith.
Such low intrinsic viscosity means that the molecular weight of the soluble polypyrrole according to the present invention is not so large.
The soluble polypyrrole of the present invention is prepared by polymerizing pyrrole monomer in the presence of a persulfate oxidant. In more detail, to a solution of dodecylbenzene sulfonic acid and pyrrole monomer in distilled water, persulfate oxidant is slowly added with stirring in an incubator at a temperature of -5° to 20° C. for 24 hrs at the costant temperature. Thereafter, methanol is added to stop the polymerization. The synthesized powdery polypyrrole was filtered, washed many times with distilled water and methanol.
It is preferred that the concentration of dodecylbenzene sulfonic acid upon polymerization of pyrrole is on the order of 0.1 to 1.0 mole based on the moles of pyrrole monomer. A concentration departing from the range results in undesirable solubility of polypyrrole.
As the persulfate oxidant, potassium persulfate or ammonium persulfate is used in the present invention with a preference to ammonium persulfate. The persulfate oxidant is added preferably at 0.1-0.5 mole per unit mole of pyrrole monomer and more preferably at 0.1-0.2 mole per unit mole of pyrrole monomer. As the concentration increases within this range, the conductivity of the film obtained by casting and the production yield increase while the solubility thereof decreases. If the mole ratio of the persulfate oxidant to pyrrole monomer is above 0.5, the solubility markedly decreases. On the other hand, if the mole ratio is less than 0.1, the conductivity of a cast film drops into less than 10 -6 S/cm while the solubility is improved.
In contrast with the electrochemically polymerized polypyrrole film having a bumpy surface as shown in FIG. 1A, the polypyrrole prepared according to the method of the present invention, when a film is formed by casting a solution that the present polypyrrole is dissolved in an organic solvent, has a smooth surface without any bumps, as shown in FIG. 1B. From this fact, it is apparent that a smooth surface with a good electroconductivity can be obtained when the soluble electroconductive polypyrrole prepared according to the present invention is coated on some surface. As a result, the polypyrrole of the present invention can be more extensively used. For example, the polypyrrole film according to the present invention is completely free of surface bumps, which are seriously problematic to electrochemically polymerized polypyrrole films used as a pair of electrodes with a very small gap, and thus, can be used as excellent electrode materials that do not have differences in the distances between the electrodes.
With reference to FIG. 2, there are shown FT-Raman spectra for a film obtained by casting the present polypyrrole solution and an electrochemically polymerized polypyrrole film. These spectra are completely the same, showing that the chemical structure of the soluble polypyrrole prepared according to the present invention is identical to that of electrochemically polymerized polypyrrole.
It is believed that one reason why the present polypyrrole is different from the electrochemically synthesized polypyrrole in solubility in spite of an identical chemical structure is that they are different from each other in molecular weight and/or crosslink density. As apparent from the solubility, the present method scarcely generates intermolecular crosslinks in polypyrrole, compared with the electrochemical polymerization method. In accordance with the present invention, the molecular weight of polypyrrole can be controlled by the concentration of the oxidant. In contrast, the polypyrrole obtained by electrochemical polymerization or chemical polymerization does not allow its molecular weight to be measured because of its absolute insolubility.
By controlling the reaction conditions including reaction temperature and concentrations of dodecylbenzene sulfonic acid and a persulfate oxidant, the solubility in organic solvents of the soluble polypyrrole obtained by the method of the present invention and the conductivity thereof can be adjusted.
The soluble polypyrrole according to the present invention is capable of being cast into films having a smooth surface.
As the surface of a conductive material is smoother, the electromagnetic functions thereof become more uniform, which allows micro-devices to be formed with high reproductivity.
In addition, when being blended with other polymeric materials in order to improve adhesiveness or strength, the conductive material with a smoother surface can be easily formed to have superior electric functions by, example, coating it on glass or polymeric film. In this case, it is possible to obtain transparent electrode plates equivalent to a transparent ITO glass plate by controlling the thickness of the polypyrrole coating.
In addition, a significance of the soluble polypyrrole according to the present invention is that it can be solution-blended with various general-purpose polymers capable of being dissolved in organic solvents, such as polystyrene (PS), amorphous nylon and poly(methylmethacrylate) (PMMA), to form conductive films with good mechanical properties.
As explained above, the electroconductive polymers obtained by the method of the present invention are easily dissolved in organic solvents, so that they show superior processability, which allows them to be applied for a wide range of uses including electroconductive coating materials and paints, electrode materials for batteries, semiconductor parts, electrolytes for solid electrolytic capacitors, solar cells utilizing solar energy as electricity and so on.
A better understanding of the present invention may be obtained in light of the following examples which are set forth to illustrate, and are not to be construed to limit, the present invention.
EXAMPLE I
24.3 g (0.0745 mol) of dodecylbenzene sulfonic acid was dissolved in 300 ml of deionized water and the solution was poured into a reactor, which was then placed in an incubator at a temperature of 5° C. 10 g (0.149 mol) of pyrrole monomer which was dried with calcium halide and distilled under reduced pressure was added to the resulting solution which was then vigorously stirred for 20 min. with a mechanical stirrer. To this solution, 3.65 g (0.016 mol) of ammonium persulfate solution in 100 ml of deionized water was added over 5 min. and reacted for 16 hrs. with stirring. The addition of 300 ml of methanol stopped the reaction and the solution was filtered to obtain a fine polypyrrole powder. The polypyrrole powder was washed with excess deionized water and methanol and filtered to give pure polypyrrole: yield 20.8%.
The solubilities of the polypyrrole in m-cresol, chloroform, THF and DMF, each, were examined and the results are given as shown in Table 1.
Using a thin disc-like specimen made by compressing the pure polypyrrole powder and a film (thickness: 100 μm) made by casting a polypyrrole solution in chloroform, voltages were detected under a constant current by the four probe method, to examine thoes conductivities, and the results are given as shown in Table 2.
As indicated in Table 1, the polypyrrole prepared according to the present invention is well dissolved in m-cresol, THF and DMF but not in chloroform. In the latter case, when dodesylbenzene sulfonic acid was further added at an amount of 50 weight % based on the weight of the polypyrrole, the polypyrrole was dissolved very well.
EXAMPLE II
Pure polypyrrole powder was prepared in a similar manner to that of Example I, except that 7.3 g (0.032 mol) of ammonium persulfate was used. Yield 63.6%.
The results of the analyses for solubility and conductivity are given as shown in Tables 1 and 2, respectively.
As indicated in Table 1, the polypyrrole prepared in this example was superior in solubility in m-cresol, THF and DMF to the polymer prepared in Example 1 but not dissolved in chloroform. In the latter case, when dodesylbenzene sulfonic acid was further added at an amount of 50 weight percent based on the weight of the polypyrrole, the polypyrrole dissolved very well. As shown in Table 2, the polypyrrole film of this example has about 700 times as high a conductivity as does that of Example I. In the case of the compressed powder, the conductivity of Example II is about 360 times as high as that of Example I. Consequently, the conductivities of the polypyrrole film and the powder of Example II are much improved relative to those of the polypyrrole film and the powder of Example I.
COMPARATIVE EXAMPLE I
Pure polypyrrole powder was prepared in a similar manner to that of Example I, except that 18.25 g (0.080 mol) of ammonium persulfate was used. Yield 87.6%.
The results of the analyses for solubility and conductivity are given as shown in Tables 1 and 2, respectively.
Although its conductivity is 14.4 S/cm, a high value when compressed, the powder is of low solubility in the organic solvents. Thus, a solution capable of being casted into films could not be obtained by using the solvents.
TABLE 1______________________________________Solubility of the Soluble Polypyrrole SolventExample No. m-Cresol THF DMF Chloroform______________________________________Example I CS CS CS PS (CS*)Example II CS CS CS PS (CS*)C. Example I PS IS IS IS______________________________________ note: PS: partially soluble, CS: completely soluble, IS: insoluble, CS*: completely soluble after addition of a certain amount of DBSA
TABLE 2______________________________________Conductivity of Soluble Polypyrrole Powderand Film from Chloroform Sol'n Conductivity (s/cm)Example No. Compressed Powder Film______________________________________Example I 2.97 × 10.sup.-3 1.25 × 10.sup.-2Example II 1.10 8.90C. Example I 14.35 Impossible Casting______________________________________
EXAMPLE III
The polypyrrole obtained in Example II in combination with polymethy(methacrylate), sold by Polyscience, Inc., under the designation of "IV: 1.3", was dissolved in various concentration ratios in chloroform with dodecylbenzene sulfonic acid, to give solution blends, which were then cast into films. The conductivities of these films were measured by the four probe method. The results are shown in FIG. 3.
As plotted in FIG. 3, when the content of the polypyrrole is 16.7, 28.6, 37.5 and 50 weight %, the conductivity is 1.5×10 -1 , 6.6×10 -1 7.6×10 -1 and 1.6 S/cm, respectively, which indicates that a higher content of polypyrrole results in a higher conductivity. Besides, up to 50 weight % of polypyrrole still resulted in a film with high mechanical strengths.
Other features, advantages and embodiments of the present invention disclosed herein will be readily apparent to those exercising ordinary skill in the art after reading the foregoing disclosures. In this regard, while specific embodiments of the invention have been described in considerable detail, variations and modifications of these embodiments can be effected without departing from the spirit and scope of the invention as described and claimed.
EXAMPLE IV
The mechanical properties of a film made by casting the polypyrrole of Example II, a conventional polypyrrole (polypyrrole-DS) and a polyanyline are given as shown in the following Table 3.
TABLE 3______________________________________ Polypyrrole- Polypyrrole- unstretched*.sup.3Mechanical Property DBSA*.sup.1 DS*.sup.2 Polyaniline______________________________________Tensile Strength at Break 17.0 68.5 54.4(MPa)Elastic Modulus (MPa) 1945 -- --Elongation at Break (MPa) 0.9 7.7 --______________________________________ *.sup.1 : dodecylbenzene sulfonic acid, *.sup.2 : dodecyl sulfate ion, J. M. Ko, H. W. Rhee and C. Y. Kim, Makromol. Chem. Macromol. Symp., 33, 353-359 (1990) *.sup.3 : "Conjugated Polymers and Related Materials", ed. W. R. Salaneck I. Lundstrom, B. Ranby, 1993, 92
As apparent from Table 3, the polypyrrole according to the present invention is comparable in mechanical properties with electrochemically synthesized polypyrrole films and cast polyaniline films. | Polypyrrole represented as the following structural formula II: ##STR1## wherein A - = ##STR2## which is synthesized by a method comprising the step of polymerizing pyrrole monomer in an aqueous solution containing dodecylbenzene sulfonic acid as a dopant, in the presence of an oxidant, resulting in polypyrrole which is easily dissolved in organic solvents. | 2 |
BACKGROUND OF THE INVENTION
In the past, oil shale deposits were mined and brought to the surface for further processing of the various components and constituents. This process was expensive, time-consuming, and dangerous. If the oil shale deposits were mined by open pit, their removal was time-consuming and expensive. Additional ecological problems render both these methods of extraction undesirable today.
A somewhat more dangerous approach involves underground tunneling into the shale oil deposits in a predetermined pattern for the purpose of blasting and rubblizing the oil shale deposit. After the deposit is rubblized, a flame front is instituted which causes an in-situ retorting of the hydrocarbon values in the shale. This process has met with varying success primarily because of difficulty of obtaining uniform rubble in the shale deposit with the attending problems of maintaining a reasonably uniform flame front and plastic flow of the rock material. If the rubble is not reasonably uniform, a substantially uniform flame front is not maintained and the retort flames are quenched by the retorting products or by-pass burning occurs. The plastic flow problems are particularly severe in the deposits richer in kerogen.
Various forms of pressure swings have been used in the past to improve recovery from oil fields. In one process, a down-holed gas/oxygen gun propagates shock waves through an oil field to crack the underground formation, thereby releasing additional pockets of oil. In another process, steam is cycled (huff and puff) so as to recover viscous oil from sand and gravel. Neither of these processes are suitable for the present invention. Shock waves play no part in the present process, and it is often desired to avoid further cracking rather than to cause it. With respect to the cycling steam process, it is applied only until the heated subsurface area of two adjacent wells come into contact and then it is replaced by continuous steam pressure drive. Moreover, the formations wherein "huff and puff" has been applied are essentially a mixture of heavy oil, sand, and gravel. They have neither the prominant horizontal layered structure nor the blind cracks of the oil shale deposits.
SUMMARY OF THE INVENTION
The present invention relates to pressure cycling of process gases in an in-place process for extracting water soluble minerals from an oil shale bed, generating and recovering oil from the artificially leached chamber produced by the mineral extraction, and the subsequent leaching of minerals which were water insoluble before retorting. This process can be used in conjunction with the process set forth in copending application Ser. No. 741,817, entitled Recovery System for Oil Shale Deposits by Hill et al. This process employs cyclic pressure swings of the process gases used in each of the recovery steps. Generally, these pressure swings may vary on the order of one cycle per minute to one cycle per day and have magnitudes of ± 35 percent of the ambient pressure in the chamber. In the absence of pressure fluctuations, process gases become stagnant in the blind fractures or cracks, i.e., those fractures or cracks which are open only at one end. When the pressure is cycled, the process gas is forced into and drawn out of the blind fractures, providing fresh processing gas and improved heat transfer with each cycle. Thus, the removal of the hydrocarbon, carbon monoxide, and hydrogen values or minerals is greatly enhanced. This effect is most clearly visualized by considering an empty blind crack. When filled with steam, the steam condenses to stagnant water, saturated with soluble minerals. Under constant pressure conditions, leaching would now cease. If the pressure is reduced, some of the water in the crack will boil, thereby expelling the saturated water, and making the crack accessible to fresh steam on the next pressure upswing.
These effects-improved material and heat transfer can also be obtained by pressure swings even when there is no phase change; since PV ≈ n RT, the pressure swings will move process gas, products, and heat in blind cracks far more effectively than under stagnant constant pressure conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the injection of the process gas into the retort chamber having a blind fracture or crack extending into the subsurface structure off the retort chamber;
FIG. 2 is an enlargement of the blind fracture or crack showing the process gas being driven under pressure into the cavity;
FIG. 3 is an enlargement of the blind fracture or crack showing mineral or hydrocarbon values being drawn out of the cavity after the pressure has been reduced; and
FIG. 4 is an enlargement of the blind fracture or cavity after it has been enlarged by repeated pressure cycling of the process gas.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to the recovery of minerals, such as nahcolite, dawsonite, nordstrandite, shortite, trona, halite, hydrocarbon, and other fuel (such as H 2 and CO) values from subsurface formations by employing pressure cycling of the process fluids. Although the principals set forth in this process may be applicable to any oil shale deposit, the Piceance Creek Basin in northwestern Colorado is particularly suitable for application of this process. This area contains recoverable oil shale, nahcolite, and dawsonite spread over an area of about 300 square miles and approximately 900 feet in thickness. By employing an integrated in-place process, the nahcolite is first extracted followed by shale oil recovery, then by alumina recovery and secondary oil recovery, and finally by tertiary recovery using in-situ combustion. In order to obtain maximal recovery of the mineral and hydrocarbon values, the process must be conducted in a sequence of specific steps. In the first step, an oversized hole is drilled into the gas-tight overburden which is then encased and grouted to preserve the integrity of the overburden. The drill patterns may be in the form of individual wells or multiple wells. Where individual wells are used, a coaxial pipe is placed down the well hole and fluids are injected into the hole through an outer pipe while products are extracted through a center pipe. In a multiple well pattern, a central injector well is placed in a particular location and producer wells are located in the vicinity in any of a number of patterns.
In the deep deposits of the Piceance Creek Basin, solution mining of nahcolite is required initially to provide in-place access to the balance of the resource. Nahcolite is soluble in water and is decomposed by heat into sodium carbonate, carbon dioxide and water. Although the nahcolite occurs as nodules, veins, or disseminated crystals, these tend to be interconnected. To accomplish the nahcolite removal from the selected subsurface horizon, hot water or preferably steam is injected into the formation at the top of the completed borehole. Because considerable amounts of the nahcolite exist in blind fractures, i.e., fractures or cracks which are open only on one end, pressure pulsing may be employed to force condensible steam or hot water into the blind cracks and permitted to be expelled from the fracture or crack when the pressure is released. In this manner, saturated and stagnant solute is not continualy filling the crack. When the pressure is increased, new solute is forced into the crack or fracture, and when the pressure is reduced, a solution of nahcolite is expelled from the crack or fracture by pressure drop induced boiling or by gas expansion. The frequency of the cycle will depend upon the underground structure, the size of the retort cavity, the nature of the process fluids, and the thermal gradients desired. Generally, the pressure cycles will range from approximately one cycle per minute to one cycle per day. The exact frequency of the cycle will, of necessity, be determined in the field, though in general, a cavity will be cycled faster when small rather than when large. Likewise, the amount of the pressure being applied will depend upon the number of factors, e.g., the depth of the chamber, the temperature of the chamber, etc. Generally, pressure swings of +35% to -35% of the ambient pressure in the chamber would be sufficient to force the solute in and out of the blind cracks or fractures. After creating porosity in the formation by leaching the water-soluble nahcolite from the shale zone, chambers are pumped dry and in-situ retorting of the oil shale is conducted by the circulation of a hot fluid, such as heated low molecular weight hydrocarbon gas, steam, heated retort off-gas comprising H 2 , CO, CO 2 , N 2 , and mixtures thereof, from the injection well through the permeable shale bed and out the producing well. Again, during the retorting process, the process fluid is pulsed as previously described.
The in-situ retorting process should be carried out in a temperature range of between 660° to 930° F, and preferably between 800° and 850° F. These temperature ranges will permit rapid completion of oil evolution from the raw shale and the decomposition of dawsonite to chi-alumina which occurs about 660° F. In addition, co-occurring with the dawsonite is nordstrandite which forms unleachable gamma-alumina at temperatures above 930° F. The retorting of oil shale at temperatures in the range of 800° to 850° F leads to a quality shale oil product with a typical pour point about 25° F, and API gravity of about 28° with a nitrogen content of less than 0.8 weight percent according to Hill and Dougen in The Characteristics of a Low-Temperature In-Situ Shale Oil, Quarterly of the Colorado School of Mines, Volume 62, No. 3, July 1967.
Oil vapor from the decomposition of kerogen is cooled by the formation ahead of the retorting front and can be condensed and drained into a pocket from which it can be pumped along with some water from the dawsonite decomposition. The off-gas produced by the kerogen in the retorting process includes four components comprising the hot fluid used for retorting, the gas from the kerogen decomposition, oil vapors, and the carbon dioxide and water vapor from the dawsonite decomposition. If the gas from the kerogen decomposition is used as the heat carrier for retorting, the resulting off-gas will have a medium heating value after the removal of the water and CO 2 . After the retorting step has been completed, alumina which was formed from dawsonite and nordstrandite can be extracted. This light base extractable alumina, which was created when the oil shale was retorted at water temperatures, was formed by dawsonite when it was heated to 350° C according to the reaction as reported by Smith and Young in Dawsonite: It's Geochemistry, Thermal Behavior, and Extraction from Green River Oil Shale, paper presented at the Eighth Oil Shale Symposium, Colorado School of Mines, Golden, Colorado, Apr. 17-18, 1975. This alumina, which includes values from nordstrandite, can be extracted from the retorted oil shale by solution of 1N sodium carbonate and a surfactant for further recovery of unmobilized oil.
The requirements which must be met by the surfactant involve both chemical stability and proper functioning in a brine system containing very high concentrations of NaHCO 3 and Na 2 CO 3 , as well as small amounts of calcium and magnesium salts. In addition, the surfactant or surfactants must not interfere with the above ground alumina precipitation which occurs when CO 2 is added to the leach solution. Furthermore, the surfactant(s) should reduce the oil-brine interfacial tension, the oil-rock interfacial tension, and the brine-rock interfacial tension so that oil droplets are efficiently mobilized, and so that the leach brine efficiently contacts the alumina minerals. Finally, the properties of the surfactant(s) must be such as to permit the oil to be separated from the brine at the surface in an economical manner. Since the cavity is a sealed system, relatively expensive surfactants can be used economically compared to those used in oil field tertiary recovery practice.
In general, two classes of surfactants are of greatest interest; essentially all of the nonionic surfactants, and many of the anionic surfactants. Examples of a few of the nonionic surfactants are:
polyoxyethylene surfactants
ethoxylated alkylphenols
ethoxylated aliphatic alcohols
carboxylic esters
carboxylic amides
polyoxyalkylene oxide block copolymers
alkanol amines
alkanol amides Examples of a few of the anionic surfactants are:
alkyl sulfates
N-acyl-N-alkyltaurates
naphthalene sulfonates
alkyl benzene sulfonates
alkane sulfonates
alkanolamide sulfates
phosphate esters
sulfated alkylphenols
Again, the leach liquor which is used to extract the alumina should be pressure pulsed as described previously.
Even with good yields from the primary and secondary recovery processes, rsidual fuel value will remain in the retort bed in the form of unmobilized oil and carbonaceous residue. Although this residue has little direct commercial value, it may yield sufficient fuel value to supply heat for the production of steam for the leach phase, the heating of retorting gas for hot gas retorting in another chamber, and the process heat required for gas treatment, etc. In addition, considerable amounts of liquid and vapor hydrocarbons will be mobilized and recovered in a tertiary stage. In view of this, a tertiary recovery step is effected which comprises removing water of the previous step from the retort chamber and instituting a flame front to combust the residue. Since much of the kerogen has already been removed, plastic flow problems are greatly reduced.
After combustion of the residue has begun, water vapor, as well as air or oxygen, is injected down the injector well hole. The water vapor reacts with the residue to hydrogenate the remaining unsaturated hydrocarbon values so that polymerization does not occur. By preventing polymerization of the hydrocarbon values during pyrolysis, the residue is fluid and readily flows as liquid or vapor in advance of the flame front. In addition, the presence of steam aids in mobilizing the fossil fuel values by means of the water gas reaction:
H.sub.2 O + C → H.sub.2 + CO
as practiced in the previous two recovery steps, pressure cycling is beneficial in the tertiary recovery step. In the tertiary recovery step, certain precautions must be taken by the pressure swings. The chief concern during the pressure swing would be the prevention of such abrupt changes as to extinguish or suppress the flame front, or to cause excessive mixing of combustible product gases with oxidizing process gas.
When all practical hydrocarbon and mineral values have been removed from the retort chamber, the chamber may be back-filled with water, solutions, or slurries to prevent subsidence of the soil and collapse of the underground structures. Aqueous solutions suitable for this purpose may comprise some of the excess minerals which were removed in the previous recovery processes. Thus, if more sodium bicarbonate is being removed than can be disposed of economically, the solutions or slurries of these materials may be pumped back into the ground for storage or later removal. Subsidence of the soil must be controlled to prevent process interruption and to minimize environmental damage. The vertical component of the stress field is governed by unit weight of the rock and the vertical depth to the opening. The reaction to this stress and size of the opening which can be tolerated without collapse will be governed by the strength of the rock immediately above the opening.
To minimize soil subsidence, extraction operations must leave pillars of undisturbed shale to support the overburden. This technique is commonly used in room and pillar mining. Thus, to reduce the possibility of earth subsidence which follows an initial roof collapse that causes stress and distruption of strata all the way to the earth's surface, backfilling with pressurized water or aqueous solutions or slurries should be considered.
After the chamber has been back-filled, the pipe may be plugged to seal the chamber. When the next level of mining has been determined, the pipe is perforated at that level and the process is repeated.
Each step of the process is integrated and interdependent upon obtaining the inputs of process fuels, chemicals, or working fluids which are supplied as outputs by some other previous stage. Thus, it would be impractical to pump large quantities of a basic leach solution into a borehole to recover alumina values unless the chamber had been leached and retorted previously. Likewise, recovery of hydrocarbon values from the oil shale would be difficult and expensive unless the chamber was first made porous and permeable by the nahcolite leach. Moreover, direct in-situ combustion of rich unretorted oil shale is not feasible due to plastic flow problems. The removal of a portion of the kerogen during retorting greatly reduces these problems. Therefore, in order to carry out the process in a logical and economic manner, the process steps must be followed in the sequence set forth previously.
Although there may be numerous modifications and alternatives apparent to those skilled in the art, it is intended that the minor deviations from the spirit of the invention be included within the scope of the appended claims, and that these claims recite the only limitations to be applied to the present invention. | A process for the in-situ recovery of hydrocarbon, carbon monoxide, and hydrogen values and associated minerals from subsurface oil shale deposits is provided by forming a gas-tight retort chamber and injecting it with various process gases which are pressure cycled over a predetermined period of time. This pressure cycling increases the extraction efficiency by improving the recovery of material contained in blind cracks in the underground formation, and by provising an independent means of controlling the thermal gradients induced in the deposit. | 4 |
This application is a continuation of application Ser. No. 744,345, filed June 13, 1985, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a process and an apparatus for dry spinning synthetic polymers, in which the yarns are blasted with hot gas be means of a blasting apparatus, radially from the inside to the outside below an annular spinning nozzle.
When dry spinning polymers, such as acrylonitrile polymers, polyurethane and aromatic polyamides, the hot spinning solution is normally forced through the bores of the spinning nozzle in a spinning shaft charged with hot gas. The solvent is thereby evaporated from the yarns.
It is important that the solvent is evaporated as quickly as possible, so that the yarns do not adhere due to too high a solvent content, when they beat against each other, this taking place particularly when the spacings between the holes on the nozzle are very small and the circulation of air in the shaft is unstable.
The hot spinning gas is at present normally blasted or blown in at the upper end of the spinning position above the spinning nozzle via screens and air filters and flows through the heated shaft in the direction in which the yarn is drawn off, the solvent being evaporated from the yarns and the gas being cooled. The gas enriched with solvent is drawn off by suction at the lower end of the shaft.
In this parallel flow of the hot spinning gas, the yarns which are removed further from the flow of gas, are not dried fast enough and show high fault rates owing to adhesion, as well as thick and thin regions.
A contrastingly improved apparatus for dry spinning is described in U.S. Pat. No. 3,737,508, in which some of the spinning gas, which is fed in parallel to the running direction of the yarns outside an annular nozzle, is drawn off by suction through the inside of the annular nozzle by means of gas supply devices, so that this partial flow flows transversely from the outside to the inside through the yarns below the nozzle. The remainder of the spinning gas flows with the yarns through a heated spinning shaft and is drawn off by suction at the end thereof. This apparatus suffers from the disadvantage that the inner row of yarns are not dried sufficiently quickly and still has a large number of points of adhesion.
In DE-OS No. 1,760,377, this disadvantage is partially compensated for in that the inner solution yarns issue from the spinning nozzle at a relatively high temperature. The technical cost of this solution is, however, exceedingly high.
Moreover, the transverse flow from the outside to the inside suffers from the disadvantage that the gas velocity from the outside to the inside increases since the space existing for the flow of gas towards the inside becomes smaller and the solvent-containing yarns act as gas sources. This produces a more substantial mechanical stressing and deflection of the yarns, which are positioned closest to the inner suction region, adhesion and splitting again being produced at weak spots.
SUMMARY OF THE INVENTION
It has now surprisingly been found that with an apparatus, in which the yarns are blasted or blown transversely from the inside to the outside, extraordinarily low error rates are achieved during dry spinning.
Thus an object of the invention is a process for dry spinning, in which a polymer solution is forced through the bores of an annular spinning nozzle in a spinning shaft which is charged with hot gas and the solvent is then evaporated from the yarns, the temperature of the shaft wall and of the spinning gas being higher than those of the spinning solution, characterized in that the spinning gas in the upper part of the shaft blasts the yarns radially from the inside to the outside, the velocity of the radial flow of gas directly below the spinning nozzle transverse to the running direction of the yarns and within a spacing of 10 mm from the nozzle, increasing from 0 to at least from 0.2 to 1 m/s.
The radial flow of gas preferably maintains its velocity transverse to the running direction of the yarns at a measured distance of from 50 to 200 mm from the nozzle.
The gas flow is deflected in the further course of the spinning shaft in a gas flow parallel to the running direction of the yarns, by the fast running yarns and the shaft wall. The spinning gas is drawn off by suction as usual at the shaft end.
A further object of the invention is an apparatus for carrying out the process according to the invention, containing a spinning shaft with an annular spinning nozzle applied at the head and a spinning gas conduit, characterized in that the spinning gas conduit is cylindrical and is applied concentrically to the annular spinning nozzle in the inside of the annular spinning nozzle, and continues below the nozzle in a 50 to 200 mm, preferably 80 to 110 mm likewise cylindrical gas distributor projecting into the spinning shaft, the cylindrical generated surface of which is gas permeable.
The base of the gas distributor is preferably gas impermeable. The length is preferably from 80 to 110 mm, the diameter of the gas distributor is from 60 to 120 mm, particularly from 80 to 90 mm in the case of the spinning shaft characterized below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a longitudinal section through the apparatus according to the invention.
FIGS. 2 to 6 show different embodiments of the spinning gas conduit and the velocity profiles thereby achieved of the air flowing radially to the outside (more detailed explanations in Example 3).
FIGS. 7 to 16 show velocity profiles produced with different spinning gas conduits (more detailed explanations in Example 4).
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, (1) represents the spinning head, in which there is an annular spinning nozzle (2) with a spinning gas conduit (3) positioned on the inside and a connected spinning solution conduit (4). The spinning gas distributor (5) is provided with woven braid fabric (6), so that (in this case) the spinning gas can flow radially to the outside and to the bottom. Not only the spinning yarns (9) can be observed through the spinning shaft window (7) of the spinning shaft (8), but the spinning gas distributor (5) can also be easily exchanged.
The spinning solution is pumped into the annular spinning nozzle and extruded through the nozzle bores into the heated spinning shaft. The spinning solution, preferably a solution of an acrylonitrile polymer in dimethyl formamide, has a dynamic viscosity at 80° C. of from about 10 to 100 Pascal sec, preferably from 20 to 40, the nozzle outlet bores have a diameter of from 0.15 to 0.8 mm, preferably from 0.20 to 0.30, and a spacing between the holes of from about 2 to 10, mm, preferably from 2.5 to 3.5 mm. The solution yarns are drawn off at a velocity of from about 50 to 1,000 m/min, preferably from 200 to 300 m/min through the heated spinning shaft from about 2 to 10 m, preferably from 5 to 8 m, in length, the shaft having a diameter of from about 20 to 40 cm, preferably from 25 to 30 cm.
The hot spinning gas has a temperature which is at least 5° C. above the temperature of the spinning yarns, preferably from about 150° to 350° C. The air distributor is positioned at from about 0.5 cm to 5 cm from the innermost row of yarns.
The spinning gas distribution according to the invention is preferably achieved with a cylinder, the casing of which is provided with a woven braid material and is preferably gas impermeable on the base in the direction of the shaft. Woven wire material is suitable as woven braid material, which woven wire material has a wire density of from 10 to 40 wires per cm in the weaving direction, preferably 21 cm, and from about 6 to 18 wires per cm, preferably 10.5 cm perpendicular to the weaving direction, the wires having a diameter of from about 0.1 to 0.5 mm, preferably 0.3 mm. The air supply conduit is well insulated in order to prevent the loss of heat and for local heating on the spinning nozzle. The air distributor is applied such that during the spinning process, it can be easily incorporated and removed for cleaning individual nozzle orifices or for cleaning the distributor itself.
When using the process according to the invention, it has been shown that good spinning results are obtained when relatively low spinning gas quantities of from 0.8 to 230 Nm 3 /kg of solution, preferably from 1 to 2 Nm 3 /kg, in the case of a 29% by weight polyacrylonitrile solution in dimethyl formamide. The small spinning gas quantity supplied also gives rise to a small quantity of waste gas.
The spinning yarns which are at a spacing of from about 0.5 to 20 cm from the gas distributor, are easily arched towards the outside during the spinning process. It has been shown that the yarns taper during spinning on a section of from 1 to 5 cm below the nozzle on the almost terminal cross-section thereof. With the process according to the invention, adhesionfree yarns can be produced, preferably from acrylonitrile polymers, with an individual spinning titre of from 2 to 80 dtex. These yarns have a high degree of uniformity in cross-section and in their textile values and are substantially free from solvent.
EXAMPLE 1
An acrylonitrile copolymer with a relative viscosity of t p =1.89 t D of 93.6% by weight of acrylonitrile (ACN), 5.7% by weight of acrylic acid methyl ester (AME) and 0.7% by weight of sodium methyllyl sulphonate are dissolved at 80° C. in dimethyl formamide (DMF), so that a 29.5% by weight spinning solution (quantity) based on quantity of solution) is obtained. (t p and t D represent the times required for predetermined amounts of solution to pass through a capillary tube, such times constituting a measure for the molecular weight. Thus, the time t p , which is required for an 0.5% polymer solution in DMF to pass through the capillary at 20° C. is compared with the time t D which is required for pure DMF to pass through the same capillary.) The solutions are heated to 130° C. in a preheater and passed into an annular spinning nozzle. The solution has a viscosity of about 10 Pascal sec. In the annular spinning nozzle, which is well insulated in relation to the spinning gas conduit and does not have its own cooling, the nozzle bores have a minimum spacing between the holes of 3.4 mm, the nozzle bores having a diameter of 0.25 mm. The spinning yarns are blasted transversely from the inside to the outside with 230° C. hot air, a hollow cylinder serving to distribute the air, which hollow cylinder has a diameter of 85 mm and a length of 95 mm. The base of the cylinder is sealed with a metal plate. The hot spinning air is blasted into the air distributor through a pipe, which is well insulated against the environment and is conveyed towards the outside through the perforated woven braid material of the cylinder casing in a radial symmetric manner. The used woven braid material has a wire thickness of 21 wires per cm in the weaving direction and 10.5 wires per cm perpendicular to the weaving direction. The wires have a diameter of 0.3 mm. 1.43 Nm 3 of air per kg of interspersed solution are blasted into the air distributor. FIG. 6, no. 1 (corresponding to the supply of spinning gas according to FIG. 2) shows the velocity profile of the transverse flow on the surface of the woven braid material as a function of the spacing of the upper edge of the woven braid material which is at the same height as the annular nozzle. The solution yarns have a temperature of about 146° C. The yarns are drawn off at about 230 m/min through the 8 m long shaft heated to 180° C. and after a spacing of about 20 mm from the nozzle already have a diameter which diverges less than 20% from the terminal diameter of the yarns. The spinning bulk, which is obtained in this manner, has a DMF-content of 11% by weight, a titre of 10 dtex±0.5 dtex, a strength of 0.58 cN/dtex±0.1 cN/dtex (unstretched) and an elongation of 102%±12%. The spinning bulk has in the case of thirty measurements, less than 5 errors per 100,000 capillaries, the following being considered as errors: adhesion, thick and thin filaments. (The values behind the sign±give the standard deviation for the measuring results).
The specific energy consumption on the air side of 0.24 kWh/kg PAN is very low in the case of the apparatus according to the invention. Furthermore, owing to the low specific use of air, there are reduced difficulties in handling the outgoing effluent air which has been contaminated with solvent-containing vapours.
EXAMPLE 2
Further spinning adjustments are undertaken on the same apparatus. The parameters changed in relation to the first Example are brought together in Table 1.
TABLE 1__________________________________________________________________________ Example 1 2 3 4 5 6 7 8__________________________________________________________________________Polymer A A A A A B A CSolvent DMF DMF DMF DMF DMF DMF DMF DMFPolymer content (%) 29.5 29.5 29.5 30 29.5 24 29.5 22Relative viscosity 1.89 1.89 1.89 1.89 1.89 2.13 1.87Dissolving temperature (°C.) 80 80 80 80 80 90 80 60Temperature according to preheater (°C.) 130 130 130 130 130 130 135 50Solution viscosity (Pas) 10 10 10 10.5 10 12 10 20Minimum spacing between holes (mm) 2.4 2.4 3.0 3.5 3.5 2.4 3.5 10.5Nozzel bore (mm) 0.25 0.25 0.25 0.3 0.25 0.25 0.3 0.3Spinning air temperature (°C.) 300 290 350 350 300 300 155 200Specific air quantity (Nm.sup.3 /kg solution) 1.43 1.63 1.15 1.38 1.43 1.3 8.5 26Shaft temperature (°C.) 180 190 200 200 190 195 120 200Spinning drawing-off (m/min) 230 315 252 200 820 100 600 300DMF content (%) 11 10 22 23 24 37 16 1Titre (dtex) 10 ± 0.5 5.9 ± 0.3 20 ± 1 35 ± 1.5 6.8 ± 0.5 18.9 2 8Strength (cN/dtex) 0.58 ± 0.1 0.58 ± 0.1 0.64 ± 0.1 0.56 ± 0.1 0.55 ± 0.1 1.0 ± 0.2 0.68 0.9Elongation (%) 102 ± 12 89 ± 8 125 ± 13 130 ± 14 50 ± 10 159 82 450Errors (per 100,000) <10 <8 <10 <5 <10 <5 <5 <5__________________________________________________________________________ A: Copolymer corresponding to Example 1 B: 100% of pure polyacrylonitrile C: Segmented polyurea polyurethane
EXAMPLE 3
The conditions of Example 1 are all adhered to. Only the velocity profile of the radial flow from the air distributors is changed by changing the air distributor. In FIG. 6, some blasting profiles of the radial flow from the air distributors are brought together. Profile 1 is thereby correlated with FIG. 2, profile 3 with FIG. 3, profile 3 with FIG. 4 and profile 4 with FIG. 5.
In this drawing, the schematic representation of some spinning gas conduits projecting into the shaft (halved longitudinal section, see also FIG. 1 detail (3)) can be seen. The cylindrical spinning gas conduit represented by 1 has a woven braid material as casing, which has a length of 95 mm and a diameter of 85 mm. A gas velocity profile of the transverse flow on the cylinder casing surface is achieved with this gas distributor, while profile is represented by the curve 1 where the axes meet. The gas velocity is measured in a cold state a room temperature with a hot wire anemometer. The spinning gas supply device according to FIG. 3 is transformed in relation to FIG. 2 in a manner such that a convex arched base is incorporated in the apparatus. A gas velocity profile of the transverse flow is thereby obtained, as represented by the curve 2. The gas supply devices according to FIGS. 4 and 5 are changed regarding length and diameter as well as regarding the weaving direction of the woven braid material, examined regarding the gas velocity profile and represented by the curves 3 and 4.
The rate of error on the spun yarns for the individual flow profiles are as follows:
______________________________________Profile No. Rate of Error per 100,000 Capillaries______________________________________1 <52 <103 <304 <30______________________________________
The other quality-determining characteristics of the yarns correspond to those in experiment 1.
EXAMPLE 4
The conditions of Example 1 are all adhered to, only the velocity profile is not produced as in Example 1 by an air distributor with woven braid material, but with air distributors, which in place of the woven braid material have a cylinder casing with electron-beam-perforated sheets with a thickness of 1 mm. The holes have a diameter of 0.2 mm.
Different blasting profiles are produced above the division of holes (triangular position). FIGS. 7 to 16 show the gas velocity profiles of the transverse flow or the surface of the cylinder casing of the gas distributor. The results of the experiments are as follows:
______________________________________Profile of FIG. Rate of Error/100,000 capillaries______________________________________ 7 <40 8 <300 9 <50010 <3011 <8012 <100013 <30014 <8015 <15016 <150______________________________________
The remaining quality-determining characteristics of the yarns have in the case of strength and elongation in relation to the yarns in Example 3 somewhat poorer values with relatively large dispersions. | Extraordinarily low ranges of error, with respect to yarn adhesion and uniformity, in dry spinning yarns are achieved when the spinning gas in the upper part of the shaft blasts the yarns radially from the inside to the outside in an apparatus designed for this purpose, the velocity of the radial flow of gas, dirctly below the spinning nozzle, transverse to the running direction of the yarns and within a spacing of 10 mm from the nozzle, increasing from 0 to at least from 0.2 to 1 m/s. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of Application No. 60/447,284 filed Feb. 14, 2003, incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention is concerned with clinched joints, and more particularly, with automated monitoring of clinching to ensure the quality of clinched joints, including, but not limited to, the quality of button diameter and button bottom thickness.
Among the well-known ways of joining sheets of metal are so-called clinched joints in which the operation of a punch relative to a die deforms contiguous metal sheets in a manner that produces a joint button interlocking the sheets. One form of clinching apparatus uses a die having die segments that are displaced laterally relative to a die anvil during formation of a joint. See, e.g., U.S. Pat. No. 5,150,513 issued Sep. 29, 1992 and U.S. Pat. No. 5,581,860 issued Dec. 10, 1996. While such clinching apparatus is capable of making excellent clinched joints, there are occasions when the joints are unacceptable, because, for example, the bottom of the joint button is too thin.
BRIEF DESCRIPTION OF THE INVENTION
The present invention provides a system for monitoring the performance of clinching apparatus of the type just described, for determining whether clinched joints are acceptable or unacceptable, and for determining whether wear of the punch and/or die is excessive.
To accomplish this, the invention monitors button diameter and amount of punch advancement in forming a joint, correlates acceptable values of each, indicates when an unacceptable joint has been produced, and indicates when wear of punch and/or die has become excessive.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further described in conjunction with the accompanying drawings, which illustrate preferred (best mode) embodiments, and wherein:
FIG. 1 is a diagrammatic view, partly in section, illustrating one embodiment of clinching apparatus with monitoring components;
FIG. 2 is a fragmentary enlarged sectional view showing a portion of the apparatus of FIG. 1 ;
FIG. 3 is a view similar to FIG. 2 , but illustrating different monitoring components;
FIG. 4 is a simplified block diagram of monitoring apparatus in accordance with the invention;
FIG. 5 is a flow chart showing the manner in which clinched joint monitoring can be performed in accordance with the invention; and
FIG. 6 is a similar flow chart for another embodiment.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 1 and 2 , a machine or apparatus suitable for implementing the invention may comprise a C-Frame, an Actuating Assembly (actuator) mounted on the C-Frame, a Forming Punch supported on the C-Frame for reciprocative movement in a Retaining Sleeve toward and away from a Joint Forming Die (see FIG. 2 ) and a Controller (see FIG. 4 ) preferably including a microprocessor. In one embodiment, the Actuating Assembly mounted on the C-Frame is powered by an electrical servo motor, and transfers rotational motion of a planetary roller screw into linear motion of the joint Forming Punch. U.S. Pat. No. 6,502,008 issued Dec. 31, 2002 discloses an example of an actuating assembly suitable for use in the present invention.
In the embodiment shown in FIGS. 1 and 2 , the control of button diameter utilizes a sensor device including individual proximity switch sensors that sense displacement of pivoting die segments (e.g. three die segments equally spaced circumferentially) that cooperate with the die anvil and the punch in forming a clinched joint by which work pieces (e.g., sheets of metal) are joined. The proximity switches, more generally sensors, sense displacement of the associated die segments. As shown in FIG. 4 , the controller (more particularly, the microprocessor thereof) receives information from the die segment sensor device and controls the punch actuator, which controls the movement of the punch. As the clinching process proceeds and the punch advances toward the die, the die segments are moved outwardly, i.e., laterally relative to the die anvil. When the button diameter reaches a predetermined size, the sensors will signal the microprocessor to stop the punch movement and to start to move the punch backwardly (i.e., retract the punch). FIG. 2 shows, in greater detail, the formation of the button by the cooperation of the punch, the die anvil and the die segments, which are biased inwardly toward the die anvil by springs or other resilient means between the die segments and a die retaining sleeve.
The microprocessor can be used to control the amount of punch movement toward the die, by, e.g., controlling the number of rotations of a servo motor which powers the actuator, in order to control the button bottom thickness. The processor can store information representative of a predetermined range of acceptable button bottom thickness. When the sensors controlling the button diameter, as described above, indicate that a desired button diameter has been reached, and the joint-forming movement of the punch is stopped, the number of rotations of the servo motor up to the time that the punch is stopped will indicate whether the button bottom thickness is within the desired range. As indicated in FIG. 4 , the punch actuator supplies such information to the controller. If the punch advances more than a predetermined amount in forming the button, meaning that the button bottom is too thin, this will indicate that the punch and/or the die are worn and need to be replaced.
Other types of actuators can be used to drive the punch. Sliding die segments can be used instead of pivoting die segments. Other types of sensors, e.g., strain gauges or load cells, can be used to sense displacement of the die segments. For example, FIG. 3 shows an embodiment in which a circular force (pressure) sensor is used to sense displacement of the die segments. The spring or springs used in each embodiment may be of any appropriate well-known type, such as coil springs, leaf springs, or wave springs. The sensor may be piezoelectric, for example. Appropriate displacement sensors can include electrical, magnetic, optical, mechanical, and electromechanical sensors, for example.
Software employed in a microprocessor of the controller can be designed so that actuation of any one sensor or any combination of sensors can be used to cut off the punch drive. Proximity switches have an on-off operating characteristic, but other sensors may have an operating characteristic that varies continuously or in discrete steps. Time delay between actuations of sensors can be used as a basis for control also. The need for punch/die replacement due to wear can depend upon a predetermined number of clinching cycles in which inappropriate button diameters and/or bottom thickness are detected.
The controller can store information representative of a predetermined range of acceptable button diameters, as well as information representative of a predetermined acceptable range of punch movement. If the punch has to move consistently (within a predetermined number of clinching cycles “X”) either more or less than the predetermined range of acceptable punch movement, for the button to reach its predetermined range of acceptable diameter, this will indicate that the punch and/or die are worn out, and that joints need to be examined.
FIG. 5 is a self-explanatory flowchart illustrating the manner in which a monitoring system of the invention can perform the functions just described. When a button is indicated to be “not o.k.” that joint can be checked individually, or joints can be checked as a group after a predetermined number of buttons have been indicated to be “not o.k.”.
In another embodiment, as shown in FIG. 6 , for example, instead of stopping punch advancement in response to the sensor device that determines button diameter and then determining joint acceptability by the amount of punch advancement, the controller can direct the actuator to advance the punch and then to stop when the punch advancement is within a predetermined range of acceptable punch advancement, and the output of the sensor device at that time can be used to determine whether the button is within a predetermined range, and hence whether the joint is acceptable. In this embodiment, a sensor device having outputs that vary continuously or in discrete steps is particularly appropriate for determining button diameter.
In general, the controller correlates the size of the button of the clinched joint with the amount of punch advancement in producing the joint and determines from such correlation whether the joint is acceptable.
While preferred embodiments of the invention have been shown and described, it will be apparent that modifications can be made without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims. For example, various described features of the invention can be used individually, or in different combinations of features, as may be desired. | A system and method for monitoring clinched joints senses lateral displacement of die segments during formation of a joint, which depends on joint button diameter. The system determines whether a joint is acceptable by correlating acceptable button diameter with acceptable amount of punch advancement. A predetermined number of unacceptable joints indicates excessive punch and/or die wear. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present invention is related to the following commonly assigned and U.S. application:
“A Produce data collector And A Produce Recognition System”, filed Nov. 10, 1998, invented by Gu, and having a Ser. No. 09/189,783.
BACKGROUND OF THE INVENTION
The present invention relates to product checkout devices and more specifically to a triggering method for a produce recognition system.
Bar code readers are well known for their usefulness in retail checkout and inventory control. Bar code readers are capable of identifying and recording most items during a typical transaction since most items are labeled with bar codes.
Items which are typically not identified and recorded by a bar code reader are produce items, since produce items are typically not labeled with bar codes. Bar code readers may include a scale for weighing produce items to assist in determining the price of such items. But identification of produce items is still a task for the checkout operator, who must identify a produce item and then manually enter an item identification code. Operator identification methods are slow and inefficient because they typically involve a visual comparison of a produce item with pictures of produce items, or a lookup of text in table. Operator identification methods are also prone to error, on the order of fifteen percent.
A produce recognition system is disclosed in the cited co-pending application. A produce item is placed over a window in a produce data collector, the produce item is illuminated, and the spectrum of the diffuse reflected light from the produce item is measured. A terminal compares the spectrum to reference spectra in a library to determine a list of candidate identifications.
The produce recognition system triggers illumination and data capture if ambient light levels fall below a threshold. This method works well under certain lighting conditions, but may not work well under other conditions, especially darker operating conditions. Operator intervention may be required if the produce data collector does not trigger when the produce item is first placed over the window of the produce data collector.
Therefore, it would be desirable to provide a triggering method which functions under a wider range of lighting conditions without operator intervention.
SUMMARY OF THE INVENTION
In accordance with the teachings of the present invention, a triggering method for a produce recognition system is provided.
The method includes the steps of obtaining first ambient light levels from an ambient light sensor of the produce data collector with a data collection aperture covered, obtaining second ambient light levels from the ambient light sensor with the data collection aperture uncovered, determining a threshold ambient light level from the first ambient light levels and a difference between the first and second ambient light levels, obtaining a third ambient light level from the ambient light sensor with a produce item adjacent the data collection aperture, comparing the third ambient light level to the threshold ambient light level, and capturing data associated with the produce item if the third ambient light level is less than the threshold ambient light level.
It is accordingly an object of the present invention to provide a triggering method for a produce recognition system.
It is another object of the present invention to provide a triggering method for a produce recognition system which works under a wide range of lighting conditions.
It is another object of the present invention to provide a triggering method for a produce recognition system which minimizes operator intervention.
It is another object of the present invention to provide a triggering method for a produce recognition system which dynamically adjusts the triggering threshold based upon ambient light level histories.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from the subsequent description of the preferred embodiments and the appended claims, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram of a transaction processing system including a produce recognition system;
FIG. 2 is a block diagram of a type of produce data collector; and
FIG. 3 is a flow diagram illustrating the produce recognition method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, transaction processing system 10 includes bar code data collector 12 , produce data collector 14 , and scale 16 .
Bar code data collector 12 reads bar code 22 on merchandise item 32 to obtain an item identification number, also know as a price look-up (PLU) number, associated with item 32 . Bar code data collector 12 may be any bar code data collector, including an optical bar code scanner which uses laser beams to read bar codes. Bar code data collector 12 may be located within a checkout counter or mounted on top of a checkout counter.
Produce data collector 14 collects data for produce item 18 . Such data may include color and color distribution data, size data, shape data, surface texture data, and aromatic data. Reference produce data is collected and stored within produce database 30 . During a transaction, produce data collector 14 is preferably self-activated upon a drop of ambient light.
Transaction terminal 20 and produce data collector 14 are the primary components of the produce recognition system.
Scale 16 determines a weight for produce item 18 . Scale 16 works in connection with bar code data collector 12 , but may be designed to operate and be mounted separately. Scale 16 sends weight information for produce item 18 to transaction terminal 20 so that transaction terminal 20 can determine a price for produce item 18 based upon the weight information.
Bar code data collector 12 and produce data collector 14 operate separately from each other, but may be integrated together. Bar code data collector 12 works in conjunction with transaction terminal 20 and transaction server 24 . Scale 16 may also work in connection with bar code data collector 12 , but may be designed to operate and be mounted separately.
Storage medium 26 preferably includes one or more hard disk drives. Produce database 30 is preferably stored within storage medium 26 , but may also be located instead at transaction terminal 20 in storage medium 38 . PLU data file 28 is stored within storage medium 26 , but may be located instead at transaction terminal 20 in storage medium 38 or within the memory of bar code data collector 12 .
Display 34 and input device 36 may be part of a touch screen or located separately.
In the case of bar coded items, transaction terminal 20 obtains the item identification number from bar code data collector 12 and retrieves a corresponding price from PLU data file 28 through transaction server 24 .
In the case of non-bar coded produce items, transaction terminal 20 executes produce recognition software 21 which obtains produce characteristics of produce item 18 from produce data collector 14 , identifies produce item 18 by comparing produce data in produce database 30 with collected produce data, and retrieves an item identification number from produce database 30 and passes it to transaction software 25 , which obtains a corresponding price from PLU data file 28 .
In an alternative embodiment, preliminary identification of produce item 18 may be handled by transaction server 24 . Transaction server 24 receives collected produce characteristics and compares them with produce data in produce database 30 . Transaction server 24 provides a candidate list to transaction terminal 20 for display and final selection. Following identification, transaction server 24 obtains a price for produce item 18 and forwards it to transaction terminal 20 .
To assist in proper identification of produce items, produce recognition software 21 additionally displays a number of candidate identifications for operator selection and verification. Produce recognition software 21 preferably arranges the candidate identifications in terms of probability of match and displays their images in predetermined locations on operator display 34 of transaction terminal 20 . The operator may accept the most likely candidate returned by produce recognition software 21 or override it with a different choice using input device 36 .
Turning now to FIG. 2, an example produce data collector 14 which relies on spectroscopic analysis is illustrated. Other types of produce data collectors are also envisioned.
Example produce data collector 14 primarily includes light source 40 , spectrometer 51 , control circuitry 56 , transparent window 60 , and housing 62 .
Light source 40 produces light 70 . Light source 40 preferably produces a white light spectral distribution, and preferably has a range from four hundred 400 nm to 700 nm, which corresponds to the visible wavelength region of light.
Light source 40 preferably includes one or more light emitting diodes (LEDs). A broad-spectrum white light producing LED, such as the one manufactured by Nichia Chemical Industries, Ltd., is preferably employed because of its long life, low power consumption, fast turn-on time, low operating temperature, good directivity. Alternate embodiments include additional LEDs having different colors in narrower wavelength ranges and which are preferably used in combination with the broad-spectrum white light LED to even out variations in the spectral distribution and supplement the spectrum of the broad-spectrum white light LED.
Other types of light sources 40 are also envisioned by the present invention, although they may be less advantageous than the broad spectrum white LED. For example, a tungsten-halogen light may be used because of its broad spectrum, but produces more heat.
A plurality of different-colored LEDs having different non-overlapping wavelength ranges may be employed, but may provide less than desirable collector performance if gaps exist in the overall spectral distribution.
Ambient light sensor 48 senses the level of ambient light through windows 60 and 61 and sends ambient light level signals 81 to control circuitry 56 . Ambient light sensor 48 is mounted anywhere within a direct view of window 61 .
Spectrometer 51 includes light separating element 52 and photodetector array 54 .
Light separating element 52 splits light 76 in the preferred embodiment into light 80 of a continuous band of wavelengths. Light separating element 52 is preferably a linear variable filter (LVF), such as the one manufactured by Optical Coating Laboratory, Inc., or may be any other functionally equivalent component, such as a prism or a grating.
Photodetector array 54 produces waveform signals 82 containing spectral data. The pixels of the array spatially sample the continuous band of wavelengths produced by light separating element 52 , and produce a set of discrete signal levels. Photodetector array 54 is preferably a complimentary metal oxide semiconductor (CMOS) array, but could be a Charge Coupled Device (CCD) array.
Control circuitry 56 controls operation of produce data collector 14 . Control circuitry 56 produces digitized produce data waveform signals 84 . Control circuitry 56 compares ambient light level readings from ambient light sensor 48 with the threshold and triggers operation when the ambient light level readings are lower than the ambient light level threshold. Control circuitry 56 includes an analog-to-digital (A/D) converter. A twelve bit A/D converter with a sampling rate of 22-44 kHz produces acceptable results.
Control circuitry 56 also controls triggering of light source 40 and capture of analog produce data signals 82 from spectrometer 51 , although produce recognition software 21 may alternatively handle this task. Control circuitry 56 uses an ambient light threshold stored within memory 58 by produce recognition software 21 . Control circuitry 56 collects ambient light levels during operation, i.e., when produce item 18 is over produce data collector 14 and when produce item 18 is not over produce data collector 14 .
Produce recognition software 21 stores light level information in ambient light level data file 39 , which is preferably stored in storage medium 38 . Produce recognition software 21 determines average light and dark levels from the light level information and programs control circuitry 56 with a threshold ambient light level between the light and dark levels so that control circuitry 56 may properly trigger illumination and data capture. Produce recognition software 21 may automatically update the ambient light level threshold on a regular basis.
Transparent window 60 is mounted above auxiliary transparent window 61 . Windows 60 and 61 include an anti-reflective surface coating to prevent light 72 reflected from windows 60 and 61 from contaminating reflected light 74 .
Housing 62 contains light source 40 , ambient light sensor 48 , spectrometer 51 , photodetector array 54 , control circuitry 56 , auxiliary transparent window 61 , and transparent window 60 .
Turning now to FIG. 3, the triggering method of the present invention begins with START 90 .
In step 92 , produce recognition software 21 collects light and dark ambient light levels. The light levels are taken with nothing over window 60 and light source 40 off. The dark levels are taken with a reference over window 60 and light source 40 off. A suitable reference is a white piece of plastic which completely covers window 60 so as to block ambient light from entering window 60 .
Due to the constraint of storage space in produce data collector 14 , the most effective method of storing the history of dark and light levels has proven to be the weighted average method as described below. The current average A t of the recent dark levels is computed using:
A t =(1 −k ) A t−1 +kD t ,
where t denotes the current sampling time, D t is the current measure of dark level, and constant k is a tunable number between 0 and 1. Constant k can be considered as a “forgetting factor” which controls how fast the history is forgotten in computing the average. The larger the value of k, the quicker the history is forgotten. In reality, k is tuned to an optimal value by experimentation.
Likewise, the current average B t of recent light levels is computed using the same method, while substituting the current dark level D t with the light level L t :
B t =(1 −k ) B t−1 +kL t .
In step 94 , produce recognition software 21 stores the light and dark ambient light levels in ambient light level data file 39 .
In step 96 , produce recognition software 21 determines a threshold from the light and dark ambient light levels and stores the threshold in memory 58 . The triggering threshold T t is then determined from the current average of dark and light levels as follows:
T t =A t +p ( B t −A t ),
where p is a weight or tunable value between 0 and 1.
In step 98 , control circuitry 56 monitors ambient light levels from ambient light sensor 48 .
In step 100 , control circuitry 56 waits for ambient light levels to fall below the threshold in memory 58 . If they do, operation proceeds to step 102 .
In step 102 , control circuitry 56 turns on light source 40 and begins processing of data from spectrometer 51 . The method ends in step 104 .
Produce recognition software 21 obtains digital produce data from control circuitry 56 and determines a list of candidate identifications from produce database 30 . Produce recognition software 21 additionally displays a number of the candidate identifications on display 34 for operator verification and selection using input device 36 .
Transaction terminal 20 uses the identification information to obtain a unit price for produce item 18 from transaction server 24 . Transaction terminal 20 then determines a total price by multiplying the unit price by weight information from scale 16 .
Although the invention has been described with particular reference to certain preferred embodiments thereof, variations and modifications of the present invention can be effected within the spirit and scope of the following claims. | A triggering method for a produce recognition system which uses historical ambient light level readings. The method includes the steps of obtaining first ambient light levels from an ambient light sensor of the produce data collector with a data collection aperture covered, obtaining second ambient light levels from the ambient light sensor with the data collection aperture uncovered, determining a threshold ambient light level from the first ambient light levels and a difference between the first and second ambient light levels, obtaining a third ambient light level from the ambient light sensor with a produce item adjacent the data collection aperture, comparing the third ambient light level to the threshold ambient light level, and capturing data associated with the produce item if the third ambient light level is less than the threshold ambient light level. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present invention is a continuation of PCT/JP2013/059656, filed Mar. 29, 2013, which claims priority to Japanese Application No. 2012-079858, filed Mar. 30, 2012, both of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to low molecular weight compounds having an erythropoietin production-enhancing activity.
BACKGROUND ART
[0003] Erythropoietin (hereinafter abbreviated as EPO) is a glycoprotein hormone that is essential for erythrocyte hematopoiesis. It is normally secreted from the kidneys and promotes production of erythrocytes by acting on erythrocyte stem cells present in bone marrow. In diseases presenting with a decrease in intrinsic EPO production (such as chronic renal failure), since erythrocyte production decreases and symptoms of anemia are exhibited, treatment is provided in the form of replacement therapy using gene-recombinant human EPO. However, this gene-recombinant human EPO has been indicated as having shortcomings such as being a biological preparation and associated with expensive health care costs, having poor convenience due to being an injection and having antigenicity.
[0004] On the other hand, for example, pyrazole derivatives substituted at the 4-position with a carboxy group (see Non Patent Document 1), 3-pyrazolone derivatives substituted at the 4-position with an aromatic heterocyclic group (see Patent Documents 1 to 6), and 4,5-fused 3-pyrazolone derivatives (Patent Document 7), are known to be low molecular weight EPO inducers. 3-pyrazolone derivatives substituted at the 4-position with an alkanoylamino group have not yet been known.
CITATION LIST
Patent Documents
Patent Document 1: German Patent Application Publication No. 10 2007 044 032
Patent Document 2: U.S. Patent Application Publication No. 2009/0269420
Patent Document 3: U.S. Patent Application Publication No. 2010/0035906
Patent Document 4: U.S. Patent Application Publication No. 2010/0093803
Patent Document 5: U.S. Patent Application Publication No. 2010/0305085
Patent Document 6: U.S. Patent Application Publication No. 2011/0294788
Patent Document 7: U.S. Patent Application Publication No. 2011/0301148
Non Patent Document
Non Patent Document 1: Bioorganic & Medicinal Chemistry Letters, 2006, Vol. 16, p. 5687-5690
SUMMARY OF INVENTION
Technical Problem of the Invention
[0005] The inventors of the present invention conducted studies for the purpose of providing novel low molecular weight compounds that have a superior EPO production-enhancing activity and that are useful for the treatment of diseases caused by decreased EPO, and for the purpose of providing a medicament containing such compounds.
Means for Solution to the Problem
[0006] In order to solve the aforementioned problems, the inventors of the present invention found that novel compounds having a 4-alkanoylamino-3-pyrazolone structure have a superior EPO production-enhancing activity and that they are effective for treating diseases caused by decreased EPO, thereby leading to completion of the present invention.
[0007] According to the present invention, novel 4-alkanoylamino-3-pyrazolone compounds represented by the following general formula (1) or pharmacologically acceptable salts thereof (hereinafter collectively referred to as compounds of the present invention), are provided.
[0008] Specifically, the present invention provides:
[0000] (1) a compound represented by the following general formula (1):
[0000]
[0000] or a pharmacologically acceptable salt thereof,
wherein
[0009] R 1 represents a group represented by -Q 1 , -Q 1 -X-Q 2 , or -Q 1 -X-Q 2 -Y-Q 3 ;
[0010] Q 1 represents a monocyclic or bicyclic aromatic heterocyclic group which may have 1 or 2 substituents independently selected from substituent group α;
[0011] substituent group α represents the group consisting of a halogen atom, a C 1 -C 6 alkyl group, a halo C 1 -C 6 alkyl group, a C 1 -C 6 alkoxy group, a C 3 -C 7 cycloalkyl group, and a 4- to 7-membered heterocycloalkyl group;
[0012] Q 2 represents an aromatic hydrocarbon ring group which may have 1 or 2 substituents independently selected from substituent group β, or a monocyclic aromatic heterocyclic group which may have 1 or 2 substituents independently selected from substituent group β;
[0013] substituent group β represents the group consisting of a halogen atom, a C 1 -C 6 alkyl group, a halo C 1 -C 6 alkyl group, a C 1 -C 6 alkoxy group, a C 3 -C 7 cycloalkyl group, and a cyano group;
[0014] Q 3 represents an aromatic hydrocarbon ring group which may have 1 or 2 substituents independently selected from substituent group γ, or a monocyclic aromatic heterocyclic group which may have 1 or 2 substituents independently selected from substituent group γ;
[0015] substituent group γ represents the group consisting of a halogen atom, a C 1 -C 6 alkyl group, a halo C 1 -C 6 alkyl group, a C 1 -C 6 alkoxy group, a C 3 -C 7 cycloalkyl group, and a cyano group;
[0016] X represents a single bond, —(CH 2 ) n —, —CH═CH—, —CONH—, —NHCO—, —CONHCH 2 —, —NHCOCH 2 —, —CH 2 NHCO—, —CH 2 CONH—, —SO 2 NH—, —CH 2 OCH 2 —, or —NHCH 2 CH 2 —;
[0017] Y represents a single bond, —O—, —(CH 2 ) n —, or —O—(CH 2 ) n —;
[0018] m and n each independently represents an integer from 1 to 3;
[0019] R 2 represents a hydrogen atom or a C 1 -C 6 alkyl group; and
[0020] R 3 represents a hydrogen atom, a C 1 -C 6 alkoxycarbonyl group, a carboxy group, an aromatic hydrocarbon ring group, or a monocyclic aromatic heterocyclic group,
[0000] (2) a compound or a pharmacologically acceptable salt thereof according to (1), wherein R 2 is a hydrogen atom or a methyl group,
(3) a compound or a pharmacologically acceptable salt thereof according to (1) or (2), wherein R 3 is a hydrogen atom, a methoxycarbonyl group, an ethoxycarbonyl group, a propoxycarbonyl group, a tert-butoxycarbonyl group, a carboxy group, a phenyl group, or a pyridyl group,
(4) a compound or a pharmacologically acceptable salt thereof according to (1) or (2), wherein R 3 is a hydrogen atom, a tert-butoxycarbonyl group, or a carboxy group,
(5) a compound or a pharmacologically acceptable salt thereof according to (1) or (2), wherein R 3 is a hydrogen atom,
(6) a compound or a pharmacologically acceptable salt thereof according to any one of (1) to (5), wherein m is 1 or 2,
(7) a compound or a pharmacologically acceptable salt thereof according to any one of (1) to (6), wherein
[0021] R 1 is a group represented by -Q 1 , and
[0022] Q 1 is a pyridyl group, a pyrimidinyl group, a pyrazinyl group, a pyridazinyl group, a quinolyl group, an isoquinolyl group, or a quinazolinyl group which may have 1 or 2 substituents independently selected from substituent group α,
[0000] (8) a compound or a pharmacologically acceptable salt thereof according to any one of (1) to (6), wherein
[0023] R 1 is a group represented by -Q 1 , and
[0024] Q 1 is a pyridyl group or a pyrimidinyl group which may have 1 or 2 substituents independently selected from substituent group α,
[0000] (9) a compound or a pharmacologically acceptable salt thereof according to (7) or (8), wherein the substituent group α is the group consisting of a fluorine atom, a chlorine atom, a bromine atom, a methyl group, a methoxy group, a morpholinyl group, and a piperidinyl group,
(10) a compound or a pharmacologically acceptable salt thereof according to (7) or (8), wherein the substituent group α is the group consisting of a morpholinyl group and a piperidinyl group,
(11) a compound or a pharmacologically acceptable salt thereof according to any one of (1) to (6), wherein
[0025] R 1 is a group represented by -Q 1 -X-Q 2 or -Q 1 -X-Q 2 -Y-Q 3 , and
[0026] Q 1 is a pyridyl group, a pyrimidinyl group, a pyrazinyl group, a pyridazinyl group, a quinolyl group, an isoquinolyl group, or a quinazolinyl group which may have 1 or 2 substituents independently selected from substituent group α,
[0000] (12) a compound or a pharmacologically acceptable salt thereof according to any one of (1) to (6), wherein
[0027] R 1 is a group represented by -Q 1 -X-Q 2 or -Q 1 -X-Q 2 -Y-Q 3 , and
[0028] Q 1 is a pyridyl group or a pyrimidinyl group which may have 1 or 2 substituents independently selected from substituent group α,
[0000] (13) a compound or a pharmacologically acceptable salt thereof according to (11) or (12), wherein the substituent group α is the group consisting of a fluorine atom, a chlorine atom, a methyl group, and a methoxy group,
(14) a compound or a pharmacologically acceptable salt thereof according to any one of (11) to (13), wherein Q 2 is a phenyl group, a pyridyl group, a pyrimidinyl group, a pyrazinyl group, or a pyridazinyl group which may have 1 or 2 substituents independently selected from substituent group β,
(15) a compound or a pharmacologically acceptable salt thereof according to any one of (11) to (13), wherein Q 2 is a phenyl group or a pyridyl group which may have 1 or 2 substituents independently selected from substituent group β,
(16) a compound or a pharmacologically acceptable salt thereof according to (14) or (15), wherein the substituent group β is the group consisting of a fluorine atom, a chlorine atom, a bromine atom, a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, an isobutyl group, a sec-butyl group, a tert-butyl group, a trifluoromethyl group, a cyclohexyl group, and a cyano group,
(17) a compound or a pharmacologically acceptable salt thereof according to (14) or (15), wherein the substituent group β is the group consisting of a chlorine atom, a bromine atom, a tert-butyl group, a trifluoromethyl group, and a cyclohexyl group,
(18) a compound or a pharmacologically acceptable salt thereof according to any one of (11) to (17), wherein X is —CH 2 —, —CH 2 CH 2 —, —CH═CH—, —CONH—, —CONHCH 2 —, —CH 2 OCH 2 —, or —NHCH 2 CH 2 —,
(19) a compound or a pharmacologically acceptable salt thereof according to any one of (11) to (17), wherein X is —CH 2 —, —CH 2 CH 2 —, —CONH—, —CONHCH 2 —, or —CH 2 OCH 2 —,
(20) a compound or a pharmacologically acceptable salt thereof according to any one of (11) to (19), wherein
[0029] R 1 is a group represented by -Q 1 -X-Q 2 -Y-Q 3 , and
[0030] Q 3 is a phenyl group, a pyridyl group, a pyrimidinyl group, a pyrazinyl group, or a pyridazinyl group which may have 1 or 2 substituents independently selected from substituent group γ,
[0000] (21) a compound or a pharmacologically acceptable salt thereof according to any one of (11) to (19), wherein
[0031] R 1 is a group represented by -Q 1 -X-Q 2 -Y-Q 3 , and
[0032] Q 3 is a phenyl group or a pyridyl group which may have 1 or 2 substituents independently selected from substituent group γ,
[0000] (22) a compound or a pharmacologically acceptable salt thereof according to (20) or (21), wherein the substituent group γ is the group consisting of a fluorine atom, a chlorine atom, a bromine atom, a methyl group, an ethyl group, a propyl group, an isopropyl group, a trifluoromethyl group, and a cyano group,
(23) a compound or a pharmacologically acceptable salt thereof according to (20) or (21), wherein the substituent group γ is the group consisting of a chlorine atom, a bromine atom, a trifluoromethyl group, and a cyano group,
(24) a compound or a pharmacologically acceptable salt thereof according to any one of (11) to (23), wherein Y is a single bond or —O—,
(25) a compound or a pharmacologically acceptable salt thereof according to (1), selected from the following:
6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-cyclohexylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(3-tert-butylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[4-(trifluoromethyl)phenyl]nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-chlorophenyl)nicotinamide, N-[2-(6-morpholin-4-ylpyrimidin-4-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-[3-oxo-2-(6-piperidin-1-ylpyrimidin-4-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-(2-{5-[(benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-(3-oxo-2-{6-[(2-phenylethyl)amino]pyrimidin-4-yl}-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-(2-{4-[(benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(biphenyl-3-ylmethyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[(2′-cyanobiphenyl-4-ylmethyl)]nicotinamide, N-[2-(5-{[(2′-cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-(2-{5-[(biphenyl-4-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-(2-{5-[(biphenyl-3-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[4-(trifluoromethyl)phenyl]nicotinamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-chlorophenyl)nicotinamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-bromophenyl)nicotinamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(6-phenylpyridin-3-yl)nicotinamide, N-[2-(5-{[(2′-cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-5-methyl-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, tert-butyl 4-[(5-methyl-3-oxo-2-{5-[(6-phenylpyridyl-3-yl)carbamoyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)amino]-4-oxobutanoate, 4-[(5-methyl-3-oxo-2-{5-[(6-phenylpyridyl-3-yl)carbamoyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)amino]-4-oxobutanoic acid, N-{5-methyl-3-oxo-2-[5-({[4-(trifluoromethyl)benzyl]oxy}methyl)pyridin-2-yl]-2,3-dihydro-1H-pyrazol-4-yl}acetamide, N-(5-methyl-3-oxo-2-{5-[4-(trifluoromethyl)benzyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-[5-methyl-3-oxo-2-(5-{2-[4-(trifluoromethyl)phenyl]ethyl}pyridin-2-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide, and N-[5-methyl-3-oxo-2-(5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridin-2-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide,
(26) a compound or a pharmacologically acceptable salt thereof according to (1), selected from the following:
6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-cyclohexylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(3-tert-butylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[4-(trifluoromethyl)phenyl]nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-chlorophenyl)nicotinamide,
[0065] N-[2-(6-morpholin-4-ylpyrimidin-4-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide,
[0066] N-[3-oxo-2-(6-piperidin-1-ylpyrimidin-4-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide,
[0067] N-(2-{5-[(benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide,
[0068] N-(2-{4-[(benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide,
6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(biphenyl-3-ylmethyl)nicotinamide, N-[2-(5-{[(2′-cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-(2-{5-[(biphenyl-4-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-(2-{5-[(biphenyl-3-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide, N-[2-(5-{[(2′-cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-5-methyl-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-{5-methyl-3-oxo-2-[5-({[4-(trifluoromethyl)benzyl]oxy}methyl)pyridin-2-yl]-2,3-dihydro-1H-pyrazol-4-yl}acetamide, N-(5-methyl-3-oxo-2-{5-[4-(trifluoromethyl)benzyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)acetamide, and N-[5-methyl-3-oxo-2-(5-{2-[4-(trifluoromethyl)phenyl]ethyl}pyridin-2-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide,
(27) a pharmaceutical composition containing as an active ingredient a compound or a pharmacologically acceptable salt thereof according to any one of (1) to (26) above,
(28) a pharmaceutical composition according to (27) above, for the prophylaxis and/or treatment of anemia,
(29) a pharmaceutical composition according to (28) above, wherein the anemia is nephrogenic anemia, anemia of prematurity, anemia incidental to chronic diseases, anemia incidental to cancer chemotherapy, cancerous anemia, inflammation-associated anemia, or anemia incidental to congestive heart failure,
(30) a pharmaceutical composition according to (28) above, wherein the anemia is anemia incidental to chronic kidney disease,
(31) a pharmaceutical composition according to (27) above, for producing erythropoietin,
(32) use of a compound or a pharmacologically acceptable salt thereof according to any one of (1) to (26) above, for producing a medicament,
(33) use according to (32) above, wherein the medicament is a medicament for the prophylaxis and/or treatment of anemia,
(34) use according to (33) above, wherein the anemia is nephrogenic anemia, anemia of prematurity, anemia incidental to chronic diseases, anemia incidental to cancer chemotherapy, cancerous anemia, inflammation-associated anemia, or anemia incidental to congestive heart failure,
(35) use according to (33) above, wherein the anemia is anemia incidental to chronic kidney disease,
(36) a method for producing erythropoietin, comprising: administering a pharmacologically effective amount of a compound or a pharmacologically acceptable salt thereof according to any one of (1) to (26) above to a mammal or bird,
(37) a method for the prophylaxis and/or treatment of a disease, comprising: administering a pharmacologically effective amount of a compound or a pharmacologically acceptable salt thereof according to any one of (1) to (26) above to a mammal,
(38) a method according to (37) above, wherein the disease is anemia,
(39) a method according to (37) above, wherein the disease is nephrogenic anemia, anemia of prematurity, anemia incidental to chronic diseases, anemia incidental to cancer chemotherapy, cancerous anemia, inflammation-associated anemia, or anemia incidental to congestive heart failure,
(40) a method according to (37) above, wherein the disease is anemia incidental to chronic kidney disease,
(41) a method according to any one of (37) to (40) above, wherein the mammal is a human,
(42) a compound or a pharmacologically acceptable salt thereof according to any one of (1) to (26) above, for use in a method for the treatment or prophylaxis of a disease,
(43) a compound or a pharmacologically acceptable salt thereof according to (42) above, wherein the disease is anemia,
(44) a compound or a pharmacologically acceptable salt thereof according to (42) above, wherein the disease is nephrogenic anemia, anemia of prematurity, anemia incidental to chronic diseases, anemia incidental to cancer chemotherapy, cancerous anemia, inflammation-associated anemia, or anemia incidental to congestive heart failure, and
(45) a compound or a pharmacologically acceptable salt thereof according to (42) above, wherein the disease is anemia incidental to chronic kidney disease.
[0078] The compounds of the present invention represented by the aforementioned general formula (1) have a 4-alkanoylamino-3-pyrazolone skeleton. A substituent at the 2-position of the pyrazolone ring has 1 to 4 cyclic groups, and these cyclic groups have a specific substituent. The compounds of the present invention or pharmacologically acceptable salts thereof have a superior EPO production-enhancing activity.
[0079] The following provides an explanation of substituents in the compounds of the present invention.
[0080] A “halogen atom” in the definitions of substituent group α, substituent group β, and substituent group γ refers to a fluorine atom, a chlorine atom, a bromine atom, or an iodine atom, preferably a chlorine atom or a bromine atom.
[0081] A “C 1 -C 6 alkyl group” in the definitions of substituent group α, substituent group β, substituent group γ, and R 2 refers to a straight or branched chain alkyl group having 1 to 6 carbon atoms. Examples include a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, an isobutyl group, a sec-butyl group, a tert-butyl group, a pentyl group, an isopentyl group, a 2-methylbutyl group, a neopentyl group, a 1-ethylpropyl group, a hexyl group, a 4-methylpentyl group, a 3-methylpentyl group, a 2-methylpentyl group, a 1-methylpentyl group, a 3,3-dimethylbutyl group, a 2,2-dimethylbutyl group, a 1,1-dimethylbutyl group, a 1,2-dimethylbutyl group, a 1,3-dimethylbutyl group, a 2,3-dimethylbutyl group, and a 2-ethylbutyl group. The C 1 -C 6 alkyl group in substituent group α, substituent group β, and substituent group γ is preferably a tert-butyl group. The C 1 -C 6 alkyl group in R 2 is preferably a methyl group.
[0082] A “halo C 1 -C 6 alkyl group” in the definitions of substituent group α, substituent group β, and substituent group γ refers to a group in which 1 to 7 hydrogen atoms on the carbon atom(s) of a straight or branched chain alkyl group having 1 to 6 carbon atoms are replaced with aforementioned “halogen atom(s)”. Examples include a fluoromethyl group, a chloromethyl group, a bromomethyl group, a difluoromethyl group, a dichloromethyl group, a dibromomethyl group, a trifluoromethyl group, a trichloromethyl group, a tribromomethyl group, a 2,2,2-trifluoroethyl group, a 2,2,2-trichloroethyl group, a 2-fluoroethyl group, a 2-chloroethyl group, a 2-bromoethyl group, a 2-iodoethyl group, a 3-chloropropyl group, a 4-fluorobutyl group, a 6-iodohexyl group, and a 2,2-dibromoethyl group. The halo C 1 -C 6 alkyl group is preferably a trifluoromethyl group.
[0083] A “C 1 -C 6 alkoxy group” in the definitions of substituent group α, substituent group β, and substituent group γ refers to a group in which an aforementioned “C 1 -C 6 alkyl group” is bonded to an oxygen atom. Examples include a methoxy group, an ethoxy group, a propoxy group, an isopropoxy group, a butoxy group, an isobutoxy group, a sec-butoxy group, a tert-butoxy group, a pentyloxy group, an isopentyloxy group, a 2-methylbutoxy group, a neopentyloxy group, a 1-ethylpropoxy group, a hexyloxy group, a 4-methylpentyloxy group, a 3-methylpentyloxy group, a 2-methylpentyloxy group, a 1-methylpentyloxy group, a 3,3-dimethylbutoxy group, a 2,2-dimethylbutoxy group, a 1,1-dimethylbutoxy group, a 1,2-dimethylbutoxy group, a 1,3-dimethylbutoxy group, a 2,3-dimethylbutoxy group, and a 2-ethylbutoxy group. The C 1 -C 6 alkoxy group is preferably a methoxy group.
[0084] A “C 1 -C 6 alkoxycarbonyl group” in the definition of R 3 refers to a group in which an aforementioned “C 1 -C 6 alkoxy group” is bonded to a carbonyl group. Examples include a methoxycarbonyl group, an ethoxycarbonyl group, a propoxycarbonyl group, an isopropoxycarbonyl group, a butoxycarbonyl group, an isobutoxycarbonyl group, a sec-butoxycarbonyl group, a tert-butoxycarbonyl group, a pentyloxycarbonyl group, an isopentyloxycarbonyl group, a 2-methylbutoxycarbonyl group, a neopentyloxycarbonyl group, a 1-ethylpropoxycarbonyl group, a hexyloxycarbonyl group, a 4-methylpentyloxycarbonyl group, a 3-methylpentyloxycarbonyl group, a 2-methylpentyloxycarbonyl group, a 1-methylpentyloxycarbonyl group, a 3,3-dimethylbutoxycarbonyl group, a 2,2-dimethylbutoxycarbonyl group, a 1,1-dimethylbutoxycarbonyl group, a 1,2-dimethylbutoxycarbonyl group, a 1,3-dimethylbutoxycarbonyl group, a 2,3-dimethylbutoxycarbonyl group, and a 2-ethylbutoxycarbonyl group. The C 1 -C 6 alkoxycarbonyl group is preferably a tert-butoxycarbonyl group.
[0085] A “C 3 -C 7 cycloalkyl group” in the definitions of substituent group α, substituent group β, and substituent group γ refers to a cycloalkyl group having 3 to 7 carbon atoms. Examples include a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a cyclohexyl group, and a cycloheptyl group. The C 3 -C 7 cycloalkyl group is preferably a cyclohexyl group.
[0086] A “4- to 7-membered heterocycloalkyl group” in the definition of substituent group α refers to a monocyclic non-aromatic heterocyclic group composed of a saturated, partially unsaturated, or unsaturated 4- to 7-membered ring containing 1 or 2 atoms selected from the group consisting of a nitrogen atom, an oxygen atom, and a sulfur atom. Examples include a tetrahydrofuranyl group, a tetrahydropyranyl group, a dioxolanyl group, a dioxanyl group, a dioxepanyl group, a pyrrolidinyl group, a piperidyl group, an azepanyl group, a dihydropyrrolyl group, a dihydropyridyl group, a tetrahydropyridyl group, a piperazinyl group, a morpholinyl group, a dihydrooxazolyl group, and a dihydrothiazolyl group. The 4- to 7-membered heterocycloalkyl group is preferably a morpholinyl group or a piperidinyl group.
[0087] A “monocyclic aromatic heterocyclic group” in the definitions of Q 1 , Q 2 , and Q 3 refers to a 5- to 7-membered monocyclic aromatic heterocyclic group containing 1 or 2 atoms selected from the group consisting of a nitrogen atom, an oxygen atom, and a sulfur atom. Examples include a pyrrolyl group, a pyridyl group, a thienyl group, a furyl group, a pyrimidinyl group, a pyranyl group, a pyridazinyl group, a pyrazinyl group, a pyrazolyl group, an imidazolyl group, a thiazolyl group, an isothiazolyl group, an oxazolyl group, and an isooxazolyl group. The monocyclic aromatic heterocyclic group in Q 1 is preferably a pyridyl group, a pyrimidinyl group, a pyrazinyl group, or a pyridazinyl group, more preferably a pyridyl group or a pyrimidinyl group. The monocyclic aromatic heterocyclic group in Q 2 and Q 3 is preferably a pyridyl group, a pyrimidinyl group, a pyrazinyl group, or a pyridazinyl group, more preferably a pyridyl group.
[0088] A “bicyclic aromatic heterocyclic group” in the definition of Q 1 refers to an aromatic heterocyclic group in which an aforementioned “monocyclic aromatic heterocyclic group” is fused with another cyclic group such as a benzene ring. Examples include a quinolyl group, an isoquinolyl group, a quinazolinyl group, a chromanyl group, an isochromanyl group, a benzofuranyl group, a dihydrobenzofuranyl group, a benzothiophenyl group, a dihydrobenzothiophenyl group, an indolyl group, an isoindolyl group, a quinoxalinyl group, a benzothiazolyl group, a tetrahydroquinolyl group, a tetrahydroisoquinolyl group, a benzoxazolyl group, a benzoxanyl group, an indolizinyl group, a thienopyridyl group, a dihydrothienopyridyl group, a furopyridyl group, a dihydrofuropyridyl group, a benzimidazolyl group, a benzothienyl group, an isobenzofuranyl group, and an indolinyl group. The bicyclic aromatic heterocyclic group is preferably a quinolyl group, an isoquinolyl group, or a quinazolinyl group.
[0089] An “aromatic hydrocarbon ring group” in the definitions of Q 2 , Q 3 , and R 3 refers to a monocyclic or bicyclic aromatic hydrocarbon ring group having 6 to 10 carbon atoms. Examples include a phenyl group, an indenyl group, a naphthyl group, an azulenyl group, a heptalenyl group, a cyclopentacyclooctenyl group, and a benzocyclooctenyl group. The aromatic hydrocarbon ring group is preferably a phenyl group.
[0090] In the compounds of the present invention, R 1 represents a group represented by -Q 1 , -Q 1 -X-Q 2 , or -Q 1 -X-Q 2 -Y-Q 3 .
[0091] In the case where R 1 represents a group represented by -Q 1 -X-Q 2 or -Q 1 -X-Q 2 -Y-Q 3 , Q 1 and Q 2 may each be a divalent substituent, which is however indicated herein in the form of a monovalent substituent.
[0092] In the case where R 1 represents a group represented by -Q 1 -X-Q 2 or -Q 1 -X-Q 2 -Y-Q 3 , the substitution position of the group-X— Q 2 or the group —X-Q 2 -Y-Q 3 on Q 1 is explained hereinafter.
[0093] In the case where Q 1 is a 5-membered ring and the position of an atom bonded to X is defined as the 1-position, the substitution position of the group —X-Q 2 or the group —X-Q 2 -Y-Q 3 is preferably the 3- or 4-position.
[0094] In the case where Q 1 is a 6-membered ring and the position of an atom bonded to X is defined as the 1-position, the substitution position of the group —X-Q 2 or the group —X-Q 2 -Y-Q 3 is preferably the 3- or 4-position.
[0095] In the case where Q 1 is a 7-membered ring and the position of an atom bonded to X is defined as the 1-position, the substitution position of the group —X-Q 2 or the group —X-Q 2 -Y-Q 3 is preferably the 4- or 5-position.
[0096] In the case where Q 1 is, for example, a pyridyl group, the substitution position of the group —X-Q 2 or the group —X-Q 2 -Y-Q 3 is preferably a substitution position as described below.
[0000]
[0097] In the case where Q 1 is, for example, a pyrimidinyl group, the substitution position of the group —X-Q 2 or the group —X-Q 2 -Y-Q 3 is preferably a substitution position as described below.
[0000]
[0098] Q 1 in the present invention is preferably a pyridyl group, a pyrimidinyl group, a pyrazinyl group, a pyridazinyl group, a quinolyl group, an isoquinolyl group, or a quinazolinyl group which may have 1 or 2 substituents independently selected from substituent group α, more preferably a pyridyl group or a pyrimidinyl group which may have 1 or 2 substituents independently selected from substituent group α.
[0099] The substituent group α in the present invention is preferably the group consisting of a fluorine atom, a chlorine atom, a bromine atom, a methyl group, a methoxy group, a morpholinyl group, and a piperidinyl group. In the case where R 1 represents a group represented by -Q 1 , the substituent group α is preferably the group consisting of a morpholinyl group and a piperidinyl group. In the case where R 1 represents a group represented by -Q 1 -X-Q 2 or -Q 1 -X-Q 2 -Y-Q 3 , the substituent group α is preferably the group consisting of a fluorine atom, a chlorine atom, a methyl group, and a methoxy group.
[0100] X in the present invention preferably represents a single bond, —(CH 2 ) n —, —CH═CH—, —CONH—, —NHCO—, —CONHCH 2 —, —NHCOCH 2 —, —CH 2 NHCO—, —CH 2 CONH—, —SO 2 NH—, —CH 2 OCH 2 —, or —NHCH 2 CH 2 — and is more preferably —CH 2 —, —CH 2 CH 2 —, —CH═CH—, —CONH—, —CONHCH 2 —, —CH 2 OCH 2 —, or —NHCH 2 CH 2 —. In this context, a bond shown on the left side in each group refers to being bonded to the aforementioned Q 1 .
[0101] n in the present invention is preferably 1 or 2.
[0102] Q 2 in the present invention is preferably a phenyl group, a pyridyl group, a pyrimidinyl group, a pyrazinyl group, or a pyridazinyl group which may have 1 or 2 substituents independently selected from substituent group β, more preferably a phenyl group or a pyridyl group which may have 1 or 2 substituents independently selected from substituent group β.
[0103] The substituent group β in the present invention is preferably the group consisting of a fluorine atom, a chlorine atom, a bromine atom, a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, an isobutyl group, a sec-butyl group, a tert-butyl group, a trifluoromethyl group, a cyclohexyl group, and a cyano group, more preferably the group consisting of a chlorine atom, a bromine atom, a trifluoromethyl group, a tert-butyl group, and a cyclohexyl group.
[0104] Y in the present invention is preferably a single bond, —O—, —(CH 2 ) n —, or —O—(CH 2 ) n —, more preferably a single bond or —O—. In this context, a bond shown on the left side in each group refers to being bonded to the aforementioned Q 2 .
[0105] Q 3 in the present invention is preferably a phenyl group, a pyridyl group, a pyrimidinyl group, a pyrazinyl group, or a pyridazinyl group which may have 1 or 2 substituents independently selected from substituent group γ, more preferably a phenyl group or a pyridyl group which may have 1 or 2 substituents independently selected from substituent group γ.
[0106] The substituent group γ in the present invention is preferably the group consisting of a fluorine atom, a chlorine atom, a bromine atom, a methyl group, an ethyl group, a propyl group, an isopropyl group, a trifluoromethyl group, and a cyano group, more preferably the group consisting of a chlorine atom, a bromine atom, a trifluoromethyl group, and a cyano group.
[0107] m in the present invention is preferably 1 or 2.
[0108] In the compounds of the present invention, R 2 is preferably a hydrogen atom or a methyl group.
[0109] In the compounds of the present invention, R 3 is preferably a hydrogen atom, a methoxycarbonyl group, an ethoxycarbonyl group, a propoxycarbonyl group, a tert-butoxycarbonyl group, a carboxy group, a phenyl group, or a pyridyl group, more preferably a hydrogen atom.
[0110] The compound of the present invention is preferably one selected from the following compounds or pharmacologically acceptable salts thereof:
6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-cyclohexylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(3-tert-butylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[4-(trifluoromethyl)phenyl]nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-chlorophenyl)nicotinamide, N-[2-(6-morpholin-4-ylpyrimidin-4-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-[3-oxo-2-(6-piperidin-1-ylpyrimidin-4-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-(2-{5-[(benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-(3-oxo-2-{6-[(2-phenylethyl)amino]pyrimidin-4-yl}-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-(2-{4-[(benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(biphenyl-3-ylmethyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[(2′-cyanobiphenyl-4-ylmethyl)]nicotinamide, N-[2-(5-{[(2′-cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-(2-{5-[(biphenyl-4-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-(2-{5-[(biphenyl-3-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[4-(trifluoromethyl)phenyl]nicotinamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-chlorophenyl)nicotinamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-bromophenyl)nicotinamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(6-phenylpyridin-3-yl)nicotinamide, N-[2-(5-{[(2′-cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-5-methyl-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, tert-butyl 4-[(5-methyl-3-oxo-2-{5-[(6-phenylpyridyl-3-yl)carbamoyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)amino]-4-oxobutanoate, 4-[(5-methyl-3-oxo-2-{5-[(6-phenylpyridyl-3-yl)carbamoyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)amino]-4-oxobutanoic acid, N-{5-methyl-3-oxo-2-[5-({[4-(trifluoromethyl)benzyl]oxy}methyl)pyridin-2-yl]-2,3-dihydro-1H-pyrazol-4-yl}acetamide, N-(5-methyl-3-oxo-2-{5-[4-(trifluoromethyl)benzyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-[5-methyl-3-oxo-2-(5-{2-[4-(trifluoromethyl)phenyl]ethyl}pyridin-2-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide, and N-[5-methyl-3-oxo-2-(5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridin-2-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide.
[0138] The compound of the present invention is more preferably one selected from the following compounds or pharmacologically acceptable salts thereof:
6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-cyclohexylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(3-tert-butylphenyl)nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[4-(trifluoromethyl)phenyl]nicotinamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-chlorophenyl)nicotinamide, N-[2-(6-morpholin-4-ylpyrimidin-4-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-[3-oxo-2-(6-piperidin-1-ylpyrimidin-4-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-(2-{5-[(benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-(2-{4-[(benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, 6-(4-acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(biphenyl-3-ylmethyl)nicotinamide, N-[2-(5-{[(2′-cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-(2-{5-[(biphenyl-4-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, N-(2-{5-[(biphenyl-3-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide, 6-(4-acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide, N-[2-(5-{[(2′-cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-5-methyl-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide, N-{5-methyl-3-oxo-2-[5-({[4-(trifluoromethyl)benzyl]oxy}methyl)pyridin-2-yl]-2,3-dihydro-1H-pyrazol-4-yl}acetamide, N-(5-methyl-3-oxo-2-{5-[4-(trifluoromethyl)benzyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)acetamide, and N-[5-methyl-3-oxo-2-(5-{2-[4-(trifluoromethyl)phenyl]ethyl}pyridin-2-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide.
[0157] In the compounds of the present invention, geometrical isomers or tautomers may be present depending on the types of substituents. The 3-pyrazolone derivative represented by the general formula (1) of the present invention may be a tautomeric pyrazol-3-ol derivative (1a).
[0000]
[0158] Further, in the case where the compounds of the present invention have an asymmetric carbon atom, optical isomers may be present. These separated isomers (e.g., enantiomers or diastereomers) and mixtures thereof (e.g., racemates or diastereomeric mixtures) are included in the present invention. Further, labeled compounds, namely compounds in which one or more atoms of compounds of the present invention have been substituted with a corresponding radioactive isotope or non-radioactive isotope in an arbitrary ratio, are also included in the present invention.
[0159] In the case where the compound of the present invention has a basic group such as an amino group, a pharmacologically acceptable acid addition salt can be formed, if desired. Examples of such acid addition salts include: hydrohalic acid salts such as hydrofluorides, hydrochlorides, hydrobromides, and hydroiodides; inorganic acid salts such as nitrates, perchlorates, sulfates, and phosphates; lower alkanesulfonates such as methanesulfonates, trifluoromethanesulfonates, and ethanesulfonates; aryl sulfonates such as benzenesulfonates and p-toluenesulfonates; organic acid salts such as formates, acetates, trifluoroacetates, malates, fumarates, succinates, citrates, tartrates, oxalates, and maleates; and amino acid salts such as ornithinates, glutamates, and aspartates, and hydrohalic acid salts and organic acid salts are preferred.
[0160] In the case where the compound of the present invention has an acidic group such as a carboxy group, generally a pharmacologically acceptable base addition salt can be formed. Examples of such base addition salts include: alkali metal salts such as sodium salts, potassium salts, and lithium salts; alkaline earth metal salts such as calcium salts and magnesium salts; inorganic salts such as ammonium salts; and organic amine salts such as dibenzylamine salts, morpholine salts, phenylglycine alkyl ester salts, ethylenediamine salts, N-methylglucamine salts, diethylamine salts, triethylamine salts, cyclohexylamine salts, dicyclohexylamine salts, N,N′-dibenzylethylenediamine salts, diethanolamine salts, N-benzyl-N-(2-phenylethoxy)amine salts, piperazine salts, tetramethylammonium salts, and tris(hydroxymethyl)aminomethane salts.
[0161] The compounds of the present invention may also be present as a non-solvate or a solvate. Although there are no particular limitations on the solvate provided it is pharmacologically acceptable, preferred specific examples include hydrates and ethanolates. Further, in the case where a nitrogen atom is present in a compound represented by the general formula (1), it may be in the form of an N-oxide, and these solvates and N-oxide forms are also included within the scope of the present invention.
[0162] Although the compounds of the present invention can be present in the form of various isomers including geometrical isomers such as a cis form or trans form, tautomers, or optical isomers such as a d form or 1 form depending on the types of substituents and combinations thereof, the compounds of the present invention also include all the isomers and mixtures of the isomers in any ratio thereof, unless otherwise specifically limited.
[0163] Further, the compounds of the present invention can contain a non-natural ratio of isotopes in one or more atoms constituting such compounds. Examples of the isotopes include deuterium ( 2 H; D), tritium ( 3 H; T), iodine-125 ( 125 I) and carbon-14 ( 14 C). Further, the compounds of the present invention can be radiolabeled with, for example, radioisotopes such as tritium ( 3 H), iodine-125 ( 125 I), or carbon-14 ( 14 C). A radiolabeled compound is useful as a therapeutic or prophylactic agent, a research reagent (e.g., an assay reagent), and a diagnostic agent (e.g., an in vivo diagnostic imaging agent). The compounds of the present invention containing all ratios of radioactive or non-radioactive isotopes are included within the scope of the present invention.
[0164] The compounds of the present invention can also be produced by applying various known synthesis methods depending on the basic skeleton thereof or types of substituents. In so doing, depending on the types of functional groups, it is possible to protect this functional group with a suitable protecting group at stages from a raw material to an intermediate, or replace it with a group that can be easily converted to this functional group. Examples of such functional groups include an amino group, a hydroxy group, and a carboxy group. Examples of their protecting groups include those described in, for example, Protective Groups in Organic Synthesis, 3rd ed., Greene, T. W., Wuts, P.G.M., John Wiley & Sons, Inc., New York, 1999, and these protecting groups can be appropriately selected and used depending on the reaction conditions thereof. According to such methods, a desired compound can be obtained by introducing this protecting group and carrying out the reaction followed by removing the protecting group as necessary, or converting it to a desired group. The resulting compounds of the present invention can be identified, and their composition or purity can be analyzed, by standard analytical technologies such as elementary analysis, NMR, mass spectroscopy, or IR analysis.
[0165] Raw materials and reagents used to produce the compounds of the present invention can be purchased from commercial suppliers, or can be synthesized according to methods described in the literature.
[0166] In the present invention, examples of anemia include nephrogenic anemia, anemia of prematurity, anemia incidental to chronic diseases, anemia incidental to cancer chemotherapy, cancerous anemia, inflammation-associated anemia, and anemia incidental to congestive heart failure. Examples of the anemia incidental to chronic diseases include anemia incidental to chronic kidney diseases, and examples of the chronic kidney diseases include chronic renal failure. Further, the patient to whom the compound of the present invention is administered can be a patient who does or does not receive dialysis.
Effects of Invention
[0167] The compounds of the present invention or pharmacologically acceptable salts thereof demonstrate a superior EPO production-enhancing activity in an assay system using Hep3B cells, and have superior safety. Specifically, EPO production can be enhanced by administering a pharmaceutical composition containing a compound of the present invention or a pharmacologically acceptable salt thereof to a mammal (such as a human, cow, horse, or pig) or a bird (such as a chicken). Thus, a pharmaceutical composition containing a compound of the present invention or a pharmacologically acceptable salt thereof can be used for the prophylaxis and/or treatment of, for example, diseases caused by decreased EPO, or diseases or pathological conditions in which EPO is decreased such as ischemic cerebrovascular disease, or for autologous transfusion in patients scheduled to undergo surgery. Examples of diseases caused by decreased EPO include anemia, and particularly nephrogenic anemia (dialysis stage, conservation stage), anemia of prematurity, anemia incidental to chronic diseases, anemia incidental to cancer chemotherapy, cancerous anemia, inflammation-associated anemia, and anemia incidental to congestive heart failure.
DESCRIPTION OF EMBODIMENTS
[0168] The following provides examples of representative methods for producing the compounds of the present invention. Furthermore, the production methods of the present invention are not limited to the examples shown below.
(Step 1)
[0169] Step 1 is a step for producing a compound having the general formula (1) from a compound having the general formula (2) to be subsequently described.
[0000]
[0170] In the above formulae, R 1 to R 3 and m have the same meanings as previously defined; R 3a represents the aforementioned R 3 or a group that can be converted to R 3 ; and Pro 1 and Pro 2 represent protecting groups of the respective functional groups selected from known protecting groups (e.g., T. W. Greene, P. G. M. Wuts, Protective Groups in Organic Synthesis, Third Edition, John Wiley & Sons Inc., 1999). Although there are no particular limitations on Pro 1 and Pro 2 provided they are stable during the reaction and do not inhibit the reaction, preferably Pro 1 represents a methyl group or an ethyl group and Pro represents an ethyl group.
[0171] The following provides a detailed description of each step.
(Step 1-1)
[0172] Step 1-1 is a step for producing a compound having the general formula (3) from a compound having the general formula (2) to be subsequently described. Examples of essential reactions include:
[0173] Step 1-1a: condensation reaction with a compound having the general formula (4) to be subsequently described; or
[0174] Step 1-1b: condensation reaction with a compound having the general formula (5).
[0175] Step 1-2: reaction for converting R 3a to R 3 can be added, as necessary.
(Step 1-1a)
[0176] This step involves the condensation reaction of the compound having the general formula (2) to be subsequently described with the compound having the general formula (4) to be subsequently described and is carried out in the presence of a base and in the presence or absence of an acid in an inert solvent.
[0177] Although there are no particular limitations on the solvent used provided it does not inhibit the reaction and dissolves the starting material to a certain degree, preferred examples include: aromatic hydrocarbons such as benzene, toluene, and xylene; halogenated hydrocarbons such as dichloromethane and chloroform; esters such as ethyl acetate and propyl acetate; ethers such as diethyl ether, tetrahydrofuran, 1,4-dioxane, and 1,2-dimethoxyethane; alcohols such as methanol, ethanol, and tert-butanol; nitriles such as acetonitrile; amides such as formamide and N,N-dimethylformamide; sulfoxides such as dimethyl sulfoxide; a mixture of multiple organic solvents in an arbitrary ratio; and a mixture thereof with water in an arbitrary ratio.
[0178] Although there are no particular limitations on the base used provided it is used as a base in conventional reactions, preferred examples include: organic bases such as triethylamine, N,N-diisopropylethylamine, N-methylmorpholine, lutidine, and pyridine; alkali metal carbonates such as sodium carbonate and potassium carbonate; alkaline earth metal carbonates such as calcium carbonate; alkali metal hydrogencarbonates such as potassium hydrogencarbonate; alkaline earth metal hydrogencarbonates such as calcium hydrogencarbonate; alkali metal hydroxides such as sodium hydroxide; alkaline earth metal hydroxides such as calcium hydroxide; and alkali metal phosphates such as tripotassium phosphate.
[0179] Although there are no particular limitations on the acid used provided it is used as an acid in conventional reactions, examples include: inorganic acids such as hydrochloric acid and sulfuric acid; Lewis acids such as boron trifluoride, boron trichloride, boron tribromide, and iodotrimethylsilane; and organic acids such as trifluoroacetic acid and acetic acid.
[0180] Varying according to the raw material compounds, reagents and the like, the reaction temperature is normally −10° C. to 150° C., preferably 20° C. to 100° C.
[0181] Varying according to the raw material compounds, reagents and the like, the reaction time is normally 5 minutes to 48 hours, preferably 10 minutes to 12 hours.
[0182] Following completion of the reaction, the desired compound of the present reaction can be obtained as a solid by, for example, concentrating the reaction mixture and adding an organic solvent such as diisopropyl ether. On the other hand, in the case where a solid is unable to be obtained, the desired compound can be obtained by extracting an organic substance with an organic solvent such as ethyl acetate, drying the organic layer with a commonly used procedure and subsequently concentrating it under reduced pressure.
[0183] The resulting compound can be further purified if necessary using a conventional method, for example, recrystallization, reprecipitation, or silica gel column chromatography.
(Step 1-1b)
[0184] This step involves the condensation reaction of the compound having the general formula (2) to be subsequently described with the compound having the general formula (5) and is carried out in the presence of a base and in the presence or absence of an acid in an inert solvent.
[0185] Although there are no particular limitations on the solvent used provided it does not inhibit the reaction and dissolves the starting material to a certain degree, preferred examples include: aromatic hydrocarbons such as benzene, toluene, and xylene; halogenated hydrocarbons such as dichloromethane and chloroform; esters such as ethyl acetate and propyl acetate; ethers such as diethyl ether, tetrahydrofuran, 1,4-dioxane, and 1,2-dimethoxyethane; alcohols such as methanol, ethanol, and tert-butanol; nitriles such as acetonitrile; amides such as formamide and N,N-dimethylformamide; sulfoxides such as dimethyl sulfoxide; a mixture of multiple organic solvents in an arbitrary ratio; and a mixture thereof with water in an arbitrary ratio.
[0186] Although there are no particular limitations on the base used provided it is used as a base in conventional reactions, preferred examples include: organic bases such as triethylamine, N,N-diisopropylethylamine, N-methylmorpholine, lutidine, and pyridine; alkali metal carbonates such as sodium carbonate and potassium carbonate; alkaline earth metal carbonates such as calcium carbonate; alkali metal hydrogencarbonates such as potassium hydrogencarbonate; alkaline earth metal hydrogencarbonates such as calcium hydrogencarbonate; alkali metal hydroxides such as sodium hydroxide; alkaline earth metal hydroxides such as calcium hydroxide; and alkali metal phosphates such as tripotassium phosphate.
[0187] Although there are no particular limitations on the acid used provided it is used as an acid in conventional reactions, examples include: inorganic acids such as hydrochloric acid and sulfuric acid; Lewis acids such as boron trifluoride, boron trichloride, boron tribromide, and iodotrimethylsilane; and organic acids such as trifluoroacetic acid and acetic acid.
[0188] Varying according to the raw material compounds, reagents and the like, the reaction temperature is normally −10° C. to 150° C., preferably 20° C. to 100° C.
[0189] Varying according to the raw material compounds, reagents and the like, the reaction time is normally 5 minutes to 48 hours, preferably 10 minutes to 12 hours.
[0190] Following completion of the reaction, the desired compound of the present reaction can be obtained as a solid by, for example, concentrating the reaction mixture and adding an organic solvent such as diisopropyl ether. On the other hand, in the case where a solid is unable to be obtained, the desired compound can be obtained by extracting an organic substance with an organic solvent such as ethyl acetate, drying the organic layer with a commonly used procedure and subsequently concentrating it under reduced pressure.
[0191] The resulting compound can be further purified if necessary using a conventional method, for example, recrystallization, reprecipitation, or silica gel column chromatography.
(Step 1-2)
[0192] This step involves a reaction for converting R 3a to a carboxy group in the case where R 3a is an alkoxycarbonyl group.
(Step 1-2a)
[0193] This step is a method for converting R 3a to a carboxy group using a suitable base in an inert solvent.
[0194] Although there are no particular limitations on the solvent used provided it does not inhibit the reaction and dissolves the starting material to a certain degree, preferred examples include: aromatic hydrocarbons such as benzene, toluene, and xylene; halogenated hydrocarbons such as dichloromethane and chloroform; ethers such as diethyl ether, tetrahydrofuran, 1,4-dioxane, and 1,2-dimethoxyethane; alcohols such as methanol, ethanol, and tert-butanol; esters such as ethyl acetate and propyl acetate; nitriles such as acetonitrile; amides such as formamide and N,N-dimethylformamide; sulfoxides such as dimethyl sulfoxide; a mixture of multiple organic solvents in an arbitrary ratio; and in addition, a mixture thereof with water in an arbitrary ratio.
[0195] Although there are no particular limitations on the base used provided it is used as a base in conventional reactions, examples include: organic bases such as triethylamine; alkali metal carbonates such as sodium carbonate and potassium carbonate; alkaline earth metal carbonates such as calcium carbonate; alkali metal hydrogencarbonates such as potassium hydrogencarbonate; alkaline earth metal hydrogencarbonates such as calcium hydrogencarbonate; alkali metal hydroxides such as sodium hydroxide and potassium hydroxide; alkaline earth metal hydroxides such as calcium hydroxide; and alkali metal phosphates such as tripotassium phosphate.
[0196] Varying according to the raw material compounds, reagents and the like, the reaction temperature is normally −10° C. to 150° C., preferably 10° C. to 90° C.
[0197] Varying according to the raw material compounds, reagents and the like, the reaction time is normally 1 minute to 24 hours, preferably 10 minutes to 6 hours.
[0198] Following completion of the reaction, the desired compound can be obtained as a solid by distilling off the organic solvent, adding water and then adding an acid. On the other hand, in the case where a solid is unable to be obtained by adding an acid, the desired compound can be obtained by extracting an organic substance with an organic solvent such as ethyl acetate followed by concentrating the organic layer after having dried it with a commonly used procedure, or concentrating it under reduced pressure after having added an acid.
[0199] The resulting compound can be further purified if necessary using a conventional method, for example, recrystallization, reprecipitation, or silica gel column chromatography.
(Step 1-2b)
[0200] This step is a step for converting R 3a to a carboxy group using a suitable acid in an inert solvent.
[0201] Although there are no particular limitations on the solvent used provided it does not inhibit the reaction and dissolves the starting material to a certain degree, preferred examples include: aromatic hydrocarbons such as benzene, toluene, and xylene; halogenated hydrocarbons such as dichloromethane and chloroform; esters such as ethyl acetate and propyl acetate; ethers such as diethyl ether, tetrahydrofuran, 1,4-dioxane, and 1,2-dimethoxyethane; alcohols such as methanol and ethanol; nitriles such as acetonitrile; amides such as formamide and N,N-dimethylformamide; sulfoxides such as dimethyl sulfoxide; a mixture of multiple organic solvents in an arbitrary ratio; and in addition, a mixture thereof with water in an arbitrary ratio.
[0202] Although there are no particular limitations on the acid used provided it is used as an acid in conventional reactions, examples include: inorganic acids such as hydrochloric acid and sulfuric acid; Lewis acids such as boron trifluoride, boron trichloride, boron tribromide, and iodotrimethylsilane; and organic acids such as trifluoroacetic acid.
[0203] Varying according to the raw material compounds, reagents and the like, the reaction temperature is normally −100° C. to 150° C., preferably −78° C. to 100° C.
[0204] Varying according to the raw material compounds, reagents and the like, the reaction time is normally 5 minutes to 24 hours, preferably 10 minutes to 12 hours.
[0205] Following completion of the reaction, the desired compound can be obtained as a solid by distilling off the organic solvent, adding water and then adding a base. On the other hand, in the case where a solid is unable to be obtained by adding a base, the desired compound can be obtained by extracting an organic substance with an organic solvent such as ethyl acetate followed by concentrating the organic layer after having dried it with a commonly used procedure, or concentrating it under reduced pressure after having added a base.
[0206] The resulting compound can be further purified if necessary using a conventional method, for example, recrystallization, reprecipitation, or silica gel column chromatography.
(Step 2)
[0207] Step 2 is a step for producing the compound having the general formula (2) for use in Step 1.
[0000]
[0208] In the above formulae, R 1 has the same meaning as previously defined; and Z represents a halogen atom or a leaving group (—OW).
[0209] Although there are no particular limitations on W in the leaving group (—OW) provided it forms a known leaving group, preferred examples include substituted or unsubstituted alkylsulfonyl groups and arylsulfonyl groups, such as a trifluoromethanesulfonyl group.
[0210] The following provides a detailed description of each step.
(Step 2)
[0211] Step 2 is a step for producing the aforementioned compound having the general formula (2) from a compound having the general formula (7). Examples of essential reactions include:
[0212] condensation reaction of the compound having the general formula (7) with hydrazine hydrate or a hydrazine salt.
[0213] This step is carried out in the presence or absence of a base in an inert solvent.
[0214] Although there are no particular limitations on the solvent used provided it does not inhibit the reaction and dissolves the starting material to a certain degree, preferred examples include: aromatic hydrocarbons such as benzene, toluene, and xylene; halogenated hydrocarbons such as dichloromethane and chloroform; esters such as ethyl acetate and propyl acetate; ethers such as diethyl ether, tetrahydrofuran, 1,4-dioxane, and 1,2-dimethoxyethane; alcohols such as methanol, ethanol, and tert-butanol; nitriles such as acetonitrile; amides such as formamide and N,N-dimethylformamide; sulfoxides such as dimethyl sulfoxide; a mixture of multiple organic solvents in an arbitrary ratio; and a mixture thereof with water in an arbitrary ratio.
[0215] Although there are no particular limitations on the base used provided it is used as a base in conventional reactions, preferred examples include: organic bases such as triethylamine, N,N-diisopropylethylamine, N-methylmorpholine, lutidine, and pyridine; alkali metal carbonates such as sodium carbonate and potassium carbonate; alkaline earth metal carbonates such as calcium carbonate; alkali metal hydrogencarbonates such as potassium hydrogencarbonate; alkaline earth metal hydrogencarbonates such as calcium hydrogencarbonate; alkali metal hydroxides such as sodium hydroxide; alkaline earth metal hydroxides such as calcium hydroxide; and alkali metal phosphates such as tripotassium phosphate.
[0216] Varying according to the raw material compounds, reagents and the like, the reaction temperature is normally −10° C. to 200° C., preferably 20° C. to 150° C.
[0217] Varying according to the raw material compounds, reagents and the like, the reaction time is normally 5 minutes to 48 hours, preferably 10 minutes to 12 hours.
[0218] Following completion of the reaction, the desired compound of the present reaction can be obtained as a solid by, for example, concentrating the reaction mixture and adding an organic solvent such as diisopropyl ether. On the other hand, in the case where a solid is unable to be obtained, the desired compound can be obtained by extracting an organic substance with an organic solvent such as ethyl acetate, drying the organic layer with a commonly used procedure and subsequently concentrating it under reduced pressure.
[0219] The resulting compound can be further purified, if necessary, using a conventional method, for example, recrystallization, reprecipitation, or silica gel column chromatography.
(Step 3)
[0220] Step 3 is a step for producing the compound having the general formula (4) for use in Step 1.
[0000]
[0221] In the above formulae, R 2 and m have the same meanings as previously defined; R 3a represents the aforementioned R 3 or a group that can be converted to R 3 ; and Pro 1 and Pro 3 represent protecting groups of the respective functional groups selected from known protecting groups (e.g., T. W. Greene, P. G. M. Wuts, Protective Groups in Organic Synthesis, Third Edition, John Wiley & Sons Inc., 1999). Although there are no particular limitations on Pro 1 and Pro 3 provided they are stable during the reaction and do not inhibit the reaction, preferably Pro 1 represents a methyl group or an ethyl group and Pro 3 represents an isobutyl group.
[0222] The following provides a detailed description of each step.
(Step 3)
[0223] Step 3 is a step for producing the aforementioned compound having the general formula (4) from a compound having the general formula (8). Examples of essential reactions include:
[0224] Step 3-a: condensation reaction of the compound having the general formula (8) with a carboxylic acid having the general formula (9);
[0225] Step 3-b: acylation reaction of the compound having the general formula (8) with an acid chloride having the general formula (10); or
[0226] Step 3-c: acylation reaction of the compound having the general formula (8) with an active ester having the general formula (11).
(Step 3-a)
[0227] This step is a step for condensing the compound having the general formula (8) with a carboxylic acid having the general formula (9) and is carried out using a condensation agent in the presence or absence of a base in an inert solvent.
[0228] Although there are no particular limitations on the solvent used provided it does not inhibit the reaction and dissolves the starting material to a certain degree, preferred examples include: aromatic hydrocarbons such as benzene, toluene, and xylene; halogenated hydrocarbons such as dichloromethane and chloroform; esters such as ethyl acetate and propyl acetate; ethers such as diethyl ether, tetrahydrofuran, 1,4-dioxane, and 1,2-dimethoxyethane; alcohols such as methanol, ethanol, and tert-butanol; nitriles such as acetonitrile; amides such as formamide and N,N-dimethylformamide; sulfoxides such as dimethyl sulfoxide; a mixture of multiple organic solvents in an arbitrary ratio; and a mixture thereof with water in an arbitrary ratio.
[0229] Although there are no particular limitations on the base used provided it is used as a base in conventional reactions, preferred examples include: organic bases such as triethylamine, N,N-diisopropylethylamine, N-methylmorpholine, lutidine, and pyridine; alkali metal carbonates such as sodium carbonate and potassium carbonate; alkaline earth metal carbonates such as calcium carbonate; alkali metal hydrogencarbonates such as potassium hydrogencarbonate; alkaline earth metal hydrogencarbonates such as calcium hydrogencarbonate; alkali metal hydroxides such as sodium hydroxide; alkaline earth metal hydroxides such as calcium hydroxide; and alkali metal phosphates such as tripotassium phosphate.
[0230] Although there are no particular limitations on the condensation agent used provided it is used as a condensation agent that forms an amide bond (e.g., Shoichi Kusumoto et al., Experimental Science Course IV, Chemical Society of Japan, Maruzen Publishing, 1990; and Nobuo Izumiya et al., Peptide Synthesis Basics and Experimentation, Maruzen Publishing, 1985), preferred examples include O-benzotriazole-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HBTU), 2-(1H-benzotriazol-1-yl)-1,1,3,3-tetramethyluronium tetrafluoroborate (TBTU), 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDCI), 4-(2-{[(cyclohexylimino)methylene]amino}ethyl-4-methylmorpholin-4-ium para-toluenesulfonate (CMC), dicyclohexylcarbodiimide (DCC), 1,1′-carbonylbis(1H-imidazole) (CDI), (1H-benzotriazol-1-yloxy)(tripyrrolidin-1-yl)phosphonium hexafluorophosphate (PyBOP), bromo(tripyrrolidin-1-yl)phosphonium hexafluorophosphate (PyBrOP), 4-(4,6-dimethoxy-1,3,5-triazin-2-yl)-4-methylmorpholinium chloride (DMT-MM), and 2-chloro-4,6-dimethoxy-1,3,5-triazine (DMT). An additive such as 1-hydroxybenzotriazole (HOBT) or N,N-dimethylaminopyridine may also be added.
[0231] Varying according to the raw material compounds, reagents and the like, the reaction temperature is normally −10° C. to 150° C., preferably 0° C. to 100° C.
[0232] Varying according to the raw material compounds, reagents and the like, the reaction time is normally 5 minutes to 48 hours, preferably 10 minutes to 24 hours.
[0233] Following completion of the reaction, the desired compound of the present reaction can be obtained by, for example, concentrating the reaction mixture, adding an organic solvent such as ethyl acetate and washing with water followed by separating the organic layer containing the desired compound, drying with anhydrous sodium sulfate and the like, and distilling off the solvent.
[0234] The resulting compound can be further purified if necessary using a conventional method, for example, recrystallization, reprecipitation, or silica gel column chromatography.
(Step 3-b)
[0235] This step is a step for condensing the compound having the general formula (8) with an acid chloride having the general formula (10) and is carried out in the presence or an absence of a base in an inert solvent.
[0236] Although there are no particular limitations on the solvent used provided it does not inhibit the reaction and dissolves the starting material to a certain degree, preferred examples include: aromatic hydrocarbons such as benzene, toluene, and xylene; halogenated hydrocarbons such as dichloromethane and chloroform; esters such as ethyl acetate and propyl acetate; ethers such as diethyl ether, tetrahydrofuran, 1,4-dioxane, and 1,2-dimethoxyethane; nitriles such as acetonitrile; amides such as formamide and N,N-dimethylformamide; sulfoxides such as dimethyl sulfoxide; a mixture of multiple organic solvents in an arbitrary ratio; and a mixture thereof with water in an arbitrary ratio.
[0237] Although there are no particular limitations on the base used provided it is used as a base in conventional reactions, preferred examples include: organic bases such as triethylamine, N,N-diisopropylethylamine, N-methylmorpholine, lutidine, and pyridine; alkali metal carbonates such as sodium carbonate and potassium carbonate; alkaline earth metal carbonates such as calcium carbonate; alkali metal hydrogencarbonates such as potassium hydrogencarbonate; alkaline earth metal hydrogencarbonates such as calcium hydrogencarbonate; alkali metal hydroxides such as sodium hydroxide; alkaline earth metal hydroxides such as calcium hydroxide; and alkali metal phosphates such as tripotassium phosphate.
[0238] Varying according to the raw material compounds, reagents and the like, the reaction temperature is normally −80° C. to 150° C., preferably 0° C. to 80° C.
[0239] Varying according to the raw material compounds, reagents and the like, the reaction time is normally 5 minutes to 48 hours, preferably 10 minutes to 24 hours.
[0240] Following completion of the reaction, the desired compound of the present reaction can be obtained by, for example, concentrating the reaction mixture, adding an organic solvent such as ethyl acetate and washing with water followed by separating the organic layer containing the desired compound, drying with anhydrous sodium sulfate and the like, and distilling off the solvent.
[0241] The resulting compound can be further purified if necessary using a conventional method, for example, recrystallization, reprecipitation, or silica gel column chromatography.
(Step 3-c)
[0242] This step is a step for condensing the compound having the general formula (8) with an active ester having the general formula (11) and is carried out in the presence or absence of a base in an inert solvent.
[0243] Although there are no particular limitations on the solvent used provided it does not inhibit the reaction and dissolves the starting material to a certain degree, preferred examples include: aromatic hydrocarbons such as benzene, toluene, and xylene; halogenated hydrocarbons such as dichloromethane and chloroform; esters such as ethyl acetate and propyl acetate; ethers such as diethyl ether, tetrahydrofuran, 1,4-dioxane, and 1,2-dimethoxyethane; nitriles such as acetonitrile; amides such as formamide and N,N-dimethylformamide; sulfoxides such as dimethyl sulfoxide; a mixture of multiple organic solvents in an arbitrary ratio; and a mixture thereof with water in an arbitrary ratio.
[0244] Although there are no particular limitations on the base used provided it is used as a base in conventional reactions, preferred examples include: organic bases such as triethylamine, N,N-diisopropylethylamine, N-methylmorpholine, lutidine, and pyridine; alkali metal carbonates such as sodium carbonate and potassium carbonate; alkaline earth metal carbonates such as calcium carbonate; alkali metal hydrogencarbonates such as potassium hydrogencarbonate; alkaline earth metal hydrogencarbonates such as calcium hydrogencarbonate; alkali metal hydroxides such as sodium hydroxide; alkaline earth metal hydroxides such as calcium hydroxide; and alkali metal phosphates such as tripotassium phosphate.
[0245] Varying according to the raw material compounds, reagents and the like, the reaction temperature is normally −10° C. to 150° C., preferably 0° C. to 100° C.
[0246] Varying according to the raw material compounds, reagents and the like, the reaction time is normally 5 minutes to 48 hours, preferably 10 minutes to 24 hours.
[0247] Following completion of the reaction, the desired compound of the present reaction can be obtained by, for example, concentrating the reaction mixture, adding an organic solvent such as ethyl acetate and washing with water followed by separating the organic layer containing the desired compound, drying with anhydrous sodium sulfate and the like, and distilling off the solvent.
[0248] The resulting compound can be further purified if necessary using a conventional method, for example, recrystallization, reprecipitation, or silica gel column chromatography.
[0249] The reaction products obtained according to each of the aforementioned steps are isolated and purified as non-solvates, salts thereof or various types of solvates such as hydrates. Salts thereof can be produced according to a conventional method. Isolation or purification is carried out by applying conventional methods such as extraction, concentration, distillation, crystallization, filtration, recrystallization, or various types of chromatography.
[0250] Each type of isomer can be isolated in accordance with conventional methods by utilizing differences in physicochemical properties between isomers. For example, optical isomers can be separated by common optical resolution methods (e.g., fractional crystallization, chromatography, etc.). Further, optical isomers can also be produced from suitable optically active raw material compounds.
[0251] A formulation containing a compound of the present invention as an active ingredient is prepared using additives such as a carrier and an excipient used for conventional formulations. Administration of a compound of the present invention may be oral administration in the form of tablets, pills, capsules, granules, powders, liquids, or the like, or parenteral administration in the form of injections (e.g., intravenous injection and intramuscular injection), suppositories, transcutaneous agents, nasal agents, inhalants, or the like. Dosage and frequency of administration of a compound of the present invention are suitably determined on an individual basis in consideration of such factors as symptoms and age or gender of the recipient. The dosage is normally 0.001 to 100 mg/kg per administration for a human adult in the case of oral administration, and in the case of intravenous administration, the dosage is normally 0.0001 to 10 mg/kg per administration for a human adult. The frequency of administration is normally 1 to 6 times a day, or once a day to once in 7 days. It is also preferred that administration to a patient who receives dialysis should be carried out once before or after each dialysis (preferably before dialysis) that the patient receives.
[0252] Solid formulations for oral administration according to the present invention may be tablets, powders, granules, or the like. Such formulations are produced in accordance with a conventional method by mixing one or more active substances with an inert excipient, lubricant, disintegrant, or dissolution aid. The excipient may be, for example, lactose, mannitol, or glucose. The lubricant may be, for example, magnesium stearate. The disintegrant may be, for example, sodium carboxymethyl starch. The tablets or pills may be provided with a sugar coating, or a gastric or enteric coating as necessary.
[0253] Liquid formulations for oral administration may be pharmaceutically acceptable emulsions, liquids, suspensions, syrups, elixirs, or the like. Such formulations may contain commonly used inert solvents (e.g., purified water or ethanol), and may further contain solubilizers, wetting agents, suspending agents, sweeteners, corrigents, fragrances, or preservatives.
[0254] Injections for parenteral administration may be sterile aqueous or non-aqueous liquid formulations, suspensions or emulsions. Aqueous solvents for injections may be, for example, distilled water or physiological saline. Non-aqueous solvents for injections may be, for example, propylene glycol, polyethylene glycol, vegetable oils such as olive oil, alcohols such as ethanol, or Polysorbate 80 (Japanese Pharmacopoeia name). Such formulations may further contain isotonic agents, preservatives, wetting agents, emulsifiers, dispersants, stabilizers, or dissolution aids. These formulations may be sterilized, for example, by passing through a bacteria-retaining filter, incorporation of a bactericide, or irradiation. Further, it is also possible to use, as these formulations, compositions obtained by dissolving or suspending a sterile solid composition in sterile water or a solvent for injection prior to use.
EXAMPLES
[0255] Although the following provides examples and test examples to explain the present invention in more detail, the scope of the present invention is not limited thereto.
Example 1
6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-cyclohexylphenyl)nicotinamide
[0256]
(1) 6-Chloro-N-(4-cyclohexylphenyl)nicotinamide
[0257]
[0258] 6-Chloronicotinoyl chloride (0.24 g) was dissolved in toluene (5 mL), and the solution was cooled to 0° C. 4-Cyclohexylaniline (0.47 g) was added thereto at 0° C., and the mixture was stirred at room temperature for 1 hour. Ethyl acetate was added thereto, and the organic layer was washed with a 1 N aqueous sodium hydroxide solution and water and dried over sodium sulfate. After concentration under reduced pressure, the obtained solid was collected by filtration and washed with diethyl ether. The solid was dried under reduced pressure to obtain the title compound (0.40 g) as a white solid (yield: 95%).
[0259] 1 H-NMR (500 MHz, CDC 3 ) δ: 8.85 (1H, d, J=2 Hz), 8.17 (1H, dd, J=8 Hz, 2 Hz), 7.68 (1H, brs), 7.52 (2H, d, J=9 Hz), 7.47 (1H, d, J=8 Hz), 7.24 (2H, d, J=9 Hz), 2.56-2.46 (1H, m), 1.92-1.80 (4H, m), 1.80-1.71 (1H, m), 1.46-1.36 (4H, m), 1.33-1.20 (1H, m).
(2) N-(4-Cyclohexylphenyl)-6-hydrazinonicotinamide
[0260]
[0261] 6-Chloro-N-(4-cyclohexylphenyl)nicotinamide (0.40 g) and hydrazine monohydrate (3 mL) were suspended in ethanol (6 mL), and the suspension was heated to reflux for 2 hours. The reaction solution was concentrated under reduced pressure, and the obtained solid was then collected by filtration and washed with an ethyl acetate-ethanol mixed solvent. The solid was dried under reduced pressure to obtain the title compound (0.39 g) as a white solid (yield: 99%).
[0262] 1 H-NMR (500 MHz, DMSO-d 6 ) δ: 9.86 (1H, s), 8.62 (1H, d, J=2 Hz), 8.13 (1H, brs), 8.00 (1H, dd, J=9 Hz, 2 Hz), 7.62 (2H, d, J=8 Hz), 7.16 (1H, d, J=8 Hz), 6.75 (2H, d, J=9 Hz), 6.50 (2H, brs), 2.50-2.39 (1H, m), 1.84-1.74 (4H, m), 1.74-1.64 (1H, m), 1.43-1.30 (4H, m), 1.28-1.16 (1H, m).
(3) 6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-cyclohexylphenyl)nicotinamide
[0263]
[0264] N-(4-Cyclohexylphenyl)-6-hydrazinonicotinamide (0.20 g) and 4-(ethoxymethylene)-2-methyl-1,3-oxazol-5(4H)-one (0.12 g) were dissolved in ethanol (30 mL), and the solution was stirred at room temperature for 1.5 hours. The solvent was distilled off under reduced pressure, and diisopropyl ether was added to the residue. The deposited solid was collected by filtration and washed with diisopropyl ether. The solid was dried under reduced pressure to obtain the title compound (0.015 g) as a white solid (yield: 5.5%).
[0265] MS m/z: 420 (M+H) +
[0266] 1 H-NMR (500 MHz, DMSO-d 6 ) δ: 10.44 (1H, s), 9.63 (1H, s), 9.01 (1H, s), 8.49 (1H, brs), 8.06 (1H, brs), 7.68 (2H, d, J=8 Hz), 7.22 (2H, d, J=8 Hz), 2.50-2.39 (1H, m), 2.03 (3H, s), 1.83-1.75 (4H, m), 1.74-1.67 (1H, m), 1.43-1.32 (4H, m), 1.29-1.19 (1H, m).
Example 2
6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide
[0267]
(1) 6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide
[0268]
[0269] In accordance with Examples 1-(1), 1-(2), and 1-(3), but using 4-tert-butylaniline instead of 4-cyclohexylaniline, the title compound (0.073 g) was obtained as a white solid (yield: 15%).
[0270] MS m/z: 394 (M+H) +
[0271] 1 H-NMR (500 MHz, DMSO-d 6 ) δ: 10.38 (1H, brs), 9.63 (1H, brs), 9.00 (1H, s), 8.63-8.44 (2H, m), 8.13 (1H, brs), 7.68 (2H, d, J=9 Hz), 7.39 (2H, d, J=9 Hz), 2.03 (3H, s), 1.29 (9H, s).
Example 3
6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(3-tert-butylphenyl)nicotinamide
[0272]
(1) 6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(3-tert-butylphenyl)nicotinamide
[0273]
[0274] In accordance with Examples 1-(1), 1-(2), and 1-(3), but using 3-tert-butylaniline instead of 4-cyclohexylaniline, the title compound (0.048 g) was obtained (yield: 6.6%).
[0275] MS m/z: 394 (M+H) +
[0276] 1 H-NMR (500 MHz, DMSO-d 6 ) δ: 11.75 (1H, brs), 10.36 (1H, s), 9.61 (1H, s), 9.01 (1H, d, J=2 Hz), 8.59 (1H, d, J=8 Hz), 8.48 (1H, d, J=8 Hz), 8.12 (1H, s), 7.77 (1H, t, J=2 Hz), 7.66 (1H, d, J=7 Hz), 7.30 (1H, t, J=8 Hz), 7.17 (1H, d, J=8 Hz), 2.03 (3H, s), 1.30 (9H, s).
Example 4
6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[4-(trifluoromethyl)phenyl]nicotinamide
[0277]
(1) 6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[4-(trifluoromethyl)phenyl]nicotinamide
[0278]
[0279] In accordance with Examples 1-(1), 1-(2), and 1-(3), but using 4-(trifluoromethyl)aniline instead of 4-cyclohexylaniline, the title compound (0.096 g) was obtained (yield: 4.3%).
[0280] MS m/z: 406 (M+H) +
[0281] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.75 (1H, brs), 10.76 (1H, s), 9.61 (1H, s), 9.03-9.02 (1H, m), 8.59 (1H, brs), 8.50 (1H, dd, J=9 Hz, 2 Hz), 8.11 (1H, brs), 8.02 (2H, d, J=9 Hz), 7.76 (2H, d, J=9 Hz), 2.03 (3H, s).
Example 5
6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-chlorophenyl)nicotinamide
[0282]
(1) 6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-chlorophenyl)nicotinamide
[0283]
[0284] In accordance with Examples 1-(1), 1-(2), and 1-(3), but using 4-chloroaniline instead of 4-cyclohexylaniline, the title compound (0.047 g) was obtained as a yellow solid (yield: 8.2%).
[0285] MS m/z: 372 (M+H) +
[0286] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.75 (2H, brs), 10.55 (1H, s), 9.52 (1H, s), 9.00 (1H, d, J=2 Hz), 8.59 (1H, d, J=9 Hz), 8.47 (1H, d, J=9 Hz), 8.13 (1H, s), 7.81 (2H, d, J=9 Hz), 7.45 (2H, d, J=9 Hz), 2.03 (3H, s).
Example 6
N-[2-(6-Morpholin-4-ylpyrimidin-4-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide formate
[0287]
(1) N-[2-(6-Morpholin-4-ylpyrimidin-4-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide formate
[0288]
[0289] In accordance with Example 1-(3), but using 4-(6-hydrazinopyrimidin-4-yl)morpholine instead of N-(4-cyclohexylphenyl)-6-hydrazinonicotinamide, the title compound (0.11 g) was obtained as a brown solid (yield: 35%).
[0290] MS m/z: 305 (M+H) +
[0291] 1 H-NMR (500 MHz, DMSO-d 6 ) δ: 11.61 (1H, br), 9.48 (1H, s), 8.47 (1H, s), 8.05 (1H, br), 7.74 (1H, br), 3.80-3.44 (8H, m), 2.01 (3H, s).
Example 7
N-[3-Oxo-2-(6-piperidin-1-ylpyrimidin-4-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide formate
[0292]
(1) N-[3-Oxo-2-(6-piperidin-1-ylpyrimidin-4-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide formate
[0293]
[0294] In accordance with Example 1-(3), but using 4-hydrazino-6-piperidin-1-ylpyrimidine instead of N-(4-cyclohexylphenyl)-6-hydrazinonicotinamide, the title compound (0.085 g) was obtained as a brown solid (yield: 24%).
[0295] MS m/z: 303 (M+H) +
[0296] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.61 (1H, br), 9.44 (1H, s), 8.41 (1H, s), 8.03 (1H, br), 7.75 (1H, br), 3.64 (4H, br), 2.00 (3H, s), 1.75-1.45 (6H, m).
Example 8
N-(2-{5-[(Benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0297]
(1) N-(2-{5-[(Benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0298]
[0299] In accordance with Example 1-(3), but using 5-[(benzyloxy)methyl]-2-hydrazinopyridine instead of N-(4-cyclohexylphenyl)-6-hydrazinonicotinamide, the title compound (0.12 g) was obtained as a white solid (yield: 36%).
[0300] MS m/z: 339 (M+H) +
[0301] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.77 (1H, br), 9.57-9.46 (1H, m), 8.43 (1H, s), 8.33 (1H, br), 7.95 (2H, br), 7.41-7.27 (5H, m), 4.57 (2H, s), 4.56 (2H, s), 2.00 (3H, s).
Example 9
N-(3-Oxo-2-{6-[(2-phenylethyl)amino]pyrimidin-4-yl}-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0302]
(1) 6-Hydrazino-N-(2-phenylethyl)pyrimidin-4-amine
[0303]
[0304] In accordance with Example 1-(2), but using 6-chloro-N-(2-phenylethyl)pyrimidin-4-amine (1.0 g) instead of 6-chloro-N-(4-cyclohexylphenyl)nicotinamide, the title compound (0.40 g) was obtained as a pale yellowish white solid (yield: 41%).
[0305] 1 H-NMR (500 MHz, CDC 3 ) δ: 8.08 (1H, s), 7.36-7.29 (2H, m), 7.28-7.20 (3H, m), 6.07 (1H, brs), 5.69 (1H, s), 4.88 (1H, brs), 3.52 (2H, q, J=7 Hz), 2.93 (2H, t, J=7 Hz).
(2) N-(3-Oxo-2-{6-[(2-phenylethyl)amino]pyrimidin-4-yl}-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0306]
[0307] In accordance with Example 1-(3), but using 6-hydrazino-N-(2-phenylethyl)pyrimidin-4-amine (0.18 g) instead of N-(4-cyclohexylphenyl)-6-hydrazinonicotinamide, the title compound (0.12 g) was obtained as a white solid (yield: 39%).
[0308] MS m/z: 339 (M+H) +
[0309] 1 H-NMR (500 MHz, DMSO-d 6 ) δ: 11.54 (1H, brs), 9.53 (1H, brs), 8.13-7.78 (2H, m), 7.51 (1H, brs), 7.36-7.11 (5H, m), 3.66-3.48 (2H, m), 2.92-2.78 (2H, m), 2.00 (3H, s).
Example 10
N-(2-{4-[(Benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0310]
(1) N-(2-{4-[(Benzyloxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0311]
[0312] In accordance with Example 1-(3), but using 4-[(benzyloxy)methyl]-2-hydrazinopyridine instead of N-(4-cyclohexylphenyl)-6-hydrazinonicotinamide, the title compound (0.093 g) was obtained as a white solid (yield: 28%).
[0313] MS m/z: 339 (M+H) +
[0314] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.59 (1H, br), 9.61-9.52 (1H, m), 8.53 (1H, s), 8.41 (2H, d, J=6 Hz), 8.05 (1H, br), 7.45-7.22 (5H, m), 4.68 (2H, s), 4.61 (2H, s), 2.02 (3H, s).
Example 11
6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(biphenyl-3-ylmethyl)nicotinamide
[0315]
(1) N-(Biphenyl-3-ylmethyl)-6-chloronicotinamide
[0316]
[0317] 6-Chloronicotinic acid (0.29 g) and 1,1′-carbonylbis(1H-imidazole) (0.34 g) were dissolved in N,N-dimethylformamide (5 mL), and the solution was heated with stirring at 100° C. for 45 minutes. The reaction solution was brought back to room temperature. 1-Biphenyl-3-ylmethanamine (0.37 g) and triethylamine (0.51 mL) were added thereto, and the mixture was stirred at 70° C. for 2 hours. Ethyl acetate was added thereto, and the organic layer was washed with water and dried over sodium sulfate. After concentration under reduced pressure, the obtained residue was purified by silica gel column chromatography (Moritex Corporation, elution solvent: hexane/ethyl acetate) to obtain the title compound (0.48 g) as a white solid (yield: 81%).
[0318] MS m/z: 323 (M+H) +
[0319] 1 H-NMR (400 MHz, CDC 3 ) δ: 8.77 (1H, d, J=2 Hz), 8.11 (1H, dd, J=8 Hz, 2 Hz), 7.60-7.54 (4H, m), 7.49-7.40 (4H, m), 7.39-7.33 (2H, m), 6.42 (1H, t, J=5 Hz), 4.72 (2H, d, J=5 Hz).
(2) 6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(biphenyl-3-ylmethyl)nicotinamide
[0320]
[0321] In accordance with Examples 1-(2) and 1-(3), but using N-(biphenyl-3-ylmethyl)-6-chloronicotinamide instead of 6-chloro-N-(4-cyclohexylphenyl)nicotinamide, the title compound (0.11 g) was obtained as a pale yellow solid (yield: 18%).
[0322] MS m/z: 428 (M+H) +
[0323] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.72 (1H, brs), 9.60 (1H, s), 9.28 (1H, t, J=5 Hz), 8.96 (1H, d, J=2 Hz), 8.54 (1H, d, J=9 Hz), 8.44 (1H, d, J=9 Hz), 8.10 (1H, s), 7.68-7.60 (3H, m), 7.56 (1H, dd, J=8 Hz, 2 Hz), 7.51-7.41 (3H, m), 7.40-7.33 (2H, m), 4.60 (2H, d, J=5 Hz), 2.02 (3H, s).
Example 12
6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[(2′-cyanobiphenyl-4-ylmethyl)]nicotinamide
[0324]
(1) 6-(4-Acetamido-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[(2′-cyanobiphenyl-4-ylmethyl)]nicotinamide
[0325]
[0326] In accordance with Examples 11-(1) and 11-(2), but using 4′-(aminomethyl)biphenyl-2-carbonitrile instead of 1-biphenyl-3-ylmethanamine, the title compound (0.17 g) was obtained as a pale yellow solid (yield: 34%).
[0327] MS m/z: 453 (M+H) +
[0328] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.75 (1H, brs), 9.62 (1H, s), 9.34 (1H, t, J=5 Hz), 8.98 (1H, d, J=2 Hz), 8.58-8.52 (1H, m), 8.47-8.42 (1H, m), 8.11 (1H, brs), 7.96 (1H, dd, J=8 Hz, 1 Hz), 7.80 (1H, dt, J=8 Hz, 1 Hz), 7.65-7.49 (6H, m), 4.61 (2H, d, J=5 Hz), 2.02 (3H, s).
Example 13
N-[2-(5-{[(2′-Cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide
[0329]
(1) 4′-{[(6-Chloropyridin-3-yl)methoxy]methyl}biphenyl-2-carbonitrile
[0330]
[0331] (6-Chloropyridin-3-yl)methanol (4.3 g) was dissolved in tetrahydrofuran (150 mL), and the solution was cooled to 0° C. Sodium hydride (63%, 1.4 g) was added thereto, and the mixture was stirred at 0° C. for 1 hour. Subsequently, 4′-(bromomethyl)biphenyl-2-carbonitrile (9.0 g) was added thereto at 0° C., and the mixture was stirred at 50° C. for 19 hours. The reaction solution was brought back to room temperature, and a saturated aqueous ammonium chloride solution was added thereto. After extraction with ethyl acetate, the organic layer was dried over sodium sulfate. The solvent was distilled off under reduced pressure, and the obtained residue was purified by silica gel column chromatography (Moritex Corporation, elution solvent: hexane/ethyl acetate) to obtain the title compound (6.2 g) as a white solid (yield: 62%).
[0332] 1 H-NMR (400 MHz, CDC 3 ) δ: 8.39 (1H, d, J=2 Hz), 7.78 (1H, d, J=8 Hz), 7.72 (1H, dd, J=8 Hz, 2 Hz), 7.66 (1H, dt, J=8 Hz, 2 Hz), 7.57 (2H, d, J=8 Hz), 7.52 (1H, d, J=8 Hz), 7.48 (2H, d, J=8 Hz), 7.45 (1H, dt, J=8 Hz, 2 Hz), 7.35 (1H, d, J=8 Hz), 4.66 (2H, s), 4.60 (2H, s).
(2) 4′-{[(6-Hydrazinopyridin-3-yl)methoxy]methyl}biphenyl-2-carbonitrile
[0333]
[0334] 4′-{[(6-Chloropyridin-3-yl)methoxy]methyl}biphenyl-2-carbonitrile (1.7 g) and hydrazine monohydrate (3 mL) were suspended in ethanol (8 mL), and the suspension was reacted at 150° C. for 2 hours using a microwave reaction apparatus (Biotage Ltd.). The reaction solution was concentrated under reduced pressure, and the obtained residue was then purified by NH-silica gel column chromatography (Moritex Corporation, elution solvent: ethyl acetate) to obtain the title compound (0.90 g) as a yellow oil (yield: 56%).
[0335] 1 H-NMR (400 MHz, CDC 3 ) δ: 8.13 (1H, d, J=2 Hz), 7.77 (1H, d, J=8 Hz), 7.65 (1H, t, J=9 Hz), 7.58-7.41 (7H, m), 6.73 (1H, d, J=9 Hz), 4.60 (2H, s), 4.49 (2H, s).
(3) N-[2-(5-{[(2′-Cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide
[0336]
[0337] In accordance with Example 1-(3), but using 4′-{[(6-hydrazinopyridin-3-yl)methoxy]methyl}biphenyl-2-carbonitrile instead of N-(4-cyclohexylphenyl)-6-hydrazinonicotinamide, the title compound (0.11 g) was obtained as a white solid (yield: 5.5%).
[0338] MS m/z: 440 (M+H) +
[0339] 1 H-NMR (500 MHz, DMSO-d 6 ) δ: 11.63 (1H, s), 9.59 (1H, s), 8.48 (1H, brs), 8.10-7.93 (2H, m), 7.80 (1H, t, J=8 Hz), 7.66-7.50 (8H, m), 4.67 (2H, s), 4.65 (2H, s), 2.02 (3H, s).
Example 14
N-(2-{5-[(Biphenyl-4-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0340]
(1) N-(2-{5-[(Biphenyl-4-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0341]
[0342] In accordance with Examples 13-(1), 13-(2), and 13-(3), but using 4-(bromomethyl)biphenyl instead of 4′-(bromomethyl)biphenyl-2-carbonitrile, the title compound (0.053 g) was obtained as a pale yellow solid (yield: 37%).
[0343] MS m/z: 415 (M+H) +
[0344] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.62 (1H, s), 8.52-8.45 (2H, m), 8.10-7.96 (2H, m), 7.74-7.66 (4H, m), 7.53-7.45 (4H, m), 7.36 (1H, t, J=8 Hz), 4.61 (4H, s), 2.01 (3H, s).
Example 15
N-(2-{5-[(Biphenyl-3-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0345]
(1) N-(2-{5-[(Biphenyl-3-ylmethoxy)methyl]pyridin-2-yl}-3-oxo-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0346]
[0347] In accordance with Examples 13-(1), 13-(2), and 13-(3), but using 3-(bromomethyl)biphenyl instead of 4′-(bromomethyl)biphenyl-2-carbonitrile, the title compound (0.14 g) was obtained as a pale yellow solid (yield: 19%).
[0348] MS m/z: 415 (M+H) +
[0349] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 9.58 (1H, s), 8.47-8.45 (2H, m), 8.09-7.95 (2H, m), 7.69-7.58 (5H, m), 7.50-7.45 (3H, m), 7.40-7.35 (2H, m), 4.65 (2H, s), 4.63 (2H, s), 2.01 (3H, s).
Example 16
6-(4-Acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[4-(trifluoromethyl)phenyl]nicotinamide
[0350]
(1) 6-Chloro-N-[4-(trifluoromethyl)phenyl]nicotinamide
[0351]
[0352] 6-Chloronicotinoyl chloride (0.83 g) was dissolved in toluene (15 mL), and the solution was cooled to 0° C. 4-(Trifluoromethyl)aniline (1.6 g) was added thereto at 0° C., and the mixture was stirred at room temperature for 10 hours. Ethyl acetate was added thereto, and the organic layer was washed with a 1 N aqueous sodium hydroxide solution and water and dried over sodium sulfate. After concentration under reduced pressure, the obtained solid was collected by filtration and washed with diethyl ether. The solid was dried under reduced pressure to obtain the title compound (0.88 g) as a white solid (yield: 29%).
[0353] MS m/z: 301 (M+H) +
[0354] 1 H-NMR (400 MHz, CDC 3 ) δ: 8.88 (1H, d, J=2 Hz), 8.20 (1H, dd, J=8 Hz, 2 Hz), 7.86 (1H, brs), 7.78 (2H, d, J=9 Hz), 7.67 (1H, d, J=8 Hz), 7.51 (2H, d, J=9 Hz).
(2) 6-Hydrazino-N-[4-(trifluoromethyl)phenyl]nicotinamide
[0355]
[0356] 6-Chloro-N-[4-(trifluoromethyl)phenyl]nicotinamide (0.49 g) and hydrazine monohydrate (4 mL) were suspended in ethanol (8 mL), and the suspension was heated to reflux for 15 hours. The reaction solution was concentrated under reduced pressure, and the obtained solid was then collected by filtration and washed with ethyl acetate. The solid was dried under reduced pressure to obtain the title compound (0.31 g) as a white solid (yield: 64%).
[0357] MS m/z: 297 (M+H) +
[0358] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 10.26 (1H, s), 8.66 (1H, d, J=2 Hz), 8.26 (1H, brs), 8.02 (1H, dd, J=9 Hz, 2 Hz), 7.98 (2H, d, J=8 Hz), 7.70 (2H, d, J=8 Hz), 6.76 (1H, d, J=9 Hz), 4.38 (2H, brs).
(3) 6-(4-Acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-[4-(trifluoromethyl)phenyl]nicotinamide
[0359]
[0360] 6-Hydrazino-N-[4-(trifluoromethyl)phenyl]nicotinamide (0.31 g) and ethyl 2-acetamido-3-oxobutanoate (0.24 g) were suspended in ethanol (25 mL), and the suspension was heated to reflux for 23 hours. The reaction solution was cooled to room temperature, and the obtained solid was collected by filtration and washed with ethanol. The solid was dried under reduced pressure to obtain the title compound (0.20 g) as a white solid (yield: 46%).
[0361] MS m/z: 420 (M+H) +
[0362] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 12.13 (1H, brs), 10.74 (1H, s), 8.99 (2H, m), 8.59-8.42 (2H, m), 8.00 (2H, d, J=8 Hz), 7.76 (2H, d, J=8 Hz), 2.09 (3H, s), 1.90 (3H, s).
Example 17
6-(4-Acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-chlorophenyl)nicotinamide
[0363]
(1) 6-(4-Acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-chlorophenyl)nicotinamide
[0364]
[0365] In accordance with Examples 16-(1), 16-(2), and 16-(3), but using 4-chloroaniline instead of 4-(trifluoromethyl)aniline, the title compound (0.21 g) was obtained as a white solid (yield: 17%).
[0366] MS m/z: 386 (M+H) +
[0367] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 12.12 (1H, brs), 10.53 (1H, s), 8.95 (2H, m), 8.54 (1H, d, J=9 Hz), 8.43 (1H, d, J=8 Hz), 7.80 (2H, d, J=8 Hz), 7.44 (2H, d, J=8 Hz), 2.09 (3H, s), 1.98 (3H, s).
Example 18
6-(4-Acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-bromophenyl)nicotinamide
[0368]
(1) 6-(4-Acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-bromophenyl)nicotinamide
[0369]
[0370] In accordance with Examples 16-(1), 16-(2), and 16-(3), but using 4-bromoaniline instead of 4-(trifluoromethyl)aniline, the title compound (0.24 g) was obtained as a pale red solid (yield: 31%).
[0371] MS m/z: 430 (M+H) +
[0372] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 12.12 (1H, brs), 10.53 (1H, s), 8.97 (2H, m), 8.54 (1H, d, J=9 Hz), 8.43 (1H, d, J=8 Hz), 7.75 (2H, d, J=8 Hz), 7.57 (2H, d, J=8 Hz), 2.09 (3H, s), 1.98 (3H, s).
Example 19
6-(4-Acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide
[0373]
(1) 6-(4-Acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(4-tert-butylphenyl)nicotinamide
[0374]
[0375] In accordance with Examples 16-(1), 16-(2), and 16-(3), but using 4-tert-butylaniline instead of 4-(trifluoromethyl)aniline, the title compound (0.57 g) was obtained as a white solid (yield: 29%).
[0376] MS m/z: 408 (M+H) +
[0377] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 12.11 (1H, brs), 10.35 (1H, s), 8.96 (2H, m), 8.53 (1H, d, J=9 Hz), 8.44 (1H, d, J=8 Hz), 7.67 (2H, d, J=8 Hz), 7.39 (2H, d, J=8 Hz), 2.09 (3H, s), 1.98 (3H, s), 1.29 (9H, s).
Example 20
6-(4-Acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(6-phenylpyridin-3-yl)nicotinamide
[0378]
(1) 6-(4-Acetamido-3-methyl-5-oxo-2,5-dihydro-1H-pyrazol-1-yl)-N-(6-phenylpyridin-3-yl)nicotinamide
[0379]
[0380] In accordance with Examples 16-(1), 16-(2), and 16-(3), but using 6-phenylpyridin-3-amine instead of 4-(trifluoromethyl)aniline, the title compound (0.24 g) was obtained as a white solid (yield: 37%).
[0381] MS m/z: 429 (M+H) +
[0382] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 12.14 (1H, brs), 10.72 (1H, s), 9.05-8.96 (3H, m), 8.56 (1H, d, J=9 Hz), 8.49 (1H, d, J=8 Hz), 8.29 (1H, dd, J=8 Hz, 2 Hz), 8.09 (2H, d, J=7 Hz), 8.03 (1H, d, J=9 Hz), 7.50 (2H, t, J=7 Hz), 7.42 (1H, t, J=7 Hz), 2.10 (3H, s), 1.98 (3H, s).
Example 21
N-[2-(5-{[(2′-Cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-5-methyl-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide
[0383]
(1) N-[2-(5-{[(2′-Cyanobiphenyl-4-yl)methoxy]methyl}pyridin-2-yl)-5-methyl-3-oxo-2,3-dihydro-1H-pyrazol-4-yl]acetamide
[0384]
[0385] In accordance with Example 16-(3), but using 4′-{[(6-hydrazinopyridin-3-yl)methoxy]methyl}biphenyl-2-carbonitrile instead of 6-hydrazino-N-[4-(trifluoromethyl)phenyl]nicotinamide, the title compound (0.91 g) was obtained as a white solid (yield: 74%).
[0386] MS m/z: 454 (M+H) +
[0387] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.95 (1H, s), 8.94 (1H, s), 8.45 (1H, d, J=2 Hz), 7.96 (1H, dd, J=6 Hz, 2 Hz), 7.80 (1H, dt, J=6 Hz, 2 Hz), 7.66-7.50 (8H, m), 4.67 (2H, s), 4.65 (2H, s), 2.06 (3H, s), 1.97 (3H, s).
Example 22
Tert-butyl 4-[(5-methyl-3-oxo-2-{5-[(6-phenylpyridyl-3-yl)carbamoyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)amino]-4-oxobutanoate
[0388]
(1) Ethyl 2-[(4-tert-butoxy-4-oxobutanoyl)amino]-3-oxobutanoate
[0389]
[0390] 4-Tert-butoxy-4-oxobutanoic acid (1.7 g) and N-methylmorpholine (1.1 mL) were dissolved in tetrahydrofuran (60 mL), and the solution was cooled to 0° C. Isobutyl chloroformate (1.3 mL) was added thereto, and the mixture was stirred at 0° C. for 30 minutes. A solution of ethyl 2-amino-3-oxobutanoate hydrochloride (1.8 g) in N,N-dimethylformamide (30 mL) was added thereto, and the mixture was stirred at 0° C. for 5 minutes. Then, N-methylmorpholine (1.1 mL) was added thereto, and the mixture was stirred at room temperature for 20 hours. Ethyl acetate was added to the reaction solution, and the organic layer was washed with water and dried over sodium sulfate. The solvent was distilled off under reduced pressure, and the obtained residue was purified by silica gel column chromatography (Moritex Corporation, elution solvent: hexane/ethyl acetate) to obtain the title compound (2.2 g) as a yellow oil (yield: 72%).
[0391] MS m/z: 300 (M−H) +
[0392] 1 H-NMR (400 MHz, CDC 3 ) δ: 6.79 (1H, d, J=6 Hz), 5.23 (1H, d, J=6 Hz), 4.27 (2H, q, J=7 Hz), 2.62-2.50 (4H, m), 2.38 (3H, s), 1.44 (9H, s), 1.31 (3H, t, J=7 Hz).
(2) Tert-butyl 4-[(5-methyl-3-oxo-2-{5-[(6-phenylpyridyl-3-yl)carbamoyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)amino]-4-oxobutanoate
[0393]
[0394] In accordance with Examples 16-(1), 16-(2), and 16-(3), but using 6-phenylpyridin-3-amine instead of 4-(trifluoromethyl)aniline and ethyl 2-[(4-tert-butoxy-4-oxobutanoyl)amino]-3-oxobutanoate instead of ethyl 2-acetamido-3-oxobutanoate, the title compound (0.24 g) was obtained as a white solid (yield: 30%).
[0395] MS m/z: 543 (M+H) +
[0396] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 12.14 (1H, brs), 10.72 (1H, s), 9.05-8.99 (3H, m), 8.57 (1H, d, J=9 Hz), 8.48 (1H, d, J=8 Hz), 8.29 (1H, dd, J=8 Hz, 2 Hz), 8.09 (2H, d, J=7 Hz), 8.02 (1H, d, J=9 Hz), 7.49 (2H, t, J=7 Hz), 7.42 (1H, t, J=7 Hz), 2.54-2.46 (4H, m), 2.08 (3H, s), 1.40 (9H, s).
Example 23
4-[(5-Methyl-3-oxo-2-{5-[(6-phenylpyridyl-3-yl)carbamoyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)amino]-4-oxobutanoic acid
[0397]
(1) 4-[(5-Methyl-3-oxo-2-{5-[(6-phenylpyridyl-3-yl)carbamoyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)amino]-4-oxobutanoic acid
[0398]
[0399] Tert-butyl 4-[(5-methyl-3-oxo-2-{5-[(6-phenylpyridyl-3-yl)carbamoyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)amino]-4-oxobutanoate (0.054 g) was dissolved in dichloromethane (10 mL). To the solution, trifluoroacetic acid (1.0 mL) was added at room temperature, and the mixture was stirred for 20 hours. The solvent was distilled off under reduced pressure, and the pH of the residue was adjusted to pH 6 by the addition of a saturated aqueous sodium hydrogencarbonate solution. The obtained solid was collected by filtration and washed with water. The solid was dried under reduced pressure to obtain the title compound (0.047 g) as a yellow solid (yield: 97%).
[0400] MS m/z: 487 (M+H) +
[0401] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 10.73 (1H, s), 9.05-8.99 (3H, m), 8.57-8.44 (2H, m), 8.29 (1H, dd, J=8 Hz, 2 Hz), 8.09 (2H, d, J=7 Hz), 8.02 (1H, d, J=9 Hz), 7.49 (2H, t, J=7 Hz), 7.43 (1H, t, J=7 Hz), 2.51 (4H, s), 2.07 (3H, s).
Example 24
N-{5-Methyl-3-oxo-2-[5-({[4-(trifluoromethyl)benzyl]oxy}methyl)pyridin-2-yl]-2,3-dihydro-1H-pyrazol-4-yl}acetamide
[0402]
(1) N-{5-Methyl-3-oxo-2-[5-({[4-(trifluoromethyl)benzyl]oxy}methyl)pyridin-2-yl]-2,3-dihydro-1H-pyrazol-4-yl}acetamide
[0403]
[0404] In accordance with Examples 13-(1), 13-(2), and 16-(3), but using 1-(bromomethyl)-4-(trifluoromethyl)benzene instead of 4′-(bromomethyl)biphenyl-2-carbonitrile, the title compound (0.11 g) was obtained as a white solid (yield: 19%).
[0405] MS m/z: 421 (M+H) +
[0406] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.97 (1H, s), 8.96 (1H, s), 8.43 (1H, s), 8.42 (1H, d, J=8 Hz), 7.95 (1H, d, J=8 Hz), 7.74 (2H, d, J=8 Hz), 7.60 (2H, d, J=8 Hz), 4.68 (2H, s), 4.61 (2H, s), 2.06 (3H, s), 1.97 (3H, s).
Example 25
N-(5-Methyl-3-oxo-2-{5-[4-(trifluoromethyl)benzyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0407]
(1) 2-Hydrazinyl-5-[4-(trifluoromethyl)benzyl]pyridine
[0408]
[0409] In accordance with Example 13-(2), but using 2-chloro-5-[4-(trifluoromethyl)benzyl]pyridine instead of 4′-{[(6-chloropyridin-3-yl)methoxy]methyl}biphenyl-2-carbonitrile, the title compound (0.41 g) was obtained (yield: 47%).
[0410] 1 H-NMR (400 MHz, CDC 3 ) δ: 8.01 (1H, s), 7.54 (1H, d, J=8 Hz), 7.31-7.24 (5H, m), 6.68 (1H, d, J=8 Hz), 5.73 (1H, brs), 3.91 (2H, s), 3.82 (2H, brs).
(2) N-(5-Methyl-3-oxo-2-{5-[4-(trifluoromethyl)benzyl]pyridin-2-yl}-2,3-dihydro-1H-pyrazol-4-yl)acetamide
[0411]
[0412] In accordance with Example 16-(3), but using 2-hydrazinyl-5-[4-(trifluoromethyl)benzyl]pyridine instead of 6-hydrazino-N-[4-(trifluoromethyl)phenyl]nicotinamide, the title compound (0.057 g) was obtained as a white solid (yield: 9.5%).
[0413] MS m/z: 391 (M+H) +
[0414] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.91 (1H, s), 8.94 (1H, s), 8.40 (1H, s), 8.34 (1H, m), 7.80 (1H, m), 7.68 (2H, d, J=8 Hz), 7.50 (2H, d, J=8 Hz), 4.10 (2H, s), 2.05 (3H, s), 1.96 (3H, s).
Example 26
N-[5-Methyl-3-oxo-2-(5-{2-[4-(trifluoromethyl)phenyl]ethyl}pyridin-2-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide
[0415]
(1) 2-Chloro-5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridine
[0416]
[0417] Triphenyl[4-(trifluoromethyl)benzyl]phosphonium bromide (6.4 g) and 6-chloropyridine-3-carboxaldehyde (1.8 g) were dissolved in ethanol (120 mL). To the solution, sodium tert-butoxide (1.2 g) was added at room temperature, and the mixture was stirred for 1 hour. The solvent was distilled off under reduced pressure, and ethyl acetate was added to the residue. The organic layer was washed with water and dried over sodium sulfate. The solvent was distilled off under reduced pressure, and the obtained residue was purified by silica gel column chromatography (Yamazen Corporation, elution solvent: hexane/ethyl acetate). The obtained solid was washed with hexane to obtain the title compound (0.89 g) (yield: 25%).
[0418] 1 H-NMR (400 MHz, CDC 3 ) δ: 8.51 (1H, d, J=2 Hz), 7.84 (1H, dd, J=8 Hz, 2 Hz), 7.67-7.59 (4H, m), 7.35 (1H, d, J=8 Hz), 7.15 (1H, s), 7.14 (1H, s).
(2) Di-tert-butyl 1-(5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridin-2-yl)hydrazine-1,2-dicarbonate
[0419]
[0420] 2-Chloro-5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridine (0.77 g) was dissolved in toluene (15 mL). To the solution, di-tert-butyl hydrazine-1,2-dicarbonate (0.63 g), tris(dibenzylideneacetone)dipalladium complex (0.20 g), 1,1′-bis(diphenylphosphino)ferrocene (0.18 g), and cesium carbonate (2.7 g) were added at room temperature, and the mixture was stirred at 100° C. for 24 hours. Insoluble matter was filtered off through celite, and the filtrate was concentrated under reduced pressure. The obtained residue was purified by silica gel column chromatography (Moritex Corporation, elution solvent: hexane/ethyl acetate) to obtain the title compound (0.72 g) (yield: 55%).
[0421] MS m/z: 480 (M+H) +
[0422] 1 H-NMR (400 MHz, CDC 3 ) δ: 8.48 (1H, d, J=2 Hz), 7.87 (1H, dd, J=8 Hz, 2 Hz), 7.78 (1H, d, J=8 Hz), 7.61 (4H, s), 7.12 (1H, s), 7.11 (1H, s), 7.00 (1H, brs), 1.54 (9H, s), 1.48 (9H, s).
(3) Di-tert-butyl 1-(5-{2-[4-(trifluoromethyl)phenyl]ethyl}pyridin-2-yl)hydrazine-1,2-dicarbonate
[0423]
[0424] Di-tert-butyl 1-(5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridin-2-yl)hydrazine-1,2-dicarbonate (0.40 g) was dissolved in ethyl acetate (20 mL). To the solution, palladium-carbon was added, and the mixture was stirred at room temperature for 10 hours under a hydrogen atmosphere. Insoluble matter was filtered off through celite, and the filtrate was concentrated under reduced pressure. The obtained residue was purified by silica gel column chromatography (Yamazen Corporation, elution solvent: hexane/ethyl acetate) to obtain the title compound (0.32 g) (yield: 81%).
[0425] 1 H-NMR (400 MHz, CDC 3 ) δ: 8.15 (1H, d, J=2 Hz), 7.62 (1H, d, J=8 Hz), 7.53 (2H, d, J=10 Hz), 7.44 (1H, dd, J=8 Hz, 2 Hz), 7.25 (2H, d, J=10 Hz), 6.99 (1H, brs), 3.00-2.86 (4H, m), 1.52 (9H, s), 1.47 (9H, s).
(4) 2-Hydrazinyl-5-{2-[4-(trifluoromethyl)phenyl]ethyl}pyridine
[0426]
[0427] Di-tert-butyl 1-(5-{2-[4-(trifluoromethyl)phenyl]ethyl}pyridin-2-yl)hydrazine-1,2-dicarbonate (0.44 g) was dissolved in a solution of hydrogen chloride in dioxane (4 N, 10 mL), and the solution was stirred at room temperature for 12 hours. A saturated aqueous sodium hydrogencarbonate solution was added to the reaction solution, followed by extraction with dichloromethane. The organic layer was dried over sodium sulfate. The solvent was distilled off under reduced pressure, and the obtained residue was purified by NH-silica gel column chromatography (Moritex Corporation, elution solvent: hexane/ethyl acetate) to obtain the title compound (0.26 g) (yield: 74%).
[0428] MS m/z: 282 (M+H) +
[0429] 1 H-NMR (500 MHz, CDC 3 ) δ: 7.90 (1H, d, J=2 Hz), 7.52 (2H, d, J=8 Hz), 7.29-7.22 (3H, m), 6.65 (1H, d, J=9 Hz), 5.71 (1H, brs), 3.78 (2H, brs), 2.95-2.90 (2H, m), 2.85-2.80 (2H, m).
(5) N-[5-Methyl-3-oxo-2-(5-{2-[4-(trifluoromethyl)phenyl]ethyl}pyridin-2-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide
[0430]
[0431] In accordance with Example 16-(3), but using 2-hydrazinyl-5-{2-[4-(trifluoromethyl)phenyl]ethyl}pyridine instead of di-tert-butyl 1-{5-[4-(trifluoromethyl)phenyl]pyridin-2-yl}hydrazine-1,2-dicarbonate, the title compound (0.15 g) was obtained as a white solid (yield: 56%).
[0432] MS m/z: 405 (M+H) +
[0433] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.88 (1H, brs), 8.92 (1H, s), 8.32 (1H, d, J=7 Hz), 8.20 (1H, d, J=2 Hz), 7.81 (1H, dd, J=7 Hz, 2 Hz), 7.64 (2H, d, J=9 Hz), 7.44 (2H, d, J=9 Hz), 3.05-2.92 (4H, m), 2.04 (3H, s), 1.96 (3H, s).
Example 27
N-[5-Methyl-3-oxo-2-(5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridin-2-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide
[0434]
(1) 2,2,2-Trifluoro-N-(5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridin-2-yl)acetohydrazide
[0435]
[0436] Di-tert-butyl 1-(5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridin-2-yl)hydrazine-1,2-dicarbonate (0.32 g) was dissolved in dichloromethane (10 mL). To the solution, trifluoroacetic acid (3 mL) was added at room temperature, and the mixture was stirred for 17 hours. After concentration under reduced pressure, a saturated aqueous sodium hydrogencarbonate solution was added to the residue. The obtained solid was collected by filtration and washed with water. The solid was dried under reduced pressure to obtain the title compound (0.18 g) (yield: 71%).
[0437] MS m/z: 376 (M+H) +
[0438] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 11.54 (1H, brs), 9.15 (1H, brs), 8.22 (1H, s), 7.94 (1H, d, J=9 Hz), 7.79-7.68 (4H, m), 7.34 (1H, d, J=17 Hz), 7.17 (1H, d, J=17 Hz), 6.78 (1H, d, J=9 Hz).
(2) 2-Hydrazinyl-5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridine
[0439]
[0440] 2,2,2-Trifluoro-N-(5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridin-2-yl)acetohydrazide (0.17 g) was dissolved in ethanol (5 mL). To the solution, concentrated hydrochloric acid (1 mL) was added at room temperature, and the mixture was heated to reflux for 2 hours. A saturated aqueous sodium hydrogencarbonate solution was added to the reaction solution, followed by extraction with dichloromethane. The organic layer was dried over sodium sulfate. The solvent was distilled off under reduced pressure, and the obtained residue was purified by NH-silica gel column chromatography (Moritex Corporation, elution solvent: ethyl acetate) to obtain the title compound (0.079 g) (yield: 63%).
[0441] MS m/z: 280 (M+H) +
[0442] 1 H-NMR (500 MHz, CDC 3 ) δ: 8.23 (1H, d, J=2 Hz), 7.76 (1H, dd, J=9 Hz, 2 Hz), 7.61-7.54 (4H, m), 7.09 (1H, d, J=16 Hz), 6.95 (1H, d, J=16 Hz), 6.76 (1H, d, J=9 Hz), 5.91 (1H, brs), 3.88 (2H, brs).
(3) N-[5-Methyl-3-oxo-2-(5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridin-2-yl)-2,3-dihydro-1H-pyrazol-4-yl]acetamide
[0443]
[0444] In accordance with Example 16-(3), but using 2-hydrazinyl-5-{(E)-2-[4-(trifluoromethyl)phenyl]ethenyl}pyridine instead of 6-hydrazino-N-[4-(trifluoromethyl)phenyl]nicotinamide, the title compound (0.054 g) was obtained as a white solid (yield: 47%).
[0445] MS m/z: 403 (M+H) +
[0446] 1 H-NMR (400 MHz, DMSO-d 6 ) δ: 12.01 (1H, brs), 8.95 (1H, brs), 8.65 (1H, s), 8.45 (1H, d, J=8 Hz), 8.27 (1H, d, J=8 Hz), 7.84 (2H, d, J=8 Hz), 7.76 (2H, d, J=8 Hz), 7.55-7.40 (2H, m), 2.07 (3H, s), 1.98 (3H, s).
Formulation Examples
Formulation Example 1
Injection
[0447] 1.5% by weight of a compound of the Examples is stirred in 10% by volume of propylene glycol, then adjusted to a fixed volume with water for injection, and subsequently sterilized to obtain an injection.
Formulation Example 2
Hard Capsule
[0448] 100 mg of a powdery compound of the Examples, 128.7 mg of lactose, 70 mg of cellulose, and 1.3 mg of magnesium stearate are mixed, and passed through 60 mesh sieve, and subsequently the resulting powders are put into 250 mg of No. 3 gelatin capsule to obtain capsules.
Formulation Example 3
Tablet
[0449] 100 mg of a powdery compound of the Examples, 124 mg of lactose, 25 mg of cellulose, and 1 mg of magnesium stearate are mixed, and tableted with a tablet-making machine to obtain tablets each having 250 mg. This tablet can be sugar-coated as necessary.
Test Example
[0450] The utility (pharmacological activity) of the compounds of the present invention was confirmed by the testing indicated below.
[0451] In vitro erythropoietin (EPO) induction activity of test compounds was evaluated using human liver cancer-derived cell line Hep3B (ATCC, Manassas, Va.). Hep3B cells were cultured overnight at 37° C. in Dulbecco's modified Eagle's medium (DMEM) in the presence of 10% fetal bovine serum (FBS) (24-well plate, 1.0×10 5 cells/well). After replacing with fresh DMEM (+10% FBS) containing a test compound dissolved in 0.5% dimethyl sulfoxide (DMSO) (prepared to a concentration of 12.5 μM) or a solvent control (0.5% DMSO), the cells were cultured for 32 hours at 37° C. After recovering the culture supernatant, EPO concentration in the culture supernatant was quantified using human EPO ELISA kits (StemCell Technologies). The EPO concentration obtained using each test compound was expressed as a multiple of the EPO concentration obtained using the control.
[0452] The results are shown in Table 1. The compounds of the present invention or pharmacologically acceptable salts thereof demonstrated a superior ability to produce EPO, and are useful as medicaments for treatment or prophylaxis of anemia.
[0000]
TABLE 1
Test compound
EPO concentration (multiple)
Control (0.5% DMSO)
1
Example 1
37
Example 2
36
Example 3
17
Example 4
17
Example 5
12
Example 6
13
Example 7
29
Example 8
26
Example 9
6.1
Example 10
23
Example 11
41
Example 12
2.8
Example 13
29
Example 14
22
Example 15
24
Example 16
3.4
Example 17
4.3
Example 18
3.3
Example 19
13
Example 20
3.7
Example 21
20
Example 22
1.9
Example 23
2.7
Example 24
22
Example 25
16
Example 26
22
Example 27
2.7
INDUSTRIAL APPLICABILITY
[0453] The compounds of the present invention or pharmacologically acceptable salts thereof have a superior EPO production-enhancing activity, and are useful for diseases or the like caused by decreased EPO. Specifically, the compounds of the present invention or pharmacologically acceptable salts thereof are useful as medicaments for the prophylaxis and/or treatment of anemia, preferably nephrogenic anemia, anemia of prematurity, anemia incidental to chronic diseases, anemia incidental to cancer chemotherapy, cancerous anemia, inflammation-associated anemia, or anemia incidental to congestive heart failure, more preferably anemia incidental to chronic kidney disease, and can also be used as medicaments for the prophylaxis and/or treatment of ischemic cerebrovascular disease or the like. | The present invention provides a compound which enhances the production of erythropoietin. The present invention provides, for example, a compound represented by the formula (1) wherein R 1 : -Q 1 , -Q 1 -X-Q 2 , or -Q 1 -X-Q 2 -Y-Q 3 : a monocyclic or bicyclic aromatic heterocyclic group; Q 2 , Q 3 : an aromatic hydrocarbon ring group or a monocyclic aromatic heterocyclic group; X: —CONH—, —CONHCH 2 —, —CH 2 OCH 2 —, —NHCH 2 CH 2 —, or the like; Y: a single bond, —O—, —(CH 2 ) n —, or —O—(CH 2 ) n —; m, n: an integer from 1 to 3; R 2 : H or an alkyl group; and R 3 : H, an alkoxycarbonyl group, a carboxy group, an aromatic hydrocarbon ring group, or a monocyclic aromatic heterocyclic group. | 2 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a method for controlling a quantity of ink in an inking unit of a printing machine using a predetermined nominal or desired value.
For metering ink into the inking unit of a printing machine, ink fountains or ducts have become known heretofore which include a fountain or duct roller, also called a ductor, that rotates in contact with fluid ink and a number of doctor blades disposed adjacent one another in the longitudinal direction of the fountain roller, the positioning of the doctor blades at the fountain roller being controllable by actuators, so that the doctor blades adjust the thickness of the ink layer, which is removed from the ink bath by the fountain roller, to a separately definable value for each individual zone.
A vibrator roller performs an oscillating movement wherein, in a first end position thereof, it engages the fountain roller in such a way that the ink layer located thereon is transferred to the vibrator roller, and in a second end position thereof, it engages an inking unit roller so as to transfer the ink portion that is picked up by the fountain roller, onto the inking unit roller.
The ink flow, i.e., the quantity of ink per unit of time, with which the inking unit is supplied, thus derives from the number of ink portions that are transferred per unit of time, and the size of each individual ink portion is determined by the thickness of the ink layer on the fountain roller (which may differ from zone to zone) and the size of the portion of the surface area of the vibrator roller that comes into contact with the fountain roller in the course of a cycle of the oscillating motion.
In the context of supplying ink to individual zones of the inking unit of a printing machine, it has been known heretofore always to overcontrol the ink supply of the affected zone when the ink quantity in this zone is changed. This means that when the desired quantity of ink for the zone is changed, the thickness of the ink layer that is appropriate in order to maintain the desired ink quantity in continuous operation is not immediately set on the fountain roller; rather, when the modification calls for an increase or a reduction of the ink quantity, a temporary value of the ink layer thickness is initially set, which is larger and smaller, respectively, than that which would be required in order to maintain the desired ink quantity in continuous operation.
But this method only functions when the desired modification of the ink quantity, including the overcontrol, can be achieved by adjusting the layer thickness on the fountain roller, for example, by an electronic ink zone control such as the aforementioned control of the positioning of the doctor blades against the fountain roller.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method for controlling an ink quantity in an inking unit by which it is also possible to make very large adjustments in the ink quantity within a short time period. Another object of the invention is to provide such a method by which an acceleration of the inking unit response is achieved, even when the ink fountains are without electronic ink zone control.
With the foregoing and other objects in view, there is provided, in accordance with the invention, a method for controlling the ink quantity in an inking unit of a printing machine by a predetermined nominal value, using a vibrator roller oscillating between a fountain roller and the inking unit, and picking up an ink portion and surrendering it to the inking unit with which the vibrator roller is in contact, which comprises varying the width of an ink stripe on the vibrator roller, depending upon the nominal value, by adjusting the size of the transferred ink portion, for a modification in the nominal value, from a size (F I ) corresponding to the nominal value prior to modification, to at least one intermediate size (F z ) lying beyond a size (F x ) corresponding to the modified nominal value and, subsequent to the expiration of a transition time interval ([t 1 ,t 2 ]), adjusting the intermediate size (F z ) of the ink portion back to the size (F x ) thereof corresponding to the modified nominal value.
In accordance with another mode of the method, the difference (F u ) between the intermediate size (F z ) and the size (F I ) corresponding to the nominal value prior to the modification thereof is proportional to the difference between the size (F I ) corresponding to the nominal value prior to modification thereof and the size (F x ) corresponding to the modified nominal value.
In accordance with a further mode of the method, the proportionality factor is between 1.5 and 2.5.
In accordance with an added mode, the method invention includes modifying the width of the ink stripe so as to adjust the ink portion between the size (F x ) corresponding to the modified nominal value and the intermediate size (F z ).
In accordance with an additional mode, the method includes modifying the thickness of the ink layer on the ink stripe so as to adjust the ink portion between the size (F x ) corresponding to the modified nominal value and the intermediate size (F z ).
In accordance with yet another mode, the method includes zonally controlling the thickness of the ink on the ink stripe.
In accordance with yet a further mode, the method includes zonally prescribing the ratio of the difference between the intermediate size (F z ) and the size (F I ) corresponding to the nominal value prior to the modification, to the difference between the size (F I ) corresponding to the nominal value prior to modification and the size (F x ) corresponding to the modified nominal value.
In accordance with yet an added mode, the method includes prescribing the ratio smaller, the larger the area is that is covered by the zone that is being controlled.
In accordance with yet an additional mode, the method includes modifying the duration of contact between the fountain roller and the vibrator roller so as to modify the width of the ink stripe.
In accordance with a concomitant mode, the method includes modifying the rate of rotation of the fountain roller so as to modify the width of the ink stripe.
It has proven expedient herein to select the difference between the temporary size of the ink portion and the size that corresponds to the nominal value prior to modification so as to be proportional to the difference between the size of the ink portion corresponding to the nominal value prior to modification and the size of the ink portion corresponding to the modified nominal value. The proportionality factor preferably is between 1.5 and 2.5. This means that the temporary size is overcontrolled compared to the size corresponding to the modified nominal value by a factor of 1.5 to 2.5.
While the modification of the ink portion from the size thereof corresponding to the nominal value prior to modification to the corresponding size thereof subsequent to modification is always accomplished by varying the width of the ink stripe, there are two logical methods for changing the size of the ink portion between the size corresponding to the modified nominal value and the temporary size. The first provides for a modification of the width of the ink stripe on the vibrator roller; i.e., the length along which the fountain roller and the vibrator roller engage one another in the course of a movement cycle of the vibrator roller is varied. This possibility also exists in machines with ink fountains without zonal control of the ink blades. The other possibility is to vary the thickness of the ink stripe that is transferred by the vibrator roller, so that, given a constant width of the ink stripe, portions of varying sizes can be transferred. Modification of the thickness is expediently accomplished by adjusting doctor blades that rest at the fountain roller, which determine the thickness of the ink layer that the fountain roller extracts from an ink fountain. This alternate embodiment can advantageously be used with ink fountains having zonally controllable blades.
It is particularly advantageous here, if the thickness of the ink stripe is controlled zonally. This makes it possible to stipulate the extent of the overcontrol separately for each zone and, for example, to select a greater overcontrol factor for a zone with a small area coverage compared to zones with larger area coverage.
Of course, the two aforementioned possibilities for modifying the size of the ink portion can also be combined. Thus, for example, it is imaginable that both the thickness of the ink stripe and the width are varied in an individual adjustment of the ink portion from the size corresponding to the modified nominal value to the temporary size, or the reverse. It would also be conceivable to perform an adjustment from the size corresponding to the modified nominal value to the temporary size by changing the width, and to perform the counteradjustment in the opposite direction by varying the thickness of the ink stripe, or the reverse, if this simplifies the control or proves otherwise expedient.
The width of the ink stripe can be influenced by shortening or lengthening the phase within the movement cycle of the vibrator roller wherein the vibrator roller is in contact with the fountain roller. Manipulation of the rate of rotation of the fountain roller is a particularly advantageous way to modify the width of the ink stripe, because this is easy to control. In this case, the width of the ink stripe that is generated on the vibrator roller during a constant contact period is approximately directly proportional to the rate of rotation of the fountain roller. The rate of rotation of the fountain roller can be selected quite freely, without having any effect on the functioning of the inking unit that is connected downline.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as a method for controlling a quantity of ink in an inking unit, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific modes of the method when read in connection with the accompanying drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side elevational view of a printing unit of a printing machine, which is suitable for performing the method according to the invention;
FIG. 2 is a plot diagram depicting the time rate of change of a nominal value of an ink quantity, and the size of the ink portion controlled by this nominal value;
FIG. 3 is a flowchart of the steps of the inventive method;
FIG. 4 is a more detailed representation of one of the steps of the flowchart of FIG. 3; and
FIGS. 5 a and 5 b are plot diagrams depicting the time rate of change, represented by the number of sheets that have been printed, of the ink thickness of the printed sheets in the course of printing processes which are controlled in accordance with various methods.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and, first, particularly to FIG. 1 thereof, there is shown therein, in a fragmentary diagrammatic view of a printing machine, a printing unit for performing the method according to the invention. The printing unit has an ink fountain 1 as an ink source, which includes a fountain roller 2 that rotates in contact with an ink bath 3 and is thereby wetted with the ink. A plurality of doctor blades 4 are disposed at a sidewall of the ink fountain 1 . The doctor blades 4 define a gap, referred to as an ink zone opening, between themselves, on the one hand, and the surface of the fountain roller 2 , on the other hand. The gap determines the thickness of the ink layer that is extracted from the ink fountain by the fountain roller 2 . The ink zone opening is adjustable for each doctor blade 4 individually with the aid of a control signal that is delivered by a non-illustrated control circuit. The fountain roller 2 can thus have a plurality of zones at the surface thereof, corresponding to the individual blades 4 , at which the thickness of the ink layer can be different.
A vibrator roller 5 is oscillatingly movable between the position thereof illustrated in FIG. 1, wherein the vibrator roller 5 engages a roller 6 of the inking unit 12 , and a second position thereof wherein it engages the fountain roller 2 . The vibrator roller 5 is rotated, respectively, by the rollers 2 or 6 with which it is in contact. The duration of the contact with the fountain roller 2 is shorter than corresponds to a complete rotation of the vibrator roller 5 , so that, during contact, the latter is covered with ink only on one part of the surface thereof. This covered portion is referred to as an ink stripe. The width thereof can be defined as an absolute in length units or, in relative terms, as a fraction of the total periphery of the vibrator roller 5 . The phase of the contact with the roller 6 encompasses several rotations of the vibrator roller 5 , so that the ink portion it picks up during contact with the fountain roller 2 is surrendered to the roller 6 virtually completely or at least in a percentage that is substantially equal for each period of the motion of the vibrator roller 5 .
The inking unit 12 includes a large number of additional rollers with different radii, which provide for a uniform distribution of the ink on the surface thereof in the peripheral direction by rolling off on one another. Simultaneous rubbing of the ink in the axial direction of the rollers, which occurs in the inking unit, insures that the as yet abrupt transitions of the ink layer thickness between zones become fluid transitions when the ink reaches the printing plate on the plate cylinder 7 .
The further construction of the printing unit with a rubber blanket cylinder 8 , a rubber blanket washing device 9 , an impression cylinder 10 , a dampening unit 11 , and so forth, is well known and, it is believed, need not be described in further detail here.
FIG. 2 shows the time rate of change of a nominal or reference value s that is prescribed for the control circuit from outside, and the size of the ink portion F, which is transported in each movement cycle of the vibrator roller 5 , that size being dependent upon this nominal value, and modifications thereof. For each nominal value, a size of the ink portion exists, which can be calculated by the control circuit or interrogated from a characteristic curve and which, for a constant nominal value, must be transported by the vibrator roller 5 in order to maintain the desired quantity of ink in the printing unit. In the time interval from 0 to t 1 , the value s 1 is present at the control circuit, and the transferred ink portion is F I . At the instant of time t 1 , the nominal value changes to s x , for example, because the ink quantity in the printing unit must be adapted to the ink consumption of a new print job not only in individual zones but in the entire printing unit. A new size of the ink portion F x corresponds to the new nominal value s x . In dependence upon F x and F I , the control circuit calculates an overelevation or increase F u of the ink portion.
According to a first mode of the method according to the invention, the control circuit modifies the width of the ink stripe on the vibrator roller so that an ink portion F z =F x +F u is transferred with each movement cycle. In the example at hand, F z −F I =2(F x −F I ); i.e. , the ink portion is overcontrolled by a factor of 2. Overcontrol factors between 1.5 and 2.5 have proven advantageous for a large range of area coverages of the printed product.
In order to increase the ink portion to F z , the control circuit varies the rotation rate of the fountain roller 2 . Because the relationship between the transferred ink quantity and the angle of rotation which is traversed by the fountain roller and vibrator roller in contact with one another is not exactly linear, the control circuit advantageously determines the angle of rotation that the fountain roller must traverse in contact with the vibrator drum in order to transfer the desired ink quantity, preferably using an empirically calculated characteristic curve, and controls the rate of rotation of the fountain roller in such a manner that the desired angle of rotation is traversed within the constant time that is available for the contact of the fountain roller and the vibrator roller, which is conditional to the construction of the printing unit.
At time t 2 the rate of rotation of the fountain roller is adjusted again, so that, from that time onward, the transferred ink portion is of a size F x , which is associated with the nominal value s x .
A second mode of the method according to the invention is described with the aid of the flowcharts of FIGS. 3 and 4. This mode differs from the first mode in the manner wherein the overelevation F u is proportioned. Whereas in the first mode, this is accomplished exactly like the modification of F I to F x by changing the width of the ink stripe, here the overelevation is controlled using the ink zone opening. Only one individual ink zone is considered in the description of the second mode; it is understood that the method is performed for each individual zone in a printing machine having several ink zones.
A modification of the nominal value from s I to s x as represented in FIG. 2 is again under consideration. In the time interval [0, t 1 ] an actual ink stripe width bfI and an actual ink zone opening DioI are set, and an ink portion F I is transferred. After prescribing a new nominal value s x at time t 1 , in step 31 of FIG. 3, the control circuit first calculates the width bfZ that the ink stripe would have to have in order to transfer the ink portion F x . The ink stripe width bfI that was set in the time interval [0,t 1 ] is known.
In step 32 , a theoretically equivalent ink zone opening DioEIt is calculated, which gives the dimension of the ink zone opening that would have to be set in the time interval [0,t 1 ] in order to transfer the ink portion F I with the ink stripe width bfX. The calculation of DioEI T is accomplished with the aid of a family of preset ink characteristic curves which are stored in the control circuit and which indicate the ink zone opening that is theoretically required for a given ink stripe width, as a function of surface coverage.
In addition, a theoretical ink zone opening DioEXt is calculated with the aid of the same preset ink characteristic curves that give the theoretical ink zone opening for the original ink stripe width bfI.
The reason for calculating DioEXt is that the ink zone opening DioI that is actually set by a user in the time interval [0,t 1 ] for optimal ink reproduction can differ from the theoretical ink zone opening DioEXt that is obtained from the characteristic curves. It is presumed that the relationship or ratio c between an ink zone opening that is theoretically computed, using the characteristic curves, for given area coverage and ink stripe width, and the real ink zone opening is the same for all area coverages and ink stripe widths. This ratio c can thus be calculated in step 33 using the actual ink zone opening DioI in the time interval 0 to t 1 and the theoretical ink zone opening DioEXt:
c=DioI/DioEXt,
and the real equivalent ink zone opening DioEI is calculated from DioEIT:
DioEI=c DioEIt.
At the conclusion of step 33 , all parameters are known which are required for the control of the ink feed adjustment: bfX, the ink stripe width that must now be set; DioI, the desired ink zone opening subsequent to the adjustment (this is the same before the adjustment is begun and after it is completed); and DioEI, the equivalent real ink zone opening. The ink stripe width is now set to the new value bfX in step 34 , and this is followed by the calculation of the time characteristic of the control of the ink zone opening dependent upon the previously specified initial parameters bfX, DioEI and DioI in step 35 .
The individual steps of this calculation will now be described with reference to FIG. 4 . In step 41 , the difference dDio between DioI and DioEI is determined. In step 42 , when this is less than a limit value dDioMin, there is no overcontrol of any sort, and the ink zone opening remains at DioI. Otherwise, the procedure branches to step 43 , wherein an overelevation factor y is specified with the aid of an overelevation characteristic curve dependent upon the area coverage. The prescription of the overelevation factors is discussed in greater detail hereinafter in connection with FIG. 6 . In step 44 , the overcontrolled ink zone opening DioU is calculated in accordance with the formula.
DioU=DioEI+dDio·y
In step 45 , when the calculated ink zone opening DioU lies within the interval of the actually adjustable ink zone openings [DioMin, DioMax], in step 46 , the time period Tu during which the overcontrol is maintained is fixed at a standard value Tu 0 . In step 47 , when DioU is less than DioMin, for example, because dDio is negative due to a drop in the nominal value and it cannot be set at the ink fountain, the time period Tu must be defined longer than in the previously described case. Therefore, in step 48 , Tu is calculated according to the formula
Tu=TuO ( DioU−DioI )/( DioMin−DioI ).
An analogous procedure is followed when DioU, in step 50 , is greater than the maximum adjustable ink zone opening DioMax. In step 51 , Tu is calculated according to the formula
Tu=TuO ( DioU−DioI )/( DioMax−DioI ),
and DioU is then corrected to the value DioMax in step 52 .
It is still possible to check, in a subsequent step 53 , whether the prescribed period Tu fails to cross an upper limit TuMax and, if so, to limit the overcontrol period to TuMax.
Once the duration Tu of the overcontrol time period and the ink zone opening DioU that must be set during this time period are known, the corresponding control can be executed (note FIG. 3, step 36 ). The modification of the ink stripe from bfI to bfX, and the adjustment of the ink zone openings from DioI to DioU are accomplished simultaneously. At the end of the overcontrol period Tu, the ink zone opening DioI is adjusted again, and the new ink stripe width bfX is retained.
FIGS. 5 a and 5 b show two examples of the time characteristic or time rate of change of the ink thickness of printed sheets, for an adjustment of the ink stripe width, once in a conventional manner without overcontrol, and again with overcontrol by a factor of two and four, respectively, in accordance with the invention, the overcontrol having been performed by temporarily increasing the width of the ink stripe in accordance with the first alternative of the method. What was measured was the respective total hue density at the start of the printing of a sheet. In order to make the measurement results easier to compare, the density modification has been normalized to 1, and the lesser of the two densities has been assigned the value 0, and the greater of the two densities, the value 1, respectively.
A first measurement was performed with an area coverage FD=80%. In this regard, an O.K. sheet was first printed with a density ratio DV=1.50, for an ink stripe width of bf=30%. The curve al from FIG. 5 shows the density values obtained in a printing of 400 sheets subsequent to an elevation of the ink stripe width to bf=50%. Subsequent to the preparation of the O.K. sheet with an ink stripe width of bf=30%, in a second measurement sequence, the ink stripe width was raised to bf=70% for 40 sheets, and then 400 sheets were printed with an ink stripe width of bf=50%. This corresponds to a twofold overcontrol of the ink stripe width during a transition period wherein the 40 sheets were printed. The curve a 2 shows the measurement results. In a third measurement sequence, as in the second, an O.K. sheet was first prepared with DV=1.50 for an ink stripe width of bf=30%, and then, for 40 sheets, the ink stripe width was raised to bf=70%. Next, the ink stripe width was reduced to bf=40%, and 400 sheets were printed at this setting. The overcontrol factor here was equal to 4. The measurement result is represented in the curve a 3 .
In the conventional control process of curve a 1 , some 100 sheets are needed before the relative density reaches the tolerance interval [0.7; 1.3] about the target value 1. With the overcontrol in the curves a 2 and a 3 , only approximately 60 sheets are needed, respectively. The curve a 3 shows a clear overshoot in the region between approximately 90 to 180 sheets; the curve a 2 corresponding to twofold overcontrol shows an overshoot that is considerably smaller but yet only slightly exits the tolerance interval.
FIG. 5 b shows the results of an analogous measurement sequence which was performed under the same conditions as in the case of FIG. 5 a except that the surface density was FD=40% instead of 80%. As a result of the lower ink consumption, the number of sheets that are printed before reaching the tolerance interval is greater than in the previous case, being approximately 110 for conventional control (curve b 1 ), and approximately 70 sheets for the overcontrol (curves b 2 , b 3 ) in accordance with the method of the invention. The overshoots are smaller than in the example previously considered.
For area coverages of from 30 to 100%, overelevation factors of between 2.5 and 1.5 yield good results. Because the area coverages of the printing copy are usually not known in advance in most situations of application, or they vary in different zones of the printing copy, a fixed overcontrol factor in the range from 2.5 to 1.5 must be preselected particularly when the overcontrol is achieved by controlling the ink stripe width and therefore is necessarily uniform for the entire printed image. By contrast, when the overcontrol is performed in zones by controlling the ink zone opening, as according to the flowcharts of FIGS. 3 and 4, it is then also possible to prescribe the overcontrol factor for each zone individually, depending upon the area coverage prevailing thereat. | A method for controlling the ink quantity in an inking unit of a printing machine by a predetermined nominal value, using a vibrator roller oscillating between a fountain roller and the inking unit, and picking up an ink portion and surrendering it to the inking unit with which the vibrator roller is in contact, includes varying the width of an ink stripe on the vibrator roller, depending upon the nominal value, by adjusting the size of the transferred ink portion, for a modification in the nominal value, from a size (F I ) corresponding to the nominal value prior to modification, to at least one intermediate size (F z ) lying beyond a size (F x ) corresponding to the modified nominal value and, subsequent to the expiration of a transition time interval ([t 1 ,t 2 ]), adjusting the intermediate size (F z ) of the ink portion back to the size (F x ) thereof corresponding to the modified nominal value. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a system for distributing electric power, particularly systems for low and medium voltage which comprise automatic protection breakers.
More specifically, the invention relates to a distribution system which comprises automatic protection breakers which are distributed hierarchically on various levels. The invention further comprises a method for controlling the intervention sequence of the automatic breakers, which are mutually interlocked so as to intervene selectively in order to cut out the faulty parts of the system.
These distribution systems are currently protected by means of automatic breakers, in which protection against a short-circuit fault with current values close to the breaking capacity is provided by means of classical electromechanical devices based on the electrodynamic effect of fault currents, which have a reaction time on the order of milliseconds.
Electric power distribution grids have a plurality of said breakers, which are distributed radially on various levels in order to selectively limit the power outage to the part or region of the network affected by the fault.
This selectivity among the various breakers is currently achieved by utilizing the different values of the current and of the intervention times of the protection devices and their different mechanical inertia, which depends on their size (and therefore on the masses involved in the opening movement).
In other words, a breaker to which several other breakers supplying an equal number of loads or subsections of the system are connected has higher settings for the protection device, is larger and has greater inertia than the breakers that it supplies, and therefore does not intervene in case of a fault downstream of the smaller breakers that it supplies. This of course occurs for all the higher levels to which the fault current can propagate.
The size of the breakers is in turn a function of the nominal current of the breaker, and therefore the size allocation of the system, by having to ensure the selectivity requirements, is based not only on the values of the working currents that are present in each node but also on the selectivity requirements, which often require to keep the short-circuit current in the system for longer than actually necessary to interrupt the fault current.
While the need to minimize the fault energy, i.e., damage, requires the fastest possible intervention, the need to select among the breakers the one that must intervene in fact entails slowing the protective intervention. Accordingly, the conventional systems of the prior art do not allow to optimize the size allocation of an electric power distribution system as regards the protection breakers.
SUMMARY OF THE INVENTION
The aim of the present invention is to overcome the drawbacks of the prior art and particularly to provide an electric power distribution system which has optimum size allocation of the breakers and ensures both characteristics, namely quick intervention and assured selectivity.
This aim is achieved by means of the present invention, which comprises a plurality of automatic protection breakers distributed on at least two levels, characterized in that each one of the breakers comprises an electronic protection unit which opens the breaker depending on the values of a current (i(t)) flowing in the breaker and of its derivative (di(t)/dt), and in that there are provided means for interconnecting the breakers in order to exchange information concerning the fault conditions in addition to their state.
The present invention further consists of a method for controlling the intervention sequence of automatic protection breakers in an electric power distribution system, which are mutually interlocked and distributed on at least two levels, characterized in that when a breaker detects a fault condition, said breaker reports it to a breaker at the next higher level, blocking its opening action; and in that the higher-level breaker, if it detects the same fault condition, reports the corresponding information to the upstream breaker, if any, blocking its opening action; and in that said reporting process stops when the highest hierarchical level of the structure is reached or when one of the breakers no longer detects any fault condition.
Advantageously, fault detection is based both on the instantaneous value of the circulating current and on its derivative.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention are described in the appended claims.
The present invention is now described with reference to the accompanying drawings, which relate to two preferred but non-limitative embodiments of the invention.
In the drawings:
FIG. 1 is a schematic view of part of an electric power distribution system according to the present invention;
FIG. 2 is a view of the structure for acquiring the current values (i(t)), digitally processing said values and actuating the opening kinematic system, provided in a breaker used in the present invention;
FIG. 3 plots an example of a set of acceptable operating conditions;
FIG. 4 is a view of the interlock structure (divided into two sections) of a single breaker;
FIG. 5 is a view of a configuration of breakers interlocked with a short connection; and
FIG. 6 is a view of a configuration of breakers interlocked by means of long connections.
In the various figures, the same reference numerals are used to designate identical or substantially equivalent components.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically illustrates part of an electric power distribution system according to the present invention, which comprises an electrical panel I which contains a breaker 10 and four breakers 11, 12, 13 and 14, cascade-connected to the breaker 10; each one of said four breakers 11-14 supplies a corresponding load. The system can be applied to three-phase distribution (with three or four wires), two-phase distribution and phase-neutral distribution, although for the sake of simplicity in illustration it is shown with a single wire in FIG. 1.
Moreover, the figure shows only the load constituted by a panel II, which in turn contains a breaker 20 to which four breakers 21, 22, 23 and 24 are cascade-connected; each one of said four breakers is in turn connected to a further load (not shown).
FIG. 1, in addition to the connections between the breakers which allow the flow of electric power (shown in thick lines), also shows connections 17, 18, 19, 27, 28, 29 over which information travels; said information is exchanged unidirectionally or bidirectionally among the various breakers.
FIG. 1 clearly shows that the breakers are distributed on various levels (four levels are shown in the figure) and that other breakers of the same level can be provided in parallel to the "main" breakers 10 and 20. Finally, the star configuration of the system shown by way of example in FIG. 1 is non-limitative.
In case of a fault that affects, for example, the breaker 24 (short circuit or ground fault current in the circuit downstream of the breaker 24), the system according to the present invention provides an interlock condition which ensures not only fast opening of the breaker 24 but also ensures that the higher-level breakers 20, 14 and 10 remain closed.
With reference also to FIG. 4, the base element of the system is constituted by the single breaker 10, which is divided into two sections, designated respectively as "father" section 10A and "child" section 10B.
Each breaker is connected with the upstream and downstream breakers that belong both to the same panel and to different panels. According to the invention, two kinds of connection, termed respectively "upward connection" and "downward connection", are defined for each breaker.
The "upward connection" identifies a connection to the so-called "child" section 10B of the breaker, while the "downward connection" identifies a connection to the so-called "father" section 10A of the breaker. Accordingly, a breaker is simultaneously father with respect to the breakers at the next lower hierarchical level and child with respect to the upstream breaker to which it is connected.
When a breaker detects a fault condition, it reports it to the "father" section of the breaker at the next higher hierarchical level, thus blocking its opening action. If the breaker that receives the information is in turn a "child" with respect to an upstream breaker and if it, too, detects the same fault condition, it reports it to its "father" breaker, and so forth. This communication process ends in one of the following two ways: either when the highest hierarchical level of the structure is reached, or when a breaker of the communication network does not detect a fault. It should be noted that a plurality of "children" can report simultaneously.
FIG. 2 illustrates in greater detail the structure of the elements that compose the part for acquiring and processing the values of the current (i(t)) that is present in a breaker used in this invention.
Said structure comprises a primary current sensor 1, which is capable of detecting the current that circulates in the power supply conductor that is connected to the breaker. The sensor 1 is connected to an electronic protection part 15 which comprises, in a mutual series arrangement, a converter 2, an A/D converter 3 and a filter 4. The filter output 4 is connected to a processing unit 6 both directly and by means of a block 5 which is capable of computing the derivative of the input signal.
The processing unit 6 has a memory 7 and its output is connected to a tripping coil 8 of the breaker, which actuates a kinematic system 9 for opening the breaker.
Operation of the above-described breaker is as follows. The sensor 1 detects the currents that circulate in the primary circuit and the resulting analog signal is converted into a voltage signal by the converter 2. The voltage signal is then converted into a digital form (for digital processing) by the analog-digital converter 3 and then filtered in the filter 4, which is of the antispike type and introduces a minimal delay.
Preferably, the filter 4 is a third-order elliptical digital filter, with a cutoff frequency at 1 kHz. Since fault detection is based on the instantaneous values of the current (converted into a voltage) and on their derivatives, filtering has the purpose of preventing signals having relatively low current values (which cannot therefore be ascribed to a short circuit) but with a high value of their first derivative from compromising the overall performance of the protection.
The block 5 computes the instantaneous values of the derivative di(t)/dt of the signal that represents the circulating current i(t). Preferably, the block 5 uses a second-order derivative (digital) filter which has a passband of 5 kHz, which is sufficient to precisely detect the derivatives of the currents of a short-circuit fault.
The processing unit 6 thus receives in input a signal which represents the current and a signal which represents its derivative, and the two values define a point or vector on the plane i(t)-di(t)/dt, as shown in FIG. 3.
FIG. 3 illustrates an acceptable operating region A; i.e., it defines the locus of the points that belong to normal operating states, including those representing overload but not a short circuit. The points outside the area A represent abnormal operating conditions or conditions which in any case require protective intervention.
In this plane, a time-variable current defines a path such as those designated by T1 and T2 in the figure. As long as said path, for example T2, remains within the area A (or non-shorting area), the situation is considered "normal".
If the path, T1 in the figure, leaves this region, the situation is considered as a short circuit. A comparison is thus performed in the block 6, moment by moment, between the pairs of variables i(t) and di(t)/dt that arrive from the primary circuit and the pairs that form the non-short circuit region.
When a fault condition is reported, the device emits a tripping signal for the solenoid of the coil 8, which opens the breaker by acting on its kinematic system.
In order to ensure the necessary selectivity, according to the present invention an exchange of information is ensured among the breakers that are present in the various nodes of the system and which may have detected the fault simultaneously.
Communication is particularly swift in order to ensure the exchange of information among the breakers in a time which on the one hand ensures the intervention of the breaker directly involved before the current reaches excessively high values and on the other hand allows to block other breakers upstream of the fault. Typically, communication with the next level is achieved in less than 100 microseconds.
Reliability of the communications system is achieved by duplicating the messages exchanged among the various breakers and by means of a self-monitoring (performed by the electronic protection itself) of the efficiency and correct functionality of the transmission medium and of the circuit components that handle transmission.
As mentioned, the aim of the system is to avoid opening breakers at a higher hierarchical level when the fault has already been recognized by a breaker located downstream. The system handles both short circuit faults and ground faults.
The communications system is capable of communicating several fault conditions. In particular, faults associated with messages designated by the codes E, G, and SOS are considered. The E message indicates a fault of the EFDP (Early Fault Detection Prevention, i.e. a short circuit fault type) detected downstream. The G message indicates a Ground Fault and the SOS message indicates an opening command due to mechanical problems downstream.
The interlock communication pattern or configuration is of the kind shown in Table 1.
TABLE 1______________________________________message0 1 0 E E G G S S______________________________________
where the level of the signal can assume a low value (0) or a high value (1). The first three bits of the message constitute a fixed synchronization signal, while the rest of the message contains data. The first three bits always have a 0 1 0 configuration, and this allows to compensate for any synchronization losses. The following Table 2 lists all possible message configurations and shows that the "010" combination always occurs in the same position, i.e., at the beginning of the synchronization configuration.
TABLE 2______________________________________ E E G G S S E E______________________________________0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 1 0 0 0 0 0 0 0 0 1 0 1 1 0 1 0 0 0 0 0 1 1 0 1 0 0 0 0 1 0 0 0 0 0 1 1 0 1 0 1 1 0 1 0 0 0 1 1 0 0 0 1 0 0 0 0 1 0 0 0 1 1 0 0 0 1 0 1 1 0 1 0 0 0 1 1 1 1 0 1 0 0 0 0 1 0 0 0 1 1 1 1 0 1 0 1 1 0 1 0 1 1 0 0 0 0 0 1 0 0 0 0 1 0 1 1 0 0 0 0 0 1 0 1 1 0 1 0 1 1 0 0 1 1 0 1 0 0 0 0 1 0 1 1 0 0 1 1 0 1 0 1 1 0 1 0 1 1 1 1 0 0 0 1 0 0 0 0 1 0 1 1 1 1 0 0 0 1 0 1 1 0 1 0 1 1 1 1 1 1 0 1 0 0 0 0 1 0 1 1 1 1 1 1 0 1 0 1 1______________________________________
The next six bits are dedicated to the three possible "simple" states E, G and S, and a state is repeated for two bits (EE, GG, SS) in order to increase immunity to noise. The level 1 of these bits indicates the presence of the corresponding fault, while the level 0 indicates that there is no fault.
During communications there is a startup step that also includes synchronization.
Depending on the allocation of the breaker (within a same panel or in different panels), two different kinds of connection are defined. A bidirectional or "short" connection is provided when the breakers belong to the same panel and therefore the communication path is not longer than approximately 10 meters. In this case, there is a father breaker connected to a plurality of child breakers, as shown by way of example in FIG. 5, which illustrates a typical configuration of interlocked breakers with a short connection 18. Only the information-carrying connections have been shown in the figure for the sake of simplicity.
A unidirectional or "long" connection is provided when the breakers belong to different panels and the communication path reaches lengths of up to 1 km. In this case there is a single connection between a father breaker connected to a single child breaker.
In long connections, owing to the length of the communication path, which is considerably longer than the previous one, electrical insulation is usually provided, as well as impedance matching of the communication line from single-ended to balanced or differential, and filtering of the noise impinging on the transmission line. The long connection can also provide for the use of optical fibers with the corresponding hardware modifications (the adapter and the transmission medium change). In some particular configurations, impedance matching (both with an isolating transformer and with optical fibers) may be omitted.
FIG. 6 illustrates a typical configuration of breakers interlocked by means of long connections, in which an external module (respectively 32 and 33 in the figure) is interposed between the line 34 and the communication modules for interlock 30 and 31. As shown schematically, each one of said modules 32, 33 comprises an isolating transformer with a winding which is balanced toward the line 34 and a noise filter block. In practice, the need to use a "short" or "long" connection depends not only on the "length" of said connection but also on the need to have more than one child or on the need, in particular architectures, to have or not have unidirectional connections. Accordingly, the connections, together with the associated hardware and algorithm, are both available for the various possible requirements. | An electric power distribution system having a number of automatic protection breakers distributed on various levels is disclosed herein. Each protection breaker includes an electronic protection unit to open the breaker, which is controlled based on the amount of current flowing through the breaker and its derivative. Each of the breakers is preferably connected in order to exchange information concerning their respective status. Also disclosed herein is method for controlling the intervention sequence of the mutually interlocked breakers, in which a breaker reports a detected fault condition to its next higher level breaker. | 7 |
The present invention relates to a method for producing an aerosol stream wherein the aerosol is produced by a flame free reaction of a mixture of gases or vapors, or both.
The invention relates, in particular, to a directed aerosol which contains solid particles as well as at least one gas and/or vapor. This invention also relates to the use of such an aerosol stream.
BACKGROUND OF THE INVENTION
Aerosols containing solid particles may be referred to as fumes and aerosols containing gases or vapors as well as liquid particles are also called fogs. An exemplary process for producing a flowing aerosol, hereinafter called and aerosol stream, provides that gaseous and/or vaporous chemical components are mixed with the aid of a diffusion process and/or a turbulent mixing process and the resulting gas and/or vapor mixture is converted by thermal reaction, e.g. flame hydrolysis, into an aerosol stream.
In an aerosol stream, the solid or liquid particles move at various angles and in various directions. An aerosol stream of this sort is often uneconomical to use when a directed stream is needed, e.g., in manufacturing facilities which do coating, where only the articles to be coated with the particles are to be covered and not their surroundings. It is obvious to direct such an aerosol stream by mechanical means, e.g., using baffles. However, this procedure is uneconomical, since the baffles are also coated by the aerosol particles, resulting in losses of the aerosol and requiring expensive cleaning procedures.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide an improved process for producing a directed aerosol stream in such a way that an economically manageable aerosol stream is produced which has the highest possible particle density and which is suitable, in particular, for coating or precipitation systems.
This object is accomplished by producing an aerosol stream by a flame free chemical reaction in a gas and/or vapor mixture and conducting the stream enveloped in an essentially aerosol free gas and/or vapor stream.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a sectional side view of an aerosol generator according to the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention will now be described in greater detail with the aid of an embodiment and with reference to the schematic drawing of FIG. 1.
FIG. 1 illustrates an aerosol generator according to the invention, which is essentially comprised of concentrically arranged pipes or conduits 21, 31, and 41, each having a cross section which is adapted to the intended use of the generated aerosol stream. For example, the cross section of the conduits may be selected to be circular or rectangular. The inner conduits 21 and 31 initially conduct gaseous and/or vaporous components in laminarly flowing streams symbolized by arrows 2 and 3, into a reaction chamber 1. In chamber 1 diffusion produces a gas and/or vapor mixture which is converted by chemical reaction to an aerosol, the aerosol stream 10. This chemical reaction may be initiated, for example, by the heat generated in a furnace 60 arranged around reaction chamber 1. The resulting, essentially laminar flow aerosol stream 10 is now conducted within an envelope of an aerosol particle free gas and/or vapor stream 20, which is introduced to surround the aerosol stream 10 through the outer concentric conduit 41. The gas and/or vapor stream 20 in essentially laminar flow prevents radial movement of the particles contained in the aerosol stream 10. This makes it possible, particularly in coating systems, to shape the cross section of aerosol stream 10 by way of nozzles to precisely direct the aerosol stream and to make the coating processes economical. The particle free gas and/or vapor stream 20, in particular, prevents clogging of the nozzles, the walls of the reaction chamber and some eventually necessary baffles by preventing the aerosol from contacting the appropriate surfaces and thus avoids costly cleaning work. The shape of the nozzle is calculated and/or experimentally determined according to the body that is to be coated. E.g. for the manufacturing of so called preforms for optical fibers it is necessary to coat the outer surface of a barlike body with several glassy layers. In that case the end of the outer concentric conduit 41 has a nozzle that is part of a tube with a rectangular cross-sectional area. This cross-sectional area has the same length and the same width as the barlike body.
FIG. 1 also shows a body 40 to be coated which is surrounded by aerodynamic guide elements 50 in such a manner that almost all particles contained in aerosol stream 10 impinge on body 40 and in this manner permit economical coating.
To enhance the rate of precipitation and reduce waste, it is possible to generate an electrical field between body 40 and guide elements 50 by which the particles contained in aerosol stream 10 are guided onto body 40. If these particles are of a dielectric nature, e.g., glass, it is possible to form the electrical field in such a manner that electrical dipoles are produced in the particles which enhance the coating of body 40. Such dipoles avoid electrostatic charges in body 40 that would make further coating difficult. The electric field is generated by a commercially available high-tension direct-current-generator which can produce an electric field of about 20 kV/cm between the guide elements 50 and the body 40. The body 40 is connected to either poles (positive or negative) of the generator whereas the other pole and the guide elements 50 are grounded. In this way an inhomogeneous electrical field is generated which polarises the particles of the aerosol stream. In such a field the polarised particles are attracted by the body 40.
EXAMPLE I
Body 40 is formed as a rod or pipe-shaped tube carrier body whose outer jacket surface is to be coated with a vitreous and/or glass forming coating in such a manner that a so-called preform results from which light waveguides, i.e., optical fibers, can be drawn. This drawing process is state of the art and consists of the following steps. The glassy and tubelike preform has a length of about 1 m and an outer diameter of about 10 cm. The thickness of the wall of the tube and the refractive index are chosen according to the optical fiber to be drawn, e.g. a graded index fiber with an outer diameter of about 125 μm. The preform is heated at one end in a way that it collapses and a fiber could be drawn out of this end.
In this example, body 40 is rotated about its longitudinal axis and conduits 21, 31, and 41 have rectangular cross sections so that simultaneous coating along a circumferential line of body 40 is possible. The constituents symbolically represented by arrows 2 and 3 comprise silicon tetrachloride (SiCl 4 ) and water vapor (H 2 O), respectively, which are converted in reaction chamber 1 under the influence of heat to a silicon dioxide (SiO 2 ) containing aerosol stream according to the following formula:
SiCl.sub.4 +2H.sub.2 O→SiO.sub.2 +4HCl
This aerosol stream is guided within a gas and/or vapor stream 20 containing an inert gas, e.g. N 2 . By adding doping substances, e.g., germanium tetrachloride (GeCl 4 ), to the gaseous silicon tetrachloride, it is possible to precipitate doped glass layers onto the carrier body. The respective flow rates within conduits 21, 31, and 41 are selected in such a manner that, on the one hand, a laminar flow is maintained but, on the other hand, rediffusion from reaction chamber 1 into the conduits is avoided. This prevents undesirable particle deposition in conduits 21, 31, and 41. For example this is acheived under the following conditions. To produce the aerosol stream 10 a gaseous mixture is led to the reaction chamber with a cross-sectional area of 120 cm 2 which is heated to about 800° C. The gaseous mixture contains nitrogen (N 2 ) as a carrier gas at a flow rate of about 240 liter/h, gaseous SiCl 4 at a flow rate of about 100 liter/h, water vapour at a flow rate of about 200 liter/h and gaseous GeCl 4 as doping material at a flow rate of up to 10 liter/h. The flow rate of GeCl 4 is altered to produce the desired index-profile of the optical fiber. The gas and/or vapor stream 20 consists of gaseous N 2 at a flow rate of about 90 liter/h. In the reaction chamber 1 there is a resulting velocity of flow of about 1 cm/sec. The mentioned chemical reaction produces Ge-doped or undoped SiO 2 -particles with a diameter of about 0.2 μm and a density of about 5×10 10 particles/cm 3 . In the reaction chamber 1 the mixture of gaseous GeCl 4 and gaseous SiCl 4 reacts to homogeneously doped particles. The reaction of GeCl 4 +2H 2 O→GeO 2 +4HCl is analogous to that of SiCl 4 with H 2 O. Therefore the desired relation of GeO 2 to SiO 2 in the preform is exactly related to the adjustable relation of gaseous GeCl 4 to gaseous SiCl 4 . For optical fibers it is necessary to rotate the body 40 around its axis to acheive glassy layers of homogeneous thickness. If this rotation is not done continuously one obtains a layer with an alternating thickness, e.g. with an elliptical cross-sectional shape. The resulting optical fiber can be used for transmitting polarized light without altering the kind of polarisation.
If the body 40 has another form, e.g. a disk or ball like form, the dimensions of the reaction chamber, the nozzle and the gasflows have to be changed respectively.
The invention is not limited to the described embodiment but can likewise be employed in a similar manner for other purposes, e.g., to coat silicon wafers.
The embodiments described herein are provided for the purpose of illustrating the invention, which is intended to include all embodiments, variations, equivalents and modifications within the scope of the claims that follow. | The present invention relates to a method for producing a directed aerosol stream by a flame free reaction which is conducted while enveloped within an aerosol free gas and/or vapor stream. It is particularly suitable for use in coating systems, as it permits economical coating without so-called wall deposits. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of copending U.S. Provisional Application Ser. No. 60/075,719, filed Feb. 24, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the pumping of water through tubes or housings and more particularly, to a ribbed impeller mounted on a shaft in a tube or housing for pumping liquid such as water through the tube or housing. In a preferred embodiment the ribbed impeller includes a tapered hub provided with at least two and preferably three blades having a variable pitch tailored to the diameter of the pump barrel or housing. The blades are further provided with ribs which may be progressive, regressive or constant in size and may be located at varying positions on the blades to further enhance the impeller pumping efficiency.
Efforts have long been made to increase the pumping efficiency of an impeller. It is generally recognized in the industry that a one to two percent increase in pumping efficiency is substantial for any water pumping application. Accordingly, even small improvements in impeller design may significantly increase the pumping efficiency of the impeller and the impeller of this invention is designed to operate at optimum pumping efficiency in pump barrels or housings of various size.
2. Description of the Prior Art
Various types of propulsion and pumping devices such as pumps, propellers and fans are known in the prior art. U.S. Pat. No. 10,124, dated Oct. 18, 1853, to E. Beard, details a “Screw Propeller”, which includes a hub fitted with radial blades having peripheral fins or ribs. U.S. Pat. No. 28,688, dated Jun. 12, 1860, to D.D. Porter, details a “Steam Vessel Propeller” having blades of dissimilar proportion, which propeller is also fitted with radial ribs. U.S. Pat. No. 170,937, dated Dec. 14, 1875, to H. G. Cook, et al, details a “Screw Propeller” having shaped peripheral ribs. U.S. Pat. No. 794,010, dated Jul. 4, 1905, to W. B. Hayden, details a “Propeller” fitted with peripheral ribs and having variable pitch. U.S. Pat. No. 834,624, dated Oct. 30, 1906, to A. S. Littlejohn, details a scimitar-shaped propeller having peripheral ribs which project beyond the plane of the propeller at one of the rib ends, respectively. U.S. Pat. No. 1,422,109, dated Jul. 11, 1922, to F. W. Lambert, details a “Tube Blade Propeller” with shaped ends configured with curved, blade-like projections for enhancing propeller efficiency. U.S. Pat. No. 2,978,040, dated Apr. 4, 1961, to O. A. Wirkkala, details a “Marine Propeller” fitted with tapered ribs located on the blade periphery thereof. U.S. Pat. No. 3,294,175, dated Dec. 27, 1966, to C. H. Bodner, details an “Adjustable Impeller”, having multiple ribs on the blades thereof, which ribs are spaced-apart from the periphery of the blades inwardly, toward the hub. U.S. Pat. No. 4,128,363, dated Dec. 5, 1978, to Fujikake, et al, details an “Axial Flow Fan” which includes multiple auxiliary blades having spaced-apart, parallel projections or fins thereon to enhance propeller efficiency. U.S. Pat. No. 4,664,593, dated May 12, 1987, to Hayashi, et al, details a “Blade Configuration For Shrouded Motor-Driven Fans”. The fan includes a hub, multiple fan blades extending from the hub and a deflector formed at the tip or periphery of the fan blades to increase the volume of air moved by the rotating blades.
It is an object of this invention to provide a new and improved propeller for pumping water through a tube or barrel at optimum efficiency, which impeller includes a tapered hub, blades extending from the blade hub, which blades are characterized by a pitch that varies proportionally with the diameter of the barrel or housing in which the impeller is rotating, and ribs provided in strategic locations on the blades for enhancing the efficiency of the impeller.
Another object of this invention is to provide a ribbed impeller for pumping water through a pump or barrel, which ribbed impeller includes a tapered hub having a shaft mount end for attachment to a shaft and rotating the impeller in the barrel or housing and a larger end, with at least two, and preferably three blades fitted with progressive, regressive or constant ribs in strategic locations on the blades to enhance the efficiency of impeller operation.
Yet another object of this invention is to provide a ribbed impeller having a tapered hub fitted with at least two, and preferably three blades provided with multiple ribs located in strategic locations, and particularly, on the trailing edges of the blades, which ribs are characterized by progressive, regressive or constant cross-section and are designed to enhance the pumping efficiency of the impeller.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in a new and improved ribbed impeller which is characterized in a preferred embodiment by a tapered hub, the small end of which is attached to a shaft for rotating the impeller in a barrel or housing to pump water through the barrel or housing. The hub is typically fitted with three blades, the pitch of which vary proportionally with the diameter of the barrel or housing, to enhance operating efficiency and the ribs provided on the blades in progressive, regressive or constant cross-sectional configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by reference to the accompanying drawings, wherein:
FIG. 1 is a front view of a preferred three-blade embodiment of the ribbed impeller of this invention, illustrating the large end of the tapered hub, with three blades attached to the hub and fitted with transverse ribs on the trailing edges of the blades;
FIG. 2 is a side view of the ribbed impeller illustrated in FIG. 1, more particularly illustrating the tapered hub, regressive ribs mounted on the periphery of the propeller blades and the transverse ribs on the trailing edges of the blades;
FIG. 3 is a perspective view of a typical mounting of the ribbed impeller illustrated in FIG. 2 on a shaft and located in a pump barrel or housing in functional configuration for pumping water or other liquid through the barrel or housing;
FIG. 4 is a top view of a typical blade of the ribbed impeller illustrated in FIG. 1, wherein a rib is located on the periphery of the blade, which rib varies in width as it progresses from the leading edge to the trailing edge of the blade;
FIG. 5 is a top view of a blade from the ribbed impeller illustrated in FIG. 2, wherein the transverse rib 14 is omitted, one of the ribs illustrated in FIG. 4 is provided on the periphery of the blade and an additional pair of ribs are located in the longitudinal center portion of the blade and at the hub curvature area of the blade;
FIG. 6 is a top view of a impeller blade illustrated in FIG. 1, with a rib of constant cross-section extending around the periphery of the blade from the leading edge to the trailing edge;
FIG. 7 is a top view of a blade of the ribbed impeller illustrated in FIG. 1, more particularly illustrating ribs located along the periphery of the blade and the center of the blade, as well as at the leading and trailing edges of the blade, which ribs are of substantially constant cross-section;
FIG. 8 is a top view of a blade of the ribbed impeller illustrated in FIG. 1, omitting the transverse rib and more particularly illustrating a shaped rib provided on the periphery of the blade and extending from the leading edge to the trailing edge;
FIG. 9 is a top view of a blade of the ribbed impeller illustrated in FIG. 1, omitting the transverse rib and more particularly illustrating a rib of constant cross-section extending from the leading edge to the trailing edge of the blade between the blade periphery and the hub curvature of the blade;
FIG. 10 is a top view of a blade of the ribbed impeller illustrated in FIG. 1 omitting the transverse rib and more particularly illustrating a curved rib of varying cross-section extending along a truncated curved leading edge of the blade;
FIG. 11 is a blade of the ribbed impeller illustrated in FIG. 1, more particularly illustrating a concave leading blade edge and a slightly convex trailing edge, with a curved transverse rib located on the convex trailing edge and a rib provided on the peripheral edge of the blade; and
FIG. 12 is a top view of a blade of the ribbed impeller illustrated in FIG. 1, omitting the transverse rib and more particularly illustrating truncated leading and trailing edges, with radial ribs extending from the periphery of the blade to the hub curvature in non-parallel relationship.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1-3 of the drawings, in a preferred embodiment the ribbed impeller of this invention is generally illustrated by reference numeral 1 . The ribbed impeller 1 is characterized by a tapered hub 2 having a hub bore 3 , in which is mounted a shaft mount ring 4 by means of ring mount struts 5 . The shaft mount ring 4 defines a ring opening 4 a for receiving an impeller shaft 20 at the shaft mount end 6 of the hub 2 , as further illustrated in FIG. 3. A round strut brace 5 a extends concentrically with the inside surface of the large end 7 of the hub 2 and the shaft mount ring 4 for strengthening the shaft mount ring 4 in the hub bore 3 . The hub 2 tapers from a large end 7 to the shaft mount end 6 , as illustrated in FIG. 2 and receives three blades 10 , the pitch of which blades vary proportionally with the diameter of the pump barrel 18 illustrated in FIG. 3 . Accordingly, as the ribbed impeller 1 is mounted on the impeller shaft 20 in the barrel bore 19 of the pump barrel 18 , it is driven in the direction indicated by the curved arrow in FIG. 3 and forces water longitudinally through the barrel bore 19 , as further illustrated by the longitudinal arrows. As further illustrated in FIG. 1, the blades 10 are provided with a transverse rib 14 which describes a 90-degree angle with the trailing edge 11 a . Furthermore, as illustrated in FIGS. 2 and 3, each of the blades 10 is fitted with a transverse rib 14 and a blade periphery rib 12 , which may be of substantially constant cross-section or tapered at one or both ends at a rib taper 17 (regressive), as illustrated in FIG. 2 . It has surprisingly been found that positioning the transverse ribs 14 (FIG. 1) and the blade periphery ribs 12 and transverse ribs 14 (FIGS. 2 and 3) on each of the blades 10 as illustrated, enhances the performance of the ribbed impeller 1 , as the pressure characteristics of the ribbed impeller 1 inside the pump barrel 18 constrain water or other liquid to flow through the pump barrel 18 in the direction indicated by the arrows. Accordingly, rotation of the ribbed impeller 1 in the direction indicated by the arrows in FIGS. 1-3 minimizes the overflow or “slippage” of water from the blade periphery 11 b of the respective blades 10 around the blades 10 between the blade periphery 11 b and the inside wall of the pump barrel 18 , and thereby increase the efficiency of the ribbed impeller 1 . Furthermore, the axial flow of water from the hub 2 outwardly along the blades 10 is caused to flow longitudinally in a spiral approximately parallel to the longitudinal axis of the hub 2 when the water strikes the transverse ribs 14 , as illustrated in FIG. 1 . This action also enhances the efficiency of impeller performance.
Referring now to FIG. 4 of the drawings, each of the blades 10 may be provided with a blade periphery rib 12 of varying cross-section, which extends from the leading edge 11 to the trailing edge 11 a of the blades 10 , along the blade periphery 11 b and may be tapered from a narrow segment at the leading edge 11 to a wider segment at the trailing edge 11 a , as illustrated. Furthermore, a transverse rib 14 may be provided on the trailing edge 11 a in combination with or in lieu of the blade periphery rib 12 , which transverse rib 14 may extend from the blade periphery 11 b to the hub curvature 11 c . Accordingly, it will be appreciated by those skilled in the art that the blade periphery rib 12 of variable cross-section, alone or in combination with the transverse rib 14 , serves to facilitate additional “entrapment” of water, or the prevention of water from curling back or excessively flowing around the blade periphery 11 b of the blades 10 to increase the efficiency of the ribbed impeller 1 .
Referring now to FIG. 5 of the drawings, in another embodiment of the invention each of the blades 10 illustrated in FIG. 1 include a blade periphery rib 12 , situated in the same relative location as the blade periphery rib 12 illustrated in FIG. 4 and having substantially the same configuration. A similar center rib 13 disposed essentially parallel to the blade periphery rib 12 , between the blade periphery rib 12 and the hub curvature 11 c of the blade 10 . Furthermore, a hub rib 15 of constant cross-section tracks the curvature of the hub curvature 11 c and may be provided with or without the blade periphery rib 12 and the center rib 13 , respectively. It will be appreciated by those skilled in the art that the blade periphery rib 12 , center rib 13 and the hub rib 15 serve to additionally “cup” water on the pressure surfaces of the blades 10 and impede the flow of water around each blade periphery 11 b as the ribbed impeller 1 operates.
As illustrated in FIG. 6 of the drawings, a blade periphery rib 12 of constant or uniform cross-section may be extended along the blade periphery 11 b , from the leading edge 11 to the trailing edge 11 a and may additionally include a feathered or tapered area at one or both ends thereof, as illustrated in FIG. 2 . In addition, a transverse rib 14 may be provided on the leading edge 11 of the blades 10 and may be of constant or uniform cross-section or slightly tapered from the blade periphery 11 b to the hub curvature 11 c , as illustrated. This combination of the blade periphery rib 12 and the transverse rib 14 effect a high efficiency of operation of the ribbed impeller 1 by providing an additional guard against “slippage” of water past the blade periphery 11 b during operation of the ribbed impeller 1 .
Referring now to FIG. 7 of the drawings, the blades 10 may be further fitted with a blade periphery rib 12 , a center rib 13 , as illustrated in FIG. 5, but of uniform cross-section, as well as a transverse rib 14 , provided along both the leading edges 11 and the trailing edges 11 a of the blades 10 . As in the case of the blades 10 illustrated in FIGS. 1-6, this configuration of the constant diameter blade periphery rib 12 , center rib 13 and transverse ribs 14 facilitates greater efficiency in operation of the ribbed impeller 1 by impeding water flow around each blade periphery 11 b and changing the axial direction of water flow to longitudinal flow.
As illustrated in FIGS. 8 and 8A of the drawings, a radial rib 16 may be provided in each of the blades 10 along the blade periphery 11 b and may include an irregular face 16 a , which may be configured as illustrated in FIG. 8A to further prevent an excess of water from slipping between the pressure or power face of the blades 10 , around the blade periphery 11 b and to thereby increase the efficiency of the ribbed impeller 1 .
Referring now to FIG. 9 of the drawings, in yet another preferred embodiment of the invention a single center rib 13 may be provided between the blade periphery 11 b and the hub curvature 11 c of each of the blades 10 and extending between the leading edge 11 and the trailing edge 11 a . In this embodiment of the invention the center rib 13 is of uniform cross-section, as illustrated in FIG. 7 and is preferably positioned closer to the hub curvature 11 c than the blade periphery 11 b , for further controlling the flow of water across the pressure surface of the blades 10 and thereby minimizing the slippage of water around the blade periphery 11 b during operation of the ribbed impeller 1 .
As illustrated in FIG. 10 of the drawings, the leading edge 11 of the blades 10 need not be truncated as illustrated in phantom, but may instead, be curved and receive a curved, transverse rib 14 of varying cross-sectional configuration, which transverse rib 14 typically extends between the blade periphery 11 b and the hub curvature 11 c at the curved leading edge 11 . As in the case of the ribbed impeller 1 illustrated in FIGS. 1-9, the irregular transverse rib 14 aids in capturing and maintaining water against the power or pressure face of the blades 10 and changes the water flow from an axial direction to a longitudinal direction, thereby improving the efficiency of the ribbed impeller 1 .
Referring now to FIG. 11 of the drawings, the leading edges 11 of the blades 10 may be configured essentially in the same concave configuration illustrated in FIG. 10, but without the transverse rib 14 , while a blade periphery rib 12 may be provided between the now curved leading edge 11 and the slightly convex trailing edge 11 a . A transverse rib 14 of uniform cross-sectional area is provided on the trailing edge 11 a , as further illustrated in FIG. 11 and both the blade periphery rib 12 and the transverse rib 14 serve to improve the efficiency of the ribbed impeller 1 by minimizing undesirable flow of water from the pressure surface of the blades 10 , around the blade periphery 11 b and changing the direction of water flow, as described above.
As illustrated in FIG. 12 of the drawings, both the leading edge 11 and the trailing edge 11 a of the blades 10 may be scimitar-shaped instead of truncated, as illustrated in phantom and three radial ribs 16 converge from the blade periphery 11 b to the hub curvature 11 c of each of the blades 10 . The shortened, scimitar-shaped blades 10 , coupled with the radial ribs 16 , serve to more efficiently move water under certain impeller applications where the ribbed impeller is operated at high speeds.
It will be appreciated by those skilled in the art that the ribbed impeller of this invention in the variations illustrated in the drawings is characterized by new and improved configurations for improving the efficiency of impeller operation. It will be further appreciated that the ribbed impeller 1 can be provided with various combinations of the blade periphery rib 12 , center rib 13 , transverse rib 14 and the hub rib 15 , as well as the radial rib 16 to facilitate various impeller applications and improved efficiency under circumstances where the diameter of the pump barrel 18 varies.
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made in the invention and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | A ribbed impeller for use in a water pump and in marine water pumps in particular, which ribbed impeller is characterized by a hub rotatably mounted on a shaft positioned inside the pump barrel or housing and multiple blades provided on the hub and fitted with ribs of varying location, length, size and character for enhancing the pumping of water through the barrel. In a preferred embodiment the hub is characterized by an open end which tapers inwardly to define a shaft mount end, to which the shaft is attached for rotation of the ribbed impeller. In another preferred embodiment of the invention the pitch of the impeller blades vary proportionally with the diameter of the pump barrel or housing for optimum pumping of the water through the barrel. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a comparator with offset voltage, more particularly, to an analogue comparator having a differential input stage.
2. Background of the Related Art
An input stage of a comparator is generally constituted with a differential circuit that amplifies the voltage difference of two input signals. The two input signals are cancelled by each other when they have opposite phases and equal magnitudes, which results in no output signal.
FIG. 1 is a diagram that shows a differential circuit enabling to control an offset voltage. FIG. 1 is a diagram from U.S. Pat. No. 4,754,169.
Referring to FIG. 1, a current I of a reference current source is I=V REF /R 1 . Additional details of the reference current source are shown in FIG. 2 . The current I further becomes I=I REF =I 1 =V REF /R 1 by a current mirror, and an offset voltage V OFF results in accordance with current I 1 between both ends of resistor R 0 as set forth by equation (1) as follows: V OFF = I 1 · R 0 = ( V REF / R 1 ) · R 0 = V REF · ( R0 / R1 ) ( 1 )
If the reference voltage V REF is constant, a predetermined offset voltage is generated by adjusting a ratio of two resistors R 0 and R 1 . In this case, the resistors R 0 and R 1 should be fabricated by the same process.
As described above, the related art differential circuit has various disadvantages. The differential circuit according to a related art, which is constituted with NMOS transistors, is unable to work normally when a common voltage lower than about 1V is applied thereto.
The above references are incorporated by reference herein where appropriate for appropriate teachings of additional or alternative details, features and/or technical background.
SUMMARY OF THE INVENTION
An object of the invention is to solve at least the above problems and/or disadvantages and to provide at least the advantages described hereinafter.
Another object of the present invention is to provide a comparator with an offset voltage that substantially obviates one or more of the problems caused by limitations and disadvantages of the related art.
Another object of the present invention is to provide an input stage of a comparator that can sufficiently amplify an input signal difference of low common voltage.
Another object of the present invention is to provide an input stage of a comparator that enables amplification of an input signal difference of low common voltage sufficiently by applying offset voltage to the common voltage in accordance with the level of the common voltage.
To achieve at least the above objects and other advantages in a whole or in part, and in accordance with the purpose of the present invention, as embodied and broadly described, a comparator according to the present invention generates an output signal of low or high level by comparing a first input voltage to a second input voltage which have a common voltage.
To further achieve the above objects in a whole or in part, and in accordance with the purpose of the present invention, as embodied and broadly described, an input stage circuit of a comparator according to the present invention includes wherein the comparator generates a comparison result signal for a first input voltage and a second input voltage that each have a common voltage, wherein the input stage circuit receives a common voltage detection signal, wherein the common voltage is supplied with a first offset voltage when the common voltage detection signal is a first level, wherein the common voltage is supplied with a second offset voltage when the common voltage detection signal, is a second level, and wherein the input stage circuit amplifies to output a voltage difference between the first input voltage and the second input voltage to the comparator.
To further achieve the above objects in a whole or in part, and in accordance with the purpose of the present invention, as embodied and broadly described, a comparator that generates an output signal by comparing a first input voltage to a second input voltage according to the present invention that includes a bias voltage generator that produces a first bias voltage and a second bias voltage, a common voltage detector that generates a common voltage detection signal responsive to a level of a common voltage of the first and second input voltages, and an input stage circuit amplifies a voltage difference between the first input voltage and the second input voltage, wherein the common voltage is supplied with a first offset voltage when the common voltage detection signal is a first level, and wherein the common voltage is supplied with a second offset voltage when the common voltage detection signal is a second level.
To further achieve the above objects in a whole or in part, and in accordance with the purpose of the present invention, as embodied and broadly described, includes an input stage circuit of a comparator, the comparator generating an output signal for a second input voltage to a first input voltage received by the input stage circuit, wherein the first and second input voltages have a common voltage, wherein the input stage circuit receives a common voltage detection signal, wherein the common voltage is supplied with a first offset voltage when the common voltage detection signal is a first level, and wherein the common voltage is supplied with a second offset voltage when the common voltage detection signal is a second level, and wherein the input stage circuit amplifies to output a voltage difference between the first input voltage and the second input voltage to the comparator.
To further achieve the above objects in a whole or in part, and in accordance with the purpose of the present invention, as embodied and broadly described, includes a method for operating a comparator that includes receiving the first and second input voltages each having a common voltage, receiving a common voltage detection signal, supplying the common voltage with a first offset value to reduce a common voltage level for the first input voltage when the common voltage detection signal is a first level, supplying the common voltage with a second offset value to increase a common voltage level of the second input voltage when the common voltage detection signal is a second level, amplifying a difference between the first and second input voltages to output a voltage difference to the comparator, and comparing the voltage difference in the comparator to output a comparison result of the first and second input voltages.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objects and advantages of the invention may be realized and attained as particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
FIG. 1 is a diagram that shows a differential circuit according to a related art;
FIG. 2 is a diagram that shows a reference current generating circuit of a differential circuit according to a related art;
FIG. 3 is a diagram that shows a circuit of a comparator with an offset voltage according to a preferred embodiment of the present invention;
FIG. 4 is a diagram that shows a circuit of a preferred embodiment of a bias voltage generator of a comparator according to the present invention;
FIG. 5 is a diagram that shows a circuit of a preferred embodiment of a common voltage detector of a comparator according to the present invention;
FIG. 6A is a diagram that shows a circuit for operational characteristics of the preferred embodiment of the comparator according to the present invention when a common voltage is lower than VDD/2;
FIG. 6B is a diagram that shows a graph of voltage characteristics of the preferred embodiment of the comparator according to the present invention when a common voltage is lower than VDD/2;
FIG. 7A is a diagram that shows a circuit for operational characteristics of the preferred embodiment of the comparator according to the present invention when a common voltage is higher than VDD/2; and
FIG. 7B is a diagram that shows a graph of voltage characteristics of the preferred embodiment of the comparator according to the present invention when a common voltage is higher than VDD/2.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 3 is a diagram that shows a circuit of a preferred embodiment of a comparator with offset voltage according to the present invention. As shown in FIG. 3, an input stage circuit 302 of a comparator 304 according to the preferred embodiment of the comparator includes a P channel driving circuit 306 , an N channel driving circuit 308 , and a current output part 310 .
The P channel driving circuit 306 includes a serial circuit controlled by P channel bias voltage V BIASP and a common voltage detection voltage S COM , and a parallel circuit controlled by an N channel input voltage V INN and P channel input voltage V INP . In the serial circuit, a couple of PMOS transistors 312 and 314 are coupled in series between power source voltage VDD and the parallel circuit. Gates of the PMOS transistors 312 and 314 are controlled by the P channel bias voltage V BIASP and the common voltage detection signal S COM , respectively. In the parallel circuit, a PMOS transistor 320 and a resistor 318 are coupled in parallel with another PMOS transistor 316 . Gates of the PMOS transistors 316 and 320 are preferably controlled by the N channel input signal V INN and the P channel input signal V INP , respectively.
The N channel driving circuit 308 includes a serial circuit controlled by N channel bias voltage V BIASN and a common voltage detection voltage S COM , and a parallel circuit controlled by an N channel input voltage V INN and P channel input voltage V INP . In the serial circuit, a couple of NMOS transistors 328 and 330 are coupled in series between ground voltage and the parallel circuit. Gates of the NMOS transistors 330 and 328 are controlled by the N channel bias voltage V BIASN and the common voltage detection signal S COM , respectively. In the parallel circuit, series coupled NMOS transistor 322 and resistor 324 together are coupled in parallel with NMOS transistor 326 . Gates of the NMOS transistors 322 and 326 are controlled by the N channel input signal V INN and the P channel input signal V INP , respectively.
In the current output part 310 , preferably a pair of PMOS transistors 332 and 334 of a diode connection type organize an active load, while four NMOS transistors 336 , 338 , 340 , and 342 constitute a current source.
The parallel circuit of the N channel driving circuit is coupled to nodes 346 and 348 . Once the N channel driving circuit 308 is activated, the PMOS transistors 332 and 334 operate as an active load of the N channel driving circuit 308 . The current source 336 , 338 , 340 , and 342 is coupled to the parallel circuit of the P channel driving circuit 306 , which works as a current source only when the P channel driving circuit 306 is activated.
A non-inversion input terminal (+) and an inversion terminal (−) of the comparator 304 are coupled to the nodes 346 and 348 , respectively. The comparator 304 generates an output signal OUT of low level when a node voltage V N346 is higher than the other node voltage V N343 , and generates the output signal OUT of high level when the node voltage V N348 is higher than the other node voltage V N346 .
FIG. 4 is a diagram that shows a circuit of a preferred embodiment of a bias voltage generator of a comparator according to the present invention. As shown in FIG. 4, PMOS transistors 402 and 404 are active loads and an NMOS transistor 408 is a constant voltage source having a diode connection structure.
Reference voltage V REF is inputted to a non-inversion input terminal (+) of a logic amplifier 412 , while an inversion input terminal (−) is coupled to a ground voltage through a resistor 410 . An output of the logic amplifier 412 controls a gate voltage of an NMOS transistor 406 . Thus, drain voltage of the NMOS transistor 406 maintains the same level of the reference voltage V REF and the current flowing through the resistor 410 is also constant as I 1 =V REF /R 410 . The reference current I 1 produces a P channel bias voltage V BIASP and an N channel bias voltage V BIASN .
FIG. 5 is a diagram that shows a circuit of a preferred embodiment of a common voltage detector of a comparator according to the present invention. As shown in FIG. 5, an N channel input voltage V INN and a P channel input voltage V INP are input to both ends of a pair of resistors 502 and 504 coupled in series to each other. As the N channel input voltage V INN and the P channel input voltage V INP have opposite phases, components of the respective alternating currents cancel each other to show only a direct current component at a node 510 .
Two inverters 506 and 508 coupled in series from the node 510 output a common voltage detection signal S COM as a logic signal by changing the DC voltage of the node 510 . The common voltage detection signal S COM is on high level when the DC level of the common voltage is equal to or higher than logic threshold voltage V LT , and on low level when the DC level of the common voltage is lower than logic threshold voltage V LT . In this case, the logic threshold voltage V LT of the inverters 506 and 508 is preferably VDD/2.
Operation of the comparator will now be described. In the input stage circuit 302 , current I P flowing through the PMOS transistor 312 of the P channel driving circuit 306 and the other current I N flowing through the NMOS transistor 330 of the N channel driving circuit 308 depend on the P channel bias voltage V BIASP and the N channel bias voltage V BIASN , respectively, where I P =I N =αI 1 (α is a coefficient).
Offset voltage V P generated from the current I P between both ends of the resistor 318 of the P channel driving circuit 306 is represented by equation (2) as follows: V P = I P · R P = α I 1 · R 318 = α ( V REF / R 410 ) · R 318 = V REF · α · ( R 318 / R 410 ) ( 2 )
Offset voltage V N generated from the current I N between both ends of the resistor 324 of the N channel driving circuit 308 is represented by equation (3) as follows: V N = I N · R N = α I 1 · R 324 = α ( V REF / R 410 ) · R 324 = α · V REF · ( R 324 / R 410 ) ( 3 )
Once the resistors 318 and 324 have the same resistance, a prescribed offset voltage is generated because V N =V P .
FIG. 6A is a diagram that shows a circuit for operational characteristics of the preferred embodiment of the comparator according to the present invention when a common voltage is lower than VDD/2. FIG. 6B is a diagram that shows a graph of voltage characteristics of the preferred embodiment of the comparator according to the present invention when a common voltage is lower than VDD/2.
As shown in FIG. 6 A and FIG. 6B, operations of the preferred embodiment of the input stage circuit when a level of common voltage V COM ranges 0 V to VDD/2 will now be described. The common voltage detection signal S COM outputted from the common voltage detector 500 becomes low level since V COM <V LT . Thus, the PMOS transistor 314 of the P channel driving circuit 306 becomes turned on, while the NMOS transistor 328 of the N channel driving circuit 308 becomes turned off.
The input stage circuit 302 of the comparator 304 according to the preferred embodiment is equalized with the circuit shown in FIG. 6A since the P channel driving circuit 306 has an influence on the current output part 310 , but the N channel driving circuit 308 has no influence thereon. In this case, the input stage circuit in FIG. 6A may be regarded as the P channel driving circuit 306 combined with the current output part 310 .
As shown in FIG. 6A, the voltage V SG316 between the node 344 and the gate of the PMOS transistor 316 and the other voltage V SG320 between the node 344 and the gate of the PMOS transistor 320 are represented by equation (4) as follows:
V SG316 =V N344 −V INN V SG320 =V N344 −V P −V INP (4)
When V SG316 <V SG320 , that is, V INN >(V INP +V P ), the current flowing through the drain of the PMOS transistor 316 is larger than that flowing through the drain of the PMOS transistor 320 . Therefore, the current flowing through the NMOS transistors 336 and 338 from the current source of the current output part 310 to the ground is larger than that flowing through the NMOS transistors 340 and 342 . As a result, an output signal OUT of the comparator 304 becomes high level since the node voltage V N348 is relatively higher than the other node voltage V N346 .
On the other hand, when V SG316 >V SG320 , that is, V INN <(V INP +V P ), the current flowing through the drain of the PMOS transistor 320 is larger than that flowing through the drain of the PMOS transistor 316 . Therefore, the current flowing through the NMOS transistors 340 and 342 from the current source of the current output part 310 to the ground is larger than that flowing through the NMOS transistors 336 and 338 . As a result, the output signal OUT of the comparator 304 becomes low level since the node voltage V N346 is higher than the other node voltage V N348 . Such voltage characteristics are shown in FIG. 6 B. As shown in FIG. 6B, when V INN <(V INP +V P ), the output signal OUT becomes high level.
FIG. 7A is a diagram that shows a circuit for operational characteristics of the preferred embodiment of the comparator according to the present invention when a common voltage is higher than VDD/2. FIG. 7B is a diagram that shows a graph of voltage characteristics of the preferred embodiment of the comparator according to the present invention when a common voltage is higher than VDD/2.
The input stage circuit 302 of the comparator 304 according to the preferred embodiment is equalized with the circuit shown in FIG. 7A since the N channel driving circuit 308 has an influence on the current output part 310 , but the P channel driving circuit 306 has no influence thereon. FIG. 7A is an equivalent circuit of an input stage circuit when VDD/2<V COM <VDD, where the active loads 332 and 334 of the current output part 310 may be regarded as combined with the N channel driving circuit 308 .
The input stage circuit 302 of the comparator 304 according to the preferred embodiment is equalized with the circuit shown in FIG. 7A since the N channel driving circuit 308 has an influence on the differential amplifier 310 , but the P channel driving circuit 306 has no influence thereon. FIG. 7A is an equivalent circuit of an input stage circuit when VDD/2<V COM <VDD, where the active loads 332 and 334 of the differential amplifier 310 may be regarded as combined with the N channel driving circuit 308 .
As shown in FIG. 7A, the voltage V GS322 between the node 350 and the gate of the NMOS transistor 322 and the other voltage V GS326 between the node 350 and the gate of the NMOS transistor 326 are represented by equation (5) as follows:
V GS322 =V INN −V N −V N350 V GS326 =V INP −V N350 (5)
When V GS322 >V GS326 , that is, V INN >(V INP +V N ), the current flowing through the drain of the NMOS transistor 322 is larger than that flowing through the drain of the NMOS transistor 326 . Therefore, the output signal OUT of the comparator 304 becomes low level since the node voltage V N346 is relatively higher than the other node voltage V N348 .
On the other hand, when V GS316 >V GS320 , that is, V INN <(V INP +V N ), the current flowing through the drain of the NMOS transistor 326 is larger than that flowing through the drain of the PMOS transistor 320 . Therefore, the output signal OUT of the comparator 304 becomes high level since the node voltage V N348 is higher than the other node voltage V N346 . Such voltage characteristics are shown in FIG. 7 B.
As shown in FIG. 7B, when V INN >(VNP+V N ), the output signal OUT becomes high level.
As described above, preferred embodiments according to the present invention have various advantages. The preferred embodiments of a comparator with offset voltage according to the present invention enables sufficient amplification of an input signal difference of low common voltage by selectively applying an offset voltage to a common voltage in accordance with the common voltage level of the input signal.
The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present invention. The present teaching can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. | A comparator according to the present invention can generate an output signal of low or high level by comparing a first and second input voltages that have a common voltage. An input stage circuit of a comparator according to the present invention receives a common voltage detection signal. The common voltage is supplied with a first offset voltage when the common voltage detection signal is on low level, and the common voltage is supplied with a second offset voltage when the common voltage detection signal is on high level. Then, the input stage circuit performs amplification to output a voltage difference between the first input voltage and the second input voltage to the comparator. Accordingly, the comparator with offset voltage according to the present invention can sufficiently amplify the input signal difference of low common voltage by selectively applying different offset voltages to a common voltage in accordance with the common voltage level of the input signal. The present invention can be applied to a comparator with offset voltage and an analogue comparator having a differential input stage. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to improvements in toasters, particularly those toasters with one or more upwardly open slots to receive a product such as a slice of bread, a crumpet, a muffin or the like to be toasted.
Although not very common, fires can occur when toasters are utilized. The cause of such fires include (1) a build up of crumb material in the toaster base; and (2) a food product being toasted for a period of time that exceeds the normal level for that product due to operator misuse or a malfunction in the toaster itself.
In U.S. patent application Ser. No. 08/146,251 filed Nov. 1, 1993 and assigned to the same assignee as the assignee hereof there is disclosed a toaster of the kind in which one or more upwardly open slots are provided to receive a product to be toasted. In this patent application there is also disclosed a single pivotal (flameproof) flap or two such flaps adapted to close or open the upper access slot or slots of the toaster. While these arrangements are satisfactory from the point of view of containment of a possible fire within the toaster, they do have a practical disadvantage, particularly when relatively narrow body single slot toasters are used. The heat within a toaster body is created by toasting or heating elements and the toasting effect is primarily generated by radiant heat from these elements. The elements also, however, create convection heat most of which normally escapes through the upper open access slot during operation of conventional toasters of this design. If, however, a cover flap closes the upper access slot during a toasting cycle most of the convection heat is retained within the toasting compartment thereby significantly affecting toasting performance and possibly harming toaster componentry as a result of the increased retained heat levels in the toaster. While the problem might be partially improved by lowering the wattage levels of the toaster heating elements, it has been found difficult to lower the wattage levels sufficiently to solve the problem of retained convection heat levels while at the same time maintaining sufficient radiant heat capability to provide a reasonable toasting performance. The problem becomes more serious upon decreasing the body width of the toaster and also when it is desired to maintain a cool touch to the outer walls of the toaster.
Accordingly it is an objective of the present invention to provide a means of permitting the escape of convection heat from a toaster of the type disclosed in the foregoing while still providing a means of preventing escape of flames from the toasting compartment in the unfortunate event of a toaster fire occurring. As a result, the invention also aims at being able to keep heating element wattage levels at a value sufficient to provide good radiant heat performance and thereby good toasting performance.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a cover member adapted in one position of use, to form part of an enclosure for a toasting chamber in a toasting device so as to prevent escape of flame therefrom but allow escape of convection heat from the toasting chamber, said cover member in said one position of use being locatable above a possible flame source in said toasting chamber, said cover member being perforated by at least one aperture extending through the cover member, and at least a second non-perforated member being provided overlying at least part of each said aperture and located in a plane vertically spaced from each said aperture. In this manner convection heat may escape from the toasting chamber through the cover member but flame is inhibited or prevented from passing outwardly of the toasting device. Conveniently the second non-perforated member covers at least 50% of the apertures in the cover member. The second non-perforated member might be a single element covering a number of apertures or a separate member for each aperture. A particularly preferred form of producing the aforesaid apertures is to form by punching or by some other metal deformation process, a plurality of slot like openings with the metal of said slot like openings forming the second member overlying the aperture and connected to the cover member by end tab means. By this means no additional metal is required and no additional machining or assembly is required beyond the one step punching operation.
It has been generally observed that flames from a fire within a narrow width toasting chamber tend to be constrained to run mostly parallel with the longitudinal walls of the toasting chamber. As a result, it is desired to dispose any apertures in the cover member transverse to the longitudinal walls of the toasting chamber. Conveniently such apertures are in the form of slots arranged at an angle of between 90° and 20° to the longitudinal direction. Preferably, the apertures comprise between 30 and 60% of the area of the cover member. Preferably the area between the second member and the cover member is at least 30% of the area of the cover member and is preferably no less than the total area of the apertures in said cover chamber.
The present invention also anticipates the use of one or more cover members as described above in a toaster device. In accordance with this aspect, the present invention provides a toaster having at least one upwardly facing opening to enable a product to be toasted to be introduced therethrough so as to be received in a toasting chamber below said opening, and a cover member adapted, in one position of use, to form part of an enclosure for the toasting chamber so as to prevent escape of flame from said toasting chamber through said cover member, said cover member further being perforated by at least one aperture extending through the cover member, and a second non-perforated means being provided overlying at least part of each said aperture, said second non-perforated means being located in a plane vertically spaced from each said aperture.
It has been observed that fire within toasters of the type having an upwardly facing access slot, tend to evolve in the longitudinal direction of the toasting chamber and will pass through any cover having upwardly facing openings. A number of types of materials have been tried in this regard including metal mesh, perforated metal sheet and spaced double layers of such materials. These have not been found satisfactory in practice. The aforementioned tendency appears to increase when any such openings are directed longitudinally of the chamber. It has, however been surprisingly found that if each upward directed opening is covered or partially covered by a spaced second member, then the tendency for flame penetration through the cover decreases to a very marked extent. Furthermore, placing slot openings transverse to the longitudinal direction of the toasting chamber, also decreases the tendency for flame to penetrate the cover member.
Conveniently the cover member is movable between one position in which the cover member at least partially overlies said slot opening and a second position wherein said cover member allows free access through said slot opening. Preferably two said cover members are provided and wherein in said one position said cover members are arranged side by side to fully overlie said slot opening. In one preferred arrangement a plurality of said apertures are provided in each said cover member, each said aperture being in the form of a slot aperture with the direction of said slot apertures being transverse to a longitudinal direction of the toasting chamber. Preferably in a second position of each cover member, the cover member is located within the confines of an outer housing of the toaster.
In a still further preferred embodiment at least two said cover members are provided as aforesaid, each said cover member having depending skirt members arranged in use in said one position to depend downwardly and outwardly of said toasting chamber.
Conveniently operating means is provided connected to said cover members to move said cover members between said one position and said second position. Preferably, said operating means moves said cover members in response to movement of a product support carriage in said toasting compartment, said operating means acting to move said cover members to said one (or closed) position when said product support carriage has moved through at least 70% and preferably between 85 and 95% of its permitted travel from its upper limit. Advantageously the operating means moves said cover members to said second (or open) position within 0 to 15% of the permitted travel of the product support carriage from the bottom toasting position of the support carriage. Conveniently, the cover members commence moving to their second (or open) position immediately the product support carriage starts to move upwardly.
A preferred embodiment of the present invention will hereinafter be described with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a toaster according to the present invention;
FIG. 1a is a partial cross-sectional view taken along the A--A of FIG. 1;
FIG. 2 is a partial perspective view of one end of the toasting compartment of the toaster of FIG. 1 with the outer casing and other parts removed for the sake of clarity;
FIG. 3 is an end elevation view of an upper part of the mechanism shown in FIG. 2;
FIG. 4 is a side elevation view of a lower part of the mechanism shown in FIG. 2; and
FIG. 5 is a view similar to FIG. 4 showing the mechanism in a different position of use.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, FIG. 1 shows a toaster 10 with an outer casing 11 (preferably formed from a non-burnable plastics material, metal or the like) having an upper access slot 12 adapted to receive a product to be toasted and to ultimately eject a toasted product therethrough after completion of a toasting cycle. As can be seen in FIGS. 1a and 2, an inner enclosure 13 is provided (conveniently produced from sheet metal) within the outer casing 11. The inner enclosure also has a generally rectangular upper access opening 14 substantially aligned with the access slot 12 in the outer casing. The inner enclosure 13 defines a toasting compartment 17 with electrical heating elements of any known configuration (not shown) located adjacent the inner face of each longitudinal side wall 15,16 directing radiant and convection heat inwardly of the toasting compartment 17 when energized. A control knob 18 is connected to any known or conventional means for selecting adjustment of the "brownness" of the product being toasted or selecting the length of the toasting cycle. A second operator gripping member 19 is provided which is directly connected to a product support carriage 20 located at least partially within the toasting compartment 17. The product support carriage is mounted on a vertical slide post (not shown) so that it is capable of movement upwardly and downwardly thereon. A spring 21 is provided to normally urge carriage 20 upwardly but against which an operator can move carriage 20 down to a lowered toasting position by gripping member 19 and moving same downwardly in slot 22 in outer casing 11. The product supporting carriage 20 has a part 23 located downwardly of toasting chamber 17 and a part 24 located within the toasting chamber on which a slice of bread or the like is supported during a toasting cycle. Part 24 extends through a vertical slot 25 in an end wall 26 of inner enclosure 13.
As shown in FIGS. 1, 1a, 2 and 3, a closure means 27 is provided arranged to overlie access openings 12,14 to toasting compartment 17. In the preferred embodiment illustrated, the closure means is conveniently located generally between outer casing 11 and inner enclosure 13 and comprises a pair of cover members 28,29. In a possible alternative arrangement the closure means may be formed as a single outwardly pivoting cover member or flap as shown for example in previously noted U.S. patent application Ser. No. 08/146,251. Any other possible form of cover member could also be employed with the performance of the present invention. In the embodiment illustrated in the drawing, each cover member 28,29 comprises an upper plate 30 covering approximately half of access opening 14 when closed, a longitudinally extending side plate 31 adapted to extend downwardly from access opening 14 outwardly of one of the inner enclosure side walls 15, 16 and a pair of end plates 32,33 adapted to extend downwardly and outwardly of the end walls of inner enclosure 13. One of the cover members 28,29 preferably has an inwardly (or outwardly) located laterally extending lip 34 adapted to overlie the small longitudinally extending space between cover members 28,29 when closed as illustrated in FIG. 1a. Conveniently, if cover members 28,29 are to be identically shaped (as may be desirable for manufacturing purposes) lip 34 may extend over only half the length of the cover member 28 or 29 so that in an assembly, the overlying lip extends from each cover member over half the length of the cover member with an overlying obstruction thereby extending the full length of access opening 14. By this means, escape of flame is prevented from toasting chamber 17 between cover members 28,29.
An operating mechanism 70 for moving cover members 28,29 from the generally closed (illustrated) position to an open position is best seen in FIGS. 2 to 5 of the annexed drawing. Each end plate 32,33 of the cover members has a downwardly depending hinge plate member 37 so as to locate a fixed hinge connection 38 to an end wall 26 of inner enclosure 13 downwardly of the lower edge of cover members 28,29 and outwardly spaced from central dividing line 42 between cover members 28,29. In addition a floating hinge connection 39 is provided acting between the two cover members 28,29. The floating hinge connection is formed by tab members 40,41 located at the lower edge of members 28,29 adjacent dividing line 42 between cover members 28,29. Each tab member 40,41 has a first portion 43 (see FIG. 2) extending outwardly from and at the same level as the lower edge of the cover member and a second portion 44 extending downwardly and towards or across dividing line 42. One or both of the portions 44 includes a slot 45 and a hinge pin 46 extends through portion 44 connecting same together with a downwardly directed link member 47. Movement of the link member 47 downwardly or upwardly causes the hinge pin 46 to move downwardly or upwardly. As a result the cover members pivot about hinge pins 38 and also tend to move outwardly when opening or inwardly when closing because of the floating hinge 39 caused by each slot 45. Thus cover members 28,29 can be arranged to completely close access opening 14 to inner enclosure 13 (when closed), or open this access opening 14 with cover members 28,29 moving to a position between outer casing 11 and inner enclosure 13.
The operating link member 47 is divided along most of its length from its lower end to form a first part 48 and a second part 49. The first part 48 has a lateral tab 50 at its lowermost end which is engaged by carriage part 23 on its downward travel near to the end of its downward travel and in so doing the final downward movement of carriage part 23 drags with it link member 47 and thereby pivot pin 46 to close cover members 28,29. FIG. 4 shows carriage part 23 at its uppermost position whereas FIG. 5 shows carriage part 23 at its lowered toasting position. In the lowered toasting position, carriage part 23 has been stopped by a physical limit ledge 51 and a manual latch member 52 has been engaged to prevent carriage part 23 from moving upwardly from the position shown in FIG. 5 whether or not a toasting cycle has been completed. Moreover in the lowered toasting position (FIG. 5), a dowel pin 53 carried by carriage part 23 is engaged in a recess 54 formed in the lower end of second part 49 of the link member 47 and is locked therein by fixed cam ledge 55. Thus when carriage part 23 is moved upwardly at the end of a toasting cycle and after delatching member 52, dowel pin 53 drives second link part 49 upwardly (and thereby link member 47 and hinge pin 46) to immediately open the cover members upon carriage 20 starting its upward eject motion. A slot 59 is formed in part 48 of link member 47 and carriage part 24 extends through this slot 59 and slot 25 into the toasting chamber 17. Carriage part 24 through spring 21 keeps link 47 in its up position in the absence of external manipulation. As will be apparent from the foregoing, latch member 52 and latch ledge 51 form an automatically engaged manual latch which must be manually delatched to enable cover members 28,29 to be opened and necessarily requires the attention of a person at the toaster when this event occurs. Thus in an unlikely event of a fire having ignited in the chamber, cover members 28,29 will not have been automatically opened by the toaster mechanism (when unattended by the operator) thereby allowing flames to escape from toasting chamber 17. Conveniently, to assist operation of the toaster, visual and/or audible indicators 57, 58 may be provided to show that a toasting cycle has commenced and separately has been completed. Although the foregoing description has been given with reference to a toaster having a carriage 23 moved manually down and a spring 21 to eject the toasted product, it should of course be appreciated that any known mechanism for driving or moving carriage 20 might also be employed.
As is best seen in FIGS. 1, 1a and 2, each cover member 28,29 includes a plurality of slots 60 formed in upper wall 30 of each member. Slots 60 are preferably formed by a punching technique so that the metal 61 formerly within the slot is displaced out of the plane of the wall 30 to be held overlying the slot 60 thus formed, by end tabs 62 connecting the part 61 to the remainder of the wall 30. Preferably the slots are arranged generally perpendicular to walls 15,16 of toasting chamber 17 or alternatively at an angle of between 90° and 30° to walls 15,16. Conveniently the metal forming the part 61 is spaced by between 0.5 and 1.5 mm from the adjacent surface of the wall 30. Preferably the length of slots 60 are between 10 and 25 mm. Preferably the spacing between adjacent slots is between 1.5 and 5 mm, preferably about 3 mm. Conveniently the width of each slot is between 1.5 and 5 mm, preferably about 3 mm.
While a preferred embodiment of the present invention has been described and illustrated, the invention should not be limited thereto but may be otherwise embodied within the scope of the following claims. | A cover for a toaster capable of retaining flame from a fire within the body of the toaster. The cover comprises a first wall adapted to overlie an access opening to a toaster compartment within the toaster, the first wall having a plurality of slot-like apertures formed therein with a second member partially or fully overlying each slot-like aperture but being located in a plane spaced from that of the first wall. The slot-like apertures are disposed transversely to a longitudinal axis of the toasting compartment whereby flame within the toasting compartment is substantially prevented from passing through the cover but convection heat from within the toasting compartment is capable of passing through the slot like apertures. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to coated ceramic parts of the type used in manufacturing articles from molten glass, and to a method of fabricating such parts. More particularly, this invention relates to the coating of ceramic parts that are to be submerged, or partly submerged, in molten glass to retard the abrasion of the molten glass contacting surfaces of such parts by the molten glass.
2. Description of the Related Art Including Information Disclosed Under 37 CFR 1.97 AND 1.98
In the manufacture of glass articles from a molten glass composition, for example, in the manufacture of glass containers from a molten soda-lime-silica glass composition by a glass container forming machine of the individual section (I.S.) type, various ceramic parts are used at locations where the parts are submerged or partly submerged in the molten glass. Such parts include a ceramic orifice ring, as generally described in U.S. Pat. No. 4,950,321 (DiFrank), which is submerged in molten glass with its upper surface in contact with molten glass, and ceramic glass flow control needles, as identified by reference numeral 32 in U.S. Pat. No. 5,660,610 (DiFrank et al.), and a ceramic feeder tube, as identified by reference numeral 80 in the aforesaid '610 patent, which are partly submerged, while in use, in molten glass. The aforesaid '321 and '610 patents are assigned to the assignee of this application, and their disclosures are incorporated by reference herein.
Molten glass compositions, including soda-lime-silica glass compositions, are very abrasive to the types of ceramic compositions that are used in the manufacture of parts for use, while submerged or partly submerged, in molten glass, and this necessitates frequent replacement of such ceramic parts, orifice rings, for example, typically requiring replacement at 30-60 day intervals, depending on glass color and temperature, and being shorter in high production installations.
BRIEF SUMMARY OF THE INVENTION
It has now been found, however, that it is possible to substantially extend the useful lives of ceramic parts used, while submerged in molten glass, to produce useful articles from the molten glass. The useful lives of the ceramic parts are substantially extended by coating all molten glass contacting surfaces of each article with a superimposed pair of these coatings, each such coating being applied in a fairly thin layer. The innermost or base or ceramic part-contacting coating which need only be applied in an approximate thickness of 0.002 in., is a composite powder coating that is made up of a nickel chromium-aluminum-cobalt-yttria composite powder. Such a coating powder is available from Metco Division of Perkin-Elmer Corporation, whose headquarters are in Westbury, Long Island, N.Y., under their product designation Metco 461. The base coated-ceramic part is then further coated, to an approximate thickness of 0.006 in., with a powder coating that is made up of a prealloyed ceria-yttria stabilized zirconium oxide, which is also available from the Metco Division of Perkin-Elmer Corporation, and this coating powder is offered under the product designation Metco 205 NS powder. It is believed that the base coat, which serves as a bond coat for the top coat, and the top coat for each such coated ceramic part will interact with the ceramic part, after being heated when the part is put into production, to produce a high strength, high resistant coating. Such a coating also produces a thermal barrier between the ceramic and the molten glass, and this thermal barrier protects the ceramic part, to reduce thermal shock thereto and to alleviate the occurrence of cracking.
Accordingly, it is an object of the present invention to provide enhanced life ceramic parts for use, while submerged or partly submerged, in molten glass, in the manufacture of articles from the molten glass. It is also an object of the present invention to provide a method for treating ceramic glass-making parts to extend the useful lives of such parts, notwithstanding that such parts are to be used, while submerged or partly submerged, in molten glass, which is otherwise highly abrasive to such ceramic parts.
For a further understanding of the present invention and the objects thereof, attention is directed to the drawing and the following brief description thereof, to the detailed description of the invention and to the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an elevation view, in cross-section, of a ceramic orifice ring according to the present invention, which has been fabricated by the method of the present invention, for use in a glass manufacturing operation;
FIG. 2 is an elevation view partly in cross-section, of a ceramic feeder tube according to the present invention, which has been fabricated by the method of the present invention, for use in a glass manufacturing operation; and
FIG. 3 is an elevation view, partly in cross-section, of a ceramic flow control needle according to the present invention, which has been fabricated by the method of the present invention, for use in a glass manufacturing operation.
DETAILED DESCRIPTION OF THE INVENTION
An orifice ring according to the present invention is identified generally by reference numeral 10 in FIG. 1 . The orifice ring 10 is made up of a ceramic element 12 , which may be of conventional construction, and is designed to be used at the outlet of a molten glass feeder bowl that is used to provide molten glass to an I.S. glass forming machine through openings 14 , 16 , in the orifice ring 10 . Thus, the orifice ring 10 is submerged in molten glass during its useful life with its upper surface in contact with the molten glass.
The ceramic element 12 of the orifice ring 10 is provided with a superimposed pair of coatings 18 , 20 on each of its glass contacting surfaces. The innermost or base coating 18 is a coating that is made up of nickel chromium-aluminum-cobalt-yttria composite powder that is applied to the ceramic element 12 to an approximate thickness of 0.002 in., by plasma spraying, and Metco 461 powder coating from Metco Division of Perkin-Elmer is a suitable coating material for use as the coating 18 .
The ceramic element 12 , with the coating 18 applied thereto, is again coated, this time with a coating 20 , which is applied to the exterior of the coating 18 on the ceramic element 12 . The coating 20 is also applied as a powder by plasma coating, and is applied to an approximate thickness of 0.006 in. A prealloyed ceria-yttria stabilized zirconium oxide, such as that available from Metco Division of Perkin-Elmer under their designation Metco 205 NS, is suitable for use as the coating 20 . The Metco brochure for the Metco 205 NS coating describes the plasma application of the coating to a ceramic element, and its disclosure is also incorporated by reference herein. The orifice ring 10 , with the coatings 18 , 20 applied to the ceramic element 12 thereof, is installed without further processing in a glass feeder bowl. It is believed that the heat required during the plasma spraying of the coatings ( 18 and 20 ) allows for interaction between the ceramic element 12 and the base coating 18 , and also interaction between the base coating 18 and the coating 20 . This interaction between the ceramic element 12 , the base coating 18 and the coating 20 creates a thermal barrier that protects the ceramic element to reduce the thermal shock it experiences upon sudden exposure to molten glass, and alleviates the occurrence of cracking of the ceramic element 12 . The dual coating 18 , 20 of the ceramic element 12 not only increases the wear resistance of the orifice ring 10 in spite of its submergence in molten glass, but it also protects those areas that have less ceramic mass, such as the bridge area (not shown) of the orifice ring, from excessive thermal gradients.
A feeder tube according to the present invention is identified generally by reference numeral 30 in FIG. 2 . The feeder tube 30 is made up of an annular ceramic element 32 , which may be of conventional construction, and is designed to have its lowermost end submerged in molten glass in a feeder bowl that is used to provide molten glass to an I.S. glass forming machine. Thus, the lowermost end of the feeder tube 30 is submerged in molten glass during its useful life.
The portion of the ceramic element 32 that is submerged in molten glass is provided with a superimposed pair of coatings 34 , 36 on all of its molten glass-exposed surfaces. The innermost or base coating 34 is a coating that is made up of a nickel chromium-aluminum-cobalt-yttria-composite powder, and this coating is applied to the submerged portion of the ceramic element 32 , to an approximate thickness of 0.002 in., by a plasma spraying. Metco 461 powder coating from Metco Division of Perkin-Elmer is a suitable coating material for use as the coating 34 .
The submerged portion of the ceramic element 32 , with the coating 34 applied thereto, is again coated with the coating 36 , which is applied to the exterior of the coating 34 on the ceramic element 32 . The coating 36 is also applied as a powder by plasma coating, and is applied to an approximate thickness of 0.006 in., a prealloyed ceria-yttria stabilized zirconium oxide, such as that available from Metco Division of Perkin-Elmer under their designation Metco 205 NS being suitable for use as the coating 36 .
The feeder tube 30 , with the coatings 34 , 36 applied to the ceramic element 32 thereof, is installed without further processing in a glass feeder bowl with molten glass extending from the lowermost end of the feeder tube 30 to a level not above the level of the coatings 34 , 36 on the ceramic element 32 thereof.
A flow control needle according to the present invention is identified generally by reference numeral 40 in FIG. 3 . The flow control needle 40 is made up of a ceramic element 42 , which may be of conventional construction, and is designed to be used to control the flow of molten glass through submerged outlets of a molten glass feeder bowl that is used to provide molten glass to an I.S. glass forming machine. Thus, the lowermost portion of the flow control needle is submerged in molten glass during its useful life.
The ceramic element 42 of the flow control needle 40 is provided, in the lowermost portion thereof, with a superimposed pair of coatings 44 , 46 on its lowermost portion, namely, the portion that is to be submerged in molten glass in a feeder bowl. The innermost or base coating 44 is a coating that is made up of a nickel chromium-aluminum-cobalt-yttria-composite powder, and this coating is applied to element 42 to an approximate thickness of 0.002 in., by plasma spraying. Metco 461 powder coating from Metco Division of Perkin-Elmer is a suitable coating material for use as the coating 44 .
The ceramic element 42 , with the coating 44 applied thereto, is again coated, with the coating 46 , which is also applied to the exterior of the coating 44 on the ceramic element 42 . The coating 46 is also applied as a powder by plasma coating, and is applied to an approximate thickness of 0.006 in., a prealloyed ceria-yttria stabilized zirconium oxide, such as that available from Metco Division of Perkin-Elmer under their designation Metco 205 NS, being suitable for use as the coating 46 .
Although the best mode contemplated by the inventors for carrying out the present invention as of the filing date hereof has been shown and described herein, it will be apparent to those skilled in the art that suitable modifications, variations and equivalents may be made without departing from the scope of the invention, such scope being limited solely by the terms of the following claims and the legal equivalents thereof. | An abrasion resistant article ( 10, 30, 40 ) for use, while submerged or partly submerged in molten glass, in a glass article manufacturing operation, the article having a ceramic element ( 12, 32, 42 ) coated on its molten glass contacting surfaces with a thin base coating of a nickel chromium-aluminum-cobalt-yttria-composite powder ( 18, 34, 44 ) and a somewhat thicker coating ( 20, 36, 46 ) of a prealloyed ceria-yttria stabilized zirconium oxide superimposed on the base coating. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to an intelligent wardrobe management system for advising appropriate clothing to a user. It also relates to a method and a computer program for advising appropriate clothing to a user.
BACKGROUND OF THE INVENTION
[0002] Wardrobes for accommodating clothes such as shirts, dresses, skirts, trousers and sweaters are well known. When a user needs a specific item, he has to get to the wardrobe and search among all the different pieces of clothing until he eventually finds what he wants.
[0003] U.S. Pat. No. 5,651,677 discloses a wardrobe management system for organizing men's and women's business wardrobes to ensure that no repetition of clothing worn at occasions attended by the same groups of people occurs. The wardrobe management system has a log book in a calendar format with specified areas therein for recording garment identification and alpha-numeric information. The log book stores information about each garment and its prior usage. A marking tag has unique alpha-numeric information and is attached to each garment. The alpha-numeric information is recorded in the log book with a description of the garment or garment accessory to which it is attached. In planning clothing to be worn to future gatherings, the history of use information can be reviewed to avoid repetition of wearing the same garments to sequential and related functions.
[0004] However, this system neither takes into account the desires of the user, nor helps in planning the luggage for a trip.
[0005] If the specific clothing is not to be found in the wardrobe, e.g. it might be in the laundry, the user has to find a substitute. In case he is going on a trip for several days, he has to first make plans for what kind of and how much clothing he will be in need of, and then he has to find all that clothing in the wardrobe. He always has to see to that the different sets of clothing match. Other factors that influence his choice of clothing are weather forecasts, climate conditions, cultural manner and customs, mode trends. The time duration he will be in need of the clothing is also of importance in his considerations.
[0006] However, this process of planning and finding clothing is very time consuming and requires substantial effort. It is well appreciated that people tend to value their time more highly now than in the past. This tendency to more highly valued time nowadays is evidenced by a trend toward modem conveniences. Household appliances, such as washing machines, dishwashers, refrigerators and so on, are time savers that are indispensable to most people.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is therefore to provide a solution to the problem above of planning and finding clothing.
[0008] This object is achieved by an intelligent wardrobe management system for advising appropriate clothing to a user according to claim 1 , a method for advising appropriate clothing to a user according to claim 13 and a computer program for advising appropriate clothing to a user according to claim 20 .
[0009] According to a first aspect of the invention, an intelligent wardrobe management system is provided comprising a wardrobe controller which is arranged to receive input data, said input data comprising information about the clothing in a wardrobe, receive user data, process said input data and said user data, and output, on the basis thereof, a clothing proposal to the user.
[0010] According to a second aspect of the invention, a method is provided in which input data is received, said input data comprising information about the clothing in a wardrobe, user data is received, said input data and said user data is processed, and, on the basis thereof, a clothing proposal to the user is output.
[0011] According to a third aspect of the invention, a computer program product is provided, which is loadable into a digital computer, comprising computer program code portions for carrying out the steps of said method.
[0012] In recent years sophisticated household inventions have been made such as intelligent homes, intelligent refrigerators, intelligent vacuum cleaners, wearables and so on. These are all part of an ambient intelligence environment that is sensitive, adaptive, and responsive to the presence of people. The ambient intelligence here means that the home automation system identifies the user and adjusts these functions according to known preferences.
[0013] The gist of the invention is to provide an ambient intelligence environment for the user in order to aid him to choose right clothing in accordance with his demands. On the basis of the selection of available clothing in the wardrobe and the user data given by the user, a clothing proposal is suggested to the user. The user data comprises information about the user, such as where he is going, what he will be doing and his planned time schedule.
[0014] The above described concept is advantageous in that it facilitates and accelerates the users access to the wardrobe. The user can ease the difficulty of having to make all these frequently recurring choices and he does not have to spend a lot of time looking for the necessary information. A lot of people find these choices hard to make, due to different reasons. Some have a hard time of making their mind up, some do not feel they have the required time, some find it boring, some are just not very capable of finding appropriate combinations of clothing, some are color-blind, and so on. The present invention helps to alleviate the burden of making these choices and speeds up the required process.
According to an advantageous embodiment of the invention, the intelligent wardrobe management system comprises a database in which the received input data is stored. The input data holds information about the clothing contained in the wardrobe such as, for example, the type of clothing, their availability, their color, their age, the season they are adapted to, their state (clean or not), or preferred matching clothing articles. The database also contains user preferences and a wearing history of the respective clothing articles. According to another advantageous embodiment of the invention, said system comprises at least one scanner, e.g. a camera, a bar-code scanner and/or a tag identification sensor which is arranged to obtain said input data. Each clothing is scanned in order to obtain said input data. If a camera is used, there is a need for using some kind of image recognition software in order to identify the clothing articles going in and out of the wardrobe. In the future the clothing articles might be provided with a chip or some other information holder which stores all the information about the clothing articles.
[0017] According to yet another advantageous embodiment of the invention, said system comprises a user interface, whereby at least one of said reception of user data and said output of clothing advice is performed. Preferably, the user interface comprises a communication interface such as a touch display, a keyboard or the like for entering the user data. Further, the user interface preferably comprises a visual display for displaying said clothing advice.
[0018] According to yet another advantageous embodiment of the invention, said system comprises a network interface which is arranged to connect the system to at least one network. Such a network is, for example a World Area Network (WAN) such as Intranet and Internet or a Local Area Network (LAN). In this way the information about the clothing in the wardrobe is remotely accessible. The user doesn't have to go to the wardrobe in order to the enter the user data and receive said clothing proposal, but he can do it from another room in the building, or even from any part of the world that has access to the network.
[0019] Further, information goes also in the opposite direction. Said system has access to information outside the system through said network. In case there is a missing wanted clothing piece, it is possible for the user to order said clothing piece over the network in order to complete the wardrobe. Information, such as weather forecasts, climate conditions, cultural conditions and mode trends with reference to any place on earth, is also obtainable through said network.
[0020] According to yet another advantageous embodiment of the invention, said system comprises information about a location that the user is to visit, and information about circumstances regarding the visit, which circumstances affect the clothing. When the user, for example, plans to go on a trip to one place or to several places, he can get very useful information, through said system, about those places. Information, such as weather forecasts, climate conditions, cultural conditions and mode trends, may affect his choice of clothing. If, for example, the user is going to a dinner with French businessmen, he can receive good advices about what to wear in order not to stand out too much in consideration to what French businessmen usually wear. Said system is arranged to obtain all the information above, e.g. through the network, for example Intranet and/or Internet.
Further, said system comprises information about a duration of said visit during which the user will be in need of clothing. The time spent away affects the amount of needed clothing. In case the user is going to spend several days away from home, he will be in need of a great deal of clothing. In order to reduce the amount of needed clothing, the system is capable of suggesting some co-ordination advantages, i.e. some of the clothing articles may be used more than once—in a new combination.
[0022] Further features of, and advantages with, the present invention will become apparent when studying the appended claims and the following description. Those skilled in the art realize that different features of the present invention can be combined to create embodiments other than those described herein. Many different alterations, modifications and combinations will become apparent for those skilled in the art. The described embodiments are therefore not intended to limit the scope of the invention, as defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The present invention will now be described in more detail, by way of example, with reference to the accompanying drawings, wherein:
[0024] FIG. 1 shows a schematic representation of an intelligent wardrobe management system according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 shows a schematic representation of an intelligent wardrobe management system 100 according to the present invention. The intelligent wardrobe management system 100 comprises a wardrobe 120 which contains diverse clothing articles. A camera 150 is used for scanning the clothing in the wardrobe 120 in order to gather information about the clothing. The clothing articles are shown in a frontal view to the camera 150 before being folded or hung up in the wardrobe 120 . The same procedure applies when taking them out. The camera 150 may be positioned on the outside or the inside of the actual wardrobe 120 . In an alternative embodiment, the wardrobe 120 houses an “in-out” compartment where the scanning takes place. In order to identify the clothing articles going in and out of the wardrobe 120 , an image recognition software is used. The information thus obtained represents input data (ID) and is received by a wardrobe controller 110 . The wardrobe controller 110 stores said input data in a database (DB) 140 .
[0026] The question “What am I supposed to wear today or what should I take with me on a business trip?” is very familiar to many people. In the following example, a business trip abroad will be undertaken in order to demonstrate this embodiment of the intelligent wardrobe management system according to the present invention.
[0027] A user 130 is going on a business trip to Japan and New Zealand for several days. In New Zealand he will be playing golf during one of the days. On his way home he will join his family on a ski holiday in the Swiss Alps. From thence they will travel to London in order to attend a wedding, before they finally go home. The user 130 is well in advance, the journey starts in a couple of days, and he is planning what clothing articles he should bring. He logs on from a user interface (UI) 160 , which in this case is a user terminal. The user terminal is, for example, located in the kitchen. The user interface (UI) 160 has access, through a network interface (NI) 180 , to a network of his house, for instance an Intranet network and it can thus establish a connection with the intelligent wardrobe management system 100 . He enters his user data (UD), for example comprising where he is going, what he will be doing and his planned time schedule.
[0028] The wardrobe controller 110 considers said received user data and searches on a WAN, for example on the Internet, for additional information such as weather forecasts, climate conditions, cultural conditions and mode trends which are associated with said locations that he is to visit and said events that he is to attend, in accordance with his time schedule. The wardrobe controller 110 finds out several factors, which are of great importance and influence the choice of clothing. The Japanese business dress code is very strict. Even though the user always favors colored shirts, they are totally out of place in this case—a white shirt with a conservative suit and tie are indispensably required. An unexpected rain weather is predicted in the area in New Zealand where he will be playing golf, so appropriate rain clothes will be needed. The holiday resort area where he will be skiing with his family, holds a great adventure bath place. Bathing attire will thus come in handy. Between Gatwick airport in London and the place of the wedding there are a couple of formal-wear shops where he can rent a tuxedo.
[0029] The wardrobe controller 110 processes said input data and said user data and outputs, on the basis thereof, a clothing proposal CP to the user 130 . He receives a summarized list telling him what bring. He also receives an event specified list telling him what to wear for the different events. It is suggested to him, in order to reduce the weight and size of the luggage, that he could reuse some of the clothing articles. He could, for example, use his jackets and trousers in diverse combinations. Since he is in need of a couple new white shirts, it is proposed to him to order said shirts over the Internet from a warehouse. The order is thus handled by the wardrobe controller 110 on user authorization.
[0030] Considering his travel plans and the surrounding circumstances, he is admonished to bring, among other things, his gray and blue suits, several dark ties, his rain clothes and his pair of galoshes, his swimming hunks and his bathrobe. He is asked the question if he wants to place an order for a tuxedo and, if affirmative, he can choose between the different alternatives.
The clothing proposal is shown on a visual display VD 170 . He can always select other clothing articles by browsing through different alternatives. Being color-blind he appreciates the help he gets, otherwise it would have been a lot harder to choose a proper set of clothing. He is presented with the option of having the clothing advice to be shown on the visual display in such a way that he appears to be dressed with the suggested clothing proposal.
[0032] The day before he is to leave he logs on to the intelligent wardrobe management system 100 over a WAN, for example the Internet, from work. He finds out that a couple of desired lacking items are now on place in his wardrobe. The ordered new white shirts have arrived and the trousers have returned from the laundry. He also finds out that weather prognosis for the day of the golfing still applies. Further, he receives a confirmation from the formal-wear shop that the chosen tuxedo is reserved for him.
[0033] In an alternative embodiment of the present invention, the scanner is a bar-code scanner or a tag identification sensor, which could be used for gathering information, i.e. input data (ID), about the clothing. This requires that the clothing articles are equipped with bar codes and identification tags, respectively. In case they identify type, color, size and so on of the clothing, the gathering of information is considerably facilitated. When the user 130 puts clothing in the wardrobe 120 and scans the clothing by means of said scanning devices, they are consequently identified and said input data (ID) is stored in the database (DB) 140 . If the clothing is equipped with some kind of intelligent sensor, in the form of e.g. a chip, the information of the clothing may, for example, also include their state (clean or not) or their using time, i.e. the actual amount of time they have been worn. The wardrobe controller 110 may, for example, propose to send a pair of trousers, which needs to be cleaned, to the laundry.
[0034] In another alternative embodiment of the present invention, the intelligent wardrobe management system 100 has access to the user's 130 digital time schedule. In this way the wardrobe controller 110 can automatically obtain a lot of the user data UD.
[0035] In another alternative embodiment of the present invention, the user has the option of entering his preferences regarding his clothing articles and his clothing style. This information is stored in the database 140 and is optionally considered. The database keeps a wearing history of the respective clothing articles and the clothing articles used longest time ago appears with priority, but if the user turns it down a certain amount of times, it is put on hold. The system is adapted to propose a list of these clothing articles to be removed from the wardrobe. The clothing articles most frequently used are assigned with a prioritized state, i.e. they belong to the users preferences. This applies not only to the single clothing articles, but also to the combinations of clothing articles used.
[0036] In conclusion, and by way of summary, an advantage of the present invention is that it facilitates and accelerates the user's access to the wardrobe. The intelligent wardrobe management system obtains all necessary information about the clothing, the user and the locations that the user is to visit and it proposes what to wear or what to bring on a trip. He can thus ease the difficulty of having to make all the frequently recurring choices of choosing clothing and he does not have to spend a lot of time looking for the necessary information.
[0037] It should be noted that the above-mentioned embodiments exemplify the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. For example, the realisation and implementation of the present invention, at least to a certain extent, may be in the form of either separate elements or computer software. The word “comprising” does not exclude the presence of elements or steps other than those listed in a claim. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. | The invention relates to an intelligent wardrobe management system for advising appropriate clothing to a user. It comprises a wardrobe controller which is arranged to: receive input data, said input data comprising information about the clothing in a wardrobe; receive user data; process said input data and said user data; and output, on the basis thereof, a clothing proposal to the user. The system facilitates and accelerates the user's access to the wardrobe. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to interface circuits between a transmission line (for example, a telephone line) and a modem adapted to transmitting and receiving data. Such interface systems especially have the function of isolating the transmission line from the rest of the user equipment, in particular due to voltage level differences between the user equipment and the signals carried by the transmission line. The present invention more specifically relates to interface systems using a barrier of capacitive isolation of the transmitted signals.
2. Discussion of the Related Art
The principle of such a capacitive isolation is based on a transposition of the useful frequency band (baseband) to a much higher frequency band by means of a modulation-demodulation system. The useful band ranges, in the example of telephone lines, from 300 to 3400 Hz. The transposition of the useful frequency band, necessary to transpose the telephone frequency band from 300 to 3400 Hz generally used as a carrier of data transmissions on the line, also enables decreasing the respective sizes of the capacitors to be used for the isolation barrier.
It is accordingly necessary to have, on either side of the capacitive isolation barrier through which the modulated signals transit, modulation and demodulation means that provide, either to the line or the user equipment, the signals in the useful frequency band.
FIGS. 1 , 2 , and 3 very schematically show a conventional example of interface with a capacitive isolation barrier between a transmission line and a modem. FIG. 1 shows in more detail the system portion on the modem side. FIG. 2 very schematically shows an example of a modulator for transposing the modem passband to the high isolation barrier crossing frequency (for example, a 1-MHz carrier). FIG. 3 shows in more detail the circuit on the line side.
An interface system to which the present invention relates, illustrated in FIGS. 1 to 3 , is based on the use of an isolation barrier 1 formed with an assembly of capacitors C 1 , C 2 , C 3 , C 4 , C 5 , and C 6 via which transit signals modulated on a high frequency carrier (for example, on the order of one MHz), between a processing circuit 2 on the equipment side (modem) and a processing circuit 3 on the line side.
As illustrated in FIG. 1 , signal processing circuit 2 on the modem side essentially includes a modulator (MOD) 21 of the signals to be transmitted on the line and a demodulator (DEMOD) 22 of the signals received from the line. Modulator 21 receives the signals to be transmitted, in differential form, from two outputs Tx+ and Tx− of an amplifier (Tx) 23 having its differential inputs E+ and E− receiving the signals to be transmitted in the baseband (for example, from 300 to 3400 Hz). Amplifier 23 forms, for example, in a simplified way, the radiofrequency transmission head of the modem. Amplifier 23 is, for example, based on a low-noise amplifier.
Modulator 21 also receives a clock signal CK provided by a generator (GEN) 24 . Clock signal CK corresponds, on the side of circuit 2 , to the high-frequency carrier to which the transmission band must be transposed to pass isolation barrier 1 . Two differential outputs St+ and St− of modulator 21 are respectively connected to a first armature of capacitors C 1 and C 2 , the second respective armatures of which are connected to inputs Et+ and Et− of a demodulator (DEMOD) 31 of processing circuit 3 on the line side, as will be seen hereafter in relation with FIG. 3 . To enable a proper crossing of isolation barrier 1 , the modulation is performed with a carrier suppression, which amounts to multiplying the signal to be modulated by 1 or −1, at the frequency of clock CK.
Symmetrically, demodulator 22 of processing circuit 2 on the equipment side includes two differential inputs Er+ and Er− originating from respective first armatures of capacitors C 3 and C 4 of isolation barrier 1 . The second respective armatures of capacitors C 3 and C 4 are connected, on the side of circuit 3 , to two output terminals Sr+ and Sr− of a reception modulator (MOD) 32 that will be described hereafter in relation with FIG. 3 .
Demodulator 22 is intended for restoring the signals received from the transmission line that have been modulated on the high-frequency carrier of crossing of isolation barrier 1 , to provide these signals Rx+ and Rx− in differential form to a receive amplifier 25 (Rx). Amplifier 25 represents, for example, the receive head of the modem and provides, on two outputs S+ and S−, the signals received in differential form. Demodulator 22 also receives clock signal CK from generator 24 to enable the demodulation.
To enable recovering the data in the telephone band, be it on the user equipment side or on the line side, the modulation and demodulation clocks must be synchronous on either side of isolation barrier 1 . For this purpose, the frequency of clock CK provided by circuit 24 is transmitted, from circuit 2 to circuit 3 , in the form of two differential input signals CK+ and CK− transiting through two capacitors C 5 and C 6 of barrier 1 .
FIG. 2 very schematically illustrates an example of structure of modulator 21 of the signals to be transmitted. Such a modulator is based on the use of switches K 1 , K 2 , K 3 , and K 4 that are controlled by clock signal CK. Switches K 1 and K 2 receive, on a first terminal, signal Tx+. A second terminal of switch K 1 forms output terminal St+ of the modulator while a second terminal of switch K 2 is connected to output terminal St− of the modulator. Signal Tx− is sent onto the first respective terminals of switches K 3 and K 4 . The second terminal of switch K 3 is connected to terminal St+ while the second terminal of switch K 4 is connected to terminal St−. Switches K 1 and K 2 are controlled to the on-state by signal CK while switches K 3 and K 4 are controlled to the off-state by signal CK. In other words, switches K 1 and K 2 are controlled by signal CK while switches K 3 and K 4 are controlled by the inverse of signal CK. In FIG. 2 , these controls have been schematized by the direction of the arrows associated with the control terminals of switches K 1 , K 2 , K 3 , and K 4 . The operation of a multiplier such as illustrated in FIG. 2 is conventional and will not be detailed further.
As illustrated in FIG. 3 , processing circuit 3 on the line side includes modulator 31 for restoring, in the transmission band, the signals to be transmitted that it receives in modulated form on terminals Et+ and Et−. The outputs of demodulator 31 are sent onto a transmission amplifier 33 (Tx) that provides the signals to be transmitted, transposed back into the base or useful band.
Demodulator 31 receives a clock signal CK′ from a circuit 34 (REGEN) for regenerating a clock signal synchronous with signal CK on the equipment side, based on a reprocessing of signals CK+ and CK− received as an input by circuit 34 .
On the receive side, modulator 32 that provides signals Sr+ and Sr− to capacitors C 3 and C 4 receives the received signals R′x+ and R′x− in the baseband from an amplifier 35 , the respective inputs of which are, like the outputs of amplifier 33 , connected to a duplexer 36 (4W/2W), the function of which is to perform a 4 wire-2 wire conversion. Circuit 36 generally includes echo cancellation means for eliminating, from the signal received from the line, the echo of the transmitted signal to enable a good reception. The telephone line has been symbolized by its two conductors TIP and RING at the output of duplexer 36 .
The operation of an interface system such as illustrated in FIGS. 1 to 3 is known and will not be explained in detail. Only the elements to which the present invention applies, that is, more specifically, the clock transmission through isolation barrier 1 , will be reviewed.
FIGS. 4A , 4 B, 4 C, 4 D, and 4 E schematically illustrate, in the form of timing diagrams, the clock transmission problem that the present invention aims at solving. FIG. 4A shows an example of a baseband signal meant to cross isolation barrier 1 . For simplification, no account will be taken of the differential structure of the signals and only one useful signal has been shown in FIG. 4 A. It may be any of signals Tx+, Tx−, R′x+, R′x−. For example, it is assumed that it is signal Tx+ referenced with respect to the common mode voltage VCM of the equipment.
FIG. 4B shows clock signal CK used for the modulation. The signal has been shown as being referenced with respect to common mode voltage VCM due to the multiplication by 1 and −1 effected by the modulator.
FIG. 4C illustrates the shape of signal St+obtained at the output of modulator 21 . This signal includes rectangular pulses at the frequency of clock signal CK in an envelope formed with signal Tx+ and its inverse.
FIG. 4D shows an example of the shape of clock signal CK′ recovered on the side of circuit 3 . FIG. 4E shows the shape of signal T′x+ recovered at the output of demodulator 31 . The demodulation is performed, like the modulation, by a multiplying by 1 or −1 by means of the clock signal, here by a multiplying of signal St+ by signal CK′.
An example of interface to which the present invention more specifically applies is described in U.S. Pat. No. 5,500,895, the content of which is incorporated in the present description by express reference.
A problem that is raised in the type of interface system has to do with disturbances that may affect clock signal CK′ and that originate from radioelectric disturbances due, for example, to electric household appliances (for example, the starting of a motor or of a compressor of a refrigerator).
In conventional systems, such disturbances cause a phase inversion of the clock restored on the line side. Now, when clock signal CK′ correctly restores signal CK, the shape of signal Tx+ is recovered. However, if the phase of signal CK′ is inverted with respect to signal CK, for example, due to a parasitic disturbance p (FIG. 4 D), the restored signal T′x+ then is in phase opposition with respect to signal Tx+. The modem that notices the error by checking algorithms must then reposition its demodulator on the new phases relation (the involved demodulator is that, not shown, of the actual modem, downstream of the receive head, and not the demodulator associated with the isolation barrier). Now, each disturbance of the modem reception causes a decrease of the transmission level to enable the modem algorithms to correct the received data. Further, once a modem has switched to a lower transmission level, it does not recover by itself to a better level until the end of the communication.
In conventional systems, the initial state of the regeneration circuit most often is random. It is thus possible to be, as soon as the beginning of a communication, in clock phase opposition. In this case, the modem already switches to a first lower level. If, afterwards, during the communication, a new parasitic pulse occurs, the modem switches to row a still lower level, due to the new clock phase inversion.
It should be noted that processing circuit 3 , on the line side, performs other functions than those illustrated in FIG. 3 . In particular, this circuit is used to detect the presence of a ringing and to detect a standardized line impedance (for example, on the order of 600 ohms). In certain cases, other capacitors are used in the isolation barrier to transmit other types of signals.
SUMMARY OF THE INVENTION
The present invention aims at overcoming the disadvantages of known capacitive isolation interface systems.
The present invention more specifically aims at providing a novel solution to enable a synchronous regeneration of a high-frequency modulation clock by a processing circuit on the line side.
The present invention also aims at providing a solution that is compatible with the rest of the functions of conventional interface circuits and, in particular, with a caller identification function during the ringing period.
A first solution that comes to mind would be to use a phase-locked loop (PLL) to obtain a correct clock on the line side. Such a solution must however be discarded, since a phase-locked loop would not detect a transient disturbance causing the phase inversion. Further, this solution would be particularly complex to implement.
It should be noted that the present invention aims at avoiding a phase inversion due to a random disturbance in the clock signal transmission and not at avoiding any phase shift between clock CK′ on the line side and clock CK on the equipment side. Indeed, there necessarily is a slight phase shift between these clocks, which will not be taken into account and which is not disturbing as long as this phase shift is approximately regular, which is the case most of the time since it is a phase shift due to physical propagation times. Further, it may be provided, as for example in above-mentioned U.S. Pat. No. 5,500,895, to take account of the delays between logic layers of the system for the clock signal transmission (element 117 , FIG. 6 ).
Another solution would be, if it was possible, to use software means to differentiate random disturbances due to the starting of an electric appliance from disturbances due to the line. Indeed, when dealing with line disturbances, it is normal for the modem to switch to a lower transmission level, while this is not justified in the case of a transient parasitic disturbance. However, nothing enables detecting the origin of the disturbance on the modem side, so that such a software solution would not be satisfactory.
The present invention originates from a novel analysis of the phenomena that cause the phase inversion problem of the regenerated clock signal on the line side. For the present inventors, this problem is due to the circuit used for this regeneration.
FIG. 5 shows a conventional example of a clock regeneration circuit 34 downstream of an isolation barrier 1 of an interface system between a telephone line and a modem. In FIG. 5 , only circuit 34 has been shown, with capacitors C 5 and C 6 of transmission barrier 1 that transmit signals CK+ and CK− coming from block 24 (FIG. 1 ). To simplify, it is assumed that signals CK+ and CK− are identical on either side of capacitors C 5 and C 6 . Circuit 34 is based on the use of a D flip-flop 40 , an output terminal Q of which provides signal CK′. Terminal QB, providing the inverse of output signal Q, is connected to the D input of flip-flop 40 . Clock input CLK of flip-flop 40 receives the output of a logic combination of signals reprocessed based on signals CK+ and CK−. Signals CK+ and CK− are, on the side of circuit 34 , referenced to a voltage VDR corresponding to the voltage on the line side, recovered by a conventional line impedance circuit. The reference to potential VDR is obtained by connecting each terminal CK+ and CK− to a reference terminal VDR via a resistor, respectively, R 1 or R 2 .
FIG. 5 will be discussed at the same time as its operation in relation with timing diagrams illustrating the characteristic signals at different points. These characteristic signals are illustrated, in an example, in FIGS. 6A to 6 I.
FIGS. 6A and 6B show the respective shapes of signals CK+ and CK− referenced to potential VDR. To simplify, the respective high and low states of the logic signals of the present description have been symbolized by +1 and −1.
Signals CK+ and CK− each cross an RC cell having a small time constant to only recover the rising edges of signals CK+ and CK−, by referencing these edges to the ground. Thus, terminal CK+ is connected, via a capacitor C 7 , to a terminal A, and terminal CK−is connected, via a capacitor C 8 , to a terminal B. Terminals A and B are each connected, via a resistor R 3 , R 4 , to ground M. Two diodes D 1 , D 2 connect terminal M to terminals A and B, the respective cathodes of diodes D 1 and D 2 being connected to terminal M. The function of the diodes is to ground the signals of nodes A and B. FIGS. 6C and 6D illustrate the respective shapes of signals VA and VB at terminals A and B. As illustrated by these drawings, only the rising edges of signals CK+ and CK− are retranscribed on signals VA and VB, respectively.
Nodes A and B are each connected to the input of an inverter 41 , 42 , the function of which is to shape signals VA and VB between the ground and potential VDR. Other circuits equivalent to inverters 41 and 42 may be used to reshape these signals. FIGS. 6E and 6F illustrate respective shapes of signals V 41 and V 42 at the output of inverters 41 and 42 . To simplify the representations of the timing diagrams, no account has been taken of the propagation times in the inverters, and it has been assumed that their switching threshold is at 0 volt. Thus, signal V 41 is high between two pulses of signal VA while signal V 42 is high between two pulses of signal VB.
The respective outputs of inverters 41 and 42 are combined within a NAND gate 43 , the output of which is connected to clock input CLK of D flip-flop 40 . Flip-flop 40 is assembled as a divider by 2, that is, one edge out of two of output signal V 43 of NAND gate 43 is selected to generate a rising edge of clock signal CK′. The shape of signal V 43 at the output of the NAND gate is shown in FIG. 6 G. This signal normally has a regular shape and exhibits a rising edge for each pulse of one of signals VA or VB.
The respective shapes of signal CK′ (output Q of flip-flop 40 ) and of its inverse (output QB) are illustrated by the timing diagrams of FIGS. 6H and 6I .
As can be seen from these timing diagrams, output Q normally provides a signal of same clock frequency CK on the equipment side. With the difference of the propagation times, signal CK′ has the same shape as signal CK+. However, in case of a transient disturbance, the phase of output Q is inverted. Such a transient disturbance is illustrated in the timing diagrams of FIG. 6 in the form of a pulse p occurring on signals VA and VB. Indeed, since it is a parasitic disturbance resulting, for example, from the powering-on of an electric household appliance, there is no reason for this disturbance to only occur on one of the signals. The occurrence of this disturbance causes an additional rising edge of signals V 41 and V 42 in a period of signals CK+ and CK−. This translates as an additional clock pulse at the input of flip-flop 40 that, accordingly, generates an excess switching at the output of this flip-flop. As illustrated in the right-hand portion of the timing diagrams of FIG. 6 , the phase of signal Q is, from pulse p, inverted with respect to the left-hand portion of these drawings.
Among its objects, the present invention aims at providing a solution that adapts to a conventional flip-flop circuit such as illustrated in FIG. 5 and that is a particularly simple way of regenerating a clock on the line side.
More specifically, the present invention provides a method for regenerating a clock signal based on a flip-flop and on two complementary signals at the clock rate, the flip-flop being assembled as a divider by two of a combination of shaping signals each translating a direction, respectively rising or falling, of the edges of one of the complementary signals, and the method including using one of said shaping signals to reset the flip-flop.
According to an embodiment of the present invention, the method is applied to regenerating a clock signal downstream of a capacitive isolation barrier carrying the two complementary signals.
According to an embodiment of the present invention, an output of the flip-flop provides an image of a first one of said complementary signals, the flip-flop being reset on edges of the shaping signal of the other complementary signal.
The present invention also provides a circuit for regenerating a clock signal based on two complementary signals by means of a D flip-flop, a clock input of which receives the result of a logic combination of two shaping signals resulting from a filtering of the respective rising edges of the complementary signals, a reset input of the flip-flop receiving one of said shaping signals.
According to an embodiment of the present invention, the logic combination is of NAND type, the shaping signals being provided by inverters.
According to an embodiment of the present invention, the reset input of the flip-flop is connected at the output of the inverter for shaping the complementary signal, of which an output of the flip-flop provides an inverted image.
The present invention also relates to an interface system between a modem and a transmission line, of the type using a capacitive isolation barrier to transmit a clock for modulating the signals to be transmitted from the modem to a processing circuit on the line side, and including a clock regeneration circuit.
The foregoing objects, features and advantages of the present invention, will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 6 , previously described, are intended for showing the state of the art and the problem to solve;
FIG. 7 partially shows an embodiment of a clock regeneration circuit according to the present invention;
FIGS. 8A and 8B illustrate, in the form of timing diagrams, an embodiment of the clock regeneration method according to the present invention; and
FIGS. 9A , 9 B, and 9 C illustrate the effect of a parasitic pulse on the recovery of the transmission signals, when implementing the present invention.
DETAILED DESCRIPTION
The same elements have been designated by the same references in the different drawings. For clarity, only those elements that are necessary to the understanding of the present invention have been shown in the drawings and will be described hereafter. In particular, the details constitutive of the processing circuits on the equipment side and on the line side will not be detailed any further since their structure and their operation are perfectly conventional.
A feature of the present invention is to provide a periodic reset of the clock generation means on the line side. In other words, the present invention provides setting the initial state of the flip-flop providing the clock signal downstream of the isolation barrier.
Another feature of the present invention is to use one of the signals regenerated by the circuit on the line side to directly reset the flip-flop.
FIG. 7 shows a partial view of a clock signal regeneration circuit 34 ′ according to the present invention. A circuit 34 ′ according to the present invention includes all the elements of a circuit 34 such as illustrated in FIG. 5 so that only the logic circuit have been shown, for simplification. Thus, FIG. 7 shows inverters 41 and 42 , NAND gate 43 , and a flip-flop 40 ′.
According to the present invention, the periodic reset of flip-flop 40 ′ is obtained by connecting a reset input R of this flip-flop to the output of inverter 42 . Thus, implementing the present invention by means of a regeneration circuit based on a D flip-flop only requires one additional connection with respect to a conventional circuit.
It should be noted that flip-flop 40 ′ is, as previously, assembled as a divider by 2, that is, one edge out of two of output signal V 43 of NAND gate 43 is chosen to generate a rising edge of clock signal CK′.
FIGS. 8A and 8B illustrate, in the form of timing diagrams, the shape of complementary signals obtained at the output of a D flip-flop 40 ′ of a regeneration circuit such as illustrated in FIG. 7 by implementing the method of the present invention. FIGS. 8A and 8B should be considered together with FIG. 6 shown on the same plate since, except for the timing diagrams of FIGS. 6H and 6I , the other timing diagrams ( 6 A to 6 G) also apply to the present invention.
According to the present invention, flip-flop 40 ′ is reset for each rising edge of signal V 42 , that is, at the output of the inverter, the falling edges of which determine the falling edges of signal Q′.
Thus, as illustrated in FIG. 8A by arrows, flip-flop 40 ′ is reset to 0 for each rising edge of signal V 42 . A consequence thereof is that the state of output Q′ of flip-flop 40 ′ is always set to 0 before the occurrence of a falling edge of signal V 41 triggering the state switching of output Q′. In other words, the D input of flip-flop 40 ′ is always set to 1 before this state is read, to generate an edge on signal Q′.
As a consequence, the occurrence of a transient disturbance (p, FIGS. 6C and 6D ) only disturbs output Q′ over a duration smaller than one clock period. Indeed, at the next clock pulse, the flip-flop has been reset and thus recovers the same phase relation as before the disturbance.
Of course, other means than a D flip-flop such as illustrated in FIGS. 5 and 7 may be used to implement the method of the present invention. For example, a flip-flop having an input for setting to one and an input for setting to 0 respectively receiving signals V 41 ad V 42 may be used. In this case, the data input of the flip-flop will be grounded and its output will be used as a clock signal CK′. Such a circuit accordingly spares the use of a NAND gate.
FIGS. 9A , 9 B, and 9 C illustrate, in the form of timing diagrams, the effects of the implementation of the method of the present invention on the baseband signal recovery by an otherwise conventional processing circuit ( 3 , FIG. 3 ), downstream of the isolation barrier ( 1 , FIGS. 1 , 3 ). FIGS. 9A to 9 C are to be considered together with previously discussed FIGS. 4C to 4 E. FIG. 9A shows the example of signal St+ of FIG. 4 A. FIG. 9B illustrates the shape of signal CK′ obtained by means of the present invention, assuming the existence of a disturbance p as in FIG. 4 D. FIG. 9C illustrates signal T′x+ obtained at the output of demodulator 31 (FIG. 3 ).
As appears from FIG. 9C , disturbance p translates as a temporary inversion inv of signal T′x+ during, at most, half a period of clock signal CK′. Afterwards, signal T′x+ recovers its normal shape since clock CK′ has recovered its former shape.
An advantage of the present invention is that it suppresses or eliminates the effects of transient disturbances that are not due to the actual transmission line and that originate from external appliances, for example electric household appliances.
Another advantage of the present invention is that it is particularly simple to implement, especially in an interface system such as described in above-mentioned U.S. Pat. No. 5,500,895.
Another advantage of the present invention is that it is compatible with a caller identification operating mode that, during a predetermined period at the beginning of the communication, suppresses one of signals Tx+ or Tx− and divides the clock by 2. In this case, the clock regeneration circuit of the present invention still operates, but without setting the phase relation during this period, since a single signal is present at the output of inverters 41 and 42 .
It should be noted that this absence of a flip-flop reset, during this caller identification period, presents a smaller risk since the rate is smaller than during data transmissions. Further, if an error occurs, this is generally less critical for the caller identification than for the actual data transmission.
Of course, the present invention is likely to have various alterations, modifications, and improvements which will readily occur to those skilled in the art. In particular, the sizing of the components of the clock regeneration circuit according to the present invention are within the abilities of those skilled in the art according to the functional indications given hereabove and to the application. Further, although the present invention has been described hereabove in relation with a telephone line interface system, it should be noted that the present invention applies to any system in which a capacitive isolation barrier is used, and which requires the transmission of a synchronous clock through this isolation barrier. Moreover, although the present invention has been described by using a given relation of the edges (rising, falling) of the different signals, adapting the present invention to the inverse relation (falling, rising) is within the abilities of those skilled in the art.
Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and the scope of the present invention. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. The present invention is limited only as defined in the following claims and the equivalents thereto. | A method and a circuit for regenerating a clock signal based on a flip-flop and on two complementary signals at the clock rate, the flip-flop being assembled as a divider by two of a combination of shaping signals each translating a direction, respectively rising or falling, of the edges of one of the complementary signals, and one of said shaping signals being used to reset the flip-flop. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to an improved metal plating method and apparatus, and more particularly relates to improvements in high speed metal plating system in which application of large current at low voltage causes relative movement between electrolyte and a workpiece to destroy an ion diffusion layer on the surface of the workpiece.
Such a conventional high speed metal plating system generally includes a pretreatment unit, a metal plating unit and an aftertreatment unit which are arranged one after another along a straight path. The system is further provided with a transfer unit which transfers workpieces through each unit and form units to unit. Each workpiece is loaded to the system at a supply port of the pretreatment unit for travel through various treatment baths in the unit being carried by the transfer unit. On arrival at the metal plating unit, the workpiece is accommodated in a metal plating bath in the unit. Under application of large current at high voltage, the bath, i.e. the electrolyte, is forced to flow at a high speed for plating of the workpiece. Next, the plated workpiece is passed through various treatment baths in the aftertreatment unit for final unloading at a discharge port of the aftertreatment unit.
Since the processing speed of the system is freely adjustable, the system can be well incorporated into a continuous line of production. Despite this advantage, the straight arrangement of the three units requires reservation of a large spacing in the continuous line of production. Further, in the case of the conventional high speed metal plating system, no special expedients are taken into consideration for efficient transfer of workpieces between the system itself and associated systems. Thus the production efficiency of the entire production line is ill influenced by presence of such a neck of transfer between the associated systems.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a high speed metal plating system which requires a reduced space for installation, in particular in a continuous line of production.
It is another object of the present invention to provide a high speed metal plating system which assures smooth and efficient transfer of workpieces between associated systems.
In accordance with the basic aspect of the present invention, a plurality of treatment bath units are arranged along an arcuate path, a transfer unit is arranged at the center of the arcuate path in an arrangement rotatable about the center and vertically shiftable, a loading unit is arranged facing the transferunit near one end of the arcuate path and an unloading unit is arranged facing the transfer unit near the other end of the arcuate path.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the entire construction of one embodiment of the apparatus in accordance with the present invention,
FIG. 2 is a front view of the apparatus shown in FIG. 1,
FIG. 3 is one sectional side view of one embodiment of an electrolytic defat bath unit used for the apparatus shown in FIG. 1,
FIG. 4 is a sectional plan view of the defat bath unit,
FIG. 5 is another sectional side view of the defat bath unit,
FIG. 6 is one sectional side view of one embodiment of a rinsing bath unit used for the apparatus shown in FIG. 1,
FIG. 7 is a sectional plan view of the rinsing bath unit,
FIG. 8 is another sectional side view of the rinsing bath unit,
FIG. 9 is one sectional side view of one embodiment of the plating bath unit used for the apparatus shown in FIG. 1,
FIG. 10 is a sectional plan view of the plating bath unit,
FIG. 11 is another sectional side view of the plating bath unit,
FIG. 12 is a sectional side view of one embodiment of the transfer unit used for the apparatus shown in FIG. 1, i.e. the section shown with a circle A in FIG. 2,
FIG. 13 is a front view of one embodiment of the loading or unloading unit used for the apparatus shown in FIG. 1,
FIG. 14 is a plan view of the loading or unloading unit,
FIG. 15 is a side view of the loading or unloading unit,
FIG. 16 is a front view of one example of the workpiece plated in accordance with the present invention,
FIG. 17 is a side view of the transfer unit,
FIG. 18 is a graph for showing the relationship between the current density and the plating speed,
FIG. 19 is a graph for showing the relationship between the electrolyte temperature and the current density,
FIG. 20 is a graph for showing the relationship between the electrolyte concentration and the maximum current density,
FIG. 21 is a graph for showing the relationship between the electrolyte flow rate and the maximum current density, and
FIGS. 22 to 24 are views of another embodiment of the plating bath unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The entire construction of one typical embodiment of the apparatus in accordance with the present invention is shown in FIGS. 1 and 2, in which the apparatus includes various treatment bath units, i.e. electrolytic defat bath units 110, rinsing bath units 130, pickling bath units 150 and a plating bath unit 170. The apparatus further includes a transfer unit 200 for transferring workpieces W from bath unit to bath unit, a loading unit 300 for supplying crude workpieces W to the apparatus and an unloading unit 400 for discharging plated workpieces W from the apparatus, in most cases for assignment to a next associated system.
In the case of the illustrated embodiment, nine treatment bath units 110 to 170 are arranged around the transfer unit 200 along an arcuate path. The arcuate path is divided into twelve equal sections into which the treatment bath units are individually allotted. Each treatment bath unit is substantially trapezoid in its horizontal configuration so that sides of adjacent treatment bath unit should face to each other on the arcuate path. Nine of the equal sections accommodate the treatment bath units and remaining three sections accommodate the loading and unloading units 300 and 400, respectively. As best seen in FIG. 2, the nine treatment bath units are mounted to a pedestal 10.
The defat bath unit 110 is used for removal of fat on workpieces W. As shown in FIGS. 3 to 5, the defat bath unit 110 is made up of an outer casing 111, an inner cylinder 112 and an electrode 113. The outer casing 111 is trapezoid in its horizontal configuration. The top end of the outer casing 111 is closed by a top closure 114 which is provided with an opening 115 for insertion of a workpiece W. A bottom closure 116 of this outer casing 111 is provided with a drain 117. This drain 117 is connected to a reservoir 118 shown in FIG. 1 by means of a collector tube not shown. The inner cylinder 112 is mounted atop the bottom closure 116 in an arrangement such that its cavity should be positioned just below the opening 115 in the top closure 114. The top end of the inner cylinder 112 is somewhat spaced from the top closure 114 of the outer casing 111. Within the upper section of the cavity of the inner cylinder 112 is accommodated the electrode 113 which is made of, e.g. stainless steel. The inner cylinder 112 is provided at its bottom end with a joint 119 for acceptance of a supply tube extending from the reservoir 118.
The rinsing bath units 130 perform rinsing of the workpieces W before and after the plating whereas the pickling bath units 150 remove acid from the crude workpieces W before the plating. The constructions of these bath units 130 and 150 are very similar to those of the defat bath unit 110 shown in FIG. 3 and, for this reason, like elements are designated with like reference numerals. The rinsing bath unit 130 includes an outer casing 111 and an inner cylinder 132 encased in the former. Near the lower end, the inner cylinder 132 is provided with several radial openings 133. The lower end of the inner cylinder 132 is also provided with a joint 119 which is connected to a given water supply such as a water faucet. The drain 117 of the outer casing 111 connected to a given drain pipe. In the case of the pickling bath unit 150, the joint 119 is connected to a reservoir 134 of pickling agent and the drain 117 is connected to a collector tube extending from the reservoir 134.
One embodiment of the plating bath unit 170 is shown in FIGS. 9 to 11, in which elements similar to those used for the preceding bath units are designated with similar reference numerals. The plating bath unit 170 is made up of an outer casing 111, a bath assembly, an upper electrode 172 and a lower electrode 173. The bath assembly 171 is made up of an upper cylinder 174 and a lower cylinder 175 secured to each other and mounted atop a bottom closure 116. The upper electrode 172 is inserted into the upper cylinder 174 whereas the lower electrode 173 is inserted into the lower cylinder 175 being somewhat spaced from the upper electrode 172. A plating bath 176 is formed whilst being surrounded by the upper and lower electrodes 172 and 173. Each electrodes is given in the form of a cylinder made of titanium and platinum plating of low electric resistance is applied to the surface of the electrode for protection against corrosion by the electrolyte and for better current flow. The inner diameter of the cylinder forming the electrode is chosed so that, when a workpiece W is inserted into the plating bath, the clearance between the electrode and the workpiece W should be 5.0 mm. or smaller. When the clearance exceeds this limit, the flow rate of the electrolyte is reduced to lower the plating speed. The electrodes 172 and 173 are connected to the positive pole of a given power source via conductors 177 and 178, respectively. A joint 119 is attached to the lower end of the lower cylinder 175 for connection with a supply tube extending from a reservoir 179 for the electrolyte. The drains 117 formed in the bottom closure 116 is connected to the reservoir 179 via collector tubes not shown.
The transfer unit 200 shown in FIGS . 1,2,12 and 17 is made up of a drive assembly 201, a rotary disc 202 and holder assemblies 203. The drive assembly 201 drives the rotary disc 202 for intermittent rotation each over a prescribed angle, each cover 30 degrees in this example, and for vertical shifting. The center of rotation of the rotary disc 202 falls on the center of the arcuate path along which the treatment bath units are arranged.
As best seen in FIG. 12, the rotary disc 202 holds the holder assemblies 203 and secured to a drive shaft 204 of the drive assembly 201. The rotary disc 202 is located at a lever above the treatment bath units.
The holder assembly 203 is used for holding the workpiece W and 12 sets of holder assemblies 203 are arranged along the periphery of the rotary disc 202 at an interval of 30 degrees. The distance of the holder assemblies 203 from the center of rotation of the rotary disc 202 is selected such that a circle formed by connecting the 12 holder assemblies 203 should coincide the one formed by connecting the openings 115 of the treatment bath units 110, 130, 150 and 170.
Each holder assembly 203 includes, as seen in FIG. 12, a brass head 205 to be tightly inserted into one end of the workpiece W to be held, a brass connecting rod 206 in screw engagement with the head 205, a brass shaft 207 in screw engagement with the connecting rod 206, a brass electric reception head 208 securely mounted atop the shaft 207 and a resin sleeve 209 embracing the lower end section of the connecting rod 206 to avoid plating thereof. The lower end of the shaft 207 is provided with an outer flange which forms a sealing closure 210 for closing the opening 115 of the treatment bath units. The rotary disc 202 is inserted over the shaft 207 via an insulating resin sleeve 211 in a vertically shiftable arrangement. A spring 212 is interposed between an outer flange of the insulating sleeve 211 and the sealing closure 210.
The loading unit 300 is adapted for supplying crude workpieces W to the transfer unit 200 and, as shown in FIG. 1, arranged near the defat bath unit 110. The unloading unit 400 is adapted for discharging plated workpieces W from the transfer unit 200 and arranged near the terminal rinsing bath unit 130 on the arcuate path.
As shown in FIGS. 13 to 15, each of the loading and unloading units includes rotary block 301 rotatable in a horizontal direction, a lifter block 302 mounted onto the rotary block 301, a mobile assembly 303 mounted to the lifter block 302 and a clamper 304 mounted to the mobile assembly 303 for clamping workpiece W.
Back to FIG. 1, a horizontal conveyer 501 is arranged on one side of the loading unit 300 and, at one end thereof closer to the loading unit 300, provided with a raising assembly 502 to raise workpieces W transported by the conveyer 501 upright for assignment to the loading unit 300. On one side of the unloading unit 400 remote from the loading unit is arranged a collector box 503 for receiving plated workpieces W.
Electric supply units 600 are arranged facing the defat and plating bath units 110 and 170 as shown in FIG. 1. In FIG. 2, each electric supply unit 600 includes a fluid cylinder 601 such as an air cylinder provided with a plunger 602 movable vertically and a copper electric supply head 603 coupled to the lower end of the plunger 602 via an insulator. The electric supply head 603 is connected to a give electric power source.
As shown in FIG. 1, the rinsing bath unit 130 is connected to a water faucet and a drainage whereas the defat bath unit 110 is accompanied with an agent supply unit composed of the 3 reservoir 118 and a pump 504. The reservoir 118 is a bath made of fiber reinforced plastics and about 20 l in capacity. The reservoir 118 is equipped with a proper electric heater and a thermometer so that the temperature of the accommodated agent should be maintained in a range from 50 to 60 degrees.
The pickling bath unit 150 is accompanied with an agent supply unit composed of the reservoir 134 and a pump 505. The reservoir 134 is a bath made of fiber reinforced plastics and about 20 l in capacity. The reservoir 134 is also equipped with a proper electric heater and a thermometer so that the temperature of the accommodated agent should be maintained in a range from 50 to 60 degrees.
The plating bath unit 170 is accompanied with an agent supply unit composed of the reservoir 179 and a pump 506. The reservoir 179 is a bath make of fiber reinforced plastics and about 40 l in capacity. The reservoir 179 is also equipped with a boiler and a thermometer so that the temperature of the accommodated electrolyte should be maintained in a range from 75 to 85 degrees. The plating bath unit 170 is connected to the first to third electrolyte baths 507 to 509. The first electrolyte bath 507 accommodates mixture of nickel sulfate, nickel chloride and boron acid, the second electrolyte bath 508 accommodates nickel carbonate used for PH adjustment, and the third electrolyte bath 509 accommodates luster. The reservoir 179 is equipped with an integrating ammeter, a PH meter and level meter so that electrolytes in the first to third electrolyte baths should be charged into the reservoir 179 when the composition and the quantity of the electrolyte in the reservoir 179 fall off the preset ranges. The reservoirs 118, 134 and 179, the first to third electrolyte baths 507 to 509 are arranged around a pedestal 510 of the plating apparatus.
Next the operation of the apparatus of the above-described construction will be explained.
Workpieces W from the preceding system in the continuous line of production are sequentially assigned at first onto the conveyer 501. One example of such a workpiece W is shown in FIG. 16 in which the workpiece W is a metallic tubular piston used for tubular musical instruments. At the end of the conveyer 501, each workpiece W is raised upright by operation of the raising assembly 502 for assignment to the loading unit 300.
In this upright position, the workpiece W is held by the clamper 304 of the loading unit 300. The loading unit 300 then rotates as shown with a chain line in FIG. 1 in order to move the workpiece W to a position below the holder assembly 203 of the transfer unit 200 as shown in FIG. 17. As the clamper 304 of the loading unit 300 is moved upwards, the head 205 of the transfer unit 200 enters into the cavity of the workpiece W as shown in FIG. 12 in order to firmly hold the same. The transfer unit 200 then performs a 30 degree rotation and moves downwards in order to insert the workpiece W into the defat bath unit 110 passing through the opening 115 in the outer casing 111. At the same time the opening 115 is closed tightly by the sealing closure 210 of the holder assembly 203.
The defat agent is supplied into the defat bath unit 110 from the reservoir 118. The defat agent quickly flows upward through the inner cylinder 112 of the defat bath unit 110, flows downwards into the cavity of the outer casing 111 via the top end of the inner cylinder 112 and finally recollected back into the reservoir 118 via the drain 117.
After supply of the defat agent into the defat bath unit 110, the electrode 113 and the workpiece W are galvanized. Electric supply to the workpiece W is carried out via the holder assembly 203 of the transfer unit 200. That is, the electric supply head 603 of the electric supply unit 600 positioned above the defat bath unit 110 is moved downwards for contact with the electric reception head 208 of the holder assembly 203 as shown in FIG. 2. Since the head 208 is made of brass, the workpiece W can be galvanized.
After the treatment in the defat bath unit 110 is over, the rotary disc 202 of the transfer unit 200 is moved upwards in order to take out the workpiece W from the defat bath unit 110. Next, the rotary disc 202 is driven for rotation over 30 degrees in order to position the workpiece W above the rinsing bath unit 130 next to the defat bath unit 110. Thereafter the rotary disc 202 is moved again downwards in order to insert the workpiece W into the inner cylinder 132 of the rinsing bath unit 130. After this insertion of the workpiece W, rinsing water in jet is supplied from the water faucet into the inner cylinder 132. The rinsing water so supplied flows from the upper end of the inner cylinder 132 towards the bottom drain 117 for discharge therethrough.
After the rinsing operation is over, supply of the water into the inner cylinder 132 is ceased. Then the water remaining in the inner cylinder 132 is discharged outside through the radial openings 133 and the level in the inner cylinder 132 is lowered to rid the workpiece W of water.
Next the rotary disc 202 is moved upwards to take out the workpiece W from the rinsing bath unit 130. The rotary disc 202 is again rotated over 30 degrees and, subsequently, moved downwards to pass the workpiece W to the next rinsing bath unit 130 for further rinsing purposes. After treatment in this second rinsing bath unit 130, the workpiece W is assigned to the next pickling bath unit 150 by operation of the transfer unit 200.
Removal of acid on the workpiece W is performed in the pickling bath unit 150 by the agent supplied into the inner cylinder 132 from the reservoir 134. Operation in this pickling bath unit 150 is basically similar to those carried out in the preceding rinsing bath units 130 and, therefore, explanation thereof is here omitted.
After complete removal of acid, the workpiece W is assigned to the third and fourth rinsing bath units 130 for removal of the agent used for removal of acid.
After operation in the fourth rinsing bath unit 130, the workpiece W is passed into the plating bath 176 of the plating bath unit 170 as shown in FIG. 9 by a subsequent combination of an upward movement, a 30 degree rotation and a downward movement of the transfer unit 200. Thereupon the top opening 115 of the outer casing 111 is closed by the sealing closure 210 of the shaft 207 of the holder assembly 203.
After this closing, electrolyte is supplied into the plating bath 176 from the reservoir 179. The electrolyte so supplied overflows the top end of the plating bath 176 into the interior of the outer casing 111 and is recollected by the reservoir 179 via the drain 117. Preferably the electrolyte to be charged into the plating bath unit 170 should be maintained at a temperature of 70 degrees or higher.
A couple of seconds after supply of the electrolyte the electric supply head 603 of the electric supply unit 600 is moved downwards for contact with the electric reception head 208 of the holder assembly 203 and the workpiece W is galvanized. Depending on the length of the workpiece W, one or both of the electrodes 172 and 173 are used for the galvanization. There is, only the upper electrode 172 is used for a short length and the lower electrode 173 is also used when the workpiece W is long enough to extend beyond the lower end of the upper electrode 172.
After termination of the plating process, the electric supply head 603 of the electric supply unit 600 is moved upwards and the rotary disc 202 of the transfer unit 200 is again moved upwards in order to take out the workpiece W from the plating bath unit 170.
After the workpiece W is taken out of the plating bath unit 170, the rotary disc 202 of the transfer unit 200 is again rotated over 30 degrees and moved downwards to pass the workpiece W to the fifth and sixth rinsing bath units 130 for final rinsing. After taking out from the sixth rinsing bath unit 130, the rotary disc 202 of the transfer unit 200 is again rotated over 30 degrees to carry the workpiece W to the unloading station.
On arrival at the unloading station, the workpiece W is held by the clamper 304 of the unloading unit 400. Next by downward movement of the clamper 304 caused by operation of the lifter block 302 as shown in FIG. 17, the workpiece W is released from the head 205 of the holder assembly 203 for discharge into the collector box 503.
The foregoing explanation is directed to processing of a single workpiece W held by one holder assembly 203. In practice, however, a plurality of workpieces W are sequentially allotted to successive holder assemblies 203 for concurrent processing of these workpieces W.
Since a plurality of treatment bath units are arranged along an arcuate path in accordance with the present invention, lots of treatment baths can be accommodated in a limited space and, as a consequence, the apparatus is very compact in construction. The trapezoid horizontal configuration of each treatment bath unit is well suited for the collected arrangement of the units. The compactness of the apparatus is furthered by arrangement of the transfer unit 200 within the space surrounded by the plurality of treatment bath units. In other words, the space in a mill can be very efficiently utilized. In addition, presence of the loading and unloading units assures smooth connection with adjacent systems in a continuous line of production. Use of various reservoirs of agents enables free supply of agents at any time required, thereby allowing compact constructions of the treatment bath units. Further, in accordance with the present invention, treating agents are brought into contact with the workpieces by means of overflow to minimize the quantity of the agents necessary for these treatments. This greatly reduces plating cost of the workpieces W.
Presence of the radial openings in the inner cylinder 132 of each rising bath unit causes instant lowering in level of the water in the inner cylinder 132 after stop of water supply and, as a consequence, removal of water from the workpieces can be performed without lifting the workpieces W, thereby allowing reduced use of water for rinsing. Rinsing time can be shortened without any malign influence on plating time.
Use of the two electrodes arranged with difference in level allows free change in the galvanizing zone so that the apparatus can be used for processing workpieces of various length without change in original design. Holding of each workpiece by insertion of the head 205 enables contact of the entire outer surface of the workpiece with the electrolyte for full plating of the workpiece. Galvanization of the workpiece is initiated a little after start of electrolyte supply to start plating under a stable flow condition of the electrolyte for ideal plating effect.
When high speed plating is carried out in accordance with the present invention, its plating speed is proportional to the current density employed as shown in FIG. 18, in which the current density in A/dm 2 is taken on the abscissa and the plating speed in μm/10 sec is taken on the ordinate. With a current density is a range from 250 to 1000 A/dm 2 , plating can be carried out at a high speed in range from 1 to 4 μm/sec or higher. It is clear that a large current density should be employed in order to carry out plating at a high speed. The maximum current density (I) is given by the following equation;
I=DnFC/δ(1-α) (1)
In this equation, D is the diffusion coefficient of the salt added to the electrolyte. The larger the value of D, the higher the plating speed. The temperature of the electrolyte bath should be raised to enlarge the value of D.
FIG. 19 shows the relationship between the electrolyte bath temperature and the maximum current density for normal plating operation. It is clearly seen that the current density increases with raise in electrolyte bath temperature. As the bath temperature exceeds 70 degrees, the maximum current density exhibits a significant increase. It is thus clear that plating should preferably carried out at a temperature over 70 degrees.
In the above-described equation (1), C is the concentration of the salt added to the electrolyte. The maximum current density increases with increase in concentration. FIG. 20 shows the relationship between the salt concentration and the maximum current density when nickel sulfate is used for the salt. It is seen in the graph that the maximum current density arrives at the peak as the salt density somewhat exceeds 350 g/l. The maximum current density, however, shows slow decay when the concentration exceeds, the value too much.
In the above-described equation (1), δ is the thickness of the diffusion layer. The thinner the diffusion layer, the larger the maximum current density and the higher the plating speed. The thickness of the diffusion layer can be reduced by increasing the flow rate of the electrolyte in the area of plating. FIG. 21 shows the relationship between the flow rate and the maximum current density. It is clear from this graph that the higher the flow rate, the larger the maximum current density. This tendency is especially remarkable in the region of the flow rate up to 1.5 m/s. From this result, it is clear that the flow rate of the electrolyte should preferably set higher than 1.5 m/s. Such a high flow rate of the electrolyte, however, requires increased power consumption for forced circulation of the electrolyte and, as a consequence, it is preferable from economic point of view to set the flow rate to a value near 1.5 m/s.
α in the above-described equation (1) is the transport number of metal ions to be plated on the workpieces. The larger the transport number, the larger the maximum current density and the higher the plating speed. In order to increase this transport number, the temperature of the electrolyte bath should preferably raised as in the case of the diffusion coefficient D.
F and n in the equation (1) are the Farady constant and the discharge electron number which are fixed factors.
Another embodiment of the plating bath unit 170 in accordance with the present invention is shown in FIGS. 22 to 24. The plating bath unit of this embodiment is different in construction of the bath assembly 171 from that of the first embodiment shown in FIGS. 9 to 11. More specifically, the bath assembly 171 is made up of a casing 701, a network electrode 702 centrally accommodated within the casing 701 and a lot of metal particles 703 filling a space between the casing 701 and the network electrode 702 which define the plaiting bath 176.
The casing 701 is given in the form of a hollow cylinder of a large diameter and preferably made of titanium. The network electrode 702 is a hollow cylinder made of a titanium network. The network electrode 702 is arranged within the casing 701 with its central axis in line with the axis of the lower cylinder 175. The metal particles 703 are made of a metal to be plated on the workpieces. For example, when nickel is to be plated, the particles 703 are made of nickel. The diameter of the particles 703 should preferably be in a range from 5 to 10 mm. The network electrode 702 and the metal particles 703 form positive electrodes during the plating process. A mask collar 704 is attached to the lower end of the plating bath 176 in a manner to cover the lower end of the network electrode 702. When the workpiece to be plated is long enough, the mask collar 704 may be removed.
The plating bath unit 170 of this embodiment operates as follows. As a workpiece W held by the holder assembly 203 of the transfer unit 200 is placed in the plating bath 176 of this plating bath unit 170, electrolyte is supplied from the reservoir 179. The electrolyte fills spaces between the metal particles 703. When the network electrode 702 is galvanized under this condition, the metal particles 703 themselves for positive electrodes. Next, the electric supply head 603 connected to a given negative electrode is moved downwards for contact with the holder assembly 203 for galvanization of the workpiece W. Then, the metal particles 703 forming positive electrodes start to melt into metal ions and arrive at the surface of the workpiece W passing through the network electrode 702.
Since the network electrode 702 is surrounded by the metal particles 703 in the case of this embodiment, damage of the positive electrode located near the workpiece W can be well prevented. That is, even when the workpiece W unexpectedly hits the network electrode 702 at insertion thereof, the metal particles 703 move to absorb a deformation of the network electrode 702. As a result, damage of the positive electrodes made up of the network electrode 702 and the metal particles 703 can be prevented. This greatly stabilizes the quality of plating. In addition, presence of metal particles 703 made of a metal same as that used for plating assures continued supply of the plating metal into the electrolyte. In addition, occasional use of the mask collar 704 makes the plating bath unit 170 suited for processing of workpieces of different lengths. | In arrangement of high speed plating system, a number of sequential treatment bath units are arranged side by side along an arcuate path at equal intervals, a rotatable transfer unit of workpieces is arranged at the center of the arcuate path to concurrently allocate different workpieces to different treatment bath units for different but concurrent treatments and loading and unloading units are annexed to the transfer unit as interfaces to adjacent systems in a continuous line of production. Arcuate arrangement of the treatment bath units well minimized space demand in a mill and use of the loading and unloading units assure easy and smooth combination of the plating system with adjacent systems. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to an improved fuel injector, having a pressure booster, for injecting fuel into an internal combustion engine.
2. Description of the Prior Art
Stroke-controlled fuel injection systems with a high-pressure collection chamber (common rail) are increasingly used for introducing fuel into the combustion chambers of direct-injection internal combustion engines. The advantage of this is that the injection pressure of the fuel into the combustion chambers can be adapted to the engine load and engine speed. For reducing emissions and to attain high specific power levels, a high injection pressure is required. Since the attainable pressure level in high-pressure fuel pumps is limited for reasons of strength, to further increase the pressure in fuel injection systems with a high-pressure collection chamber (common rail), a pressure booster can be used in the fuel injector.
German Patent Disclosure DE 101 23 913 relates to a fuel injection system for internal combustion engines that has a fuel injector which can be supplied from a high-pressure fuel source. A pressure booster device that has a movable pressure booster piston is connected between the fuel injector and the high-pressure source. The pressure booster piston divides a chamber, which can be connected to the high-pressure source, from a high-pressure chamber that can be made to communicate with the fuel injector. By filling a return chamber of the pressure booster with fuel, or evacuating fuel from the return chamber, the fuel pressure in the high-pressure chamber can be varied. The fuel injector has a movable closing piston for opening and closing injection openings. The closing piston protrudes into a closing pressure chamber, so that the closing piston can be acted upon by fuel pressure, to attain a force acting on the closing piston in the closing direction. The closing pressure chamber and the return chamber are formed by a common closing-pressure return chamber, in which all the portions of the chamber communicate permanently with one another for exchanging fuel. A pressure chamber is provided for supplying injection openings with fuel and for acting upon the closing piston with a force acting in the opening direction. A high-pressure chamber communicates with the high-pressure fuel source in such a way that in the high-pressure chamber, aside from pressure fluctuations, at least the fuel pressure of the high-pressure fuel source can be constantly applied. The pressure chamber and the high-pressure chamber are formed by a common injection chamber, and all the portions of the injection chamber communicate permanently with one another for exchanging fuel.
German Patent Disclosure DE 102 47 903.8 relates to a pressure-boosted fuel injection device with a control line embodied on the inside. The fuel injection device communicates with a high-pressure source and includes a multi-part injector body. Received in the injector body is a pressure booster, which can be actuated via a differential pressure chamber and whose pressure booster piston divides a work chamber from the differential pressure chamber. The fuel injection device can be actuated via a switching valve. A pressure change in the differential pressure chamber of the pressure booster is effected via a central control line that extends through the pressure booster piston. The switching valve can be embodied as either a magnet valve or a servohydraulic 3/2-way valve.
OBJECT AND SUMMARY OF THE INVENTION
With the embodiment proposed according to the invention, it becomes possible to control a servo piston of a servo valve with the diversion quantity of fuel from the return chamber of the pressure booster. The quantity of fuel flowing out of the return chamber of the pressure booster must be both depressurized and diverted into the return, so that an injection can be made. With the embodiment of the invention, filling of the control chamber of the servo valve with precisely this quantity of fuel diverted from the return chamber of the pressure booster is possible, so that in the fuel injector configured according to the invention, the servo valve control does not cause any additional loss of fuel quantity.
The valve provided on the fuel injector proposed according to the invention still has no leakage at the servo piston in the state of repose, and as a result the injector efficiency is improved, and in particular the guide lengths of the servo piston can be kept short. In an advantageous version, the servo valve, which contains the servo piston, can be designed as a 3/2-way seat-to-seat valve, in which a sealing seat—to name one example—can be embodied as a flat seat, and a housing comprising multiple housing parts can be employed. Embodying the 3/2-way valve as a 3/2-way seat-to-seat valve offers the opportunity of completely eliminating the problems of sealing and tolerances that occur in slide seals with short overlapping lengths.
The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of preferred embodiments taken in conjunction with the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a first exemplary embodiment of a servo valve according to the invention which is assigned to a fuel injector and has a leakage-free servo piston, with control via the return chamber of a pressure booster; and
FIG. 2 shows a further exemplary embodiment of the servo valve proposed according to the invention, with a conical sealing seat.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , an exemplary embodiment of a servo valve with a leakage-free servo piston is shown, which is associated with a fuel injector with a pressure booster; the servo valve is triggered via the return chamber of the pressure booster. The fuel injector 18 shown in FIG. 1 is subjected to fuel that is at high pressure via a high-pressure line 2 that extends from a pressure source 1 embodied as a high-pressure collection chamber. The fuel flowing to the fuel injector 18 via the high-pressure line 2 acts on a work chamber 5 of a pressure booster 3 . The work chamber 5 is acted upon permanently by the fuel, which is at high pressure, of the high-pressure source 1 . Via a piston 4 of the pressure booster 3 , the work chamber 5 is divided from a differential pressure chamber (return chamber) 6 . An end face 20 of the pressure booster piston 4 acts upon a compression chamber 9 of the pressure booster 3 . The booster piston 4 of the pressure booster 3 is acted upon via a restoring spring 8 , which is braced on a support disk 7 that is let into the injector body 19 of the fuel injector 18 .
From the differential pressure chamber 6 (return chamber) of the pressure booster 3 , an overflow line 10 , which contains a first throttle restriction 11 , leads to a control chamber 12 . Received inside the control chamber 12 for an injection valve member 14 is a spring element 13 , which is braced on a boundary wall of the needle control chamber 12 and acts upon a face end of the injection valve member 14 . The injection valve member 14 can be embodied as a nozzle needle, for instance. In addition, the compression chamber 9 of the pressure booster 3 and the control chamber 12 communicate with one another via a line that contains a second throttle restriction 15 .
The injection valve member 14 is surrounded by a nozzle chamber 16 . The injection valve member 14 has a pressure step, which is engaged by the fuel at high pressure flowing into the nozzle chamber 16 when the injection valve member 14 is actuated in the opening direction. The compression chamber 9 of the pressure booster 3 communicates with the nozzle chamber 16 via a nozzle chamber inlet 17 that carries high pressure.
From the differential pressure chamber 6 (return chamber) of the pressure booster 3 , a diversion line 21 leads to a servo valve, identified by reference numeral 22 . The servo valve 22 is received in a valve body 28 that is located above the fuel injector 18 . Via the diversion line 21 , fuel diverted from the differential pressure chamber 6 (return chamber) flows into a first hydraulic chamber 29 of the valve body 28 . The valve body 28 surrounds a servo valve piston 23 , which in the exemplary embodiment shown in FIG. 1 has a through conduit 23 . 1 . Via the through conduit 23 . 1 that connects the first hydraulic chamber 29 with a control chamber 36 , the control chamber 36 of the servo valve 22 is filled with fuel. A pressure relief of the control chamber 36 of the servo valve 22 is effected by actuation of a relief valve 33 , indicated here only schematically. From the relief valve 33 , a first return 32 leads to a fuel reservoir, not shown in further detail here.
The servo valve piston 23 of the servo valve 22 has a face end 25 which defines the control chamber 36 of the servo valve 22 . A throttle restriction 24 is integrated with the through conduit 23 . 1 of the servo valve piston 23 , as shown in FIG. 1 .
From the high-pressure line 2 that supplies the work chamber 5 of the pressure booster 3 with fuel that is at high pressure, a branch leads through the valve body 28 , and by way of it a second hydraulic chamber 30 of the servo valve 22 is subjected to fuel that is at high pressure. As shown in FIG. 1 , a sealing edge 26 is embodied on the underside of the servo valve piston 23 having the through conduit 23 . 1 , and this sealing edge seals off an outflow control chamber 35 , which discharges into a second return 34 on the low-pressure side of the fuel injector 18 . The servo valve piston 23 furthermore has a portion of mushroom-shaped configuration that cooperates with a sealing edge 27 embodied in the valve body 28 and with it, upon contact, forms a sealing seat 31 . Both the sealing edge 26 embodied on the underside of the servo valve piston 23 having the through conduit 23 . 1 and the sealing edge 27 embodied on the valve body 28 can be embodied as either a flat seat, conical seat, ball seat, or slide edge. In the illustration in FIG. 1 , the sealing edge 27 is embodied as a conical seat.
MODE OF OPERATION
In the state of repose of the fuel injector 18 , the sealing edge 26 is closed as shown in FIG. 1 ; that is, the second return 34 is closed. Conversely, in the state of repose the sealing seat 31 is open, and the servo valve body 23 with the through conduit 23 . 1 is guided in a manner proof against high pressure in the valve body 28 of the servo valve 22 ; that is, no fuel flows between the control chamber 36 and the second hydraulic chamber 30 . Within this guide region, in the state of repose, system pressure prevails both on the side of the control chamber 36 and on the side of the second hydraulic chamber 30 , so that no leakage flow to the return occurs. The entire region of the servo piston 23 with the through conduit, that is, the control chamber 36 , first and second hydraulic chambers 29 and 30 , and the sealing seat 31 , is acted upon by system pressure, which is sealed off from the second return 34 in leakage-free fashion by the sealing edge 26 that is moved into its closing position.
In the state of repose, the pressure booster 3 , the differential pressure chamber 6 (return chamber), via the opened sealing seat 31 , and the high-pressure supply line 2 that discharges into the work chamber 5 are acted upon by system pressure. In this case, the piston 4 of the pressure booster 3 is in pressure equilibrium, and no pressure boosting occurs.
For triggering the pressure booster 3 , the differential pressure chamber 6 (return chamber) of the pressure booster 3 is pressure-relieved. For the pressure relief, first the relief valve 33 is activated, that is, opened; as a result, the control chamber 36 that actuates the servo valve 22 is pressure-relieved into the first return 32 . The servo valve piston 23 with the through conduit moves upward as a result of the pressure force that engages the underside of the mushroom-shaped portion in the first hydraulic chamber 29 and thus opens the sealing edge 26 , while conversely the sealing seat 31 is closed. The sealing edge 26 or the second return 34 or both are designed such that even in the opened state, a slight residual pressure is preserved in the first hydraulic chamber 29 , thus assuring that the servo valve piston 23 will remain in its open position and that the sealing seat 31 will remain securely closed. The control flow that flows out via the relief valve 33 into the first return 32 and via the throttle restriction 24 and the open sealing edge 26 into the second return 34 is not a lost quantity, since it is taken from the differential pressure chamber 6 (return chamber) of the pressure booster 3 , and this quantity flows to the second return 34 via the sealing edge 26 every time the pressure booster 3 is activated.
When the servo valve piston 23 with the through conduit is open, the differential pressure chamber of the pressure booster is disconnected from the pressure level prevailing in the high-pressure source 1 . A pressure relief of the differential pressure chamber 6 (return chamber) takes place via the diversion line 21 into the second return 34 . The pressure in the compression chamber 9 is raised in accordance with the inward motion of the end face 20 of the booster piston 4 , as a function of the boosting ratio of the pressure booster 3 , and via the nozzle chamber inlet 17 , it is delivered to injection openings 45 into the combustion chamber 46 of an internal combustion engine. Because of the pressure step embodied on the injection valve member 14 , the injection valve member 14 opens when pressure is exerted on the nozzle chamber 16 and uncovers the injection openings 45 , and the injection begins. When the injection valve member 14 is completely open, the line that contains the compression chamber 9 and the needle control chamber 12 and a second throttle restriction 15 is closed, so that during the injection event, no lost flow occurs. For damping the opening speed of the injection valve member 14 , a separate damping piston can be used. Filling of the compression chamber 9 can be alternatively effected via a check valve, instead of via a line that contains a second throttle restriction 15 .
For terminating the injection event, the relief valve 33 is closed. By an overflow of fuel from the first hydraulic chamber 29 via the through conduit 23 . 1 of the servo valve piston 23 , the pressure level prevailing in the first hydraulic chamber 29 builds up in the control chamber 36 . Since by design a residual pressure level remains in the first hydraulic chamber 29 , a pressure force acting in the closing direction and generated in the control chamber 36 is established, which acts upon the face end 25 of the servo valve piston 23 having the through conduit 23 . 1 . The servo valve piston 23 with the through conduit 23 . 1 moves downward into its outset position, whereupon the sealing edge 26 is returned to its closing position relative to the outflow control chamber 35 , and the sealing seat 31 on the valve body 28 of the servo valve 22 is opened again. To reinforce the motion of the servo valve piston 23 with the through conduit 23 . 1 , it is entirely possible for additional spring elements, which however are not shown in FIG. 1 to be received in the valve body 28 of the servo valve 22 .
In the work chamber 5 of the pressure booster 3 and in the control chamber 36 of the servo valve 22 , a pressure buildup takes place via the open sealing seat 31 , to the pressure level prevailing in the high-pressure source 1 . Because of this, the pressure in the compression chamber 9 of the pressure booster 3 and thereupon the pressure prevailing in the nozzle chamber 16 both drop, so that the spring 13 disposed in the control chamber 12 moves the injection valve member 14 into its closing position, and the injection openings 45 that discharge into the combustion chamber 46 of the self-igniting engine are closed.
The sealing edge 26 of the servo valve piston 23 and the sealing edge 27 , acting as the sealing seat 31 , embodied on the valve body 28 can be embodied in manifold ways. Combinations of a flat seat, conical seat, ball seat or slide edges can be achieved. In order to design both the sealing edge 26 and the sealing edge 27 embodied in the valve body 28 as sealing seats, the valve body 28 is constructed in multiple parts, for instance in two parts, these being the components 28 and 28 . 1 . If the sealing edge 26 is embodied as a flat seat, for instance, then production tolerances in terms of an axial offset of the two valve body components 28 and 28 . 1 can very easily be compensated for. The sealing edge 26 is acted upon by a strong hydraulic sealing force, generated in the control chamber 36 of the servo valve 22 , so that tightness of the sealing edge 26 , which seals off the outflow control chamber 35 from the second return 34 , at the production precision levels that are attainable at present, is assured even for fuel at extremely high pressure.
From the exemplary embodiment shown in FIG. 2 , a servo valve piston of a servo valve can be seen, whose sealing edge on the low-pressure side is embodied as a conical seat. In contrast to the exemplary embodiment shown in FIG. 1 , of a fuel injector 18 with a servo valve 22 , which includes a servo valve piston 23 with a through conduit 23 . 1 , in the illustration in FIG. 2 the servo valve piston 43 of the servo valve 22 is embodied without such a through conduit 23 . 1 . Moreover, the valve body 28 that receives the servo valve 22 is embodied in one piece. To facilitate assembly, the servo valve piston 43 in the exemplary embodiment shown in FIG. 2 has a slide portion 47 , which is embodied with the same diameter as the head region of the servo valve piston 43 , whose face end 25 defines the control chamber 36 of the servo valve 22 . In a distinction from what is shown in FIG. 1 filling of the control chamber 36 is effected via a separate line, branching off from the diversion line 21 , that contains a throttle restriction 44 toward the valve housing.
The slide portion 47 is embodied with an axial length adapted to the servo valve piston 43 such as to enable an overlap of the slide edge 40 , embodied in the one-piece valve body 28 of the servo valve 22 , upon closure. Besides a slide seal edge 40 , a sealing face can also be embodied here. The sealing force on the servo piston 43 is adjusted via a pressure face facing the diversion chamber 35 . When a sealing face is used, an optimal layout of the pressure per unit of surface area is possible, and as a result both adequate tightness and low wear can be attained. In a distinction from the servo valve piston 23 with the through conduit of FIG. 1 , a sealing edge 41 that closes the outlet of the diversion chamber 35 to the second return 34 is embodied as a conical sealing seat. The mode of operation of the servo valve 22 in the second exemplary embodiment of FIG. 2 is equivalent to that of the fuel injector 18 and the servo valve 22 that have already been described in conjunction with FIG. 1 . The relief valve 33 for relieving the pressure of the control chamber 36 of the servo valve 22 can be embodied as a 2/2-way valve or as a 3/2-way valve. Besides the variant embodiment as a magnet valve shown in FIG. 2 , the relief valve 33 can also be embodied as a piezoelectric actuator.
Upon pressure relief of the differential pressure chamber 6 (return chamber) of the pressure booster 3 , in the exemplary embodiment shown in FIG. 1 an overflow of fuel takes place via the diversion line 21 into the first hydraulic chamber 29 , and from there, via the through conduit embodied in the servo valve piston 23 , filling of the control chamber 36 of the servo valve takes place. In the exemplary embodiment shown in FIG. 2 , upon pressure relief of the differential pressure chamber 6 (return chamber) of the pressure booster 3 , filling of the first hydraulic chamber 29 and of the control chamber 36 , containing a stop 42 for the face end 25 of the servo valve piston 43 , takes place in parallel, via two line segments branching off from the diversion line 21 . In the exemplary embodiment of FIG. 1 , a throttle restriction 24 is provided in the through conduit of the servo valve piston 23 , and in the exemplary embodiment of FIG. 2 a throttle restriction 44 toward the valve body is likewise disposed in the line segment by way of which the control chamber 36 of the servo valve 22 is filled. The pressure relief of the control chamber 36 of the servo valve 22 takes place analogously to FIG. 1 , via an actuation of the switching valve 33 and a diversion of a control quantity from the control chamber 36 into the first return 32 .
In the exemplary embodiment shown in FIG. 2 , the high-pressure supply line 2 extending from the high-pressure source 1 (common rail) into the work chamber 5 of the pressure booster 3 discharges directly into the work chamber 5 of the pressure booster 3 . From there, a line branches off that enables filling of the second hydraulic chamber 30 of the servo valve 22 . The construction of the fuel injector 18 with regard to the components contained in the injector body 19 is equivalent to the construction that has already been described in conjunction with the first exemplary embodiment of the fuel injector 18 according to the invention, and its valve body 19 .
Instead of the conical sealing seat 41 , shown in the exemplary embodiment of FIG. 2 , on the underside of the servo valve piston 43 , it is readily possible to embody this seat as a flat seat, ball seat, or slide edge, depending on the sealing tolerances attainable by the production technology employed. The sealing force acting on the sealing edge 26 (of FIG. 1 ) or the conical sealing seat 41 (of FIG. 2 ) is adjusted by way of the pressure level generated in the control chamber 36 of the servo valve 22 . The higher this pressure level, the higher the pressure force is that is established above the outflow control chamber 36 in the direction of the second return 34 .
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | A fuel injector for injecting fuel into a combustion chamber of an internal combustion engine, having a pressure booster in which the piston divides a work chamber, acted upon permanently by fuel via a pressure source, from a pressure-relievable differential pressure chamber. A pressure change in the differential pressure chamber is effected via an actuation of a servo valve. The control chamber of the servo valve can be pressure-relieved via a relief valve and which opens or closes a hydraulic connection of the differential pressure chamber with a return. For closing the servo valve piston, the control chamber can be acted upon by a fuel volume diverted from the differential pressure chamber. The action of fuel on the control chamber is effected via lines that contain throttle restrictions. A pressure relief of the control chamber is effected via a relief valve into a return on the low-pressure side. | 5 |
BACKGROUND
[0001] Presentations to an audience are frequently made with the assistance of images projected onto a front or rear projection screen. With either type of screen it is necessary at an appropriate time for the presenter to change to the next image. Buttons on a computer keyboard are designated to advance a frame or to back up a frame. A presenter may use an off-stage assistant that brings up the next image frame at his signal, or spoken request, “Next slide please”.
[0002] Effort has been made to eliminate the keyboard, verbal request, hand signals and gestures. Cordless remote controls can be used to advance to the next image, or return to the previously projected image. In applications where image changes occur rapidly (near real time) it is not practical to use a remote control for switching to the next image.
[0003] As a means of increasing alert attention and holding the interest of an audience, iSkia™, a device produced by iMatte Inc. U.S. Pat. No. 6,361,173, selectively inhibits the projected image in the silhouette area of a presenter. The presenter may then come out from behind the podium and walk out in front of the screen. He may look directly at his audience without being blinded by the projector. He may walk across the stage in front of the screen and point directly to elements in the projected image.
[0004] The above invention generates a matte silhouette of the presenter for identifying those pixels to inhibit. This matte can also be used to locate the presenter's screen position. A change in the presenter's position with respect to the display screen, from a first position to a second position may be used to generate a control signal.
BRIEF SUMMARY OF THE INVENTION
[0005] The distance across a screen, occupied by a displayed image, is divided into segments of selected widths. A presenter crossing from one segment to another, and the direction of crossing, is used to develop a control signal that selects the next image for projection. The change in distance as a presenter walks from the face of the screen toward his audience generates an independent control signal that may be used to dim or defocus the displayed image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 illustrates the projection of an image onto a front projection screen and the elements needed to generate a switching signal.
[0007] FIG. 2 is an illustration of an image of a projection screen divided into many small segments with a wide segment at each end.
[0008] FIG. 3 is an image of a projection screen divided into a small number of segments with a wide segment at each end.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The basic concept of this invention is the use of changes in a presenter's physical position, in front of a displayed image, to generate a control signal for selecting the next image to be projected or to effect a change in the projected image. This concept has a number of applications. Three such applications are described below to illustrate how this invention may be applied to control the change from one screen image to another, or to alter a current projected image. These applications require knowledge of the presenter's position with respect to the display screen, which can be determined by various types of range finders. Examples of suitable range finders for this application include those used in cameras. Their range finder operates motors to drive the camera lens to the point of best focus for the distance of the subject. These same motors can generate signals which can be connected to the computer and calibrated for distance.
[0010] FIG. 1 is an illustration of a front projection screen 1 , a presenter 2 standing in front of screen 1 , audience area 3 , image projector 4 , projected image selective inhibitor 5 , and memory 6 . Projector 4 is an electronic projector receiving its images from memory 6 .
[0011] Projected image selective inhibitor 5 includes an infrared projector and camera to generate a matte, a black silhouette of the presenter. This matte connected to projector 4 inhibits (to near zero) the signal level of all pixels within the silhouette area of the presenter. This silhouette provides the position of the presenter with respect to the projection screen at all times.
[0012] The distance across that part of the screen occupied by the projected image is divided into a number of contiguous segments of selected width as shown in figures two and three. Normally the projected image fills the projection screen. The x-axis start and end (or width) of each segment are stored in a memory. The number of segments is determined by the application. The more that smooth, real time changes in the displayed image are required, the more segments are required.
[0013] There is little difficulty in locating the screen segment occupied by the presenter when there are only a few large segments. For example, when more than half of the silhouette pixels are in a given segment, the subject is considered to be in that segment. To prevent chatter (indecision) the number of pixels in a given segment must exceed 50% by a selected margin.
[0014] However, when there are a few hundred closely spaced segments, it becomes necessary to represent the presenter by a single X axis address. The availability of the presenter's silhouette which is generated by projected image selective inhibitor 5 permits calculation of the silhouette's centroid, a point often referred to as the center of mass. This point is then used to represent the presenter's position. A comparison of the presenter's position with that of the stored screen segments will identify the segment occupied by the presenter.
[0015] The use of many screen segments permits a presenter to show, for example, the front end of an automobile when the presenter begins in screen segment A in FIG. 2 . As the presenter walks across the stage toward segment B, imaging software, using the presenter's segment position results in the car appearing to turn slowly until at segment B the rear of the car is seen. The presenter may stop at any time to discuss a particular feature, such as a keyless lock along the window edge of the driver's door. When the presenter stops his motion across the screen, the image progression also stops. In effect, the presenter is functioning as a pointing device where what is displayed is a function of the current position of the pointer, i.e., presenter.
[0016] Segment A is a single screen segment at one edge of the screen that a presenter may occupy before beginning his presentation. Segment B at the opposite edge serves a similar purpose.
[0017] In this application enough image frames are stored (about 300) to provide flicker-free motion of the turning automobile when the presenter walks across the stage in front of the screen.
[0018] A presenter beginning his presentation in segment A also begins with image # 1 . There is no need to identify an individual image frame with an individual screen segment. However, each screen segment may be numbered as well as each image in a sequence. Thus when the presenter already occupies a given screen segment other than A or B, a specific image of matching number will be projected.
[0000] Arming and Disarming
[0019] FIG. 3 is an example of an image of a projection screen divided into six segments and is suitable for a presenter who discusses each image before changing to the next image. In this application the presenter may arm and disarm the switching function to permit the presenter a wide range of motion across the screen without causing an image change. His entry into segment A or B may be used to arm or disarm the image switch function. Several unique control functions can be derived from a small number of screen segments by using the direction of detected segment boundary crossings.
[0000] The Z Axis
[0020] The development of a control signal in the above examples involves a presenter walking on the floor across the front of a display screen. In these two applications the presenter remains fairly close to the screen to be able to identify items in the projected image. However, the presenter may also turn and walk away from the screen toward his audience. In this case, a range finder keeping track of the presenter's distance from the screen permits the generation of an independent control signal. This control signal can be used (for example) to defocus or to darken the projected image thereby encouraging the audience to pay attention to the presenter as he moves toward them.
[0021] The return of the presenter towards the projected image generates a signal that can be used to undo the effort created on his walk off from the screen toward the audience. However, his return to the screen could be used to advance the projector to the next image.
[0022] The determination of the distance of a presenter from the screen can be obtained by any one of several range finding techniques. This Z axis position can also be derived from the silhouette provided by projected image selective inhibitor 5 as follows. The detection of the presenter's silhouette area is achieved by observing a displacement of a projected pattern by an offset camera. This displacement is proportional to the separation of an object from the face of the screen. Pattern separation may be calibrated in terms of subject distance from screen surface.
[0023] The presenter's change of position on the Z axis becomes a second control signal and is independent of the X axis control signal. Since the presenter's change of position is under his control, the amount or degree of out of focus or darkening is under his control, and may be linear if desired.
[0024] Finding applications is not the purpose of this invention. The above examples are given to demonstrate the utility of using a change in the presenter's position for controlling some aspect of the displayed image.
[0000] Implementation
[0025] The position of a presenter along the X axis of a projection screen may be located by a range finder near one edge of the projection screen. Whether one uses a range finder or the centroid of a silhouette produced by projected image selective inhibitor 5 , both will provide an acceptable approximation of the presenter's X-axis position.
[0026] In two of the applications described earlier, one utilized about 300 relatively narrow screen segments while the second utilized only six relatively wide screen segments. Each new application for using a presenter's position to generate an image control signal will require a unique number and spacing of distance segments. The number of required segments and their spacing depends on each application and the use to be made of the generated control signal. In most applications, it is important for the presenter to enter from an off-screen position to a position before the screen, without small motions triggering an image change. A wide segment at one or both ends of the screen is a simple way to achieve this objective.
[0027] In the case of the independent control signal generated by a presenters change in his distance from the screen, this signal is easily made binary by selecting a distance from the screen as a switching point. However, the control signal may be fully proportional to the presenter's distance from the screen. | A method for displaying a series of images on a projection screen as a function of a position of a presenter in front of the projection screen. First, the width of the screen is divided into a number of segments of selected widths. The positions of each of the segments is stored in a memory. The position of the presenter is compared with the stored segments to identify the segment currently occupied by the presenter. An image control signal is generated when the presenter changes position from a first segment to a second segment | 6 |
This is a continuation of application Ser. No. 08/030,029 filed on Aug. 30, 1993, abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a reed for a high-speed loom and, more particularly, to a reed for a high-speed loom which has reed blades coated with a hard film in order to increase their resistance to wear.
A reed is a component of a loom used to align and press the warps and wefts, respectively, of the loom, thereby straightening the weave pattern. The reed is formed by arranging a large number of reed blades, each comprising a thin metal plate, parallel to each other at small gaps, and attaching the blades to a frame having right and left side master blades and upper and lower metal portions. In a high-speed loom, reed blades made of stainless steel are generally used. However, due to increases in the operating speeds of looms and the introduction of new material fibers, wear of the reed blades has become severe. Increasing the wear resistance of reed blades poses an important problem.
More specifically, wear of the reed blades causes raising of the woven fabric and end breakage. Because replacement of the reed requires a large amount of labor and cost, the durability of the reed blades is the most significant factor that determines the operating efficiency and cost of the loom. In a woven fabric, since the width of the woven fabric becomes smaller than the total width of the arranged warps to cause a phenomenon called "crimp", an especially large frictional force acts on the reed blades arranged in the vicinities of the two sides of the reed. Hence, the durability of these portions determines the service life of the entire reed.
Therefore, in order to improve the durability of the reed, it is proposed to coat the surfaces of the reed blades, especially in the vicinities of the two sides of the reed, with a hard film which has an excellent wear resistance, e.g., a hard chrome plating film, a ceramic film (Japanese Patent Laid-Open No. 60-52658) made of tungsten carbide, titanium carbide, titanium nitride or the like, or a chrome oxide film (Japanese Patent Laid-Open No. 61-245346, and U.S. Pat. No. 4,822,662).
A hard chrome plating film is formed by electroplating. However, the hard chrome plating film has poor wear resistance as well as poor adhesive properties and corrosion resistance. A ceramic film is formed in accordance with Physical Vapor Deposition (PVD), Chemical Vapor Deposition (CVD), flame spraying, or the like. However, the ceramic film has poor adhesive properties and causes softening of the base material upon high temperature treatment. A chrome oxide film is formed thermochemically and is effective when formed on reed blades for use with polyester fibers. However, the chrome oxide film is not sufficiently effective when formed on reed blades for use with natural or new material fibers.
Wear of the reed blades is a phenomenon in which the types of fibers, frictional force, vibration characteristics of the reed, and the like are closely related to each other in a complex manner. It is known that a hard film having a high surface hardness does not always provide a good effect. Accordingly, although a hard film matched with the types of fibers, the operating speed of the loom, and other conditions is employed, it provides an improvement in durability of only about two to five times that of a stainless steel base material not coated with a hard film.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a reed blade suitable for use with many types of fibers, ranging from natural to synthetic and new material fibers, and having a remarkably improved durability at a relatively low cost.
In order to achieve the above object, according to the present invention, a Diamond-Like Carbon (DLC) film is formed on a portion of a reed blade requiring the highest wear resistance. When a stainless steel is used as the base material of the reed blade, an intermediate layer comprising, e.g., a titanium carbide layer is interposed between the base material and the DLC film to improve the adhesive properties. Furthermore, reed blades coated with a DLC film are arranged in the vicinities of the two sides of the reed where wear progresses most quickly, while reed blades coated with a hard film requiring a relatively low cost, or non-coated reed blades, are arranged in the central portion of the reed, thereby uniforming the blade wear throughout the entire reed. As a result, an improvement in total durability is realized at a relatively low cost.
The DLC film employed in the present invention is a hydrogen-coupled amorphous carbon film and is introduced in, e.g., L. P. Anderson, A Review of Recent Work On Hard i-C Films, Thin Solid Films, 86 (1981), pp. 193-200.
An example of a method of forming a DLC film is plasma CVD in a hydrocarbon gas atmosphere. A DLC film exhibits a hardness like diamond, a thermal conductivity about five times that of copper, and a very small coefficient of friction. These characteristics have been utilized in the slidable surfaces of mechanical components and the like. Moreover, since the large tensile strength and small internal friction of DLC films realize vibration characteristics suitable for acoustic appliances, DLC films have also been formed on the diaphragms of loudspeakers and the like. Not much is known regarding the behavior of DLC films on the high-wear portions of reed blades driven at high speeds. However, the large surface hardness, small coefficient of friction, thermal conductivity, and vibration characteristics are assumed to contribute to an improvement in the durability of the reed blades.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a reed.
FIG. 2 is a plan view of a flat reed blade.
FIG. 3 is a plan view of a modified reed blade.
FIG. 4 is a partial sectional view of the reed blade of FIG. 3 made according to the present invention.
FIG. 5 is a partially cutaway front view of the reed of the present invention.
FIG. 6 is a graph showing the relationship between the reed blade position and the amount of wear.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will be described with reference to the accompanying drawings.
As shown in FIG. 1, a reed 10 holds a large number of reed blades 20 at predetermined gaps with a frame 16 constituted by upper and lower metal portions 12 and right and left side master blades 14. The reed blades 20 comprise thin metal plates and have a shape as shown in FIG. 2 or 3.
The reed blade 20A shown in FIG. 2 is called a flat reed blade. The reed blade 20B shown in FIG. 3 is called a profiled reed blade and is used in water jet or air jet looms. For either reed blade, a hatched portion 22A or 22B shown in FIG. 2 or 3, i.e., the central portion of the reed blade, is the maximum wear portion. In the reed blade of the present invention, at least this portion is coated with a DLC film.
A stainless steel is generally used as the base material of the reed blade. However, when a DLC film is directly formed on the surface of the stainless steel, sufficiently high adhesive properties cannot be obtained, and the object of the present invention cannot be attained.
Therefore, according to the present invention, an intermediate film is interposed between the stainless steel base material and the DLC film to improve the adhesive properties. As the intermediate layer, a two-layered film having a chromium (Cr) or titanium (Ti) lower layer exhibiting good adhesive properties with the stainless steel and a silicon (Si) upper layer exhibiting good adhesive properties with the DLC film is effective. Single layered carbide films of, e.g., titanium (Ti), zirconium (Zr), and hafnium (Hf) exhibiting good adhesive properties with both the stainless steel and the DLC film are also effective as the intermediate layer. A titanium carbide film (Japanese Patent Laid-Open No. 64-79372) containing an excessive amount of carbon is most effective.
FIG. 4 is a partial sectional view of the maximum wear portion 22B of the reed blade 20B shown in FIG. 3. A titanium carbide film is formed as an intermediate layer 26 on the surface of a base material 24 made of a stainless steel, and a DLC film 28 is formed on the surface of the intermediate layer 26. The titanium carbide film can be formed in accordance with plasma CVD in a vacuum chamber in which a hydrocarbon gas is introduced.
FIG. 6 is a graph schematically showing the relationship between the position and wear amount of the reed blades under average operating conditions of a high-speed loom for three types of reed blades. The axis of abscissa represents the position of a reed blade by way of the number of reed blades counted from a side portion of the reed. A curve ADHM indicates the wear amount of reed blades made of a non-coated stainless steel base material, a curve BEFKN indicates the wear amount of reed blades coated with hard chrome plating films, and a curve CGL indicates the wear amount of reed blades coated with DLC films according to the present invention.
The service life of the reed is determined by the wear of the outermost (1st) reed blades which are worn most, as described above. However, when the hard chrome plating films are formed on the reed blades made of the stainless steel base material, the wear amount of the outermost reed blades is decreased to half from A to B. Since this wear amount B corresponds to a wear amount D of the non-coated 30th reed blades, the wear amount of the entire reed can be decreased to a level of B or less by coating the 1st to 30th reed blades with hard chrome plating films. However, even if plating films are formed on the internal reed blades following the 30th reed blades, the service life of the entire reed is not prolonged.
In contrast, when DLC films are formed on the reed blades according to the present invention, the wear amount of the outermost reed blades is greatly decreased from A to C. This wear amount C corresponds to a wear amount H of the non-coated 110th reed blades. Therefore, in order to obtain a sufficiently wear-resistant reed by forming DLC films, at least the 1st thru 110th reed blades must be coated with the DLC films.
To form a DLC film requires a relatively high cost. However, since the DLC film improves the durability of the reed remarkably, it has a sufficiently high practicality, depending on the weaving conditions. To combine a DLC film with other hard films is also a very effective means. As shown in FIG. 6, the wear amount C of the outermost reed blades coated with the DLC films corresponds to a wear amount F of the 45th reed blades coated with hard chrome plating films. Therefore, when DLC films are formed on the 1st to 45th reed blades and hard chrome plating films are formed on the 46th to 110th reed blades, the same practical effect as that obtained when DLC films are formed on all the reed blades can be obtained. In this manner, when a plurality of hard films having different coating costs and wear resistances are combined to uniform the blade wear throughout the entire reed, the durability of the reed can be remarkably improved at a relatively low cost.
FIG. 5 is a front view of a reed showing the arranged state of reed blades according to the present invention. Reed blades 20 are divided into first, second, and third groups 201, 202, and 203 from the group of blades adjacent to master blades 14 on each side of the reed. Each first group 201 is a group of reed blades having a DLC film formed on the surface of a stainless steel base material through an intermediate layer, each second group 202 is a group of reed blades having a hard film different from the DLC film formed on the surface of a stainless steel base material, and each third group 203 is a group of reed blades made from a non-coated stainless steel base material.
Various types of fibers were woven into fabrics by using a reed according to the present invention having a plurality of reed blades grouped in this manner, a reed according to the present invention in which only DLC films were formed on the reed blades, a reed of the prior art in which hard films other than DLC were formed on the reed blades, and a general reed in which the reed blades are made only of a stainless steel base material. The durabilities of the reeds were studied. Tables 1, 2 and 3 show the obtained results.
TABLE 1__________________________________________________________________________Fiber: Cotton Yarn Operating Ratio of Side Portions-Central Portion Time Durability Cost__________________________________________________________________________Comparative Stainless steel (SS) 12 hr 1.0 1.0Example 1 base material 100%Comparative Chrome plating SS base material 36 hr 2.2 1.1Example 2 10% 90%Comparative Cr.sub.2 O.sub.3 SS base material 36 hr 3.0 1.8Example 3 20% 80%Example 1 DLC film SS base material 80 hr 6.7 4.7 40% 60%Example 2 DLC film Cr.sub.2 O.sub.3 Chrome SS base material 80 hr 6.7 2.5 10% 10% 20% 60%__________________________________________________________________________
Table 1 shows the result of a durability test wherein standard weaving was performed by a high-speed loom using a cotton yarn as the fiber. As shown in Comparative Example 1, when weaving was executed under fixed conditions using a conventional reed made of only the stainless steel base material, defects such as end breakage and raising of the woven fabric occurred after an operation of about twelve hours. The ratios of durability were calculated by using the operating time of Comparative Example 1 as the reference. Hence, the ratio of durability for Comparative Example 1 is 1.0.
As shown in Comparative Example 2, in the conventional reed in which hard chrome plating films are formed on 10% of all the reed blades (5% per side), the durability is increased twice or more. As shown in Comparative Example 3, in a conventional reed in which chrome oxide (Cr 2 O 3 ) films are formed on 20% of all the reed blades, the durability is increased about three times or more.
In contrast, as shown in Example 1, in the reed of the present invention in which DLC films are formed on 40% of all the reed blades, the durability is increased to about seven times. Although the cost of the reed is increased to about five times that of Comparative Example 1, when the quality of the woven fabric and the operating efficiency of the loom are considered, the cost of the reed can be justified.
In Example 2, three groups of reed blades made of a stainless steel are arranged in a reed. In the first group, DLC films are formed on 10% of all the reed blades upon which the largest frictional force acts. In the second group, reed blades coated with chrome oxide films and hard chrome plating films are arranged. In the third group, corresponding to 60% of the reed blades and the central portion of the reed, reed blades made of a non-coated stainless steel base material are arranged. In this reed, a durability similar to that of Example 1 can be obtained with the cost decreased in half. In this manner, the blade wear throughout the whole reed is made uniform by adopting a plurality of hard films at a cost less than the reed of Example 1.
TABLE 2__________________________________________________________________________Fiber: Modified Polyester Operating Ratio of Side Portions-Central Portion Time Durability Cost__________________________________________________________________________Comparative Stainless Steel (SS) 4 1.0 1.0Example 4 100%Comparative Chrome plating SS base material 22 5.5 1.3Example 5 30% 70%Example 3 DLC film SS base material 42 10.5 7.3 70% 30%Example 4 DLC film Chrome plating SS base material 40 10.0 4.9 40% 30% 30%__________________________________________________________________________
It is known that when modified polyester fibers having complex sectional shapes are to be woven into a fabric, wear of reed blades made only of a stainless steel base material is severe, and the operating efficiency of the loom is considerably low. Table 2 shows examples of operating times and durabilities for various reeds used in the weaving of modified polyester fibers. As shown in Comparative Example 4, wear of reed blades made from a non-coated stainless steel base material is severe, and the operating time is decreased to about 30% of that obtained when weaving was performed with cotton yarn. Hence, as shown in Comparative Example 5, using hard chrome plating films on the reed blades in the vicinities of the side portions of the reed increases the operating time substantially.
In contrast, as shown in Example 3, in a reed in which DLC films are formed on 70% of all the reed blades, the durability is remarkably improved. Furthermore, as shown in Example 4, when DLC films and hard chrome plating films are used together with non-coated reed blades, the cost can be decreased from that of Example 3 with little, if any, decrease in the durability.
TABLE 3__________________________________________________________________________Fiber: New Material Operating Ratio of Side Portions-Central Portion Time Durability Cost__________________________________________________________________________Comparative Stainless steel (SS) 0.33 1.0 1.0Example 6 100%Comparative Titanium nitride (TiN) film 2.5 7.6 5.0Example 7 100%Example 5 DLC film 8.0 24.0 10.0 100%Example 6 DLC film Titanium nitride film 8.0 24.0 6.5 30% 70%__________________________________________________________________________
A specially-sized fiber on which a fine ceramic powder is applied is attracting attention as a functional new material fabric. As shown in Comparative Example 6, when such a new material fiber is woven into a fabric using conventional stainless steel reed blades, a defect occurs within a very short period of time, and thus a practical operation using this fiber is impossible. Hence, as shown in Comparative Example 7, a reed in which titanium nitride (TiN) films, known as ultra-hard films, are formed on all the reed blades was used. In this case, however, the wear amount of the reed blades is still large enough to cause a defect within two to three hours. Therefore, the operability is poor, and the operating efficiency of the loom is very low.
In contrast, as shown in Example 5, when a reed in which DLC films are formed on all the reed blades is used, a continuous operation of eight hours is possible, and no problem occurs in the weaving operability. In addition, when reed blades coated with DLC films are arranged in the vicinities of the two side portions of the reed and reed blades coated with titanium nitride films are arranged at the central portion of the reed, a similar effect to that of Example 5 can be obtained while decreasing the cost.
As described above, according to the present invention, the following specific effects can be obtained:
(1) The reed of the present invention is suitable to various types of fibers, ranging from natural to synthetic and new material fibers, and exhibits an excellent durability.
(2) Since a sufficient effect can be obtained with a DLC film having a thickness of two to three microns, including the intermediate layer, the DLC film can be applied to a reed having a small blade pitch.
(3) When the quality of the fabric and the operating efficiency of the loom are considered, a decrease in total cost is enabled.
There are various changes and modifications which may be made to the invention as would be apparent to those skilled in the art. However, these changes or modifications are included in the teaching of the disclosure, and it is intended that the invention be limited only by the scope of the claims appended hereto. | A diamond-like carbon (DLC) film is formed on a portion of a reed blade in a high-speed loom which requires the highest wear resistance. When a stainless steel is used as the base material of the reed blade, the DLC film is formed through an intermediate layer comprising, e.g., a titanium carbide layer. Reed blades coated with a DLC film are arranged at the side portions of the reed where wear progresses quickly, while reed blades coated with hard films requiring a relatively low cost, or non-coated reed blades, are arranged in the central portion of the reed, thereby uniforming the blade wear throughout the entire reed. The reed is suitable to many types of fibers, ranging from natural to synthetic and new material fibers. | 3 |
The present patent application is a Utility claiming the benefit of Application No. PCT/FR2007/000529, filed Mar. 27, 2007.
BACKGROUND OF THE INVENTION
This present invention concerns a new type of two-wheeled vehicle equipped with a pedal-crank system that is propelled by the feet of the rider, and which transforms reciprocal vertical alternating movement in translation into a unidirectional rotational movement.
The conventional two-wheeled vehicles, known as bicycles, propelled by the rider, are not efficient for use by the general public, in particular because they are not “propellable” at high speed, and are uncomfortable when pedalling uphill on steep slopes.
BRIEF SUMMARY OF THE INVENTION
This new bicycle allows one to achieve better performance with the same force employed as that used in a conventional bicycle.
This two-wheeled vehicle is equipped with a pedalling system that allows one to transmit a greater moment of force by virtue of the increased length of the pedal crank and rack of the chainset.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-6 show a first embodiment of the invented bicycle in which transmission of the forces generated by the feet of the rider is achieved by means of a rack and transmission ring gears installed in several diameters.
FIG. 6 is a detailed view illustrating the connecting-rod/pedal/crank arms.
FIG. 7 is a detailed view of a single unit front frame.
FIGS. 8 and 9 illustrate an alternate embodiment in which the rack is replaced by a system of a connecting rod and a pedal crank arm.
FIGS. 10 and 11 are detailed views showing the embodiment illustrated in FIGS. 8 and 9 .
FIG. 12 is a perspective view of the first embodiment.
FIGS. 13 and 14 are perspective views showing chains connected to pedal crank arms.
DETAILED DESCRIPTION OF THE INVENTION
Transmission of the forces generated by the feet of the rider by pushing vertically downwards on one of the pedal of the bicycle ( FIGS. 1 , 2 , 3 , 4 , 5 , 6 ), is achieved by means of a rack ( 3 ) fixed onto these pedal crank set ( 1 D for the right pedal-crank set, 1 G for the left pedal-crank set), and operates the pinion ( 4 ) fixed onto the rotating axis of the chainring ( 5 ), causing the rear wheel ( 25 ) to advance by means of a link of a chain ( 6 ) to the cog cassette ( 8 ) of the rear wheel.
In order to ensure that the pedal-crank set ( 1 D, 1 G) are able to describe a reciprocating vertical alternating movement, and that a pedal is always accessible at the top for a foot thrust by the rider without the rider being obliged to push back the pedal, thereby executing two controlled muscular efforts, a differential case device with several conical or non-conical pinions ( 15 ) has been provided. For example, when the left pedal rises, obliging its differential pinion to turn toward the rear, the differential pinion receivers cause the right pedal to descend by its own differential pinions which have become sensors, and then vice versa continuously. In order to propel the bicycle in the pedal crank arms-connecting-rod solution, in which the differential case device is not present, the rider must start the sequence by pressing on the pedal located nearest to the top (in FIGS. 8 , 9 , 10 and 11 , it is the left pedal).
The more the length of the pedal crank arms ( 1 D, 1 G) increases, the greater the development allows one to cope with steeper slopes.
According to particular embodiments of this two-wheeled vehicle propelled by the rider:
the rack ( 3 ) can be replaced by a system of connecting-rod crank ( FIGS. 8 , 9 , 10 , 11 ) to transform the reciprocating vertical movement in translation into a rotational movement.
This system includes an intermediate connecting-rod pivoting on an axis (Dx) located on the pedal crank arm ( 18 ), and a second connecting-rod ( 17 ) turning with the ring gears around the central axis (Cx) of the chainring ( 5 ). The intermediate pivoting connecting-rod and the connecting-rod of the chainring articulate ( 18 ) freely on a axis (Bx), which is able to turn without causing any propulsion toward the rear, by virtue of the unidirectional freewheel system in the hub cassette. This possible technical transmission solution allows one to reciprocally push back the pedal that is already located at the bottom, and after a turn of the ring gear toward the front, located at the top without needing to install a differential case system with several conical or non-conical pinions, according to FIG. 1 and FIG. 2 .
In order to offer the user a wide margin in the choice of speeds designed for maximum convenience on this vehicle with rack/crank/pedal ( FIGS. 1 , 2 , 3 , 4 ) or connecting-rod/crank/pedal propelled by the rider during his muscular efforts, the transmission ring gears can be installed in several diameters ( 5 ) and with several numbers of teeth in order to obtain several speeds using a derailleur assembly.
For the technical solution by propulsion with connecting-rod/crank/pedal, the receiving connecting-rod ( 19 ) can be equipped with an adjustable extension device to allow the length of the latter to be increased or decreased, and replacement of the different diameters of the chainrings which are used to change the speeds. By increasing or decreasing the length of this connecting-rod, distances between the axis of rotation change, and the momenta of force can be altered. By increasing the length of the chainring connecting-rod, the energy put into the propulsion also increases by virtue of the momentum of force. By reducing this distance, propulsion at high speed is possible by moving the pedal less rapidly.
The length of the vertical movements of the connecting-rod/pedal-crank arms ( 1 D, 1 G) is bounded by the distance between the rotating axes of these two parts of the mechanism ( 17 , 19 ) and also the distance between the central axis (Ex) of the connecting-rods/pedal crank arms and the central axis of rotation of the ring gear (Cx).
The frame of this bicycle is composed of two separate parts:
the front part with the steering assembly and the fork (possibly telescopic), with the whole forming an assembly with the frame which can be in a single unit ( 21 , 22 , 23 ); the second part includes the rear fork ( 11 ), the top tube of the rear frame ( 14 ) which includes the horizontal axis (Cx), the differential case device ( 15 ) to ensure reciprocity of the vertical movements of the pedals, and the reinforcing fork ( 12 ) which takes up the high stresses coming from the top tube of the rear frame, distributing the forces to the fixing centre of the rear wheel.
The whole of the single-unit front frame ( 21 , 22 , 23 ) and the rear frame can be joined at the intermediate axis (Fx). The latter can pivot horizontally, by including the shock-absorber system assembled with the technical assembly method known as “split heads”. The pivot head ( 20 ) of the main rear frame is dimensioned so that the head of the single-unit frame inserts into it. To this end, either the main head is a single-unit and the secondary head can be dismantled, or the main head can be dismantled into two parts and the secondary head is a single-unit. These solutions allow the use of an assembly of different frames with a given main part. For example, it is possible to change the main frame or the single-unit front frame in order to obtain another (multi-assembly) type of bicycle.
The horizontal tube includes two independent transmission hub systems, which are linked to the chainring, and used to propel the ring gears toward the front ( 13 or 13 BIS). The principle of this mechanism is applied in two directions: when one of the two racks rises by virtue of the differential case device of the pinions ( 15 ) built into the central rotating-pivoting axis (Ex) of the pedal-crank set, the other pedal-crank set is loaded by the force from the bicycle user, and propels the chainrings toward the front. The rising rack causes the unidirectional freewheel transmission set ( 13 or 13 BIS) to turn in the reverse direction, and therefore plays no part in the propulsion by turning in the other direction. At the chainring, the unidirectional freewheel system acts in the same way when the corresponding rack causes it to turn toward the rear. In FIG. 1 , FIG. 2 , FIG. 3 , and FIG. 4 , the right pedal is in up position. By descending, the pedal of the right rack propels the pinion of the chainring, with the whole of the chain and the transmission hub of the rear wheel. At the same time, the left pedal rises, and causes the unidirectional freewheel system to turn in the reverse direction.
In order to prevent the rack cranks from detaching from the pinion ( 4 ) of the ring gears, and in order to limit the trajectory of the pedal crank arm, an anti-rotation braking device has been incorporated into the differential case device of the pinions ( 15 ). The braking occurs from a certain limit of slope of the pedal crank arm with specially positioned teeth on the pinions.
For one particular embodiment, in order to avoid the differential case device of the pinions, the pedal crank arm can be made with a connecting-rod/crank system as follows: the connecting-rods of the ring gear ( 19 ) are fixed to the chainring ( 5 ), and propelled around axis Bx (articulated link) ( 18 ) by means of the intermediate connecting-rod ( 17 ) that pivots around the axis of the articulation unit ( 16 ).
The connecting-rod/crank pedal-crank set solution is not equipped with unidirectional freewheel transmissions at the chainring. The latter is able to turn freely around its axis toward the front and the rear. The only unidirectional-freewheel transmission is incorporated into the cog cassette ( 8 ) allowing propulsion toward the front only.
The whole of the rear frame carrying the propulsion systems pivots around axis Fx, using a shock-absorber system that is incorporated into the frame head ( 20 ) or an outside shock-absorber system fixed onto the frame part. The front frame is assembled to include the single-unit ( 21 ) and rotating axis Gx, or the front fork ( 22 ) with the shock-absorber and the front wheel ( 24 ) turning to determine the movement direction of the bicycle.
As a variant, the rack and pinion propulsion system can be created by replacing the rack 3 by a chain fixed onto the pedal crank arms.
FIGS. 13-14 show several embodiments of the invention by way of example and should not be construed as limiting the invention. Accordingly, the figures are illustrative and not limiting. | A device for assembling a bicycle equipped with a pedal crank system to improve the mechanics of the kinetic energy put in by the rider by simplifying the movement of the rider's feet into a reciprocating up and down movement. It consists of right and left cranksets ( 1 D, 1 G) pivoting about the axis (Ex) of the shafts ( 2 ), a chainset which includes a rack ( 3 ) that propels the ring gear ( 4 ) and the set of ring gears and chains ( 5, 6 ) by transforming the play forces through a rear changer ( 7 ) and moves forward the rear wheel via its hub receiving the propelling force of the play of the hubs of the cassettes ( 8 ) integrated in the hub of the wheel ( 9 ), or external with a system of one-way freewheel ( 8 ), fixed on the rear fork ( 12 ) by the rotating pin (Ax) also maintaining the wheel fastener ( 25 ). | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a tool specifying method in an NC automatic programming system.
2. Description of the Background Art
When a machining program or the like is defined in an NC automatic programming system employing an automatic programming unit, a CNC unit, etc., the particular tool to be used may be specified according to each machining process in the machining program.
It is known in the art that a particular tool to be used may be specified in a program by entering a corresponding tool management number. That number is selected from plural specific tool management numbers, each corresponding to a respective tool and each having been set and stored beforehand in the system. To specify a tool in this method, it is necessary for an operator to understand the relationships between the tools and corresponding tool management numbers in advance. When a large number of tools are handled, however, it is virtually impossible for an operator to memorize such correspondences. Accordingly, the operator identifies the tool management numbers corresponding to the tools to be used by referring to a prepared correspondence chart or the like indicating the relationships between the tools and tool management numbers. However, this method consumes much time and labor to retrieve the required tool management number and may result in specifying an incorrect tool due to misreading of the chart.
To solve such disadvantages, a tool specifying method as disclosed in Japanese Patent Disclosure Publication No. 83106 of 1991 has been devised, in which a pre-defined tool management name consisting of a tool name, a nominal diameter, etc. is entered to specify a tool.
The art disclosed in Japanese Patent Disclosure Publication No. 83106 of 1991 will now be described. FIG. 22 is a block diagram showing the major components of an NC automatic programming unit serving as an automatic programming system. The numeral 1A indicates a processor (hereinafter referred to as the "CPU"), 2A a ROM storing a control program for controlling said automatic programming unit, 3A a RAM acting as storing means for storing various programs and data loaded from a floppy disk FL, the operation processing results of the CPU 1A, etc., 4A an NC data memory for storing NC data created, 5A a keyboard, 6A a disk controller, and 7A a CRT device serving as an interactive visual display. Elements 1A to 7A are connected by a bus line 8A.
The keyboard 5A serving as data entry means is provided with alphanumeric keys, an execute key, cursor moving keys, etc. The CRT display device 7A may have a plurality of soft keys 9a to 9e (FIG. 20) and menu keys (not shown), which constitute part of the data entry means and are disposed along the bottom of the display screen.
Available as a floppy disk FL is a system disk having a preset storage area (hereinafter referred to as the "file") for correspondingly storing tools and tool identifying data, in addition to various programs required to create NC data, register tool data and specify tools.
A tool specifying method in this example will now be described with reference to a flowchart in FIG. 18, illustrating the general processing of registering the tool data stored on the floppy disk FL acting as the system disk, and a flowchart illustrating general tool specifying processing in FIG. 19.
The operator first powers up the NC automatic programming unit, sets the floppy disk FL into the disk controller 6A, and loads various programs and data stored on the floppy disk FL into the RAM 3A in accordance with the processing of the CPU 1A driven on the basis of the control program stored in the ROM 3A.
The CPU 1A then displays options, which represent processings corresponding to various programs loaded into the RAM 3A, on the CRT display device 7A in an interactive mode, and waits for the operator to select any option by depressing a corresponding menu key. The operator depresses the desired menu key to select the option to be executed.
When the option for "registering tool data" has been selected, the CPU 1A switches the display of the CRT display device 7A to a tool data setting screen, initiates the tool data registering processing, and waits for data input.
FIG. 20 is a schematic diagram showing the tool data setting screen. The operator hereafter enters various data representing tool attributes sequentially via the tool data setting screen serving as an interactive screen. The data that can be registered as data indicating the tool attributes includes: a tool management number, a nominal diameter, a tool name, a material, a T code (tool number), an H code (tool length offset number) and a D code (tool diameter offset number). In this example, the nominal diameter, tool name and material are necessary and sufficient as data specifying a tool. Character string data displaying the nominal diameter, tool name and material constitutes a "tool management name". As previously explained, the "tool management number" is data comprising a character string (numeral) corresponding one-for-one with each tool.
Now, the operator first controls the cursor moving keys on the keyboard 5A to move a cursor 10A on the CRT display device 7A to the position of a required item, and depresses the soft key 9a (INPUT key) to declare to the CPU 1A that the processing to be performed from now on is data input. Then, the operator sets character strings to each item by controlling the alphanumeric keys of the keyboard 5A. When the displayed string is found to be correct, the operator depresses the EXECUTE key to store the character strings into the RAM 3A on an item basis, thereby registering the character strings of the tool management number, nominal diameter, tool name, material, T code, H code and D code on a tool basis (FIG. 20). The data of each tool thus registered is finally stored into the file of the floppy disk FL via the disk controller 6A (for the above operation, refer to step S101A in FIG. 18). By specifying the processing to be executed by depressing any of the soft keys 9b to 9e with the tool data setting screen displayed, data can be inserted (key 9c), deleted (key 9d) or retrieved (key 9e). These functions are conventional and will not be described further.
While the item equivalent to the soft key 9b is left blank in FIG. 20, it indicates that there is no item corresponding to the soft key 9b on this screen.
The machining of a workpiece using desired tools is conducted on the basis of input NC data, under the control of a program that is assembled in blocks. To create the necessary NC data, the operator selects an "NC DATA CREATING" option from among the options displayed on the CRT display device 7A to activate a program for NC data creation and to load the file of the floppy disk FL into the RAM 3A.
If a block, for which a tool to be used must be specified, has been appropriately programmed during the creation of NC data, the CPU 1A automatically responds to the programming and initiates a "tool specifying processing".
When the tool specifying processing is initiated as seen in FIG. 19, the CPU 1A first displays a message (SPECIFY TOOL) prompting the operator to enter a tool management name or a tool management number on the CRT display device 7A and waits for the operator to select an input mode on the basis of the display in FIG. 21. By controlling the cursor moving keys of the keyboard 5A, the operator moves the cursor 10A on the CRT display device 7A, selects the specifying mode by means of said cursor 10A, then sets the character string for the selected TOOL MANAGEMENT NAME or TOOL MANAGEMENT NUMBER mode by controlling the alphanumeric keys of the keyboard 5A, and enters the character string by depressing the execute key, thereby temporarily storing it into the CPU 1A. Also, the CPU 1A stores which specifying mode, tool management name or tool management number, has been selected according to the position of the cursor 10A. This selection process is identified in step S201A of FIG. 19.
The CPU 1A then judges whether the specifying mode is the TOOL MANAGEMENT NAME mode or not on the basis of the data stored (step S202A). If it is the TOOL MANAGEMENT NAME mode, the CPU 1A searches the file loaded into the RAM 3A on the basis of the character string representing the tool management name entered, i.e. nominal diameter, tool name and material (step S203A), and determines whether or not a tool management name matching the one entered exists in the file (step S204A). If the matching tool management name exists, the CPU 1A reads the tool management number corresponding to that tool management name from the file and writes and stores it into the currently created program (step 205A), then terminates the tool specifying processing and returns to the NC data creation processing.
If it has been determined in the step S204A that the tool management name entered does not exist in the file, the CPU 1A judged it as a tool management name input error, shifts to step S206A, displays on the CRT display device 7A a message prompting the operator to re-enter the tool management name or tool management number, returns to the step S201A, and waits for the tool management name or tool management number to be re-entered.
If it has been determined in the step S202A that the specifying mode does not use the tool management name, it means that the specifying mode is the TOOL MANAGEMENT NUMBER mode. Hence, the CPU 1A searches the file loaded in the RAM 3A on the basis of the tool number entered (step S207A) and determines whether a tool management number matching the one entered exists in the file (step S208A). If the matching tool management number exists, the CPU 1A writes and stores that number into the currently created program (step 205A), then terminates the tool specifying processing and returns to the NC data creation processing.
If it has been determined in the step S208A that the tool management number matching the one entered does not exist in the file, the CPU 1A judges it as a tool management number input error, shifts to step S209, displays on the CRT display device 7A a message prompting the operator to re-enter the tool management name or tool management number, returns to the step S201A, and waits for the tool management name or tool management number to be re-entered.
In such a method, simple tool selection mistakes can be prevented. However as the number of tools employed increases, particularly where many tools of the same type exist, a tool list must be prepared and tools selected on the tool data screen. When the number of tools is large, it still takes a long time to select the most appropriate one from among the many available tools, as previously.
In another conventional system, as disclosed in Japanese Patent Disclosure Publication No. 126303 of 1990, the disadvantage of a fully automatic tool selection system is discussed. In such fully automatic system, tool determination data is first gathered and a tool file containing tool groups organized on the basis of tool determination data is searched. The most appropriate tool group and the most appropriate tool in the group is selected automatically, without operator input. Recognizing that the operator may have substantial know how with regard to tool selection, the disclosed system adds to a fully automated mode an operator determination mode.
FIG. 23, taken from the reference, illustrates the process used in the dual mode operation. First, a selection is made of a tool determination mode (step S1). If the automatic mode is selected, the tool is determined by gathering tool data (step S2), searching for a tool file on the basis of that data (step S3), extracting the most appropriate tool group from memory (step S4), determining the appropriate tool in the group (step S5) and displaying the tool (step S6).
If the operator determination mode is selected, the tool determination data is collected from set machining information (step S7), the tool file including tool groups is searched for a corresponding tool group on the basis of tool determination data (step S8), a decision on the group mode (step S9) and the group is displayed (step S10). The operator refers to the displayed group and selects the most appropriate tool using the keyboard (step S11). The reference suggests that the data for the selected tool may be displayed (step S12) but does not teach the content of such data.
This generic description of the operator selection process does not identify in detail (i) the quantity or identity of the tool selection criteria, (ii) how the tool selection criteria are identified or (iii) whether or how that process may be modified. Where the number of tools from which a selection is to be made becomes very large, the operator still is burdened by the need to select the most appropriate one from many tools.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the present invention to overcome the disadvantages in the background art by providing a tool specifying method in an NC automatic programming system which can specify a tool to be used rapidly and properly.
It is another object of the present invention to provide a tool determining method which selects the most appropriate tool for machining in sequence from among a plurality of tools.
A criterion table is provided to set selection reference data for selecting tools appropriate for each machining, and a machining tool matching data in said criterion table is determined as the most appropriate tool.
When the machining tool is selected, tools are displayed on the screen in the order from the most to least appropriate ones so that the operator is allowed to select the tool.
Tools adequate for each machining are selected from among a plurality of tools and displayed on the screen in order of tool preferability, whereby the operator can select the most appropriate tool easily, rapidly and reliably.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the major components of an NC automatic programming unit acting as an automatic programming system for carrying out a method of the presentation.
FIG. 2 is a schematic diagram illustrating an operation board of the present invention.
FIG. 3 is an external view of an offline type NC automatic programming system according to another preferred embodiment of the present invention.
FIG. 4 is a schematic diagram illustrating a tool data setting screen of the present invention.
FIG. 5 is a schematic diagram illustrating a setting table in a criterion data setting screen of the present invention.
FIG. 6 provides an example of a machining drawing.
FIG. 7 provides an example of a machining program.
FIG. 8 provides a display example of tool data according to the present invention.
FIG. 9 is a main tool selection block diagram according to the present invention.
FIG. 10 is a flowchart illustrating tool selection processing according to the present invention.
FIG. 11 is a flowchart illustrating tool determination processing according to the present invention.
FIG. 12 illustrates processing for tool selection according to the present invention.
FIG. 13 is a flowchart illustrating tool determination processing according to the present invention.
FIG. 14 illustrates processing for tool determination according to present invention.
FIG. 15 is a schematic diagram illustrating a criterion data setting table according to another preferred embodiment of the present invention.
FIGS. 16(A) and 16(B) illustrate tool data display according to the present invention.
FIG. 17 is a flowchart illustrating a general operating procedure according to the present invention.
FIG. 18 is a flowchart illustrating conventional tool data register processing.
FIG. 19 is a flowchart illustrating conventional tool specifying processing.
FIG. 20 is a schematic diagram illustrating an example of a conventional tool data setting screen.
FIG. 21 is a schematic diagram illustrating an example of a display screen in the conventional tool specifying processing.
FIG. 23 is a block diagram illustrating the main components of an NC automatic programming unit serving as an automatic programming system for executing a conventional method.
FIG. 23 is a flowchart illustrating a conventional tool specifying processing using both automatic and operator selection of tools.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described with reference to the appended drawings. FIG. 1 is a block diagram showing the main components of an NC automatic programming unit serving as an automatic programming system for executing the method of the present invention, wherein the numeral 1 indicates a processor (hereinafter referred to as the "CPU"), 2 a ROM storing a control program for controlling said automatic programming unit, 3 a RAM acting as storing means for storing various data, the operation processing results of the CPU 1, etc., 4 a keyboard, 5 a CRT display device serving as an interactive screen, 6 a machining program memory for storing NC machining programs created, 7 a tool data memory for storing the data of each tool, and 8 a criterion table memory for storing a criterion table which indicates the basis of selecting the most appropriate tool for each machining. Elements 1 to 8 are connected by a bus line 9.
FIG. 2 illustrates an example of an operation board comprising the keyboard 4 and CRT display device 5. The keyboard 4, acting as data entry means, is provided with data setting keys 11 comprising numeric keys (0 to 9), cursor moving keys, an input key (INPUT), a clear key (CLEAR) and screen switching keys, and other various machine control keys 12. The CRT display device 5 has a plurality of menu keys 10 constituting part of the data entry means disposed along the bottom edge of the display screen. The NC automatic programming system contained in the numerical controller, which is indicated in the present embodiment as an example, may be replaced by an offline type NC automatic programming system installed separately from the numerical controller.
The offline NC automatic programming system, comprising a keyboard 4 and a CRT display device 5 as shown in FIG. 3, has the same hardware configuration as generally available work stations or personal computers. In this case, the various machine control keys 12 shown in FIG. 2 are not needed because of an off line system, and the menu keys 10 may be substituted by the function keys on the keyboard 4.
The tool specifying method in the present embodiment will now be described in accordance with a flowchart indicating a general operating procedure of the present invention in FIG. 17.
The operator first powers up the NC automatic programming unit (step 400), and the CPU 1 displays options, which represent processings corresponding to various programs on the basis of the control program stored in the ROM 2, on the CRT display device 5 in an interactive mode (step 401), and waits for the operator to select any option by depressing the corresponding menu key 10.
The operator depresses the required menu key 10 to select the option to be executed.
If a menu for registering tool data is selected (step 402), the CPU 1 switches the display of the CRT display device 5 to a tool data setting screen and displays tool data on the screen (step 403). If it is desired to correct the tool data (step 411), the operator makes tool data correction (step 412). If the display or correction of the tool data is complete (step 413), the processing jumps to step 410. If the operator does not power down the unit in the step 410, the CPU 1 returns to the step 401 and displays the menu.
FIG. 4 is a schematic diagram showing the tool data setting screen. Hereafter, the operator sequentially enters various data indicating tool attributes via the tool data setting screen serving as an interactive screen.
Referring to FIG. 4:
"T No." indicates a tool number.
"SPARE" indicates a spare tool number and is used to specify which tool will replace a tool that has reached its life.
"SHAPE" indicates a tool type and a machined portion.
For turning, for instance, the tool type includes the following:
GNL: general turning tool
GRV: grooving tool
THR: threading tool
DRL: drilling tool
TAP: tap
SPT: special tool
SENSOR: tactile sensor
The machined portion includes the following:
OUT: outside diameter machining
IN: inside diameter machining
FCE: end facing
"NOSE R" indicates a tool nose radius or a tool diameter.
"ROTATION/HAND" indicates the direction of rotation of a spindle and the right- or left-handedness of a tool, allowing any of the following options to be selected:
1: forward rotation/right hand
2: reverse rotation/right hand
3: forward rotation/left hand
4: reverse rotation/left hand
"GROOVE DEPTH/ENTERING ANGLE" is used to specify the entering angle of a tool, or if a grooving tool is used, to specify the maximum grooving depth.
"NOSE WIDTH/NOSE ANGLE" is used to specify the nose angle of a tool, or if a grooving tool is used, to specify the width of a tool nose.
"CODE NAME" is used to specify the name of a tool.
"HOLDER" is used to specify the type of a tool holder.
"TOOL WIDTH" is used to specify the width of a tool.
"TOOL LENGTH" is used to specify the length of a tool.
12 indicates a screen page when the tool data setting screen comprises a plurality of screens. The numeral 13 indicates a screen mode display representing that this screen is the tool setting screen. 14 indicates a menu display from which a required menu is selected by depressing the corresponding menu key 10.
Now, the operator first moves a cursor 15 of the CRT display device 5 to the position of a required item by controlling the cursor moving keys of the keyboard 4, and enters the required data from the keys on the keyboard 4.
The operator thus enters data on all tools loaded on the machine tool. Tool data 7a thus entered is all stored into the tool data memory 7 shown in FIG. 1. Once set, the tool data 7a need not be set unless any tool loaded on the machine tool is replaced.
If a menu for registering criterion data is then selected (step 404), the CPU 1 switches the display of the CRT display device 5 to a criterion data setting screen and displays criterion data on the screen (step 405). If it is desired to correct the criterion data (step 414), the operator makes criterion data correction (step 415). if the display or correction of the criterion data is complete (step 416), the processing jumps to the step 410.
FIG. 5 is a schematic diagram showing a setting table in the criterion data setting screen. Hereafter, the operator sequentially enters various data indicating the selection reference data of tools via the criterion data setting screen acting as an interactive screen.
Referring to FIG. 5:
"MACHINING MODE" indicates a machining type and a machined portion.
For turning, for example, the machining type includes the following:
BAR: bar work process
CPY: copying process
CNR: corner rounding process
EDG: end facing process
THR: threading process
GRV: grooving process
DRL: drilling process
TAP: tapping process
MES: measuring process
The machined portion includes the following:
OUT: outside diameter machining
IN: inside diameter machining
FCE: end facing
"DIVISION" differentiates between roughing (R) and finishing (F). When there are roughing and finishing in the machining mode, criteria are set separately for roughing and finishing.
"TOOL TYPE 1", "TOOL TYPE 2" and "TOOL TYPE 3" are used to specify the most appropriate tool types and machined portions in each machining mode. The tool types and machined portions are identical to those of "SHAPE" described in FIG. 4. Selection priority is given in order of tool types 1, 2 and 3. Ordinarily in one machining mode, only one tool type is appropriate for machining. However, if the tool type 1 does not exist and the tool type 2 or 3 may be used instead, the tool types 2 and 3 are specified. Where there are no replaceable tools, the tool types 2 and 3 are left blank.
"CONDITION 1" to "CONDITION 6" are used to specify conditions to be satisfied by the tools to be selected for those specified in the tool types. Tool selection is made with priority given in order of conditions 1, 2, 3, 4, 5 and 6. Namely, tools satisfying the condition 2 are selected from among those satisfying the condition 1, and further tools satisfying the condition 3 are selected from such tools. Where there are fewer than six conditions to be set, any unset conditions are left blank.
The conditions to be set are as follows:
R: nose radius
K: rotation/hand
A: groove depth/entering angle
B: nose width/nose angle
H: holder
W: tool width
L: tool length
These conditions are employed to specify which of the data shown in FIG. 4 is used to select the most appropriate tool.
A value following any of R, K, A, B, H, W and L indicates a criterion. A condition of a:b indicates that a tool having a value within the range a to b is selected. When there are a plurality of tools that satisfy this condition, tool selection is performed in the order from a to b. The magnitude relationship of a and b may either be a>b or a<b. If a>b, the tools are selected in descending order, and if a<b, they are selected in ascending order, i.e. a is the most appropriate value and the permissible value is up to b.
For example, R0.2:* indicates that the tool to be selected has the nose radius value of not less than 0.2 mm and selection is made in order of tools whose nose radius value is closer to 0.2 mm. "*" indicates the maximum value. Although the maximum value usually indicates the largest value among data set as the tool data, it should indicate the value of a groove width to be machined when "*" is specified in the nose width data of "B" in the grooving mode. Also, when "*" is specified in the tool width data of "W" in the drilling mode, the maximum value should indicate the value of a hole diameter to be drilled. In this manner, the value of "*" may be the maximum machinable value according to the machining mode.
R*:0.2 indicates that the tool to be selected has the nose radius value of not less than 0.2 mm and selection is made in order of tools whose nose radius values are larger.
As described in the case of the tool data, the operator moves the cursor 15 to the position of a required item by controlling the cursor moving keys of the keyboard 4, and enters the required data from the keys on the keyboard 4.
The criterion data thus entered is all stored into the criterion table memory 8 shown in FIG. 1. Once set, the criterion data need not be reset unless the criteria are changed.
When creating an NC machining program, the operator selects an NC machining program creation menu from among the options displayed on the CRT display device 5 (step 406). The CPU 1 then switches the display of the CRT display device 5 to an NC machining program display screen and displays an NC machining program on the screen (step 407). If it is desired to correct the NC machining program, the operator makes NC machining program correction (step 418). If the display or correction of the machining program is complete (step 419), the processing jumps to the step 410.
In creating or correcting the NC machining program, the operator enters the NC machining program on the basis of a machining drawing as shown in FIG. 6 via an NC machining program edit screen serving as an interactive screen (step 407).
FIG. 7 shows a machining program thus entered on the basis of the machining drawing shown in FIG. 6. "P No." indicates a process number which is incremented in sequence, beginning with 0. The process number of "0" is used to specify the data of stock, and "MATERIAL" indicates the material of the stock, "OD" the maximum outside diameter of the stock, "ID" the minimum inside diameter of the stock, and "STOCK LENGTH" the overall length of the stock. The process numbers from "1" onward each indicate the machining processes and comprise one-line process data which defines each machining and multi-line sequence data (SEQ) which defines a machining shape. A tool used in the corresponding process is defined in the process data. "R TOOL" is employed to specify a tool used for roughing and "F TOOL" to specify a tool used for finishing.
When the cursor 15 has reached a position requiring a tool to be specified, i.e. when the cursor 15 has come to the position of R TOOL (tool used for roughing) or F TOOL (tool used for finishing) in FIG. 7, during the creation of the NC machining program and the operator depresses the "TOOL SELECT" menu key (not shown) (step 408), automatic tool selection is performed and the tools appropriate for the machining are displayed on the CRT display device 5 as shown in FIG. 8 in the order in which they seem to be more appropriate (step 409).
The tools are displayed on the screen in the order in which they seem to be more appropriate on the basis of the criteria. The top tool number in T No. is highlighted, indicating that it is the tool judged as the most appropriate for the corresponding machining. If the system-selected tool is satisfactory, the operator depress the "INPUT" key which means that the tool is acknowledged. This causes the highlighted tool to be entered as the "R TOOL" or "F TOOL" data.
If the operator does not desire to select the most appropriate tool selected by the system, i.e. highlighted tool, the operator moves the cursor to the position of the tool desired to be highlighted by depressing the cursor moving keys, and depresses the "INPUT" key. This allows the tool other than the system-selected, most appropriate tool to be selected.
FIG. 9 is a tool selection block diagram. To cause a tool to be automatically selected during the edition of an NC machining program 6, appropriate tools are determined in accordance with the tool data 7a and criterion table 8a and displayed on the screen in order of appropriateness, from which the operator is prompted to select.
The processing wherein the operator makes tool selection will now be described with reference to a general tool selection flowchart shown in FIG. 10. The operator creates the NC machining program by entering the data of the NC machining program shown in FIG. 7 from the keys on the keyboard 4 on the basis of the machining drawing shown in FIG. 6. At this time, the cursor is displayed (not shown) at a data input position on the CRT display device 5. When this cursor is at a tool data setting position (i.e. "R TOOL" or "F TOOL" position in FIG. 7) (step 101), depressing the "TOOL SELECT". menu key (step 102) causes automatic tool determination to be started (step 103). The tool determination method will be detailed later. If the tool number to be specified is known beforehand, that tool number (T No.) may be directly entered and set as data from the keyboard 4. In this case, the automatic tool determination is not carried out.
When the automatic tool determination is complete, tool data is displayed on the CRT display device 5 in order of appropriate tools (step 104). At this time, the tool data which seems to be the most appropriate is highlighted as shown in FIG. 8. By depressing the input key (INPUT) in that state, that tool number is set. The tool data is displayed in the order in which the tools seem to be more appropriate, and the tool data conforming to the criterion conditions 1 to 6 is marked "*" so that it may be differentiated from the other tools.
For the tools that do not conform to the conditions, their tool data is displayed next to the tools satisfying the criteria in order of tool numbers. In the example of FIG. 8, the tool numbers (T No.) of the tools conforming to the conditions are 3, 7 and 2 and are marked "*" indicating that they are conforming. The conforming tools are displayed in order of conformance and the tool 3 seeming to be the most appropriate is highlighted. The non-conforming tools are displayed in order of tool numbers (1, 4, 5, 6, 8, 9, . . . ) without the conforming tools.
Then, the operator shifts the highlight by depressing the cursor moving keys on the keyboard 4 so that the tool data desired to be selected is highlighted (step 105). When the tool data to be selected has been highlighted, the operator depresses the input key (INPUT) (step 106). The highlighted tool is then selected and its tool number is entered as the tool data (step 107).
The tool determination method will now be described with reference to a flowchart in FIG. 11 and structure of FIG. 12. First, a work table 20 and a display table 30 are all cleared (step 200). The work table 20 consists of extraction flags 21 indicating extracted tools and tool numbers 22 as shown in a diagram illustrating the processing for tool selection in FIG. 12, and has a sufficient capacity to store the data of all tools. The display table 30 consists of selection flags 31 indicating selected tools and tool numbers 32 as shown in FIG. 12, and has a sufficient capacity to store the data of all tools.
The tool numbers of all tools in the tool data 7a are then set in order of tool numbers 22 in the work table 20 (step 201). Since the data in the tool data 7a is arranged in order of tool numbers, the data of the work table 20 is also arranged in order of tool numbers.
Variables N and DN are initialized (step 202). The variable N indicates a tool type number (1 to 3) shown in FIG. 5 and the variable DN indicates a data setting position in the display table 30. It is determined whether the data of the tool type N has already been set (step 203). If it has been set, the processing progresses to step 204. If not yet set, the processing jumps to step 205.
The tools satisfying the conditions shown in FIG. 5 are then selected (step 204). The selection method will be described later in detail. This step selects the tools of which types have been specified in the tool type N appropriate for the machining mode of the machining program, where tool data is to be set, and which satisfy the conditions 1 to 6.
The value of N is then incremented by 1 (step 205). It is determined whether the N value has exceeded 3 or not (step 206). If it has not yet exceeded 3, the processing is repeated, beginning with the step 203. If it has exceeded 3, the judgement on all the tool types 1 to 3 is complete and the remaining data in the work table 20, i.e. the tools that did not satisfy the conditions shown in FIG. 5, are set to the display table 30 in sequence (step 207).
The tools that did not satisfy the conditions are data of which extraction flags 21 in the work table 20 in FIG. 12 are OFF. These tools are set to the display table 30 in order of tool numbers.
The tool selection method in the step 203 will now be described with reference to a flowchart shown in FIG. 13.
The data to be judged is extracted from the criterion table 8a (step 300a). Since the machining mode has already been set in the "MODE" data in the process data specified in the machining program, the data to be judged is extracted in accordance with the machining mode and the machining division (roughing or finishing) in the tool data.
In FIG. 7, for example, assuming that tool selection is made with the cursor 15 located in the position of "R TOOL," since data "BAR-OUT" has already been set in "MODE," the data of which "MACHINING MODE" is "BAR-OUT" and "DIVISION" is "R" in the criterion table 8a in FIG. 5 is extracted and defined as tool judgement reference data.
Variable K is initialized (step 300). The variable K indicates the position of data in the work table 20.
It is judged whether the extraction flag 21 of the Kth data in the work table 20 is OFF or not (step 301). If it is OFF, the processing advances to step 302. If it is ON, the processing jumps to step 311.
The tool number TN of the Kth data in the work table 20 is extracted (step 302).
It is determined whether the shape of the data equivalent to the tool number TN of the tool data 7a is the tool type N or not (step 303). If they match, the processing moves on to step 304. If they do not match, the processing jumps to the step 311.
Variable L is initialized (step 304). The variable L indicates the condition number of the conditions 1 to 6.
It is judged whether the tool having the tool number TN conforms to the condition L (step 305). If it conforms, the processing proceeds to step 306. If not, the processing jumps to the step 311. The value of the variable L is incremented by 1 (step 306).
It is determined whether the value of the variable L has exceeded 6 (step 307). If it is 6 or less, the processing is repeated from the step 305 onward. If it is over 6, all the conditions 1 to 6 are regarded as satisfied and the processing advances to step 308.
The extraction flag 21 in the work table 20 is switched ON (step 308).
The value of TN is set to the DNth tool number 32 in the display table 30 (step 309).
The value of the variable DN is incremented by 1 (step 310).
The value of the variable K is incremented by 1 (step 311).
It is determined whether or not the value of the variable K has exceeded the value of TMAX indicating the number of tools (step 312). If TMAX has not been exceeded, it is regarded that there are unjudged tools and the processing is repeated from the step 301 onward. If TMAX has been exceeded, the processing progresses to step 313.
Among the data stored in the display table 30, the data of which selection flags 31 are OFF are rearranged in order of condition 1 (step 313).
Then, in regards to the already set data of the display table 30, all the selection flags are switched ON (step 314).
Namely, as shown in FIG. 14, for example, this is to change the data indicated on the left-hand side 33 in FIG. 14 to that indicated on the right-hand side 34.
Referring to FIG. 14, assume that the nose radius values of the tools are as follows, with the data of the tool numbers 3, 8, 15 and 21 added as indicated on the left-hand side 33:
______________________________________Tool Number Nose Radius Value______________________________________ 3 0.7 8 0.515 0.221 0.8______________________________________
If R0.2:* has been specified in the condition 1, i.e. it is has been specified to arrange the tool numbers in the order in which their nose radius values are closer to 0.2, the tool numbers satisfying this condition are rearranged in order of:
15, 8, 3, 21
and the selection flags 31 of these data are switched ON.
Whereas are three tool types, 1 to 3, and six conditions, 1 to 6, in the tool selection criterion table 8 in the present embodiment, these numbers may be changed as required.
Also, while all of the tool types 1 to 3 are judged by the conditions 1 to 6 in the present embodiment, the conditions may be set individually to each tool type as shown in FIG. 15.
In this case, the first tool type appropriate for the "BAR-FCE" machining mode is: "GNL-FCE" and its selection conditions are:
a1 to a6.
The second appropriate tool type is:
"GNL-OUT"
and its selection conditions are:
b1 to b6.
For the display of the tools selected, while the tool data is displayed in a window provided in some part of the screen as shown in FIG. 16(A) in the present embodiment, the entire screen may be switched as shown in FIG. 16(B).
Whereas the machining modes and tool data for turning machines, such as lathes, are indicated in the present embodiment, the present embodiment is also applicable to machining centers, etc.
The "*" marks employed in the present embodiment to differentiate between the tools satisfying the criteria and the other tools may be replaced by other marks. In addition, this differentiation may be made in another method, e.g. the tools satisfying the criteria may be displayed in a different color or the tools satisfying the criteria and the other tools may be displayed in separate positions.
Also, while the data of the tool judged as the most appropriate is highlighted in the present embodiment, it may be displayed in another way, e.g. the most appropriate tool may be indicated by the cursor or only the most appropriate tool may be displayed in a different color.
Further, the present embodiment is not restricted to the machining modes, machined portions and tool data indicated herein.
It will be apparent that the invention, as described above, achieves a tool specifying method which allows conditions for selection of the most appropriate tool to be specified optionally for each machining mode, whereby selection reference can be provided so that tool selection may be made according to a machining status.
The tool selection reference of this tool specifying method is so definite that which tool will be selected can be expected and know how on the tool selection of each operator can be incorporated by correcting the conditions.
Since a tool to be used is specified by the operator out of selected tools displayed on the screen in the order in which they seem to be more appropriate for machining, the tool selected can be changed optionally if it is not satisfactory. To ensure ease of selection for the operator, the tools are displayed on the screen in the order in which they seem to be more appropriate for machining.
The operator specifies a required tool while simultaneously viewing the tool data displayed on the screen, whereby simple input mistakes can be prevented and the tool to be used can be specified rapidly and reliably.
The entire disclosure of each and every foreign patent application from which the benefit of foreign priority has been claimed in the present application is incorporated herein by reference, as if fully set forth.
Although this invention has been described in at least one preferred embodiment with a certain degree of particularity, it is to be understood that the present disclosure of the preferred embodiment has been made only by way of example and that numerous changes in the details and arrangement of components may be made without departing from the spirit and scope of the invention as hereinafter claimed. | In an NC automatic programming system for defining the process and equipment for machining a workpiece, a method and apparatus for automatically selecting a tool out of a plurality of available tools for machining the workpiece. The data defining the tools and data defining the criteria for selecting the most appropriate tool on the basis of machining mode are entered and stored. On the basis of the entered data, the available tools are arranged automatically according to preference for the desired machining. The recommended tool may be accepted or another of the recommended tools may be selected at operator discretion and based on operator experience. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to wireless communication equipment.
[0003] 2. Description of the Related Art
[0004] Medium-size (e.g., 10-50 cm) radio antennas are often used for wireless communication and various broadband applications. Such an antenna may be installed outside (e.g., on the roof) of a home or commercial building. During installation, the antenna is typically aligned, e.g., by manually pointing the antenna, for optimal signal strength. The antenna is then fixed in an optimal orientation. Special equipment and a qualified technician are often needed to properly align the antenna. In addition, it is not unusual that the alignment of the antenna needs to be adjusted weeks or months after the installation. This typically occurs due to changes in the surroundings (e.g., a new building) and/or changes in the network configuration (e.g., an added or moved base station).
SUMMARY OF THE INVENTION
[0005] Problems in the prior art are addressed in accordance with the principles of the present invention by a system having a steerable antenna coupled to a temperature-dependent driver. The driver has a shape-memory element fabricated using a shape-memory alloy (SMA) and having the ability to change its shape as a function of temperature. The element is adapted to steer the antenna to improve signal reception and is controlled by a control circuit, which resistively heats the element while using the strength of the electrical signal generated by the antenna in response to a received radio-frequency signal as a feedback signal. The temperature of the element is adjusted to optimize the signal strength. Systems of the invention may enable customer-performed antenna alignment and are relatively simple and inexpensive to implement.
[0006] According to one embodiment, the present invention is an apparatus for controlling orientation of an antenna, comprising: a shape-memory element mechanically coupled between the antenna and a mounting structure; and a control circuit electrically coupled to the shape-memory element, wherein: the control circuit is designed to control temperature of the shape-memory element; and in response to a change in the temperature, the shape-memory element changes shape, which changes the orientation of the antenna relative to the mounting structure.
[0007] According to another embodiment, the present invention is a communication system, comprising: a steerable antenna; a shape-memory element mechanically coupled between the antenna and a mounting structure; and a control circuit electrically coupled to the shape-memory element, wherein: the control circuit is designed to control temperature of the shape-memory element; and in response to a change in the temperature, the shape-memory element changes shape, which changes the orientation of the antenna relative to the mounting structure.
[0008] According to yet another embodiment, the present invention is a method of controlling orientation of an antenna, comprising changing temperature of a shape-memory element, wherein: the shape-memory element is mechanically coupled between the antenna and a mounting structure; and in response to a change in the temperature, the shape-memory element changes shape, which changes the orientation of the antenna relative to the mounting structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other aspects, features, and benefits of the present invention will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings in which:
[0010] [0010]FIG. 1 shows a three-dimensional perspective view of a representative communication system according to one embodiment of the present invention;
[0011] [0011]FIG. 2 shows an enlarged perspective view of the driver/antenna assembly used in the system of FIG. 1;
[0012] FIGS. 3 A-B schematically illustrate antenna rotation in the assembly of FIG. 2;
[0013] [0013]FIG. 4 schematically shows a perspective view of a driver/antenna assembly that can be used in a communication system similar to the system of FIG. 1 according to another embodiment of the present invention;
[0014] FIGS. 5 A-B schematically illustrate antenna rotation in the assembly of FIG. 4;
[0015] [0015]FIG. 6 schematically shows a temperature-dependent driver that can be used in the driver/antenna assembly of FIG. 4 according to another embodiment of the present invention;
[0016] FIGS. 7 A-B schematically show perspective and side views of a driver/antenna assembly that can be used in a communication system similar to the system of FIG. 1 according to yet another embodiment of the present invention; and
[0017] [0017]FIGS. 8-11 schematically show various shape-memory elements that can be used in the driver/antenna assembly of FIG. 7 according to certain embodiments of the present invention.
DETAILED DESCRIPTION
[0018] Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments.
[0019] [0019]FIG. 1 shows a three-dimensional perspective view of a representative communication system 100 according to one embodiment of the present invention. System 100 includes a steerable antenna 102 rotatably mounted on a frame 104 and connected to a signal processor (e.g., a local area network transceiver, not shown) by a cable 110 . Antenna 102 is coupled to a temperature-dependent driver 106 , which is configured to rotate the antenna about a vertical axis as indicated by the double-headed arrow in FIG. 1. The angle of rotation (i.e., the azimuth angle) is determined by the temperature of a shape-memory element 108 in driver 106 , the principle of operation of which will be described in more detail below. The temperature of shape-memory element 108 is controlled by a control circuit 114 , which resistively heats the element by passing current through it while using the strength of the signal received from antenna 102 as a feedback signal. Circuit 114 is designed to control the azimuth angle of antenna 102 to increase the signal strength by adjusting the current passing through element 108 .
[0020] [0020]FIG. 2 shows an enlarged perspective view of the driver/antenna ( 106 / 102 ) assembly in system 100 of FIG. 1. Driver 106 is configured to rotate antenna 102 about axis AB and includes shape-memory element 108 , a bias spring 218 , and a pivot 220 . Shape-memory element 108 is a twisting strip-element connected between frame 104 (FIG. 1) and antenna 102 . Bias spring 218 is a helical spring connected between pivot 220 (which is rigidly connected to frame 104 ) and antenna 102 and configured to oppose the shape-restoring force generated by shape-memory element 108 . As a result, antenna 102 adopts an orientation in which the forces generated by element 108 and spring 218 compensate each other. In one embodiment, driver 106 includes an orientation-locking mechanism (not shown), e.g., a friction lock, that can be engaged to lock antenna 102 in position, e.g., to fix the antenna at a present azimuth angle. Control circuit 114 may include appropriate circuitry for controlling (i.e., engaging/disengaging) the orientation-locking mechanism.
[0021] In one embodiment, shape-memory element 108 is fabricated using a shape-memory alloy (SMA), e.g., a nickel titanium alloy, available from Shape Memory Applications, Inc., of San Jose, Calif. SMA alloys belong to a group of materials characterized by the ability to return to a predetermined shape when heated. This ability is usually referred to as a shape-memory effect. The shape-memory effect occurs due to a phase transition in the SMA alloy between a weaker low-temperature (Martensite) phase and a stronger high-temperature (Austenite) phase. When an SMA alloy is in its Martensite phase, it is relatively easily deformed into a new shape. However, when the alloy is heated and transformed into its Austenite phase, it recovers its initial shape with relatively great force.
[0022] The Martensite/Austenite phase transition occurs over a temperature range, within which the two phases coexist. Within this transition temperature range, the phase ratio and therefore the shape-restoring force generated by a shape-memory element are functions of temperature. In addition, the Martensite/Austenite phase transition exhibits a hysteresis, that is, the phase ratio and the force are functions of the transition direction, i.e., Martensite to Austenite or Austenite to Martensite. The upper and lower temperature bounds of the transition temperature range can themselves depend on the transition direction. For example, a first set of temperature bounds may characterize the Martensite-to-Austenite transition while a second set of temperature bounds, different from the first set, characterizes the Austenite-to-Martensite transition. The upper and lower temperature bounds can be selected during manufacture of the SMA alloy, e.g., based on the SMA composition and/or special heat treatment. In one implementation, shape-memory element 108 is fabricated using an SMA alloy having the transition temperature range of 95° C. to 100° C. In another implementation, element 108 is fabricated such that the corresponding transition temperature range is separated from the highest expected environment temperature for element 108 by about 10 degrees.
[0023] FIGS. 3 A-B schematically illustrate rotation of antenna 102 by driver 106 in system 100 . More specifically, FIGS. 3 A-B show positions of antenna 102 , when shape-memory element 108 is at temperatures below and above, respectively, the SMA transition temperature range. Shape-memory element 108 is fabricated such that it has a twisted-strip shape in its high-temperature (Austenite) phase. When the temperature of shape-memory element 108 is lowered, e.g., below the lower transition temperature bound, shape-memory element 108 is untwisted by the action of bias spring 218 as illustrated in FIG. 3A, which rotates antenna 102 clockwise as viewed from the top of FIG. 3A. Similarly, when the temperature of shape-memory element 108 is elevated, e.g., above the upper transition temperature bound, element 108 overcomes the force of bias spring 218 to return to its original twisted shape as illustrated by FIG. 3B, which rotates antenna 102 counterclockwise as viewed from the top of FIG. 3B. Intermediate rotation angles (e.g., between the angles shown in FIGS. 3 A-B) can be obtained by appropriately selecting the temperature of shape-memory element 108 .
[0024] The following describes a representative alignment procedure for antenna 102 (FIGS. 1-3) according to one embodiment of the present invention. When shape-memory element 108 is at a temperature below the SMA transition temperature range (e.g., ambient temperature) and the orientation-locking mechanism (not shown) is disengaged, the action of bias spring 218 deforms shape-memory element 108 and moves antenna 102 into a first terminal position, e.g., shown in FIG. 3A. Next, control circuit 114 is turned on and begins to pass current through and increase the temperature of shape-memory element 108 . When the temperature reaches the lower transition temperature bound, shape-memory element 108 begins to recover its original shape and thereby rotate antenna 102 toward a second terminal position, e.g., shown in FIG. 3B, which position corresponds to the original shape of shape-memory element 108 . In a preferred implementation, the second terminal position corresponds to a 360° turn of antenna 102 with respect to the first terminal position. During the rotation, control circuit 114 monitors the signal strength from antenna 102 and adjusts the temperature of shape-memory element 108 accordingly to find an azimuth angle corresponding to optimal signal reception. Control circuit 114 is preferably designed to implement one or more side-lobe avoiding techniques, as known in the art, to ascertain that antenna 102 is steered into an orientation corresponding to the main lobe and not to a side lobe. When an optimal azimuth angle is found, control circuit 114 engages the orientation-locking mechanism to fix that azimuth angle for antenna 102 , after which control circuit 114 may be turned off until the antenna needs to be realigned.
[0025] [0025]FIG. 4 schematically shows a perspective view of a driver/antenna assembly 400 that can be used in a communication system similar to system 100 of FIG. 1 according to another embodiment of the present invention. Assembly 400 includes a steerable antenna 402 mounted on two pivots 420 a - b. Antenna 402 is coupled to a temperature-dependent driver 406 configured to rotate the antenna about the axis defined by pivots 420 a - b. Driver 406 includes a shape-memory coil-element 408 and a bias coil-spring 418 . Each of element 408 and spring 418 is connected between antenna 402 and a housing (not shown) such that the shape-restoring force generated by element 408 opposes the spring force generated by spring 418 . Similar to shape-memory element 108 (FIGS. 1-3), shape-memory element 408 is fabricated using an SMA alloy and can be resistively heated, e.g., using a control circuit similar to circuit 114 of system 100 .
[0026] FIGS. 5 A-B schematically illustrate rotation of antenna 402 using driver 406 in assembly 400 . More specifically, FIGS. 5 A-B show positions of antenna 402 , when shape-memory element 408 is at temperatures below and above, respectively, the SMA transition-temperature range. Shape-memory element 408 is fabricated such that it has a tightly coiled shape in the high-temperature (Austenite) phase. At a low temperature illustrated by FIG. 5A, shape-memory element 408 is deformed into a loosely coiled shape by the action of bias spring 418 . However, as the temperature of shape-memory element 408 is elevated, element 408 begins to recover the original tightly coiled shape due to the above-described shape-memory effect. As a result, antenna 402 will rotate counterclockwise as indicated by the arrow in FIG. 5B. Antenna 402 will return to the position shown in FIG. 5A when the temperature is lowered.
[0027] [0027]FIG. 6 schematically shows a temperature-dependent driver 606 that can be used in driver/antenna assembly 400 of FIG. 4 according to another embodiment of the present invention. Driver 606 is similar to driver 406 except that, instead of coil spring 418 of driver 406 , driver 606 has a U-shaped strip spring 618 . As can be appreciated by one skilled in the art, in different embodiments, differently shaped and configured shape-memory elements and/or bias springs can be used.
[0028] FIGS. 7 A-B schematically show a driver/antenna assembly 700 that can be used in a communication system similar to system 100 of FIG. 1 according to yet another embodiment of the present invention. More specifically, FIG. 7A shows a perspective view of assembly 700 , and FIG. 7B shows a side view of that assembly. Assembly 700 is designed to provide a capability to adjust both the azimuth angle and the tilt angle of a steerable antenna 702 . Antenna 702 is mounted on a movable support plate 704 , which is coupled to a first temperature-dependent driver 706 . Driver 706 has a shape-memory element 708 and a bias spring 718 and is similar to driver 106 of FIGS. 1-3. A second temperature-dependent driver 726 is coupled between support plate 704 and antenna 702 . Driver 726 has a shape-memory element 728 and a bias spring 738 and is similar to driver 606 of FIG. 6. Driver 706 is configured to rotate support plate 704 (and therefore antenna 702 ) about axis AB as indicated in FIG. 7A. Similarly, driver 726 is configured to rotate antenna 702 with respect to support plate 704 about axis CD. Therefore, by independently controlling the temperatures of shape-memory elements 708 and 728 , one can adjust both azimuth and tilt angles of antenna 702 . In one configuration, elements 708 and 728 are controlled by a control circuit analogous to control circuit 114 of FIG. 1.
[0029] [0029]FIG. 8 schematically shows a sectional shape-memory element 808 that can be used as element 708 in antenna assembly 700 according to one embodiment of the present invention. Sectional shape-memory element 808 is a twisting strip-element comprising n sections 810 - 1 810 -n. Each section 810 has a specific SMA composition and therefore specific properties such as, for example, the transition temperature range and value of spring constant. By appropriately choosing the SMA composition for each segment, shape-memory element 808 can be designed to have a linear temperature-force or current-force behavior. In addition or alternatively, element 808 may be designed to exhibit reduced hysteresis. Element 808 can be fabricated, for example, by mechanically fastening segments 810 together or by a controlled alloying process.
[0030] [0030]FIGS. 9-11 schematically show various shape-memory elements, each of which can be used in antenna assemblies (e.g., assembly 700 ) according to certain embodiments of the present invention. More specifically, FIG. 9 shows a multi-strip (two or more) shape-memory element 908 . Illustratively, element 908 is shown as comprising three twisting strip-elements 910 - 1 , 910 - 2 , and 910 - 3 bundled together. Each element 910 is similar to shape-memory element 108 (FIGS. 1-3). However, different elements 910 can have different SMA compositions and mechanical properties. FIG. 10 shows a sectional shape-memory coil-element 1008 comprising four coil sections 1010 - 1 - 1010 - 4 , each having a different SMA composition and mechanical properties. FIG. 11 shows a multi-coil shape-memory element 1108 illustratively comprising two shape-memory coil-elements 1110 - 1 and 1110 - 2 , one inside the other and each having a different SMA composition and mechanical properties.
[0031] Different modes of operation may be implemented for communication systems employing driver/antenna assemblies of the present invention. For example, system 100 of FIG. 1 can be configured to operate in a continuous feedback mode, during which the azimuth angle of antenna 102 is continuously adjusted in real time to maintain optimal signal strength. This mode may be useful, for example, when antenna 102 is employed for communication with a mobile station. Depending on the location of (direction to) the mobile station, system 100 dynamically adjusts the azimuth angle of antenna 102 for optimal signal reception. Alternatively, system 100 can be configured to operate in an open-loop mode, during which control circuit 114 steers antenna 102 independent of the received signal strength. This feature may be useful, for example, if it is desired to reduce the number of remote stations accessing a particular base station that is over capacity by temporarily diverting part of the communication traffic to a different base station.
[0032] In one embodiment, a temperature-dependent driver of the present invention is configured with an element similar to one of elements 808 , 908 , 1008 , and 1108 , which element is designed to have a substantially linear dependence of the shape-restoring force on the current passing through the element within specified current and ambient temperature ranges. As a result, the angle of rotation of the corresponding steerable antenna becomes a linear function of the current. As can be appreciated by one skilled in the art, this linearity significantly simplifies the circuitry for the corresponding control circuit (analogous to control circuit 114 of system 100 ), e.g., for implementing the above-mentioned open-loop mode. In addition, orientation of the antenna coupled to such a linear shape-memory element can be determined (monitored) very straightforwardly by observing the current.
[0033] In another embodiment, a temperature-dependent driver of the present invention is configured with a two-state shape-memory element. As known in the art, material (typically an SMA alloy) of the two-state shape-memory element is formulated and treated to “remember” two different shapes (states), a low-temperature shape and a high-temperature shape. As a result, the two-state shape-memory element adopts the low-temperature shape upon cooling and the high-temperature shape upon heating, thereby providing a bi-directional actuator even without the use of a bias spring. Consequently, in a temperature-dependent driver having a two-state shape-memory element, a bias spring is optional.
[0034] While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Differently shaped and configured shape-memory elements and/or bias springs can be used without departing from the principle of the invention. In certain embodiments, instead of a bias spring, a second, separately controlled shape-memory element can be used, e.g., spring 418 of FIG. 4 may be a second shape-memory element, where the memorized shape of shape-memory element 418 corresponds to the antenna orientation shown in FIG. 5A. In operation, only one of the shape memory elements might be heated at a time. Although the present invention was described in reference to shape-memory elements fabricated using SMA alloys, different shape-memory materials, e.g., shape-memory polymers may also be used. A different heater may be used for temperature regulation of a shape-memory element in addition to or instead of resistive heating. A control circuit analogous to control circuit 114 may be implemented in an integrated circuit and combined with an antenna package, e.g., mounted on support plate 704 or included into antenna 702 . Various modifications of the described embodiments, as well as other embodiments of the invention, which are apparent to persons skilled in the art to which the invention pertains are deemed to lie within the principle and scope of the invention as expressed in the following claims. | A system having a steerable antenna coupled to a temperature-dependent driver. The driver has a shape-memory element fabricated using a shape-memory alloy (SMA) and having the ability to change its shape as a function of temperature. The element is adapted to steer the antenna to improve signal reception and is controlled by a control circuit, which resistively heats the element while using the strength of the electrical signal generated by the antenna in response to a received radio-frequency signal as a feedback signal. The temperature of the element is adjusted to optimize the signal strength. Systems of the invention may enable customer-performed antenna alignment and are relatively simple and inexpensive to implement. | 7 |
BACKGROUND OF THE INVENTION
This invention relates generally to air conditioning systems. More particularly the invention relates to a condensate slinger for an air conditioner having an outside vertically oriented axial flow type fan.
Warm air is frequently also humid, i.e., it contains entrained water vapor. During operation of an air conditioning system in the cooling mode, the system refrigerant evaporator reduces the temperature of the air passing through it to below the dew point. In that condition, water vapor condenses on the evaporator. Some means must be provided to dispose of this condensate. In small unitary air conditioners, such as window room air conditioners, a common means to accomplish condensate disposal is by providing a condensate collection and drain path that communicates between the inside section and the outside section of the air conditioner. Condensate formed on the systems evaporator drains into a collector in the inside section and then flows to a collector located under the condenser fan in the outside section. The outside section condensate collector and the condenser fan are arranged so that the fan will contact the condensate in the collector and sling it on to the hot surfaces of the system condenser where the condensate water evaporates. The arrangement is such that the fan will sling the condensate before the water in the collector rises to a level where it can overflow. A slinger arrangement eliminates the need for an inconvenient, unsightly and costly condensate drain from the air conditioner. Another benefit from such an arrangement, is that the heat necessary to evaporate the water from the condenser is taken from and thus assists in cooling the warm refrigerant in the condenser, resulting in an improvement in system efficiency.
Numerous prior art designs are known for providing a condensate slinging capacity in an axial flow type fan where the axis of rotation is generally parallel to the base of the unit. Typical of such a condensate slinging fan is that shown and described in U.S. Pat. No. 5,215,441, Air Conditioner With Condensate Slinging Fan assigned to the assignee of the present invention and issued on Jun. 1, 1993.
U.S. patent application Ser. No. 07/993,880, assigned to the assignee of the present invention and entitled Room Air Conditioner was filed on Dec. 23, 1992. This application describes a condensate slinger of the type which may be used in an air conditioner where the outside section fan is of the axial flow type and has an axis of rotation that is generally perpendicular to and is directly driven by the outside fan motor. The condensate slinger comprises a truncated conical cup having an upper and lower end and a sloping conical wall which extends from the upper to the lower end and surrounds an interior volume. The cup includes a bottom closing the lower end which has passages therethrough to allow fluid to flow into the interior volume.
It is an object of the present invention to provide a condensate disposal system using a cone pump type slinger which cooperates with the condensate collection well of the air conditioner to enhance the condensate disposal.
It is a further object of the present invention to provide louver type condensate inlet openings in a cone pump type condensate slinger.
SUMMARY OF THE INVENTION
A condensate disposal system for an air conditioning unit of the type where moisture removed from inside air being cooled and dehumidified is conducted to a condensate collector in an outside section of the air conditioner. The system includes a condensate slinger which extends into the condensate collector to pick up and distribute condensate collected therein into contact with the units condenser coil. The condensate slinger is of the type including a truncated conical cup having an upper and lower end and a sloping conical wall extending from the upper to the lower end and surrounding an interior volume. The cup includes a bottom closing the lower end which has passages therein to allow condensate to flow into the interior volume. The passages in the bottom of the condensate slinger comprise circular openings extending from an inner surface to an outer surface thereof. The circular openings have a louvered section defining an inclined transition from the inner surface to the outer surface which define a leading edge at the lower surface. The leading edge encourages passage of water from the condensate collector through the passages into the interior volume of the slinger.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a portable room air conditioner which embodies the features of this invention;
FIG. 2 is a simplified front view of the air conditioner of FIG. 1 with the grill removed showing the relative positions of the indoor coil, the filter and the thermostat capillary mounting;
FIG. 3 is a sectional side view of the evaporator, filter and thermostat capillary shown in FIG. 2;
FIG. 3A is an enlarged perspective view of the end of the capillary engaging the discharge deck;
FIG. 4 is an exploded perspective view of the portable window air conditioner unit of FIG. 1;
FIG. 5 is a top elevational view of the air conditioner of FIG. 1 with the top cover, outdoor inlet grill, front grill and discharge deck removed;
FIG. 6 is a top elevational view of the air conditioner of FIG. 1, similar to FIG. 5, with the indoor covers installed and a number of the outdoor components removed;
FIG. 7 is a perspective view of the condensate drain pan which shows in a simplified manner its cooperation with the condensate opening in the partition wall of the air conditioner of FIG. 1;
FIG. 8 is a sectional view showing the prior art relationship between a condensate base pan, the drain pan and the condensate opening;
FIG. 9 is a sectional view, similar to FIG. 8, showing the condensate outlet of the present invention;
FIG. 10 is an exploded view of the control box enclosure;
FIG. 11 is a side view of the control box with a portion of the upper cover broken away;
FIG. 12 is a side view of the control box with only the lower cover installed, prior to routing the power cord through the strain relief;
FIG. 13 is a view similar to FIG. 12 showing the power cord installed in the strain relief;
FIG. 14 is a plan view of the lower cover of the control box;
FIG. 15 is a view taken along the line 15--15 of FIG. 14;
FIG. 16 is a fragmentary showing of the lower right hand corner of FIG. 13 with the power cord cut away where it exits from the strain relief;
FIG. 17 is a side view of the control box with both covers removed showing the internal components mounted therein;
FIG. 18 is a simplified left hand end view of the base pan and vertical partition of the air conditioner of FIG. 1 illustrating the indoor fan scroll being moved into its assembled position therewith;
FIG. 19 is a view similar to FIG. 18 showing the control box being moved into its assembled position;
FIG. 20 is a view similar to FIG. 18 showing the control box and indoor coil in their assembled condition;
FIG. 21 is a view similar to FIG. 18 showing the bearing bracket engaging the indoor coil;
FIG. 22 is a view similar to FIG. 18 showing the bearing bracket moving into engagement with the scroll;
FIG. 23 shows the bearing bracket and coil in their final positions, and, the discharge deck being assembled thereto;
FIGS. 24 through 26 illustrate the assembly of the indoor grill to the assembled front end;
FIGS. 27 and 28 are perspective views showing in detail, respectively, the right and left hand ends of the air conditioner following assembly of the control box and the bearing support structure respectively;
FIG. 29 shows a sectional right hand end view of the air conditioner of FIG. 1 with the control box discharge deck and indoor coil installed;
FIG. 30 is a fragmentary view of the upper right hand corner of FIG. 29 with a portion of the discharge deck broken away to show engagement of the control box with the center partition;
FIG. 31 is a view similar to FIG. 29 showing the left hand end of the air conditioner with the front end fully assembled;
FIG. 32 is a front view of the indoor coil of the air conditioner of FIG. 1;
FIG. 33 is an enlarged view showing the tube seal assembled to the inlet and outlet tubes of the coil of FIG. 32;
FIG. 34 is a sectional view taken along the line 34--34 of FIG. 33;
FIGS. 35 through 37 illustrate in a simplified manner the method of assembling the indoor coil with the tube seal assembled thereto through the opening in the partition, and, engagement of the seal with the opening when the coil is positioned in the base pan;
FIG. 38 is a partial plan view of the air conditioner of FIG. 1 with the covers removed and showing the indoor coil in its intermediate assembly position and its engagement with the positioning components of the air conditioning unit;
FIG. 39 is a perspective showing of the polymer stud, molded into the base pan of the air conditioner of FIG. 1, for use in mounting the compressor;
FIG. 40 is a sectional view through the stud as shown in FIG. 39 illustrating the details of the support of the compressor mounting plate thereby;
FIG. 41 is a simplified view of the outside fan, evaporator base pan and slinger arrangement of the air conditioner of FIG. 1;
FIG. 42 is a top view of the slinger of FIG. 41 as viewed along the line 42--42 thereof;
FIG. 43 is a sectional view of the slinger of FIG. 42 taken along the line 43--43 thereof;
FIG. 43A is a enlarged view of the slinger opening shown in FIG. 43;
FIG. 44 is a simplified diagrammatic showing of the grounding system of the air conditioner illustrated in FIG. 1;
FIG. 45 is a top view of the air deflector assembly removed from the discharge deck;
FIG. 46 is a sectional view of the deflector assembly of FIG. 45 showing its relative position as mounted in the discharge deck assembly;
FIG. 47 is a partial plan view of the deflector assembly of FIG. 45 illustrating the engagement of several deflectors with a gang bar;
FIGS. 48 and 49 illustrate the engagement and relative movement of a single deflector and its gang bar relative to the discharge louver housing;
FIG. 50 illustrates a plan view of a single deflector with a handle as engaged with the gang bar; and
FIGS. 51 and 52 illustrate the engagement of a deflector, without and with a handle, with the discharge louver.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference initially to FIG. 1, a portable window-type air conditioner unit 10 is formed of an indoor section 12 and an outdoor section 14. The unit is adapted to be positioned on a windowsill in a room where cooling is desired, with the indoor section facing into the room. The window sash is closed onto the top of the unit 10, and left and right side curtains 16, 18 open outward to close the remaining window space. The inside section 12 comprises an inside refrigerant-to-air heat exchanger 20 and an inside fan 22. Air from the space to be conditioned by the system enters the inside section 12 through air inlet louvers formed in an inside grill 24, and passed through the heat exchanger 20 where the air is either heated or cooled, and the inside fan 22 before exiting from the inside section 12 through an inside air discharge assembly, generally 26.
The outside section 14, of the unit is outside of the space whose air is to be conditioned. This section contains, as best seen with reference to FIGS. 4 and 5 an outside refrigerant-to-air heat exchanger 28, an outside fan 30, an outside fan motor 31, and a compressor 32. In operation, outside air enters the outside section 14 through a circular louvered air inlet 34 positioned above the outside fan in an otherwise solid outside top cover 36. The air entering the outside section then passes through the outside fan 30 into the interior of the outside section from where it is forced through the outside heat exchanger 28 before exiting from the outside section 14 through discharge louvers 38. The louvers 38 are formed in a U-shaped rear enclosure 40. The louvers 38 are configured so as to direct the warm air exiting from the outside section downwardly and away from the air intake 34 so that exiting air will not be "short cycled" through the air inlet 34 directly back into the outside section.
As best seen in FIGS. 4 and 6, the entire air conditioning unit 10 is supported by a single piece base pan 42. The basepan includes a vertically extending partition 44 which separates the indoor 12 and outdoor 14 sections.
The base pan/partition assembly 42, 44 is precision molded from a polymer material, preferably a foamed glass-filled polycarbonate. As will be appreciated the basepan 42 contains a number of contoured areas and other sections which are designed to cooperate with other components of the air conditioner 10 in order to facilitate assembly of the unit with precision alignment of all components, while at the same time requiring a minimum number of fastening devices such as screws or the like.
Referring now to FIG. 4 a previously unmentioned extremely important component of the air conditioner unit 10 is the control box assembly 46, which will be described in considerably more detail below. The control box is also molded from a polymer material and comprises three pieces, the box itself 48 and upper and lower covers 50 and 52 respectively, as seen in FIG. 10. The control box is designed to house three capacitors, the unit on-off/function switch, the thermostat, the service cord and the indoor fan motor. A further extremely important function of the control box 46 is that, once it is assembled into the unit, it serves to position and align other components of the air conditioning unit as well as to actually position and support the outside grill, as will be seen.
The indoor fan 22 as best seen in FIGS. 4, 5 and 38 is of the type known as a transverse fan. An impeller for a transverse fan of the type which may be used in connection with this unit is shown and described in U.S. Pat. No. 5,266,007, Impeller For Transverse Fan, assigned to the assignee of the present invention. Generally, the inlet plenum of the transverse fan is defined by the previously described air inlet described in connection with the inside grill 24. The flow path in and around the fan is defined generally by a scroll element 54 as best seen in FIGS. 4 and 18.
The scroll 54 is an elongated molded plastic piece having a lower wall 57 adapted to engage the basepan 42 and a rear wall 59 adapted to engage the partition 44. An elongated curvilinear surface 61 extending between a front edge 63 and a rear, upper edge 65 defines in part the inlet air flow path. The upper edge 65 of the scroll 54 cooperates with a downwardly extending portion 56 of the inside air discharge assembly 26 as best illustrated in FIG. 46. The general principles of operation of a transverse fan are well known and will not be elaborated upon in any more detail herein.
INDOOR SECTION ASSEMBLY
The assembly of all of the indoor components of the air conditioner unit 10 contained in the indoor section 12 will now be described in detail. First, with reference to FIGS. 4 and 7, the condensate pan 56 is first placed in position in the base pan 42. The condensate pan is made from a rigid foam material and comprises an inverted L-shaped section having the longer leg thereof 58 adapted to receive the lower portion of the indoor heat exchanger 20. The shorter leg 60 of the condensate pan is adapted to receive condensate draining from the coil and to direct it through a channel 62 formed therein to the units condensate collection system which will be subsequently described in detail. The condensate pan 56 is positioned in the base pan by an upstanding rib 64 formed in the base pan which contacts an extended portion 66 on the right hand end of the leg 60 of the condensate pan, and by the front flange 68 of the base pan itself.
The indoor fan scroll 54 is then installed. With reference to FIG. 18 it will be seen that the front edge 63 of the scroll is provided with a groove 70 which is adapted to engage a mating surface 72 provided on the back of the long leg 58 of the condensate pan 56. The scroll 54 is thus assembled to the unit as oriented in FIG. 18 with the groove 70 and the mating surface 72 first engaging one another and then rotating the scroll rearwardly until the upper longitudinal edge 65 engages a portion of the inwardly facing wall 76 of the partition 44. The scroll is positioned left to right by a gusset 74 formed in the partition wall 44, a portion of this gusset is broken away in FIG. 18 and it is fully shown in FIG. 4. The right hand end 77 of the scroll is positioned by contact with the short leg 60 of the condensate pan. Accordingly as thus assembled the scroll 54 is self located.
The next step is to install the indoor evaporator coil assembly 20. Looking at FIG. 32 the evaporator coil comprises a continuous section of tubing having a inlet and outlet end 78 and 80 respectively interconnected by a series of serpentine sections supported at the left and right hand ends respectively by left and right hand tube sheets 82 and 84. The tubes are interconnected by a multiplicity of parallel heat exchange enhancing fins 86. The coil inlet and outlet tubes 78 and 80 are adapted to extend from the front end of the basepan 42 of the air conditioning unit 10 through an opening 88 in the partition 44 to the outdoor section 14 where they are eventually interconnected with the rest of the closed refrigeration system.
With reference now to FIGS. 33 through 37, in order to prevent air leakage and water leakage from the outdoor section 14 into the indoor section 12 it is desirable to seal the opening 88 surrounding the two refrigerant tubes passing therethrough. In order to achieve this in an inexpensive, expeditious and highly efficient manner a section of foam rubber hose 90 is slid over the open ends of both hoses and positioned to extend on the longitudinal stretch of tube that extends from the inside section through the opening 88 and into the outdoor section. The insulating tube 90 is then taped 91 to the refrigerant tubes 78 and 80 to prevent the tube from sliding on the tubing as the coil assembly is installed and the tubes are passed through the opening 88. The taping 91 at the end of the tubes that passes through the opening creates a tapered transition thus assuring smooth installation the insulating section 90 enters the hole 88 drawing assembly.
The hole 88 is slightly smaller than the insulating tube 90 so that the tube is compressed slightly during installation. This provides an inexpensive, yet effective air and water tight seal.
Following installation of the coil as described above the evaporator coil 20 is bent forward by about 15 degrees from the vertical, as illustrated in FIGS. 20, 21 and 38. This bending of the coil is temporary and facilitates installation of the control box assembly 46 as will now be described in connection with FIGS. 19 and 20. It should be noted that the indoor coil is not shown in FIG. 19 in order to facilitate the description of the installation of the control box assembly 46.
As previously indicated the control box assembly 46 includes the indoor fan motor 92. The indoor fan motor 92 has a support bushing 94 on both ends thereof. With reference to FIG. 10 it will be seen that one bushing 94 is adapted to be operatively received in an opening 95 in the lower control box cover 52. With reference to FIG. 19 it will be seen that the other motor bushing extends through an opening 97 in the left hand facing wall 96 of the box 48. While the details of the control box structure and the assembly thereof and other novel features associated therewith will be described in detail hereinbelow, for purposes of the present description, the side of the control box defined by the upper and lower covers 50 and 52 respectively will generally be referred to as the right hand side of the control box.
The power cord strain relief generally, 98 extending from the right hand side of the control box will be referred to in connection with installation of the control box assembly. The bottom of the control box will generally be referred to as 100 while the top of the control box will be referred to as 102. As best seen in FIGS. 27 and 28 the front of the control box is stepped having a proximal facing front surface 104 and a distal front facing surface 106. Located in the distal front facing surface 106 of the control box is a vertically extending slot 108.
Installation of the control box is carried out by engaging the slot 108 with the rear flange 110 of the right hand tube sheet 84. As thus engaged the control box relationship to the unit appears as illustrated in FIG. 19. As the control box is moved downwardly the cord strain relief 98 moves into engagement with an arcuate slot 112, which, as best seen in FIGS. 4 and 27, is provided in the right hand base pan gusset 113. The control box 46 is thus guided by the engagement of the slot 108 and the tube sheet, and, the strain relief 98 and the arcuate slot 112.
When the control box has moved downward and rearward as far as it can a protrusion 114 on the top of the control box snaps under an L-shaped rib 116 which is formed on the upper most end of the partition wall 44 as shown in FIGS. 20, 27 and 30. It is important to note that the L-shaped rib 116 extends substantially the full width of the upper partition wall. The control box assembly 46 thus has also been assembled to the air conditioning unit in a precision self locating manner.
Referring now to FIG. 20, as thus installed the axis 117 of the indoor fan motor 92 is an alignment with a semi-circular bearing support 118 formed in the left hand end 120 of the scroll 54. At this point the indoor fan impeller 22 is drivingly attached to the indoor fan drive motor 92, and, a rubber support bearing 120 is placed on the left hand end of the indoor fan impeller. The support bearing 120 is then operatively placed into the bearing support 118 formed in the scroll as shown in FIGS. 4 and 38.
The left hand bearing bracket 122 as best seen in FIGS. 4, 21 and 28 is provided with a vertically extending channel 124, and, a diagonally extending surface 126 which has a semi-circular bearing support structure 128 formed therein. The diagonal surface 126 is adapted to matingly engage a corresponding surface 130 formed on the left hand end of the scroll 54. Extending from the diagonal surface 126 on the bearing bracket are a pair of tabs 132 which are adapted to operatively engage a mating pair of slots 134 provided in the diagonal surface 130 of the scroll.
The bearing bracket 122 is assembled by engaging the channel 124 against the left side of the left tube sheet 82 and sliding it downward until the lower tab 132 on the bracket enters the lower slot 134 in the scroll. The bracket 122 is then rotated rearwardly until the upper tab 132 on the bracket enters the upper slot 134 on the scroll, and, a rearwardly extending protrusion 136 on the upper surface of the bracket 122 snaps under the rib 116 formed at the upper end of the partition 44. The bracket 122 is then locked in place in a precision self locating manner. It should be appreciated, with reference to FIGS. 21 and 28, that as the bracket 122 is rotated rearwardly into its assembled position the indoor coil 20 by virtue of engagement of the bracket with the left hand tube sheet is moved back into its proper vertically oriented position.
Referring now to FIGS. 27 and 28 it will be noted that the top of the control box 102 and the top 138 of the bearing bracket 122 are each provided with an upstanding cone shaped locator pin 140. These locator pins 140, as will be seen in the description hereinbelow, are the primary mounting structure for the inside grille 24.
Continuing now with the indoor section assembly, the indoor air discharge assembly 26 includes a discharge deck 142 which includes an elongated substantially rectangular opening 144 in the top thereof in which is mounted an air deflector assembly 146. The air deflector assembly 146 is shown in detail in FIGS. 45 through 52 and will be described in detail hereinbelow.
The discharge deck 142 includes two spaced apart openings 148 in the right hand top surface thereof which are adapted to allow control shafts 150, 152 of the unit control switch 154 and thermostat 156, respectively, to pass there through.
Assembly and precise positioning of the discharge deck 142 is facilitated by the upper edge 158 of the partition 44 and the previously described L-shaped rib 116 also formed at the upper end of the partition 44, as shown in FIGS. 29, 30 and 31. With continued reference to these figures it will be seen that the deck 142 is provided with a downwardly extending lip 160 on its rear, underside which extends substantially the entire width of the deck. Also, adjacent each end of the deck, and extending from the underside thereof, forward of the lip 160 are a pair of J-shaped ears 162.
With reference to FIG. 23 installation of the deck is achieved by angling the deck away from the horizontal position so as to engage the lip 160 with the upper edge 158 of the partition and substantially rotating the deck downwardly to the horizontal position so that the ears 162 move under the L-shaped rib 116. Reference to FIGS. 27 and 28 illustrate in detail the openings into which the J-shaped ears 162 are received on the right hand end and the left hand end of the unit, respectively.
With reference to FIG. 27 the recess 164 in which the right hand ear 162 is received is defined by the L-shaped rib 116 and a portion cut away in the corner of the control box 46 adjacent to the protruding section 114 which extends under the L-shaped rib 116 of the partition to position the control box. Likewise FIG. 28 shows the recess 166 for receiving the left hand ear 162 which is defined by the rib 116 and a cut out portion 168 adjacent to the protrusion 136 on the bearing bracket 122 which engages the rib 116.
With the lip 160 and the ears 162 so engaged, as the front of the deck is rotated downwardly a downwardly extending offset 170 formed in the front underside of the deck is received in mating notches 172 formed in both the left and right hand tube sheets 82, 84. This engagement of the deck with the notches stops the rotation of the deck downwardly and thus locates the deck and locks the evaporator coil 20 in its final assembled position. FIGS. 29 and 30 illustrate this relationship in detail.
The discharge deck 142 is provided with a substantially triangularly shaped mounting ear 174 extending downwardly from the underside thereof at both the right and left hand ends thereof. Each of the mounting ears 174 is provided with a hole 176 therein. The hole 176 in the right hand mounting ear is in alignment with an engagement hole 178 provided in the upper cover of control box housing 48. Similarly, the opening 182 in the left hand mounting ear 174 is in alignment with an engagement hole 184 formed in the upper end of the bearing bracket 122.
With reference to FIGS. 4, 29 and 31, one screw 180, is installed in each end of the deck 142 through the respective openings 178 and 182 in the ears 174 and into engagement with the holes 178 and 184 of the control box cover and bearing bracket. With the screws 180 appropriately fastened, the entire indoor section is then locked together. Specifically, the discharge deck 142, the control box assembly 146, the bearing bracket 122, the scroll 54, the indoor coil 20 and the basepan 42 are all interlocked, as described hereinabove and fastened with two threaded fasteners such that cannot move in any direction.
Disassembly of the entire front end may be readily accomplished by removing the two fastening screws 180, and easily disassembling each of the components.
FRONT INLET GRILLE MOUNTING
It will be noted with reference to FIGS. 1, 4, 24, 29 and 31 that with the indoor section assembled as described above, the discharged deck 142 covers substantially the entire upper part of the indoor section 12 of the unit. In order to make the unit aesthetically attractive, the inside or front grille 24 is designed to slide under the discharge deck and top of the filter (the filter will be described hereinbelow) which make up the top of the unit, cover the sides and the front, wrap around the bottom edges and precisely line up with other adjoining parts of the unit.
Reference is made to the previous description, in connection with FIGS. 27 and 28, of the conically shaped locator pins 140 located on the top 138 of the bracket 122 and the top 102 of the control box. It will be noted, with reference to FIGS. 24, 29 and 31 that with the discharge deck 142 installed, a space is defined between the underside of the discharge deck 142 and the top 102 of the control box on the right hand side (186) and the top of the bearing bracket 122 on the left hand side (188).
Referring now to FIGS. 4, 24 through 26 and 29 and 31, the indoor grille 24 is a one piece, molded plastic member, which is adapted to cooperate with the indoor section as illustrated in FIG. 1. The grille 24 has a substantially elongated U-shape, which contains a rectangularly shaped louvered intake section 190 forming the front thereof and a pair of shorter solid sections forming left and right hand sides 192, 194 respectively. The grille 24 includes a top flange 196 extending about the entire upper periphery thereof. Extending from the top flange 196 on both the left and right hand ends thereof are inwardly extending extensions 198 each of which is provided with a locator hole 200 which is adapted to cooperate with the locator pins 140 as will be explained in more detail. A bottom flange 202 extends about the lower perimeter of the grille 26.
The grille 26 is installed by sliding the top flange 196 and the flange extensions 198 into the spaces 186, 188 on the right and left hand sides of the unit respectively. The grille is pushed rearwardly until the flange extensions 198 contact the locator pins 140. The flange extensions 198 then are cammed upwardly due to the conical shape of the locator pins 140 until the locator holes 200 engage the pins and locate the upper part of the grille 26.
At this point the weight of the grille 26 tries to rotate the entire grille downward thus pivoting it on the locator pins 140. When the rear edges 204 of the left and right hand portions 192, 194 of the grille contact a structural rib 206 of the basepan the grille is installed to the unit.
Removal of the grille 26 is accomplished by placing one hand on each side of the grille and simply pulling it forward with sufficient force to cause the flange extensions 198 to cam upwardly causing the locator holes 200 to move out of engagement with the locator pins 140.
As a result, the grill installs easily, is removed easily, and because of the precision location of the locator pins 140, as described hereinabove, the grille lines up precisely with all adjacent parts.
A further benefit is that the grille may be easily removed without tools. This satisfies Underwriters Laboratory® requirement UL-494 and therefore allows the information plate for the air conditioner to be inside the outer grille 26.
THERMOSTAT CAPILLARY INSTALLATION
With the indoor section 12 of the unit 10 assembled as described above the inside grille 24 and the front edge 208 of the discharge deck 142 cooperate to define a narrow elongated slot 210 which is adapted to received a removable one piece air filter 212. The air filter 212 has a top portion 214 which has a handle section 216 which when the filter is inserted from the top of the unit downwardly into the slot 210 forms an aesthetically pleasing integral portion of the front of the unit. The filter 212 is shown in its installed position in FIGS. 1, 2 and 4 and, as is conventional, in its installed position is in coextensive closely adjacent relationship to the front of the evaporator coil 20 to intercept and collect any airborne particulate being drawn into the front of the unit through the inside grille 24.
It is common practice in room air conditioner units to mount the units thermostat capillary 214 across the face of the indoor coil 20 so that it may sense the room air as it flows into the unit and across the capillary before entering the coil to be cooled. The capillary is generally located close to the coil surface (about 1/8 to 1/4 inch away). As a result, if the coil begins to ice up the ice will build up until it touches the capillary causing the thermostat to open and shut the compressor off. Also, typically, capillaries are sleeved in plastic to protect them from radiant cooling from the coil. Typically the capillary and the sleeve in which it is contained are attached to the coil by retainers which extend outwardly from the coil so as to space the capillary as discussed above. Such retainers can and have been known to interfere with the installation of slide-in filters of the type also described above. Referring now to FIGS. 2, 3 and 3A, the relationship of the thermostat capillary 214, the air filter 212, the indoor coil 20 and the front edge 216 of the discharge deck 142 are shown.
As shown in FIG. 2 the capillary 214, encased in a plastic sleeve 220, extends from the left hand facing surface 218 of the control box 48 and extends to the left into confronting relationship with the inside coil 20. The front edge of the right hand tube sheet 84 is provided with a notch 222 into which the plastic sleeve 220 is pushed as shown in FIG. 3.
The front edge 216 of the deck is provided with a L-shaped downwardly extending configuration 224 which defines a horizontal wall portion 226. Spaced to the right of the horizontal wall portion 226 is a vertically, downwardly extending wall section 228 which defines a space 230 therebehind. The horizontal wall 226 and the left hand edge 232 of the vertical wall 228 define an opening 234 therebetween.
Accordingly, after the plastic sleeve 220 is inserted into the notch 222 the upper end 236 of the sleeve 220 is snapped into the opening 234 with a portion of the upper end resting on horizontal wall 226 and a lower portion of the upper end of the sleeve trapped in the space 230 behind the wall 228.
As a result the capillary is readily supported by the structure molded into the front edge 216 of the deck, and, is supported in close proximity to the heat exchanger 20. Referring to FIG. 3, when the filter 212 is slid into place in front of the sleeve 220 it slides downward smoothly in front of the sleeve without interference. No further retainers are needed to positively retain the capillary and its sleeve 220 in position.
CONDENSATE HANDLING SYSTEM
Conventional condensate handling systems in a room air conditioner include means for collecting condensate water draining from the inside heat exchanger and directing the collected condensate to the outside section of the air conditioner where a slinger, usually a "ring" type slinger attached to the periphery of a vertically disposed outside fan will distribute the condensate to the outdoor coil. The present air conditioning unit 10 differs from typical prior art systems in that the outdoor fan 30 and fan motor 31 are oriented vertically and accordingly an unconventional slinger design is required. Further, unlike most room air conditioners as a result of the arrangement of the outdoor fan and the outdoor fan inlet 34 the outdoor section 14 is pressurized by the fan.
Looking now at FIG. 7 the condensate pan 56 of the present air conditioning unit 10 is shown as it is mounted in the basepan 42. The condensate pan 56 comprises an elongated trough 36 which collects condensate dripping from the inside heat exchanger 20. The trough 56 makes a right angle turn and communicates through an extension of the pan 56 with a condensate opening 238 provided in the wall of the partition 44. Condensate collecting in the trough passes through the opening 238 and through an appropriate condensate channelling recess 240 formed in the basepan which communicates with a condensate well 242 also molded in the basepan, both of which are illustrated in FIG. 6.
FIG. 8 illustrates a typical prior art indoor-outdoor transition, showing water passing from the trough 236 of the condensate pan 56 through the opening 238 in the partition wall and into the condensate recess 240 of the basepan. As illustrated in FIG. 8, while the flow of condensate water is readily facilitated by such an arrangement, pressurization of the outside section 14 of the unit can result in air and water carried by the air being blown from the outside section to the inside section to the extent that water over flows the condensate pan and the basepan and leaks from the unit on the indoor side.
According to the present invention, and as illustrated in FIG. 9, a condensate outlet hood 244 is molded into the partition wall 44 on the outside section of the unit. This hood 244, as is illustrated in FIG. 9 extends downwardly into the condensate recess 240 formed in the basepan on the outside of the unit to thereby place the condensate water outlet so that it is below the outdoor water level 245 formed in the basepan. As a result of the condensate outlet being below the normal water level, not only is leaking due to air flow from outside to inside stopped, but, it also acts as an air seal which prevents thermal losses due to air migrating from the outside section to the inside section.
Looking now at FIGS. 41 through 43A the outside fan motor 31, in addition to driving the outside fan 30, also directly drives through a shaft extension 246 a condensate slinger 248. This slinger 248 extends into the condensate drain collector well 242.
The slinger 248 is of the cone pump type and has the overall shape of a truncated cone. Slopping conical wall 250 has a upper end that defines an open top and extends from the open top to a lower end closed by a bottom 252. A socket 254 is affixed to the center of the bottom 252 and rises along the longitudinal axis of the cone to provide means for attaching the slinger 248 to the shaft extension 246.
In the illustrated embodiment there are three holes 254 provided in the bottom 252 of the slinger. Each of these holes is provided with a flush louver configuration 256 as best shown in FIG. 43A. Each of these louvers comprises a slanted surface extending from the upper surface of the bottom 252 to the lower surface thereof where it defines a leading edge 258. When the leading edge is immersed in condensate in the condensate well 242 it facilitates pumping water into the interior of the slinger. It should be appreciated that the rotation of the fan motor and the slinger is such that the leading edge 258 moves in the direction illustrated in FIG. 43A to encourage the pick up of condensate.
The condensate collection well 242 is configured to have a flat bottom and slanted sides which conform somewhat to the shape of the slinger. Also when the slinger is operatively positioned in the well the bottom of the slinger is spaced very closely to the bottom of the well, a preferred spacing is approximately a 1/4 of an inch.
As a result of the described arrangement, when the slinger bottom 252 is immersed in liquid, liquid flows into the interior of the slinger through the louvered holes 254. Rotation of the slinger accordingly results in a centrifugal force which causes the liquid passing into the interior of the slinger to be drawn away from the axis of the slinger and up the interior of the slopping conical wall 250. When the liquid reaches the top of wall 250 it continues to flow upward and outward away from the slinger 248 as indicated by the upper arrows 260 in FIG. 41.
At the same time, water picked up on the outside of the conical wall 250 is also caused to be slung outward and is deflected off the slanted sides 262 of the recess 240 further resulting in spray being directed toward the outdoor coil 28 as indicated by the lower arrows 264. The result is an extremely quiet slinger resulting in spray being thrown over the entire outside coil 28.
It should be appreciated that the water spray is carried by the outside air passing through the outdoor heat exchanger 28 where, because of the elevated temperature of the heat exchanger, the water evaporates. The resulting water vapor is then carried out of the air conditioning system 10 with the existing air. The condensate formed in the inside heat exchanger 20 is thus disposed of without the need of drains or other means of condensate disposal. Disposing the water onto the outside heat exchanger 28 is extremely desirable in that it improves the overall operating efficiency of the system 10 as the transfer of heat necessary to vaporize the condensate serves to cool the hot refrigerant flowing through the outside heat exchanger 28.
COMPRESSOR MOUNTING STUD
Referring now to FIGS. 5 and 6 the molded stud mounting arrangement of the present invention is shown at 266 as applied to a horizontal rotary compressor 32 which is mounted to the basepan 42 of the outdoor section 14 of the air conditioning unit 10. The compressor 32 includes a plurality of mounting devices not shown which mounts the compressor directly to a mounting plate 268. The mounting plate in turn is attached directly to the basepan 42 with the compressor mounting devices 266 in accordance with the present invention.
A compressor mount 266 is shown in detail in FIGS. 39 and 40 wherein the mounting is accomplished by assembly of the mounting plate 268 directly to a compressor stud 270 which is molded from the same polymer material as the basepan as a integral part of the basepan mold. As is evident from the drawings figure the stud is molded with a design radius 272 where it meets the basepan in order to impart the necessary strength to the stud. A central opening 274 is molded directly into the stud which facilitates the simply mounting arrangement of the present invention.
Mounting of the compressor and mounting plate is then achieved by first assembling elastomeric isolator grommets 276 to each of the three openings provided in the compressor mounting plate 268. The mounting plate 268 with the compressor mounted thereupon is then set in place with the three integrally formed studs 270 passing through each of the grommets 276. A simple "fender" washer is then placed over each of the grommets with its central opening in alignment with the opening 274 in the stud. A simple screw, such as a #8-B sheet metal screw 278 is then threaded directly into the opening 274 in the stud and tightened to a predetermined torque to avoid stripping of the threads formed within the openings 274 as the screw is attached thereto.
As thus mounted the compressor is mounted through the mounting plate 268 to the integrally formed studs in a manner which is extremely simple, inexpensive and easy to accomplish.
In a preferred embodiment the basepan 42 and the integrally molded studs are formed from a foamed glass-filled polycarbonate. The studs are formed with a radius of between 2.0 to 4.0 mm, a 3.0 mm radius being preferred. The through openings in the studs are 3.56 mm in diameter for use with #8-B sheet metal screws. The specified torque for this combination is 12.5 inch-lbs.
INSIDE AIR DISCHARGE ASSEMBLY
As seen generally, and in a simplified manner in FIGS. 1, 4 and 6 the inside air discharge assembly 26 comprises the discharge deck 142 mounted at the top front of the unit and the air deflector assembly 146 mounted in the rectangular opening 144 in the top of the deck.
The air deflector assembly 146 comprises a one piece elongated discharge louver unit 280 best shown in FIGS. 45 and 46. The louver unit comprises five angularly disposed horizontal parallel spaced louvers 282. The top and bottom louvers 282 extend into end portions 284 of the louver unit to form a substantially continuous outer periphery of the louver unit. Each of the ends 284 is provided with a molded in mounting pin 286 each of which is adapted to be receive in mating openings (not shown) provided in the left and right hand ends of the rectangular opening 144 in the discharge deck 142. FIG. 146 shows across section of the discharge louver unit mounted within the discharge deck. It is will be noted in FIG. 46 that the discharge deck 142 is inclined slightly forward from the horizontal. Such inclination and the configuration of the downwardly extending portion 56 of the discharge deck 142 which defines the outlet path of the fan cooperate to encourage discharge of air forwardly into the room being cooled. Further, the pivotally mounted discharge louver unit 280 as shown in FIG. 46 may be pivoted forward about the pins 286 to further direct air discharge therethrough in a forward direction into the room being cooled.
With reference to FIG. 45 the individual louvers 282 are interconnected at their rearward or trailing edges by a plurality of perpendicular connecting ribs 288, which are circular in cross section as shown in FIGS. 48, 49, 51 and 52. Mounted to the connecting ribs 288 are two sets 290 of ganged air deflector assemblies. With reference to FIG. 45 it will be seen that a first set of deflectors 290 is mounted on the four ribs 288 on the right side of the louver unit 280 and a second set is mounted on the four ribs 288 on the left side of the louver unit 280. The units are identical and as will be seen, because they are independently mounted, may each be used to direct discharge air to the left or right or any position in between.
Each individual deflector 292 comprises a planar portion 294 and includes a plurality of mounting tabs 296 integrally formed therewith and extruding from the front edge 298 thereof. Each of the mounting tabs 296 comprises an arcuate portion 300 thereof which is adapted to engage one side of a connecting rib 288. In the preferred embodiment as shown in FIG. 50, the right and left hand tabs 296 have their arcuate portions facing upwardly while the interior mounting tabs 296 have their actuate portions facing downwardly. FIG. 51 illustrates a deflector 292 prior to being snap fit onto its corresponding rib 288. It should be appreciated that the mounting tabs 296 are sufficiently flexible to allow outward flexing to facilitate engagement with the connecting ribs 288.
The deflector 292 shown in FIGS. 48, 49, 50, and 52 contains a finger tab 302 formed as an extension of one of the mounting tabs 296. The finger tab allows movement of the deflector and the other deflectors ganged together therewith as will be appreciated. Other deflectors in any ganged group do not require a finger tab as for example the deflector shown in FIG. 51.
As best shown in FIGS. 46 and 50 the right hand edge 304 of each of the deflectors 292 is provided with a slot 306. The slot includes a large dimension intermediate section 308 a reduced dimension 310 at the entrance thereof defined by an upstanding protrusion 310, and a very narrow slit like portion 312 extending inwardly from the intermediate section 308. The slot is adapted to receive in a snap fit fashion a "gang bar" 314 which ties the individual deflectors 292 together as will be described. It should be appreciated that the slit like portion 312 of the slot facilitates opening of the slot to receive the gang bar through the narrow section 310 into the intermediate section 308 where it is retained for motion as will now be described.
The gang bar 314 is shown interconnecting four individual deflectors 292 in FIG. 47. The bar 314 is circular in cross section except at each of the locations therealong 316 where it is configured to snap fit into the slots 306 in the deflectors 292 which it interconnects.
With reference to FIGS. 48, 49 and 50 it will be seen that each of the slot engaging locations 316 along the gang bar is provided with an arcuate shaped section 318 on one side and a slot engaging U-shaped recess 320 on the other side. The recess 320 engages and longitudinally retains the deflector 292 with respect to the bar 314. With reference to FIGS. 48 and 49 it will be appreciated how such engagement laterally fixes the deflector 292 with respect to the bar 314 and yet allows pivotal movement of the deflector with respect to the bar. With each of the deflectors in a ganged deflector unit 290 installed as described, movement of the deflector 292 having a finger tab 302 will result in parallel ganged movement of each of the deflectors in the ganged group with the gang bar 314 moving laterally from left to right to achieve the desired deflector position.
CONTROL BOX/POWER CORD STRAIN RELIEF/GROUNDING SYSTEM
As previously described the control box assembly 46 serves a number of functions in the design of the present air conditioning unit 10. Included among those described already include, housing the indoor fan motor 92, and, serving as an integral part of the support structure of the indoor fan 22 and the indoor grille 24.
Looking now at the control box in detail, FIG. 10 illustrates the box 48, with its upper 50, and lower 52 covers disassembled therefrom. In that figure the indoor fan motor 92 and the compressor capacitor 322 are also shown mounted therein in a manner which will be described. Also illustrated in FIG. 10 are the control shafts 150, 152 of the units control switch 154 and thermostat 156, respectively extending from the top 102 of the control box. For further reference, the locator pin 140 for the inside grille is also identified on the top 102 of the control box.
Looking now at FIG. 17 all of the electrical components housed within the control box 48 will be identified. It should be noted that the internal wiring of the control box is not shown in this figure facilitate illustration and description of the components. First, the previously described indoor fan motor 92 is supported by a first bushing 94 on the back side of the motor as viewed in FIG. 17 which passes through and is supported by an opening 97 in the wall 96 of the control box as illustrated in FIGS. 19 through 21. The side of the motor 92 shown in FIG. 17 includes the bushing 94 which is supported in an opening 326 provided in the lower cover 52 of the control box.
Located in the lower right hand corner is the indoor fan motor capacitor 328. Also located in the control box is the outdoor fan motor capacitor 332, the unit control switch 154, the thermostat 156 and the previously mentioned compressor capacitor 322. Also contained within the control box is an L-shaped grounding plate 332 which serves as the central grounding terminal for all of the electrical components of the present air conditioning unit 10.
It should be appreciated that the basepan 42 and all of the support and enclosing structure of the present air conditioning unit 10 is made from plastic construction. Correctly grounding all electrical devices in a manner acceptable to Underwriters Laboratories®and other safety requirement however continues to be necessary however not as easy as a unit with a metal chassis.
With reference now to FIG. 4 the grounding plate 332 consists of a horizontal leg 334 and vertical leg 336. The horizontal leg 334 has a locator tab 338 extending from the axial end thereof. The vertical leg also has formed integrally therewith a capacitor mounting tab 340, which has two stiffener ears 342, which is adapted to receive a lip 344 on the compressor capacitor 322 as will be described. The grounding plate 332 also includes a bent flange 346 which is provided with a sheet metal screw hole 348 and a pair of quick connect tabs 350 and 352.
Assembly of all of the electrical components into the control box 48 is preceded by installing the grounding plate 332 by inserting the locator tab 338 into a matching slot (not shown) in the control box 48. With reference to FIG. 10 the locator tab 338 is shown extending through the slot to the outside of the control box. The end of the vertical leg 336 of the grounding plate is snapped over a retaining rib 354 as shown in FIG. 17 to thereby mount the plate in the box.
The unit control switch 154 and the thermostat 156 are then mounted in the box so that they are in tight electrical contact with the surface of the grounding plate 332. This is accomplished by four sheet metal screws passing from the outside top 102 of the control box or, through the plate, and into the switch and thermostat as seen in FIG. 10. Tightening of the screws pulls electrically conductive surfaces on the components into conductive engagement with the plate 332.
The compressor capacitor 322 is then placed in the box so the lip 344 is located between the vertical leg 336 and the capacitor mounting tab 340. A screw, as seen in FIGS. 17 and 44 pulls the tab 340 toward the leg 336 thus squeezing the capacitor lip 344 tightly into electrical contact with the grounding plate. The indoor motor 92 is then mounted in the control box and a grounding wire 356 from the motor is attached to the quick connect tab 350 located on the grounding plate flange 346, as shown in FIGS. 12 and 13.
The power service cord 358 is then wired into the control box with one of the power leads 360 connected to the switch 154 and the other to the compressor capacitor 322. The service cord ground wire 364 is attached to the hole 348 in the flange 346 of the grounding plate with a screw 366. The screw connection 366 is required by Underwriters Laboratories® for grounding service cords.
Appropriate wiring (not shown) is then connected to the indoor fan motor capacitor 328 and the capacitor is pushed into the control box between a pair of positioning ribs 368 until a locking ear 370 snaps over the capacitor locking it in place. Similarly, the outdoor fan motor capacitor 330 is pushed into the box until a lock ear 372 snaps over it there by locking it in place.
At this point the lower control box cover 52 is installed onto the control box 48 by inserting a tab 374 formed in one end thereof into a matting slot 376 formed in the control box 48. The opening 326 in the lower cover is pushed over the indoor motor rear mounting bushing 94. The completion of installation of the lower cover 52 is carried out by snapping a second lower cover mounting ear at the other end of the cover 378 into a mating slot 380 provided in the box. With the lower cover thus installed the indoor motor 92 is positively retained in the control box.
Completion of the grounding wiring is achieved by attaching a ground wire 386 to the second tab 352 of the flange 346 and feeding the wire through the opening 382 in the back of the control box and then through hole 384 provided in the partition 44. Also passing through the control box opening and the partition opening 384 are wires for the outdoor fan motor and the compressor.
With reference to FIG. 44 the ground wire 386 having been passed through the partition hole 384 is attached to a ground tab 388 which has been appropriately formed in the condenser coil tube sheet 390. This connection serves to ground the compressor 32 and the indoor coil 20 through the copper refrigerant piping.
The outdoor fan motor has a ground wire 392 that is also connected to a grounding tab 392 also formed in the condenser coil tube sheet 390.
In summary, the unit service cord 358 is grounded to the grounding plate 332 through a screw connection 366 as required by Underwriters Laboratories®. The switch 154, thermostat 156, and capacitor 322, are grounded by being mounted by tight contact to the grounding plate 332. The capacitor mount serves to squeeze the capacitor lip 344 to ground and mounts the capacitor without the out the use of straps or clips. The compressor 32 is connected to the condenser coil 28 by the refrigerant tubing, and the coil is grounded to the grounding plate 332 by a wire 386. The outdoor fan motor 31 is grounded through lead 392 to the condenser coil.
As thus assembled, the control box may be pulled out of the unit for service with all components remaining grounded, as is required by Underwriters Laboratories®.
Following assembly of the control box 46 with all components in place and wired, and with the lower cover 52 installed as described above the service cord 358 is engaged with the strain relief structure 98 of the present invention which is molded directly into the lower cover 52. As best seen with reference to FIGS. 10 through 16 the cord 358 is placed into an S-shaped cord receiving channel 394 formed in the lower cover. The channel runs from a narrow, entrance end thereof 396 where the flat power cord 358 is initially fed in a vertical orientation and passes through an enlarged section 398 of the S-shaped channel where the cord is then rotated ninety degrees and placed flat in the channel. The cord then passes through a path defined by a retainer ear 400, as best shown in FIGS. 14 and 15, which imparts a ninety degree bend in the cord 358.
As thus installed, when the power service cord 358 is subjected to the Underwriters Laboratories® pull test there is sufficient resistance between the cord and the tortuous path defined by the S-shaped channel 39 panel and the retainer ear 400 to pass the requirements of the UL test.
Completion of the control box assembly 46 is achieved by installing the upper cover 50 onto the box 48 by inserting a first ear 402 into a mating slot 404 in the control box and then rotating the cover downwardly and snapping a second retaining tab 406 into a receiving structure 408 in the control box 48.
Disassembly of the control box is readily accomplished by simply prying the snap on upper and lower covers from the control box retaining slots.
When the control box is fully assembled and the box is installed into the unit 10 as described above it will be recalled that the discharge deck 142 is fastened to the control box 48 by a retaining screw 180 that extends through an ear 174 forming a part of the deck 142 and through a hole in the upper cover 50 of the control box and into an opening 410 formed in the grounding plate 332. This arrangement satisfies the Underwriters Laboratories® requirement that the control box 46 may not be disassembled without the use of tools.
While the present invention has been disclosed with particular reference to a preferred embodiment incorporated into a particular room air conditioning unit, the concepts of this invention are readily adaptable to other embodiments and applications, as those skilled in the art may vary the structure thereof without departing from the essential spirit of the invention. | A condensate disposal system for an air conditioning unit of the type where moisture removed from inside air being cooled and dehumidified is conducted to a condensate collector in an outside section of the air conditioner. The system includes a condensate slinger which extends into the condensate collector to pick up and distribute condensate collected therein into contact with the units condenser coil. The condensate slinger is of the type including a truncated conical cup having an upper and lower end and a sloping conical wall extending from the upper to the lower end and surrounding an interior volume. The cup includes a bottom closing the lower end which has passages therein to allow condensate to flow into the interior volume. The passages in the bottom of the condensate slinger comprise circular openings extending from an inner surface to an outer surface thereof. The circular openings have a louvered section defining an inclined transition from the inner surface to the outer surface which define a leading edge at the lower surface. The leading edge encourages passage of water from the condensate collector through the passages into the interior volume of the slinger. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to new and useful improvements in crib rocking devices.
Conventionally, automatic baby rocking devices employ a relatively noisy motor and gear reducer systems to actuate the rocking or swinging motion and usually require a specially built crib in which the body portion is pivotally mounted to the frame. This is costly to manufacture, complicated to install, bulky and noisy.
Most of the conventional devices are not fully automatic inasmuch as when the baby is crying, an attendant has to switch on the rocking device.
SUMMARY OF THE INVENTION
The present invention overcomes all of the above mentioned disadvantages by providing a device which is easily attached to a conventional crib or which, alternatively, can be attached to a pivotally mounted type crib.
The principal object and essence of the invention is to provide a device of the character herewithin described which although it can be actuated manually, is normally actuated by the baby's cry impinging upon a microphone which starts the crib rocking action.
Another object of the invention is to provide a device of the character herewithin described which includes a sensitivity control so that only the baby's voice will actuate the crib rocking action, and which furthermore includes a timer so that the duration of the rocking action can be controlled also. Further circuitry also allows the attendant to set the periodicity of the rocking action depending upon the construction of the crib and the desires of the attendant.
A still further object of the invention is to provide a device of the character herewithin described which is very simply attached to a conventional crib in order to give the normal relatively short throw type of rocking action desired. With conventional cribs, it is quite normal to grasp the head or footboard and just rock the crib slightly using the flexibility of construction in order to give the necessary to and fro action.
Another object of the invention is to provide a device of the character herewithin described in which the electronic portion can either be transistorized or, alternatively, can readily be adapted for use with integrated circuits.
A still further object of the invention is to provide a device of the character herewithin described which is simple in construction, economical in manufacture and otherwise well suited to the purpose for which it is desired.
With the foregoing objects in view, and other such objects and advantages as well become apparent to those skilled in the art to which this invention relates as this specification proceeds, my invention consists essentially in the arrangement and construction of parts all as hereinafter more particularly described, reference being had to the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic wiring diagram showing a transistorized circuit.
FIG. 2 is an enlarged partially sectioned schematic view of the solenoid showing the switch mechaism connected thereto.
FIG. 3 is a schematic wiring diagram of the switch mechanism shown in FIG. 2.
FIG. 4 is a fragmentary isometric view of a conventional crib showing the spring system attached thereto.
FIG. 5 is a schematic wiring diagram similar to FIG. 1, but showing integrated circuits incorporated therein.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
Proceeding therefore to describe the invention in detail, reference should first be made to FIG. 4 in which 10 generally illustrates a crib having a headboard 11, a footboard 12 and barred sides 13, only one of which is illustrated.
A wire spring frame 14 normally spans the crib intermediate the upper and lower sides thereof and upon this wire spring 14, the conventional crib mattress (not illustrated) is supported.
A normally stable spring system collectively designated 15 is provided with the invention and consists of a pair of springs 16 being secured by one end thereof and spaced apart as at 17 on the headboard 12. The other ends of these springs are connected to a common locus 18 and a third spring 19 is connected by one end thereof to this locus and extends towards the footboard 11.
A relatively short length of cable 20 is connected to the other end of spring 19 and in turn extends to an anchor point 21 on the headboard 11 and means are provided as well hereinafter be described, to pull on the spring 19 and to release this pull at an adjustable periodicity thus extending springs 16 and 19 and releasing them alternately thus giving the desired slight rocking action to the crib in a lengthwise direction, similar to a person rocking the crib by grasping the top of the foot or headboard and moving same fore and aft very slightly.
Reference character 22 illustrates the electronic package to accomplish the desired motion and this can be enclosed within a casing 23 and attached to the head or footboard underneath the wire spring frame 14.
The electronic package includes a solenoid coil assembly collectively designated 24 which in turn includes the moving solenoid 25 extending from one end thereof and the end of this solenoid 25 is connected to the end of spring 19 where same joins cable 20, said point of attachment being indicated in FIG. 4 by reference character 26.
The circuitry of the electronic package 23 is shown in detail in FIG. 1. It includes a power supply input 27 one side of which is fused as at 28. A main switch 29 is also included and this power supply is connected to a transformer 28A, the output of which is rectified by diodes 29.
D.C. Current is filtered by means of capacitors 30 and connected to an audio amplifier circuit collectively designated 31.
This circuit includes a microphone or microphones 32 which is situated near the crib but out of reach of the occupant thereof. Any sound picked up by the microphone is transmitted through condenser C3 to the first stage or transistor TR1 of the high gain audio amplifier 31.
The output from TR1 is connected to the base of the second transistor TR2 via the sensitivity control 33 and this control permits the operation of the device to be adjusted to respond to the baby's cry and not to extraneous sounds.
Therefore, when the baby cries, the sound is picked up by the microphone which sound is amplified by TR1 and TR2 to provide a relatively large A.C. output voltage at point 34.
This is connected to a silicon controlled rectifier (SCR1) identified by reference character 35 and triggers this rectifier which in turn operates a solenoid coil (RC1) identified by reference character 36. The operation of this solenoid coil 36 closes normally open switches 37 and 38. Normally open switch 37, when closed, connects the power supply from 27, to the solenoid coil control circuit portion collectively designated 39.
The closing of the normally open switch 38 connects the rectified current to the timer control circuit portion collectively designated 40.
Summarizing therefore, there is no voltage at point 34 until the baby cries at which time voltage appears at 34 to operate the silicon control rectifier 35 and to close switches 37 and 38.
The solenoid coil 36 is used in conjunction with a double-pull double-throw relay which includes the aforementioned switches or contacts 37 and 38.
Dealing first with the operation of the solenoid coil portion of the circuit 39, this includes a further silicon controlled rectifier 41 (SCR2) and a speed control mechanism collectively designated 42. This includes a condenser 43 (C11) and an adjustable potentiometer 44 (R16) inserted as shown. During half cycles of the A.C. current from the power supply 27, when the anode of (SCR2) 41 is positive, the charging current for condenser 43 (C11) passes through R17 to the gate of 41 (SCR2) and through normally closed switch 49 to point 45A. It then passes through condenser 43, through the adjustable potentiometer 44 and thence through diode D8 to complete the circuit which will thus trigger the rectifier 41 (SCR2) thus actuating the solenoid coil assembly 24. This pulls solenoid 25 in the direction of arrow 46 (see FIG. 4) thus extending the springs of the system 15.
Reference to FIG. 2 will show the switching mechanism 49 within the solenoid assembly 24.
When the coil 47 is energized as aforesaid, the solenoid 25 moves in the direction of arrow 46 until it strikes the actuator 48 of switch 49 (SW3). The movable contact 50 is connected to point 45 (see FIG. 1) and being a normally closed switch, the connection is between point 45 and point 45A thus indicated in FIG. 1 by the normally closed switch 49.
However, when the solenoid 25 strikes the actuator 48, it moves away from its normal contact to a contact 51 thus closing what is normally open switch 52. This, of course, disconnects the current from the solenoid coil 47 thus permitting the spring system 15 to withdraw the solenoid 25 to the uppermost position shown in FIG. 2. This permits the actuator 48 to return to the original position thus closing switch 49 and opening switch 52 and once again re-energizing the solenoid coil assembly 24.
By the adjustment of R16 (potentiometer 44) the periodicity of the actuation of the solenoid coil assembly can be controlled.
It will also be observed that a double-pull double-throw switch 53 is inserted which can be closed manually to initiate the rocking action rather than waiting for the baby's cry to actuate the audio amplifier circuitry 31.
Summarizing, the charging of condenser C11 triggers the rectifier 41 (SCR2) thus actuating the solenoid coil which in turn actuates the switch (SW3) 49 which in turn breaks the circuit to the solenoid coil 47 so that the cycle is repeated, controlled by the speed control 44.
The holding current of the rectifier 41 (SCR2) is also controlled by the combination of R18 and C12 as clearly illustrated in FIG. 1.
The timer circuit 40 controls the length of time that the solenoid coil assembly 24 operates when in the automatic mode shown in FIG. 1. This circuit includes a condenser 55 (C9) which takes a certain time to charge, controlled by an adjustable potentiometer 56 in circuit therewith. When charged, it triggers transistor TR3 to energize a further relay control 56A which thus opens a normally closed switch 57 in the cathode circuit of the rectifier 35 (SCR1) which thus returns to the non-conducting state and therefore de-energizes the solenoid coil 36 opening switches or contacts 37 and 38 and thus de-activating the mechanism until such time as the baby cries again which will be picked up by microphone 32. The delay time or time operating is dependent upon the RC time constant of R13, R14 and condenser C9 (55).
As mentioned previously, the mechanism can be manually actuated by closing the manual switch 53. Under these circumstances, the solenoid coil assembly 53 also actuates a normally closed contact or switch 58 in the manual circuit to the solenoid coil assembly 39.
FIG. 5 shows the circitry similar to FIG. 1 but adapted for use with integrated circuits and where applicable, similar reference characters have been used.
The baby's cries are picked up by microphone 32 and fed to the amplifier circuit and the signal is amplified by IC1 together with the sensitivity control 33. The ouptut voltage from IC1 appears at point 34 to switch the timer circuit 40 on. Therefore the output of IC2, pin 3, is high or equal approximately to B+ voltage at 59. The amount of time delay depends on the RC time constant R13 R14, R13, and C9.
The output from timer circuit IC2 appears at point 59 and is connected to the astable multivibrator circuit 42 and to the speed control potentiometer 44 (R16) to provide B+ voltage to operate this circuit 42 and IC3. The output of IC3 at point 60 is connected to the gate of a triac 61 which in turn operates the solenoid coil assembly 24 in a manner hereinbefore described.
The timer switch circuitry 40 takes the form of a monostable multivibrator and the solenoid circuitry for solenoid 24 takes the form of an astable multivibrator.
Summarizing, the microphone 32 picks up the signal from the baby and this signal is amplified by IC1 thus giving a signal at point 34 which triggers IC2. This turns IC2 on and its output at pin 3 of IC2 is high and equal approximately to the B+ voltage. The length of time that the signal appears at 59 is determined by the timer potentiometer 56 and is determined by the RC time constant of the values of R13, R14 and C9 as hereinbefore described.
When point 59 is at B+ potential, the astable multivibrator circuit is operated and the output of IC3 at point 60 triggers the triac 61. This triggered voltage at point 60 triggers the triac on and off, the periodicity being determined by the speed control 44 (R19, R16 + R9 C11) to energize and de-energize the solenoid 24. This circuitry of course eliminates the necessity for the solenoid switch 49 (SW3) thus simplifying the circuitry still further.
After the set period of time set by time control, potentiometer 56 (R14), IC2 stops conducting so that the voltage is practically 0 at point 59. This therefore switches off the astable multivibrator circuitry to stop the rocking action until the next time the device is actuated by operation of microphone 32.
Manual switching means 53A is also provided in the form of a spring-loaded pushbutton to trigger the timer switch circuitry 40 manually. The operation of the astable circuitry is once again controlled by the speed control potentiometer 44 (R16) R19, R9 and C11.
The integrated circuits used in FIG. 5 are as follows:
RC1 - CA3020 RC2 - NE555 or MC - NE555 MC - 1555RC3 - NE555 or MC1555
However, all three integrated circuits can of course be replaced by other integrated circuits on the market having similar operating characteristics.
Since various modifications can be made in my invention as hereinabove described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | Conventional crib rockers and the like are operated mechanically by means of an electric motor linkage and a timer mechanism connected to the cradle portion of the crib which is mounted in pivots upon the frame and they are normally switched on and off as required. The present device is electronically actuated and may be connected to a conventional crib which is often manually rocked by pushing and pulling on the foot or headboard to give the slight rocking action desired. The device is preferably actuated by a baby's voice picked up by a microphone or microphones and the periodicity and duration of the rocking may be adjusted within limits. It can also be set into motion by manual actuation of a switch. | 0 |
FIELD OF THE INVENTION
This invention is related to laboratory tests designed to identify and quantify the cholesterol ester transferring protein (CETP) in both biological and synthetic samples for clinical use, with the purpose of evaluating risk of atherogenesis and for use in research related to CETP.
BACKGROUND
In the 1970's, a definitive correlation was established between the levels and types of lipoproteins and heart disease. It has been observed that high levels of low density lipoproteins (LDL) can cause an increase in the incidence of heart disease, and that delay in the removal of these particles increases the time they remain in the plasma, exposes them to structural modifications and increases their interaction with the arterial walls. Furthermore, alterations in Apo B reduce the capacity of these particles to bind to their receptors and they are therefore largely recognized by macrophage receptors. The incapacity of the macrophages to regulate the internalization of modified LDL causes an accumulation of cholesterol esters and the formation of foam cells, a phenomenon that favors the development of atherogenesis.
Atherosclerosis is a phenomenon that begins in childhood and adolescence and progresses throughout life. Its consequences, such as arterial occlusion and its will known clinical manifestations (acute myocardial infarction, cerebral vascular accidents, gangrene of the lower limbs, etc.) begin many years before they are detected with the alteration of the vascular walls. Some patients who present serumal lipid levels that are higher than normal, also present a greater incidence of this type of ailment, as is the case of diabetics, nephropaths or congenital hyperlipidemics, among many others. In order to detect the possibility of these patients developing atherosclerosis and its clinical manifestations, the so-called “Coronary Risk Factors” are evaluated. These factors indicate the degree of exposure of the individual to circumstances that may determine a greater risk of presenting ailments related to this possibility; that is, they are used to determine the risk of atherogenesis. Coronary risk factors are as follows:
High low density total cholesterol and lipoproteins High blood pressure Smoking Diagnosis of ischemic cardiopathy Hypoalphalipoproteinemia (Low levels of high density lipoproteins or HDL) Diabetes Obesity Family history of premature heart disease Masculine sex Proteinuria Hypertriglyceridemia
In order to establish if the patient is exposed to coronary disease risk factors, directed interrogations, exploration, determination of the lipid profile, electrocardiogram and radiograph of the thorax are performed. When peripheral vascular insufficiency is suspected, a Doppler Ultrasound and arteriography are included.
All the elements considered in this evaluation are used in the detection and follow-up of patients who are within the so-called “risk groups”, which include individuals, who due to different pathologies, show one, some are all of the coronary risk factors. However, there is a large number of persons at risk from atherogenesis who have not been detected as they do not yet present the related clinical manifestations and therefore have not been placed within the risk groups. As there is no early diagnosis of these individuals, many valuable years of prevention are lost and when clinical manifestations do present themselves, the damage is mainly irreversible.
Furthermore, studies that assess atherogenesis risk factors based on the concentration of lipoproteins in the plasma of subjects included in some of the risk groups are inconsistent. Then, there are patients who are included in the risk groups who do not present the typical clinical description that denotes risk of atherogenesis, such as painless development with only a sensation of fatigue and lack of air, and some others go by unnoticed as they are confused with various pathologies. Hence, it is necessary to broaden the examination of the patient in the search for atypical manifestations.
There are also cases in which even when individuals are exposed to risk factors they do not develop atherosclerosis. Not all the factors to be assessed to determine the risk of atherogenesis are reliable. Some of the most widely discussed ones are included in the lipid profile, such as the high levels of total cholesterol and LDL and low levels of HDL in the blood, which are used to calculate the atherogenic index. This index is an arbitrary parameter that has experimentally proved to be unreliable in evaluating risk of atherogenesis: For example, in tests with rabbits submitted to diets high in cholesterol for long periods of time, high levels of total cholesterol, free cholesterol, esterified cholesterol and cholesterol associated with LDL, low levels of HDL associated cholesterol, hypertriglyceridemia, a high percentage of esterification and a high atherogenic index were obtained; however, they did not present atherogenesis.
In conclusion, the method for evaluating risk of atherogenesis used at present has severe limitations; first, the size and type of population likely to be evaluated is limited, due to the cost in time and money that is implied in carrying out the diagnosis tests and this makes the early detection of individuals at risk of atherogenesis who are not placed in risk groups difficult, therefore prevention of its complications is deficient. Second, even when the diagnosis parameters used at present allow certain certainty, most of them are qualitative and some of the quantitative parameters, the most important ones, are under discussion and it is therefore only possible to speak of a “high clinical suspicion of risk of atherosclerosis” since the results are not completely reliable. Third, not much is known about the homeostasis of lipids in humans and in mammals in general and it has not been possible to establish a clear relationship between many of the parameters considered as atherogenesis risk factors and their clinical manifestations, hence the determination of said risk cannot lie on solid bases, without a true understanding of the factors intervening in atherogenesis and their clinical manifestations.
There are other factors that can be useful in establishing the risk of atherogenesis in a more reliable way, such as the determination of the levels of the cholesterol ester transferring protein (CETP) in the plasma. This protein has been widely studied and is one of the best known factors intervening in lipid homeostasis. CETP has an important role in lipoprotein metabolism and in the development of arterial coronary disease, since it tends to generate high levels of LDL and VLDL that are associated with the progression of atherosclerosis (Marotti-K R, Castle-C K, Boyle-T P, Lin-A H, Murray-R W and Melchior-G W, 1993, Nature 364(6432):73-5). CETP is a multifunctional protein that promotes the exchange of cholesterol esters between HDL and LDL and the exchange of cholesterol esters and triacylglycerols between HDL and VLDL; its effect on the catabolism of HDL has an influence on its cholesterol ester content as well as on its composition, size and spherical structure (Rye-K A, Hime-N J & Barter-P J, 1995, J. Biol. Chem. 270(1):189-196) (Bruce-C, Chouinerd-R A y Tall-A R, 1998, Annu. Rev. Nutr. 18:297-330).
CETP also participates in the recycling of cholesterol deposited in the peripheral tissues during lipolysis of the lipoproteins (Jiang-XC, Moulin-P, Quinet-E, Goldberg-I J, Yacoub-L K, Agellon-L B, Compton-D, Schnitzer-Polokoff-R and Tall-A R, 1991, J. Biol. Chem. 266(7):4631-9) (Nagashima-M, McLean-J and Lawn-R, 1988, J. Lipid. Res. 29:1643-1649) (Tall-A, 1995, Annu. Rev. Biochem. 64:235-257). This transport, which we call “cholesterol reverse transport” confers on CETP the character of an anti-atherogenic protein, hence its importance in susceptibility or resistance to atherosclerosis (Kondo-I, Berg-K, Drayna-D, Lawn-R, 1989, Clin. Genet. 35(1): 49-56) (Bruce-C, Chouinerd-R A y Tall-A R, 1998, Annu. Rev. Nutr. 18:297-330). In accordance with the above, the factor that determines its anti-atherogenic capacity is not the level of HDL in plasma, but the distribution of sizes of its population, which has a strong correlation with CETP levels (Brown-M L, Inazu-A, Hesler-C B, Agellon-L B, Mann-C, Whitlock-M E, Marcel-Y L, Milne-R W, Koizumi-J, Mabuchi-H, 1989, Nature 342(6248):448-51).
In experimental work, it has been observed that mammal species lacking CETP in a normal way are resistant to developing arterial heart disease.
In contrast, in transgenic individuals of these same species that express CETP a decrease in size and HDL levels can be observed. As a consequence, CETP expression increases susceptibility to suffer from diet induced arterial heart disease (Rye-KA, Hime-NJ & Barter-PJ, 1995, J. Biol. Chem. 270(1):189-196). Similarly, it has been observed that humans with a genetic deficiency of CETP present HDL levels that are much higher than the levels of normal subjects (hypoalphalipoproteinemia). These individuals seem to have a lower incidence of heart disease (Inazu-A, Quinet-E M, Wang-S, Browun-M L, Stevenson-S, Barr-M L, Moulin-P and Tall-A R, 1992, Biochemistry 31(8):2352-8). However, transgenic mice with hypertriglyceridemia that express CETP are protected against atherogenesis (Homanics-G E, de Silva-H V, Osada-J, Zhang-S H, Wong-H, Borensztajin-J and Maeda-N, 1995, J. Biol. Chem. 269:16376-16382).
This invention is related to laboratory tests designed to identify and quantify the cholesterol ester transferring protein (CETP) in both biological and synthetic samples for clinical use, with the purpose of evaluating risk of atherogenesis and for use in research related to CETP.
BRIEF SUMMARY OF THE INVENTION
In accordance with the above, the atherogenic or anti-atherogenic character of CETP is established in correlation with the HDL level and can act as atherogenic agent by increasing levels of low density lipoproteins, removing HDL cholesterol esters to incorporate them into LDL and VLDL. The anti-atherogenic character of CETP is based on its capacity to accelerate the transfer of cholesterol in the peripheral tissues to incorporate it in HDL, that is, counteracting the atherogenic effect through the “Reverse Transport of Cholesterol”. We can therefore say that on evaluating CETP levels in correlation with the distribution of sizes and contents of cholesterol of the HDLs, its atherogenic or anti-atherogenic capacity can be established together with the risk of atherogenesis in all types of dyslipidemias. Based on the result of this test, it can be established if it is necessary or not to continue with the evaluation of the rest of the risk factors. Follow-up can also done of patients that have been diagnosed, evaluating the effectiveness of prevention programs or, where appropriate, the effectiveness of diets and/or treatments.
Even though there are references to other systems for the quantification of CETP in plasma, to date, given the nature of the equipment required, only methods whose technical complications restrict their use have been established. Such is the case of American U.S. Pat. No. 5,770,355, registered by Brocia, Robert W. In April 1998, entitled “Heart disease test kit and method of determining heart disease risk factor and efficacy of treatment for heart diseases”. This patent requires the synthesis of an artificial particle and the use of cholesterol joined to a fluorescent molecule, which limits its use to laboratories that have the equipment necessary to measure fluorescence.
The reason for the present invention is to provide a system to detect and quantify CETP levels in biological and synthetic samples in a simple, fast way, that will make it possible to improve detection, diagnosis and follow-up of individuals at risk of atherosclerosis, with or without clinical manifestations related to this is pathology, and that may or may not be included in risk groups. This will be done through the incorporation of this system into protocols and equipment routinely used in human and veterinary clinical laboratories.
DESCRIPTION OF THE FIGURES
FIG. 1 . Western-Blot type tests using the polyclonal antibody Anti-CETP H486-S496 against human plasma (lane A) and rabbit plasma (lane B). The polyclonal antibody Anti-CETP H486-S496 recognizes the CETP of ˜67 KDa. In tests with raw extracts depleted of lipids and perfused tissues exactly the same result was obtained. In order to discard the possibility of false positives in which the antibody recognizes albumin in plasma, controls against BSA (lane C) were included in all the tests. The result of these controls is negative, therefore the polyclonal antibody recognizes CETP specifically.
FIG. 2 . This figure shows a graph whose standard curve values were obtained using synthetic peptide H486-S496 and the result of CETP quantification in 25 samples of human plasma. According to these results, CETP levels in the sample group are found between 2 to 3 μg/ml, which is the equivalent of 28-31 pM/ml. These results were obtained with this system of CETP quantification.
DESCRIPTION OF THE SEQUENCES
SEQ ID NO: 1 Sequence. Sequence of sense oligonucleotides, compatible with the antisense oligonucleotide with SEQ ID NO: 2 sequence in PCR amplifications. It corresponds to the sequence from bases 1391 to 1414 in exon 15 of CETP mRNA. It is 24 nt long, G-C content 45.8%, fusion temperature 55.9° C.
SEQ ID NO: 2 Sequence. Antisense oligonucleotide sequence, compatible with the sense oligonucleotide with SEQ ID NO:1 sequence, in PCR amplifications. It is complementary to the sequence from bases 1852 to 1828 in exon 16 of CETP mRNA. It is 25 nt long, G-C content 48.0% fusion temperature 55.3° C.
SEQ ID NO: 3 Sequence. Nucleotide sequence of the CETP fragment recovered from the clone pMosBlueICETP3′ and subcloned in pGex-2T, generating clone pGex-2T/CETP3′. On subcloning the CETP fragment, three nucleotide of the pMos vector (underlined) are transported in such a way that the clone pGex-2T/CETP3′ includes these nucleotide between the region coding for GST and the one coding for CETP.
ID-4 Sequence. Amino acid sequence corresponding to the CETP section in recombinant protein GST/CETPCOH, coded by clone pGex2T-CETP 3′. This sequence corresponds to the last 33 residues of its carboxyl terminal, from I464 to S496, among which the residues F481, L488, F491 and L495 are included, which are important for maintaining cholesterol ester transfer activity (Tall-A, 1995, Annu. Rev. Biochem. 64:235-257). This epitope has a high content of alpha helix structure and includes the whole cholesterol ester binding motif (from G473 to S496) (Matsunaga-A, Araki -K, Moriyama-K, Handa-K, Arakawa-F, Nishi-K, Sasaki-J and Arakawa-K, 1993, Biochim. Biophys. Acta. 1166(1):131-4) (Wang-S, Wang-X, Deng-L, Rassart-E, Milne-RW, Tall-AR, 1993, J. Biol. Chem. 268(3):1955-9. The molecular weight (M.W.), isoelectric point (I.P.) and charge to pH7 were obtained with the help of the DNAstar program (Lasergene).
SEQ ID NO: 5 Sequence. Sequence of the synthetic CETP peptide H486-S496, designed for the production of the polyclonal antibody IgY Anti-CETP H486-S496. This peptide has a cysteine residue in the amino end that is used to join it to the transporting protein. The secondary structure was reported by Tall-A (1995), Annu. Rev. Biochem. 64:235-257 and confirmed by us with Chou-Fasman and Gamier-Robson algorithms. The peptide includes three of the four residues that are of special importance for conserving binding capacity to neutral lipids, these are F481, L488, F491 and L495. The molecular weight (M.W.), isoelectric point (P.I.) and charge to pH7 data were obtained with the help of the DNAstar program (Lasergene); the pH value with which the peptide becomes soluble in water was obtained experimentally.
DETAILED DESCRIPTION OF THE INVENTION
This invention consists of a system to detect and quantify CETP. The system requires the use of fused protein GST/CETPCOH, synthetic peptide CETP H486-S496 and polyclonal antibody H486-S496. The use of this system makes it possible to identify, evaluate and give follow-up to patients with dyslipidemias, whose effects are related to alterations in the level of CETP circulating in plasma with the purpose of evaluating their risk of developing atherosclerosis. This system is designed for use in clinical practice and/or research related to CETP. Samples of different origins, both biological and synthetic, can be used, preferably plasma or serum, cellular extracts or from tissues, culture media and purified or semi-purified antigens.
Fused Protein GST/CETPCOH
GST/CETPCOH has an approximate weight of 67 KDa, 3.7 KDa correspond to the CETP carboxyl terminal, the rest correspond to glutathione-S transferase. GST/CETPCOH is designed for use in both ELISA and Western-Blot tests, as a standard that permits the identification and quantification of CETP through the use of antibodies directed specifically against their carboxyl terminal.
The sequence of the section corresponding to CETP, in the fused protein GST/CETPCOH is presented as an ID-4 sequence. This covers the last 33 residues of the CETP carboxyl terminal, from I464 to S496, and has a high content of alpha helix structure and includes the whole cholesterol ester binding motive (from G473 to S496). In the design of the standard for the ELISA and Western-Blot tests, the CETP carboxyl end was chosen because it includes F481, L488, F491 and L495 residues and it has been experimentally demonstrated that these residues are of special importance for maintaining the cholesterol ester transfer activity (Wang-S, Kussie-P, Deng-L and Tall-A, 1995, J. Biol. Chem 270(2):612-618), (Jiang-X, Bruce-C, Cocke-T Wang-S, Boguski-M and Tall-A, Biocem. 34:7258-7263). (Matsunaga-A, Araki-K, Moriyama-K, Handa-K, Arakawa-F, Nishi-K, Sasaki-J and Arakawa-K, 1993, Biochim. Biophys. Acta. 1166(1): 131-4) (Wang-S, Wang-X, Deng-L, Rassart-E, Milne-R W, Tall-A R, 1993, J. Biol. Chem. 268(3):1955-9). In this way, the quantification of CETP will have as standard only the CETP carboxyl that includes the sites necessary for maintaining its binding capacity to cholesterol esters.
Another of the advantages of using this standard is that it does not require the purification of CETP from natural sources. Purification of the recombinant protein is simpler and faster than purification of CETP from plasma; a greater amount of recombinant protein can be obtained from bacterial cultures than CETP from plasma; the purity of recombinant preparations is greater than that of purifications of plasma, and greater purity reduces the risk of false positives and erroneous quantifications. The generation of recombinant proteins can be done under controlled conditions unlike those that occur in biological samples that depend on a large amount of variables and most of these cannot be controlled. Finally, the recombinant protein only includes the carboxyl end, and therefore it not only avoids a cross reaction against other proteins but against other CETP epitopes as well.
Design of Synthetic Peptide CETP H486-S496 and the Obtaining of Polyclonal Antibody Anti-CETP H486-S496.
The CETP detection and quantification system requires the use of an antibody specifically directed against the neutral lipids binding site in order to guarantee that only the CETP conserving this epitope will be detected and that therefore conserves the capacity to bind to neutral lipids, including cholesterol esters. We must add here that until now a large of mutations and alternative editions of cholesterol esters have been reported most of which do not translate or translate into proteins that do not secrete plasma. Only one of these CETP variations, depleted from exon nine (CETPΔ9), is poorly secreted into the extracellular medium (Quinet-E, Yang-T P, Marinos-C and Tall-A1993, J. Biol. Chem 268(23):16891-16894).
Although this CETPΔ9 version is inactive in lipid transfer, it conserves the neutral lipid binding epitope and therefore is potentially detectable by antibody Anti-CETP H486-S496; however, it is known that it is poorly secreted into the extracellular medium and there are no reports of its presence in plasma, hence its effect on CETP quantification using this system will be minimum or nil.
However, during research prior to this document, we found another version of CETP without the cholesterol esters binding motif (CETPAΔ16) and therefore without a neutral lipid binding capacity. This version of CETPAΔ16 can be found in large quantities in the plasma and could be detected by antibodies directed against any epitope of the original version of CETP, except for antibodies directed against the cholesterol ester binding motif.
Given the above, the antibody generated for this system should not recognize quantification of the CETPΔ16 variety, furthermore, it should avoid generating antibodies against any other protein present in mammal plasma and against any other CETP epitope; it is also a safety measure that avoids false positives and erroneous quantifications. For this reason, it was discarded as an antigen to complete, purified CETP of any mammal species and instead a synthetic peptide was designed as antigen. A synthetic peptide can be obtained with a high degree of purity and, depending on its design, it permits the generation of antibodies against a specific epitope.
In order to design this peptide, the RT-PCR product, amplified with a pair of oligonucleotides with SEQ ID NO: 1: and SEQ ID NO: 2: sequences, was sequenced. This sequence was translated to an amino acid sequence and analyzed with the help of the DNAstar program (Lasergene), from which the prediction of the Kyte-Doolittle type hydrophobicity index and the secondary structure were obtained with the Chou-Fasman and Garnier-Robson alrogithms.
Based on this information and on the characteristics required for this CETP quantification system, we designed the synthetic peptide, taking into account the following considerations:
It must be included within the neutral lipid binding motive. That is, among the last 26 residues of the CETP carboxyl (Wang-S, Deng-L, Milne-R S and Tall-A R, 1992, J. Biol. Chem. 267(25):17487-17490). In this way, the antibody can only recognize the CETP version that includes this epitope.
It must include the greatest possible number of residues reported as important to maintain lipid binding capacity. F481, L488, F491 and L495 residues important in the cholesterol ester transfer activity are included among the 26 amino acids of the lipid binding motive (Tall-A, 1995, Annu. Rev. Biochem. 64:235-257). With this, we not only focused recognition of the antibody against the neutral lipid binding motive but also against the residues that are most important in maintaining this capacity.
Its sequence does not have homology with other CETP epitopes or other proteins expressed in mammals or hens. Although antibodies can be obtained using any animal model that does not express CETP in order to obtain the adequate antibody for this system, hens are preferably used and in this way a strong immune response due to the phylogenetic difference is ensured. For this reason, peptide design must not permit homology with proteins expressed in hens. On the other hand, the antibody must recognize CETP only and only in an epitope, therefore the synthetic peptide should not have homology with other proteins or with any other CETP epitope.
Its size must permit the smallest possible number of recognition windows by the immune system. A peptide that fulfils this condition permits the generation of polyclonal antibodies that recognize specific epitopes with the same or greater precision than a monoclonal antibody.
It must have a cysteine residue in its amino end in order to direct its binding to the transporting protein. A cysteine residue in the amino end of the peptide makes it possible to direct its binding to a transporting protein so that all recognition windows for the immune system are exposed.
It must be in a region whose immune response has been proved. In earlier works, it was demonstrated that the carboxyl end of human CETP generates an immune response obtaining a monoclonal antibody against this motif (Swenso-T, Hesler-C B, Browun-M L, Quinet-E, Trotta-P P, Haslanger-M F, Gaeta-F C, Marcel-y l, Miline-R W and Tall-A R, 1989, J. Biol. Chem. 264:14318-14326). However, the recognition windows of this antibody have not been determined within the 26 amino acids that comprise this epitope. Due to the above, we could not discard the possibility of there existing non antigenic windows in this epitope and that one of them could coincide with the synthetic peptide sequence that we designed, and therefore our design was experimentally proved.
In accordance with the above, we designed synthetic peptide CETP H486-S496 whose sequence is shown as ID-5 sequence and that has the following characteristics: The peptide sequence is found within the cholesterol ester binding motif and corresponds to the sequence of residues H486 to S496 of rabbit CETP; that is, the last eleven residues of the protein, and therefore it is unable to recognize the CETPAΔ16 version. Its sequence includes three of the four residues that are of special importance in maintaining the lipid binding union: L488, F491 and L495. The synthetic peptide sequence does not have homology with other CETP epitopes or with other mammal or hen proteins, in contrast it presents high homology with the carboxyl terminal of CETP of several species: 100% with the rabbit, human and monkey and 90% with the hamster. Since the peptide is made up of only eleven residues, it presents only one recognition window to the immune system. A cysteine residue was added to the original CETP sequence in order to direct binding to the transporting protein. The antigenic capacity of the synthetic peptide CETP H486-S496 was demonstrated through obtaining polyclonal antibody Anti-CETP H486-S496.
In order to obtain polyclonal antibody Anti-CETP H486-S496, peptide CETP H486-S496 was joined to the KLH transporting protein. KLH was used instead of bovine serum albumin in order to avoid the generation of antibodies that would recognize the albumin present in plasma, which would give rise to false positives and erroneous quantifications in the test results. Antibodies are obtained in model animals, preferably LEGHORN white hens, that are subcutaneously inoculated once a week using a standard 63 day protocol. The titer of the antibodies in the plasma is determined using the ELISA technique. The ages in the eggs are isolated. In the case of using other model animals IgGs in the plasma are isolated. Although this antibody can be obtained from several model animals that do not express CETP, the titer in hens will be much higher.
It should be pointed out that due to the design of the synthetic peptide used as antigen, the polyclonal antibody generated for this system exclusively recognizes H486 to S496 residues within the cholesterol ester binding motive. This epitope includes three of the four residues that are of special importance in maintaining the lipid binding capacity: L488, F491 and L495. Furthermore it only has one recognition window and therefore has greater precision than the monoclonal antibody mentioned above. According to the design of the antigen and the experimental tests of the antibody, it does not recognize the CETPΔ16 version, other mammal or hen proteins or other CETP epitopes; nevertheless it can recognize the CETP of other species since the region chosen in the design of the antigen is highly conserved in several species of mammals.
Cross reaction tests were performed using ELISA and Western Blot techniques against the free and joined synthetic peptic, the recombinant protein GST/CETPCOH and bovine serumal albumin; with this the specificity of the antibody for its antigen was determined. As well as in the use of ELISA and the Western-Blot, this antibody could be used in the future in therapy protocols in patients with dyslipidemia, associated with CETP levels in plasma as well as in CETP purification systems and other proteins with homologue sequences to the carboxyl in this one.
System For CETP Detection and Quantification
The objective of this system is to detect and quantify CETP in the largest number of samples possible in a simple, rapid way. To do so the classic ELISA (Enzyme-Linked Immunosorbent Assay) method is used. As standards in this test, the recombinant protein GST/CETPCOH and/or synthetic peptide CETP H486-S496 is used. The control antigen as well as the samples to be quantified, preferably plasma or serum, are joined to the ELISA plate following the routine procedures of clinical laboratories.
If samples of plasma or serum are used, a sample of 20-5 pl is preferably required which does not need any previous treatment. The minimum level of detection of this system is 0.018 pM (1 pg) of CETP, the maximum level is 360 pM (20 μg). The standard curve suggested for human and rabbit plasma is:
(pM/100 μL)
0.250
0.166
0.125
0.100
0.083
0.071
0.062
0.055
An initial dilution of plasma or serum of 1:15,000, 100 μl per well is recommended. This dilution must be adjusted should the level of CETP in the sample exceed the limits of the curve.
Polyclonal antibody Anti-CETP H486-S496 is used as primary antibody to exclusively detect the motive responsible for the binding of neutral lipids to CETP in both standards and samples. Depending on the origin of the primary antibody, hen or mammal, the secondary antibody, preferably commercial, joined to peroxidase, Anti-IgY or Anti-IgG respectively, is chosen. In order to use the primary antibody in ELISA the preferable dilution is 1:5000. The secondary antibody must be preferably commercial, preferably joined to peroxidase, the dilution of the secondary antibody must be the one recommended by its manufacturer.
The maximum number of samples that can be handled by duplicate in each box is 39, in a protocol that includes the standard curve and a negative control. Experimentally, we have discarded false positives by means of the use of a combination of negative controls, but the negative control must be included in duplicate in order to consider the experimental error of the user of the system.
Since CETP is highly conserved in mammals, the system is able to recognize CETP in the plasma of species that express CETP in a natural way or of transgenic species with this gene, providing homology with the last 11 residues of the carboxyl terminal is conserved. For this reason, this system is used in human and veterinarian clinical work.
Kit For the Quantification of the Cholesterol Transferring Protein in Biological Samples
The system described above is the basis for the design of a diagnostic kit, of use in determining CETP levels in a large number of samples that is quick and simple to use, and which does not exist to date. This kit is designed for clinical use, preferably using plasma or serum samples from species that express CETP in a natural way or transgenic species with this gene. They must conserve homology in the last 11 amino acids of the carboxyl end.
This kit can be easily adapted to samples of different origins, both biological and synthetic, for both the human or veterinarian clinical laboratory and for various research uses.
The kit is composed of:
Solutions
PBS 10×
Binding buffer, pH 9.6 50 mM(Na 2 CO 3 35 mM+NaCO 3 15 mM+NaN 3 20 μg/ml)
Phosphate-Citrate Buffer Phosphate of Na- Ac. Citric 0.05M, pH 5
Antigens
Recombinant protein GST/CETPCOH
Synthetic peptide CETP H486-S496
Antibody
1st Antibody IgY or IgG Anti-CETP H486-S496
Procedure
1. The control antigen (GST/CETPCOH and/or CETP H486-S496) as well as the standard curve are diluted in 100 μl of binding buffer.
2. Join antigens and samples to the ELISA plate, incubating for 2 hrs at 37° C.
3. Remove the antigens and block with 200 μl of Ovoalbumin 0.5 mg/ml, in a carbonate buffer for 1 hr at 37° C. At the end of the incubation, wash four times with 0.1% PBS-Tween (PBST).
4. Incubate with 100 μl of Anti-CETP H486-S496, in a dilution of 1:5000 in PBST, for 1 hr, at 37° C. At the end of the incubation, wash four times with PBST.
5. Incubate with 100 μl of the secondary antibody joined to peroxidase, Anti-IgY or Anti-IgG, as the case may be, at the dilution recommended by the manufacturer in PBST. Incubate for 1 hr at 37° C. At the end of the incubation, wash four times with PBST and twice with H 2 O.
6. Develop with 100 μl of substrate for peroxidase, preferably OPD, in the conditions recommended by the manufacturer.
7. Incubate for 20 min in darkness, stop the reaction with 50 μl of H 2 SO 4 1.5M to read at 490 nm.
The whole procedure is done with the ELISA plate covered, avoiding temperature gradients.
By including CETP quantification among the parameters for diagnosing atherogenesis risk, the certainty of diagnosis is increased significantly, since it is a quantitative parameter that has been able to establish a clear relationship with many of the parameters considered as atherogenesis risk factors and their clinical manifestations. For this reason, in order to facilitate the implementation of this system in clinics, we designed the Kit described above. The ease of use of this kit permits its routine use in clinical practice, making it possible to identify individuals who have no clinical manifestations of atherosclerosis and do not fall within the risk groups. The foregoing facilitates the detection of individuals at risk of non-diagnosed atherogenesis or with atypical syndromes. It also facilitates the diagnosis and follow-up of patients and the evaluation of the effectiveness of the treatments they are given.
Comments
The tools generated in the development of this CETP quantification Kit can have different uses. The oligonucleotides with SEQ ID NO: 1: and SEQ ID NO: 2: sequences were designed for use in amplifications by PCR, however, they can also be used as molecular probes against DNA and PCR products containing their sequence. The oligonucleotide with SEQ ID NO: 2 sequence can also be used as a probe against the CETP messenger, but not the SEQ ID NO: 1 sequence oligonucleotide. Both can be tools in future work, in both research and in the treatment of patients with dyslipidemias, related to CETP expression.
The clones pMosBlue/CETP3′ and pGex2T/CETP3′ can also be used to obtain specific probes against DNA, mRNA and CETP RCR products. The clone pMosBlue/CETP3′ can be used to subclone the cDNA fragment of CETP in other vectors for different purposes, from obtaining probes and other recombinant proteins to experimental protocols for the treatment of patients with dyslipidemias related to CETP. The clone pGex2T/CETP3′ can also be used for subcloning and for obtaining recombinant protein GST/CETPCOH in large amounts and in a soluble form by means of a simple, cheap method.
Recombinant protein GST/CETPCOH is designed for use as standard in both ELISA and Western-Blot tests in clinical practice that permits the identification and quantification of CETP by means of the use of antibodies directed specifically against the carboxyl terminal. In Western-Blot type tests it is a positive standard and/or control that is easy to manage, that would not be possible with proteins or low weight peptides. The obtaining of this fused or recombinant protein provides a standard for the identification and quantification of CETP that is more reliable than those purified from natural sources. This recombinant protein also has applications in the research area, for example, in structure studies with high resolution systems such as crystallography of X-Rays; in activity studies since it contains the epitope that gives the capacity to bind to lipids; in affinity chromatography for the purification of antibodies or other molecules similar to the carboxyl terminal of CETP; in the production of antibodies against the CETP carboxyl, without the need to bind to transporting proteins, among many others.
The synthetic peptide CETP H486-S496, is useful not only for the production of antibodies and as a standard in the ELISA protocol, but it can also be an important tool in structure and activity studies.
The use of the CETP detection and quantification system makes it possible to identify, evaluate and give follow-up to patients with dyslipidemias, whose effects are related to alterations at the level of CETP circulating in the plasma, with the purpose of evaluating the risk of atherogenesis. This system will facilitate the handling of a large number of samples in a quick, simple way, permitting the routine use of this test in human and veterinary clinical laboratories and in this way the size of the population that can be evaluated is expanded. Although it preferably uses plasma or serum samples, it can also be adapted for use with cell or tissue extracts, culture media, purified or semi-purified antigens, etc., which enormously increases its field of use in research.
The use of the kit can be extended to research into the facts and phenomena involved in lipid homeostasis, as well as in the study of the physical, chemical and biological characteristics of CETP and molecules related to it, using samples obtained from experimental biological or non-biological models, preferably extracts of tissues, organs or cells in culture, culture media, recombinant proteins and synthetic peptides.
Examples Of Use
1.—Oligonucleotide Design:
Taking as model the New Zealand white rabbit ( Oryctolagus cuniculus ), total RNA from the liver was obtained using the method described by Sumikawa-K; Parker-I and Miledi-R (1989, Methods in Neurosciences 1:30-45), the RNA poly(A + ) fragment was isolated using chromatography in the oligo(dt)-cellulose method. cDNA was synthesized using the commercial system for RT-PCR (Perkin Elmer), using mRNA from the liver. For the RT-PCR protocol, a set of oligonucleotides was designed with the help of the Mac Vector program. The oligonucleotide design allows for the specific amplification of the 3′ end of the cDNA of CETP, which is specially difficult given the characteristics of the cDNA sequence characteristics of CETP, the most determining of which is its high content of G-C (over 65%). As a result of the above, the following parameters were established in the design of the oligonucleotides used in the PCR protocol:
SEQUENCE: cDNA of rabbit CETP, published by Nagashima-M, McLean-J and Lawn-R in 1988 ( J. Lipid. Res. 29:1643-1649). SEQUENCE ANALYZED: from nucleotide 1 to nucleotide 1870. SIZE OF OLIGONUCLEOTIDES: from 18 to 30 bases. FUSION TEMPERATURE: 55-80° C. G-C CONTENT: 45-55%. PRODUCT SIZE: 400-1000 pb. MAXIMUM COHERENCE NUMBER IN CONSECUTIVE BASES:
Oligonucleotide Versus Oligonucleotide (any)=4. Oligonucleotide Versus Oligonucleotide (only G-C)=2. 3′ end versus 3′ end=2.
No Restriction Sites Were Adapted Or Added.
This design allows only one option of sense oligonucleotides near to the 3′ end and one of the antisense oligonucleotides that it is compatible with. The sequences in this set of oligonucleotides are shown as SEQ ID NO: 1 sequence (sense oligonucleotide) and SEQ ID NO: 2 sequence (antisense oligonucleotide). This set of oligonucleotides generates a product of 462 bp, from bases 1391 to 1852, that extends from the 3′ end of exon 15 to the non-coding region of exon 16 of the CETP mRNA. The temperature for optimum alignment is 59.9° C., the percentage of G-C 60.4% and fusion temperature 83.2° C.
2.—Cloning the C-terminal End of CETP
The PCR product generated by this set of oligonucleotides was cloned in the pMosBlueT vector (Amersham). This strategy made it possible to integrate the BamHI and SmaI restriction sites to the PCR product in order to permit their subcloning in the pGex-2T expression vector (Pharmacia LKB Biothec), in the correct orientation and reading framework for the expression of the fused protein. In this way, two recombinant plasmids cloned with the 3′ end of the cDNA of CETP, called clone pMosBlue/CETP3′ and clone pGex-2T/CETP3′, were generated.
The clone pGex-2T/CETP3′ was transformed in the bacterial strain Escherichia coli DH5α, in order to obtain recombinant proteins fused to glutathion-S Transferase (GST). The transformed strain is cultivated for 8 hrs at 37° C., in 500 ml of Super Luria culture medium with 50 μg/ml of ampicillin added. Culture induction is conducted with 0.4 mM of IPTG for three hours. After incubation, the bacteria are mechanically lysed and the fused protein GST/CETPCOH is recovered in a Glutathion-Agarose column (SIGMA), using a known protocol (Smith-DB and Corcoran-LM, 1995, Expression and Purification of Glutathion-S Transferase Fusion Proteins. In Short Protocols in Molecular Biology [Ausbel-MF, Brent-R, KingstonRE, Moore-DDR, Seidman-JG and Strhl-K], WILEY, 3rd ed. pp16.18-16.31).
3.—Obtaining Antibodies of the IgY Anti-CETP Type
The peptides joined to KLH were used for the production of the antibodies, preferably in hens, using a standard 63 day protocol, inoculating them subcutaneously once a week. The inocula consisted of 200 μg BSA/200 μl PBS+200 μl of complete Freund adjuvant (Sigma Inmuno Chemicals) in the first application and 200 μg BSA/150 μl PBS+150 μl of incomplete Freund adjuvant (Sigma Inmuno Chemicals) in subsequent applications. The antibody titer in the plasma was determined by the ELISA technique. The IgYs were isolated from eggs collected over 2 weeks. Both the binding and the production of antibodies and titration using ELISA of the first plasma sample was done with ADI (Alpha Diagnostic International).
4.—Western-Blot Assay for the Detection of CETP
The conditions of use of the polyclonal antibody Anti-CETP H486-S496 were standardized in Western-Blot type tests against human and rabbit plasma and raw and depleted lipid extracts from perfused tissues. The primary antibody in 1:5,000 dilutions and the secondary antibody Anti-Chicken IgG, (H+L) conjugated with peroxidase (PIERCE) 1:10,000 were used. Both the blocks and the incubations were done with a 2.5% powdered skimmed mild suspension in 0.1% TBS-Tween at 37.degree. C., for 1 hr. Visualization was done with SuperSignal Substrate (PIRCE) in X-OMAT autoradiographic plates (Kodak), for the quantitative or qualitative determination of CETP. BSA was used as a negative control in these tests. In order to discard the possibility of the antibody unspecifically recognizing albumin, whose molecular weight is close to CETP (.about.67 KDa), negative controls with BSA were included. In all the tests run, antibody Anti-CETP H486-S496 specifically recognizes CETP. The results of these tests can be seen in FIG. 1 .
5.—ELISA Assay For the Detection of CETP
The conditions of use of polyclonal antibody Anti-CETP H486-S496 in ELISA tests against human and rabbit plasma were standardized. Primary antibody in dilutions of 1:2,000, and secondary antibody Anti-Chicken IgG, (H+L) conjugated with peroxidase (PIRCE) 1:2,000 were used. Both the blocks and the incubations were done with 0.1% PBS-Tween at room temperature for 1 hr. Visualization was done with OPD (o-Phenylenediamine Dihydrochloride, SIGMA). The O.D. readings were done at 450 nm. BSA was used as a negative control in these tests. In order to discard the possibility that the antibody unspecifically recognizes albumin, negative controls with BSA were included. Some results obtained with this CETP quantification system are shown in FIG. 2 . | The invention relates to an immunoenzymatic method for the quantification of protein CETP in plasma, which requires the utilization of fusion protein GST/CETP, the synthetic peptide CETP 11486-S496 and polyclonal antibody anti-CEPT 11486-S496. The method is used in the study of pathologies involving alterations in the CETP levels in plasma or in seric lipids and makes it possible to detect, evaluate and follow-up patients suffering from dyslipidemia and/or risk of altergenesis. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to the processing of cottonseeds, and more particularly, to the removing of lint or linters from the seeds.
In the processing of cotton, cotton picked from its plant is ginned so as to remove the long, staple fibers from the seeds. The seeds are then processed so as to remove remaining lint or linters, used as a cellulosic material in industry. The delinted cottonseed is then processed to separate the meat from the hulls with oil extracted from the meat and the meat then used as livestock feed and the like.
DESCRIPTION OF THE PRIOR ART
Seed delinting apparatus for removing lint fibers from cottonseeds and the like have been known, but none have performed entirely satisfactorily.
Some of the prior art have employed a series of cylindrical saws that effect a clawing action to remove the lint from the seeds. These saw type delinters have been noisy in operation and chip and scale small particles of the outer pigment layer of the seed coat resulting in contamination of the lint. Such contamination reduces the quality and value of the lint.
Brush type delinters cause excessive breakage of the seed also resulting in lint contamination and clogging of the brushes resulting in operational difficulties. Some of these processes are disclosed in U.S. Pat. Nos. 2,644,986 and 2,724,148.
U.S. Pat. No. 3,805,332 discloses an apparatus for delinting cottonseed lined with abrasive material and employing a rotor disposed within the casing to force the seeds along a generally spiral path in contact with the abrasive material. An air stream passing through the casing entrains the lint and carries it through the lint outlets.
SUMMARY OF THE INVENTION
In accordance with the invention claimed, a new and improved apparatus is disclosed for delinting cottonseed. This apparatus employs a delinting chamber consisting of a generally cylindrical casing which is at least partially tapered and at least partially covered with abrasive material, and a revolving drum surrounding the abrasive roll. The revolving drum is at least partially covered with perforated metal, wire mesh, or other material suitable to allow immediate passage of the lint as it is detached from the seeds and yet retain the seeds in a position close to the abrasive roll. The revolving drum rotates past at least one air nozzle or hood which immediately removes the lint from the apparatus as the lint passes through the drum. An undelinted seed chute is employed to introduce the undelinted seeds into a feeder roll having a helical flight to force feed the seeds into the delinting chamber.
It is, therefore, one object of this invention to provide a new and improved cottonseed delinter device which will effect substantially complete separation of the lint from the seed.
Another object of this invention is to provide a new and improved cottonseed delinter apparatus employing an abrasive roll in cooperation with a revolving wire mesh drum for removing lint from the seeds with minimum damage to the seeds.
A further object of the invention is to provide a seed delinter employing an abrasive roll within a revolving wire mesh drum, the cooperating parts of which are relatively adjustable to compensate for wear of the abrasive roll.
A still further object of this invention is to provide a conveyor system extending along the length of its casing for separating and removing trash from the lint.
Further objects and advantages of the invention will become apparent as the following description proceeds and the features of novelty which characterize this invention will be pointed out with particularity in the claims annexed to and forming a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be more readily described by reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a seed delinter embodying the invention;
FIG. 2 is a cross-sectional view of FIG. 1 taken along the line 2--2;
FIG. 3 is an enlarged view of the circled area of FIG. 2 given the reference character 3;
FIG. 4 is a cross-sectional view of FIG. 2 taken along the line 4--4;
FIG. 5 is a cross-sectional view of FIG. 2 taken along the line 5--5; and
FIG. 6 is a cross-sectional view of FIG. 2 taken along the line 6--6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawing by characters of reference, FIGS. 1-6 disclose a seed delinter 10 comprising an elongated housing 11 preferably enclosed at both ends by plates 12 and 13, as shown in FIGS. 1 and 2. The sides 14 and 15 of housing 11 may be of any suitable elongated geometrical form enclosing within them and spaced therefrom a generally cylindrical hood 16 which fits around and substantially encloses the seed delinting apparatus.
The seed delinting apparatus comprises a metallic shaft 17 extending longitudinally through housing 11 and its end plates 12 and 13 and is journaled at each end in suitable bearings 18 and 19 attached to each end of the housing.
An abrasive roll 20 is formed on shaft 17 by the assembly thereon of a plurality of disc or sleeve shaped segments illustrated in FIG. 2 as 20A-20J, but not being limited to a specific quantity. At least one of the abrasive segments is conical in shape as illustrated by segments 20A and 20J and the arrangement of said segments is not limited to that shown. The left end of shaft 17 is provided with a drum shaped configuration 21 of a diameter substantially equal to the smallest diameter of segment 20A with its outer surface 22 provided with a plurality of helical ridges 23 which are intended to convey undelinted seeds 24 dropped from a suitable feeder through an opening 25 formed in housing 11 onto the outer surface 22 of the drum shaped configuration 21 which are then conveyed over the outer surface of segments 20A-20J of the abrasive roll formed thereby from left to right, as shown in FIG. 2.
As may be seen in FIG. 2, shaft 17 is rotatably journaled within housing 11 with a pulley 26 attached to its left end with suitable belts coacting with the pulley of a motor (not shown) for purposes of driving the abrasive roll 20.
As shown in FIGS. 2, 4, 5 and 6, a revolving wire mesh or perforated drum 27 is coaxially mounted around a rotor or roll 20 for holding the seed, such as cottonseed, close to the outer surface of the abrasive roll 20 while it is rotating so as to cause removal of the lint from the cottonseed by abrasive action.
The drum 27 is adjustably mounted within housing 11 so that its mesh wire surface may be moved close to the outer periphery of the abrasive roll 20 as the diameter of the segments 20A-20J decrease as a result of wear.
It should be noted that an annular space 28 is provided between the outer periphery of the segments 20A-20H of the roll 20 and the interior surface of the wire mesh forming the drum 27. This annular space 28 should be greater than the average minor dimension of the seeds being processed and preferably is of a width of about 1/2 of an inch to about 1 inch for cottonseed so as to provide sufficient but not excessive clearance between the wire mesh of drum 27 and the outer surface of the abrasive segments 20A-20J so that the seeds are not crushed or broken as they pass longitudinally through this annular space 28. If excessive clearance is provided between mesh surface of drum 27 and the abrasive segments 20A-20J, the seeds will not make intimate contact with the abrasive material for purposes of separating lint from the seed.
Thus, as the seed is dropped from a suitable feeder (not shown) through the opening 25 onto the outer surface of drum shaped configuration 21, it is moved by the helical ridges 23 on drum shaped configuration 21 through the annular space 28 in substantially tangential relationship to the inner surface of the wire mesh of drum 27 and the outer surface of roll 20.
A seed outlet 29 is formed at the right end of the delinter, as shown in FIG. 2, for withdrawing the delinted seed from the apparatus. A cover 30 may be adjusted to increase or decrease the open area of the seed outlet 29 depending upon the amount of seed to be retained within delinter 10 for a given length of time. As shown in FIG. 2, the seeds passing through the seed outlet pass downwardly and out of housing 11 through a chute 31 into a suitable receptacle (not shown).
With regard to the drum shaped configuration 21 and its helical ridges 23, feeding of the seeds through the delinter may occur at a fixed rate and with cover 30 open, the seeds pass through the delinter in a thin layer and in a relatively short time. At the same feed rate, if cover 30 is partially closed, the layer of seed in the delinter becomes more dense and thicker and remains in the delinter a longer period of time. Thus, the cover 30 may be adjusted to hold seed in the delinter long enough to take off the desired amount of lint from the seed.
In accordance with the invention disclosed, the wire mesh drum 27 is axially mounted around roll 20 formed by the abrasive segments 20A-20J and is adjustably held in a given arrangement therewith by a plurality of guide rollers 32.
The wire mesh drum 27 is rotated relative to the mandrel formed by the abrasive segments 20A-20J forming roll 20 and may be rotated in the same direction as the rotation of roll 20 at approximately 10 percent of the speed of rotation of roll 20. For example, the wire mesh drum may rotate at a speed of approximately 15 to 45 RPM with an abrasive roll 20 having approximately a 24 inch diameter rotating at approximately 150 to 450 RPM.
The wire mesh drum 27 is rotated by an electric motor 33 through a drive shaft 34 and its associated sprocket 35, sprocket chain 36 and sprocket wheel 37 mounted on the left end of the wire mesh drum, as shown in FIGS. 2 and 6.
As noted from FIG. 4, cylindrical hood 16 is mounted to surround at least the top half of the coaxially mounted roll 20 and wire mesh drum 27. The bottom portion of the hood is open for receiving a flow of air which is drawn into the housing 11 through a pair of openings 38 and 39, located longitudinally along each side of the housing. The openings 38 and 39 are each controlled by a hinged cover or door 40 and 41, respectively, and forming a part of the surface of the sides 14 and 15 of housing 11. A pair of baffles 42 and 43 mounted inside the lower porton 44 of housing 11 direct the air introduced or drawn into the housing into the annular space 45 formed between the outer periphery of the wire mesh drum 27 and the inside surface of hood 16. Some of the indrawn air also passes through the annular space 28 between the outer periphery of roll 20 and inner surface of the wire mesh drum 27. As the air passes upward through annular spaces 28 and 45, it becomes laden with lint that is being removed from the cottonseed and then exits through the housing 11 by means of an exhaust port 46 at the top of the hood 16. A fan, cyclone collector, and corresponding duct work is appropriately attached to exhaust port 46 so as to create the air flow heretowith described and provide means of collecting the lint.
Referring to FIGS. 2 and 4, a motes outlet 47 is formed at the bottom of the wire mesh screen and preferably extends substantially the length of the roll 20. In forming the motes outlet, the walls of the lower portion 44 of housing 11 taper inwardly forming a trough 48 within which is mounted a conveyor in the form of an auger 49 which move motes falling thereon to the right end of the trough, as shown in FIG. 2, and into an outlet 50 which communicates with a suitable receiver.
As the seeds enter the delinting apparatus and move along and around the outer periphery of the abrasive segments 20A-20J and held thereon by the rotating wire mesh drum 27, they travel in a circular spiral path from the left to the right of the delinter, as shown in FIG. 2. As the seed moves along this path rubbing on the abrasive surface of the segments back and forth between it and the wire mesh drum 27, the lint is dislodged from the seeds and is entrained in the air stream moving through the delinter which carries it out of the apparatus, passing through exhaust port 46 and into the attached duct work (not shown).
As the abrasive segments 20A-20J wear, and the diameter of the mandrel formed, thereby reducing in size, the diameter of the wire mesh drum 27 is adjusted to compensate for this wearing activity thereby keeping the annular space 28 substantially the same along the perimeter of the roll 20 where the delinting action takes place.
As the seeds make their way around the interior of the housing and toward the end thereof, trash particles, such as dirt, hulls, meats and the like, fall between the mesh of drum 27 to be collected in trough 48 and drawn by auger 49 into outlet 50.
As will now be appreciated in view of the foregoing description of the preferred embodiment, the disclosed delinter apparatus provides a relatively noiseless and energy efficient means of delinting cottonseed as compared with some conventional equipment. The rotor assembly of the roll segment structure moves the seeds through the device with minimal hold-up time thereby enhancing the quality of the lint by minimizing the absorbtion of seed oils, reducing seed breakage and pluggage of the wire mesh screen of drum 27.
Although but one embodiment of the present invention has been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims. | An apparatus for delinting cottonseed employing an abrasive surface rotor having a wire mesh drum coaxially mounted therearound defining an annular space therebetween and both mounted for rotation relative to each other, means for forcing cottonseeds into said annular space and in contact with said abrasive surface to remove lint therefrom and out of a controlled seed outlet, and an air stream passing through said annular space and out of said apparatus with lint entrained within it and means for trash to drop through spacings of the wire mesh drum onto a conveyor. | 3 |
This application is based on Japanese Patent Application No. 11-156675 filed Jun. 3, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrically operated power steering apparatus in which a drive force of a motor assists a required value of steering torque applied to a steering wheel operated by an operator of an automotive vehicle.
2. Discussion of the Related Art
An electrically operated power steering apparatus for an automotive vehicle is generally constructed to include (a) a torque transmitting system transmitting steering torque which is applied to a steering wheel by a vehicle operator, to a steerable wheel of the vehicle laying on a road surface, so as to assist the steering torque, (b) a motor applying a drive force thereof to the torque transmitting system, and (c) a controlling device controlling an electric power supply to the motor.
Japanese Patent Publication No. 10-100913 discloses an example of a conventional type of the electrically operated power steering apparatus identified above. In this example, the temperature of a winding of a motor is estimated on the basis of a voltage and a current value of the motor, without the provision of a temperature sensor detecting a temperature of the motor. The estimated temperature results in preventing overheat of the motor.
However, in general, what can be accurately estimated in relation to the temperature of a winding of a motor by the use of a voltage and a current value of the motor is an increase of temperature of the motor winding at each one of a plurality of discrete points of time after a reference point of time. The increase is calculated from the temperature of the heated portion obtained at the reference point of time. The increase is a relative value, not an absolute value of temperature of the motor winding. In addition, the example explained above is not designed to detect or estimate an absolute value of temperature of the motor winding at the reference point of time. Consequently, this example fails to obtain the temperature of the motor with an adequately high precision.
In the case where a temperature sensor is arranged sufficiently near a winding of a motor, the temperature of the motor can be sequentially detected at a high precision. However, in this case, since such a temperature senor is generally expensive, there arises a problem that the substantial increase in the cost of an electrically operated power steering apparatus is unavoidable.
In addition, a problem of generation of heat as a result of a supply of an electric power to a motor arises about the motor in an electrically operated power steering apparatus, but the same problem can also arise about other electrical parts of the apparatus.
BRIEF SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an electrically operated power steering apparatus in which the temperature of a heated portion of the apparatus which emits heat as a result of a supply of electric power to a motor can be more precisely obtained in lower cost.
The object may be achieved according to any one of the following modes of this invention. Each of these modes of the invention is numbered like the appended claims, and depends from the other mode or modes, where appropriate. This type of explanation about the present invention is for better understanding of some ones of a plurality of technical features and a plurality of combinations thereof disclosed in this specification, and does not mean that the plurality of technical feature and the plurality of combinations in this specification are interpreted to encompass only the following modes of this invention:
(1) An electrically operated power steering apparatus for an automotive vehicle having a steering wheel to be operated by an operator of the vehicle and a steerable wheel thereof laying on a road surface, comprising:
a torque transmitting system transmitting a steering torque which is applied to the steering wheel by the operator, to the steerable wheels;
a motor applying a drive force thereof to the torque transmitting system so as to assist the steering torque;
a controlling device controlling an electric power supply to the motor, thereby permitting reduction in a required value of the steering torque with the assist of the drive force of the motor; and
a power supply restricting device utilizing a temperature of a heated portion of the electrically operated power steering apparatus which emits heat as a result of the electric power supply to the motor, at a reference point of time, as an initial temperature of the heated portion, utilizing a plurality of electric power-related values each of which is related to at least one of a current and a voltage value of the motor, as a plurality of physical quantities related to temperature increases of the heated portion each of which is an increase of the temperature of the heated portion from that at the reference point of time, and restricting the electric power supply to the motor such that an actual value of the temperature of the heated portion does not exceed a predetermined upper limit thereof.
In general, the temperature of the heated portion, if not changed or gently changed, forms a constant relationship thereof with an ambient temperature of the heated portion. In addition, the ambient temperature of the heated portion can be detected without using a temperature sensor exclusively used for detection of the temperature of the heated portion. Accordingly, the temperature of the heated portion, if not changed or gently changed, can be easily detected or estimated.
The use of at least one of a current and a voltage value of the motor permits estimation of an increase of the temperature of the heated portion from that at a reference point of time. In addition, control of the motor is usually effected with feedback of at least one of a current and a voltage value of the motor. Therefore, a sensor detecting at least one of a current and a voltage value of the motor is usually provided with the electrically operated power steering apparatus. Consequently, in many cases, at least one of a current and a voltage value of the motor can be easily detected.
There exists a technology of using the temperature of the heated portion detected or estimated in the manner mentioned above, as an initial temperature of the heated portion. There also exists a technology of using at least one of a current and a voltage value of the motor as a physical quantity related to an increase of the temperature of the heated portion from that at a time when the initial temperature of the heated portion has been obtained. These two technologies can cooperate with each other to estimate the temperature of the heated portion at each one of a plurality of discrete points of time after the initial temperature of the heated portion has been obtained.
Based on the above findings, the apparatus according to this mode ( 1 ) utilizes the temperature of the heated portion at a reference point of time as an initial temperature of the heated portion, and utilizes at least one of a current and a voltage value of the motor as a physical quantity related to an increase of the temperature of the heated portion from that at the reference point of time. Further, the apparatus according to this mode ( 1 ) restricts an electric power supply to the motor so as to prevent an actual value of the temperature of the heated portion from exceeding a predetermined upper limit of the temperature of the heated portion.
Consequently, in the apparatus according to this mode ( 1 ), it is not indispensable to employ a temperature sensor which exclusively detects the temperature of the heated portion with a high precision and which is expensive. Therefore, a substantial increase in the cost of the apparatus resulting from the addition of a function of obtaining the temperature of the heated portion to an electrically operated power steering apparatus can be easily avoided.
Further, in the apparatus according to this mode ( 1 ), a determination as to whether the restriction on the electric power supply to the motor is necessary or not is performed using both of an initial value and a subsequent increase of the temperature of the heated portion from the initial value, both of which are reflected by the actual condition of the heated portion. As a result, the presence of an unnecessary restriction on the electric power supply at lower temperature of the heated portion can be easily avoided, and the absence of a necessary restriction on the electric power supply at higher temperature of the heated portion can also be easily avoided.
The apparatus according to this mode ( 1 ) may be adapted to include a temperature sensor capable of precisely detecting the temperature of the heated portion as long as the temperature is substantially in a stable condition thereof. The apparatus according to this mode ( 1 ) may be also adapted to include a temperature sensor capable of precisely detecting the temperature of the heated portion not only in a stable condition thereof but also in a transitional condition thereof.
In the apparatus according to this mode ( 1 ), the heated portion may be defined as the motor, a switching element connected to the motor and a power supply to the motor, at least one of a plurality of media for transferring current from the power supply to the motor, including such as a wire, a connector, etc., for example. The heated portion also may be defined as at least one of the plurality of media which is especially required to be prevented from being overheated.
In the apparatus according to this mode ( 1 ), the torque transmitting system is generally constructed to include (a) a steering shaft rotatable with the steering wheel, (b) an axially movable steering rod permitting the orientation of the steerable wheel to change, and (c) a coupling device operatively coupling the steering shaft and steering rod such that a rotary motion of the steering shaft is converted into a linear motion of the steering rod. In this arrangement, the motor is engaged to at least one of the steering shaft, steering rod and coupling device so as to apply to the at least one of these three elements a drive force of the motor for assisting the steering torque of the steering wheel applied by the vehicle operator.
In the apparatus according to this mode ( 1 ), the restriction on the electric power supply may be effected by reducing an actual and absolute value of current (i.e., electric current) of the motor to a certain value. The certain value is smaller than a nominal value of current of the motor available when the restriction on the electric power supply is unnecessary, but is not equal to zero. The restriction on the electric power supply also may be effected by reducing the actual and absolute value to zero.
(2) The apparatus according to the above mode ( 1 ), wherein the power supply restricting device comprises:
a temperature estimating means for repeating obtaining one of the plurality of electric power-related values after the reference point of time, for obtaining a sum of the plurality of electric power-related values which have been already obtained, each time a new one of the plurality of electric power-related values has been obtained, the obtained sum being defined as an integrated value of the already obtained plurality of electric power-related values, for estimating the temperature increase of the heated portion on the basis of the obtained integrated value, and for estimating the temperature of the heated portion at each one of a plurality of discrete points of time after the reference point of time, on the basis of the initial temperature and the estimated temperature increase of the heated portion; and
a power supply restricting means for restricting the electric power supply to the motor such that the actual value of the temperature of the heated portion does not exceed the predetermined upper limit, on the basis of the estimated temperature of the heated portion.
In the apparatus according to this mode ( 2 ), an increase of the temperature of the heated portion is estimated on the basis of an integrated value of a plurality of electric power-related values. As a result, the temperature increase of the heated portion is estimated by the adequate consideration of a time-dependent change in the electric power-related value. Therefore, in the apparatus according to this mode ( 2 ), the precision in estimation of the temperature increase of the heated portion is improved, resulting in another improvement in estimation of the temperature of the heating portion.
(3) The apparatus according to the above mode ( 2 ), wherein the power supply restricting means comprises a restricting amount determining means for, when the estimated temperature of the heated portion has reached a reference temperature formulated to be lower than the predetermined upper limit, restricting the electric power supply to the motor, and for repeating determining a restricting amount by which the electric power supply to the motor is to be restricted, on the basis of the estimated temperature of the heated portion at a corresponding one of a plurality of discrete points of time.
In the apparatus according to this mode ( 3 ), a restricting amount by which the electric power supply is to be restricted is repeatedly determined after the commencement of restriction on the electric power supply to the motor, on the basis of the temperature of the heated portion estimated at a corresponding one of a plurality of discrete points of time. Therefore, it can surely be avoided that an actual temperature of the heated portion exceeds the predetermined upper limit thereof.
(4) The apparatus according to the above mode ( 1 ), wherein the power supply restricting device comprises:
an allowable supply time period determining means for utilizing an initiation point of time of a holding operation of the steering wheel during which the vehicle operator is holding the steering wheel substantially at one steering position thereof which is other than a neutral position thereof, and for determining a time period which is estimated to pass from the initiation point of time of the holding operation until the temperature of the heated portion has reached the reference temperature, on the basis of the initial temperature of the heated portion, a reference temperature of the heated portion at which the restriction on the electric power supply to the motor is to be initiated, and the electric power-related value obtained at the initiation point of time of the holding operation, the determined time period being defined as an allowable supply time period for the electric power supply to the motor; and
a supply restricting means for starting restricting the electric power supply to the motor when the determined allowable time period has passed.
In a holding operation during which the vehicle operator holds the steering wheel at one steering angle thereof, a change in the magnitude of the electric power supply to the motor, i.e., the electric power-related value of the motor is not as large as in a steering operation during which the vehicle operator operates the steering wheel so as to increase a steering angle thereof. Accordingly, if the magnitude of the electric power-related value at an initiation of the holding operation can be recognized, an increase of the temperature of the heated portion at each one of a plurality of discrete points of time after the initiation of the holding operation can be represented as a function of time, during the holding operation.
Based on this finding, in the apparatus according to this mode ( 4 ), an allowable power supply time period for the motor is determined as a time period which is estimated to pass from an initiation of a holding operation until the temperature of the heated portion has reached a reference temperature, on the basis of the initial temperature of the heated portion, and the electric power-related value obtained at the initiation of the holding operation. Further, when the determined allowable time period has passed, the restriction on the electric power supply to the motor is initiated.
Therefore, the apparatus according to this mode ( 4 ) can easily prevent an actual value of the temperature of the heated portion from exceeding the predetermined upper limit without an indispensable performance of integration of the plurality of electric power-related values.
In the apparatus according to this mode ( 4 ), the term “a holding operation” may be defined as an operation during which the rate of change in a steering angle of the steering wheel or an amount of change in the steering angel per a certain time period is not larger than a reference value. The term “a holding operation” also may be defined as an operation during which the rate of change in the electric power-related value or an amount of change in the electric power-related value is not larger than a reference value.
(5) The apparatus according to the above mode ( 4 ), further comprising a second allowable time period determining means for, at a change point of time when a time-dependent change of the electric power-related value occurs, whose amount is not less than a predetermined reference value thereof, during the holding operation, estimating the temperature increase which is an increase of the temperature of the heated portion from that at the initiation point of time of the holding operation, on the basis of an integrated value of the plurality of electric power-related values obtained during a period from the initiation point of time of the holding operation to the change point of time, and for estimating a time period which is expected to pass from the change point of time until the temperature of the heated portion has reached the reference temperature, on the basis of a sum of the estimated temperature increase and the initial temperature of the heated portion, and the electric power-related value obtained at the change point of time, the estimated time period being defined as a second allowable supply time period for the electric power supply to the motor.
There exists a fact that the electric power-related value, i.e., a physical quantity related to the temperature of the heated portion can vary even during a holding operation of the steering wheel by the vehicle operator. There also exists a fact that the temperature of the heated portion when a time-dependent change in the electric power-related value can be estimated on the basis of an integrated value of a plurality of electric-power related values which have been obtained since the initiation of the holding operation, and the initial temperature of the heated portion. In light of these facts, the apparatus according to this mode ( 5 ) determines a time period which is estimated to pass from the occurrence of the time-dependent change until the temperature of the heated portion has reached a reference temperature as a second allowable supply time period for the motor.
Accordingly, the apparatus according to this mode ( 5 ) can prevent an actual value of the temperature of the heated portion from exceeding the predetermined upper limit thereof due to a time-dependent change in the electric-power-related value during a holding operation of the steering wheel by the vehicle operator.
(6) The apparatus according to the above mode ( 4 ) or ( 5 ), wherein the allowable time period determining means comprises:
a first means for determining an allowable increase of the temperature of the heated portion on the basis of a difference between the reference temperature and the initial temperature of the heated portion; and
a second means for determining the allowable supply time period corresponding to both the electric power-related value obtained at the initiation point of time of the holding operation and the determined allowable increase of the heated portion, according to a predetermined relationship among the electric power-related value obtained at the initiation point of time of the holding operation, the allowable increase, and the allowable supply time period.
(7) The apparatus according to the above mode ( 6 ), wherein the second means comprises a means for determining the allowable supply time period such that the allowable supply time period decreases as the allowable increase decreases, and decreases as the electric power-related value at the initiation point of time of the holding operation increases.
(8) The apparatus according to any one of the above modes ( 1 )-( 7 ), wherein the power supply restricting device comprises an initial temperature determining means for determining an ambient temperature of the heated portion at the reference point of time, as the initial temperature of the heated portion.
(9) The apparatus according to any one of the above modes ( 1 )-( 8 ), further comprising a torque detecting device detecting the steering torque, the torque detecting device including a temperature sensor detecting a temperature of the torque detecting device, the power supply restricting device comprising an initial temperature obtaining means for obtaining the initial temperature of the heated portion on the basis of the temperature detected by the temperature sensor.
In the apparatus according to this mode ( 9 ), the same temperature sensor performs both detection of the temperature of the heated portion and acquisition of an initial temperature of the heated portion. Accordingly, the apparatus according to this mode ( 9 ) can eliminate the total number of temperature sensors installed in an automotive vehicle, compared with the case where detection of the temperature of the heated portion and acquisition of an initial temperature of the heated portion are separately performed by respective temperature sensors. As a result, the apparatus according to this mode ( 9 ) can reduce increase in the cost of the apparatus due to the addition of a function for obtaining the temperature of the heated portion.
(10) The apparatus according to the above mode ( 9 ), wherein the temperature sensor is located near the heated portion in the electrically operated power steering apparatus.
(11) The apparatus according to the above mode ( 9 ) of ( 10 ), wherein the temperature sensor detects the temperature of the torque detecting device as a temperature to be changed according to a substantially constant correlation thereof with an ambient temperature of the heated portion.
(12) The apparatus according to any one of the above modes ( 9 )-( 11 ), wherein the controlling device comprises a means for controlling the electric power supply to the motor on the basis of the steering torque detected by the torque detecting device.
(13) The apparatus according to the above mode ( 1 ), wherein the power supply restricting device comprises:
a first allowable supply time period determining means for using an initiation point of time of one continuous steering operation of the steering wheel by the vehicle operator, and for determining a time period which is expected to pass from the initiation point of one continuous steering operation until the temperature of the heated portion has reached a reference temperature at which the restriction on the electric power supply to the motor is to be initiated, on the basis of the initial temperature of the heated portion, a reference temperature formulated to be lower than the predetermined upper limit, and the electric power-related value obtained at the initiation point of time of one continuous steering operation, the determined time period being defined as a first allowable supply time period for the electric power supply to the motor; and
a second allowable supply time period determining means for, at each one of a plurality of discrete points of time after the initiation point of time of one continuous steering operation, estimating the temperature increase which is an increase of the temperature of the heated portion from that at the initiation point of time of one continuous steering operation, on the basis of an integrated value of at least one of the plurality of electrical power-related values which has been obtained since the initiation point of time of one continuous steering operation, and for determining a time period which is expected to pass from each one of the plurality of discrete points of time until the temperature of the heated portion has reached the reference temperature, on the basis of a sum of the estimated temperature increase and the initial temperature of the heated portion, and the electric power-related value obtained at a corresponding one of the plurality of discrete points of time, the determined time period being defined as a second allowable supply time period for the electric power supply to the motor; and
a supply restricting means for starting restricting the power supply to the motor when the first or second allowable supply time period determined by the first or second allowable supply time period determining means has passed.
The apparatus according to this mode ( 13 ) can prevent an actual value of the temperature of the heated portion from exceeding the predetermined upper limit, according to the principle corresponding to a principle which is employed in the apparatus according to the above mode ( 4 ).
The apparatus according to this mode ( 13 ) may be used, irrespective of whether one continuous steering operation set forth in this mode ( 13 ) is defined as the holding operation set forth in the above mode ( 4 ).
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
FIG. 1 is a cross sectional front view illustrating a mechanical arrangement of an electrically operated power steering apparatus constructed according to a first embodiment of this invention;
FIG. 2 is a cross sectional front view exclusively illustrating in enlargement a gear box 60 of FIG. 1;
FIG. 3 is an electric circuit diagram illustrating a torque detecting device 80 equipped with the electrically operated power steering apparatus of FIG. 1;
FIG. 4 is a block diagram illustrating a software arrangement of the electrically operated power steering apparatus of FIG. 1;
FIG. 5 is a flow chart illustrating a motor temperature estimation routine executed by a computer 100 of FIG. 4;
FIG. 6 is a graph representing a relationship between a coil temperature θ C and an initial temperature θ M0 of the motor utilized in the motor temperature estimation routine of FIG. 5;
FIG. 7 is a flow chart illustrating a reference motor-current-value determination routine executed by the computer 100 of FIG. 4;
FIG. 8 is a flow chart illustrating a desired motor-current-value determination routine executed by the computer 100 of FIG. 4;
FIG. 9 is a flow chart illustrating a motor drive routine executed by the computer 100 of FIG. 4;
FIG. 10 is a graph for explaining changes with time τ in a motor-current-value I, a coil temperature θ C and a motor temperature θ M in the electrically operated power steering apparatus of FIG. 1;
FIG. 11 is a flow chart representing a desired motor-current-value determination routine executed by a computer in an electrically operated power steering apparatus constructed according to a second embodiment of the present invention;
FIG. 12 is a graph illustrating a relationship among an allowable temperature increase Δθ, an actual motor-current-value I act at the initiation of a holding operation of a steering wheel by a vehicle operator, and an allowable supply time period T 0 utilized in the desired motor-current-value determination routine of FIG. 11;
FIG. 13 is a graph for explaining changes with time τ in a motor-current-value I by execution of the desired motor-current-value determination routine of FIG. 11, and
FIG. 14 is a flow chart representing a desired motor-current-value determination routine executed by a computer in an electrically operated power steering apparatus constructed according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the drawings, like numerals are used to indicate like elements throughout.
Referring first to FIG. 1, there will be described a mechanical arrangement of a first embodiment of the present invention in the form of an electrically operated power steering apparatus (hereinafter referred to simply as “a steering apparatus”) for an automotive vehicle. The steering apparatus includes a steering shaft (not shown) rotatable with a steering wheel 10 . The steering shaft is fixed at one of ends thereof which is remote from the steering wheel 10 , to one end of a torsion bar 20 .
The steering apparatus further includes a pair of tie rods 22 , 22 pivotably connected to a pair of knuckle arms (not shown), respectively. The pair of knuckles are attached to a pair of steerable wheels 24 , 24 (e.g., a front set of steerable wheels) of the vehicle, respectively. The pair of tie rods 22 , 22 are connected to each other through a steering rod 26 extending in a lateral direction of the vehicle such that the pair of tie rods 22 , 22 are bendable and rotatable relative to the steering rod 26 .
The steering apparatus further includes a hollow main housing 30 fixedly mounted at a body of the vehicle. The main housing 30 is passed through by the steering rod 26 with a radial clearance therebetween so that the steering rod 26 is axially movable relative to the main housing 30 .
The main housing 30 further accommodates a motor 40 and a motion converting mechanism in the form of a ball screw 42 .
The motor 40 is constructed to include a stator 44 fixed to the main housing 30 and a cylindrical rotor 46 with the stator 44 and rotor 46 being rotatably fitted to each other. The rotor 46 is supported on the main housing 30 via a plurality of bearings 48 such that the rotor 46 is rotatable but is not axially movable relative to the main housing 30 . A motor coil 50 is wound around the stator 44 , and a cylindrical magnet 52 is fixed to the rotor 46 at its outer circumference. The rotor 46 is rotated as a result of interaction of an electromagnetic force of the motor coil 50 and a magnetic force of the magnet 52 .
The ball screw 42 identified above is in the form of a combination of a nut 54 and a shaft 56 wherein the nut 54 and shaft 56 are rotatably fitted to each other via a plurality of balls. The nut 54 is coaxially fixed to the rotor 46 , and the shaft 56 is integrally formed at the steering rod 26 described above. In the ball screw 42 , a rotary motion of the nut 54 is converted into an axial motion of the shaft 56 .
The steering apparatus further includes a gear box 60 . As shown in the enlarged view of FIG. 2, the gear box 60 is equipped with (a) a gear box housing 62 fixedly mounted within the vehicle body, and (b) a pinion shaft 66 rotatably supported on the gear box housing 62 through a bearing 64 . A pinion 68 is coaxially and integrally formed at the pinion shaft 66 . The steering rod 26 forms a plane portion on its outer circumferential surface 26 . The plane portion extends in parallel with the steering rod 26 , forming a rack 70 . The rack 70 meshes with the pinion 68 explained above, whereby the rack 70 is axially moved due to a rotation of the pinion 68 . That is, they cooperate with each other to constitute a so-called rack and pinion mechanism. Consequently, the steering rod 26 is axially moved due to a rotary motion of the pinion 68 and a rotary motion of the motor 40 . The pinion 68 is fixed to a remaining end of the torsion bar 20 described above so as to permit the pinion 68 to rotate with the steering wheel 10 mentioned above.
When the vehicle operator applies a steering torque to the steering wheel 10 , the torsion bar 20 is then twisted accordingly. In addition, there is established a constant relationship between the magnitude of the steering torque and an angle of twist of the torsion bar 20 . Consequently, the magnitude of the steering torque can be detected from the angle of twist of the torsion bar 20 . In the present embodiment, for obtaining the angle of twist of the torsion bar 26 , the torsion bar 26 extends through a rotatable member in the form of a sleeve 74 . One of opposite ends of the sleeve 74 is fixed to one of opposite ends of the torsion bar 20 which is remote from the other end at which the torsion bar 20 is connected to the pinion shaft 66 . The other end of the sleeve 74 is rotatably fitted with the pinion shaft 66 . The sleeve 74 is rotatably supported at the gear box housing 82 described above via a bearing 76 .
The gear box 60 is equipped with a torque detecting device 80 detecting the steering torque applied to the steering wheel 10 using the sleeve 74 described above. The torque detecting device 80 accommodates a first member 82 and a second member 84 . The first member 82 is coaxially fixed to the sleeve 74 on its outer side so that the first member 82 rotates with the sleeve 74 . On the other hand, the second member 84 is fixed to the pinion shaft 66 at a position at which the second member 84 is coaxially opposing to the pinion shaft 66 and which is close to the pinion shaft 66 . The first member 82 has a plurality of teeth (not shown) forming one circular line on a first member end face which is one of opposite end faces of the first member 82 opposing to the second member 84 . Similarly, the second member 84 has a plurality of teeth (not shown) forming one circular line on a second member end face which is one of opposite end faces of the second member 84 opposing to the first member 82 . Consequently, depending upon a change in a relative angular position between the first and second member end face, an area (hereinafter referred to as “an overlapping area”) of a portion where a tip of each tooth on the first member end face and a tip of each tooth on the second member end face overlap each other is changed.
The torque detecting device 80 explained above is farther equipped with a ring-shaped coil 90 for detecting a torque, coaxially with the first and second member 82 , 84 . The coil 90 is fixed to the gear box housing 62 described above on the outside of the first and second member 82 , 84 at a position close to the first and second member end face mentioned above, via a small clearance. The coil 90 is surrounded by a member 91 for facilitating a magnetic path to be formed therein on the outside of the coil 90 . When a magnetic flux is generated within the coil 90 , the magnetic flux passes through the first and second member 82 , 84 together, with a permeance of the magnetic flux being changed depending upon the overlapping area described above. This means that an inductance of the coil 90 is changed relying on the overlapping area. Eventually, the inductance of the coil 90 is changed depending upon the magnitude of the steering torque of the steering wheel 10 .
The torque detecting device 80 further includes a torque detecting circuit 92 shown in FIG. 3 . As shown in FIG. 2, the torque detecting device 80 is mounted at the main housing 62 described above. As shown in FIG. 3, the torque detecting circuit 92 is equipped with a resistor 93 connected to the coil 90 explained above in series therewith, and an oscillation circuit 94 connected to the resistor 93 . The oscillation circuit 94 outputs a predetermined pulse signal to the coil 90 through the resistor 93 . The torque detecting circuit 92 further includes a torque signal generating circuit 95 . The torque signal generating circuit 95 receives a signal output from the coil 90 in response to the pulse signal from the oscillation circuit 94 , and then generates a torque signal representing the inductance of the coil 94 , that is, the steering torque of the steering wheel 10 . Additionally, the torque signal generating circuit 95 outputs the generated torque signal to a motor controller 96 (See FIG. 4 ).
The torque detecting device 92 further includes a temperature detecting circuit 98 connected to the coil 90 explained above. The temperature detecting circuit 98 detects the temperature of the coil 90 on the basis of a resistance thereof, and outputs a coil temperature signal representing the detected temperature of the coil 90 . The motor controller 96 calculates a provisional value of the steering torque on the basis of the received torque signal, and then corrects the previously calculated provisional value of the steering torque into a final value which does not depend on the temperature of the coil 90 , on the basis of the received coil temperature signal.
It is added that, although temperature compensation is thus performed in order that a change in the finally detected steering torque due to change in the temperature of the coil 90 to be compensated, using a computer in a software manner in the present embodiment, the temperature compensation may be performed using an electrical circuit in a hardware manner by accepting an arrangement where an additional coil of the same type with the coil 90 is disposed close to the coil 90 as a coil for detecting the temperature of the coil 90 , and a component of the torque signal output from the coil 90 depending upon the temperature thereof is cancelled by a coil temperature signal output from the additional coil.
A software arrangement of the present steering apparatus is illustrated in FIG. 4 . The steering apparatus includes the motor controller 96 mentioned above. The motor controller 96 is principally constructed by a computer incorporating a central processing unit (CPU), a read-only memory (ROM), and a random-access memory (RAM). To the input side of the motor controller 96 , there are connected the torque detecting device 80 described above, and a motor-current-value sensor 110 . The motor-current-value sensor 110 detects an actual current value flowing through the motor coil 50 . To the output side of the motor controller 96 , there is connected the motor coil 50 of the motor 40 as explained above.
The ROM explained above has stored various control programs. These programs include (a) a motor-temperature estimation routine executed to estimate the temperature (hereinafter referred to simply as “motor temperature ”) of the motor coil 50 , (b) a reference motor-current value determination routine executed to determine a reference motor-current-value as being equal to a desired motor-current-value used in the case where restriction on an electric power supply to the motor 40 is unnecessary, (c) a desired motor-current-value determination routine executed to the desired motor-current-value so as to selectively restrict the electric power supply to the motor 40 , and (d) a motor drive routine executed to supply a drive signal to the motor 40 for driving the motor 40 . These routines will be described below in this descriptive sequence.
The motor-temperature estimation routine is illustrated in the flow chart of FIG. 5 .
Described conceptually first, the present routine is formulated by especially taking account of a fact that there exists a constant correlation between the coil temperature θ C detected by the temperature detecting circuit 98 , and an initial motor-temperature θ M0 which is the temperature of the motor 40 at initiation of a driving operation of the motor 40 during one continuous steering operation of the steering wheel 10 by the vehicle operator. The present routine is executed to estimate the initial motor-temperature θ M0 from the coil temperature θ C . That is, in the present embodiment, the initiation of one continuous drive operation of the motor 40 corresponds to “a reference point of time.” The present routine is further executed to sequentially detect an actual motor-current-value I act using the motor-current-value sensor 110 after the initiation of drive operation of the motor 40 . The execution is to calculate an integrated value ε of a plurality of actual motor-current-values I act , and to estimate a current motor-temperature θ M on the basis of the calculated integrated value ε. The estimation is performed using a constant correlation between the integrated value ε and the motor-temperature θ M .
Described in detail, this routine is cyclically executed by the computer 100 . Each cycle of execution of this routine begins in step S 1 to read the actual motor-current-value I act from the motor-current-value sensor 110 . This routine proceeds to step S 2 where a determination is made as to whether the actual motor-current-value I act is substantially equal to zero. That is, this step is implemented to determine whether it is at initiation of a drive operation of the motor 40 . If the actual motor-current-value I act is substantially equal to zero, the determination is affirmative (YES), and then one cycle of execution of this routine is terminated.
To the contrary, unless the actual motor-current-value I act is substantially equal to zero, the determination is negative (NO), and then this routine proceeds to S 3 where the coil temperature θ C is read out from the temperature detecting circuit 98 . In step S 4 , the initial motor-temperature θ M0 is then estimated on the basis of the previously read coil temperature θ C . In the present embodiment, the ROM has stored a relationship as shown in the graph of FIG. 6 between the coil temperature θ C and the initial motor-temperature θ M0 , in the form of a table, a map, an expression, etc. According to the stored relationship, the initial motor-temperature θ M0 is estimated from the coil temperature θ C .
In the step S 5 of FIG. 5, the actual motor-current-value I act is then read out from the motor-current-value sensor 110 . In step S 6 , a present value of the integrated value ε is updated by adding an absolute value of the actual motor-current-value I act to the present value of the integrated value ε. It is noted that the integrated value ε is designed to be initialized as zero when an electric power is first applied to the computer 100 .
In step S 7 , estimation is preformed as to a motor-temperature increase Δθ which is an increase of the motor-temperature θ M from that at the initiation of the drive operation of the motor 40 , on the basis of the present value of the integrated value ε. In the present embodiment, the ROM has stored a relationship between the integrated value ε and the motor-temperature increase Δθ, in the form of a table, a map, an expression, etc. According to the stored relationship, the motor-temperature increase Δθ is estimated from the integrated value ε.
In step S 8 , a present value of the motor-temperature θ M is then estimated by adding the estimated motor-temperature increase Δθ to the estimated initial motor-temperature θ M0 . The estimated motor-temperature θ M is stored in the RAM described above.
In step S 9 , the actual motor-current-values I act is then read out from the motor-current-value sensor 110 . In step S 10 , a determination is then made as to whether a condition that the actual motor-current-values I act is substantially equal to zero has been consecutively repeated a predetermined number of times. This step is implemented to determine whether the drive operation of the motor 40 has been terminated or not. If the actual motor-current-values I act is not substantially equal to zero, the determination is negative, and then this routine proceeds back to step S 5 . If the condition above-mentioned has been consecutively repeated the predetermined number of times, as a result of repeated execution of a loop including steps S 5 -S 10 , the determination in step S 10 is affirmative, and then this routine proceeds to step S 11 where the present value of the integrated value ε is initialized as zero for subsequent execution of this routine. Then, one cycle of execution of this routine is terminated.
The reference motor-current-value determination routine is represented in the flow chart of FIG. 7 . This routine is cyclically executed by the computer 100 , like the motor-temperature estimation routine as previously described. In each cycle of execution of this routine, step S 21 is initially implemented to read the steering torque t from the torque detecting device 80 . This routine then proceeds to step S 22 where the reference motor-current-value I REF is determined on the basis of the previously read steering torque t. The reference motor-current-value I REF is a current value which is allowed to be supplied to the motor coil 50 when the motor-temperature θ M has not exceeded a predetermined upper limit temperature θ LIMIT . In the present embodiment, the ROM has stored a relationship between the steering torque t and the reference motor-current-value I REF , in the form of a table, a map, an expression, etc. According to the stored relationship, the reference motor-current-value I REF is determined from the steering torque t. The determined reference motor-current-value I REF is stored in the RAM described above. Then, one cycle of execution of this routine is terminated.
The desired motor-current-value determination routine mentioned above is illustrated in the flow chart of FIG. 8 . This routine is cyclically executed by the computer 100 , like the other routines as already described. In each cycle of execution of this routine, step S 41 is initially implemented to read a present value of the estimated motor-temperature θ M from the RAM. This routine then proceeds to step S 42 where a determination is made as to whether the estimated motor-temperature θ M is not lower than a predetermined reference temperature θ REF lower than the upper limit temperature θ LIMIT . If the estimated motor-temperature θ M is lower than the predetermined reference temperature θ REF , the determination is negative, and then this routine proceeds to step S 43 . In this step, a present value of the reference motor-current-value I REF is read out from the RAM, and then the reference motor-current-value I REF as such is utilized as a present value of the desired motor-current-value I*. The desired motor-current-value I* is stored in the RAM. Then, one cycle of execution of this routine is terminated.
To the contrary, if the estimated motor-temperature θ M is not lower than the predetermined reference temperature θ REF , the determination in step S 42 is affirmative, and then this routine proceeds to step S 44 where the restriction on the electric power supply to the motor 40 is effected. Described in more detail, a present value of the reference motor-current-value I REF is read out from the RAM, the reference motor-current-value I REF is then multiplied by a predetermined correction factor k larger than “0” and smaller than “1.” The predetermined correction factor k is determined such that it decreases as a difference between the estimated motor-temperature θ M at that time and the upper limit temperature θ LIMIT decreases, whereby the motor-temperature θ M is prevented from exceeding the upper limit temperature θ LIMIT after initiation of the restriction on the electric power supply to the motor 40 . A product of the reference motor-current-value I REF and the correction factor k is stored as a present value of the desired motor-current-value I* in the RAM. Then, one cycle of execution of this routine is terminated.
The motor drive routine is illustrated in the flow chart of FIG. 9 . This routine is cyclically executed by the computer 100 , like the other routines as already described. In each cycle of execution of this routine, step S 61 is initially implemented to read a present value of the desired motor-current-value I* from the RAM. This routine then proceeds to step S 62 to read the actual motor-current-value I act from the motor-current-value sensor 110 . In the step S 63 , a motor drive signal suitable to be supplied to the motor coil 50 for substantial coincidence of the actual motor-current-value I act with the desire motor-current-value I* is determined by feedback of the actual motor-current-value I act . In step S 64 , the determined motor drive signal is then supplied to the motor coil 50 thereby driving the motor 40 . Then, one cycle of execution of this routine is terminated.
Changes with time τ in the reference motor-current-value I REF , the desire motor-current-value I*, the coil-temperature θ C (not by its actual value but by its detected value), and the motor-temperature θ M are illustrated in the graph of FIG. 10 . Referring to FIG. 10, when the motor-temperature θ M is raised to the reference motor-current-value I REF , the restriction on the electric power supply to the motor coil 50 is initiated, whereby the desire motor-current-value I* is reduced below the reference motor-current-value I REF . Consequently, an increasing gradient of the motor-temperature θ M becomes more gentle, and as a result, the motor-temperature θ M is prevented from exceeding the upper limit temperature θ LIMIT .
It will be understood from the foregoing description of the present embodiment that the motor coil 50 constitutes an example of a “heated portion” of the steering apparatus, a portion of the motor controller 96 assigned to execute the reference motor-current-value determination routine of FIG. 7, to implement step S 43 of the desired motor-current-value determination routine of FIG. 8, and to execute the motor drive routine of FIG. 9 cooperates with the torque detecting device 80 and the motor-current-value sensor 110 to constitute an example of a “controlling device” of the steering apparatus, and a portion of the motor controller 96 assigned to execute the motor-temperature estimation routine of FIG. 5 and steps S 41 , S 42 , and S 44 of the desired motor-current-value determination routine of FIG. 8 constitutes an example of a “power supply restricting device” of the steering apparatus. Moreover, a portion of the motor controller 96 assigned to execute the motor-temperature estimation routine of FIG. 5 constitutes an example of a “temperature estimating means” of the steering apparatus, and a portion of the motor controller 96 assigned to implement steps S 42 and S 44 of FIG. 8 constitutes an example of a “power supply restricting means” of the steering apparatus. Furthermore, the coil 90 for detecting the steering torque and the temperature detecting circuit 98 cooperate with each other to constitute an example of a “temperature sensor” of the steering apparatus, and a portion of the motor controller 96 assigned to implement steps S 3 and S 4 of FIG. 5 constitutes an example of an “initial temperature determining means” of the steering apparatus.
There will next be described an electrically operated power steering apparatus for an automotive vehicle, constructed according to a second embodiment of this invention. However, since the second embodiment is similar to the first embodiment in many elements except only ones associated with a motor-temperature estimation routine and a desired motor-current-value determination routine, only these different elements will be described in detail, while those similar elements will be identified by the same reference signs as used in relation to the first embodiment, for omission of detailed and redundant description on those similar elements in description of the second embodiment.
In the present embodiment, an initiation of one continuous holding operation during which the steering torque is rarely changed, which operation is a part of one continuous steering operation, is defined as a “reference point of time” of the steering apparatus. There exists a fact that it is reasonably possible to assume that an actual motor-current-value I act is placed in a stable condition thereof at an initiation of the holding operation. There also exists a fact that it is reasonably possible to estimate that a plurality of actual motor-current-values I act obtained from an initiation to a termination of one continuous holding operation are substantially equal to the actual motor-current-value I act obtained at the initiation of the same holding operation. In light of these two facts, the steering apparatus according to the present embodiment determines an allowable supply time period as a time period which is estimated to pass while the motor-temperature θ M is raised from the initial motor-temperature θ M0 to the reference temperature θ REF , on the basis of the actual motor-current-value I act obtained at the initiation of the holding operation. Further, after the determined allowable supply time period T 0 has passed, the steering apparatus according to the present embodiment is adapted to start restricting the electric power supply to the motor coil 50 , thereby preventing the motor-temperature θ M from exceeding the upper limit temperature θ LIMIT .
Thus, in the present embodiment, in addition to a assumption that the motor-temperature θ M is a parameter defined as a function of time τ, the determined allowable supply time period T 0 is employed in place of the reference temperature θ REF , and as a result, a motor-temperature estimation routine is not utilized like in the first embodiment.
A desired motor-current-value determination routine used in the present embodiment is illustrated in the flow chart of FIG. 11 . This routine is cyclically executed by the computer 100 , like the other routines as already described. In each cycle of execution of this routine, step S 101 is initially implemented to read a currently detected value I act(n) of the actual motor-current-value I act from the motor-current-value sensor 110 . This routine then proceeds to step S 102 to subtract a previously detected value I act(n−1) of the actual motor-current-value I act from the currently detected value I act(n) which has been previously read, thereby calculating an amount ΔI of change in the actual motor-current-value I act . In step S 103 , a determination is then made as to whether a first condition which is met when the currently detected value I act(n) is not substantially zero and a second condition which is met when an absolute value of the calculated amount ΔI of change is substantially equal to zero are met at the same time. If these two conditions are not met concurrently, the determination is negative, and then this routine proceeds back to step S 101 . Afterwards, if these two conditions are met concurrently after repeated execution of a loop including steps S 101 -S 103 , the determination in step S 103 is affirmative, and then this routine proceeds to step S 104 .
In step S 104 , the coil temperature θ C is read from the temperature detecting circuit 98 . This routine then proceeds to step S 105 where the initial motor-temperature θ M0 is estimated on the basis of the previously read coil temperature θ C in the same manner with the first embodiment. Then, in step S 106 , an allowable temperature-increase Δθ defined as an allowable increase of the motor-temperature θ M from the initial motor-temperature θ M0 , by subtracting the estimated initial motor-temperature θ M0 from the reference temperature θ REF .
In step S 107 , the allowable supply time period T 0 is then determined. In the present embodiment, the ROM has stored a relationship between the allowable supply time period T 0 , the allowable temperature-increase Δθ, and the actual motor-temperature θ M at the initiation of one continuous holding operation by the vehicle operator, in the form of a table, a map, an expression, etc. According to the stored relationship, the allowable supply time period T 0 is determined from the determined allowable temperature-increase Δθ and the actual motor-temperature θ M at the initiation of the holding operation. In the present embodiment, as shown in the graph of FIG. 12, the relationship is formulated such that the allowable supply time period T 0 is reduced as the allowable temperature-increase Δθ is raised, and is reduced as the actual motor-temperature θ M at the initiation of the holding operation is raised.
In step S 108 , a passed time T period to be calculated from the initiation of the holding operation is initialized to be zeroed. This routine then proceeds to step S 109 wherein a determination is made as to whether a present value of the passed time T is not shorter than the determined allowable supply time period T 0 . If the present value of the passed time T is shorter than the determined allowable supply time period T 0 , the determination is negative, and then, in step S 110 , the present value of the passed time T is updated by adding a predetermined cycle time period of this routine to the present value of the passed time T. Afterwards, in step S 111 , a present value of the reference motor-current-value I REF is read from the RAM, and then the reference motor-current-value I REF itself is used as a desired motor-current-value I*. The desired motor-current-value I* is stored in the RAM. This routine then returns to step S 109 .
If the present value of the passed time T becomes not shorter than the allowable supply time period T 0 during repeated execution of a loop including steps S 109 -S 111 , the determination in step S 109 is affirmative, and then, in step S 112 , the restriction on the electric power to the motor 40 is effected. More specifically, a present value of the reference motor-current-value I REF is read out from the RAM, the reference motor-current-value I REF is multiplied by a predetermined correction factor k (here a fixed constant value) larger than “0” and smaller than “1.” The result of multiplication is used as a new value of the desired motor-current-value I*. The desired motor-current-value I* is stored in the RAM.
In step S 113 , the actual motor-current-values I act is then read out from the motor-current-value sensor 110 , and a determination is then made as to whether a condition that the actual motor-current-values I act is substantially equal to zero has been consecutively repeated a predetermined number of times. This step is implemented to determine whether the holding operation of the steering wheel 10 by the vehicle operator has been terminated or not. If the condition above-mentioned has not yet been consecutively repeated the predetermined number of times, the determination is negative, and then this routine proceeds back to step S 112 . To the contrary, if the condition above-identified has been consecutively repeated the predetermined number of times, the determination is affirmative, and then one cycle of execution of this routine is terminated.
Changes with time τ in a relationship between the reference motor-current-value I REF and the desired motor-current-value I* is illustrated in the graph of FIG. 13 . Upon initiation of a holding operation of the steering wheel 10 , the allowable supply time period T 0 is determined on the basis of the actual motor-current-values I act and the allowable temperature-increase Δθ. If the allowable supply time period T 0 has passed since the initiation of the holding operation, the desired motor-current-value I* is reduced below the reference motor-current-value I REF . The reduction means to restrict the electric power supply to the motor 40 , thereby preventing the motor-temperature θ from exceeding the upper limit temperature θ LIMIT .
It will be understood from the foregoing description of the present embodiment that the motor coil 50 constitutes an example of a “heated portion” of the steering apparatus, a portion of the motor controller 96 assigned to execute the reference motor-current-value determination routine of FIG. 7, to implement step S 111 of the desired motor-current-value determination routine of FIG. 11, and to execute the motor drive routine of FIG. 9 cooperates with the torque detecting device 80 and the motor-current-value sensor 110 to constitute an example of a “controlling device” of the steering apparatus, and a portion of the motor controller 96 assigned to implement steps S 101 -S 110 , S 112 and S 113 of the desired motor-current-value determination routine of FIG. 11 constitutes an example of a “power supply restricting device” of the steering apparatus. Moreover, a portion of the motor controller 96 assigned to implement steps S 101 -S 107 of FIG. 11 constitutes an example of an “allowable supply time period determining means” of the steering apparatus, and a portion of the motor controller 96 assigned to implement steps S 108 -S 110 , S 112 and S 113 of FIG. 11 constitutes an example of a “power supply restricting means” of the steering apparatus. Furthermore, the coil 90 for detecting the steering torque and the temperature detecting circuit 98 cooperate with each other to constitute an example of a “temperature sensor” of the steering apparatus, and a portion of the motor controller 96 assigned to implement steps S 3 and S 4 of FIG. 5 constitutes an example of an “initial temperature determining means” of the steering apparatus.
There will next be described an electrically operated power steering apparatus for an automotive vehicle, constructed according to a third embodiment of this invention. However, since the third embodiment is similar to the second embodiment in many elements except ones associated with a desired motor-current-value determination routine, only this routine will be described in detail, while those similar elements will be identified by the same reference signs as used in the second embodiment, for omission of detailed and redundant description on those similar elements in description of the third embodiment.
In the second embodiment, the allowable supply time period T 0 is determined only once at initiation of a continuous holding operation of the steering wheel 10 during the continuous holding operation. In the present embodiment, additionally, at a point of time when an amount of time-dependent change in the actual motor-current-values I act becomes not less than a predetermined reference value during the continuous holding operation, an actual increase Δθ act of the actual motor-temperature θ from that at the initiation of the continuous holding operation, on the basis of an integrated value of a plurality of actual motor-current-values I act obtained from the initiation of the continuous holding operation to the occurrence of the excessive amount of time-dependent change identified above. Furthermore, in the present embodiment, a second allowable supply time period T 0 is determined as a time period which is expected to pass since the occurrence of the excessive amount of time-dependent change until the actual motor-temperature θ M has reached the reference temperature θ REF , on the basis of a sum of the estimated increase Δθ and the initial motor-temperature θ M0 , and the actual motor-current-values I act at the initiation of the continuous holding operation.
A desired motor-current-value determination routine used in the present embodiment is illustrated in the flow chart of FIG. 14 . This routine is cyclically executed by the computer 100 . Each cycle of execution of this routine is initiated with step S 201 in which a determination is made as to whether a continuous holding operation of the steering wheel 10 has been initiated, in the same manner as steps S 101 -S 103 in the second embodiment. If a continuous holding operation has been initiated, the determination is affirmative, and then the computer 100 implements steps S 202 -S 205 in the same manner as steps S 101 -S 107 in the second embodiment.
In step S 206 , the passed time T as already described in relation to the second embodiment is reset to zero similarly with step S 108 in the second embodiment, and then this routine proceeds to step S 207 where a determination is made as to whether a present value of the passed time T is not shorter than the allowable supply time period T 0 previously determined in step S 205 . If the present value of the passed time T is shorter than the determined allowable supply time period T 0 , the determination is negative, and then this routine proceeds to step S 208 where an amount ΔI of change of a currently detected value I act(n) from a previously detected value I act(n−1) of the actual motor-current-value I act is not less than a reference value A. If the amount ΔI of change is less than the reference value A, the determination is negative, and then the computer 100 implements steps S 209 and S 210 in the same manner as steps S 110 and S 112 in the second embodiment. This routine then proceeds back to step S 207 .
After repeated implementation of steps S 207 -S 210 , if the determination in step S 208 is affirmative, and then this routine proceeds to step S 211 . In this step, an integrated value of a plurality of actual motor-current-values I act obtained from a time when the determination in step S 210 has become affirmative (i.e., at the initiation of continuous holding operation) to a time when the determination in step S 208 has become affirmative (i.e., at the occurrence of the excessive amount ΔI of change) is calculated. Further, in this step, the actual increase Δθ act of the actual motor-temperature θ at the occurrence of the excessive amount ΔI of change from that at the initiation of the continuous holding operation is calculated on the basis of the calculated integrated value. The estimation is performed in the same manner as in step S 203 .
In step S 212 , the actual motor-temperature θ M is then estimated as a sum of the initial motor-temperature θ M0 and the estimated actual increase Δθ act , and an allowable increase Δθ is determined by subtracting the estimated actual motor-temperature Δ M from the reference temperature Δ REF . This routine then proceeds back to step S 205 wherein an new allowable supply time period T 0 is determined on the basis of the determined allowable increase Δθ and a present value of the actual motor-temperature θ M (i.e., a sum of the estimated increase Δθ and the initial motor-temperature θ M0 ) and according to a predetermined relationship between the allowable increase Δθ and the actual motor-temperature θ M , represented by a graph similar to the graph of FIG. 12 . This routine then proceeds to step S 206 wherein the passed time T is reset to zero. Afterwards, the computer 100 implements steps including step S 207 and the following ones, in the same manner as in the foregoing explanation.
Then, if a present value of the passed time T has become not less than the present value of the allowable supply time period T 0 , the determination in step S 207 is affirmative, and then the computer 100 implements steps S 213 and S 214 in the same manner as in steps S 112 and S 113 . Then, one cycle of execution of this routine is terminated.
It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims. | An electrically operated power steering apparatus for an automotive vehicle having a steering wheel to be operated by the vehicle operator includes a motor and a power supply restricting device. The motor applies a drive force thereof to a torque transmitting system so as to assist a steering torque applied to the steering wheel by the vehicle operator. The power supply restricting device utilizes a temperature of a heated portion of the electrically operated power steering apparatus which emits heat as a result of a supply of an electric power to the motor, at a reference point of time, as an initial temperature of the heated portion, utilizes a plurality of electric power-related values each of which is related to at least one of a current and a voltage value of the motor, as a plurality of physical quantities related to temperature increases of the heated portion each of which is an increase of the temperature of the heated portion from that at the reference point of time, and restricts the electric power supply to the motor such that an actual value of the temperature of the heated portion does not exceed a predetermined upper limit thereof. | 1 |
BACKGROUND OF THE INVENTION
This application is a continuation-in-part application of copending U.S. patent application Ser. No. 470,792 filed Feb. 28, 1983, now U.S. Pat. No. 4,524,845 and entitled Low Frequency Speaker Enclosure.
The prior art is replete with speaker enclosure constructions, which are designed to alter the direction of rear-cone sound waves emminating from the speaker element, as can be seen by reference to the following patents:
U.S. Pat. No. 3,962,544 discloses a dual speaker enclosure, which is designed to direct rear-cone radiation out the sides of the enclosure, to improve radiation effeciency and transient response.
U.S. Pat. No. 3,909,531 provides a rectangular cavity for the midrange speaker, with a forward facing enclosure opening, that houses the tweeter speaker.
U.S. Pat. No. 4,213,008 discloses an interior rearwardly facing horn, which directs the rear-cone sound downwardly and rearwardly through an expanding horn opening. This horn body is formed by the exterior walls of the cabinet and large rectangular slats.
U.S. Pat. No. 4,325,454 discloses a speaker system that inverts and redirects the speaker backwave out of the cabinet, by directing the sound wave against a slant board and thence through an enlarged triangular opening.
U.S. Pat. No. 4,213,515 discloses a speaker enclosure, which has at least one passageway leading from the interior of the enclosure, to the front and rear of this passageway to be one and one half times larger than the central section of the passageway. In addition, the interior cavity, that forms part of the passageway from the rear of the speaker to the face of the cabinet, is provided with sharp edges on opposing wall surfaces, that will have a deleterious effect on the sound waves emminating from the rear of the speaker.
While all of the aforementioned prior art devices have the same ultimate goal (i.e., the redirection of rear-cone sound waves) their results have been as diverse as their proposed solutions to the problem.
The present invention accomplishes this end, with minimum distortion, maximum amplification, and a strong sound wave dispersion at the outlet of the horn.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a low frequency speaker enclosure, that will redirect rear-cone sound waves to the front of the enclosure with minimum sound wave distortion.
Another object of the present invention is to provide an internal enclosure construction, that will have a pre-formed horn passageway amplifying and directing low frequency sound waves, from the front of the enclosure cabinet.
Still another object of the present invention is to provide a foamed sectional internal enclosure construction, that will provide support for the exterior walls of the enclosure, in addition to suspending and supporting the pre-formed horn passageway.
A further object of the present invention is to provide an enclosure construction, wherein sectional interior foamed elements occupy all of the interior cabinet space, with the exception of the pre-formed sound transmitting passageway.
Yet another object of the present invention is the provision of a low frequency speaker interior enclosure construction, to produce phase inversion, as opposed to using inner cabinet baffling and cabinet walls, to amplify the sound pressure levels and tonal qualities of the speaker element.
A yet further object of the present invention is to provide an internal horn passageway within a speaker enclosure, that produces very little sound wave energy loss, due to sound wave reflection from angular surfaces found in the prior art horn construction.
Another object of the present invention is the provision of a foam support for the horn passageway which isolates the cabinet walls from the sound wave energy transmitted through the horn passageway.
These and other objects, advantages and novel features of the invention will become apparent from the detailed description that follows, when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the foamed cabinet enclosure interior, the pre-formed horn passageway the associated cabinet structure for the low frequecy speaker assembly.
FIG. 2 is a top cross-sectional view of the upper segment of the speaker enclosure.
FIG. 3 is a front elevation view of the speaker enclosure.
FIG. 4 is a side cross-sectional view of the enclosure, showing the disposition of the horn configuration with respect to the other structural components of the assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The low frequency speaker enclosure, which forms the basis of the present invention, comprises in general; a speaker element 10; and upper 100 and lower 200 cabinet structure; and an internal enclosure member 300 surrounding a pre-formed horn passageway member 500.
The upper cabinet structure 100 comprises a plurality of side panels 110, an apertured bottom panel 120, a top panel 130, an apertured face panel 140, and a rear panel which forms the upper cabinet external enclosure.
The lower cabinet structure 200 comprises a plurality of side panels 210, a bottom panel 220, an apertured top panel 230, an apertured face panel and a rear panel 260 which form a lower cabinet external enclosure.
While the upper and lower cabinet structure as illustrate in FIGS. 1 and 2 are contoured, it is to be understood that the external configuration of the cabinet structures do not form a part of this invention, and any aesthetically pleasing geometric or non-geometric cabinet configuration may be employed. All of the panels likewise may be fabricated from wood, chipboard, plastic or other suitable rigid material.
As best can be seen by reference to FIGS. 1 thru 3, the side panels 110 and 210 are further provided with stiffening ribs 111 and 211 respectively, which are intended to provide rigidity and support to the cabinet structures. In addition, both of the cabinet structures may optionally be provided with apertured internal partition members 150 and 250 respectively, which would divide the interiors of the upper and lower cabinet structures into front and rear compartments. The partition members 150, 250 would only be provided in certain instances to the cabinet structures when necessary.
As can best be seen by reference to FIG. 4, the pre-formed horn passageway member 500 comprises a generally constant diameter upper horn passageway portion 501 in the upper cabinet structure 100, and a gradually increasing diameter lower horn passageway portion 502 in the lower cabinet structure 200. In the preferred embodiment of this invention depicted in the drawings, both the upper 501 and lower 502 horn passageway portions comprise pre-formed thin walled molded fiberglass inserts 501' and 502', having a smooth interior finish to promote maximum sound amplification with minimum sound distortion.
As shown in FIG. 4, the upper fiberglass insert 501', that forms the upper horn passageway portion 501, defines an opening 503 having a generally constant diameter D; wherein, the opening 503 extends from the face panel 140 to the bottom panel 120 and transcribes an arc of 90 degrees.
As can also be seen in FIG. 4, the lower fiberglass insert 502', that forms the lower horn passageway portion 502, defines an opening 504; wherein, the opening 504 transcribes an arc of 90 degrees, and extends from the top panel 230 to the face panel 240 of the lower cabinet structure 200.
As mentioned previously the lower cabinet structure 200 has a gradually increasing diameter horn passageway portion 502; wherein the smaller diameter opening D' is disposed proximate the internal terminus of the generally constant diameter opening D in the upper cabinet structure, and wherein the values of D and D' are approximately equal. In addition, the larger diameter opening D" is disposed proximate the face panel 240 in the lower cabinet structure 200, and the value of D" is substantially greater than the value of either D or D'.
In order that the horn passageways 501 and 502 are acoustically isolated from the exterior walls of the respective cabinet sections, and in order that the inserts 501' and 502' are supported and suspending within the interior of the respective cabinet sections a filler material designated generally as 300 is introduced into the cabinet sections during the assembly thereof.
In the preferred embodiment, the filler material 300 comprises a polyurethane foam 301 that is introduced into the respective cabinet sections prior to final assembly, wherein the foam 301 expands and fills the voids between the inserts and the cabinet, whereby the foam 301 encapulates the exterior surfaces of the inserts 501' and 502' and conforms itself to the interior dimensions of the cabinet structures.
An example of one proposed method of fabrication will be described herein with respect to the upper cabinet structure 100. It being understood that virtually the same method would be employed in the fabrication of the lower cabinet structure with only minor variations. To begin with the upper end of the fiberglass insert 501' is installed in the apertured face panel 140 whereby the upper end of the insert 501' is flush with the enlarged aperture 141 in the face panel 140. The lower end of the fiberglass insert 501' is then installed in a like manner with respect to the apertured bottom panel 120. Then the side panels 110 and top panels 130 are joined together, leaving the rear panel 160 unattached at this point.
At this point the polyurethane foam 301 would be introduced into the partially assembled upper cabinet structure 100 and allowed to expand until it occupied the interior volume defined by the assembled panels. Once the foam 301 had cured, the portion of the foam, that projected outside the cabinet enclosure, would be trimmed off and the rear panel 160 would be installed to complete the upper cabinet structure assembly.
It should be appreciated at this juncture that there are myriad ways of assembling or fabricating the finished structure in question and the aforementioned description has merely been offered as an example of one conceivable method.
Prior to assemblying the upper and lower cabinet structures together to form the low-frequency speaker enclosure, an apertured resilient sealing element 400, preferably in the form of a rubber mat 401, is interposed between the respective cabinet structures to dampen any vibration therebetween. Suitable securing means (not shown) are provided to secure the cabinet structures together to complete the assembly.
It should be appreciated at this point that a low frequency speaker 10 mounted in the front of the upper cabinet structure 100 will re-direct the rear-cone sound waves from the speaker along a smooth surfaced generally constant diameter tube horn. The sound waves will experience minimum distortion, maximum amplification, and will project a long strong sound wave dispersion as they leave the forward end of the lower cabinet structure 200.
In addition, the foam 301 that surrounds the performed horn passageway 500, not only will isolate the sound waves from the reflections from baffles that conventional enclosures experience; but will also eliminate the need for inner cabinet bracing, since the lightweight foam becomes essentially an integral part of the inner cabinet structure and reduces the overall weight of the finished product. Furthermore, the tube horn passageway produces a high sound pressure level, which is required by bands during on-stage performances, where a long sound projecting dispersion is necessary.
Having thereby disclosed the subject matter of this invention, it should be obvious that many substitutions, modifications, and variations of the invention are possible in light of the above teachings. It is therefore to be understood that the invention as taught and described is only to be limited to the extent of the breadth and scope of the appended claims. | This invention relates to low-frequency speaker enclosures in general, and more specifically to dual cabinet construction, wherein each of the cabinet structures contains a portion of a pre-formed generally semi-circular variable diameter horn passageway, surrounded by contoured foam elements that provide sound insulation for the horn passageway wherein the pre-formed horn passageway produces redirection and amplification of rear-cone sound wave energy, through the forward face of the combined cabinet construction. | 7 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/733,391, filed on Dec. 4, 2012 and U.S. Provisional Application No. 61/638,419, filed on Apr. 25, 2012.
The entire teachings of the above applications are incorporated herein by reference.
BACKGROUND
A head mounted computer has a display and is mounted to a user's head to enable the user to view the display. The display shows images to the user, for example, from a computer or a remote device. The user can control the head mounted computer or another remote device, which in turn affects the images shown on the display.
SUMMARY
Head mounted computers are bulky systems which, due to their shape necessary for head-mounted operation, are difficult to store or operate by hand when not mounted to the user's head. In one embodiment, the present head mounted computer overcomes these shortcomings of the prior art by providing an articulating support beam to secure a display unit to a user's head, whereby the joints of the support beam can be used to collapse the head mounted computer into a more compact configuration when removed from the user's head and still allow the user to view the display.
In an example embodiment of the present invention, a collapsible head mounted computer (or collapsible headset/head worn computer) can include a head support beam including two ends and at least one joint to enable articulation between a collapsed form and a headset form. The head support beam, in its headset form, can be configured to wrap around a portion of a user's head. The portion can be any area of a user's head sufficient to secure the head support beam using an attachment means or existing head or eyewear on the user. In this position, the two ends of the head support beam can be located at the front of the user's head, with each of the two ends being on opposite sides of the user's head. The location of the two ends can be on the outside of the user's head and adjacent to the user's left and right eye, respectively. When in collapsed form, by articulating the joint or joints of head support beam, the two ends of the head support beam can be placed closer together than in the headset form. A display support beam can be attached to the head support beam at one end of the display support beam. A display unit can be attached to the other end of the display support beam. In one embodiment, the portion of the head covered by the support beam can be either the back or top of the user's head. In another embodiment, the portion of the user's head wrapped by the support beam can include the top or back of the user's head, or any portion between the top and back.
In one embodiment, the head mounted computer can be converted between the collapsed form and the headset form via joints embedded in the structure of the headset. Joints can be at least in the back of the headset or the sides of the headset to fold it into a small compact volume. The head mounted computer in the headset form is configured to be mounted on the user's head, like a head mounted computer that holds a wearable computing headset. The headset form can present the display in front of the user's eye, or in the peripheral vision of the user's eye. The headset in the collapsed form can minimize empty space to fill a smaller volume. In this manner, the physical structure of the headset itself can be stored away easily (e.g., in a pocket). The collapsible headset in the folded form can be similar to a mobile/cellular phone because can be used as a handheld device. In another embodiment, the collapsible headset in the folded form can be arranged such that it surrounds a client device (e.g., cellular phone, smart device, tablet, etc.), so the headset in the collapsed form is a case of the client device. After being converted to the collapsed form, the headset can be converted to the headset form again to be worn as a head mounted computer.
In another embodiment, the collapsible head mounted computer can include an electronics module with a processor and a memory coupled to the head support beam. In another embodiment, a power source module can be coupled to the head support beam.
In another embodiment, a support device can be attached to the head support beam to secure the head support beam to the user's head. The support device can be a strap, stabilizer, ear attachment, or meant to connect to existing eyewear.
In yet another embodiment, the head support beam can be further configured to have a folded form allowing hand-held operation of the display screen. In this configuration, the head set computer can be interfaced as a hand-held device with the same display unit as placed before the user's eyes in its mounted configuration.
In another embodiment, the head support beam and display support beams can be both of user adjustable length.
In another embodiment, the collapsible head mounted computer can further include a central processing printed circuit board (CPUPCB) including a central processing unit (CPU) operatively coupled to a first near field communications (NFC) module. The collapsible head mounted computer can further include an auxiliary printed circuit board (AUXPCB) including one or more auxiliary modules operatively coupled to a second NFC module. The second NFC module can be arranged to be located within a near field range of the first NFC module. The first and second NFC modules can be configured to establish an NFC link, and the first and second NFC modules are housed by the head support beam and separated by the at least one joint.
The head mounted computer can also include at least two mounts. Each front can be at a corresponding front end of the head support beam. Each of the two mounts can be configured to mount an accessory. The accessory can include at least one of a camera, sensor, microphone, and illumination device.
The head mounted computer can also include at least two sliding stabilizer mounts. Each sliding stabilizer mount can be coupled to opposite sides of the head support beam. The sliding stabilizer mounts can be configured to slide along a defined slide path on the head support beam. The at least two sliding stabilizer mounts can include a brake or other locking mechanism.
In another embodiment, the head mounted computer includes at least two stabilizers. Each stabilizer can be configured to mount in a corresponding sliding stabilizer mount. Each stabilizer can be configured to move between an open position (e.g., an unsecured position, a moveable position) and a locked position (e.g., a secured position, a stationary position). The open position can unlock the brake of the corresponding sliding stabilizer mount such that the corresponding sliding stabilizer mount can change its position on the defined slide path. The locked position can lock the brake of the corresponding sliding stabilizer mount such that the corresponding sliding stabilizer mount locks its position on the defined slide path.
In another embodiment, a stabilizer can support the head mounted computer by wrapping around the user's head. The stabilizer can also support the head mounted computer by clipping to a user's headwear or locking into a predefined receptacle in a user's headwear. The stabilizer can support the head mounted computer by supporting against the user's ear. The stabilizers can be removably connected to the stabilizer mounts.
In another embodiment, a head mounted computer includes a pressure mounting head support beam configured to wrap around a back of user's head, the pressure mounting head support beam including two ends, the two ends located at the front of the user's head, each of the two ends being on opposite sides of the user's head. The head mounted computer can include a display support beam configured to (a) couple with one of the two ends at a first end of the display support beam and (b) couple with a display at the second end of the display support beam. The head support beam can provide tension towards the user's head through the two ends, the tension supporting the head mounted computer. The support beam can also provide compression, pressure, inward tension, an inward force, or other force against the user's head.
The head mounted computer can further include a strap with two ends. Each end can be coupled to an opposite one of two mounts at each of the two ends. The strap can provide tension to the user's head to hold the head mounted computer in place. The strap can also provide compression, pressure, inward tension, an inward force, or other force against the user's head. The pressure mounting head support beam can have a radius of curvature that matches a radius of curvature of the user's head to enable retention of the head mounted computer on the user's head.
The pressure mounting head support beam can be configured to have a particular amount of elasticity (e.g., flexibility or adjustability) for mounting and dismounting the pressure mounting head support beam on the user's head.
In another embodiment, a method of displaying visual information to a user can include connecting a display to a first end of a display support beam. The method can further include coupling a second end of the display beam to a head support beam. The head support beam can include two ends and at least one joint to enable articulation of the head support beam between a collapsed form and a headset form. The head support beam in headset form can be configured to wrap around a portion of a user's head. The two ends can be located at the front of the user's head. Each of the two ends can be on opposite sides of the user's head. The head support beam in collapsed form can be configured to place the two ends closer together than the particular distance in headset form. The method can further include displaying visual information to the user on the display.
In another embodiment, the method can include operatively coupling a central processing printed circuit board (CPUPCB) including a central processing unit (CPU) to a first near field communications (NFC) module. The method can further include operatively coupling an auxiliary printed circuit board (AUXPCB) including one or more auxiliary modules to a second NFC module. The method can also include arranging the second NFC module to be located within a near field range of the first NFC module. The method can additionally include housing the first and second NFC modules are housed by the head support beam such that the first NFC module and second NFC module are separated by the at least one joint. The method can also include establishing an NFC link between the first NFC module and second NFC module.
In another embodiment, a computing device can include a central processing printed circuit board (CPUPCB) including a central processing unit (CPU) operatively coupled to a first near field communications (NFC) module. The computing device can further include an auxiliary printed circuit board (AUXPCB) including one or more auxiliary modules operatively coupled to a second NFC module. The second NFC module can be arranged to be located within a near field range of the first NFC module. The first NFC module and the second NFC module can be configured to establish a NFC link.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.
FIG. 1 is a diagram illustrating an example embodiment of a collapsible headset computer in headset mode.
FIG. 2A is a diagram illustrating an example embodiment of the display boom and display from a top perspective.
FIG. 2B is a diagram illustrating an example embodiment of the display boom and display.
FIG. 2C is a diagram illustrating an example embodiment of the sliding arm of the display.
FIG. 2D is a diagram illustrating an example embodiment of a user wearing the headset computer.
FIG. 3A is a diagram illustrating an example embodiment of horizontal orientation of the display relative to a pivot.
FIG. 3B is a diagram illustrating an example embodiment of the display boom.
FIGS. 3C-G are diagrams illustrating example embodiments of the display boom including different configurations with multiple pivots that are configured to rotate the display or position the display in different locations.
FIG. 4A is a diagram illustrating an example embodiment of the headset computer from a top perspective.
FIG. 4B is a diagram illustrating an example embodiment of the headset computer in a collapsed configuration.
FIG. 4C is a diagram illustrating an example embodiment of the headset computer in another stable configuration.
FIG. 4D is a diagram illustrating an example embodiment of the headset computer in a partially folded state.
FIG. 4E is a diagram illustrating an example embodiment of a soft bend and twist mechanism that couples the display to the boom.
FIG. 5 is a diagram illustrating an example embodiment of the headset computer with two joints in a collapsed form from a top perspective.
FIG. 6 is a diagram illustrating an example embodiment of the headset computer with two joints in a collapsed form from an angled perspective.
FIG. 7 is a diagram illustrating an example embodiment of the headset computer with multiple joints in a headset form from an angled perspective.
FIG. 8 is a diagram illustrating an example embodiment of the headset computer with multiple joints in a collapsed form.
FIG. 9 is a diagram illustrating an example embodiment of the headset computer, including a rotatable earpiece.
FIG. 10 is a diagram illustrating an example embodiment of the headset computer from a back position.
FIG. 11 is a diagram illustrating an example embodiment of the headset computer.
FIG. 12 is a diagram illustrating an example embodiment of the headset computer.
FIG. 13 is a diagram illustrating an example embodiment of the headset computer.
FIGS. 14A-C are diagrams illustrating example embodiments of the P1B optic employed by the headset computer.
FIG. 15 is a diagram illustrating an example embodiment of different modes of a transforming collapsible headset.
FIG. 16A is a diagram illustrating an example embodiment of a headset computer employed to use inward tension to mount to the user's head.
FIG. 16B is a diagram illustrating an example embodiment of the headset computer using inward tension to mount to the user's head.
FIGS. 17A-17B are high-level schematic diagrams illustrating example embodiments of electrical circuits employing near field communications that can be used to transfer data between electronics modules of a collapsible headset computer.
FIGS. 18A-18C are example arrangements of PCBs equipped with NFC modules.
DETAILED DESCRIPTION
A description of example embodiments of the invention follows.
FIG. 1 is a diagram 100 illustrating an example embodiment of a headset computer 102 in headset form. The headset computer 102 includes a computer 118 , a power supply 116 , and a display boom 118 . The display boom further includes a display 110 , a display board 104 , and an antenna 106 . The headset computer 102 can include additional electronics or antennas.
The headset computer 102 further includes stabilizer mounts 114 a - b . The stabilizer mounts 114 a - b are coupled to stabilizers 112 a - b . The stabilizers 112 a - b and the stabilizer mounts 114 a - b are removable from the headset computer 102 . The stabilizers 112 a - b in FIG. 1 wrap around the top of the user's head without connecting to each other. However, other variations of stabilizers 112 a - b can be employed. Examples of other stabilizers 112 a - b can be stabilizers which rest on the user's ear, stabilizers that connect at the top over the user's head (e.g., the stabilizer 112 a connecting to the stabilizer 112 b ), stabilizers that connect to headwear, such as a hardhat, or stabilizers that clip to a user's hair or a baseball cap, etc.
The stabilizer mounts 114 a - b can also slide along a head brace 120 to allow the user to adjust where the stabilizers 112 a - b contact the user's head. Each user can have a different shaped head, so allowing adjustment of the location of the stabilizers 112 a - b provides a comfortable fit for wearing of the headset computer. The stabilizers 112 a - b can be configured to engage or disengage a locking mechanism 122 a - b within the stabilizer mount 114 a - b . In this manner, the user can wear the headset computer 102 with the stabilizers 112 a - b in a comfortable, user selected position.
In one embodiment, the stabilizers 112 a - b are made from plastic (e.g., polycarbonate). The plastic can be clear. The stabilizers can be 20 mm wide, 8 mm thick, and 75 mm long. However, the stabilizers can be of many other dimensions as well. The stabilizer mounts 114 a - b can be made from plastic, and can also be clear. The stabilizer mounts 114 a - b can be 30 mm by 28 mm by 7 mm. The head brace can be made of metal (e.g., magnesium). The head mounted computer overall can have dimensions of 200 mm wide, 240 mm front-to-back, and 50 mm tall. In a compact, storage mode, the head mounted computer can be 160 mm wide by 100 mm front-to-back and 50 mm tall. The head mounted computer can weigh 8 ounces. However, the stabilizers, stabilizer mounts, head mounted computer can be of many other dimensions and/or weights as well.
FIG. 2A is a diagram 200 illustrating an example embodiment of the display boom and display from a top perspective. The display boom can include a combination of pivots and or joints to allow for adjustment of the location of the display. The display can have an open or closed position, as shown by FIG. 2A . The display can also be positioned between the open and closed position.
FIG. 2B is a diagram 210 illustrating an example embodiment of the display boom and display. The display boom can also slide inward and outward using a telescoping boom to adjust the distance between the user's eye and the display. Throughout this process, the display remains vertical. The display can flip 180° and allow the user to flip the entire headset computer. This allows the user to effectively shift the display from the left to right eye, or vice versa, without disconnecting the display and re-connecting it at the other side of the headset computer. The display can be flipped to 180°, and upon turning the headset computer upside down, the display is in position for the opposite eye.
FIG. 2C is a diagram 220 illustrating an example embodiment of the sliding arm of the display. The sliding arm can move the display away from or closer to the user.
FIG. 2D is a diagram 230 illustrating an example embodiment of a user wearing the headset computer. The user can slide the display away from or closer to his or her eye. In addition, the display rotates out and the sliding arm can slide back and forth.
FIG. 3A is a diagram illustrating an example embodiment of a horizontal orientation of the display relative to a pivot. The horizontal orientation makes switching the display from left to right and vice versa simpler than a vertical orientation, also illustrated in FIG. 3A .
FIG. 3B is a diagram illustrating an example embodiment of the display boom. The display boom includes a telescoping arm that can slide out and retract to move the display closer to and away from the user's eye. The display can also swivel 180° to switch from the left to right eye. This display can also swing out to retract into a retractable position.
FIGS. 3C-G are diagrams illustrating an example embodiments of the display boom including different configurations with multiple pivots that are configured to rotate the display or position the display in different locations.
FIG. 4A is a diagram illustrating an example embodiment of the collapsible headset computer from a top perspective. The headset computer includes a plurality of joints 400 a - e which allow the headset computer to fold into a storable configuration.
FIG. 4B is a diagram illustrating an example embodiment of the headset computer in a partially folded configuration. By folding the joints 400 a - e , the headset computer becomes more compact.
FIG. 4C is a diagram illustrating an example embodiment of the headset computer in a fully collapsed configuration. In this configuration, the headset computer is completely folded and occupies a smaller volume. This enables easier carrying by the user.
FIG. 4D is a diagram illustrating an example embodiment of the headset computer in a partially folded state. The headset computer is configured to fold along its body. The headset computer includes an optionally removable head strap, mounts that can rotate up to 180°, and joints that can bend up to 180°. In addition, the display can bend and twist 180° for storage and to flip the display from the left to the right orientation.
FIG. 4E is a diagram illustrating an example embodiment of the soft bend and twist mechanism that couples the display to the boom. The mechanism includes a left position and a right position, and additionally a spring that forces the display to be naturally deployed either in the left or right position, but not linger in between the two positions, barring other mechanical forces.
FIG. 5 is a diagram illustrating an example embodiment of the headset computer 501 with two joints 502 a - b in a collapsed form from a top perspective. Head support beam 503 is configured to wrap around the user's head supported by stabilizers 504 a - b . Display beam 505 connects display 506 and to the head support beam 503 . In this embodiment, the headset computer 501 joints 502 a - b bend in an axis orthogonal to a long axis of the head support beam 503 . The two ends 503 a - b of head support beam 503 are positioned closer together in the depicted collapsed form than in the headset form shown in FIG. 1 .
FIG. 6 is a diagram illustrating an example embodiment of the headset computer 501 with two joints 502 a - b in a collapsed form from an angled perspective. Support beam 503 is configured to wrap around the users head supported by stabilizers 504 a - b . Display beam 505 connects display 506 to support beam 503 . Electronics module 607 and power supply 608 are integrated with support beam 503 .
FIG. 7 a diagram illustrating an example embodiment of the headset computer 501 with 3 head support beam 503 joints 702 a - c in a headset form from an angled perspective. Instead of a display beam, display 506 is attached as an accessory to an end of the head support beam at joint 702 a . On the other end of the head support beam 503 is a camera 710 accessory mounted at joint 702 c . Both the camera and display accessories are mounted by multiple joints 709 a - h on support beams 712 and 713 to enable a more compact collapsed form, as shown in FIG. 8 . Also in this embodiment, head support beam 503 is secured to the user's head in headset mode using an attached support means, shown here as a flexible strap 711 configured to wrap around the top of the user's head and support the weight of the headset computer 501 .
FIG. 8 is a diagram illustrating an example embodiment of the headset computer 501 of FIG. 7 in collapsed form. Joint 702 b is bent on an axis orthogonal to the long axis of head support beam 503 to fold the head support beam 503 , while joints 702 a and 702 c are bent on axes orthogonal to the long axis of head support beam 503 to fold the camera support beam 712 and display support beam 713 between the head support beam 503 . In this collapsed configuration, display 506 faces outwardly from the headset computer 501 , enabling the user to view the display in collapsed form.
FIG. 9 is a diagram 900 illustrating an example embodiment of the headset computer in headset form, including a rotatable earpiece 902 .
FIG. 10 is diagram 1000 illustrating an example embodiment of the headset computer from a back position. The headset computer is shown in headset form to be operating and showing a picture of a vehicle on its display 100 . In addition, the wheel 1002 in the back can be used to expand or contract the housing/head brace of the headset computer to fit different sized heads.
FIG. 11 is a diagram 1100 of an embodiment of the headset computer in headset form. The wheel 1002 , as described in FIG. 10 , can be seen at the back the headset computer from a different angle. In addition, the embodiment of FIG. 11 employs a horizontal display 1100 .
FIG. 12 is diagram 1200 of an embodiment of the headset computer. In this embodiment, the display is a P 1 B optic display, as shown in FIG. 14 .
FIG. 13 is a diagram 1300 illustrating an example embodiment of the headset computer. The earpiece 902 can be rotated to flip from a right to left side when the entire headset computer is flipped. This allows the user to clearly hear output of the headset computer.
FIGS. 14A-C are diagrams illustrating example embodiments of the P 1 B optic employed by the headset computer. In addition, FIGS. 14A-C illustrate the mounts that the P 1 B optic can be housed in the headset computer. Other optics can be used other than the P 1 B optic.
FIG. 15 is a diagram illustrating an example embodiment of different modes of a collapsible headset 314 . The transforming headset 314 includes an electronic board and or folded electronics 302 , a power source 304 , and an optic/display 306 . The power source 304 can include a 400 milliamp hour battery although other types of batteries can be employed.
A first mode of the transforming headset 314 is a handheld mode 308 . A user can easily hold or stow away the transforming headset in the handheld mode 308 because it is rectangular. In one embodiment, the collapsible headset 314 in handheld mode 308 is the approximate size of a cellular phone or other handheld device. Further, the optic/display 306 can be viewable when the unit is in this mode. The collapsible headset 314 can operate in the handheld mode 308 , and the optic/display 306 is operational.
The transformation mode 310 converts the transforming headset 314 from the handheld mode 308 to a head mounted mode 312 . The transforming headset 314 is still operational in the head mounted mode 312 , and includes the parts as the handheld mode 308 . The user, however, can wear the transforming headset 314 in the head mounted mode 312 such that the transforming headset 314 wraps around the user's head and the display is in front of the user's eye, instead of being protected by the foldable casing of the collapsible headset 314 . The transformation mode 310 can convert the collapsible headset 314 from the collapsed handheld mode 308 to the headset mode 312 .
FIG. 16A is a diagram 2700 illustrating an example embodiment of a headset computer with a head support beam configured to use inward tension to mount to the user's head. The headset computer includes friction hinges 2702 , and spring zones 2704 that push the headset inward. Further, the headset includes a rotatable speaker 2708 that allows for sound output to the user. Further, each of the front ends can be coupled to a digital camera or mount for other device, allowing for accessories to be mounted to the headset computer. Further, mounts on each of the front ends of the headset computer can also provide a setup for a strap mount, which holds the headset computer to the user's head in an even more effective manner.
FIG. 16B is a diagram 2750 illustrating an example embodiment of the headset computer. The speaker 2708 , as mentioned above can rotate up to 220°. Further, multiple speakers 2708 , 2754 , one on both sides to give the user stereo audio. In addition the boom mount 2762 can slide up to 1¼ inches. The boom angle 2760 can rotate 50°. The boom rotation 2758 can be 240°. The boom 2756 can be twisted 25°, and a knuckle 2754 connecting the display to the boom can rotate 45° fore and 20° aft. The optic pod 2752 itself can rotate 60° to 75°.
FIGS. 17A-17B are high-level schematic diagrams of electrical circuits employing near field communications that can be used to transfer data between electronics modules of a collapsible headset computer.
Near field communications (NFC) is a set of standards for establishing radio communications between devices by touching the devices or bringing them into close proximity, usually no more than a few centimeters. Smartphones and similar devices currently employ NFC technology. Present applications include contactless transactions, data exchange, and simplified setup of more complex communications, such as Wi-Fi. Communication is also possible between an NFC device and an unpowered NFC chip, called a “tag”.
Recent developments in NFC technology have enabled near-field high speed data transfer, including, for example, a “near-field high speed data transfer technology” (e.g., 375 Mb/sec.). Such NFC technology can be used for convenience in mobile devices; consumers find such high speed downloads or data transfer rates useful for transferring files, particularly for large files, such as movies. The Toshiba Transfer Jet is a NFC technology that provides wireless near-field high speed data transfer, can operate up to a distance of 3.5 centimeters, and has a near-field radiated power dissipation level that is similar to very low power near-field Bluetooth power levels. The Transfer Jet is available from Toshiba America Electronic Components, Inc., 19900 MacArthur Boulevard, Suite 400, Irvine, Calif.
NFC modules can be used as a near-field high speed wireless data transfer to interface between electronics modules or printed circuit boards (PCBs) (also referred to herein as printed circuit board assemblies (PCBAs)). In general, PCBs are used to mechanically support and electrically connect electronic components using conductive pathways, tracks, or signal traces etched from copper sheets laminated onto a non-conductive substrate. Multiple PCBs are typically interconnected using large multi-wire busses or, sometimes, vias are used for “stacked” configurations or for multi-layer boards.
The PCBs of the collapsible headset computer can be equipped with NFC modules. The NFC modules can replace the large multi-wire busses and vias used to interface between multiple PCBs. The NFC module equipped PCBs can be arranged in a stacked configuration (e.g., the PCB are in a parallel configuration) or placed end-to-end (e.g., the PCBs are in a series configuration). NFC modules allow the PCBAs to be placed in a thinner or lower profile stack, because the volume needed for large multi-pin PCBA to PCBA connectors is no longer required.
In whichever arrangement of PCBs is used, a first NFC module is located within a NFC range of a second NFC module to enable an interfacing wireless communications link between the two NFC modules. An example NFC range, such as the Transfer Jet is up to 3.5 centimeters, although the data transmit and reception range can be controlled by system software. Control of operating NFC ranges may be based on particular use and application to optimize a feature of system performance, such as transfer rate or battery life.
For embodiments of a collapsible headset computer that uses two or more NFC interfaces, when the NFC module is used for high speed data transfer between the headset computer and another device, such as a Smartphone or another collapsible headset computer, application software (or operating system instructions) can select a single NFC module as the data transfer point to interface with the other device.
For practical purposes, PCBAs can be sealed to the outside having only a power and/or ground external connection. By equipping individual collapsible headset computer PCBAs with NFC modules, the PCBAs (including the NFC modules) can be more easily hermetically sealed, because there are large number of external connection points of the multi-wire busses and vias have been eliminated. Thus, higher levels of system reliability and system life-span are possible because exposure to dust and moisture are greatly reduced.
NFC modules allow the PCBAs to move or flex within the physical constraints of a system architecture or industrial design free from the possibility of physical damage associated with the multi-wire busses, flex circuit interfaces, or connectors becoming loose or making intermittent contact during vibration or other PCBA to PCBA movement.
Using near field wireless high speed data transfer technology can eliminate large multiple pin connectors on two or more adjoining PCBAs, as well as any high speed multiple wire data bus or flex circuit interfaces. Eliminating the sharp right angle connection of PCBAs to PCBAs and the speed multi-wire bus or cables from PCBA to PCBA can improve and lower high speed system EMI and regional RF emission certifications.
Thus, use of PCBs equipped with NFC modules may allow collapsible headset computers to employ hinges and system housing flex points in its industrial design and be freed from the problems of passing large multi-wire busses or flex circuits interfaces through or about the hinges or flex points.
FIG. 17A is a high-level schematic diagram of circuit 1700 , an example embedment of PCBs equipped with NFC modules arranged to be within the near field range of each other and configured to establish a communications link. The circuit 1700 includes a central processing unit printed circuit board assembly 1701 (CPU PCB) and an auxiliary printed circuit board assembly 1711 (AUX PCB). CPU PCB 1701 includes a central processing unit 1703 (CPU) communicatively coupled 1715 to a NFC module 1705 . The CPU 1703 can be, for example, an OMAP4430 multimedia application processor available from Texas Instruments Inc., 12500 TI Boulevard Dallas, Tex. For reasons of simplicity, details of the CPU PCB 1703 have been omitted, including, but not limited to: a power companion chip, battery connector, camera connector, USB on-the-go micro-AB connector, PCB temperature sensor, display connector, debug connector, status LEDs, user switches, etc. and communications pathways, such as traces, wires, etc. As such, the CPU PCB 1703 can include any or more of these details.
The AUX PCB 1711 includes an auxiliary module 1703 (AUX) communicatively coupled 1715 to a NFC module 1705 . NFC modules 1705 are arranged in close proximity, that is, within an operable near field range of one another. Further, the NFC modules are configured to establish a bi-directional wireless communications link 1750 . Such a bi-directional wireless communications link 1750 can be established using any appropriate NFC protocol and/or data exchange format. Although not shown in FIG. 17A for reasons of simplicity, the AUX PCB 1711 can include multiple AUXs 1713 , such as an audio codec and mini-DSP module, head tracker module, micro-SD card, power regulators, GPS receivers, wireless communications modules employing protocols such as Wi-Fi, Bluetooth, etc., eMMC embedded storage. The AUX PCB 1711 can not only include additional AUXs 1713 , such as those listed above, but also include communications pathways, such as traces, wires, etc. that enable operable coupling.
FIG. 17B is a schematic diagram of the AUX PCB 1711 showing more details of the NFC module 1705 . The AUX PCB 1711 includes the AUX module 1713 , operable coupling 1715 , and NFC module 1705 . The NFC module 1705 can include NFC integrated circuit (NFC IC) 1755 and radio frequency (RF) circuit 1760 .
FIGS. 18A-18C are example arrangements of PCBs equipped with NFC modules.
FIG. 18A illustrates a series arrangement 1800 a (also referred to as end-to-end) of PCBs including CPU PCB 1801 and AUX PCB 1811 . The CPU PCB 1801 includes the CPU 1803 and NFC module 1805 a . The AUX PCB 1811 includes multiple AUXs 1813 and NFC module 1805 b . The NFC modules 1805 a,b are arranged to be positioned at an end of their respective PCBs. In other words, a first NFC module 1805 a is located at an end, near the edge of the CPU PCB 1801 and a second NFC module 1805 b is located at an end, near an edge of the AUX PCB 1811 . The CPU PCB 1801 and AUX PCB 1811 are arranged such that the location of each respective NFC module 1805 a,b is located within the near field range of its respective communications link partner to enable the wireless transfer of data through communications link 1850 .
FIG. 18B illustrates a parallel arrangement 1800 b (also referred to as stacked) of PCBs including CPU PCB 1801 and AUX PCB 1811 . Similar to FIG. 18A , the CPU PCB 1801 includes the CPU 1803 and NFC module 1805 a , and the AUX PCB 1811 includes multiple AUXs 1813 and NFC module 1805 b . Unlike the series arrangement 1800 a , the in parallel arrangement 1800 b the NFC 1805 b of AUX PCB 1811 is mounted on the underside so as to enable the NFC modules 1805 a,b to be located within the near field range of each other.
FIG. 18C illustrates a series arrangement 1800 c of PCBs, including CPU PCB 1801 and AUX PCB 1811 , that is similar to series arrangement 1800 a but for the CPU PCB 1801 and AUX PCB 1811 each being encased in a housing 1860 a,b , respectively. The housings 1860 a,b can each be coupled to a joint 1865 , enabling the housings 1860 a,b and the PCBs respectively encased by each, to rotate about an axis of the joint 1865 . The housings 1860 a,b and joint 1865 a should be designed to enable the NFC modules 1805 a,b to be located within the near field range of each other in at least one operational position.
For the sake of simplicity, the example embodiments presented have been limited to embodiments having two printed circuit board assemblies communicating using NFC. However, it should be understood by those of skill in the art that the inventive principle described herein can be applied to any other embodiment including those of any number of additional printed circuit board assemblies.
While this invention has been particularly shown and described with references to example 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 scope of the invention encompassed by the appended claims. | In one embodiment, collapsible head mounted computer (CHMC) transforms between a collapsed and headset form via joints embedded in the structure of the headset. Joints can be in the back or sides of the CHMC. The CHMC in the headset form is configured to be mounted on the user's head. The headset form presents the display in front of the user's eye, or in the peripheral vision of the user's eye. The CHMC in the collapsed form is designed to minimize empty space to fill a smaller volume. In this manner, the CHMC can be stored away easily. The CHMC may also include an electronics module enabling onboard processing or an onboard power source to operate electronics modules and a display without an outside electrical connection. The CMHC may also employ near field communication on circuit board near joints to allow for communication regardless of the form of the device. | 6 |
INCORPORATION BY REFERENCE
[0001] The present application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2005-0059354 filed on Jul. 1, 2005. The content of the application is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an arylphenoxy catalyst system for producing ethylene homopolymer or copolymers of ethylene and α-olefins. More particularly, the present invention pertains to a group IV transition metal catalyst expressed by Formula 1, a catalyst system which includes the arylphenoxy-based transition metal catalyst and an aluminoxane cocatalyst or a boron compound cocatalyst, and a method of producing an ethylene homopolymer or copolymers of ethylene and α-olefins using the same. In the transition metal catalyst, a cyclopentadiene derivative and an arylphenoxide as fixed ligands are located around a group IV transition metal, arylphenoxide ligand is substituted with at least one aryl derivative and is located at ortho position thereof, and the ligands are not crosslinked to each other.
[0004] In Formula 1, wherein M is the group IV transition metal of the periodic table;
[0005] Cp is cyclopentadienyl group capable of forming an η 5 -bond along with the central metal, or derivatives thereof;
[0006] R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 of the arylphenoxide ligand are independently a hydrogen atom, a halogen atom, a C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, a silyl group which contains the C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, a C 6 -C 30 aryl group arbitrarily substituted with one or more halogen atoms, a C 7 -C 30 arylalkyl group arbitrarily substituted with one or more halogen atoms, an alkoxy group which contains the C 1 -C 20 alkyl group arbitrarily substituted with one or more halogen atoms, or a C 3 -C 20 alkyl-substituted or C 6 -C 20 aryl-substituted siloxy group, where the substituent groups may be arbitrarily bonded to form rings;
[0007] X can be independently selected from a group including the halogen atom, the C 1 -C 20 alkyl group which is not a Cp derivative, the C 7 -C 30 arylalkyl group, an alkoxy group which contains the C 1 -C 20 alkyl group, the C 3 -C 20 alkyl-substituted siloxy group, and an amido group which has a C 1 -C 20 hydrocarbon group;
[0008] Y is the hydrogen atom, the halogen atom, the C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, the silyl group which contains the C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, the C 6 -C 30 aryl group arbitrarily substituted with one or more halogen atoms, the C 7 -C 30 arylalkyl group arbitrarily substituted with one or more halogen atoms, the alkoxy group which contains the C 1 -C 20 alkyl group arbitrarily substituted with one or more halogen atoms, the C 3 -C 20 alkyl-substituted or C 6 -C 20 aryl-substituted siloxy group, the amido group or a phosphido group which contains the C 1 -C 20 hydrocarbon group, or a C 1 -C 20 alkyl-substituted mercapto or nitro group; and
[0009] n is 1 or 2 depending on the oxidation state of the transition metal.
[0010] 2. Description of the Related Art
[0011] Conventionally, Ziegler-Natta catalyst system which includes a main catalyst component of titanium or vanadium compounds and a cocatalyst component of alkyl aluminum compounds has been used to produce an ethylene homopolymer or copolymers of ethylene and α-olefins. However, the Ziegler-Natta catalyst system is disadvantageous in that, even though it is highly active in the polymerization of ethylene, the molecular weight distribution of a resultant polymer is wide, and particularly, a compositional distribution is non-uniform in the copolymer of ethylene and α-olefin due to heterogeneous catalyst active sites.
[0012] Recently, the metallocene catalyst system which comprises a metallocene compound of a group IV transition metal in the periodic table, such as titanium, zirconium, or hafnium, and methylaluminoxane as a cocatalyst has been developed. Since the metallocene catalyst system is a homogeneous catalyst having one kind of catalytic active site, it can be used to produce polyethylene having a narrow molecular weight distribution and a uniform compositional distribution in comparison with the conventional Ziegler-Natta catalyst system. For example, EP Pat. Nos. 320762 and 372632, and Japanese Patent Laid-Open Publication Nos. Sho. 63-092621, Hei. 02-84405, and Hei. 03-2347 disclose metallocene compounds, such as Cp 2 TiCl 2 , Cp 2 ZrCl 2 , Cp 2 ZrMeCl, Cp 2 ZrMe 2 , or (ethylene-bis tetrahydroindenyl)ZrCl 2 , activated with methylaluminoxane as a cocatalyst to polymerize ethylene at high catalytic activity, thereby making it possible to produce polyethylene having a molecular weight distribution (Mw/Mn) of 1.5-2.0. However, it is difficult to produce a polymer having a high molecular weight using the above catalyst system. Particularly, if it is applied to a solution polymerization process which is conducted at high temperatures of 140° C. or higher, polymerization activity is rapidly reduced and a β-hydrogen elimination reaction is dominant, thus it is unsuitable for producing a high molecular weight polymer having a weight average molecular weight (Mw) of 100,000 or more.
[0013] Meanwhile, a constrained geometry non-metallocene catalyst (a so-called single-site catalyst) in which a transition metal is connected to a ligand system in a ring shape has been suggested as a catalyst which has high catalytic activity and is capable of producing a polymer having a high molecular weight in polymerization of only ethylene or in copolymerization of ethylene and α-olefin under a solution polymerization condition. EP Pat. Nos. 0416815 and 0420436 suggest a catalytic system in which a transition metal is connected to cyclopentadiene ligand and an amide group in a ring shape, and EP Pat. No. 0842939 discloses a catalyst in which a phenol-based ligand as an electron donor compound is connected with a cyclopentadiene ligand in a ring shape. However, since the cyclization of the ligands along with the transition metal compound is achieved at very low yield during synthesis of the constrained geometry catalyst, it is difficult to commercialize them.
[0014] Meanwhile, an example of non-metallocene catalysts which is not a constrained geometry catalyst and is capable of being used under a high temperature solution condition are disclosed in U.S. Pat. No. 6,329,478 and Korean Patent Laid-Open Publication No. 2001-0074722. The patents disclose a single-site catalyst using one or more phosphinimine compounds as a ligand, having high ethylene conversion during copolymerization of ethylene and α-olefins under the high temperature solution polymerization condition at 140° C. or higher. However, a limited range of phosphine compounds may be used to produce the phosphinimine ligand, and, since these compounds are harmful to the environment and to humans, it might have some difficulties in using them to produce general-purpose olefin polymers. U.S. Pat. No. 5,079,205 discloses a catalyst having a bis-phenoxide ligand, but it has too low catalytic acitivity to be commercially used.
[0015] In addition to the above-mentioned examples, Nomura et al., Organometallics 1998, 17, 2152 discloses the synthesis of a non-metallocene catalyst with a phenol-based ligand and polymerization using the same, in which the substituents on the phenol ligand are limited to only simple alkyl substituents such as isopropyl group. On the other hand, Rothwell, P. et al., J. Organomet. Chem. 1999, 591, 148 discloses an arylphenoxy ligand, but does not suggest the effects of aryl substituent at the ortho-position.
SUMMARY OF THE INVENTION
[0016] To overcome the above problems occurring in the prior art, the present inventors have conducted extensive studies, resulting in the finding that a non-bridged type transition metal catalyst, in which cyclopentadiene derivatives and arylphenoxide substituted with at least one aryl derivative at the ortho-position thereof are used as fixed ligands, shows an excellent thermal stability. Based on the above finding, a catalyst, which is used to produce an ethylene homopolymer or copolymers of ethylene and α-olefins having a high molecular weight, at a high activity during a solution polymerization process at high temperatures of 80° C. or higher, has been developed, thereby the present invention is accomplished.
[0017] Accordingly, an object of the present invention is to provide a single-site catalyst and a high temperature solution polymerization method using the same. The single-site catalyst includes environmentally-friendly raw materials, synthesis of the catalyst is very economical and thermal stability of the catalyst is excellent. In the solution polymerization method, it is possible to easily and commercially produce an ethylene homopolymer or copolymers of ethylene and α-olefins having various physical properties using the catalyst.
[0018] In order to accomplish the above object, an aspect of the present invention provides an arylphenoxy-based transition metal catalyst expressed by Formula 1, which includes a cyclopentadiene derivative and arylphenoxide as fixed ligands around a transition metal. Arylphenoxide is substituted with at least one aryl derivative and is located at the ortho position thereof, and the ligands are not crosslinked to each other.
[0019] In Formula 1, wherein M is the group IV transition metal of a periodic table;
[0020] Cp is cyclopentadienyl group, capable of forming an η 5 -bond along with the central metal, or a derivative thereof;
[0021] R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 of the arylphenoxide ligand are independently a hydrogen atom, a halogen atom, a C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, a silyl group which contains the C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, a C 6 -C 30 aryl group arbitrarily substituted with one or more halogen atoms, a C 7 -C 30 arylalkyl group arbitrarily substituted with one or more halogen atoms, an alkoxy group which has the C 1 -C 20 alkyl group arbitrarily substituted with one or more halogen atoms, or a C 3 -C 20 alkyl-substituted or C 6 -C 20 aryl-substituted siloxy group, optionally with the proviso that the substituent groups may be arbitrarily bonded to form rings;
[0022] X can include the halogen atom, the C 1 -C 20 alkyl group which is not a Cp derivative, the C 7 -C 30 arylalkyl group, an alkoxy group which contains the C 1 -C 20 alkyl group, the C 3 -C 20 alkyl-substituted siloxy group, and an amido group which contains a C 1 -C 20 hydrocarbon group;
[0023] Y is the hydrogen atom, the halogen atom, the C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, the silyl group which contains the C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, the C 6 -C 30 aryl group arbitrarily substituted with one or more halogen atoms, the C 7 -C 30 arylalkyl group arbitrarily substituted with one or more halogen atoms, the alkoxy group which has the C 1 -C 20 alkyl group arbitrarily substituted with one or more halogen atoms, the C 3 -C 20 alkyl-substituted or C 6 -C 20 aryl-substituted siloxy group, the amido group or a phosphido group which has the C 1 -C 20 hydrocarbon group, or a C 1 -C 20 alkyl-substituted mercapto or nitro group; and
[0024] n is 1 or 2 depending on the oxidation state of the transition metal.
[0025] Another aspect of the present invention relates to a catalyst system which includes the transition metal catalyst, and aluminum or a boron compound as a cocatalyst.
[0026] Still another aspect of the present invention relates to a method of producing ethylene polymers using the transition metal catalyst.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0028] FIG. 1 illustrates a crystalline structure of a (dichloro)(cyclopentadienyl)(4-methyl-2,6-bis(2′-isopropylphenyl)phenoxy)titanium(IV) catalyst according to an embodiment of the present invention; and
[0029] FIG. 2 illustrates a crystalline structure of a (dichloro)(pentamethylcyclopentadienyl)(2-phenylphenoxy)titanium(IV) catalyst according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Hereinafter, a detailed description will be given of the present invention.
[0031] M of the transition metal catalyst in Formula 1 is preferably titanium, zirconium, or hafnium. Furthermore, Cp is a cyclopentadiene anion capable of forming an η 5 -bond along with a central metal, or a derivative thereof. In detail, it is exemplified by cyclopentadienyl, methylcyclopentadienyl, dimethylcyclopentadienyl, tetramethylcyclopentadienyl, pentamethylcyclopentadienyl, butylcyclopentadienyl, sec-butylcyclopentadienyl, tert-butylmethylcyclopentadienyl, trimethylsilylcyclopentadienyl, indenyl, methylindenyl, dimethylindenyl, ethylindenyl, isopropylindenyl, fluorenyl, methylfluorenyl, dimethylfluorenyl, ethylfluorenyl, and isopropylfluorenyl.
[0032] With respect to R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 of an arylphenoxide ligand, a halogen atom is exemplified by fluorine, chlorine, bromine, and iodine atoms; and a C 1 -C 20 alkyl group is exemplified by methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, sec-butyl group, tert-butyl group, n-pentyl group, neopentyl group, amyl group, n-hexyl group, n-octyl group, n-decyl group, n-dodecyl group, n-pentadecyl group, and n-eicosyl group, and preferably, methyl group, ethyl group, isopropyl group, tert-butyl group, and amyl group. The alkyl group may arbitrarily be substituted with one or more halogen atoms, and is exemplified by fluoromethyl group, difluoromethyl group, trifluoromethyl group, chloromethyl group, dichloromethyl group, trichloromethyl group, bromomethyl group, dibromomethyl group, tribromomethyl group, iodomethyl group, diiodomethyl group, triiodomethyl group, fluoroethyl group, difluoroethyl group, trifluoroethyl group, tetrafluoroethyl group, pentafluoroethyl group, chloroethyl group, dichloroethyl group, trichloroethyl group, tetrachloroethyl group, pentachloroethyl group, bromoethyl group, dibromoethyl group, tribromoethyl group, tetrabromoethyl group, pentabromoethyl group, perfluoropropyl group, perfluorobutyl group, perfluoropentyl group, perfluorohexyl group, perfluorooctyl group, perfluorododecyl group, perfluoropentadecyl group, perfluoroeicosyl group, perchloropropyl group, perchlorobutyl group, perchloropentyl group, perchlorohexyl group, perchlorooctyl group, perchlorododecyl group, perchloropentadecyl group, perchloroeicosyl group, perbromopropyl group, perbromobutyl group, perbromopentyl group, perbromohexyl group, perbromooctyl group, perbromododecyl group, perbromopentadecyl group, or perbromoeicosyl group. Among them, trifluoromethyl group is preferable. In R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 , a C 1 -C 20 alkyl-substituted silyl group is exemplified by methylsilyl group, ethylsilyl group, phenylsilyl group, dimethylsilyl group, diethylsilyl group, diphenylsilyl group, trimethylsilyl group, triethylsilyl group, tri-n-propylsilyl group, triisopropylsilyl group, tri-n-butylsilyl group, tri-sec-butylsilyl group, tri-tert-butylsilyl group, tri-isobutylsilyl group, tert-butyldimethylsilyl group, tri-n-pentylsilyl group, tri-n-hexylsilyl group, tricyclohexylsilyl group, or triphenylsilyl group, and preferably trimethylsilyl group, tert-butyldimethylsilyl group, and triphenylsilyl group. A C 6 -C 30 aryl group is exemplified by phenyl group, 2-tolyl group, 3-tolyl group, 4-tolyl group, 2,3-xylyl group, 2,4-xylyl group, 2,5-xylyl group, 2,6-xylyl group, 3,4-xylyl group, 3,5-xylyl group, 2,3,4-trimethylphenyl group, 2,3,5-trimethylphenyl group, 2,3,6-trimethylphenyl group, 2,4,6-trimethylphenyl group, 3,4,5-trimethylphenyl group, 2,3,4,5-tetramethylphenyl group, 2,3,4,6-tetramethylphenyl group, 2,3,5,6-tetramethylphenyl group, pentamethylphenyl group, ethylphenyl group, n-propylphenyl group, isopropylphenyl group, n-butylphenyl group, sec-butylphenyl group, tert-butylphenyl group, n-pentylphenyl group, neopentylphenyl group, n-hexylphenyl group, n-octylphenyl group, n-decylphenyl group, n-dodecylphenyl group, n-tetradecylphenyl group, biphenyl group, fluorenyl group, triphenyl group, naphthyl group, or anthracenyl group, and preferably, phenyl group, naphthyl group, biphenyl group, 2-isopropylphenyl group, 3,5-xylyl group, and 2,4,6-trimethylphenyl group. A C 7 -C 30 arylalkyl group is exemplified by benzyl group, (2-methylphenyl)methyl group, (3-methylphenyl)methyl group, (4-methylphenyl)methyl group, (2,3-dimethylphenyl)methyl group, (2,4-dimethylphenyl)methyl group, (2,5-dimethylphenyl)methyl group, (2,6-dimethylphenyl)methyl group, (3,4-dimethylphenyl)methyl group, (4,6-dimethylphenyl)methyl group, (2,3,4-trimethylphenyl)methyl group, (2,3,5-trimethylphenyl)methyl group, (2,3,6-trimethylphenyl)methyl group, (3,4,5-trimethylphenyl)methyl group, (2,4,6-trimethylphenyl)methyl group, (2,3,4,5-tetramethylphenyl)methyl group, (2,3,4,6-tetramethylphenyl)methyl group, (2,3,5,6 -tetramethylphenyl)methyl group, (pentamethylphenyl)methyl group, (ethylphenyl)methyl group, (n-propylphenyl)methyl group, (isopropylphenyl)methyl group, (n-butylphenyl)methyl group, (sec-butylphenyl)methyl group, (tert-butylphenyl)methyl group, (n-pentylphenyl)methyl group, (neopentylphenyl)methyl group, (n-hexylphenyl)methyl group, (n-octylphenyl)methyl group, (n-decylphenyl)methyl group, (n-dodecylphenyl)methyl group, (n-tetradecylphenyl)methyl group, naphthylmethyl group, or anthracenylmethyl group, and preferably, benzyl group. A C 1 -C 20 alkoxy group is exemplified by methoxy group, ethoxy group, n-propoxy group, isopropoxy group, n-butoxy group, sec-butoxy group, tert-butoxy group, n-pentoxy group, neopentoxy group, n-hexoxy group, n-octoxy group, n-dodecoxy group, n-pentadecoxy group, or n-eicosoxy group, and preferably, methoxy group, ethoxy group, isopropoxy group, and tert-butoxy group. A C 3 -C 20 alkyl-substituted or C 6 -C 20 aryl-substituted siloxy group is exemplified by trimethylsiloxy group, triethylsiloxy group, tri-n-propylsiloxy group, triisopropylsiloxy group, tri-n-butylsiloxy group, tri-sec-butylsiloxy group, tri-tert-butylsiloxy group, tri-isobutylsiloxy group, tert-butyldimethylsiloxy group, tri-n-pentylsiloxy group, tri-n-hexylsiloxy group, tricyclohexylsiloxy group, or triphenylsiloxy group, and preferably, trimethylsiloxy group, tert-butyldimethylsiloxy group, and triphenylsiloxy group. The above-mentioned substituent groups may be arbitrarily substituted with one or more halogen atoms.
[0033] In X, a halogen atom is exemplified by fluorine, chlorine, bromine, and iodine atoms and a C 1 -C 20 alkyl group which is not the Cp derivative is exemplified by methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, sec-butyl group, tert-butyl group, n-pentyl group, neopentyl group, amyl group, n-hexyl group, n-octyl group, n-decyl group, n-dodecyl group, n-pentadecyl group, and n-eicosyl group, and preferably, methyl group, ethyl group, isopropyl group, tert-butyl group, and amyl group. A C 7 -C 30 arylalkyl group is exemplified by benzyl group, (2-methylphenyl)methyl group, (3-methylphenyl)methyl group, (4-methylphenyl)methyl group, (2,3-dimethylphenyl)methyl group, (2,4-dimethylphenyl)methyl group, (2,5-dimethylphenyl)methyl group, (2,6-dimethylphenyl)methyl group, (3,4-dimethylphenyl)methyl group, (4,6-dimethylphenyl)methyl group, (2,3,4-trimethylphenyl)methyl group, (2,3,5-trimethylphenyl)methyl group, (2,3,6-trimethylphenyl)methyl group, (3,4,5-trimethylphenyl)methyl group, (2,4,6-trimethylphenyl)methyl group, (2,3,4,5-tetramethylphenyl)methyl group, (2,3,4,6-tetramethylphenyl)methyl group, (2,3,5,6-tetramethylphenyl)methyl group, (pentamethylphenyl)methyl group, (ethylphenyl)methyl group, (n-propylphenyl)methyl group, (isopropylphenyl)methyl group, (n-butylphenyl)methyl group, (sec-butylphenyl)methyl group, (tert-butylphenyl)methyl group, (n-pentylphenyl)methyl group, (neopentylphenyl)methyl group, (n-hexylphenyl)methyl group, (n-octylphenyl)methyl group, (n-decylphenyl)methyl group, (n-dodecylphenyl)methyl group, (n-tetradecylphenyl)methyl group, naphthylmethyl group, or anthracenylmethyl group, and preferably, benzyl group. A C 1 -C 20 alkoxy group is exemplified by methoxy group, ethoxy group, n-propoxy group, isopropoxy group, n-butoxy group, sec-butoxy group, tert-butoxy group, n-pentoxy group, neopentoxy group, n-hexoxy group, n-octoxy group, n-dodecoxy group, n-pentadecoxy group, or n-eicosoxy group, and preferably, methoxy group, ethoxy group, isopropoxy group, and tert-butoxy group. A C 3 -C 20 alkyl-substituted siloxy group is exemplified by trimethylsiloxy group, triethylsiloxy group, tri-n-propylsiloxy group, triisopropylsiloxy group, tri-n-butylsiloxy group, tri-sec-butylsiloxy group, tri-tert-butylsiloxy group, tri-isobutylsiloxy group, tert-butyldimethylsiloxy group, tri-n-pentylsiloxy group, tri-n-hexylsiloxy group, or tricyclohexylsiloxy group, and preferably, trimethylsiloxy group and tert-butyldimethylsiloxy group.
[0034] An amido group or a phosphido group having a C 1 -C 20 hydrocarbon group is exemplified by dimethylamino group, diethylamino group, di-n-propylamino group, diisopropylamino group, di-n-butylamino group, di-sec-butylamino group, di-tert-butylamino group, diisobutylamino group, tert-butylisopropylamino group, di-n-hexylamino group, di-n-octylamino group, di-n-decylamino group, diphenylamino group, dibenzylamide group, methylethylamide group, methylphenylamide group, benzylhexylamide group, bistrimethylsilylamino group, or bis-tert-butyldimethylsilylamino group, or phosphido group which is substituted with the same alkyl. Among them, dimethylamino group, diethylamino group, and diphenylamide group are preferable.
[0035] In Y, a halogen atom is exemplified by fluorine, chlorine, bromine, and iodine atom; and a C 1 -C 20 alkyl group is exemplified by methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, sec-butyl group, tert-butyl group, n-pentyl group, neopentyl group, amyl group, n-hexyl group, n-octyl group, n-decyl group, n-dodecyl group, n-pentadecyl group, and n-eicosyl group, and preferably, methyl group, ethyl group, isopropyl group, tert-butyl group, and amyl group. The C 1 -C 20 alkyl group which is arbitrarily substituted with one or more halogen atoms is exemplified by fluoromethyl group, difluoromethyl group, trifluoromethyl group, chloromethyl group, dichloromethyl group, trichloromethyl group, bromomethyl group, dibromomethyl group, tribromomethyl group, iodomethyl group, diiodomethyl group, triiodomethyl group, fluoroethyl group, difluoroethyl group, trifluoroethyl group, tetrafluoroethyl group, pentafluoroethyl group, chloroethyl group, dichloroethyl group, trichloroethyl group, tetrachloroethyl group, pentachloroethyl group, bromoethyl group, dibromoethyl group, tribromoethyl group, tetrabromoethyl group, pentabromoethyl group, perfluoropropyl group, perfluorobutyl group, perfluoropentyl group, perfluorohexyl group, perfluorooctyl group, perfluorododecyl group, perfluoropentadecyl group, perfluoroeicosyl group, perchloropropyl group, perchlorobutyl group, perchloropentyl group, perchlorohexyl group, perchlorooctyl group, perchlorododecyl group, perchloropentadecyl group, perchloroeicosyl group, perbromopropyl group, perbromobutyl group, perbromopentyl group, perbromohexyl group, perbromooctyl group, perbromododecyl group, perbromopentadecyl group, or perbromoeicosyl group, and preferably, trifluoromethyl group. Furthermore, in Y, a C 1 -C 20 alkyl-substituted silyl group is exemplified by methylsilyl group, ethylsilyl group, phenylsilyl group, dimethylsilyl group, diethylsilyl group, diphenylsilyl group, trimethylsilyl group, triethylsilyl group, tri-n-propylsilyl group, triisopropylsilyl group, tri-n-butylsilyl group, tri-sec-butylsilyl group, tri-tert-butylsilyl group, tri-isobutylsilyl group, tert-butyldimethylsilyl group, tri-n-pentylsilyl group, tri-n-hexylsilyl group, tricyclohexylsilyl group, or triphenylsilyl group, and preferably trimethylsilyl group, tert-butyldimethylsilyl group, and triphenylsilyl group. A C 6 -C 30 aryl group is exemplified by phenyl group, 2-tolyl group, 3-tolyl group, 4-tolyl group, 2,3-xylyl group, 2,4-xylyl group, 2,5-xylyl group, 2,6-xylyl group, 3,4-xylyl group, 3,5-xylyl group, 2,3,4-trimethylphenyl group, 2,3,5-trimethylphenyl group, 2,3,6-trimethylphenyl group, 2,4,6-trimethylphenyl group, 3,4,5-trimethylphenyl group, 2,3,4,5-tetramethylphenyl group, 2,3,4,6-tetramethylphenyl group, 2,3,5,6-tetramethylphenyl group, pentamethylphenyl group, ethylphenyl group, n-propylphenyl group, isopropylphenyl group, n-butylphenyl group, sec-butylphenyl group, tert-butylphenyl group, n-pentylphenyl group, neopentylphenyl group, n-hexylphenyl group, n-octylphenyl group, n-decylphenyl group, n-dodecylphenyl group, n-tetradecylphenyl group, biphenyl group, fluorenyl group, triphenyl group, naphthyl group, or anthracenyl group, and preferably, phenyl group, naphthyl group, biphenyl group, 2-isopropylphenyl group, 3,5-xylyl group, and 2,4,6-trimethylphenyl group. A C 7 -C 30 arylalkyl group is exemplified by benzyl group, (2-methylphenyl)methyl group, (3-methylphenyl)methyl group, (4-methylphenyl)methyl group, (2,3-dimethylphenyl)methyl group, (2,4-dimethylphenyl)methyl group, (2,5-dimethylphenyl)methyl group, (2,6-dimethylphenyl)methyl group, (3,4-dimethylphenyl)methyl group, (4,6-dimethylphenyl)methyl group, (2,3,4-trimethylphenyl)methyl group, (2,3,5-trimethylphenyl)methyl group, (2,3,6-trimethylphenyl)methyl group, (3,4,5-trimethylphenyl)methyl group, (2,4,6-trimethylphenyl)methyl group, (2,3,4,5-tetramethylphenyl)methyl group, (2,3,4,6-tetramethylphenyl)methyl group, (2,3,5,6-tetramethylphenyl)methyl group, (pentamethylphenyl)methyl group, (ethylphenyl)methyl group, (n-propylphenyl)methyl group, (isopropylphenyl)methyl group, (n-butylphenyl)methyl group, (sec-butylphenyl)methyl group, (tert-butylphenyl)methyl group, (n-pentylphenyl)methyl group, (neopentylphenyl)methyl group, (n-hexylphenyl)methyl group, (n-octylphenyl)methyl group, (n-decylphenyl)methyl group, (n-dodecylphenyl)methyl group, (n-tetradecylphenyl)methyl group, naphthylmethyl group, or anthracenylmethyl group, and preferably, benzyl group. A C 1 -C 20 alkoxy group is exemplified by methoxy group, ethoxy group, n-propoxy group, isopropoxy group, n-butoxy group, sec-butoxy group, tert-butoxy group, n-pentoxy group, neopentoxy group, n-hexoxy group, n-octoxy group, n-dodecoxy group, n-pentadecoxy group, or n-eicosoxy group, and preferably, methoxy group, ethoxy group, isopropoxy group, and tert-butoxy group. A C 3 -C 20 alkyl-substituted or C 6 -C 20 aryl-substituted siloxy group is exemplified by trimethylsiloxy group, triethylsiloxy group, tri-n-propylsiloxy group, triisopropylsiloxy group, tri-n-butylsiloxy group, tri-sec-butylsiloxy group, tri-tert-butylsiloxy group, tri-isobutylsiloxy group, tert-butyldimethylsiloxy group, tri-n-pentylsiloxy group, tri-n-hexylsiloxy group, tricyclohexylsiloxy group, or triphenylsiloxy group, and preferably, trimethylsiloxy group, tert-butyldimethylsiloxy group, and triphenylsiloxy group. The above-mentioned substituent groups may be substituted with one or more halogen atoms. As well, with respect to Y, an amido group or a phosphido group having a C 1 -C 20 hydrocarbon group is exemplified by dimethylamino group, diethylamino group, di-n-propylamino group, diisopropylamino group, di-n-butylamino group, di-sec-butylamino group, di-tert-butylamino group, diisobutylamino group, tert-butylisopropylamino group, di-n-hexylamino group, di-n-octylamino group, di-n-decylamino group, diphenylamino group, dibenzylamide group, methylethylamide group, methylphenylamide group, benzylhexylamide group, bistrimethylsilylamino group, or bis-tert-butyldimethylsilylamino group, or phosphido group which is substituted with the same alkyl. Among them, dimethylamino group, diethylamino group, and diphenylamide group are preferable. A C 1 -C 20 mercapto group is exemplified by methyl mercaptan, ethyl mercaptan, propyl mercaptan, isopropyl mercaptan, 1-butyl mercaptan, or isopentyl mercaptan, and preferably, ethyl mercaptan and isopropyl mercaptan.
[0036] In a representative process of synthesizing the transition metal complex of Formula 1, a substituted or unsubstituted arylphenoxide-based ligand is produced and reacted with a group IV transition metal compound having one cyclopentadiene derivative. To produce a substituted or unsubstituted arylphenol-based ligand, an anisole compound, which is expressed by Formula 2 and substituted with one or two halogen atoms, and a substituted or unsubstituted arylboronic acid, which is as shown in Formula 3, are reacted with an organic phosphine ligand using a palladium metal compound as a catalyst in an organic solvent at preferably −20 to 120° C. to produce an aryl-substituted anisole compound, and reacted with a tribromoboron compound in an organic solvent at a temperature preferably ranging from −78 to 50° C. to produce an aryl-substituted phenoxide ligand. The ligand thus produced is reacted with sodium hydride, alkyl lithium, or alkyl magnesium halide compound in an organic solvent at a temperature preferably ranging from −78 to 120° C. so as to be converted into anions, and then subjected to a ligand exchange reaction along with the group IV transition metal compound which is expressed by Formula 4 and has one cyclopentadiene derivative at −20 to 120° C. in an equivalent ratio. The resulting product is purified to produce an arylphenoxide-based transition metal catalyst component.
[0037] In the above Formula 2 or 3, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 are independently a hydrogen atom, a halogen atom, a C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, a silyl group which contains the C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, a C 6 -C 30 aryl group arbitrarily substituted with one or more halogen atoms, a C 7 -C 30 arylalkyl group arbitrarily substituted with one or more halogen atoms, a C 1 -C 20 alkylalkoxy group arbitrarily substituted with one or more halogen atoms, or a C 3 -C 20 alkyl-substituted siloxy group or C 6 -C 20 aryl-substituted siloxy group, optionally with the proviso that the substituent groups may be arbitrarily bonded to form rings; Q is the halogen atom; and Y is the hydrogen atom, the halogen atom, the C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, the silyl group which contains the C 1 -C 20 linear or nonlinear alkyl group arbitrarily substituted with one or more halogen atoms, the C 6 -C 30 aryl group arbitrarily substituted with one or more halogen atoms, the C 7 -C 30 arylalkyl group arbitrarily substituted with one or more halogen atoms, the C 1 -C 20 alkylalkoxy group arbitrarily substituted with one or more halogen atoms, the C 3 -C 20 alkyl-substituted siloxy group or C 6 -C 20 aryl-substituted siloxy group, the amido group or a phosphido group which has the C 1 -C 20 hydrocarbon group, or a C 1 -C 20 alkyl-substituted mercapto or nitro group.
CpM(X) m Formula 4
[0038] In Formula 4, Cp is cyclopentadienyl capable of forming an η 5 -bond along with a central metal, or a derivative thereof, M is a group IV transition metal in a periodic table, X is a halogen atom, a C 1 -C 20 alkyl group which is not a Cp derivative, a C 7 -C 30 arylalkyl group, a C 1 -C 20 alkylalkoxy group, a C 3 -C 20 alkyl-substituted siloxy group, or an amido group having a C 1 -C 20 hydrocarbon group, and m is 2 or 3 depending on the oxidation state of the transition metal.
[0039] Meanwhile, in order to use the transition metal catalyst of Formula 1 as an active catalyst component which is used to produce an ethylene homopolymer or copolymer of ethylene and an α-olefin comonomers, an X ligand is extracted from a transition metal complex to convert the central metal into cations, and aluminoxane compounds or boron compounds which are capable of acting as opposite ions having weak bonding strength, that is, anions, are used along with a cocatalyst.
[0040] As well known in the art, aluminoxane, which is expressed by the following Formula 5 or 6, is frequently used as the aluminoxane compound used in the present invention.
(—Al(R 9 )—O—) m Formula 5
(R 9 ) 2 Al—(—O(R 9 )—) p —(R 9 ) 2 Formula 6
[0041] In the above Formula, R 9 is a C 1 -C 20 alkyl group, and preferably, a methyl group or an isobutyl group, and m and p are integers ranging from 5 to 20.
[0042] In order to use the transition metal catalyst of the present invention as an active catalyst, the mixing ratio of the two components is set so that the molar ratio of the central metal to aluminum is preferably 1:20 to 1:10,000, and more preferably, 1:50 to 1:5,000.
[0043] Furthermore, a boron compound which is capable of being used as a cocatalyst of the present invention may be selected from compounds of the following Formula 7 to 9 as disclosed in U.S. Pat. No. 5,198,401.
B(R 10 ) 3 Formula 7
[R 11 ] + [B(R 10 ) 4 ] − Formula 8
[(R 12 ) q ZH] + [B(R 10 ) 4 ] − Formula 9
[0044] In the above Formulae, B is a boron atom; R 10 is an unsubstituted phenyl group, or a phenyl group which is substituted with 3 to 5 substituent groups selected from the group consisting of a C 1 -C 4 alkyl group which is substituted or unsubstituted with a fluorine atom and a C 1 -C 4 alkoxy group which is substituted or unsubstituted with the fluorine atom; R 11 is a C 5 -C 7 cyclic aromatic cation or an alkyl-substituted aromatic cation, for example, triphenylmethyl cation; Z is a nitrogen atom or a phosphorus atom; R 12 is a C 1 -C 4 alkyl radical or an anilinium radical which is substituted with two C 1 -C 4 alkyl groups along with a nitrogen atom; and q is an integer of 2 or 3.
[0045] Examples of the boron-based cocatalyst include tris(pentafluorophenyl)borane, tris(2,3,5,6-tetrafluorophenyl)borane, tris(2,3,4,5-tetrafluorophenyl)borane, tris(3,4,5-trifluorophenyl)borane, tris(2,3,4-trifluorophenyl)borane, phenylbis(pentafluorophenyl)borane, tetrakis(pentafluorophenyl)borate, tetrakis(2,3,5,6-tetrafluorophenyl)borate, tetrakis(2,3,4,5-tetrafluorophenyl)borate, tetrakis(3,4,5-tetrafluorophenyl)borate, tetrakis(2,2,4-trifluorophenyl)borate, phenylbis(pentafluorophenyl)borate, and tetrakis(3,5-bistrifluoromethylphenyl)borate. Furthermore, a combination of the above-mentioned examples is exemplified by ferrocenium tetrakis(pentafluorophenyl)borate, 1,1′-dimethylferrocenium tetrakis(pentafluorophenyl)borate, silver tetrakis(pentafluorophenyl)borate, triphenylmethyl tetrakis(pentafluorophenyl)borate, triphenylmethyl tetrakis(3,5-bistrifluoromethylphenyl)borate, triethylammonium tetrakis(pentafluorophenyl)borate, tripropylammonium tetrakis(pentafluorophenyl)borate, tri(n-butyl)ammonium tetrakis(pentafluorophenyl)borate, tri(n-butyl)ammonium tetrakis(3,5 -bistrifluoromethylphenyl)borate, N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate, N,N-diethylanilinium tetrakis(pentafluorophenyl)borate, N,N-2,4,6-pentamethylanilinium tetrakis(pentafluorophenyl)borate, N,N-dimethylanilinium tetrakis(3,5-bistrifluoromethylphenyl)borate, diisopropylammonium tetrakis(pentafluorophenyl)borate, dicyclohexylammonium tetrakis(pentafluorophenyl)borate, triphenylphosphonium tetrakis(pentafluorophenyl)borate, tri(methylphenyl)phosphonium tetrakis(pentafluorophenyl)borate, or tri(dimethylphenyl)phosphonium tetrakis(pentafluorophenyl)borate, and preferably, N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate, triphenylmethylinium tetrakis(pentafluorophenyl)borate, and tris(pentafluoro)borane.
[0046] In a catalyst system using the boron-based cocatalyst, the molar ratio of the central metal to the boron atom is preferably 1:0.01-1:100, and more preferably, 1:0.5-1:5.
[0047] Meanwhile, a mixture of the boron compound and the organic aluminum compound or a mixture of the boron compound and the aluminoxane compound may be used, if necessary. In connection with this, the aluminum compound is used to remove polar compounds acting as a catalytic poison from a reaction solvent, and may act as an alkylating agent if X of the catalyst components is halogen.
[0048] The organic aluminum compound is expressed by the following Formula 10.
(R 13 ) r Al(E) 3-r Formula 10
[0049] In the above Formula, R 13 is a C 1 -C 8 alkyl group, E is a hydrogen atom or a halogen atom, and r is an integer ranging from 1 to 3.
[0050] The organic aluminum compound is exemplified by trialkylaluminum including trimethylaluminum, triethylaluminum, tripropylaluminum, triisobutylaluminum, and trihexylaluminum; dialkylaluminum chloride including dimethylaluminum chloride, diethylaluminum chloride, dipropylaluminum chloride, diisobutylaluminum chloride, and dihexylaluminum chloride; alkylaluminum dichloride including methylaluminum dichloride, ethylaluminum dichloride, propylaluminum dichloride, isobutylaluminum dichloride, and hexylaluminum dichloride; or dialkylaluminum hydride including dimethylaluminum hydride, diethylaluminum hydride, dipropylaluminum hydride, diisobutylaluminum hydride, and dihexylaluminum hydride. Trialkylaluminum is preferable, and triethylaluminum and triisobutylaluminum are more preferable.
[0051] In connection with this, the molar ratio of the central metal:the boron atom:the aluminum atom is preferably 1:0.1-100:10-1000, and more preferably, 1:0.5-5:25-500.
[0052] According to another aspect of the present invention, in a method of producing ethylene polymers using the transition metal catalyst system, the transition metal catalyst, the cocatalyst, and ethylene or a vinyl-based comonomer come into contact with each other in the presence of a predetermined organic solvent. At this stage, the transition metal catalyst and the cocatalyst are separately loaded into a reactor, or loaded into the reactor after they are previously mixed with each other. There are no limits to mixing conditions, such as the order of addition, temperature, or concentration.
[0053] The organic solvent useful in the method is C 3 -C 20 hydrocarbons, and is exemplified by butane, isobutane, pentane, hexane, heptane, octane, isooctane, nonane, decane, dodecane, cyclohexane, methylcyclohexane, benzene, toluene, or xylene.
[0054] In detail, when the ethylene homopolymer, that is, high density polyethylene (HDPE), is produced, ethylene is used alone as a monomer, and pressure of ethylene useful to the present invention is 1-1000 atm, and preferably, 10-150 atm. Furthermore, a polymerization temperature is 80-300° C., and preferably, 120-250° C.
[0055] Additionally, when the copolymers of ethylene and α-olefins are produced, C 3 -C 18 α-olefins are used as comonomers along with ethylene, and are selected from the group consisting of propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-hexadecene, and 1-octadecene. More preferably, 1-butene, 1-hexene, 1-octene, or 1-decene is copolymerized with ethylene. In connection with this, the pressure of ethylene and the polymerization temperature are preferably the same as in the method of producing high density polyethylene. The ethylene copolymers produced according to the present invention include 60 wt % or more ethylene, and preferably, 75 wt % ethylene. As described above, linear low density polyethylene (LLDPE) which is produced using C 4 -C 10 α-olefin as the comonomer has a density of 0.910-0.940 g/cc, and, in connection with this, it is possible to produce very or ultra low density polyethylene (VLDPE or ULDPE) having a density of 0.910 g/cc or less. As well, in the course of producing the ethylene homopolymer or copolymers according to the present invention, hydrogen may be used as a molecular weight controlling agent to control a molecular weight, and the ethylene homopolymer or copolymers typically has weight average molecular weight (Mw) of 80,000.
[0056] Since the catalyst system of the present invention is homogeneous in a polymerization reactor, it is preferable for application to a solution polymerization process which is conducted at a temperature of a melting point or higher of the polymer to be produced. However, as disclosed in U.S. Pat. No. 4,752,597, the transition metal catalyst and the cocatalyst may be supported by a porous metal oxide supporter so as to be used in a slurry polymerization process or a gaseous polymerization process as a heterogeneous catalyst system.
[0057] A better understanding of the present invention may be obtained through the following examples which are set forth to illustrate, but are not to be construed as the limit of the present invention.
[0058] Syntheses of all ligands and catalysts were conducted using standard Schlenk or globe box technology in a nitrogen atmosphere if not specifically described otherwise. The organic solvents used in the reactions were refluxed in the presence of sodium metal and benzophenone to remove moisture, and distilled immediately before they were used. 1 H-NMR analyses of the produced ligands and catalysts were carried out at normal temperature using Varian Oxford 300 MHz.
[0059] n-heptane as a polymerization solvent was passed through a column in which a molecular sieve 5A and activated alumina were packed, and bubbling was conducted using highly pure nitrogen to sufficiently remove moisture, oxygen, and other catalytic poison materials before it was used. The resulting polymers were analyzed using the following methods.
[0060] 1. Melt index (MI)
[0061] Measurement was conducted based on ASTM D 2839.
[0062] 2. Density
[0063] Measurement was conducted using a density gradient column based on ASTM D 1505.
[0064] 3. Analysis of a melting point (T m )
[0065] Measurement was conducted using Dupont DSC2910 in a nitrogen atmosphere at a rate of 10° C./min under a 2 nd heating condition.
[0066] 4. Molecular weight and molecular weight distribution
[0067] Measurement was conducted using PL210 GPC which was equipped with PL Mixed-BX2+preCol in a 1,2,3-trichlorobenzene solvent at 135° C. and a rate of 1.0 mL/min, and the molecular weight was revised using a PL polystyrene standard material.
[0068] 5. α-olefin content of copolymer (wt %)
[0069] Measurement was conducted using a Bruker DRX500 nuclear magnetic resonance spectroscope at 125 MHz in a mixed solvent of 1,2,4-trichlorobenzene/C 6 D 6 (7/3 weight fraction) at 120° C. in a 13 C-NMR mode (Bibliography: Randal, J. C. JMS - Rev. Macromol. Chem. Phys. 1980, C29, 201).
PREPARATION EXAMPLE 1
Synthesis of 4-methyl-2,6-bis(2′-isopropylphenyl)phenol
[0070] A mixed solution of 1 mL of water and 4 mL of dimethoxyethane was added into a flask into which 2,6-dibromo-4-methylanisole (400 mg, 1.43 mmol), 2-isopropylphenylboronic acid (720 mg, 4.39 mmol), palladium acetate (14 mg, 0.062 mmol), triphenylphosphine (60 mg, 0.23 mmol), and potassium phosphate (940 mg, 4.43 mmol) were already added, and then refluxed at normal temperature for 6 hours. After cooling to normal temperature, an ammonium chloride aqueous solution (5 mL) and 10 mL of diethylether were added thereto to separate an organic layer and extract residues using diethylether. The separated organic layer was dried with magnesium sulfate and volatile materials were then removed to produce 670 mg of grey 4-methyl-2,6-bis(2′-isopropylphenyl)anisole solid. The anisole thus produced was dissolved in 5 mL of methylene chloride without separate purification, 3 mL of boron tribromide (1 M methylene chloride solution) was dropped thereon at −78° C., and a reaction was carried out while the temperature was slowly increased to normal temperature. After the reaction, a mixed solution of water (5 mL) and diethylether (10 mL) was added to separate an organic layer and extract an aqueous solution layer using diethylether (5 mL×3), and the separated organic layer was dried. Residues from which volatile components were removed at reduced pressure were purified using a silica gel chromatography tube in a mixed solvent of hexane and methylene chloride to produce 0.47 g of white 4-methyl-2,6-bis(2′-isopropylphenyl)phenol solid.
[0071] Yield: 95%, 1 H-NMR (CDCl 3 ) δ=1.12-1.19 (m, 12H), 2.34 (s, 3H), 2.93 (m, 2H), 4.51 (s, 1H), 6.95 (s, 2H), 7.24 (d, 4H), 7.42 (t, 4H) ppm
Synthesis of (dichloro)(pentamethylcyclopentadienyl)(4-methyl-2,6-bis(2′-isoprolpylphenyl)phenoxy)titanium(IV)
[0072] 4-methyl-2,6-bis(2′-isopropylphenyl)phenol (344 mg, 1 mmol) and sodium hydride (72 mg, 3 mmol) were dissolved in 10 mL of toluene, and then refluxed for 4 hours. Subsequently, cooling to normal temperature was conducted, a solution in which (trichloro)(pentamethylcyclopentadienyl)titanium(IV) (289 mg, 1 mmol) was dissolved in 5 mL of toluene was slowly added thereto, and reflux was conducted for 24 hours. After the reaction was finished, volatile materials were removed, washing was conducted using purified hexane, recrystallization was conducted using a mixed solution of toluene/hexane at −35° C., filtration was conducted, and drying was conducted at reduced pressure to produce 352 mg of red solid component.
[0073] Yield: 67%, 1 H-NMR (C 6 D 6 ) δ=0.95-1.26 (m, 12H), 1.62 (s, 15H), 1.88 (s, 3H), 3.17 (m, 2H), 6.94-7.29 (m, 10H) ppm
EXAMPLE 1
[0074] 300 mL of n-heptane was added into a stainless steel reactor which was purged with nitrogen after sufficient drying and had a volume of 500 m/L, and 0.5 mL of triisobutylaluminum (Aldrich) (200 mM n-heptane solution) was added thereto. The temperature of the reactor was then increased to 140° C., and, subsequently, 0.2 mL of (dichloro)(pentamethylcyclopentadienyl)(4-methyl-2,6-bis(2′-isopropylphenyl)phenoxy)titanium(IV) (5 mM toluene solution), produced according to preparation example 1, and 0.3 mL of triphenylmethylinium tetrakis(pentafluorophenyl)borate (99%, Boulder Scientific) (5 mM toluene solution) were sequentially added thereto. Ethylene was then injected into the reactor until the pressure in the reactor was 30 atm, and was continuously fed for polymerization. 10 min after the reaction started, 10 mL of ethanol (including 10 vol % hydrochloric acid aqueous solution) were added to finish the polymerization, agitation was conducted for 4 hours along with 1500 mL of additional ethanol, and products were filtered and separated. The resulting product was dried in a vacuum oven at 60° C. for 8 hours to produce 7.3 g of polymer. The polymer had a melting point of 132.1° C. and a melt index of 0.001 g/10 min or less, and a weight average molecular weight of 393,000 and a molecular weight distribution of 3.36, which were determined through gel chromatography analysis.
EXAMPLE 2
[0075] 15 mL of 1-octene were injected into a reactor which was the same as in example 1, and polymerization was then conducted through the same procedure as in example 1 except that 0.3 mL of (dichloro)(pentamethylcyclopentadienyl)(4-methyl-2,6-bis(2′-isopropylphenyl)phenoxy)titanium(IV) (5 mM toluene solution) and 0.45 mL of triphenylmethylinium tetrakis(pentafluorophenyl)borate (Boulder Scientific) (5 mM toluene solution) were added after 0.75 mL of triisobutylaluminum (Aldrich) (200 mM n-heptane solution) were added. 4.0 g of dried polymer was obtained. The weight average molecular weight was 175,000 and a molecular weight distribution was 5.91, which were determined through gel chromatography analysis. The melt index was 0.12 g/10 min, the melting point of the polymer was 114.7° C., the density was 0.9215 g/cc, and the content of 1-octene was 7.8 wt %.
PREPARATION EXAMPLE 2
Synthesis of 4-methyl-2-(2′-isoprolpylphenyl)phenol
[0076] A mixed solution of 1 mL of water and 4 mL of dimethoxyethane was added into a flask into which 2-bromo-4-methylanisole (600 mg, 2.98 mmol), 2-isopropylphenylboronic acid (734 mg, 4.47 mmol), palladium acetate (16 mg, 0.074 mmol), triphenylphosphine (72 mg, 0.27 mmol), and potassium phosphate (1.12 g, 5.28 mmol) were already added, and then refluxed at normal temperature for 6 hours. After cooling to normal temperature, an ammonium chloride aqueous solution (5 mL) and 10 mL of diethylether were added thereto to separate an organic layer and extract residues with diethylether. The separated organic layer was dried with magnesium sulfate and volatile materials were removed to produce 850 mg of grey 4-methyl-2-(2′-isopropylphenyl)anisole solid. The anisole thus produced was dissolved in 5 mL of methylene chloride without separate purification, 3 mL of boron tribromide (1 M methylene chloride solution) was dropped thereonto at −78° C., and a reaction was carried out while the temperature slowly increased to normal temperature. After the reaction, a mixed solution of water (5 mL) and diethylether (10 mL) was added to separate an organic layer and extract an aqueous solution layer using diethylether (5 mL×3), and the separated organic layer was dried. Residues from which volatile components were removed at reduced pressure were purified using a silica gel chromatography tube in a mixed solvent of hexane and methylene chloride to produce 633 mg of white 4-methyl-2,6-(2′-isopropylphenyl)phenol solid.
[0077] Yield: 93%, 1 H-NMR (CDCl 3 ) δ=1.10-1.21(q, 6H), 2.33 (s, 3H), 2.91 (m, 1H), 4.63 (s, 1H), 6.87-7.51 (m, 7H) ppm
Synthesis of (dichloro)(pentamethylcyclopentadienyl)(4-methyl-2-(2-isopropylphenyl)phenoxy)titanium(IV)
[0078] 4-methyl-2-(2′-isopropylphenyl)phenol (1 g, 4.41 mmol) and sodium hydride (318 mg, 13.25 mmol) were dissolved in 10 mL of toluene, and then refluxed for 4 hours. Subsequently, cooling to normal temperature was conducted, a solution in which (trichloro)(pentamethylcyclopentadienyl)titanium(IV) (1.15 g, 4.0 mmol) was dissolved in 5 mL of toluene was slowly dropped thereonto, and reflux was conducted for 24 hours. After the reaction was finished, volatile materials were removed, washing was conducted using purified hexane, recrystallization was conducted using a mixed solution of toluene/hexane at −35° C., filtration was conducted, and drying was conducted at reduced pressure to produce 1.53 g of red solid component.
[0079] Yield: 67%, 1 H-NMR (C 6 D 6 ) δ=0.96-1.07 (m, 6H), 1.76 (s, 15H), 1.89 (s, 3H), 2.99 (m, 1H), 6.85-7.37 (m, 7H) ppm
EXAMPLE 3
[0080] Polymerization was conducted through the same procedure as in example 2 except that 0.2 mL of (dichloro)(pentamethylcyclopentadienyl)(4-methyl-2-(2′-isopropylphenyl)phenoxy)titanium(IV) (5 mM toluene solution) produced according to preparation example 2 were used. The product was dried to produce 5.5 g of polymer. The polymer had a melting point of 132.1° C. and a melt index of 0.06 g/10 min, and a weight average molecular weight of 188,000 and a molecular weight distribution of 4.30 which were determined through gel chromatography analysis.
PREPARATION EXAMPLE 3
Synthesis of 4-methyl-2,6-diphenylphenol
[0081] A mixed solution of 1 mL of water and 4 mL of dimethoxyethane was added into a flask into which 2,6-dibromo-4-methylanisole (400 mg, 1.43 mmol), phenylboronic acid (535 mg, 4.39 mmol), palladium acetate (14 mg, 0.062 mmol), triphenylphosphine (60 mg, 0.23 mmol), and potassium phosphate (940 mg, 4.43 mmol) were already added, and then refluxed at normal temperature for 6 hours. After cooling to normal temperature, an ammonium chloride aqueous solution (5 mL) and 10 mL of diethylether were added thereto to separate an organic layer and extract residues using diethylether. The separated organic layer was dried with magnesium sulfate and volatile materials were removed to produce 420 mg of grey 4-methyl-2,6-diphenylanisole solid. The anisole thus produced was dissolved in 5 mL of methylene chloride without separate purification, 3 mL of boron tribromide (1 M methylene chloride solution) were dropped thereonto at −78° C., and the reaction was carried out while the temperature was slowly increased to normal temperature. After the reaction, a mixed solution of water (5 mL) and diethylether (10 mL) was added to separate an organic layer and extract an aqueous solution layer using diethylether (5 mL×3), and the separated organic layer was dried. Residues from which volatile components were removed at reduced pressure were purified using a silica gel chromatography tube in a mixed solvent of hexane and methylene chloride to produce 333 mg of white 4-methyl-2,6-diphenylphenol solid.
[0082] Yield: 89%, 1 H-NMR (CDCl 3 ) δ=2.36 (s, 3H), 5.24 (s, 1H), 7.01 (s, 2H), 7.37 (t, 2H), 7.47 (t, 4H), 7.54 (d, 4H) ppm
Synthesis of (dichloro)(pentamethylcyclopentadienyl)(4-methyl-2,6-diphenylphenoxy)titanium(IV)
[0083] 4-methyl-2,6-diphenylphenol (400 mg, 1.53 mmol) and sodium hydride (110 mg, 4.60 mmol) were dissolved in 10 mL of toluene, and then refluxed for 4 hours. Subsequently, cooling to normal temperature was conducted, a solution in which (trichloro)(pentamethylcyclopentadienyl)titanium(IV) (376 mg, 1.30 mmol) was dissolved in 5 mL of toluene was slowly dropped thereonto, and reflux was conducted for 24 hours. After the reaction finished, volatile materials were removed, washing was conducted using purified hexane, recrystallization was conducted using a mixed solution of toluene/hexane at −35° C., filtration was conducted, and drying was conducted at reduced pressure to produce 308 mg of red solid component.
[0084] Yield: 46%, 1 H-NMR (C 6 D 6 ) δ=1.87 (s, 3H), 1.67 (s, 15H), 6.97-7.18 (m, 12H) ppm
EXAMPLE 4
[0085] Polymerization was conducted through the same procedure as in example 2 except that 0.2 mL of (dichloro)(pentamethylcyclopentadienyl)(4-methyl-2,6-diphenylphenoxy)titanium(IV) (5 mM toluene solution) produced according to preparation example 3 were used. The product was dried to produce 5.8 g of polymer. The polymer had a melting point of 131.4° C. and a melt index of 0.011 g/10 min, and a weight average molecular weight of 349,000 and a molecular weight distribution of 2.74, which were determined through gel chromatography analysis.
PREPARATION EXAMPLE 4
Synthesis of (dichloro)(pentamethylcyclopentadienyl)(2-phenylphenoxy)titanium(IV)
[0086] After 0.86 g of 2-phenylphenol (5.07 mmol) (Aldrich, 99%) were dissolved in 40 mL of toluene, 2.4 mL of butyl lithium (2.5 M hexane solution) were slowly dropped thereonto at 0° C. After the reaction was conducted at normal temperature for 12 hours, a solution in which (trichloro)(pentamethylcyclopentadienyl)titanium(IV) (1.32 g, 4.56 mmol) was dissolved in 10 mL of toluene was slowly dropped thereonto at 0° C. After agitation was conducted at normal temperature for 12 hours, filtration was conducted, volatile materials were removed, and recrystallization was conducted using a mixed solution of toluene/hexane at −35° C. to produce 1.64 g of an orange-colored solid component.
[0087] Yield: 85%; 1 H-NMR (C 6 D 6 ) δ=1.68 (s, 15H), 6.82-7.26 (m, 9H) ppm
EXAMPLE 5
[0088] Polymerization was conducted through the same procedure as in example 2 except that 0.2 mL of (dichloro)(pentamethylcyclopentadienyl)(2-phenylphenoxy)titanium(IV) (5 mM toluene solution) produced according to preparation example 4 were used. The product was dried to produce 10.5 g of polymer. The polymer had a melting point of 130.3° C. and a melt index of 0.001 g/10 min or less, and a weight average molecular weight of 303,000 and a molecular weight distribution of 3.4, which were determined through gel chromatography analysis.
EXAMPLE 6
[0089] Polymerization was conducted through the same procedure as in example 2 except that 0.3 mL of (dichloro)(pentamethylcyclopentadienyl)(2-phenylphenoxy)titanium(IV) (5 mM toluene solution) produced according to preparation example 4 were used. 7.8 g of dried polymer were obtained. The weight average molecular weight was 139,000 and the molecular weight distribution was 2.5, as determined through gel chromatography analysis. The melt index was 0.2 g/10 min, the melting point was 118.7° C., the density was 0.9197 g/cc, and the content of 1-octene was 4.5 wt %.
PREPARATION EXAMPLE 5
Synthesis of 2-isopropyl-6-phenylphenol
[0090] A mixed solution of 8 mL of water and 32 mL of dimethoxyethane was added into a flask into which 2-bromo-6-isopropylanisole (1.98 g, 8.64 mmol), phenylboronic acid (2.10 g, 17.28 mmol), palladium acetate (96 mg, 0.43 mmol), triphenylphosphine (0.225 g, 0.86 mmol), and potassium phosphate (11 g, 51.84 mmol) were already added, and then refluxed at normal temperature for 12 hours. After cooling to normal temperature, an ammonium chloride aqueous solution (15 mL) and 30 mL of diethylether were added thereto to separate an organic layer and extract residues using diethylether. The separated organic layer was dried with magnesium sulfate and volatile materials were removed to produce 2 g of grey 2-isopropyl-6-phenylanisole solid. The anisole thus produced was dissolved in 15 mL of methylene chloride without separate purification, 12 mL of boron tribromide (1 M methylene chloride solution) were dropped thereonto at −78° C., and the reaction was carried out for 12 hours while the temperature was slowly increased to normal temperature. After the reaction, a mixed solution of water (15 mL) and diethylether (30 mL) was added to separate an organic layer and extract an aqueous solution layer using diethylether (15 mL×3), and the separated organic layer was dried. Residues from which volatile components were removed at reduced pressure were purified using a silica gel chromatography tube in a mixed solvent of hexane and methylene chloride to produce 1.72 g of white 2-isopropyl-6-phenylphenol solid.
[0091] Yield: 94%, 1 H-NMR (CDCl 3 ) δ=1.307 (d, 6H), 3.45 (m, 1H), 5.09 (s, 1H), 6.95-7.43 (m, 8H) ppm
Synthesis of (dichloro)(pentamethylcyclopentadienyl)(2-isopropyl-6-phenylphenoxy)titanium(IV)
[0092] 2-isopropyl-6-phenylphenol (700 mg, 3.28 mmol) and sodium hydride (236 mg, 9.84 mmol) were dissolved in 10 mL of toluene, and then refluxed for 4 hours. Subsequently, cooling to normal temperature was conducted, a solution in which (trichloro)(pentamethylcyclopentadienyl)titanium(IV) (930 mg, 3.21 mmol) was dissolved in 5 mL of toluene was slowly dropped thereonto, and reflux was conducted for 24 hours. After the reaction was finished, volatile materials were removed, washing was conducted using purified hexane, recrystallization was conducted using a mixed solution of toluene/hexane at −35° C., filtration was conducted, and drying was conducted at reduced pressure to produce 1.0 g of red solid component.
[0093] Yield: 64%, 1 H-NMR (C 6 D 6 ) δ=1.324 (d, 6H), 1.63 (s, 15H), 3.53 (m, 1H), 7.05-7.66 (m, 8H) ppm
EXAMPLE 7
[0094] Polymerization was conducted through the same procedure as in example 2 except that 0.2 mL of (dichloro)(pentamethylcyclopentadienyl)(2-isopropyl-6-phenylphenoxy)titanium(IV) (5 mM toluene solution) produced according to preparation example 5 were used. The product was dried to produce 5.5 g of polymer. The polymer had a melting point of 132.6° C. and a melt index of 0.002 g/10 min, and a weight average molecular weight of 390,000 and a molecular weight distribution of 4.08, as determined through gel chromatography analysis.
PREPARATION EXAMPLE 6
Synthesis of 4-methyl-2,6-bis(3′,5′-dimethylphenyl)phenol
[0095] A mixed solution of 1 mL of water and 4 mL of dimethoxyethane was added into a flask into which 2,6-dibromo-4-methylanisole (400 mg, 1.43 mmol), 3,5-dimethylphenylboronic acid (658 mg, 4.39 mmol), palladium acetate (14 mg, 0.062 mmol), triphenylphosphine (60 mg, 0.23 mmol), and potassium phosphate (940 mg, 4.43 mmol) were already added, and then refluxed at normal temperature for 6 hours. After cooling to normal temperature, an ammonium chloride aqueous solution (5 mL) and 10 mL of diethylether were added thereto to separate an organic layer and extract residues using diethylether. The separated organic layer was dried with magnesium sulfate and volatile materials were removed to produce 453 mg of white 4-methyl-2,6-bis(3′,5′-dimethylphenyl)anisole solid (yield 96%). The anisole thus produced was dissolved in 5 mL of methylene chloride without separate purification, 3 mL of boron tribromide (1 M methylene chloride solution) were dropped thereonto at −78° C., and the reaction was carried out while the temperature was slowly increased to normal temperature. After the reaction, a mixed solution of water (5 mL) and diethylether (10 mL) was added to separate an organic layer and extract an aqueous solution layer using diethylether (5 mL×3), and the separated organic layer was dried. Residues from which volatile components were removed at reduced pressure were purified using a silica gel chromatography tube in a mixed solvent of hexane and methylene chloride to produce 0.41 g of white 4-methyl-2,6-bis(3′,5′-dimethylphenyl)phenol solid.
[0096] Yield: 92%, 1 H-NMR (CDCl 3 ) δ=1.55 (s, 3H), 2.37 (s, 12H), 5.35 (s, 1H), 7.05 (s, 2H), 7.15 (s, 4H), 7.27 (4, 2H) ppm
PREPARATION EXAMPLE 7
Synthesis of 4-methyl-2,6-bis(biphenyl)phenol
[0097] A mixed solution of 1 mL of water and 4 mL of dimethoxyethane was added into a flask into which 2,6-dibromo-4-methylanisole (400 mg, 1.43 mmol), biphenylboronic acid (870 mg, 4.39 mmol), palladium acetate (14 mg, 0.062 mmol), triphenylphosphine (60 mg, 0.23 mmol), and potassium phosphate (940 mg, 4.43 mmol) were already added, and then refluxed at normal temperature for 6 hours. After cooling to normal temperature, an ammonium chloride aqueous solution (5 mL) and 10 mL of diethylether were added thereto to separate an organic layer and extract residues using diethylether. The separated organic layer was dried with magnesium sulfate and volatile materials were removed to produce 560 mg of white 4-methyl-2,6-bis(biphenyl)anisole solid (yield 95%). The anisole thus produced was dissolved in 5 mL of methylene chloride without separate purification, 3 mL of boron tribromide (1 M methylene chloride solution) were dropped thereonto at −78° C., and the reaction was carried out while the temperature was slowly increased to normal temperature. After the reaction, a mixed solution of water (5 mL) and diethylether (10 mL) was added to separate an organic layer and extract an aqueous solution layer using diethylether (5 mL×3), and the separated organic layer was dried. Residues from which volatile components were removed at reduced pressure were purified using a silica gel chromatography tube in a mixed solvent of hexane and methylene chloride to produce 540 mg of white 4-methyl-2,6-bis(biphenyl)phenol solid.
[0098] Yield: 92%, 1 H-NMR (CDCl 3 ) δ=2.39 (s, 3H), 5.34 (s, 1H), 7.16-7.72 (m, 20H) ppm
Synthesis of (dichloro)(pentamethylcyclopentadienyl)(4-methyl-2,6-bis(biphenyl)phenoxy)titanium(IV)
[0099] 4-methyl-2,6-bis(biphenyl)phenol (206 mg, 0.5 mmol) and sodium hydride (36 mg, 1.5 mmol) were dissolved in 10 mL of toluene, and then refluxed for 1 hour. Subsequently, cooling to normal temperature was conducted, a solution in which (trichloro)(pentamethylcyclopentadienyl)titanium(IV) (130 mg, 0.45 mmol) was dissolved in 10 mL of toluene was slowly dropped thereonto, and reflux was conducted for 24 hours. After the reaction was finished, volatile materials were removed, washing was conducted using purified hexane, recrystallization was conducted using a mixed solution of toluene/hexane at −35° C., filtration was conducted, and drying was conducted at reduced pressure to produce 0.12 g of yellow solid component.
[0100] Yield: 42%, 1 H-NMR (CDCl 3 ) δ=1.60 (s, 15H), 2.48 (s, 3H), 7.08-8.15 (m, 20H) ppm
PREPARATION EXAMPLE 8
Synthesis of 4-methyl-2,6-bis(1′-naphthyl)phenol
[0101] A mixed solution of 1 mL of water and 4 mL of dimethoxyethane was added into a flask into which 2,6-dibromo-4-methylanisole (700 mg, 2.63 mmol), 1-naphthylboronic acid (1.39 g, 8.07 mmol), palladium acetate (25 mg, 0.12 mmol), triphenylphosphine (94 mg, 0.35 mmol), and potassium phosphate (1.9 g, 8.9 mmol) were already added, and then refluxed at normal temperature for 6 hours. After cooling to normal temperature, an ammonium chloride aqueous solution (5 mL) and 10 mL of diethylether were added thereto to separate an organic layer and extract residues using diethylether. The separated organic layer was dried with magnesium sulfate and volatile materials were removed to produce 880 mg of grey 4-methyl-2,6-bis(1′-naphthyl)anisole solid (yield 89%). The anisole thus produced was dissolved in 10 mL of methylene chloride without separate purification, 5 mL of boron tribromide (1 M methylene chloride solution) were dropped thereonto at −78° C., and the reaction was carried out while the temperature was slowly increased to normal temperature. After the reaction, a mixed solution of water (5 mL) and diethylether (10 mL) was added to separate an organic layer and extract an aqueous solution layer using diethylether (5 mL×3), and the separated organic layer was dried. Residues from which volatile components were removed at reduced pressure were purified using a silica gel chromatography tube in a mixed solvent of hexane and methylene chloride to produce 805 mg of white 4-methyl-2,6-bis(1′-naphthyl)phenol solid.
[0102] Yield: 85%, 1 H-NMR(CDCl 3 ) δ=2.41(s,3H), 4.71(s,1H), 7.21-7.92 (m,16H) ppm
COMPARATIVE PREPARATION EXAMPLE 1
Synthesis of (dichloro)(pentamethylcyclopentadienyl) (2,6-di-tert-butylphenoxy)titanium(IV)
[0103] After 600 mg of 2,6-di-tert-butylphenol (2.91 mmol) (Aldrich, 99%) were dissolved in 30 mL of diethylether, 1.28 mL of butyl lithium (2.5 M hexane solution) were slowly dropped thereonto at −31° C. After 1 hour, agitation was conducted at normal temperature for 6 hours. The resulting mixture was dissolved in diethylether, and a solution in which (trichloro)(pentamethylcyclopentadienyl)titanium(IV) (752 mg, 2.60 mmol) was dissolved in 10 mL of diethylether was slowly dropped thereonto at −30° C. After 1 hour, agitation was conducted at normal temperature for 6 hours. The solvent was removed from the resulting product, and the solvent-free product was dissolved in 10 mL of toluene and then recrystallized to produce 829 mg of red solid component.
[0104] Yield: 69%; 1 H-NMR (CDCl 3 ) δ=1.37 (s, 18H), 2.10 (s, 15H), 6.50-7.20 (m, 3H) ppm
COMPARATIVE EXAMPLE 1
[0105] Polymerization was conducted through the same procedure as in example 1 except that 0.2 mL of (dichloro)(pentamethylcyclopentadienyl)(2,6-di-tert-butylphenoxy)titanium(IV) (5 mM toluene solution) produced according to comparative preparation example 1 were used. The product was dried to produce 1.4 g of polymer. The polymer had a melting point of 133.1° C. and a melt index of 0.25 g/10 min, and a weight average molecular weight of 182,000 and a molecular weight distribution of 5.76, which were determined through gel chromatography analysis.
COMPARATIVE EXAMPLE 2
[0106] Polymerization was conducted through the same procedure as in example 2 except that 0.2 mL of (trimethyl)(pentamethylcyclopentadienyl)titanium(IV) (97%, Strem) (5 mM toluene solution), 0.24 mL of triisobutylaluminum (200 mM n-heptane solution) (Aldrich), and 0.25 mL of triphenylmethylinium tetrakis(pentafluorophenyl)borate (99%, Boulder Scientific) (5 mM toluene solution) were used. The product was dried to produce 3.0 g of polymer. The polymer had a melting point of 132.0° C. and a melt index of 0.16 g/10 min, and a weight average molecular weight of 150,000 and a molecular weight distribution of 5.47, which were determined through gel chromatography analysis.
COMPARATIVE EXAMPLE 3
[0107] Polymerization was conducted through the same procedure as in example 3 except that 0.4 mL of (trimethyl)(pentamethylcyclopentadienyl)titanium(IV) (97%, Strem) (5 mM toluene solution), 1.0 mL of triisobutylaluminum (200 mM n-heptane solution) (Aldrich), and 0.6 mL of triphenylmethylinium tetrakis(pentafluorophenyl)borate (99%, Boulder Scientific) (5 mM toluene solution) were used. 1.1 g of dried polymer were produced.
COMPARATIVE EXAMPLE 4
[0108] Polymerization was conducted through the same procedure as in example 1 except that 0.2 mL of rac-dimethylsilylbis(2-methylindenyl)zirconium dichloride (Boulder Scientific) (5 mM toluene solution) were used as a catalyst component. The product was dried to produce 25.0 g of polymer. The polymer had a melting point of 132.5° C. and a melt index of 4.4 g/10 min, and a weight average molecular weight of 59,000 and a molecular weight distribution of 8.9, which were determined through gel chromatography analysis.
COMPARATIVE EXAMPLE 5
[0109] Polymerization was conducted through the same procedure as in example 3 except that 0.3 mL of rac-dimethylsilylbis(2-methylindenyl)zirconium dichloride (Boulder Scientific) (5 mM toluene solution) were used as a catalyst component. The product was dried to produce 15.0 g of polymer. The polymer had a melting point of 123.2° C. and a melt index of 110 g/10 min, and a weight average molecular weight of 28,000 and a molecular weight distribution of 12.0, which were determined through gel chromatography analysis. The 1-octene content of the polymer was 2.4 wt %.
[0110] The arylphenoxy catalyst system according to the present invention is advantageous in that it is easy to handle, it is possible to produce it using environmentally-friendly raw materials at high yield, and it has high catalytic activity in a high temperature solution polymerization condition due to its excellent thermal stability in the course of producing a polymer having a high molecular weight, thus it is more useful than a conventional non-metallocene single-site catalyst. Therefore, it is useful for producing an ethylene homopolymer or copolymers of ethylene and α-olefins having various physical properties. | The present invention relates to an arylphenoxy catalyst system producing an ethylene homopolymer or copolymers of ethylene and α-olefins, and a method of producing an ethylene homopolymer or copolymers of ethylene and α-olefins having a high molecular weight under a high temperature solution polymerization condition using the same. The catalyst system includes a group IV arylphenoxy-based transition metal catalyst and an aluminoxane cocatalyst or a boron compound cocatalyst. In the transition metal catalyst, a cyclopentadiene derivative and arylphenoxide as fixed ligands are located around the group IV transition metal, arylphenoxide is substituted with at least one aryl derivative and is located at the ortho position thereof, and the ligands are not crosslinked to each other. The catalyst includes an environmentally-friendly raw material, synthesis of the catalyst is economical, and thermal stability of the catalyst is excellent. It is useful for producing an ethylene homopolymer or copolymers of ethylene and α-olefins having various physical properties in commercial polymerization processes. | 2 |
REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/078,413, filed on Mar. 18, 1998 and incorporated herein by reference.
BACKGROUND OF THE INVENTION
Physical therapists, chiropractors, and other medical providers have used nerve and muscle stimulation to treat a variety of ailments. These medical providers have used electronic muscle stimulation (EMS) and transcutaneous electrical nerve stimulation (TENS) as a treatment for muscle and joint rehabilitation as well as chronic pain. Urologists and obstetrician/gynecologists have used a form of TENS for pelvic floor stimulation to treat incontinence and pelvic pain. In addition, medical providers have used a variety of implantable and percutaneous stimulators to manage pain, to create local nerve blocks, and to treat incontinence, Parkinson's disease, and multiple sclerosis.
Transcutaneous stimulators, i.e., stimulators which do not physically penetrate the skin surface, are less invasive than percutaneous and implantable stimulators. However, transcutaneous stimulators often require higher current levels than percutaneous and implantable stimulators. Higher current levels can cause irritation and discomfort when used for extended periods. Also, since transcutaneous stimulators stimulate on the skin surface, their target site usually covers a large area. Thus, transcutaneous stimulators may not be highly effective for direct nerve stimulation.
More typically, providers use implantable stimulators when there is a need for direct nerve stimulation or continuous stimulation. Implantable stimulators can free a patient from the need for constant and frequent manual treatment. However, implantable stimulators can cause mild discomfort, and often cause more severe implant-site pain.
Percutaneous stimulators provide direct nerve stimulation without the invasiveness of an implant. However, traditional percutaneous stimulators need to be in close proximity to a target nerve. Movement of the stimulating needle can result in a loss of the ability to stimulate a target nerve. A medical provider often needs to re-insert and/or re-locate the percutaneous needle during treatment. In addition, the load impedance provided by sub-cutaneous tissue is low. Such low impedance can result in unwanted or accidental transmission of relatively high current levels. Such relatively high current levels can result in nerve and tissue damage.
It is an object of the invention to provide stimulator systems and methods that provide the non-invasiveness of transcutaneous systems with the effectiveness of percutaneous systems.
It is another object of the invention to provide systems and methods that are less likely to result in nerve and tissue damage.
It is yet another object of the invention to provide inexpensive and durable electro-nerve stimulation systems.
Other general and more specific objects of this invention will in part be obvious and will in part be evident from the drawings and the description which follow.
SUMMARY OF THE INVENTION
In one aspect, the present invention is directed to transcutaneous-percutaneous electro-nerve stimulator systems and methods that are minimally invasive and that are effective in direct nerve stimulation. A system according to one aspect of the invention includes a pulse generator, a transcutaneous electrode electrically coupled to the pulse generator, and a percutaneous electrode electrically coupled to the pulse generator and having an end for insertion into a patient's body. The pulse generator produces pulses which couple between the transcutaneous electrode and the percutaneous needle. The transcutaneous electrode is positioned proximate to the selected stimulation site on the surface of the skin. Preferably, the transcutaneous electrode is positioned distal from the stimulation site. The percutaneous electrode is inserted through the skin in proximity to an internal stimulation site, preferably in proximity to the nerve to be stimulated. The pulses from the pulse generator traverse the internal stimulation site by passing between the transcutaneous electrode and the internal percutaneous electrode.
In another aspect of this invention, the transcutaneous electrode allows for maximum current dispersion at the application site. In one embodiment, an internal layer of the electrode is coated with a high conductive metal, such as silver, to disperse the stimulating current quickly over the entire electrode surface.
In another aspect of this invention, since the direction of the electric field can reduce the required intensity, the system includes a mechanism to assure a particular polarity of the stimulating current. According to this aspect of the invention, the system has a transcutaneous electrode that is fixedly attached to the first lead wire. In addition, the first and second lead wires are combined at one end into a single cable for interfacing with the pulse generator. The cable is “keyed” to interface with the pulse generator so that the transcutaneous electrode is always positive and the percutaneous electrode is always negative. In other words, the cable can be plugged into the pulse generator in only one way.
In another aspect of this invention, the electrical circuit of the pulse generator has an AC coupled current pulse output, and includes an element for measuring the amount of current delivered directly to the patient. Patient stimulators are safest when the output circuitry is AC coupled. AC coupled circuits guarantee that no net DC current will pass to the body. Traditional stimulators have accomplished an AC coupled output using a current transformer. A system according to one embodiment of the present invention includes circuitry which creates an AC coupled output without the need for a current transformer by using a DC blocking capacitor in conjunction with the following circuit features: a pulse shaping circuit, a DC-DC step up voltage source, a switching circuit, and a current sense/stimulation adjustment feedback control.
In another aspect of this invention, the circuitry includes a discharge path for the DC blocking capacitor which has an optimal discharge time-constant to accommodate the desired pulse width, duty cycle, and expected load range of the output pulse. A capacitor can serve as a DC block yet pass current pulses with sufficiently fast rise and fall times. However, after a number of pulses the capacitor can become charged if a discharge path is not provided. This accumulated charge voltage effectively subtracts from the available supply voltage so little or no pulse energy is delivered to the load. The discharge path in this circuitry is preferably designed to minimize droop during the output pulse yet assure full discharge by the time of the next pulse arrives.
In another aspect of this invention, the pulse generator circuitry includes the option of an active or passive discharge configuration. In the passive configuration, a discharge resistor can be included in the output circuit parallel to the DC blocking capacitor and output load. In the active configuration, a transistor type switch can be used to discharge the blocking capacitor. The switch can momentarily discharge the capacitor when the output pulse is not active.
In another aspect of this invention, the electrical output circuit has the frequency and pulse width fixed to a value optimal for a given application. The electrical output circuit only allows a user to adjust the stimulation current threshold. Thus the electrical output circuit prevents the user from setting the parameters to values that are sub-optimal or even harmful while making the device easier to use.
In another aspect of this invention, the percutaneous electrode can be in the form of a needle having a portion coated or insulated to allow for more precise stimulation points. In one embodiment, a portion of the needle shaft is covered or coated with an electrically-insulating material, while the needle tip is exposed to permit electrical contact with the patient's tissue.
In another aspect of this invention, the pulse generator is battery powered and is small enough to be comfortably worn or carried by the patient. For example, the pulse generator can be small enough to be worn around a leg or other body extremity using a small wrap similar to a blood pressure cuff.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be more fully understood by reference to the following detailed description in conjunction with the attached drawings in which like reference numerals refer to like elements and in which:
FIG. 1 is a schematic illustration of the components of a electro-nerve stimulation system according to one embodiment of the invention;
FIG. 1A is a schematic illustration of a pulse generator of the electro-nerve stimulation system of FIG. 1 according to one embodiment of the invention;
FIG. 1B is a schematic illustration of a pulse generator of the electro-nerve stimulation system of FIG. 1 according to a second embodiment of the invention;
FIG. 2 is a block diagram of the circuitry of the pulse generator of FIG. 1;
FIG. 2A is a schematic diagram of the blocking capacitor and a passive discharge circuit of the pulse generator of the electro-nerve stimulation system of FIG. 1;
FIG. 2B is a schematic diagram of the blocking capacitor and an active discharge circuit of the pulse generator of the electro-nerve stimulation system of FIG. 1;
FIG. 3 is the output current waveform from the stimulation system of FIG. 1;
FIG. 4 shows a cross-sectional view of the transcutane ous electrode of FIG. 1; and
FIG. 5 shows a cross-sectional view of the percutaneous needle of FIG. 1 .
DETAILED DESCRIPTION
FIG. 1 shows one embodiment of a combined transcutaneous-percutaneous stimulator system according to the invention. The system 11 includes a pulse generator 10 , a first lead wire 16 electrically coupled to the pulse generator 10 , a transcutaneous electrode 14 electrically coupled to the first lead wire 16 , a second lead wire 18 electrically coupled to the pulse generator 10 , and a percutaneous electrode needle 12 electrically coupled to the second lead wire 18 .
A pulse generator 10 according to one aspect of the invention is illustrated in FIG. 1 A and includes an electrically isolating housing 13 for electronic components and connector ports 22 , 23 for the first and second lead wires 16 , and 18 , respectively. Alternatively, the lead wires can be combined into a single cable at one end for interfacing with a single interface on the pulse generator. The pulse generator 10 can include an On/Off switch and an intensity control 20 .
Referring again to FIG. 1, according to one embodiment of the invention, the pulse generator 10 is a small hand-held, battery operated pulse generator that produces small current pulses which pass between a transcutaneous electrode 14 and a percutaneous needle 12 . The electrode 14 is positioned ‘down-stream’, i.e., distal, from the selected stimulation site 15 on the surface of the skin. The percutaneous electrode needle 12 is inserted through the skin at a location and to a depth that brings the tip in close proximity to a nerve or nerves to be stimulated. Current pulses traverse the internal stimulation site by passing from the transcutaneous electrode 14 to the internal percutaneous electrode needle 12 , as indicated by arrow i in FIG. 1 .
Advantageously, the current density and subsequent electric field intensity generated between the surface electrode and the percutaneous needle is greater than that generated by traditional percutaneous stimulators. A greater electric field intensity makes site location for the transcutaneous electrode and percutaneous needle easier. Furthermore, the load impedance through the surface of the skin is much higher than the internal impedance. This relatively high load impedance lessens the likelihood of damage to tissue and nerves due to high current pulses. The transcutaneous electrode also creates a capacitive interface which attenuates harmful DC currents. Moreover, the system, according to one embodiment of the invention, has only one percutaneous needle, which lessens the invasiveness of the nerve stimulation procedure.
The system 11 of the present invention is particularly suited for the treatment of urinary urge incontinence in accordance with the following exemplary procedure. The transcutaneous electrode 14 is placed on a patient's skin distal to the selected stimulation site 15 . The percutaneous needle 12 is then positioned to penetrate the patient's skin and is advanced into proximity with the stimulation site 15 . The pulse generator 10 is then activated to generate current pulses. The current pulses from the pulse generator 10 traverse the internal stimulation site 15 by passing from the transcutaneous electrode 14 to the percutaneous needle 15 .
Those skilled in the art will appreciate that the nerve stimulation system of the present invention is effective not only for the treatment of urge incontinence, but can also be effective for both nerve and muscle stimulation to treat other numerous conditions, including, for example, muscle and joint rehabilitation, chronic pain, Parkinson's disease, and multiple sclerosis. In addition, the system can be used to manage pain and create local nerve blocks, as well as in any other application in which it is desirable to provide electrical nerve and/or muscle stimulation.
The current intensity required to produce a desired result, e.g., symptomatic relief to a patient, can vary at least in part, based on the direction of the electric field. Thus, the system 11 can include a mechanism to assure a particular polarity of the stimulating current. This can be accomplished by pre-attaching the transcutaneous electrode 14 to the first lead wire 16 and combining the first and second lead wires 16 , 18 into a single cable 17 at one end for interfacing with the pulse generator 10 , as illustrated in FIG. 1 B. Additionally, the cable 17 can be ‘keyed’ to prevent plugging the cable in backwards. With these safeguards, during a current pulse, current flows from the transcutaneous electrode to the percutaneous needle.
The pulse generator 10 preferably has an AC coupled current pulse output and can include an element for measuring the amount of current delivered directly to the patient. Patient stimulators are safest when the output circuitry is AC coupled. AC coupled circuits ensure that no net DC current will pass to a patient's body. Traditional stimulators have often accomplished AC coupling using current transformers. However, a transformer is often large and heavy. The stress caused by a transformer on a circuit board and internal supporting structures can cause circuit failures. The transformer output circuit usually measures primary current and does not actually measure the delivered secondary current.
With reference to FIG. 2, one embodiment of this invention includes circuitry which creates an AC coupled output without the need for a current transformer by using a DC blocking capacitor 40 in conjunction with the following circuit features: a current control 30 preferably including a pulse shaping circuit, a step-up DC-DC voltage converter 38 , a switching circuit 37 , and a current sense/stimulation adjustment feedback control 46 . As a result, the pulse generator 10 is a current source. A controller 44 , such as a MAX773 integrated circuit, available from Maxim Integrated Products of Sunnyvale, Calif., controls the operation of the pulse generator 10 , including serving as a feedback controller for the DC-DC converter 38 and driving a low voltage detector 32 . A low voltage indicator 34 and On/Off indicator 36 are also driven by controller 44 . The sense/stimulation adjustment feedback control 46 can measure actual current delivered to the patient's skin. In addition, the patient intensity control adjust 20 allows the patient to adjust the delivered current.
The pulse generator 10 can include a discharge path in the form of a discharge circuit 42 for the DC blocking capacitor 40 . The discharge circuit 42 has an optimal discharge time-constant to accommodate the desired pulse width, duty cycle, and expected load range of the output pulse. A capacitor, such DC blocking capacitor 40 , can serve as a DC block yet pass current pulses with sufficiently fast rise and fall times. However, after a number of pulses the capacitor can become charged if a discharge path is not provided. This accumulated charge voltage effectively subtracts from the available supply voltage so little or no pulse energy is delivered to the load. The discharge path in this embodiment minimizes droop during the output pulse yet assure full discharge by the time of the next pulse arrives.
The discharge circuit 42 can be provided in an active or passive discharge configuration. In the active configuration, a transistor type switch 112 , such as BSS123LT available from Motorola, Inc., is used to discharge the blocking capacitor 140 , as illustrated in FIG. 2 B. The switch 140 can momentarily discharge the capacitor when the output pulse is not active. During active discharge, discharge circuit 42 can be controlled by controller 44 through electrical connection 43 (FIG. 2 ).
In the passive configuration, a discharge resistor 102 is included in the output circuit parallel to the DC blocking capacitor and across output load 103 through the percutaneous electrode, as illustrated in FIG. 2 A. During passive discharge, discharge circuit 42 is coupled (shown as dashed line 45 in FIG. 2) to percutaneous needle 12 as well as to transcutaneous electrode 14 . Controller 44 does not interact with discharge circuit 42 in the passive discharge configuration and connection 43 need not be present.
The pulse generator 10 , through the current sense/stimulation adjustment feedback control 46 , can have the frequency and pulse width fixed to a value optimal for a given application and only allow the user adjustment of the stimulation current threshold. This prevents the user from setting the parameters to values that are suboptimal while making the device easier to use when compared to stimulators that allow adjustment of both frequency and pulse width.
The pulse generator 10 is preferably battery powered through battery 24 and is preferably small enough to be comfortably worn or carried by the patient. For example, the pulse generator can be small enough to be worn around a leg or other body extremity using a small wrap similar to a blood pressure cuff. Further , the pulse generator can be small enough to be hand held, belt-mounted, or pocket size.
With reference to FIG. 3, a preferred output waveform 48 produced by a pulse generator according to one embodiment of the invention has a pulse width 52 of 100-300 sec, a pulse intensity 50 of 1-10 mA, and a pulse cycle time 56 of 20-80 msec. It will be appreciated that a pulse generator 10 according to one embodiment of the invention can provide other waveforms, having different pulse widths, pulse cycle times, or pulse intensities, to achieve a therapeutic result.
With reference to FIG. 4, the transcutaneous electrode 14 according to one embodiment of the invention is designed for maximum signal dispersion by having the internal contact layer 64 coated with a high conductive material, such as silver. Traditional electrodes, used in monitoring applications, do not have a highly conductive internal layer. The absence of a highly conductive internal layer is less important for high input impedance monitoring circuits since they experience small current flow. For larger current level stimulators, however, hot spots can result if the electrode is constructed out of low conductivity materials.
Thus, in a preferred embodiment, the transcutaneous electrode is constructed to have high conductivity, e.g., to avoid “hot spots.” FIG. 4 shows a transcutaneous electrode 14 with an attached lead wire 16 and including a series of layers including non-conductive foam 60 , pressure sensitive adhesive 62 , silver 64 , carbon film 66 , and biocompatible hypoallergenic hydrogel 68 . These layers are pressed or sandwiched together to form transcutaneous electrode 14 .
With reference to FIG. 5, the illustrated percutaneous electrode needle 12 is constructed out of medical grade stainless steel or other biocompatible metal. The needle diameter is preferably small (less than 0.24 mm) which minimizes trauma during insertion. Part of the extended needle can consist of a metal or plastic handle 70 , e.g., to provide a secure grip for the user, while minimizing the risk of shock to the user.
In another aspect of the invention, the needle preferably can be coated with Teflon or similar insulative material 72 except for an exposed tip area 74 . This allows for a higher field density at the tip for more precise operation. The exposed needle tip area should have a sufficiently large surface area so as not to create too high a local current field that may cause irritation or pain. For example, the needle tip can have a terminal portion (exposed tip) 74 which extends between 0.5 and 10 mm and preferably 2.0 mm from the needle tip.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are officially attained. Since certain changes may be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all generic and specific features of the invention described herein, and all statements of the scope of the invention which as a matter of language might be the to fall therebetween. | An electro-nerve stimulator system includes a pulse generator for generating current pulses with a transcutaneous patch and percutaneous needle for delivering current pulses to selected stimulation sites. The stimulator is a small battery operated external device that allows adjustment of stimulation levels and interfaces, via a connector, to the trans-percutaneous cable. The transcutaneous electrode is attached to the skin distal from the desired stimulated nerve site. A percutaneous needle is inserted close to the internal nerve site. Stimulation current pulses are designed to flow between the transcutaneous electrode and the internal percutaneous needle. The field generated at the needle site causes the nerve to fire. | 0 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a container having a body and a cover such as a notebook type personal computer, and more particularly to a mechanism for latching and releasing the cover with and from the body.
2. Description of the Related Art
A notebook PC generally has a latch mechanism for latching and releasing the cover with and from the system body, because it is necessary to prevent the closed cover from coming loose and from opening accidentally. An example of such a mechanism is disclosed in Japanese Published Unexamined Patent Application (PUPA) No. 4-80786. The latch mechanism is conventional, and provides latching hooks to a cover so as to engage the cover with a system body. In order to open the cover from the system body, an operation for releasing the hooks from the system body and an operation for lifting the cover itself are executed consecutively with the hooks held in the releasing position. If the latch mechanisms are provided to both of the right and left sides of the cover, the operations for releasing the right latch mechanism by the right hand and for releasing the left latch mechanism by the left hand must be done simultaneously and then held in the released state while lifting the cover by both hands. Therefore, the conventional latch mechanism is inconvenient to open, and impossible to open the cover using only one hand.
JA PUPA No. 3-101298 discloses a notebook PC having a handle for carrying extending from the cover. A latch mechanism is released in response to the operation of pushing the handle into the cover. In this mechanism, it is possible to open the cover using only one hand, since the handle can be pushed and the cover can be lifted by the same hand. However, in order to hold the latch mechanism in the released state, it is necessary to continue to push the handle. That is, since it is necessary to lift the cover simultaneously with pushing the handle. This mechanism is not convenient to operate either. Moreover, in this mechanism, complicated construction is required for linking the motion of the handle to the latch mechanism.
Also known is a mechanism including a spring for lifting a latching hook after release from a system body, thereby lifting a cover so as to keep a latch mechanism in a released state. However, such a mechanism, does not exhibit simplicity in construction since the spring for lifting the cover must be added. Besides, the proper strength of the spring depends on the weight of a cover to be lifted, friction caused by the rotation of a mounting shaft for the cover and the like. Accordingly, it is difficult to mount a relatively heavy cover including a color display apparatus and a relatively light cover including a monochrome display apparatus on a common system body so that they can be exchanged each other.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a container having a body and a cover, wherein an operation for releasing the state where the cover is latched with the body and an operation for lifting the cover itself are not required to be executed simultaneously in order to open the cover.
It is a further object to provide simplified construction of such a container.
The above and other objects are met by the present invention which provides a container having a body and a cover, in which the cover can be conveniently opened using only one hand from a latched state of the body and the cover. Engaging members between cover and body are movable under force, when the cover is closed, between an engaging position where the cover is engaged with said body and a releasing position where the cover is not engaged with the body. However, the engaging member cannot be returned to the engaging position while the cover is closed. Lock means prevent the engaging member from moving from the releasing position to the engaging position in spite of application of force. Once the cover is opened the engaging member is allowed to move from said releasing position to said engaging position.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a notebook PC in the state where a cover is closed.
FIG. 2 is a perspective view showing a notebook PC in the state where a cover is opened.
FIG. 3 is an exploded view of a preferred embodiment of the latch mechanism of the invention.
FIG. 4 is an exploded view showing an engaging member and a slider of said first embodiment.
FIG. 5 is a perspective view showing the engaging member and the slider of said embodiment in the state where they are assembled.
FIG. 6 is a perspective view showing mounting of the engaging member on the cover.
FIG. 7 is a perspective view showing the latch mechanism of the first embodiment in the state where the cover is opened from a system body.
FIG. 8 is a perspective view showing the latch mechanism of the first embodiment in the state where the cover is latched with the system body.
FIG. 9 is a perspective view showing the latch mechanism of the first embodiment in the state where the cover is closed on the system body, but is unlatched.
FIG. 10 is a partial sectional view showing the latch mechanism of the first embodiment in the state where the cover is lifted from the system body.
FIG. 11 is a partial sectional view showing the construction of the latch mechanism of the first embodiment in the state where the cover is latched with the system body.
FIG. 12 is a sectional view showing the construction of the latch mechanism of said embodiment in the state where the cover is closed on the system body, but is unlatched.
FIG. 13 is a sectional view taken in the line XIII--XIII of FIG. 11.
FIG. 14 is a sectional view showing a state that a convex section of a leg of the first embodiment takes when disposed over a convex section of a hollow.
FIG. 15 is a sectional view taken in the line XV--XV of FIG. 12.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 and FIG. 2 show an enclosure having a body and a cover, which is applied to a notebook PC. Mounted on a system body 1 is a cover 2. The cover 2 is capable of opening from the system body 1 on hinges 5. A latch mechanism 3 is provided to each of both sides of the cover 2. The latch mechanism 3 is for latching the cover 2 with the system body 1 and for releasing the cover from the body 1. In FIG. 2, a keyboard 4 as input means is provided on the top of the system body 1. The cover 2 is mounted on the system body 1 through hinges 5 at the rear of the system body 1. A flat display panel 6 is provided inside of the cover 2.
FIG. 3 is an exploded view of the latch mechanism 3. The latch mechanism 3 includes an engaging member 10, a slider 12, a spring 14, and a hollow 30. The engaging member 10, which is disposed inside the cover 2, is fixed to the slider 12 disposed outside the cover 2, through a slider guiding opening 18 which is formed in a side plate of the cover 2. It is preferable that the engaging member 10 and the slider 12 should be integrally formed by plastic materials. The slider guiding opening 18 supports the engaging member 10 and the slider 12 integrally formed, so that they can move only within a predetermined range along the longitudinal direction of the side plate of the cover 2. Formed in an exposed surface in the state where the slider 12 is attached to the cover 2 are a nonskid section 12K, a mark 12M, and a stopper 12N. The nonskid section 12K is intended to make the use of fingers for sliding the slider 12 easy. The mark 12M indicates the direction of operation of the slider 12. Further, an operator can operate the slider 12 not only by hitching a nail tip to the stopper 12N, but also by hitching a tip of such a stick as a mouse stick to the stopper 12N.
FIG. 4 and FIG. 5 show the mounting relationship between the engaging member 10 and the slider 12 in FIG. 3, which are turned upside down. Planted into the inner wall of the slider 12 are a plurality of protrusions 12A for mounting. The tips of at least one part of a plurality of the protrusions 12A for mounting are shaped into a locking sections. On the other hand, the engaging member 10 has a plurality of female sections 10A so that the protrusions 12A for mounting are mounted into the female sections 10A. After the protrusions 12A for mounting are once mounted into the female sections 10 A, the slider 12 is kept in the state where it does not easily come off the engaging member 10 by means of the locking sections 12B.
In FIG. 3, the engaging member 10 has a shaft 20 which extends in the direction of movement of the engaging member 10 and the slider 12, and the spring 14 is attached to the shaft 20. The spring 14 is intended to spring the engaging member 10 toward the front end of the cover 2, that is, the left side in the figure. The engaging member 10 has a leg 40, and the leg 40 extends downward in the vertical direction toward the system body 1 in the figure. A tip 40A of the leg 40 is bent in an L-shape toward the left side in the figure, that is, toward the front end of the cover 2. On the other hand, the hollow 30 as an engaged member is formed in the top surface of the system body 1 so that the leg 40 can be housed into the hollow 30 in the state where the cover 2 is closed.
FIG. 6 shows the state where the engaging member 10 is mounted into the cover 2. In the figure, the cover 2 is shown from the inside. Formed in both sides close to the front edge of the inside of the cover 2 is a receptor 50 of the box-like type. The upper part of the receptor 50 in the figure is opened so that the engaging member 10 can be housed in the receptor 50 from its opening. Provided to the receptor 50 is a bearing 52. The bearing 52 is formed by notching part of peripheral walls which form the receptor 50 and supports the shaft 20 of the engaging member 10. One end of the spring 14 attached to the shaft 20 contacts an inside wall of the receptor 50, and the other end contacts a part of the engaging member 10 around the base end of the shaft 20. The spring 14 applies tensile force on the engaging member 10 in the receptor 50 toward the left side in the figure, that is, the front edge of the cover 2.
FIGS. 7 to 9 are enlarged perspective views of the latch mechanism 3. In the figures, a convex section 60B is formed in the hollow 30. On the other hand, as shown in FIGS. 4 to 6, a convex section 60A is formed also in the leg 40 of the engaging member 10. The convex sections 60A and 60B compose lock means 60 (see FIGS. 13 to 15). In the following, the lock means 60 is described in detail by reference to FIGS. 9 to 15 as well.
FIG. 7 and FIG. 10 show the state presented immediately before the cover 2 is closed or the state presented immediately after the cover 2 is opened from the system body 1. The engaging member 10 is at a leftmost position shown by FIG. 10 within a full range of its movement. When the engaging member 10 is at the position, the tip 40A of the leg 40 is located further left than the leftmost end of the opening of the hollow 30 in the figure. While the cover 2 is closed, the tip 40A contacts the top surface of the system body 1, gets over the leftmost end of the opening of the hollow 30 in the figure and then goes round the lower side of said end. When the tip 40A gets over the leftmost end of the opening of the hollow 30 in the figure, the engaging member 10 once moves to the right in the figure against the tensile force of the spring 14.
FIG. 8 and FIG. 11 show the state where the cover 2 is latched with the system body 1 after it is closed. The engaging member 10 is at a leftmost position shown by FIG. 11 within a full range of its movement in the hollow 30. The position of the engaging member 10 at this point is an engaging position. When the engaging member 10 is at the engaging position, the tip 40A of the leg 40 is located on the lower side of an engaged section 40B and prevents the cover from being opened from the system body 1. The spring 14 always applies tensile force on the engaging member 10 toward the left side in the figure so that such a state can be kept. As shown in FIG. 13, the convex sections 60A and 60B do not prevent the engaging member 10 from being at the engaging position.
To open the cover 2, the engaging member 10 may be moved toward the right side in FIG. 11 by operating the slider 12. The direction of its movement is indicated by the arrow 12M. As shown in FIG. 14, with the movement of the engaging member 10, the convex section 40A of the leg 40 is intended to get over the convex section 40B of the hollow 30. That is, the convex section 40A of the leg 40 and the convex section 40B of the hollow 30 are intended not to prevent the engaging member 10 from moving toward the right side in the figure. A slope for helping such movement is formed in each of the convex section 40A of the leg 40 and the convex section 40B of the hollow 30. In the process of moving the engaging member 10 toward the right side in the figure, as shown in FIG. 14, the convex section 40A of the leg 40 once strikes on the convex section 40B of the hollow 30. When striking on it, at least the part of the convex section 40A of the leg 40 must move also vertically to the direction of movement of the entire engaging member 10, but the shape and size of the hollow 30, the material of the engaging member 10, and the positioning scope of the engaging member 10 during assembling into the receptor 50 allow for such movement.
FIG. 9, FIG. 12, and FIG. 15 show the state that the engaging member 10 was once moved along the arrow 12M before the cover 2 is opened. In the state, the tip 40A of the leg 40 is released from the engaged section 40B. A position of the engaging member 10 at this point is a releasing position. When the engaging member 10 is moved to the releasing position in the state where the cover 2 is closed, the convex section 40A of the leg 40 is prevented from moving toward the left side in the figure by the convex section 40B of the hollow 30. Therefore, the cover 2 remains unlatched to the system body 1 since the engaging member 10 is held at the releasing position against the force of the spring 14. When the cover 2 is lifted, the engaging member 10 is returned to the state shown in FIG. 7 and FIG. 10, that is, the engaging position, due to the tensile force of the spring 14 since the convex section 40A of the leg 40 rises and separates from the convex section 40B of the hollow 30.
According to such an embodiment as described above, once the slider 12 is pushed backward in the state where the cover 2 is closed, the state is kept where the latch mechanism 3 of the cover 2 to the system body 1 is released. Therefore, it is possible to open a cover even if an operation for releasing the state where the cover is latched with a body and an operation for lifting the cover itself are not practiced simultaneously. Accordingly, even if the latch mechanism 3 is provided to each of both sides of the cover 2, it is also possible to open the cover 2 by one hand by releasing the latch, one side at a time, and then by lifting the cover 2. Further, since the engaging member 10 and the slider 12 return to the engaging position once the cover 2 is opened, any operation to the engaging member 10 and the slider 12 for returning them to the engaging position is not needed. Still further, since the direction of the operation of the slider 12 is from the front to the rear and the stopper 12N is also provided to the slider 12, it is also possible to release the state where the cover 2 is latched using such a cylindrical body as a mouse stick.
Further, since the lock means 60 has a very simple construction which is composed of the two convex sections 60A and 60B, the installation of the lock means 60 does not cause a latch mechanism to be complicated. Further, since parts to be adjusted according to variations in weight etc. of the cover side are not included, it is possible to mount, without any hindrance, covers 2 different from one another in weight etc. on a common system body 1 so that they can be exchanged each other.
Though the latch mechanism 3 is illustrated on each of both sides of the cover 2, a single latch mechanism 3 may be provided to the front edge etc. of the cover 2. Further, the latch mechanism 3 may have such construction as the state where the cover 2 is latched is released when the slider 12 is slid from the rear to the front. Still further, convex sections which compose lock means may not be provided to both, but only one of an engaging member and a body. Further, an engaging member and a member equivalent to a leg may be provided to a body, instead of a cover, and a section to be engaged may be provided to the cover. Still further, it will be appreciated that the present invention may be applied not only to a notebook PC, but also to other various enclosures having a cover.
According to the present invention, it is possible to provide an enclosure having a cover, in which the cover can be opened even if the latching mechanism is not held open during lifting of the cover. Complication in construction is avoided, and parts to be adjusted according to variations in weight and frictional resistance of the cover are not included.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. | A container having a body and a cover, in which the cover can be conveniently opened using only one hand from a latched state of the body and the cover. Engaging members between cover and body are movable under force, when the cover is closed, between an engaging position where the cover is engaged with said body and a releasing position where the cover is not engaged with the body. However, the engaging member cannot be returned to the engaging position while the cover is closed. Lock means prevent the engaging member from moving from the releasing position to the engaging position in spite of application of force. Once the cover is opened the engaging member moves from said releasing position to said engaging position. | 4 |
BACKGROUND OF THE INVENTION
The present invention pertains to an automatic feeder operated with a photographic copying machine, for feeding originals from a stack to an exposure plate or window of the copying machine for projecting the original and from the exposure plate back to the stack.
A feeder of the type under consideration is disclosed in German patent publication No. DE-AS 25 50 985. When originals enter the region of the exposure plate in the disclosed feeder the front edge of the respective original is held during the transport path by pivotable aligning pads. Such an arrangement can, however, cause damage to the original being processed. Furthermore, the conventional device has no means for adjusting the feeder to certain format lengths of the originals being processed.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved feeder for transporting originals across the exposure window of the photographic copying machine.
It is a further object of the invention to provide an automatic feeder which can be adjusted to differing lengths of originals to be processed in the copying machine.
These and other objects of the invention are attained by an automatic feeder for feeding originals in a photographic copying machine of the type in which an original is transported across a transparent exposure plate for projecting in an exposure station of the copying machine, comprising supporting means for receiving a stack of originals lying in said stack in a predetermined orientation in which lower sides of the originals face said supporting means, means for transporting the originals from said stack towards said exposure plate and from said exposure plate back to said stack and operative for returning the originals to said stack in said predetermined orientation, said exposure plate having a front end and a rear end as viewed in the direction of transportation of an original; a number of non-driven tappet rollers positioned against said exposure plate at the front end thereof for receiving a front edge of the original when the latter is positioned on said exposure plate; displaceable stop means on said supporting means for adjusting said supporting means to differing lengths of originals being processed; first adjustment means for displacing said stop means and adjusting the latter on said supporting means; second adjustment means connected to said tappet rollers for adjusting the latter relative to said exposure plate in said direction of transportation, said first adjustment means being operatively connected to said second adjustment means so that the adjustment of said stop means to a predetermined format length of the originals by said first adjustment means causes a corresponding adjustment of said tappet rollers by said second adjustment means. The tappet rollers may be biased by springs or operate under the action of weight.
According to a further feature of the invention the first adjustment means may include a first slider connected to said stop means and said second adjustment means include a second slide convected to said tappet rollers, the feeder further including an adjustment lever operatively connected to said first slide and said second slide.
Furthermore, the transporting means may include first transport rollers arranged before said exposure plate in said direction of transportion, said first transport rollers being disposed from said tappet rollers at such a distance which ensures that a rear edge of the original transported across said exposure plate leaves said first transport rollers before the front edge of said original contacts said tappet rollers.
The tappet rollers may be liftable away from the exposure plate.
The feeder may further include second transport rollers mounted against said exposure plate and pivotable to and away therefrom, the second transport rollers holding an original on the exposure plate after the rollers have been pivoted to the exposure plate.
The feeder may further include means for lifting the tappet rollers away from said exposure plate and means for pivoting the second transport rollers to and away from the exposure plate.
According to a still further feature of the invention the feeder may be provided with first magnet means for actuating said lifting means and second magnet means for actuating said pivoting means, said first and second magnet means being controllable by an operator from a central control unit of the copying machine.
The feeder may be enclosed with a housing, said housing being pivotally connected to the copying machine and being pivotable between an open position and a closed position. The housing may include a transparent cover pivotally supported to said housing.
The feeder may further include means for locking the housing in its closed position.
The feeder may also include arresting means cooperating with said locking means to hold the housing in the closed position during a copying process.
The arresting means may include a slide with a hook and a magnet for actuating said slide, said magnet being controllable by an operator from the central control unit of the copying machine.
The locking means may include a lever having a stop, said stop engaging with said hook when said slide is actuated by the magnet.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, 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 DRAWING
The single FIGURE of the drawing shows a schematic sectional view of an automatic feeder for feeding originals to an exposure station of the copying machine, according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing, a reference character 1 designates a copying machine on which an exposure plate 2 for supporting originals to be projected is provided. A projection optics or scanning mirror 3 serves for imaging strip-like sectors of the originals onto a sheet or web of recording medium disposed in the copying machine. The projection optics 3 is arranged in the copying machine so that a structure 4, conveying optics 3 is guided along a rail 6 by means of guide rollers 5.
A bearing block 7 is mounted to the upper edge of the copying machine 1. A housing 8 of the automatic feeder according to the invention is pivotally supported on a pivot of bearing block 7. Housing 8 is covered with a cover 10 which is pivotally supported on a pivot 9 with respect to housing 8, whereby cover 10 can be pivoted by an operator in the upward direction about pivot 9. A gripping depression 10a is provided at the end of cover 10 for facilitating the opening of the latter.
A support plate 11 for supporting a stack 12 of originals thereon is mounted within housing 8 of the feeder. Stack 12 is supported at its front end by means of a stack support 13. The limiting of the stack in the rearward direction is provided by means of slidable stops 14a arranged on a slide 14. In the preferred embodiment stops 14a are formed integral with slide 14. The latter is able to slide along a guide plate 15 in the lengthwise direction thereof. Plate 15 is connected to support plate 11. The slidable stops 14a with slide 14 are connected to an adjustment lever 17 by means of a push rod 16, lever 17 being supported on an axle 18 of housing 8. Therefore stops 14a are displaceable to and from support 13 to adjust plate 11 to differing format lengths of originals disposed in stack 12.
Plate 11 is provided in the region of support 13 with a recess 11a. The separation of a lowermost sheet in the stack from the superposed originals is carried out by means of a pivotable suction feeder 19 which cooperates in the known fashion with the end of the lowermost sheet in the stack through the recess 11a of plate 11. The suction feeder 19 while pivoting seizes the front end of the lowermost original, separates it from the stack and feeds it between a transport or carrier roller 21 arranged on a stationary axle 20 and a pivotable transport or carrier roller 22. Transport roller 22 is positioned on a pivotable lever 23 which is pivotally supported on an axle 24 mounted to housing 8.
A paper guide 25, 26 is coupled to the transport roller-pair 21, 22. A further transport roller-pair comprised of rollers 27, 28 is arranged on the paper guide 25, 26 provided for a further transport of the separated original received from the transport roller-pair 21, 22 upon pivoting of transport roller 22.
Transport rollers 27, 28 convey the original in the direction of arrow A over transparent exposure plate 2 towards tappet rollers 33 which abut against the surface of support plate 2 under action of respective compression springs 32. Tappet rollers 33 clamp the front edge of the original, when the latter reaches tappet rollers, between the outer surfaces of the rollers 33 and the upper face of plate 2. Due to the fact that the front edge of the original enters a wedge like gap framed between the outer face of plate 2 and the peripheral surfaces of the tappet rollers 33 this front edge is protected against being damaged. Furthermore, the peripheral surfaces of non-driven or freely rotated or slightly braked tappet rollers 33, which are supported on a carrier arm 34, under the action of compression springs 32 are themselves subjected to no unilateral wear while the rollers 33 are further rotated over a small distance during each step of the advancement of the original under the rollers 33 so that during each step new portions of the peripheral surfaces of rollers 33 continuously come into contact with the front edge of the original being advanced.
Transport rollers 27, 28 are arranged distant from tappet rollers 33 as viewed in the direction of transportation denoted by arrow A whereby, if the feeder has been correctly adjusted to the certain format of the originals, the rear edge of the original being transported leaves the gap between rollers 27, 28 before the front edge of the original reaches the tappet rollers 33. The entrance of the original into the gap between rollers 33 and the upper face of plate 2 is effected exclusively due to the action of inertia which contributes to a careful treatment of the front edge of the original. Furthermore, slipping of the original held by the peripheral surfaces of tappet rollers 33 back to transport rollers 27, 28 is also prevented from occurring.
For further transport of originals after the projection of the latter the feeder is provided with transport rollers 29 which are arranged in the region of transparent exposure plate 2. Rollers 29 are positioned on pivotable levers 30 and can lie against the face of support plate 2 under the action of tension springs 60. It is to be understood that a number of tappet rollers 33 spaced from each other along the width of plate 2 as well as a number of transport rollers 29 also spaced from each other along the width of plate 2 are provided on the feeder according to the invention although only one tappet roller 33 and one transport roller 29 are shown in the FIGURE of the drawing. Transport rollers 29 during the projection phase of the process are lifted from the exposure plate 2 by means of a pulling rod 61 actuated by a magnet 62 which is controlled from a central control unit provided in the copying machine. Another magnet 63 connected to the arm 34 of tappet rollers 33 and also controlled from a central control unit of the copying machine interrupts contact of tappet rollers 33 with the face of support plate 2.
Displaceable carrier arm 34 serves the purpose of adjusting the position of tappet rollers 33 to a predetermined format of the originals being transported. To carry out such an adjustment arm 34 is positioned on a slide 35 which is guided at one side thereof in a guide 36 secured to housing 8. Slide 35 has at one end thereof a fork 35a the recess of which is in engagement with a pin 37 formed on the adjustment lever 17. When stops 14a are adjusted to a greater format length tappet rollers 33 which engage the front edge of the original being processed are adjusted accordingly due to the connection of lever 17 with slide 14, on the one hand, and with slide 35, on the other hand, whereby the distance between the rear edge of the original and transport rollers 27, 28 as well as the initial point of the projection optics 3 shown in FIG. 1 are maintained independently on the format length to which stops 14a and rollers 33 have been adjusted.
After projecting of originals transport rollers 29, which have been continuously driven but lifted away from plate 2 during the projection phase, are now, upon actuating magnet 62 and under the action of spring 60, pivoted towards the original on plate 2 whereas tappet rollers 33 by means of magnet 63 are lifted up whereby the original is set to a position to be moved in the direction of arrow A. The original, upon transporting in the direction of arrow A, enters a curved guide 38, 39 and is conveyed through continuously driven transport roller-pairs 40, 41; 42, 43 and 44, 45. The original leaves the guide 38, 39, then moves in the direction of arrow B to stack 12 and lies down onto the upper surface of stack 12. The original in its path through guide 25, 26 and curved guide 38, 39 is turned over twice so that the original which was positioned in the stack with its film impression side exposed enters the copying station with its film-impression side in the underlying position and is laid down on the stack 12, after passing guide 38, 39, again with its film-impression side exposed, e.g. in the orientation corresponding to the original orientation of the sheet in stack 12. In this final position is the film-impression side of the original seen through transparent cover 10 whereby the complete path of the original is easily observed and controlled. Cover 10 is opened at gripping depression 10a for replacing the stack in the feeder or for repairing transport means if necessary and closed by clamping gripping depression 10a with the projection on the end of cover 10 on housing 8.
In the case when the original should be placed onto the transparent plate 2 manually, e.g. by a hand of an operator, the operator can open the whole housing 8 by pivoting the latter on bearing block 7 away from exposure plate 2 to free this plate. To prevent undesired pivoting of housing 8 on the pivot of bearing block 7 from occurring the housing 8 is provided with a locking means which includes a shackle 46 mounted to housing of the copying machine and a locking lever 47 which is the housing of the shackle 46 in the locking position. Lever 47 is biased with a compression spring 48 and is connected to an operating button 49 projected outwardly from housing 8. Locking lever 47 is unlocked by operating the button 49 against the action of spring 48.
Furthermore, an arresting slide 50 cooperates with its arresting hook 50a with the locking lever 47. Arresting hook 50a is maintained in disengagement with lever 47 due to the action of spring 51. Lever 47 is also provided with a stop 47a. The arresting slide 50 is coupled with an armature of a magnet 52 and when magnet 52 is actuated hook 50a of arresting slide 50 is forced into engagement with stop 47a. Magnet 52 which is also controlled from the central control unit of the copying machine is in the actuated position as long as the copying process lasts and until respective originals return to stack 12. The above described locking means prevents an inadvertent opening of housing 8 during the copying process.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of automatic feeders differing from the types described above.
While the invention has been illustrated and described as embodied in an automatic feeder, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | An automatic feeder for a photographic copying machine includes a housing and a plate for supporting a stack of originals which are consecutively conveyed towards a transparent exposure plate positioned on the copying machine. The feeder is provided with adjustable tappet rollers mounted against the exposure plate to receive a front edge of an original moved along the exposure plate, without damaging the front edge. The plate for supporting the stack of originals includes adjustable stops for adjusting the plate to differing formats of the originals being processed. An adjusting lever connected to the adjustable stops for adjusting the latter is operatively connected to an adjustment device for adjusting the position of tappet rollers along the exposure plate. Pivotable transport rollers are provided to hold the original against the exposure plate. The housing of the feeder is pivotable relative to the housing of the copying machine between an open and closed position. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rubber plug fitting apparatus for fitting a rubber plug on an end portion of a wire.
2. Description of the Related Art
The present disclosure relates to subject matters contained in Japanese Patent Application Laid-Open No. HEI 7-7833, filed on May 2, 1994, the disclosure of which is expressly incorporated herein by reference in its entirety. FIGS. 1 to 3 are schematic configuration views illustrating respective steps of the rubber plug fitting apparatus. In FIGS. 1 to 3 , a rubber plug feeding unit 2 , a rubber plug positioning unit 3 and a rubber plug holder 4 are respectively arranged at 90° intervals around a rotation center of a rotary unit 1 and at positions corresponding to an outer periphery thereof.
The rotary unit 1 has rubber plug holding rods 1 a which are respectively arranged at 90° intervals and which are rotationally movable. The rubber plug feeding unit 2 has a rubber plug accommodation passage 2 a where a number of rubber plugs 5 are arranged, and it comprises an inside pin 2 b which is movable from a position where the inside pin 2 b is inserted into a wire passing-through hole (not shown) of the forefront one of the rubber plugs 5 which have been accommodated in the rubber plug accommodation passage 2 a up to a position where the forefront rubber plug 5 abuts on the rubber plug holding rod 1 a of the rotary unit 1 , and a pushing rod 2 c for pushing the forefront rubber plug 5 onto the rubber plug holding rod 1 a of the rotary unit 1 .
The rubber plug positioning unit 3 has a positioning plate 3 a formed with a small hole 3 b , and the positioning plate 3 a is movable between a spaced position (shown in FIG. 1) where it is spaced from the rotary unit 1 and an approached position (shown in FIGS. 2 and 3) where it approaches to the rotary unit 1 . Also, the rubber plug holder 4 comprises a pair of rubber holding portions 4 a , 4 a which can be opened/closed and which are movable between a spaced position (shown in FIG. 3) where they are spaced from the rotary unit 1 and an approached position (shown in FIGS. 1, 2 ) where they approach to the rotary unit 1 , and a pair of wire guide portions 4 b , 4 b which can be opened/closed and which are movable between a spaced position (shown in FIGS. 1, 2 ) where they are spaced from the pair of rubber plug holding portions 4 a , 4 a and an approached position (shown in FIG. 1) where they approach to the pair of rubber plug holding portions 4 a , 4 a . A wire W whose outer cover has been stripped at its end portion Wa is disposed at a position corresponding to the rubber plug holder 4 .
Next, operation of the above structure will be explained. Each rubber plug holding rod 1 a of the rotary unit 1 is stopped at positions corresponding to the rubber plug feeding unit 2 , the rubber plug positioning unit 3 and the rubber plug holder 4 sequentially according to rotation of the rotary unit 1 . Then, at the position corresponding to the rubber plug feeding unit 2 , the inside pin 2 b is caused to pass through the wire passing-through hole of the forefront one of the rubber plugs 5 which have been accommodated in the rubber plug accommodation passage 2 a and a leading end of the forefront rubber 5 is caused to abut on the rubber plug holding rod 1 a . Next, the pushing rod 2 c pushes the forefront rubber plug 5 to the rubber plug holding rod 1 a side, and, by the pushing force of the pushing rod 2 c , the rubber plug 5 is guided by the inside pin 2 b to be fitted on the rubber plug holding rod 1 a . At the position corresponding to the rubber plug positioning unit 3 , the positioning plate 3 a is moved from the spaced position to the approached position. In the course of movement of the positioning plate 3 a , the rubber plug 5 is pushed by the positioning plate 3 a while the rubber plug holding rod 1 a is being inserted into the small hole 3 b . By this pushing, the rubber plug 5 is fitted up to a predetermined position on the rubber plug holding rod 1 a . At the position corresponding to the rubber plug holder 4 , the rubber plug 5 is released from the rubber plug holding rod 1 a by the pair of rubber holding portions 4 a , 4 a and the pair of wire guide portions 4 b , 4 b , and the rubber plug 5 which has been released is fitted on the wire W.
In the conventional rubber plug fitting apparatus, however, since the inside pin 2 b is inserted into the rubber plug 5 so as to guide the same, it is necessary to set the diameter of the inside pin 2 b to be equal to or less than the inner diameter (diameter of the wire passing-through hole) of the rubber plug 5 . Accordingly, for a rubber plug 5 with a very small inner diameter, the diameter of the inside pin 2 b is reduced according to the very small inner diameter, and the inside pin 2 b is easy to break, which results in lack of durability of the inside pin 2 b.
Also, since positioning the rubber plug 5 which has been fitted on the rubber plug holding rod 1 a is performed by the rubber plug positioning unit 3 independent of the rubber plug feeding unit 2 , there is a problem where, in view of the whole body of the conventional rubber plug fitting apparatus, its structure becomes complicated and its manufacturing cost is increased.
SUMMARY OF THE INVENTION
In view of the above, the present invention has been achieved, and an object thereof is to provide an inexpensive rubber plug fitting apparatus which can perform a fitting of a rubber plug on a wire without any possibility of injury of parts or the like irrespective of the inner diameter of a rubber plug, which has an excellent durability, and which can perform a positioning of the rubber plug with a simple structure where a dedicated positioning unit is not used.
According to a first aspect of the present invention, there is provided a rubber plug fitting apparatus, comprising: a rubber plug feeding unit for feeding each of rubber plugs to a rubber plug feeding port; a rubber plug holder for holding one of the rubber plugs to fit the rubber plug on an end portion of a wire; and a rotary unit having a plurality of rubber plug holding rods which are fitted into each of the rubber plugs to hold the rubber plugs, the rotary unit rotationally moving each of the rubber plug holding rods between the rubber plug feeding unit and the rubber plug holder so that each of the rubber plugs can be delivered from the rubber plug feeding unit to the rubber plug holder through each of the rubber plug holding rods, wherein a pair of rubber plug guides are provided so as to be capable of being opened/closed at a side of the rubber plug feeding port of the rubber plug feeding unit; and wherein guide grooves are respectively provided at positions of the pair of rubber plug guides facing the rubber plug feeding port, so that the guide grooves guide an outer periphery of each of the rubber plugs which moves from the rubber plug feeding port to a side of each rubber plug holding rod when the pair of rubber plug guides are closed.
In the rubber plug fitting apparatus according to the first aspect, since a rubber plug is fitted on each of rubber plug holding rods by guiding the outer periphery of the rubber plug by respective grooves of a pair of rubber plug guides, there occurs no weak portion on the pair of rubber plug guides even when the inner diameter of the rubber plug is small, fitting of the rubber plug can be performed without injuring parts of the rubber plug fitting apparatus or the like irrespective of the diameter of the rubber plug, and the durability of a rubber plug fitting apparatus can be improved. Also, since there occurs no trouble such as a part injury and a rubber feeding can be surely carried out, the rubber plug fitting apparatus is prevented from being stopped due to any feeding failure, which results in improvement in productivity.
According to a second aspect of the present invention, as it depends from the first aspect, there is provided a rubber plug fitting apparatus, wherein stopper portions are respectively provided at the respective guide grooves of the pair of rubber plug guides so that the stopper portions restrict movement stroke of the rubber plug where the rubber plug moves from the rubber plug feeding port to the side of the rubber plug holding rod.
In the rubber plug fitting apparatus according to the second aspect, since stopper portions for restricting movement of a rubber plug moving from a rubber plug feeding port to a side of each rubber plug holding rod are respectively provided at respective guide grooves of a pair of rubber plug guides, a rubber plug is fitted up to a position on each rubber plug holding rod the where it abuts on the respective stopper portions, so that the rubber plug can be positioned on a predetermined position on each rubber plug holding rod. Thereby, positioning a rubber plug can be performed with a simple structure and without using a dedicated unit, so that cost of the whole body of the apparatus can be reduced. Also, since a step of positioning a rubber plug can be omitted, productivity can be further improved owing to the omission.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The above and further objects and novel features of the present invention will more fully appear from the following detailed description when the same is read in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic configuration view illustrating a rubber plug fitting apparatus according to a conventional example;
FIG. 2 is a schematic configuration view illustrating the rubber plug fitting apparatus according to the conventional example;
FIG. 3 is a schematic configuration view illustrating the rubber plug fitting apparatus according to the conventional example;
FIG. 4A is a side view illustrating of a rubber plug fitting apparatus according to one embodiment with a partial section;
FIG. 4B is an enlarged sectional view of a main portion of the rubber fitting apparatus;
FIG. 5 is a plan view of a main portion illustrating a state where a pair of rubber plug guides used in the rubber plug fitting apparatus have been opened;
FIG. 6 is a front view of a main portion illustrating a state where the pair of rubber plug guides have been closed;
FIG. 7 is a plan view of a main portion illustrating a state where the pair of rubber plug guides have been closed; and
FIG. 8 is a front view of a main portion illustrating a state where the pair of rubber plug guides have been closed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
There will be detailed below the preferred embodiments of the present invention with reference to the accompanying drawings. Like members are designated by like reference characters.
FIG. 4A is a side view of a rubber plug fitting apparatus according to an embodiment of the present invention, FIG. 4B is an enlarged sectional view of a main portion of the rubber plug fitting apparatus, FIG. 5 is a plan view of a main portion of a pair of rubber plug guides used in the rubber plug fitting apparatus which have been opened, FIG. 6 is a front view of a main portion of the pair of rubber plug guides which have been opened, FIG. 7 is a plan view of a main portion of the pair of rubber plug guides which have been closed, and FIG. 8 is a front view of a main portion of the pair of rubber plug guides which have been closed.
As illustrated in FIG. 4A, a rubber plug fitting apparatus is provided with a rotary unit 10 , and it includes a rubber plug feeding unit 11 and a rubber plug holder 12 which are respectively provided at 90° intervals about a rotation center of the rotary unit 10 and at positions opposed to the outer periphery of the rotary unit 10 .
The rotary unit 10 has rubber plug holding rods 10 a which are respectively disposed at 90° rotation intervals, and the respective rubber plug holding rods 10 a are constituted so as be rotationally movable integrally. The rotary unit 10 has a driving motor 13 , and rotation of the driving motor 13 is transmitted to the respective rubber plug holding rods 10 a via a belt 13 a and the like.
The rubber plug feeding unit 11 has a straight advancing feeder 14 , and the straight advancing feeder 14 is provided with a rubber plug accommodation passage where a number of rubber plugs 15 are aligned and disposed. A distal end of the rubber plug accommodation passage 14 a is opened to a rubber plug feeding port 16 a of a rubber plug feeding body 16 , and the forefront rubber plug 15 of rubber plugs 15 in the rubber plug accommodation passage 14 a is disposed in the rubber plug feeding port 16 a . The rubber plug feeding body 16 is provided with a pushing rod 17 movable upward and downward, and the pushing rod 17 is disposed so as to be positioned below the rubber plug feeding port 16 a when it is put in its lower position. When the pushing rod 17 is moved upward, the rubber plug 15 at the rubber plug feeding port 16 a is pushed to a side of the rubber plug holding rod 10 a of the rotary unit 10 .
Also, a pair of rubber plug guides 18 , 19 are provided on the rubber plug feeding body 16 , and the pair of rubber plug guides 18 , 19 are moved in a opening/closing manner between an opened position and a closed position by parallel cylinders (driving source) 20 . As illustrated in FIGS. 5 and 6, when the pair of rubber plug guides 18 , 19 are opened, respective opposing faces of the pair of rubber plug holding rods 10 a are positioned to be spaced from each other, and thus the rubber plug holding rods 10 a are positioned at positions where they do not interfere with rotational movement of each rubber plug holding rod 10 a . Also, as illustrated in FIGS. 4A, 4 B, 7 and 8 the respective opposing faces of the pair of rubber plug guides 18 , 19 are positioned to be caused to abut on each other, when the pair of rubber plug guides are closed.
A semicircular guide grooves 18 a , 19 a are provided on the respective opposed faces of the pair of rubber plug guides 18 , 19 , and a cylindrical space is formed by the pair of guide grooves 18 a , 19 a , when the pair of rubber plug guides 18 , 19 are closed. The diameter of the guide space is set to be equal to or slightly more than the maximum outer diameter of the rubber plug 15 . A distal end of each rubber plug holding rod 10 a is disposed in the guide space and a lower face of the guide space is opened to the rubber plug feeding port 16 a.
Also, stopper portions 18 b , 19 b projecting above the respective guide grooves 18 a , 19 a are integrally formed on upper end portions of the pair of rubber plug guides 18 , 19 , and upward movement of the rubber plug 15 is restricted by the respective stopper portions 18 b , 19 b when the pair of rubber plug guides 18 , 19 are put in a closed position. Semicircular grooves 18 c , 19 c through which the rubber plug holding rod 10 a passes are respectively provided on the stopper portions 18 b , 19 b.
The rubber plug holder 12 is structured so as to pull the rubber plug 15 from the rubber plug holding rod 10 a and fit the rubber plug 15 which has been pulled out on an end portion Wa of a wire W. Unlike the conventional example, fitting operation of the wire W is performed without stripping an outer cover on the end portion Wa.
Next, operation of the structure will be explained. When the pair of rubber plug guides 18 , 19 are positioned at the closed position illustrated in FIGS. 5, 6 and one of the rubber plug holding rods 10 a of the rotary unit 10 is positioned to face the rubber plug feeding unit 11 according to its rotational movement, the pair of rubber plug guides 18 , 19 are moved at the closed position illustrated in FIGS. 7, 8 . The guide space is formed by the respective guide grooves 18 a , 19 a of the pair of rubber plug guides 18 , 19 . Next, the pushing rod 17 positioned at the lower position is moved upward so that the rubber plug 15 in the rubber plug feeding port 16 a is moved upward in the guide space. Here, the rubber plug 15 is moved while an outer periphery thereof is being guided by the respective guide grooves 18 a , 19 a . In the course of this movement, the rubber plug holding rod 10 a is inserted into a wire passing-through hole 15 a of the rubber plug 15 . Then, insertion of the rubber plug holding rod 10 a into the rubber plug 15 is limited or stopped at a position where an upper end face of the rubber plug 15 abuts on the stopper portions 18 b , 19 b.
Next, the pushing rod 17 which has pushed the rubber plug 15 is moved downward to the lower position and the pair of rubber plug guides 18 , 19 are moved to the opened position illustrated in FIGS. 5, 6 . Then, the rotary unit 10 is rotated at 90° in a clockwise direction and the rubber plug holding rod 10 a holding the rubber plug 15 fitted thereon is stopped at the position of the rubber plug holder 12 . The rubber plug holder 12 pulls the rubber plug 15 from the rubber plug holding rod 10 a , and the rubber plug 15 which has been pulled out is fitted on the end portion Wa of the wire W. Such processing actions are performed on respective rubber plug holding rods 10 a so that rubber plugs 15 are automatically fitted sequentially on end portions Wa of wires W. An outer cover of the end portion Wa of the wire W is stripped off after fitting of the rubber plug 15 .
In the above operation course, as illustrated in FIG. 4B, the rubber plug 15 is fitted on the rubber plug holding rod 10 a while an outer periphery of the rubber plug 15 is being guided by the respective guide grooves 18 a , 19 a of the pair of rubber plug guides 18 , 19 . Accordingly, when the inner diameter of the rubber plug 15 is small, the diameters of the respective guide grooves 18 a , 19 a may simply be reduced, so that there is no portion where rigidity is weak in the respective rubber plug guides 18 , 19 and the rubber plug 15 can be performed without injuring parts or the like, which results in improvement in durability. In this manner, since such a trouble as a part injury does not occur and feeding of the rubber plug 15 is securely performed, a machine stoppage due to feeding failure is prevented, so that productivity can be improved.
Also, since fitting of one of the rubber plugs 15 on each rubber plug holding rods 10 a is restricted by the respective stopper portions 18 b , 19 b provided above the upper portions of the respective guide grooves 18 a , 19 a , the rubber plug 15 is fitted on the rubber plug holding rods at a position where it abuts on the stopper portions 18 b , 19 b so that the rubber plug 15 can securely be fitted and positioned at a predetermined fitting position of each rubber plug holding rod 10 a . Accordingly, unlike the conventional example, it is unnecessary to provide another positioning unit in addition to the rubber plug feeding unit 11 , the structure of the rubber plug fitting apparatus is simplified, and manufacturing cost is reduced. Furthermore, since the rubber plug 15 is positioned and mounted on the predetermined fitted position of each rubber plug holding rod 10 a , a delivery of the rubber plug 15 to the rubber plug holder 12 is securely performed at the next step. A machine stoppage due to feed failure is prevented, which also results in improvement in productivity. Also, since the positioning step of the rubber plug 15 can be omitted, which also results in improvement in productivity.
Furthermore, as set forth above, since lower face positions of the respective stopper portions 18 b , 19 b defines a position of the lower end face of the rubber plug 15 fitted on each rubber plug holding rod 10 a , a fitting position of the rubber plug 15 on the rubber plug holding rod 10 a can arbitrarily be adjusted by the position of the respective stopper portions 18 b , 19 b.
The entire contents of Japanese Patent Application P10-355093 (filed on Dec. 14, 1998) are incorporated herein by reference.
Although the invention has been described above by reference to certain embodiments of the invention, the invention is not limited to the embodiments described above. Modifications and variations of the embodiments described above will occur to those skilled in the art, in light of the above teachings. The scope of the invention is defined with reference to the following claims. | A rubber plug fitting apparatus includes: a rubber plug feeding unit for feeding each of rubber plugs to a rubber plug feeding port; a rubber plug holder for holding one of the rubber plugs to fit the rubber plug on a wire; and a rotary unit having a plurality of rubber plug holding rods which are fitted into each of the rubber plugs to hold the rubber plugs. The rotary unit rotationally moves each of the rubber plug holding rods between the rubber plug feeding unit and the rubber plug holder. In the apparatus, a pair of rubber plug guides are provided so as to be capable of being opened/closed at a side of the rubber plug feeding port of the rubber plug feeding unit; and guide grooves are respectively provided at positions of the pair of rubber plug guides facing the rubber plug feeding port. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to combined barriers and guide means for sliding windows, doors or other closure members to prevent unauthorized intrusion into a building or vehicle through a sliding window or door opening and to aid in guiding the same.
2. Description of the Prior Art
Barriers, such as crossbars secured at spaced intervals across sliding windows, have long been used to prevent entrance of burglars or other intruders into a building through the window openings when such windows are opened. Such barriers, although effective, tend to obstruct the view through such a window and, more importantly, prevent escape of a person through the window opening from inside the building in the event of a fire or other emergency.
SUMMARY OF THE INVENTION
A principal object of the present invention is to provide a barrier to prevent intrusion through the opening of a sliding window or other closure member from the exterior of a building while permitting an unobstructed view through such window.
Another object is to provide a barrier to prevent intrusion through the opening of a window or other closure member of the above type from the exterior while permitting ready exit through such opening from the interior.
Another object is to provide a barrier of the above type which is hidden from view from the outside when the window is closed.
A further object is to provide a barrier of the above type for a sliding window door or the like which also prevents binding or sticking of the window or door in its slide bearings during movement between open and closed positions.
A still further object is to provide a simple, compact and inexpensive barrier for a sliding window or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner in which the above and other objects of the invention are accomplished will be readily understood on reference to the following specification when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a front view of sliding window and its frame when viewed from the inside of a building or vehicle, embodying a preferred form of the present invention, and showing the window in open condition and the barrier in place.
FIG. 2 is a view similar to FIG. 1 but showing the window in closed condition.
FIG. 3 is a view similar to FIG. 1 but showing the window in open condition, and the barrier in open condition.
FIG. 4 is a transverse sectional view taken along the line 4--4 of FIG. 1.
FIG. 5 is a front view illustrating a modified form of the invention.
FIG. 6 is a diagramatic view illustrating the operation of the linkage comprising the combined guide and barrier.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 to 4 in particular, the embodiment of the present invention is shown therein as applied to a window 11 which is slidably mounted for vertical movement in a frame comprising side frame members 12 and 13 attached to a suitable top frame member, not shown, and to a combined cross frame member 14 and sill 15, the latter being suitably secured to the upper edge of the member 14. The frame members 12, 13 and 14 may be mounted in a window opening formed in a building or vehicle side wall in the usual manner. The side frame members 12 and 13 form slide bearings for guiding the window vertically.
The window 11 is movable through a window opening 16 from an open position shown in FIG. 1 to a closed position shown in FIG. 2. Suitable means, not shown, may be provided to maintain the window in its fully open position or fully closed position or in any other position therebetween, and to lock the window in closed position.
According to the present invention, a combined guide and intrusion barrier, generally indicated at 19, is provided to prevent entry through the window opening 16 from the exterior of the building, vehicle or the like, when the window is in open or in partially open position and to aid the slide bearings in guiding the window in a parallel movement during opening or closing movement. The barrier 19 comprises a first pair of parallel links 17 and 18 pivotally connected at 20 and 21 at their upper ends to a lower frame element 22 of the window 11. A second pair of parallel links 23 and 24 are pivotally connected at 25 and 26 at their lower ends to a cross bar 27 and are pivotally connected at 28 and 30 at their upper ends to respective lower ends of the parallel links 17 and 18. Cross bar 27 is normally locked to the sill 15 by a latch, generally indicated at 29, as will be explained later.
A cross or guide link 31 is pivotally connected at 32 to link 17 of the first pair of parallel links and at 33 to the link 24 of the second pair.
It will be noted that the parallel links 17, 18, 23 and 24 are all of the same length and that the distance between the pivots 28 and 32 is the same as the distance between the pivots 30 and 33.
The cross link 31 constrains the parallel links to move in a generally parallel manner. However, due to a non-symmetrical relationship between the parallel links and the cross-link 31, as will be described presently, the link 31 tends to guide the parallel links in a slightly non-parallel movement and this would, in the absence of additional guiding means, tend to allow binding of the window in its slide bearings. Accordingly, an equalizer linkage is provided comprising additional links 34, 35 and 36, all pivotally connected together at adjacent ends at 37. The link 36 is pivotally connected at its opposite end to cross link 31 at 38. Link 34 is pivotally connected at its opposite end at 28 to links 17 and 23, and link 35 is pivotally connected at its opposite end at 30 to the links 18 and 24.
It should be noted here that each of the pivots 20, 21, 25, 26, 28, 30, 32, 33, 37 and 38 comprises a suitable pin (not shown) freely pivotal in a bearing hole formed in a respective one or ones of the connected links and therefore a minute clearance exists between each pin and its associated bearing.
FIG. 6 diagramatically illustrates the relationship of the various links in both the open and substantially closed position of the window. The full lines illustrate the position of the links with the window open, as depicted in FIG. 1, and the dotted lines illustrate the positions of the links when the window is substantially closed.
Describing now the operation of the various links, as the window is moved downward toward its closed position, the link pairs 17, 23 and 18, 24 collapse toward their alternate dotted line positions 17a, 23a, and 18a, 24a. As noted above, an unsymmetrical relationship exists between the links, as evidenced by the fact that the point of intersection "x" between cross link 31 and a center line "a" passing through pivots 28 and 30 shifts to the right toward point "x a " as the window is closed. Therefore, assuming that the pivot 21, connecting link 18 to the left end of the window 11, is constrained to move in a vertical path 60, and in the absence of the equalizing links 34, 35, and 36, the cross link 31 would tend to force the links 17 and 23 into their dot-dash line positions 17b and 23b, thereby tending to move the pivot 20, connecting the link 17 to the right hand of the window 11, upwardly relative to the pivot 21 and out of the intended path 61, resulting in a tendency to allow the window to bind in its slide bearings. Links 34, 35 and 36 counteract this tendency and force links 17 and 23 to move in parallel relation to links 18 and 24. That is, as the link pairs collapse, link 35 causes link 36 to turn clockwise about its pivot 38, causing link 34 to exert a controlling force on the pivot 28, thereby constraining link 23 to follow about pivot 25. Link 17, pivotally connected to link 31 is constrained to follow in substantially parallel relation with link 18.
The location of pivot 38 may be changed somewhat to correct for minor errors in dimensions between various pivots, and for this purpose, spaced pivot bearing holes 63 are provided along link 36 so that the pivot pin (not shown) forming pivot 38 may be inserted in any combination of such bearing holes to effectively change the position of pivot 38.
A bar 40 is pivotally connected at 41 to the parallel links 17 and 18 midway between their ends. Likewise, a second bar 42 is pivotally connected at 43 to the parallel links 23 and 24 midway between their ends. Such bars 40 and 42 thus extend parallel to the cross bar 27 and move in a parallel manner during opening and closing of the window 11 to cooperate with the cross link 31 to prevent intrusion through the window opening 16. Equalizer links 34, 35 and 36 also contribute in barring the window opening.
As will be seen in FIG. 2, when the window is closed, the bars 40 and 42 nest next to each other and behind the window frame member 22 so as to be hidden from view from the exterior of the building or vehicle.
The cross bar 27 is normally attached on top of the sill 15 and for this purpose a depending latch tongue 44 is suitably secured to the latch bar intermediate the ends thereof. Normally, the tongue 44 extends through a close fitting opening 45 in the sill, as shown in FIG. 4, and has a notch 46 therein engaged by a latch bolt 47 of the latch 29. Bolt 47 is slidable in a slide bearing 48 secured to the bottom frame member 14 of the window frame. Thus, the latch 29 is hidden from view from the exterior of the window and cannot be seen by a would-be intruder. However, in the event of a fire or other emergency, the latch would be readily visible to anyone within the building and the bolt 47 may be readily slid back to release the tongue 44, permitting the barrier 17 to be collasped upwardly into its position shown in FIG. 3 to permit escape through the window opening 16.
FIG. 5 illustrates a modified form of the invention as applied to a door or window 50 which is slideable horizontally within a frame 51 for movement between open and closed positions. A linkage generally indicated at 52, and generally similar to linkage 19, except for the omission of parallel bars 40 and 41, is provided principally to assist the slide bearings provided by the frame 51 in enforcing a straight line parallel movement of the member 50. In this case, cross bar 27 is omitted. Also, pivots 25a and 26a, similar to pivots 25 and 26, are mounted directly on a frame member 54 forming part of the frame 51. Pivots 20a and 21a, similar to pivots 20 and 21, are mounted on the door 50.
It will be noted that the pivots 20a and 21a are located within an elongate slot 55 formed in the edge of the door 50. Also, the pivots 25a and 26a are likewise located within an elongate slot 56 formed in the edge of the frame member 54. Thus, when the door 50 is moved fully to the right, the collapsed linkage 52 will be contained within such slots 55 and 56 and will thus be substantially hidden from view from both sides of the door.
In cases where the door frame 51 is fitted within a hollow wall, the linkage 52 will be hidden from view at all times.
It will obvious to those skilled in the art that many variations may be made in the exact structure shown without departing from the spirit of this invention. | A barrier for barring the opening of a sliding window, door, etc., from intrusion from the exterior of a building or vehicle, the barrier being collapsible to permit escape of persons from the inside of the building or vehicle through the open window in the event of fire or other emergency. The barrier also constrains the window or door to move in a straight line parallel motion to prevent binding or sticking of the same in its slide bearings during opening or closing of the window or door. | 4 |
[0001] This application claims the benefit of Japanese Patent Application No. 2000-089048 which is hereby incorporated by reference.
BACKCROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an improvement in a rotation transmitting device incorporating a one-way clutch therein which can be used typically as a driven pulley fixed to an end of a rotary shaft of an alternator which serves as a power generator in a car, or a pinion fixed to an end of a rotary shaft for constituting a starter motor of a starting system of a car.
[0004] 2. Related Background Art
[0005] The structure of an alternator which generates electric power necessary for a car by using an engine of the car as its driving source is disclosed, for instance, in Japanese Patent Application Laid-Open No. 7-139550. FIG. 6 illustrates an alternator 1 which is described in the above application. Referring to FIG. 6, a rotary shaft 3 is rotatably supported by a pair of rolling bearings 4 and 4 inside a housing 2 . A rotor 5 and a rectifier 6 are provided in a middle part of this rotary shaft 3 . In addition, a driven pulley 7 is fixed to an end portion (the right end portion in FIG. 6) of this rotary shaft 3 which is protruded outward from the housing 2 . In a state in which the alternator is assembled in the engine, an endless belt is wound around this driven pulley 7 so that the rotary shaft 3 is driven to rotate freely by means of a crank shaft of the engine.
[0006] As the driven pulley 7 described above, a pulley which is simply fixed to the rotary shaft 3 has been conventionally employed. However, various types of a pulley device incorporating a one-way clutch therein have been recently proposed as rotation transmitting devices incorporating a one-way clutch therein which are arranged to transmit the driving power from the endless belt to the rotary shaft when the running speed of the endless belt is fixed or on the increase, while allowing relative rotation between the driven pulley and the rotary shaft when the running speed of the endless belt is on the decrease. Some of such pulley devices have been put into practice use. For instance, pulley devices incorporating a one-way clutch therein and having a function as described above are disclosed in Japanese Patent Application Laid-Open Nos. 56-101353, 7-317807, 8-61443, 8-226462 and 7-72585, French Patent Publication FR2726059A1, and the like.
[0007] FIGS. 7 to 9 illustrate a pulley device incorporating a one-way clutch conventionally known by being described in either of the above publications. This pulley device incorporating a one-way clutch therein comprises a sleeve 8 which serves as an inner diameter side member and can be fitted and fixed onto the rotary shaft 3 of the alternator 1 (see FIG. 6). Around this sleeve 8 , there is provided a driven pulley 7 a which serves as an outer diameter side member in a cylindrical form to be concentric with this sleeve 8 . Then, a pair of support bearings 9 , 9 and a roller clutch 10 serving as the one-way clutch are provided between the outer peripheral surface of the sleeve 8 and the inner peripheral surface of the driven pulley 7 a.
[0008] The sleeve 8 is formed to be cylindrical as a whole, and is fitted and fixed onto an end portion of the rotary shaft 3 of the alternator 1 to be rotatable with this rotary shaft 3 . To this end, in the illustrated example, a threaded hole portion 11 is formed in a middle part on the inner peripheral surface of the sleeve 8 , and this threaded hole portion and a male screw portion which is formed on the outer peripheral surface at the tip end portion of the rotary shaft 3 are arranged to be thread-engaged with each other. A latch hole portion 12 having a hexagonal cross section is also formed at the tip end portion on the inner peripheral surface of the sleeve 8 (the left end portion in FIG. 7). The tip end portion of a tool such as a hexagonal wrench can be latched by this latch hole portion 12 . Furthermore, the base portion (the right end portion in FIG. 7) of the inner peripheral surface of the sleeve 8 serves as a circular hole portion 13 which can be fitted on a portion near the middle part of the tip end portion of the rotary shaft 3 with no play. Note that a spline engagement, non-circular fitting, key engagement, or another arrangement may be employed as the arrangement for combining the sleeve 8 with the rotary shaft 3 in such a manner that they are not relatively rotated with each other. In addition, the central portion of the outer peripheral surface of the sleeve 8 serves as a large diameter portion 14 which has a larger diameter size than that of another portion.
[0009] On the other hand, a tip half portion of the outer peripheral surface of the driven pulley 7 a has a cross section in a waveform along the widthwise direction, around which a part of the endless belt called a poly-V belt can be wound. Then, the above-mentioned roller clutch 10 is disposed in a middle part in the axial direction of a space existing between the outer peripheral surface of the sleeve 8 and the inner peripheral surface of the driven pulley 7 a , while the support bearings 9 , 9 are respectively disposed at positions to sandwich this roller clutch 10 from the both sides in the axial direction near the both ends of this space in the axial direction.
[0010] Out of these members, the support bearings 9 , 9 allow, while supporting a radial load applied on the driven pulley 7 a , a relative rotation between this driven pulley 7 a and the sleeve 8 . In the illustrated example, ball bearings of a deep groove type are used as the support bearings 9 , 9 . More specifically, these support bearings 9 , 9 comprise outer races 16 , 16 respectively having outer raceways 15 , 15 of the deep groove type on the respective inner peripheral surfaces thereof, inner races 18 , 18 respectively having inner raceways 17 , 17 of the deep groove type on the respective outer peripheral surfaces thereof, and balls 19 , 19 provided in plural sets as capable of rolling between the outer raceways 15 , 15 and the inner raceways 17 , 17 . Then, the outer races 16 , 16 are fitted and fixed onto the inner peripheral surface near the both ends of the driven pulley 7 a , while the inner races 18 , 18 are onto the outer peripheral surfaces near the both ends of the sleeve 8 , respectively. In this state, the inner races 18 , 18 in the axial direction are brought into contact with the respective end surfaces (step surfaces) in the axial direction of the large diameter portion 14 . Also, in the illustrated example, seal rings 20 , 20 are provided between the inner peripheral surfaces of the both end portions of the outer races 16 , 16 and the outer peripheral surfaces of the both end portions of the inner races 18 , 18 , respectively, thereby sealing openings at the both ends of the space provided with the balls 19 , 19 described above.
[0011] It is preferable that a communication hole is formed in a part of each of the seal rings 20 , 20 on the side facing a space which is formed by and between the support bearings 9 , 9 , out of the above-described seal rings 20 , 20 , so that this space and the space receiving therein the balls 19 , 19 of the support bearings 9 , 9 are communicated to each other, in order to prevent excessive rise of the pressure inside the space formed by and between the support bearings 9 , 9 when the support bearings 9 , 9 are inserted with pressure between the inner peripheral surface of the driven pulley 7 a and the outer peripheral surface of sleeve 8 . When the outer races 16 , 16 are interference-fitted and fixed into the inner peripheral surface of the driven pulley 7 a , it is preferable that, out of the inner peripheral surface of this driven pulley 7 a , a part in which the outer races 16 , 16 are fitted is made a large diameter portion, while a part in which a clutch outer race 25 , which is described later, is fitted is made a small diameter portion, so that the large diameter portion and the small diameter portion are in a stepped form continued by the paired step surfaces, since a flaw in a groove shape is easily created along the axial direction on the inner peripheral surface of the driven pulley 7 a when the clutch outer race 25 is thrust into the inner peripheral surface of this driven pulley 7 a in case that the inner peripheral surface of the driven pulley 7 a is a single cylindrical surface. Then, when such a groove is created, there is a possibility that the grease enclosed in the gap between the both support bearings 9 , 9 is leaked out through the gap between the groove and the outer peripheral surfaces of the outer races 16 , 16 . On the contrary, if the size of a part in which the clutch outer race 25 is fitted is set to be smaller than that of a part in which the outer races 16 , 16 are fitted, such a flaw as described above can be prevented.
[0012] The roller clutch 10 is arranged to allow transmission of the force of rotation between the driven pulley 7 a and the sleeve 8 only when the driven pulley 7 a has a tendency to rotate in a predetermined direction relatively to the sleeve 8 . In order to arrange the roller clutch 10 as described above, the clutch inner race 21 is interference-fitted and fixed onto the large diameter portion 14 of the sleeve 8 . This clutch inner race 21 is formed to be cylindrical as a whole by press working, or other plastic working, of a steel plate of, for instance, cemented steel, and on the outer surface of which, a cam surface 22 is formed. More specifically, a plurality of concave portions 23 , 23 each called a ramp portion are formed on the outer peripheral surface of the clutch inner race 21 at regular intervals in the circumferential direction, whereby the outer peripheral surface serves as the cam surface 22 mentioned above. Note that, in the illustrated example, a concave chamfered portion 24 is formed on one end portion (the left end portion in FIG. 7 ) on the inner peripheral surface of the clutch inner race 21 , and this chamfered portion 24 serves as a guide surface when the clutch inner race 21 is to be thrust with pressure into the outer peripheral surface of the large diameter portion 14 .
[0013] On the contrary, out of the inner peripheral surface of the clutch outer race 25 which is interference-fitted and fixed in the middle part on the inner peripheral surface of the driven pulley 7 a , at least a middle part in the axial direction in contact with rollers 26 , which is described later, is simply formed as a cylindrical surface. Such clutch outer race 25 is formed to be cylindrical as a whole also by press working or other plastic working of a steel plate of, for instance, cemented steel, and inward flange portions 27 a and 27 b are formed at the both ends of the clutch outer race 25 in the axial direction. Note that one flange portion 27 a (the left one in FIG. 7) out of the two flange portions 27 a and 27 b is formed prior to the manufacturing of the clutch outer race 25 , so that this flange portion 27 a has the thickness equal to that of the cylindrical portion of the clutch outer race 25 . On the other hand, the other flange portion 27 b (the right one in FIG. 7) is formed after a roller 26 which is described later and the clutch retainer 28 are assembled in the clutch outer race 25 inward in the radial direction. Consequently, the flange portion 27 b is formed thin.
[0014] A plurality of rollers 26 for constituting the roller clutch 10 together with the clutch inner race 21 and the clutch outer race 25 are supported to allow a slight displacement in the rolling and circumferential directions by a clutch retainer 28 which is fitted on the clutch inner race 21 to allow no rotation with respect to the clutch inner race 21 . This clutch retainer 28 is formed in a cylindrical form of a cage type as a whole of synthetic resin (for instance, synthetic resin of polyamide 66 , polyamide 46 , polyphenylene sulfide, or the like, mixed with 20% of glass fiber). This clutch retainer 28 is provided with a pair of rim portions 29 , 29 each formed in an annular shape, and a plurality of column portions 30 , 30 for connecting the both rim portions 29 , 29 to each other.
[0015] Portions surrounded on the four sides by the inner side surfaces of the rim portions 29 , 29 and the side surfaces of the column portions 30 , 30 in the circumferential direction are called the pockets 31 , 31 for holding the rollers 26 to allow a slight displacement in the rolling and circumferential directions. Then, arcuate convex portions 32 , 32 which are formed at a plurality of positions on the inner peripheral surfaces of the rim portions 29 , 29 are engaged with the concave portions 23 , 23 formed on the outer peripheral surface of the clutch inner race 21 , whereby the clutch retainer 28 is attached to the clutch inner race 21 in such a manner that a relative rotation with this clutch inner race 21 is not allowed.
[0016] Between the column portions 30 , 30 for constituting this clutch retainer 28 and the rollers 26 , there are provided, respectively, leaf springs or springs each typically made of a synthetic resin and integrally formed with this clutch retainer 28 . These springs elastically press the respective rollers 26 in the same direction with respect to the circumferential direction of the clutch retainer 28 toward a portion, out of a cylindrical gap formed between the outer peripheral surface of the cam surface 22 and the inner peripheral surface (cylindrical surface) of a middle part of the clutch outer race 25 , which is narrower in the radial direction. The both end surfaces in the axial direction of the clutch retainer 28 as described above are approximated to face the inner side surfaces of the two flange portions 27 a , 27 b for constituting the clutch outer race 25 , thereby preventing a displacement of this clutch retainer 28 in the axial direction.
[0017] By the use of the pulley device incorporating a one-way clutch arranged as described above, when the driven pulley 7 a and the sleeve 8 have a tendency to rotate relatively to each other in a predetermined direction, each roller 29 enters into the narrower portion in the radial direction of the cylindrical gap, whereby the relative rotation between the driven pulley 7 a and the sleeve 8 becomes impossible (in a locked state). On the other hand, when the driven pulley 7 a and the sleeve 8 are rotated relatively to each other in a direction opposite to the predetermined direction, each of the rollers 26 is retracted to a portion having the greater width in the radial direction of the cylindrical gap, thereby allowing the relative rotation between the driven pulley 7 a and the sleeve 8 (in an over-run state).
[0018] There are two reasons for employing the pulley device incorporating a one-way clutch for an alternator having a structure as described above, as described below. The first reason is to prolong the life of the endless belt. For instance, by the use of a diesel engine as the driving engine, a fluctuation in angular speed of rotation of the crank shaft becomes great at the time of low rotation such as an idling time. As a result, the running speed of the endless belt which is wound around the driving pulley fluctuates finely On the other hand, the rotary shaft 3 of the alternator which is driven to rotate through the driven pulley by the use of this endless belt does not fluctuate so rapidly owing to the inertia masses of the rotary shaft 3 and a rotor, or the like, fixed to this rotary shaft 3 . Thus, when the driven pulley is merely fixed to the rotary shaft, the endless belt and the driven pulley are inclined to rub each other in the both directions upon a fluctuation in the angular speed of rotation of the crank shaft. As a result, the stress works on the endless belt which rubs this driven pulley repeatedly in different directions, to easily cause a slip between this endless belt and the driven pulley, or to reduce the life of this endless belt.
[0019] Accordingly, by employing the pulley device incorporating a one-way clutch for an alternator having a structure as described above as the driven pulley described above, it is arranged such that the force of rotation can be transmitted from the driven pulley to the rotary shaft 3 when the running speed of the endless belt is fixed or on the increase, while the relative rotation is allowed between the driven pulley and the rotary shaft 3 when the running speed of the endless belt is on the decrease. More specifically, when the running speed of the endless belt is on the decrease, the angular speed of rotation of the driven pulley is set to be slower than the angular speed of rotation of the rotary shaft so as to prevent strong friction between the endless belt and the driven pulley in a contact portion therebetween. Thus, the direction of the stress acting on the frictional portion between the driven pulley and the endless belt is fixed so as to prevent a slip between this endless belt and the driven pulley or reduction of the life of this endless belt.
[0020] The second reason is to enhance the efficiency in power generation by the alternator. The rotary shaft 3 to which the rotor of the alternator is fixed is driven to rotate by the driving engine of the car through the endless belt and the driven pulley. When a driven pulley of a fixed type is used, if the speed of rotation of the driving engine is rapidly decreased, the speed of rotation of the rotor is also rapidly decreased, whereupon an amount of power generation by the alternator also rapidly decreases. On the contrary, when the pulley device incorporating a one-way clutch for an alternator described above is used as a driven pulley to be attached to the alternator, even if the speed of rotation of the driving engine is rapidly decreased, the speed of rotation of the rotor is gradually decreased due to the force of inertia, and the alternator continues to generate power all the time. As a result, compared with a case in which the driven pulley of a fixed type is used, the kinetic energies of the rotary shaft and the rotor can be effectively utilized, so as to increase an amount of power generation by the alternator.
[0021] With the conventional structure described above, the displacement of the clutch retainer 28 in the axial direction is prevented by the paired flange portions 27 a , 27 b which are provided at the both ends of the clutch outer race 25 . More specifically, when the clutch retainer 28 is to be displaced in the axial direction at the time of over-run at which the driven pulley 7 a and the sleeve 8 are rotated relatively to each other, an end surface in the axial direction of this clutch retainer 28 and the inner side surface of one 27 a (or 27 b ) of the paired flange portions are brought into contact (sliding contact) to prevent the displacement in the axial direction of the clutch retainer 28 . However, in case of the pulley device incorporating a one-way clutch for an alternator as described above, a relative speed of rotation between the pulley 7 a and the sleeve 8 may reach several hundred min −1 (r.p.m.) to several thousand min −1 (r.p.m.) in an extreme case. For this reason, if the both end surfaces in the axial direction of the clutch retainer 28 and the inner side surfaces of the flange portions 27 a , 27 b are brought into sliding contact as described above, the both end surfaces in the axial direction of the clutch retainer 28 may be easily worn away, or a frictional heat which is generated in the sliding contact portions between the both end surfaces in the axial direction of this clutch retainer 28 and the inner side surfaces of the flange portions 27 a , 27 b may be excessively high.
[0022] Then, when abraded powder which is generated due to the abrasion of the both end surfaces in the axial direction of the clutch retainer 28 is mixed into the grease for lubricating the roller clutch 10 , there is a possibility that the lubricating performance of this grease may be deteriorated. Also, when the frictional heat generated in the sliding contact portions becomes excessively high, the grease may be deteriorated by the heat in an early stage. The deterioration of the grease may cause a damage to the durability of the roller clutch 10 undesirably. Note that such a problem occurs in the same manner in a structure which does not comprise the pair of flange portions 27 a , 27 b even when the both end surfaces in the axial direction of the clutch retainer 28 are brought into sliding contact with another member which is rotated relatively to this clutch retainer 28 .
SUMMARY OF THE INVENTION
[0023] The rotation transmitting device incorporating a one-way clutch therein according to the present invention has been contrived taking the circumstances as described above into consideration.
[0024] According to the present invention, there is provided a rotation transmitting device incorporating a one-way clutch therein which comprises, an inner diameter side member fixed to an end of a rotary shaft, an outer diameter side member in a cylindrical form disposed around the inner diameter side member to be concentric with the inner diameter side member, a one-way clutch disposed between a middle part in the axial direction on the outer peripheral surface of the inner diameter side member and a middle part in the axial direction on the inner peripheral surface of the outer diameter side member for transmitting rotation between the outer diameter side member and the inner diameter side member only when the outer diameter side member has a tendency to relatively rotate in a predetermined direction with respect to the inner diameter side member, and a pair of support bearings disposed between the outer peripheral surface of the inner diameter side member and the inner peripheral surface of the outer diameter side member at a position to pinch this one-way clutch from the both sides thereof in the axial direction for allowing a relative rotation between the inner diameter side member and the outer diameter side member while supporting a radial load applied on this outer diameter side member.
[0025] Specifically, in the rotation transmitting device incorporating a one-way clutch therein, a clutch retainer for constituting the one-way clutch is arranged, based on that a part of the peripheral surface of this clutch retainer is brought into engagement directly or through another member with either one of the inner peripheral surface of the outer diameter side member and the outer peripheral surface of the inner diameter side member, to be rotated together with a member disposed on the one peripheral surface. In addition, a convex portion formed in a protruding manner toward the above one peripheral surface at an end portion in the axial direction of the clutch retainer is disposed between a step surface formed on the above one peripheral surface or an end surface in the axial direction of a member fitted and fixed on this one peripheral surface and another step surface formed on the one peripheral surface or an end surface in the axial direction of the other member fitted and fixed to this one peripheral surface so as to regulate a displacement of the clutch retainer in the axial direction, thereby preventing the both end surfaces of this clutch retainer in the axial direction from contacting with a member which is rotated relatively to this clutch retainer.
[0026] Furthermore, in a rotation transmitting device corporation a one-way clutch therein of the present invention, a clutch outer race having a pair of flanges extending inward in the radial direction at the both ends in the axial direction thereof may be fitted and fixed into a middle part of the outer diameter side member in the axial direction with one of the peripheral surfaces serving as the outer peripheral surface of the inner diameter side member, and the inner side surfaces of the flanges which are opposited to each other may be approximated to face the both end surfaces in the axial direction of the clutch retainer.
[0027] As describe above, in case of the rotation transmitting device incorporating a one-way clutch therein according to the present invention, it is possible to prevent the both end surfaces in the axial direction of the clutch retainer from being brought into contact (sliding contact) with a member which relatively rotates with respect to this clutch retainer. More specifically, according to the present invention, when the clutch retainer has a tendency to displace in the axial direction, prior to the contact of the end surfaces in the axial direction of this clutch retainer with the portion rotating relatively to the clutch retainer, a convex portion provided on an end portion in the axial direction of this clutch retainer is brought into contact with the step surface formed on the above one peripheral surface or an end surface in the axial direction of the member which is fitted and fixed on this one peripheral surface. Since the step surface and the end surface are portions rotating with the clutch retainer, the step surface and the end surface do not rub the contact portion of the convex portion when the one-way clutch overruns. Thus, in case of the rotation transmitting device incorporating a one-way clutch therein according to the present invention, there is no possibility of abrasion of the both end surfaces in the axial direction of the clutch retainer or generation of frictional heat on the both end surfaces in the axial direction of the clutch retainer. For this reason, the abraded powder of the clutch retainer is not mixed into the grease for lubricating the one-way clutch, or this grease is not deteriorated by the heat. Consequently, it is possible to realize a rotation transmitting device incorporating a one-way clutch therein which maintains the state of lubrication of the one-way clutch over a long term satisfactorily and has a sufficient durability.
[0028] Furthermore, the structure may be arranged such that a gap is present all the time between the inner side surfaces of the paired round wheel portions formed at the both end portions in the axial direction of the clutch outer race and the both end surfaces in the axial direction of the clutch retainer. For this reason, this gap portion may be used as a grease pool, so as to conduct lubrication of the one-way clutch satisfactorily. More specifically, when the rotation transmitting device incorporating a one-way clutch therein is used, the centrifugal force acts upon the grease which is thick on the gap portion. Then, the grease thus receiving the centrifugal force is diffused uniformly on the inner peripheral surface of the clutch outer race. As a result, it is possible to sufficiently supply the grease into a gap portion between the surfaces of a plurality of locking members for constituting the one-way clutch and the inner peripheral surface of the clutch outer race. For this reason, the state of lubrication of the one-way clutch can be satisfactorily maintained for a long term, so as to realize a rotation transmitting device incorporating a one-way clutch therein which has a sufficient durability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] [0029]FIG. 1 is a half cross-sectional view for showing the first embodiment of the present invention;
[0030] [0030]FIG. 2 is a half cross-sectional view for illustrating the second embodiment, only with the essential portion taken out from the embodiment;
[0031] [0031]FIG. 3 is a view for illustrating the third embodiment, in the same manner as that for FIG. 2;
[0032] [0032]FIG. 4 is a half cross-sectional view for illustrating the fourth embodiment, only with the essential portion taken out from the embodiment;
[0033] [0033]FIG. 5 is a half cross-sectional view for showing the fifth embodiment of the present invention;
[0034] [0034]FIG. 6 is a cross-sectional view for showing a alternator which is conventionally known;
[0035] [0035]FIG. 7 is a half cross-sectional view for showing a conventional structure;
[0036] [0036]FIG. 8 is a partial perspective view of a clutch retainer; and
[0037] [0037]FIG. 9 is a partial lateral view for showing only a clutch inner race and a clutch retainer taken out of the structure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] [0038]FIG. 1 shows a first embodiment of the present invention. Note that the present invention is characterized in that a displacement in the axial direction of a clutch retainer 28 a is restricted to prevent the contact (sliding contact) between the both end surfaces in the axial direction of the clutch retainer 28 a and the inner side surfaces of a pair of flange portions 27 a , 27 b for constituting a clutch outer race 25 . Other structures and operations are the same as those of the conventional structure shown in FIGS. 7 to 9 , including the arrangement that this clutch retainer 28 a is formed to be rotatable together with this clutch inner race 21 due to the engagement between a plurality of convex portions 32 , 32 provided on the inner peripheral surface of the clutch retainer 28 a and a plurality of concave portions 23 provided on the outer peripheral surface of the clutch inner race 21 . For this reason, the same reference numerals and symbols are given to the identical members to those in the conventional structure, and description of the redundant portions will be omitted or will be made briefly. In the following, the present invention will be described centering around the characteristic part thereof.
[0039] A step surface 33 is formed on the outer peripheral surface of a part near an end (the portion near the left end portion in FIG. 1) of a large diameter portion 14 which is provided in a middle part in the axial direction of the sleeve 8 , by protruding the outer peripheral surface of an end portion of this large diameter portion 14 outwardly in the radial direction. On the other hand, on the inner peripheral surface of an end portion (the left end portion in FIG. 1) of the clutch retainer 28 a for constituting a roller clutch 10 , a convex portion 34 protruding inward in the radial direction is formed along the entire circumference thereof, or at least at one position in the circumferential direction. Then, a part on the tip end side (the inner diameter side) of this convex portion 34 is disposed between the step surface 33 and an end surface (the left end surface in FIG. 1) of the clutch inner race 21 which is fitted and fixed onto a middle part of the large diameter portion 14 , whereby a displacement in the axial direction of the clutch retainer 28 a is restricted so as to prevent the both end surfaces in the axial direction of this clutch retainer 28 a from being brought into contact with the inner side surfaces of the paired flange portions 27 a , 27 b provided at the both end portions in the axial direction of the clutch outer race 25 which paired flange portions are members for rotating relatively to the clutch retainer 28 a . More specifically, the dimensions of the respective members are so regulated that, when the clutch retainer 28 a has a tendency to displace in the axial direction, the side surface of the convex portion 34 and the step surface 33 described above or one of the end surfaces of the clutch inner race 21 are brought into contact, so as to avoid the contact between the end surface in the axial direction of this clutch retainer 28 a and the inner side surface of one 27 a (or 27 b ) of the paired flange portions.
[0040] In this embodiment, in order to effect such restriction, when the thickness of the convex portion 34 in the axial direction is denoted by A, the distance between the step surface 33 and the end surface of the clutch inner race 21 is by B, and the distance between the both end surfaces of the clutch retainer 28 a and the inner side surfaces of the flange portions 27 a , 27 b is by C, respectively, the values for A to C are set to satisfy the relation C>B−A, taking an error in assembly and the assembling performance into consideration. For instance, when a difference B−A is 0 to 0.5 (mm), the distance C is set to be larger than 0.05 (mm). Note that the step surface 33 and the end surface of the clutch inner race 21 are the portions rotating together with the clutch retainer 28 a . For this reason, when a side surface of the convex portion 34 and the step surface 33 or one of the end surfaces of the clutch inner race 21 are brought into contact as described above and the roller clutch 10 is overrun, the contact portions of the both surfaces do not rub each other. Moreover, if the dimensions and the positional relations of the respective parts can be strictly regulated without considering an error in assembly, the object of the present invention can be attained by satisfying the relation C>(B−A)/2. In this case, however, it should be arranged such that the distances C between the clutch retainer 28 a and the flange portions 27 a , 27 b are equal to each other in a state in which the convex portion 34 is disposed at a neutral position in the direction of displacement.
[0041] As described above, in case of a pulley device incorporating a one-way clutch of the present invention, it is possible to prevent the both end surfaces of the clutch retainer 28 a from being brought into contact (sliding contact) with the inner side surfaces of the paired flange portions 27 a , 27 b which are rotated relatively to this clutch retainer 28 a . Thus, the both end surfaces in the axial direction of this clutch retainer 28 a are not abraded, or the frictional heat is not produced on the both surface portions in the axial direction of this clutch retainer 28 a . As a result, it is possible to prevent the abraded powder of the clutch retainer 28 a from being mixed into the grease for lubricating the roller clutch 10 or this grease from being exposed to high temperature, so as to avoid earlier deterioration of this grease.
[0042] Furthermore, in case of the present embodiment, a gap is present all the time between the inner side surface of each of the paired flange portions 27 a , 27 b and each of the end surfaces in the axial direction of the clutch retainer 28 a . For this reason, this gap portion is used as a grease pool so that lubrication of the roller clutch 10 can be conducted sufficiently. That is, when the pulley device incorporating a one-way clutch is used, the centrifugal force works on the grease which gathers in this gap portion. Then, the grease thus receiving the centrifugal force is diffused uniformly over the inner peripheral surface of the clutch outer race 25 . As a result, the grease can be fully supplied into the spaces between the rolling surfaces of a plurality of rollers 26 for constituting the roller clutch 10 and the inner peripheral surface of the clutch outer race 25 , which spaces are parts requiring the grease at the time of overrun at which the driven pulley 7 a and the sleeve 8 are rotated relatively to each other. For this reason, it is possible to realize a pulley device incorporating a one-way clutch which maintains the state of lubrication of the roller clutch 10 excellently over a long term and has a sufficient durability.
[0043] Though the convex portion 34 is disposed on one end side of the clutch retainer 28 a in the foregoing embodiment, this convex portion 34 may be disposed on the other end side (the right end side in FIG. 1) of the clutch retainer 28 a.
[0044] Next, FIGS. 2 to 3 show second and third embodiments of the present invention. In these second and third embodiments, the step surface 33 (see FIG. 1) is not provided on the outer peripheral surface near the end (the left end in FIGS. 2 and 3) of the large diameter portion 14 which constitutes the sleeve 8 a , and the outer peripheral surface of this large diameter portion 14 is formed in a simple cylindrical shape along the entire length in the axial direction. Instead, an annular restricting member 36 having a rectangular cross section is interference-fitted and fixed typically onto a part which is near one end of the outer peripheral surface of the sleeve 8 a and adjacent to the large diameter portion 14 (in case of the second embodiment shown in FIG. 2) or an end portion on the outer peripheral surface of this large diameter portion 14 (in case of the third embodiment shown in FIG. 3). Then, it is arranged such that the convex portion 34 (see FIG. 1) of the clutch retainer 28 a is disposed between the end surface (the right end surface in FIGS. 2 and 3) in the axial direction of this restricting member 36 and the end surface (the left end surface in FIG. 1) in the axial direction of the clutch inner race 21 (see FIG. 1) which is fitted and fixed onto the large diameter portion 14 . In these second and third embodiments, the outer peripheral surface of the large diameter portion 14 can be formed in a simple cylindrical shape along the entire length in the axial direction, so that the material cost and the processing cost of the sleeve 8 a can be reduced. Other arrangements and operations in the second and third embodiments are the same as those in the first embodiment described above.
[0045] Next, FIG. 4 shows a fourth embodiment of the present invention. In the fourth embodiment, the large diameter portion 14 (see FIGS. 1 to 3 ) is not provided on the outer peripheral surface of a sleeve 8 b , and the outer peripheral surface of this sleeve 8 b is formed in a simple cylindrical shape along the entire length in the axial direction. Then, a second sleeve 37 which is formed in a substantially cylindrical shape as a whole is fitted and fixed onto the outer peripheral surface of a middle part of this sleeve 8 a . This second sleeve 37 comprises a cylindrical portion 38 to be interference-fitted and fixed onto the outer peripheral surface of the sleeve 8 b and an outward flange portion 39 which is provided on one end portion (the left end portion in FIG. 4) of this cylindrical portion 38 in the axial direction along the entire circumference thereof. Also, the clutch inner race 21 is fitted and fixed onto the outer peripheral surface of a middle part of the cylindrical portion 38 . Then, in case of the present embodiment, it is arranged such that the convex portion 34 (see FIG. 1) of the clutch retainer 28 a is disposed between a side surface (the right side surface in FIG. 4) of the flange portion 39 and one end surface (the left end surface in FIG. 4) in the axial direction of the clutch inner race 21 . In case of the present embodiment having such structure, since the outer peripheral surface of the sleeve 8 b can be formed in a simple cylindrical shape along the entire length in the axial direction, the material cost and the processing cost of this sleeve 8 b can be further reduced. Other arrangements and operations are the same as those in the first embodiment described before.
[0046] Next, FIG. 5 shows a fifth embodiment of the present invention. In case of the fifth embodiment, an eaves-shaped portion 35 which is protruding outward in the axial direction (to the left in FIG. 5) is formed at the tip end of the convex portion 34 a which is formed in a protruding manner on one end portion (the left end portion in FIG. 5) of the clutch retainer 28 b . Then, this eaves-shaped portion 35 is disposed between the inner end surface (the right end surface) of the inner race 18 for constituting one of the support bearings (the left one in FIG. 5) and one end surface (the left end surface in FIG. 5) of the clutch inner race 21 for constituting the roller clutch 10 . With this arrangement, a displacement of the clutch retainer 28 b in the axial direction is restricted so as to prevent the both end surfaces of this clutch retainer 28 b in the axial direction from being brought into contact (sliding contact) with the inner side surfaces of the paired flange portions 27 a , 27 b . Other arrangements and operations are the same as those in the first embodiment described above, except that the form and the position of the convex 34 a are changed.
[0047] Note that, a low clutch is employed as the one-way clutch in the foregoing embodiments. However, the same effects can be obtained even when a conventional one-way clutch of another type, including a sprag clutch or a cam clutch, is used as this one-way clutch of the present invention. When a cam clutch is used, any of such peripheral surfaces as engaging with the cam becomes a cylindrical surface. Accordingly, there is a possibility that a member for constituting the cam clutch is not fitted on any of such peripheral surfaces. In such a case, another step surface is formed directly on a surface serving as this peripheral surface so as to be subjected to a restriction on the position of the clutch retainer in the axial direction. The same effect can be obtained not only when a pair of ball bearings are used as the paired support bearings, but also when a pair of rolling bearings or one ball bearing and one rolling bearing are used as these paired support bearings.
[0048] Furthermore, in the foregoing embodiments, the present invention is applied to a pulley for an alternator. However, the present invention is not limited to this. For instance, when the present invention is applied to a rotation transmitting device of a starter motor which constitutes a starting system of a car, a pinion gear which can be meshed with a ring gear formed on the outer peripheral surface of a flywheel is formed on the outer peripheral surface of the outer diameter side member in a cylindrical shape.
[0049] Since the rotation transmitting device incorporating a one-way clutch therein of the present invention is constituted and operated as described above, it is possible to prevent abraded powder of the clutch retainer from mixing with the grease for lubricating the one-way clutch, or to prevent deterioration of this grease in an earlier stage due to exposure of this grease to high temperature, for example. For this reason, the state of lubrication of the one-way clutch can be excellently maintained over a long term to improve the durability of the one-way clutch. | A one-way clutch therein which comprises an inner diameter side member fixed to an end of a rotary shaft, an outer diameter side member in a cylindrical form disposed around the inner diameter side member to be concentric with the inner diameter side member, a one-way clutch disposed between a middle part in the axial direction on the outer peripheral surface of the inner diameter side member and a middle part in the axial direction on the inner peripheral surface of the outer diameter side member for transmitting rotation between the outer diameter side member and the inner diameter side member only when the outer diameter side member has a tendency to relatively rotate in a predetermined direction with respect to the inner diameter side member, and a pair of support bearings disposed between the outer peripheral surface of the inner diameter side member and the inner peripheral surface of the outer diameter side member at a position to pinch this one-way clutch from the both sides thereof in the axial direction for allowing a relative rotation between the inner diameter side member and the outer diameter side member while supporting a radial load applied on this outer diameter side member. | 5 |
This invention relates to a method and means for containing a propellant or explosive which is used in high energy or controlled pulse fracturing.
BACKGROUND OF THE INVENTION
Stimulation of wells through mechanical fracturing can be accomplished by a method known as controlled pulse fracturing or high energy gas fracturing. A good description of this method appears in an article by Cuderman, J. F., entitled "High Energy Gas Fracturing Development," Sandia National Laboratories, SAND 83-2137, October 1983. Using this method enables the multiple fracturing of a formation or reservoir in a radial manner which increases the possibility of contacting a natural fracture. In the practice of this method, a canister containing a propellant is suspended into a wellbore. This canister is placed downhole next to the oil or hydrocarbonaceous fluid productive interval.
The canister can be made of plastic or metal. While metal canisters can be used, a potential debris problem can arise during well cleanout, maintenance and production. Plastic canisters can be bailed, drilled, or pumped from the wellbore, however, their removal may damage the wellbore.
To avoid the debris problem caused by metal and plastic propellant canisters, it is desirable to have a method and means for disposing of the canister within the wellbore without presenting a debris cleanout problem and which will not damage the wellbore. The present invention is directed to a method and means for disposing of the propellant or explosive container within the wellbore which avoids the debris cleanout problem. Wellbore damage is also minimized.
SUMMARY
This invention relates to a method for making a disposable propellant device for utilization in high energy or controlled pulse fracturing.
In the practice of this invention, a disposable outer liner is constructed of a flexible porous material which is consumable upon ignition of a propellant or explosive subsequently placed into said liner. Afterwards, said porous material is impregnated with a consumable, solidifiable gel which can form a solid liner of a thickness capable of holding said propellant or explosive. Later, the gel is solidified and forms a solid liner. Subsequently, a propellant or explosive means, along with a means for igniting said propellant or explosive means is enclosed in said liner. After being enclosed, the device is inserted into the desired wellbore for utilization. When the propellant or explosive means is ignited, said solidifed canister decomposes.
It is therefore an object of the present invention to provide a method which will obviate the need to remove the canister remnants from the wellbore.
It is another object of this invention to provide a method which will facilitate varying the density of the gel canister to increase its strength.
Yet another object of the present invention is to minimize damage to a wellbore of formation when removing the canister.
A further object of the present invention is to provide for a method which will allow for variations in the stability and rigidity of the gelled canister or container as required.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphic representation of a canister containing the propellant before ignition.
FIG. 2 is a cross-sectional view of the disposable gelled canister.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows the relationship of the solidified gel canister utilized in this invention along with other members used in controlled pulse fracturing.
Referring to FIG. 1, a solidified canister containing a propellant 16 is placed into a wellbore 12 which penetrates a hydrocarbonaceous fluid producing formation 10. Canister 16 is suspended into the wellbore 12 via a retrieval means, which generally will be a cable 18. In order to ignite the propellant contained in the canister 16, a means for igniting the propellant is connected to the retainer stem 14. The retainer stem 14 forms an integral part of said canister and is positioned on its upwardly directed end. Preferably, retainer stem 14 is made in a manner similar to gel canister 16, thus becoming an integral and unified part of said canister. The other end of the means for ignition is connected or affixed to a location at or above ground level above wellbore 12. The means for igniting will generally be a conduit 20 containing an electrical wire which wire can be used to generate an electrical spark within canister 16 containing the propellant. Conduit 20 and cable 18 are directed through plug stem or cover seal 22 for connection to a support means outside of and above said wellbore 12. FIG. 2 shows a cross-sectional view of canister 16.
To prevent canister 16 from causing a removal problem after deflagration of a propellant contained therein, the canister is made of materials which are destroyed upon ignition of the propellant or explosive therein. Pressures generated upon ignition will vary from about 10,000 psig to about 80,000 psig. Instantaneous heat generated upon ignition of the propellant may be grater than about 1,000° F. in the vicinity of the deflagration but is quickly dissipated with propagation.
The disposable canister or device of the present invention is made by forming a flexible porous material 30 into a desired shape. Generally, this shape will be cylindrical. Flexible porous material 30 which can be utilized include nylon materials which is of a gauge sufficient to be used in women's stockings. This gauge is sufficient to prevent the liquified gel from flowing through said material. Another material which can be used is plastic screening which is found in most home screens.
The disposable outer liner 30 is placed into a mold of a cylindrical shape and about four inches across. Into these openings at the top of said mold is placed a smaller mold which is suspended so as to provide about one inch of space at the bottom and sides of said mold. A liquefied gel capable of solidification is placed in the space within said mold. The gel impregnates the porous material 30, which is suspended within said gel, and fills the space. The gel is then allowed to solidify thus forming the bottom and sides of canister 16. Sufficient space is left at the top of said mold for forming the top of the canister. Subsquently, the smaller mold is removed which leaves a void for placement of a propellant. A desired propellant 34 is placed within said void. Thereafter, additional gel is placed over the propellant which gel is sufficient to form the top of the canister 16. After the gel has solidified, the outer mold is removed and the canister containing the propellant is ready to be connected for suspension into wellbore 12. The canister closure is now complete.
Gel mixtures can be varied to obtain the desired stability and rigidity. A preferred mixture used to obtain the desired stability and rigidity, for example, is a mixture of hydropropyl guar cross linked with transitional metals and ions thereof. The purpose of the transitional metal ions is to provide increased strength, stability and rigidity for the gel canister 16.
Hydropropyl guar is placed into the gel mixture in an amount of from about 0.70 to about 10.0 weight percent of said mixture. As preferred, hydropropyl guar is placed in said mixture in about 7.2 percent by weight of said mixture.
Metallic ions which can be used in the gel mixture include titanium, zirconium, chromium, antimony and aluminum. The concentration of these transitional metals in the gel fluid will of course vary depending upon the requirements for the particular propellant being used and the nature of the wellbore and formation into which the canister containing the propellant is placed. Although the exact amounts of the metals required will vary depending on the particular application, it is anticipated that the metals should be included within the pumpable gel fluid in amounts of from about 0.005 weight percent to about 0.50 weight percent, preferably about 0.01 weight percent of said pumpable gel fluid mixture.
In one embodiment of the practice of this invention, a slurry is formed with 1,000 gallons of water. This slurry comprises about 40 pounds of base gel such as hydroxypropyl guar gum which forms a hydrate in the water. To this mixture is added about 600 pounds of chemically treated hydroxypropyl guar gum which has delayed hydration or thickening qualities. Approximately 20 pounds of a buffer or catalyst suitable to obtain the desired pH and reaction time is added to this mixture. Cross-linking agents, such as borates and chromates, are then added in an amount of about 20 pounds.
There are several methods of preparing the types of polymer systems which are used to obtain the solidified gel canister described herein. The ranges of polymer, buffer, and crosslinker concentrations given encompass two primary methods of forming said solidified gel canister.
The first method involves guar gum or hydroxypropyl guar as the base polymer. These products are widely used in the petroleum and food industries and are commercially available from chemical suppliers such as Celanese, Henkel, Hercules, and Millmaster Onyx. For this method, base gel containing the described concentration of 40 lbs per 1000 gallons of water (several types of water such as 2% KCl water, city water, formation water, etc. are used) is mixed into a holding tank at the surface (500 bbl frac tank, for example). The purpose of the base gel is to suspend additional unhydrated guar or hydroxypropyl guar (up to 600 or so lbs/1000 gals). The "secondary" polymer is pre-treated by the supplier with glyoxal or similar material to retard hydration. A buffer (such as sodium acetate or sodium pyrophosphate) is added with the additional polymer to maintain a fluid pH value sufficient to hydrate the additional polymer. The hydration of the additional material occurs slowly enough to allow placement within said mold. The buffers and gelling agents are readily available from the various service companies. In recent years improvements in fluid chemistry have led to "one bag" systems which contain all the described dry additives in one container. Comparable gel canisters can be prepared using hydroxyethyl cellulose (HEC) in the described manner using the primary and secondary polymer approach. The HEC is available from Hercules and Henkel.
The second method involves the use of much lower polymer concentrations (60 to 100 lbs/1000 gals of water) where viscosity and stability characteristics have been greatly enhanced by crosslinking with solutions of metallic salts. Because of the molecular structure, guar and derivatized guar (hydroxypropyl guar) lend themselves more satisfactorily to crosslinking than HEC. Therefore, the crosslinked guars are most useful in the present invention. The base gel in this instance would consist of the guar in solution at the described concentrations. Buffers are then used, depending on the crosslinker, to maintain a fluid pH necessary for the crosslink reaction. Several methods have been developed and are known in the prior art as has been suggested herein.
For the guar or hydroxypropyl guar crosslinked with borate, sodium pyrophosphate is used as the buffer, for example, and sodium tetraborate used as the croslinking agent. The buffer concentration ranges from 10 to 20 lbs/1000 gals for example and the borate required ranges from 5 to 15 lbs/1000 gals depending on the amount of guar or hydroxypropyl guar in the base gel. These materials are available from chemical suppliers and service companies such as have been described herein.
Other crosslinkers which are used include salt solutions of transitional metals such as titanium, chromium, and zirconium. Several crosslinker systems using titanium in solution have been developed by DuPont. These include titanium chemically combined with triethanolamine (TYZOR TE) and acetylacetonate (TYZOR AA), as examples. Because of their flexibility and utility, hydroxypropyl guar crosslinked with titanium is a very common present-day fracturing fluid and is available from several service companies; these fluid systems are also known in the prior art. Although not developed to the extent of the titanium crosslinked gel systems, fluids crosslinked with zirconium and chromium are available through the service companies.
Titanium crosslinked gels are more shear and temperature stable than borate gel systems. The buffer system used for titanium crosslinked gel include sodium acetate, sodium bicarbonate, and organic acids. The buffer(s) are mixed into the base gel and the crosslinker is added as the fluid is pumped. Reaction of the crosslink can be controlled by fluid pH and type and concentration of crosslinker solution used.
Of course, as is understood by those skilled in the art, appropriate scaling down of the above proportions can be made depending upon the amount of gel required for said canister 16 and integral retainer stem 14.
In order to withstand pressure generated from a hydrostatic head in deep wells, O-rings can be used to prevent leakage into or out of the solidified gel container. An embodiment of these O-rings is shown in U.S. Pat. No. 4,039,030 issued to Godfrey et al. and which is incorporated by reference herein.
The following example illustrates the invention:
EXAMPLE 1
According to the invention, a slurry is formed with 3785.4 liters (1000 gallons) of water. This slurry comprises 18.4 Kg (40 pounds) of base gel, hydroxypropyl guar gum, which forms a hydrate in the water. To this mixture is added 272.1 Kg (600 pounds) of chemically treated hydroxypropyl guar gum which has delayed hydration or thickening qualities. Then, 9.2 Kg (20 pounds) of sodium pyrophosphate buffer which is suitable to obtain the desired pH and reaction time is added to this mixture. A cross-linking agent consisting of sodium tetra-borate is then added in an amount of 9.2 Kg (20 pounds). This mixture is then poured into the mold containing the flexible porous material as discussed above and allowed to solidify.
Upon ignition of the propellant, heat and pressure is released within the wellbore and into the formation which expands into the formation 10 causing additional fracturing. This heat and pressure produced at a controlled rate causes a fracturing of the hydrocarbonaceous producing formation 10. Upon ignition, the heat and pressure created by the propellant causes a disintegration of the canister 16 which contained the propellant. However, the retrieval cable 18 and ignition line 20 remain intact. Retainer stem 14 formed of materials similar to those used in canister 16 is also disintegrated.
As is understood by those skilled in the art, the composition of a gel canister will depend upon many variables including the propellant used and formation conditions. The above examples are mentioned as two possible variations among many others.
Although the present invention has been described with preferred embodiments, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of this invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims. | A method and apparatus for making an in situ disposable propellant canister for utilization in controlled pulse fracturing. Said canister is composed of a porous light fabric material in combination with a gel solution. The gel creates a formable mass after solidification. Said mass can be made of a gel thickness sufficient to support and contain a propellant. Upon ignition of said propellant, the gelled canister is destroyed thereby alleviating a clean up operation. | 5 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/204,880.
[0002] This invention relates generally to development apparatus for mixing and applying developer material to a latent image on an image-bearing member in an electrostatographic reproduction machine, such as a copier or printer. More particularly, this invention relates to a blender of the type for mixing electrostatographic developer comprising a plurality of blender segments mounted on a shaft.
[0003] Development apparatus, for example a magnetic brush development apparatus, are well known for mixing and applying developer material to a latent electrostatic image on a photoconductor in an electrostatographic reproduction machine such as a copier or printer. Such a development apparatus typically includes an elongate housing which has a sump portion for containing the developer material. A two-component developer material comprises a mixture of carrier particles and toner particles. These particles are usually moved and mixed by a mixing device in the sump portion of the housing for triboelectrically charging the particles. Mixing also promotes uniformity in the concentration of toner particles throughout the sump portion, and in the distribution of developer material within the sump. The mixed and charged developer material can then be fed from the sump portion for development of the latent image on the photoconductor, which is generally a film or drum.
[0004] The quality of such an image development depends, in significant part, on factors such as the level of charge on the toner particles achieved triboelectrically for example, and such as the level and uniformity of the concentration of toner particles in the developer material being applied. As is well known, these factors are mainly determined by the effectiveness of a mixing device used in the sump portion of the development apparatus housing for moving, mixing and charging the developer material particles.
[0005] Certain prior blender assemblies implement a row of blender segments mounted on a shaft. Such assemblies typically exhibit a looseness in the blender segments after assembly due to tolerance stack-up. The segments are able to move small distance relative to the shaft and relative to each other. This movement, although limited, can cause toner flakes in the developer which, in turn, causes objectionable artifacts in the developed image. In addition, the outside diameter of certain blenders is ground during manufacturing to ensure an accurate fit with the developer housing. Looseness in the segments can cause the segments to chatter during the grinding operation.
SUMMARY OF THE INVENTION
[0006] According to an aspect of the invention, a blender for mixing electrostatographic developer is provided, comprising a shaft having a pair of stops spaced along a length thereof, a plurality of blender segments of the type for mixing electrostatographic developer, each blender segment having an aperture, the shaft being received within the aperture of each blender segment, and a resilient spacer, wherein the resilient spacer and the plurality of blender segments are compressed between the pair of stops.
[0007] According to a further aspect of the invention, a method of fabricating a blender for mixing electrostatographic developer is provided, comprising disposing a resilient spacer and a plurality of blender segments of the type for mixing electrostatographic developer on a shaft, each blender segment having an aperture, the shaft being received within the aperture of each blender segment, and compressing the resilient spacer and the plurality of blender between a pair of stops on the shaft.
[0008] According to a still further aspect of the invention a blender for mixing electrostatographic developer is provided, comprising a shaft having a pair of stops spaced along a length thereof and a plurality of serrations, one of the stops comprising a snap ring engaging one of the serrations, a plurality of blender segments of the type for mixing electrostatographic developer, each blender segment having an aperture, the shaft being received within the aperture of each blender segment, and at least one belleville washer disposed immediately adjacent one of the stops, wherein the resilient spacer and the plurality of blender segments are compressed between the pair of stops.
[0009] A blender according to the present invention has a plurality of blender segments exhibiting no residual looseness due to tolerance stack-up.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 presents a side view of a blender comprising a plurality of segments according to an aspect of the invention.
[0011] [0011]FIG. 2 presents a side view of a blender segment implemented in the blender of FIG. 1, according to an aspect of the invention.
[0012] [0012]FIG. 3 presents an end view of a blender segment according to an aspect of the invention taken along line 3 - 3 of FIG. 2.
[0013] [0013]FIG. 4 presents a side view of a shaft implemented in the blender of FIG. 1.
[0014] [0014]FIG. 5 presents cross-section view of a shaft taken along line 5 - 5 of FIG. 4.
[0015] [0015]FIG. 6 presents a side view of a blender comprising a plurality of segments according to a further aspect of the invention.
[0016] [0016]FIG. 7 presents side view of a blender segment according to an aspect of the invention.
[0017] [0017]FIG. 8 presents an end view of a blender segment according to an aspect of the invention taken along line 8 - 8 of FIG. 7.
[0018] [0018]FIG. 9 presents a side view of the shaft implemented in the blender of FIG. 6.
[0019] [0019]FIG. 10 presents a cross-sectional view of the shaft taken along line 10 - 10 of FIG. 9.
[0020] [0020]FIG. 11 presents an enlarged exploded view of the blender of FIG. 6 with parts broken away.
[0021] [0021]FIG. 12 presents a plan view of a snap ring implemented in the blender of FIG. 6.
[0022] [0022]FIG. 13 presents a plan view of an e-ring implemented in the blender of FIG. 6.
[0023] [0023]FIG. 14 presents a side cross-sectional view of the blender assembly with tooling for installing the snap ring.
DETAILED DESCRIPTION
[0024] Various aspects of the invention are presented in FIGS. 1 - 14 , which are not drawn to scale, and wherein like components are numbered alike. Referring now specifically to FIGS. 1 - 4 , a blender 10 for mixing electrostatographic developer is presented according to an aspect of the invention comprising a shaft 12 having a pair of stops 14 and 16 spaced along a length L. A plurality of blender segments 18 of the type for mixing electrostatographic developer are provided, each blender segment 18 having an aperture 20 . The shaft 12 is received within the aperture 20 of each blender segment 18 . A resilient spacer 22 is provided, the resilient spacer 22 and the plurality of blender segments 18 being compressed between the pair of stops 14 and 16 .
[0025] According to an aspect of the invention, the resilient spacer 22 provides a greater degree of elastic compression than the blender segments 18 and compensates for variations in the width of the row of blender segments 18 induced by tolerance stack-up. Each blender segment 18 is manufactured to prescribed dimensions, each dimension having a tolerance. Of particular interest here, with reference to FIG. 2, is the width W of each blender segment, and the tolerance dW associated with the width W.
[0026] The tolerance dW may be expressed in numerous ways as an absolute positive or negative value, or as a positive/negative (+/−), in accordance with the particular tolerance system employed. In any event, each blender segment 18 typically includes a small amount of variation in the manufactured width. Such variation is magnified when several blender segments 18 are placed in a row, a phenomena known as “tolerance stack-up.”
[0027] The maximum variation in the total width of the row is the sum of the tolerances dW of each blender segment 18 (and the tolerances of any intermediate structures). Since the blender segments 18 are generally manufactured from a relatively incompressible material such as plastic or metal, the length L between the first and second stops 14 and 16 is set to approximately the greatest possible width of the stack. This ensures that all of the blender segments 18 will fit between the stops 14 and 16 .
[0028] In practice, the actual width of the row of blender segments 18 is usually less than the maximum possible width since the width of each blender segment 18 is usually less than the maximum allowed by the tolerances. If left uncompensated, the individual blender segments 18 , after assembly of the blender 10 , are able to move a small distance relative to the shaft and relative to each other. This residual looseness is undesirable. The resilient spacer 22 solves this problem by maintaining the blender segments 18 under compression over the relatively large variation in total width induced by tolerance stack-up, thus eliminating the residual looseness. The resilient spacer 22 may comprise a coil spring, a belleville washer, or other resilient structure that compensates for tolerance stack-up in the blender segments 28 .
[0029] In a typical installation, the blender 10 is mounted in a developer sump and the shaft 12 is rotationally driven about its longitudinal axis. Examples of development apparatus that may implement a blender according to the present invention are described in U.S. Pat. Nos. 4,634,286; 4,825,244; and 4,887,132. While not limited to any particular toner or developer, the present invention is particularly useful with two-component developer that implements a mixture of toner and carrier. Driving the blender 10 in a two-component developer induces tribocharging of the toner and carrier particles. The phenomena of tribocharging is well known in the electrostatographic arts. The blender segments may be configured in numerous ways, including knives, paddles, scoops, and/or ribbons, without limitation.
[0030] The blender segments 18 are preferably driven by the shaft 12 . As best shown in FIG. 5, the shaft 12 may have a key 13 that mates with the apertures 20 of the blender segments 18 . The key 13 ensures rotation of the blender segments 18 with the shaft 12 , although other geometries that render the shaft 12 and apertures 20 non-circular in cross section may be implemented.
[0031] The blender segments 18 may be formed from any suitable material, including plastics and metals. They may be made by molding, casting, machining from bulk material, or any other suitable manufacturing processes for rendering geometries useful in a developer blender.
[0032] According to a preferred embodiment, the plurality of blender segments 18 are disposed in seriatim with the resilient spacer 22 adjacent one of the pair of stops 14 and 16 , as presented in FIG. 1. In FIG. 1, the resilient spacer 22 is immediately adjacent the stop 14 .
[0033] Referring now to FIGS. 6 - 10 , an embodiment of a blender 100 for mixing electrostatographic developer is presented, according to a further aspect of the invention. Blender 100 comprises a shaft 112 having a pair of stops 114 and 116 spaced along a length L. A plurality of blender segments 118 of the type for mixing electrostatographic developer are provided, each blender segment 118 having an aperture 120 . The shaft 112 is received within the aperture 120 of each the blender segment 118 . Resilient spacers 122 and 124 are provided, the resilient spacers 122 and 124 and the plurality of blender segments 118 being compressed between the pair of stops 114 and 116 . In the embodiment presented in FIG. 6, the resilient spacer 122 is adjacent the stop 114 , and the resilient spacer 124 is adjacent the stop 116 . Wipers 115 , or other structure, may be provided immediately adjacent the stops 114 and 1 16 , as presented in FIG. 6.
[0034] According to a further aspect of the invention, the shaft 112 may comprise a plurality of serrations 126 , and one of the stops 114 comprises a snap ring 128 engaging one of the serrations 126 . The other stop 116 may also comprise a snap ring 132 engaging a mating groove 134 in the shaft 112 .
[0035] According to a preferred embodiment, the blender segments 118 form a ribbon blender, and the resilient spacer 122 comprises a plurality of stacked belleville washers 130 . One or more additional spacers, such as resilient spacer 124 , may also comprise a plurality of stacked belleville washers 130 . The blender segments 118 may form a ribbon blender having a double helix 136 and 138 . Various ribbon blenders that may be implemented in the practice of the present invention are described in U.S. Pat. Nos. 4,634,286; 4,956,675; and 5,146,277.
[0036] The blender segments 118 are of three general configurations; a first configuration 140 wherein helix 136 is outside helix 138 , a second configuration 142 wherein helix 138 is outside 136 , and a transition configuration 144 wherein the helixes 138 and 136 switch relative position. This geometry greatly enhances mixing of the developer, as described by U.S. Pat. No. 4,634,286.
[0037] Referring now specifically to FIGS. 7 and 8, each blender segment 18 comprises a ferrule 119 and an integral rib 121 . Referring again to FIG. 6, the individual ribs 121 are aligned and form a rib that runs along the length of the blender segments 118 .
[0038] Referring again to FIGS. 1 - 4 , a method of fabricating a blender for mixing electrostatographic developer is provided, according to a further aspect of the invention, comprising disposing a resilient spacer 22 and a plurality of blender segments 18 of the type for mixing electrostatographic developer on a shaft 12 , each blender segment 18 having an aperture 20 , the shaft 12 being received within the aperture of each the blender segment 18 , and compressing the resilient spacer 22 and the plurality of blender segments 18 between a pair of stops 114 and 116 on the shaft 112 . The method may further comprise disposing the plurality of blender segments 18 in seriatim with the resilient spacer 22 adjacent one of the pair of stops 114 and 116 .
[0039] Referring again to FIGS. 6 - 10 , one of the stops, stop 114 for example, may comprise a snap ring 128 , and the method may further comprise pressing the snap ring 128 toward another of the stops into engagement with one of the plurality of serrations 126 .
[0040] Referring now to FIG. 11, an enlarged exploded view of blender 100 with portions broken away is presented. Only the left-most blender segment 118 and right-most blender segment of FIG. 6 are presented in FIG. 11 for the sake of clarity. According to a certain embodiment, snap ring 126 is configured as shown in FIG. 12, and snap ring 132 is configured as shown in FIG. 13. Referring again to FIG. 11, blender 100 is fabricated by installing inserting the end of the shaft 112 into the apertures of the belleville washers 130 and the wiper 115 . The snap ring 132 is then installed into a mating groove on the shaft 112 . The blender segments 118 are installed onto the shaft from the opposite end. The belleville washers 130 on that end are then installed, followed by the wiper 115 . The snap ring 128 is then installed on the shaft resting against the wiper 115 . The entire assembly is then placed in a press that forces the snap ring 128 onto the serrations 126 . A press having a load indicator is preferred in order to avoid overloading the assembly. The snap ring 128 may engage any one of the serrations 126 , depending upon the prescribed load.
[0041] Referring now to FIG. 14, a side-cross sectional view of the blender 100 is presented with tooling that may be employed to press snap ring 128 onto the serrations 126 . The end of the shaft 112 proximate the snap ring 132 is placed in a cylindrical end-piece 146 . The other end of the shaft 112 proximate the snap ring 128 is placed in a cylindrical end-piece 148 , and is pressed toward the end-piece 146 . The assembly may be placed in a lathe, for example, and the tail stock may be used to apply the force. The cylindrical end-piece 146 preferably does not contact the snap ring 132 .
[0042] In a certain embodiment, a blender 100 has twenty-one (21) blender segments having a total nominal width of 14.7 inches. Allowable manufactured width, including tolerances, ranges from 14.616 inches to 14.784 inches (a range of 0.168 inches). Four belleville washers are stacked on each end, as shown in FIG. 11, that provide a total deflection of 0.051 inches at a force of 150 lbf. The length of the section having the serrations is 0.180 inches (three serrations at 0.060 inches per serration). The overall range of adjustment is the sum of 0.180 inches for the serrated section plus 0.051 inches for compression of the belleville washers. This provides more than sufficient adjustment for the 0.168 inches worst case variation due to tolerance stack-up.
[0043] Although the invention has been described and illustrated with reference to specific illustrative embodiments thereof, it is not intended that the invention be limited to those illustrative embodiments. Those skilled in the art will recognize that variations and modifications can be made without departing from the true scope and spirit of the invention as defined by the claims that follow. It is therefore intended to include within the invention all such variations and modifications as fall within the scope of the appended claims and equivalents thereof. | The invention relates generally to development apparatus for mixing and applying developer material to a latent image on an image-bearing member in an electrostatographic reproduction machine, such as a copier or printer. More particularly, this invention relates to a blender of the type for mixing electrostatographic developer comprising a plurality of blender segments mounted on a shaft. A resilient spacer is provided, according to an aspect of the invention, wherein said resilient spacer and said plurality of blender segments are compressed between said pair of stops. Residual looseness due to tolerance stack-up is eliminated. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to the production of a copolyester from a diol, a dicarboxylic compound, and a chain branching agent, all three being reacted during the esterification stage of the polymerization action. Heretofore, many efforts have been directed to the particular methods for the production of copolyester resins. These copolyester resins have been used frequently in fiber production, coatings, containers and other conventional applications. The molecular weight of the copolyester resin so produced, according to measurement of intrinsic viscosity, vary according to the particular application, and the method for making the differentiated copolyester resins is adjusted accordingly.
A suitable copolyester resin for coatings was disclosed by this inventor and another in U.S. Pat. No. 4,124,570. However, the copolyester so produced had an acid number from about 10 to about 30, indicating the existence of carboxyl terminated end groups. These acid groups not only react slowly with conventional curing agents used for hydroxyl end groups, but also produce a by-product of carbon dioxide which is deleterious to the clarity of the resin. Therefore, it was necessary to produce a copolyester resin which minimizes the existence of carboxyl terminated end groups. Further, to the extent necessary the excess reactant creating the carboxyl terminated end groups should be eliminated.
The creation of branched copolyester resins has typically employed multi-functional agents to interreact with the chain of an oligomer and become incorporated therein withh at least one functional reactive site remaining. When these multi-functional compounds react at the end of an oligomer or incipient copolyester, the functionality is wasted at the end of the chain maintaining carboxyl groups in a superfluous position with respect to the use of curing agents compatible with hydroxyl end groups. U.S. Pat. Nos. 4,065,438; 4,080,316; 4,058,496; 3,975,566; 3,224,922; and Re. 30,102 all disclose the addition of a multi-functional anhydride compound at percentage concentrations exceeding that found to be necessary for incorporating the multi-functional group in the chain of the backbone rather than the end location. Further, U.S. Pat. Nos. 2,936,296; 3,182,041; 3,281,498; and 3,296,335 all teach the use of an excessive concentration of polyhydric multi-functional compounds for that necessary to place all of the functional groups within the chain of the polyester. Also, U.S. Pat. No. 3,027,279 discloses a multi-functional compound for the purpose of creating a high number of carboxyl end groups.
As described above, the end use of the copolyester resin is determinative of the intrinsic viscosity of the copolyester so produced, and the amount of chain branching necessary in the production of the polyester. U.S. Pat. Nos. 2,895,946; 3,251,809; 3,576,773; and 3,692,744 all disclose polyesters and copolyesters suitable for extrusion, fiber, or film-forming processes where the amount of chain branching is minimized, and hence the concentration of a multi-functional compound is all but eliminated.
Because previous work has not suggested the minimization of the chain branching agent for a polyester or copolyester useful as an industrial coating resin or decorative finish, it is necessary to alter the concentrations and processes from that disclosed in U.S. Pat. No. 4,124,570 to minimize the carboxyl terminated end groups and the excessive concentrations of the multi-functional compound.
OBJECTS OF THE INVENTION
It is therefore an object of the invention to provide a method for the production of a copolyester resin where the reactants are added prior to the condensation stage of the polymerization process.
It is another object of the invention to provide a method for the production of a copolyester resin, wherein the chain branching agent is charged during the esterification stage near its completion.
It is another object of the invention to provide a method for the production of a copolyester resin, wherein the chain branching agent is charged at the beginning of the esterification stage.
It is yet another object of the invention to provide a method for the production of a copolyester resin, wherein the concentration of the chain branching agent is minimized to minimize the formation of deleterious end groups during cross-linkage.
It is yet another object of the invention to provide a copolyester produced by the method as above, wherein the acid number of the copolyester is less than 10.
Moreover, it is an object of the invention to provide a copolyester produced by the method as described above, wherein a chain branching agent produces funtionality within the chain of the polyester suitable for calculated intrinsic viscosities.
It is yet another object of the invention to provide a copolyester resin produced by a method as above, wherein the polyester has a glass transition temperature sufficient to prevent the agglomeration of the resin during storage.
These and other objects, which will become apparent as the detailed description of the preferred embodiment proceeds, are achieved by the method of production of a copolyester resin, comprising: (a) reacting a diol, a dicarboxylic compound, and a chain branching agent in an esterification stage to form a polyester prepolymer; said dicarboxylic compound selected from the group consisting of dicarboxylic acids and dicarboxylic esters, said dicarboxylic acids selected from the group consisting of alkyl dicarboxylic acids having a total of from 2 to 16 carbon atoms, and aryl dicarboxylic acids having a total of from 8 to 16 carbon atoms, said dicarboxylic esters selected from the group consisting of alkyl diesters having from 2 to 20 carbon atoms, and alkyl substituted aryl diesters having from 10 to 20 carbon atoms; said diol in a concentration from about 115 to 220 mole percent of the concentration of said dicarboxylic compound and selected from the group consisting of diols having from 2 to 10 carbon atoms; said chain branching agent in a concentration less than about 10 mole percent of the concentration of said dicarboxylic compound and selected from the group consisting of trimellitic anhydride, pentaerythritol, glycerol, trimethylol propane, triethylol propane, and combinations thereof; and (b) polymerizing said polyester prepolymer in a condensation stage to form a polycondensed copolyester having an intrinsic viscosity from about 0.13 to about 0.26 dl/g, a glass transition temperature of at least 50° C., a hydroxyl number from about 30 to about 70 and an acid number below about 10.
The objects of the invention are also achieved by a copolyester resin comprising: a copolyester produced from the precondensation reaction of a diol, a dicarboxylic compound, and a chain branching agent, said copolyester subsequently condensed; said dicarboxylic compound selected from the group consisting of dicarboxylic acids and dicarboxylic esters, said dicarboxylic acids selected from the group consisting of alkyl dicarboxylic acids having a total of from 2 to 16 carbon atoms, and aryl dicarboxylic acids having a total of from 8 to 16 carbon atoms, said dicarboxylic esters selected from the group consisting of alkyl diesters having from 2 to 20 carbon atoms and alkyl substituted aryl diesters having from 10 to 20 carbon atoms; said diol in a concentration from about 115 to 220 mole percent of the concentration of said dicarboxylic compound and selected from the group consisting of diols having from 2 to 10 carbon atoms; said chain branching agent in a concentration less than about 10 mole percent of the concentration of said dicarboxylic compound and selected from the group consisting of trimellitic anhydride, pentaerythritol, glycerol, trimethylol propane, triethylol propane, and combinations thereof; said condensed copolyester having an intrinsic viscosity from about 0.13 to about 0.26 dl/g, a glass transition temperature of at least 50° C., a hydroxyl number from 30 to about 70 and an acid number below about 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The production of the copolyester resin of the present invention employs three stages: an esterification stage, a condensation stage, and a finishing stage. The preparation of the polyester prepolymer occurs in the esterification stage by the reaction of a diol, a dicarboxylic compound, and a chain branching agent. The polyester prepolymer is polycondensed in a condensation stage to produce a copolyester resin having an intrinsic viscosity from about 0.13 to about 0.26 dl/g and preferably from about 0.19 to about 0.21 dl/g.
The dicarboxylic compound of the present invention may be either a dicarboxylic acid or a dicarboxylic ester. The dicarboxylic acids may be an alkyl dicarboxylic acid having a total of from 2 to 16 carbon atoms, or an aryl dicarboxylic acid having a total of from 8 to 16 carbon atoms. Specific examples of alkyl dicarboxylic acids suitable for the present invention are oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, and the like. Specific examples of an aryl acid include the various isomers of phthalic acid, such as paraphthalic (terephthalic) acid and naphthalic acid. Specific examples of alkyl substituted aryl acids include the various isomers of dimethylphthalic acid, such as dimethylisophthalic acid, dimethylorthophthalic acid, and dimethylterephthalic acid; the various isomers of diethylphthlic acid, such as diethylisophthalic acid, diethylorthophthalic acid, and diethylterephthalic acid; the various isomers of dimethylnaphthalic acid, such as 2,6-dimethylnaphthalic acid and 2,5-dimethylnaphthalic acid; and the various isomers of diethylnaphthalic acid. Generally dimethylterephthalic acid and terephthalic acid are the preferred dicarboxylic acids.
In lieu of the various dicarboxylic acids, the various diesters thereof may be utilized. Thus, the dicarboxylic compound may be an alkyl diester containing a total of from about 2 to 20 carbon atoms, as well as the alkyl substituted aryl diesters containing from about 10 to about 20 carbon atoms. Examples of specific alkyl diesters include dimethyl adipate, diethyl adipate, and the like. Specific examples of the various alkyl substituted aryl diesters include the various isomers of dimethylphthalate, the various isomers of diethylphthalate, the various isomers of dimethylnaphthalate, and the various isomers of diethylnaphthalate. Of the dicarboxylic diesters, preferably, the various isomers of dimethylphthalate (dimethylterephthalate) are used. Of the dicarboxylic compounds, the various isomers of dimethylterephthalate are most preferred.
These carboxylic acids or the diesters thereof react in the esterification stage with a diol containing from about 2 to 10 carbon atoms. The glycols may be straight-chained or branched. Specific examples include ethylene glycol, propylene glycol, trimethylene glycol, 1,2-butane diol, 1,3-butane diol, 1,4-butane diol, b 2,3-butane diol, neopentyl glycol, hexamethylene glycol, cyclohexane dimethanol, and the ester diol product of neopentyl glycol and hydropavalic acid (propanoic acid, 3-hydroxy-2,2 dimethyl-3 hydroxy-2,2 dimethyl propyl ester). Of the various diols, neopentyl glycol is most preferred. The diol is added to the esterification stage in the reactant charging step in a concentration in comparison to the dicarboxylic compound in a mole ratio from about 2.20 to about 1.15:1. Preferably, the mole ratio is from about 1.7 to about 1.5:1.
The chain branching agent of the present invention is a compound having at least a functionality of three to incorporate within the chain of the polyester prepolymer and retain a branch reactive site. Chain branching agents having at least a trifunctionality include trimellitic anhydride, pentaerythritol, glycerol, trimethylol propane, triethylol propane, and other multi-functional alcohols. The chain branching agent is reacted in the esterification stage in a concentration in comparison with the concentration of the dicarboxylic compound in a mole ratio less than about 0.10:1. Desirably the chain branching agent has a concentration from about 2 to 8 mole percent, comparative to the concentration of the dicarboxylic compound, and preferably in a concentration from about 4 to 5 mole percent.
The esterification stage comprises a reactant charging step and a chain branching agent addition step. The chain branching agent addition step occurs simultaneously with the reactant charging step when the chain branching agent is a multifunctional alchohol such as trimethylol propane, triethylol propane, pentaerythritol, and glycerol. The reactant charging step precedes the chain branching agent addition step when trimellitic anhydride is the chain branching agent. In such later case, the chain branching addition step proceeds after at least 90 percent of the dicarboxylic compound and diol have completed methanolysis. Whereas the esterification stage proceeds uninterrupted or undelayed when the chain branching agent is one of the multi-functional alcohols, an additional 20 minutes is required in the esterification stage before the condensation stage when the trimellitic anhydride is the chain branching agent.
The alteration to the esterification stage by the initial charge of the chain branching agent or near the completion of esterification eliminates the steps disclosed in the condensation stage in U.S. Pat. No. 4,124,570. The condensation stage may proceed according to the present invention unencumbered by the return of the reaction vessel in the condensation stage to an atmospheric pressure for the addition of trimellitic anhydride. It has been found that the precision with which the accurate trimellitic anhydride addition point way occur encumbers the overall economy of the polymerization reaction, which the reduction of the concentration of the chain branching agent and its prior addition avoids, according to the concepts of the present invention. The alterations to the esterification stage unexpectedly generate a more precise reaction process, yielding a copolyester resin having greater clarity and reduced acid numbers. For an understanding of the alterations to the process and its effect upon the copolyester resin so produced, reference is had to the following example.
EXAMPLE I
ESTERIFICATION STAGE
The reactants were charged in a ratio of 1.8/1.0/0.04 neopentyl glycol/dimethylterephthalate/trimethylol propane into a reactor. The reactants were heated in the reactor and agitation was begun when the batch became molten. When the internal temperature reached 190° C., a catalyst, comprising dibutyl tin oxide, was charged into the reactors.
The column head temperature was controlled at 54° C. to 70° C. with the lower half of the column and liquid return line being heated to prevent freezing of the glycol rich reflux. When the column head temperature began to rise, indicating a methanolysis reaction, the vessel jacket temperature was raised to 215° C. to 220° C. This temperature was maintained at atmospheric pressure until at least 90 percent of the methanolysis reaction was completed. The internal temperature of the reactor was controlled so that the neopentyl glycol did not boil at 215° C. After a reaction time of about 150 minutes, the batch was transferred to the condensation reactor through a fine pore size filter.
Condensation Stage
The second stage vessel jacket oil temperature was set at 220° C. to 225° C. until the batch from the esterification stage was transferred to this vessel. The oil temperature was then set at about 240° C. to 260° C. and adjusted to provide an internal temperature of about 200° to about 250° C. After the transfer of the batch to the condensation reaction vessel was complete, a vacuum cycle was initiated at about 15 millimeters/minutes from atmospheric pressure to about 100 millimeters Hg. The rate was then changed to 8 millimeters/minute until a base pressure of about 40 millimeters Hg was reached. With an internal temperature of about 200° C., polycondensation proceeded until the desired reaction end point was reached. The pressure was then raised rapidly to about 1/2 atmosphere in the batch transfer to the cooling vessel which was held at atmospheric pressure. A fine pore size filtration was employed during the transfer.
Finishing Stage
The cooling vessel jacket temperature was set at about 125° C. when the batch was transferred in. The batch was cooled with mild agitation to about 150° C. at a vessel pressure range of 500 to 760 millimeters Hg. The vessel jacket was regulated to control the product temperature at 150° C. for discharge. The product was discharged, cooled, and flaked.
The differentiation between the reactant step and the chain branching step in the esterification stage is illustrated by Example II.
EXAMPLE II
The reaction parameters and processes of Example I were repeated, except that the chain branching agent was not initially charged prior to the methanolysis reaction of the dimethylterephthalate and the neopentyl glycol. When at least 90 percent of the methanolysis reaction was complete, the trimellitic anhydride, in a concentration of 4 mole percent relative to the initial charge of dimethylterephthalate, was added to the esterification reactor. The internal reaction temperature was maintained at about 190° C. for an additional 20 minutes prior to the completion of the esterification stage. All other aspects of Example I remained the same. The experimentation conducted according to production of copolyesters illustrated by Examples I and II may be examined by reference to Table I and Table II.
As may be seen with reference to Table I, the acid number is minimized when the mole percentage of trimellitic anhydride is less than 10 in comparison with the dicarboxylic compound. This indicates that the probability of carboxyl terminated end groups for the copolyester resin is minimized or eliminated. Further, in the desired range of intrinsic viscosity from about 0.13 to about 0.26, as little as 3 mole percent of the trimellitic anhydride may produce the desired result.
With reference to Table II, similar results employing a minimal percentage of trimethylol propane is seen. In the desired intrinsic viscosity from about 0.13 to about 0.26, carboxyl terminated end groups are minimized or eliminated with a mole percentage as low as 4 percent relative to the dicarboxylic compound.
TABLE I______________________________________PROPERTIES OF NEOPENTYLTEREPHTHALATE/TRIMELLITIC ANHYDRIDEMole % IV Acid Hydroxyl TgTMA dl/g No. No. (°C.)______________________________________3 0.097 0 87.5 463 0.018 0 66.0 543 0.133 0 52.1 57.53 0.203 0 38.1 623 0.246 0 31.0 653 0.294 0 26.1 653 0.353 0 31.1 676 0.125 0.9 58.4 576 0.160 0.1 52.6 606 0.182 0.06 45.1 626 0.233 0.06 37.9 646 0.281 0.06 36.2 6510 0.129 2 69.8 55.510 0.146 1.3 60.6 5810 0.153 0.95 57.3 6010 0.188 0.73 55.2 6110 0.246 0.22 48.2 63.510 0.418 0.22 41.8 6515 0.125 10.8 73.8 56.515 0.153 8.3 66.6 5915 0.178 6.8 60.4 60.515 0.185 6.1 59.1 6115 0.225 5.2 52.5 6215 0.272 4.6 51.1 63______________________________________
TABLE II______________________________________PROPERTIES OF NEOPENTYL TEREPHTHALATE/TRIMETHYLOL PROPANE COPOLYMERSMole % IV Acid Hydroxyl TgTMA dl/g No. No. (°C.)______________________________________4 0.114 0 68.9 554 0.122 0 63.6 554 0.130 0 59.5 584 0.147 0.17 47.5 604 0.176 0 42.0 644 0.188 0 37.7 644 0.199 0 37.5 644 0.245 0 32.7 664 0.160 0 48.3 614 0.168 0 45.7 61.54 0.181 0 43.1 634 0.215 0 38.4 664 0.262 0 38.2 674 0.351 0 -- 67.58 0.113 0.4 77.3 528 0.130 0.2 63.2 568 0.140 0.1 60.0 588 0.154 0 59.3 608 0.169 0.2 52.4 628 0.179 0 51.8 638 0.187 0 49.7 6310 0.123 0 77.1 5410 0.141 0.1 55.2 5810 0.164 0 56.8 6010 0.179 0 51.1 6210 0.195 0 49.4 6210 0.212 0 44.5 63______________________________________
Thus, a copolyester resin suitable for industrial coating or decorative finishes is produced with the minimum percentage of the chain branching agent incorporated into the polyester backbone. Any excess chain branching agent which is free to disrupt the clarity and the rapidity of the reaction is minimized or eliminated by reduced initial concentration of that agent.
In the esterification stage, various catalysts may be used. Examples of these catalysts include dibutyl tin oxide, sodium acetate, stannous octoate, butyl hydroxy tin chloride, zinc acetate, and titanium glycollate.
Curing agents suitable for the hydroxyl terminated end groups may be used. Representative examples include a caprolactam-blocked isophorone diisocyanate such as Cargill CR2400 and a melamine such as American Cyanamid Cymel 300.
To prevent agglomeration of the powder during storage the resins of the invention should have a Tg range at least from 50 to about 80. As seen in Table I and Table II, the minimized mole percentages of the chain branching agent within the desired intrinsic viscosity range produces copolymers having a glass transition temperature within the range of 50 to 80. Also seen in Table I and Table II are the hydroxyl numbers for the resin of the present invention, ranging from about 30 to about 70 and preferably 40 to about 45.
Powder coating resins may be produced from the copolyester resin of the present invention by compounding with pigments, flow agents, and curing agents and curing agents for application to appliances, outdoor furniture, and the like.
While in accordance with patent statutes a best mode and preferred embodiment of the invention have been disclosed, the invention is not to be limited thereto or thereby. Consequently for an understanding of the scope of the invention, reference is had to the following claims. | A copolyester resin having minimal carboxyl terminated ends, is disclosed, as well as the method for making it. The esterification-condensation reaction is employed reacting a diol, a dicarboxylic compound, and a chain branching agent. The chain branching agent is limited in concentration to less than 10 mole percent of the dicarboxylic compound and is charged prior to the condensation stage of the reaction. The copolyester resin so produced achieves minimal carboxyl terminated ends, which when used in coatings, yields a clear resin free of carbon dioxide impurities. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of copending U.S. utility application entitled, “Higher Picture Rate HD Encoding and Transmission with Legacy HD Backward Compatibility,” having Ser. No. 11/132,060, filed May 18, 2005, which is entirely incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to digital television and, more specifically to receivers with different capabilities for receiving, processing and displaying the same emission of a compressed video signal, each receiver providing one in a plurality of picture formats according to its respective capability.
BACKGROUND OF THE INVENTION
[0003] There are many different digital television compressed video picture formats, some of which are HD. HDTV currently has the highest digital television spatial resolution available. The picture formats currently used in HDTV are 1280×720 pixels progressive, 1920×1080 pixels interlaced, and 1920×1080 pixels progressive. These picture formats are more commonly referred to as 720P, 1080i and 1080P, respectively. The 1080i format, which comprises of interlaced pictures, each picture or frame being two fields, shows 30 frames per second and it is deemed as the MPEG-2 video format requiring the most severe consumption of processing resources. The 1080P format shows 60 frames per second, each frame being a progressive picture, and results in a doubling of the most severe consumption of processing resources. A receiver capable of processing a maximum of 1080i-60 is also capable of processing a maximum 1080P-30. However, broadcasters intend to introduce 1080P-60 emissions and CE manufacturers intend to provide HDTVs and HDTV monitors capable of rendering 1080P-60, in the near future. 1080P-60 includes twice as much picture data as either 1080i-60 or 1080P-30. Dual carrying channels or programs as 1080P-60 and 1080i-60 would not be an acceptable solution because it triples the channel consumption of a single 1080i-60 transmission.
[0004] Therefore, there is a need for encoding 1080P-60 video for transmission in a way that facilitates the superior picture quality benefits of a 1080P-60 signal to 1080P-60 capable receivers while simultaneously enabling legacy 1080i-60 capable receivers to fulfill the equivalent of a 1080P-30 signal from the transmitted 1080P-60 signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a high-level block diagram depicting a non-limiting example of a subscriber television system.
[0006] FIG. 2 is a block diagram of a DHCT in accordance with one embodiment of the present invention.
[0007] FIG. 3 illustrates program specific information (PSI) of a program having elementary streams including encoded video streams which may be combined to form a single video stream encoded as 1080P-60.
[0008] FIG. 4A illustrates first and second video streams in display order.
[0009] FIG. 4B illustrates pictures according to picture types in display order.
[0010] FIG. 4C illustrates transmission order of the pictures in display order of FIG. 2B .
DETAILED DESCRIPTION
[0011] The present invention will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which an exemplary embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, the embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The present invention is described more fully hereinbelow.
[0012] It is noted that “picture” is used throughout this specification as one from a sequence of pictures that constitutes video, or digital video, in one of any of a plurality of forms. Furthermore, in this specification a “frame” means a picture, either as a full progressive picture or in reference to a whole instance of a full frame comprising both fields of an interlaced picture.
[0013] Video Decoder in Receiver
[0014] FIG. 1 is a block diagram depicting a non-limiting example of a subscriber television system (STS) 100 . In this example, the STS 100 includes a headend 110 and a DHCT 200 that are coupled via a network 130 . The DHCT 200 is typically situated at a user's residence or place of business and may be a stand-alone unit or integrated into another device such as, for example, the display device 140 or a personal computer (not shown). The DHCT 200 receives signals (video, audio and/or other data) including, for example, MPEG-2 streams, among others, from the headend 110 through the network 130 and provides any reverse information to the headend 110 through the network 130 . The network 130 may be any suitable means for communicating television services data including, for example, a cable television network or a satellite television network, among others. The headend 110 may include one or more server devices (not shown) for providing video, audio, and textual data to client devices such as DHCT 200 . Television services are provided via the display device 140 which is typically a television set. However, the display device 140 may also be any other device capable of displaying video images including, for example, a computer monitor.
[0015] FIG. 2 is a block diagram illustrating selected components of a DHCT 200 in accordance with one embodiment of the present invention. It will be understood that the DHCT 200 shown in FIG. 2 is merely illustrative and should not be construed as implying any limitations upon the scope of the preferred embodiments of the invention. For example, in another embodiment, the DHCT 200 may have fewer, additional, and/or different components than illustrated in FIG. 2 . A DHCT 200 is typically situated at a user's residence or place of business and may be a stand alone unit or integrated into another device such as, for example, a television set or a personal computer. The DHCT 200 preferably includes a communications interface 242 for receiving signals (video, audio and/or other data) from the headend 110 through the network 130 ( FIG. 1 ) and for providing any reverse information to the headend 110 .
[0016] DHCT 200 is referred to as a receiver such as receiver 200 throughout this specification. The DHCT 200 further preferably includes at least one processor 244 for controlling operations of the DHCT 200 , an output system 248 for driving the television display 140 , and a tuner system 245 for tuning to a particular television channel or frequency and for sending and receiving various types of data to/from the headend 110 . The DHCT 200 may, in another embodiment, include multiple tuners for receiving downloaded (or transmitted) data. Tuner system 245 can select from a plurality of transmission signals provided by the subscriber television system 100 , including a 1080P-60 program. Tuner system 245 enables the DHCT 200 to tune to downstream media and data transmissions, thereby allowing a user to receive digital media content such as a 1080P-60 program via the subscriber television system. The tuner system 245 includes, in one implementation, an out-of-band tuner for bi-directional quadrature phase shift keying (QPSK) data communication and a quadrature amplitude modulation (QAM) tuner (in band) for receiving television signals. Additionally, a user command interface 246 receives externally-generated user inputs or commands from an input device such as, for example, a remote control. User inputs could be alternatively received via communication port 274 .
[0017] The DHCT 200 may include one or more wireless or wired interfaces, also called communication ports 274 , for receiving and/or transmitting data to other devices. For instance, the DHCT 200 may feature USB (Universal Serial Bus), Ethernet, IEEE-1394, serial, and/or parallel ports, etc. DHCT 200 may also include an analog video input port for receiving analog video signals. User input may be provided via an input device such as, for example, a hand-held remote control device or a keyboard.
[0018] The DHCT 200 includes signal processing system 214 , which comprises a demodulating system 213 and a transport demultiplexing and parsing system 215 (herein demultiplexing system) for processing broadcast media content and/or data. One or more of the components of the signal processing system 214 can be implemented with software, a combination of software and hardware, or preferably in hardware. Demodulating system 213 comprises functionality for demodulating analog or digital transmission signals. For instance, demodulating system 213 can demodulate a digital transmission signal in a carrier frequency that was modulated, among others, as a QAM-modulated signal. When tuned to a carrier frequency corresponding to an analog TV signal, demultiplexing system 215 is bypassed and the demodulated analog TV signal that is output by demodulating system 213 is instead routed to analog video decoder 216 . Analog video decoder 216 converts the analog TV signal into a sequence of digitized pictures and their respective digitized audio. The analog TV decoder 216 and other analog video signal components may not exist in receivers or DHCTs that do not process analog video or TV channels.
[0019] A compression engine in the headend processes a sequence of 1080P-60 pictures and associated digitized audio and converts them into compressed video and audio streams, respectively. The compressed video and audio streams are produced in accordance with the syntax and semantics of a designated audio and video coding method, such as, for example, MPEG-2, so that they can be interpreted by video decoder 223 and audio decoder 225 for decompression and reconstruction after transmission of the two video streams corresponding to the 1080P-60 compressed signal. Each compressed stream consists of a sequence of data packets containing a header and a payload. Each header contains a unique packet identification code, or packet_identifier (PID) as is the casein MPEG-2 Transport specification, associated with the respective compressed stream. The compression engine or a multiplexer at the headend multiplexes the first and second video streams into a transport stream, such as an MPEG-2 transport stream.
[0020] Video decoder 223 may be capable of decoding a first compressed video stream encoded according to a first video specification and a second compressed video stream encoded according to a second video specification that is different than the first video specification. Video decoder 223 may comprise of two different video decoders, each respectively designated to decode a compressed video stream according to the respective video specification.
[0021] Parsing capabilities 215 within signal processing 214 allow for interpretation of sequence and picture headers. The packetized compressed streams can be output by signal processing 214 and presented as input to media engine 222 for decompression by video decoder 223 and audio decoder 225 for subsequent output to the display device 140 ( FIG. 1 ).
[0022] Demultiplexing system 215 can include MPEG-2 transport demultiplexing. When tuned to carrier frequencies carrying a digital transmission signal, demultiplexing system 215 enables the separation of packets of data, corresponding to the desired video streams, for further processing. Concurrently, demultiplexing system 215 precludes further processing of packets in the multiplexed transport stream that are irrelevant or not desired such as, for example in a 1080i-60 capable receiver, packets of data corresponding to the second video stream of the 1080P-60 program.
[0023] The components of signal processing system 214 are preferably capable of QAM demodulation, forward error correction, demultiplexing MPEG-2 transport streams, and parsing packetized elementary streams and elementary streams. The signal processing system 214 further communicates with processor 244 via interrupt and messaging capabilities of DHCT 200 .
[0024] The components of signal processing system 214 are further capable of performing PID filtering to reject packetized data associated with programs or services that are not requested by a user or unauthorized to DHCT 200 , such rejection being performed according to the PID value of the packetized streams. PID filtering is performed according to values for the filters under the control of processor 244 . PID filtering allows for one or more desired and authorized programs and/or services to penetrate into DHCT 200 for processing and presentation. PID filtering is further effected to allow one or more desired packetized streams corresponding to a program (e.g., a 1080P — 60 program) to penetrate DHCT 200 for processing, while simultaneously rejecting one or more different packetized stream also corresponding to the same program. Processor 244 determines values for one or more PIDS to allow to penetrate, or to reject, from received information such as tables carrying PID values as described later in this specification. In an alternate embodiment, undesirable video streams of a program are allowed to penetrate into DHCT 200 but disregarded by video decoder 223 .
[0025] A compressed video stream corresponding to a tuned carrier frequency carrying a digital transmission signal can be output as a transport stream by signal processing 214 and presented as input for storage in storage device 273 via interface 275 . The packetized compressed streams can be also output by signal processing system 214 and presented as input to media engine 222 for decompression by the video decoder 223 and audio decoder 225 .
[0026] One having ordinary skill in the art will appreciate that signal processing system 214 may include other components not shown, including memory, decryptors, samplers, digitizers (e.g. analog-to-digital converters), and multiplexers, among others. Further, other embodiments will be understood, by those having ordinary skill in the art, to be within the scope of the preferred embodiments of the present invention. For example, analog signals (e.g., NTSC) may bypass one or more elements of the signal processing system 214 and may be forwarded directly to the output system 248 . Outputs presented at corresponding next-stage inputs for the aforementioned signal processing flow may be connected via accessible memory 252 in which an outputting device stores the output data and from which an inputting device retrieves it. Outputting and inputting devices may include analog video decoder 216 , media engine 222 , signal processing system 214 , and components or sub-components thereof. It will be understood by those having ordinary skill in the art that components of signal processing system 214 can be spatially located in different areas of the DHCT 200 .
[0027] In one embodiment of the invention, a first and second tuners and respective first and second demodulating systems 213 , demultiplexing systems 215 , and signal processing systems 214 may simultaneously receive and process the first and second video streams of a 1080P-60 program, respectively. Alternatively, a single demodulating system 213 , a single demultiplexing system 215 , and a single signal processing system 214 , each with sufficient processing capabilities may be used to process the first and second video streams in a 1080P-60 capable receiver.
[0028] The DHCT 200 may include at least one storage device 273 for storing video streams received by the DHCT 200 . A PVR application 277 , in cooperation with the operating system 253 and the device driver 211 , effects, among other functions, read and/or write operations to the storage device 273 . The device driver 211 is a software module preferably resident in the operating system 253 . The device driver 211 , under management of the operating system 253 , communicates with the storage device controller 279 to provide the operating instructions for the storage device 273 . Storage device 273 could be internal to DHCT 200 , coupled to a common bus 205 through a communication interface 275 .
[0029] Received first and second video streams are deposited transferred to DRAM 252 , and then processed for playback according to mechanisms that would be understood by those having ordinary skill in the art. In some embodiments, the video streams are retrieved and routed from the hard disk 201 to the digital video decoder 223 and digital audio decoder 225 simultaneously, and then further processed for subsequent presentation via the display device 140 .
[0030] Compressed pictures in the second video stream may be compressed independent of reconstructed pictures in the first video stream. On the other hand, an aspect of the invention is that pictures in the second video stream, although compressed according to a second video specification that is different to the first video specification, can depend on decompressed and reconstructed pictures in the first video stream for their own decompression and reconstruction.
[0031] Examples of dependent pictures are predicted pictures that reference at most one picture (from a set of at least one reconstructed picture) for each of its sub-blocks or macroblocks to effect its own reconstruction. That is, predicted pictures in the second video stream, can possibly depend one or more referenced pictures in the first video stream.
[0032] Bi-predicted pictures (B-pictures) can reference at most two pictures from a set of reconstructed pictures for reconstruction of each of its sub-blocks or macroblocks to effect their own reconstruction.
[0033] In one embodiment, pictures in the second video stream reference decompressed and reconstructed pictures (i.e., reference pictures) from the first video stream. In another embodiment, pictures in the second video stream employ reference pictures from both the first and second video streams. In yet another embodiment, a first type of picture in the second video stream references decompressed pictures from the second video stream and a second type of picture references decompressed pictures from the first video stream.
[0000] Enabling Receivers with Different Capabilities
[0034] The present invention includes several methods based on two separate video streams assigned to a program rather than a single stream with inherent built-in temporal scalability. Existing receivers capable of processing 1080i-60 video streams today would be deemed “legacy HD receivers” at the time that broadcasters start emissions of 1080P-60 programs. If a 1080P-60 program was transmitted without the advantage of this invention the “then” legacy HD receivers would not know how to process a 1080P-60 video stream, nor be capable of parsing the video stream to extract a 1080P-30 signal from the received 1080P-60. The legacy HD receivers were not designed to identify and discard pictures from a single 1080P-60 video stream. Furthermore, 1080P-60 in the standard bodies is specified for a 1080P-60 receiver without backward compatibility to 1080i-60 receivers.
[0035] This invention enables 1080i-60 receivers to process the portion of the 1080P-60 program corresponding to a first video stream and reject a complementary second video stream based on PID filtering. Thus, by processing the first video stream, a 1080i-60 receiver provides a portion of the 1080P-60 program that is equivalent to 1080P-30. The invention is equally applicable, for example, to 1080P-50, assigning two separate video streams to a program. Future 1080P50-capable receivers process the 1080P-50 video from the two separate video streams according to the invention, while legacy 1080i-50-capable receivers process a 1080P-25 portion of the 1080P-50 video program.
[0036] Hereinafter, 1080P-60 is used for simplicity to refer to a picture sequence with twice the picture rate of a progressive 1080P-30 picture sequence, or to a picture sequence with twice the amount of picture elements as an interlaced picture sequence displayed as fields rather than full frames. However, it should be understood that the invention is applicable to any pair of video formats with the same picture spatial resolution, in which a first video format has twice the “picture rate” of the second. The invention is also applicable to any pair of video formats with the same picture spatial resolution, in which a first video format has “progressive picture rate” and the second has an “interlaced” or field picture rate, the first video format resulting in twice the number of processed or displayed pixels per second. The invention is further applicable to any two video formats in which the first video format's picture rate is an integer number times that of the second video format or in which the number of pixels of a first video format divided by the number of pixels of a second video format is an integer number.
[0037] Stream Types and Unique PIDs
[0038] The MPEG-2 Transport specification referred to in this invention is described in the two documents: ISO/IEC 13818-1:2000 (E), International Standard, Information technology—Generic coding of moving pictures and associated audio information: Systems, and ISO/IEC 13818-1/Amd. 3: 2003 Amendment 3 : Transport of AVC video data over ITU-T Rec. H.222.0 |ISO/IEC 13818-1 streams.
[0039] In accordance with MPEG-2 Transport syntax, a multiplexed transport carries Program Specific Information (PSI) that includes the Program Association Table (PAT) and the Program Map Table (PMT). Information required to identify and extract a PMT from the multiplexed transport stream is transmitted in the PAT. The PAT carries the program number and packet_identifier (PID) corresponding to each of a plurality of programs, at least one such program's video being transmitted as encoded 1080P-60 video according to the invention.
[0040] As shown in the FIG. 3 , the PMT corresponding to a 1080P-60 program carries two video streams, each uniquely identified by a corresponding PID. The first video stream in the PMT has a unique corresponding PID 341 and the second video stream has its unique corresponding PID 342 , for example. Likewise, the first and second video streams of the 1080P-60 program have corresponding stream type values. A stream type is typically a byte. The stream type value for the first and second video streams are video_type 1 and video_type 2 , respectively.
[0041] In one embodiment, the stream type value, video_type 1 equals video_type 2 , therefore, both video streams are encoded according to the syntax and semantics of the same video specification (e.g., both as MPEG-2 video or as MPEG-4 AVC). A receiver is then able to identify and differentiate between the first video stream and the second video stream by their PID values and the relationship of the two PID values. For example, the lower PID value of video_type 1 would be associated with the first video stream. However, legacy HD receivers would not be able to incorporate such a processing step as a feature. However, there may be two types of legacy receivers. During a first era, legacy receivers may be HD receivers that are capable of processing a first video stream encoded according to the MPEG-2 video specification described in ISO/IEC 13818-2:2000 (E), International Standard, Information technology—Generic coding of moving pictures and associated audio information: Video. The second video stream would likely be encoded with a video specification that provides superior compression performance, for example, MPEG-4 AVC as described by the three documents: ISO/IEC 14496-10 (ITU-T H.264), International Standard (2003), Advanced video coding for generic audiovisual services; ISO/IEC 14496-10/Cor. 1: 2004 Technical Corrigendum 1; and ISO/IEC 14496-10/Amd. 1,2004, Advanced Video Coding AMENDMENT 1: AVC fidelity range extensions. A second era, on the other hand, may comprise legacy HD receivers that are capable of processing 1080i-60 video encoded according to the MPEG-4 AVC specification. Because the latter legacy receivers have yet to be deployed, these receivers could be designed to support identification of the first video stream in a multiple video stream program from the lowest PID value corresponding to video_type 1 in the PMT. Alternatively, the first video entry in the PMT table, regardless of its PID value, would be considered the first video stream.
[0042] In another alternate embodiment, the streams are encoded according to different video specifications and the values of video_type 1 and video_type 2 in the PMT differ. For example, the first video stream would be encoded and identified as MPEG-2 video in the PMT by a video_type 1 value that corresponds to MPEG-2 video. The second video stream would be encoded with MPEG-4 AVC and identified by a video_type 2 value corresponding to MPEG-4 AVC.
[0043] In yet another alternate embodiment, video_type 2 corresponds to a stream type specifically designated to specify the complementary video stream (i.e, the second video stream of a 1080P-60 program). Both video streams could be encoded according to the syntax and semantics of the same video specification (e.g, with MPEG-4 AVC) or with different video specifications. Thus, while the values of video_type 1 and video_type 2 are different in the PMT table for a 1080P-60 program, both video streams composing the 1080P-60 program could adhere to the same video specification. Thus, video_type 1 's value identifies the video specification used to encode the first video stream, but video_type 2 's value identifies both:
(1) the video stream that corresponds to the second video stream of the 1080P-60 program, and (2) the video specification (or video coding format) used to encode the second video stream.
[0046] A first video_type 2 value then corresponds to a stream type associated with the second stream of a 1080P-60 program that is encoded according to the MPEG-2 video specification. A second video_type 2 value corresponds to a stream type associated with the second stream of a 1080P-60 program that is encoded according to the MPEG-4 AVC specification. Likewise, other video_type 2 values can correspond to respective stream types, each associated with the second stream of a 1080P-60 program and encoded according to a respective video coding specification.
[0047] In yet another novel aspect of the invention, when video_type 2 does not equal video_type 1 and their values signify different video specifications, pictures in the second stream can still use reconstructed pictures from the first video stream as reference pictures.
Transmission Order of Pictures
[0048] Encoded pictures in the first and second video streams are multiplexed in the transport multiplex according to a defined sequence that allows a single video decoder in a 1080P-60 receiver to receive and decode the pictures sequentially as if the pictures were transmitted in a single video stream. However, because they are two separate video streams, a 1080i-60 receiver can reject transport packets belonging to the second video stream and allow video packets corresponding to the first video stream to penetrate into its memory to process a portion equal to 1080P-30 video. Encoded pictures in the first video stream are transmitted in transmission order, adhering to the timing requirement and bit-buffer management policies required for a decoder to process the first video stream as a 1080P-30 encoded video signal.
[0049] In one embodiment of the invention, FIG. 4A depicts the first and second video streams in display order. P represents a picture and not a type of picture. Pi is the ith picture in display order. In a 1080P-60 receiver, the blank squares represent gaps of when the picture being displayed is from the complementary video stream. The width of a blank square is one “picture display” time. Non-blank squares represent the time interval in which the corresponding picture is being displayed.
[0050] Still referring to FIG. 4A , in a 1080i-60 receiver, a 1080P-30 picture corresponding to the first video stream is displayed and the width of two squares represents the picture display time. Video stream 1 is specified as 30 Hertz in alternating 60 Hertz intervals that correspond to even integers. Video stream 2 is specified as 30 Hertz in alternating 60 Hertz intervals that correspond to odd integers.
[0051] FIG. 4B depicts pictures according to picture types in display order. Ni signifies the ith Picture in display order, where N is the type of picture designated by the letter I, P or B. In one embodiment, all the pictures in video stream 2 are B pictures and the 1080P-60 receiver uses decoded pictures from video stream 1 as reference pictures to reconstruct the B pictures.
[0052] FIG. 4C corresponds to the transmission order of the pictures in display order in FIG. 4B . Each picture is transmitted (and thus received by the receiver) at least one 60 Hz interval prior to its designated display time. I pictures are displayed six 60 Hz interval after being received and decoded. I pictures are thus transmitted at least seven 60 Hz intervals prior to its corresponding display time. The arrows from FIG. 4C to FIG. 4B reflect the relationship of the pictures' transmission order to their display order.
[0053] Blank squares in FIG. 4C represent gaps when no picture data is transmitted for the respective video stream. The width of a blank square can be approximately one “picture display” time. Non-blank squares represent the time interval in which the corresponding picture is transmitted. One or more smaller transmission gaps of no data transmission may exist within the time interval in which a picture is transmitted. In essence, video stream 1 and video stream 2 are multiplexed at the emission point in a way to effect the transmission order reflected in FIG. 4C and transmission time relationship depicted in FIG. 4C .
Bit-Buffer Management
[0054] A sequence of video pictures is presented at an encoder for compression and production of a compressed 1080P-60 program. Every other picture is referred as an N picture and every subsequent picture as an N+1 picture. The sequence of all the N pictures is the first video stream of the 1080P-60 program and the sequence all the N+1 pictures is the second video stream.
[0055] A video encoder produces the first video stream according to a first video specification (e.g., MPEG-2 video) and the second video stream according to a second video specification (e.g., MPEG-4 AVC). In one embodiment the second video specification is different than the first video specification. In an alternate embodiment, the first and second video specifications are the same (e.g., MPEG-4 AVC).
[0056] The video encoder produces compressed pictures for the first video stream by depositing the compressed pictures into a first bit-buffer in memory, such memory being coupled to the encoder. Depositing of compressed pictures into the first bit-buffer is according to the buffer management policy (or policies) of the first video specification. The first bit-buffer is read for transmission by the video encoder in one embodiment. In an alternate embodiment, a multiplexer or transmitter reads the compressed pictures out of the first bit-buffer. The read potions of the first bit buffer are packetized and transmitted according to a transport stream specifications such as MPEG-2 transport.
[0057] Furthermore, the video encoder, the multiplexer, or the transmitter, or the entity performing the first bit-buffer reading and packetization of the compressed pictures, prepends a first PID to packets belonging to the first video stream. The packetized first video stream is then transmitted via a first transmission channel.
[0058] Similarly, the second video stream is produced by the video encoder and deposited into the first bit buffer. The second video stream is read from the first bit-buffer by the entity performing the packetization, and the entity prepends a second PID to packets belonging to the second video stream, and the transport packets are transmitted via a first transmission channel.
[0059] In an alternate embodiment, the second video stream is produced by the video encoder and deposited into a second bit buffer. The entity performing the packetization reads the second video stream from the second bit buffer and prepends the second PID to packets belonging to the second video stream. The packetized second video stream is then transmitted via a first transmission channel.
[0060] Both first and second video streams are packetized according to a transport stream specification, such as MPEG-2 Transport. Packets belonging to the second video stream are thus identifiable by a 1080P-60 capable receiver and become capable of being rejected by a receiver that is not capable of processing 1080P-60 programs.
[0061] The bit buffer management policies of depositing compressed picture data into the first and/or second bit-buffers and reading (or drawing) compressed-picture data from the first and/or second bit-buffers, are according to the first video specification. These operations may be further in accordance with bit-buffer management policies of the transport stream specification. Furthermore, the bit-buffer management policies implemented on the one or two bit-buffers may be according to the second video specification rather than the first video specification. In one embodiment, the first video stream's compressed data in the bit-buffer is managed according to both: the bit buffer management policies of the first video specification and the transport stream specification, while the second video stream's compressed data in the applicable bit-buffer is managed according to the bit buffer management policies of the second video specification as well as the transport stream specification.
[0062] The bit-buffer management policies described above are applicable at the emission or transmission point in the network, such as by the encoder and the entity producing the multiplexing and/or transmission. Bit-buffer management policies, consistent with the actual implementation at the emission or transmission point, are applicable at the receiver to process the one or more received video streams of a 1080P-60 program. The bit-buffer management policy implemented at the emission or transmission point may be provided to the receiver a priori for each program (e.g., with metadata) or according to an agreed one of the alternatives described above that is employed indefinitely.
[0000] Enabling More than Two Receivers with Different Respective Processing Capabilities
[0063] In an alternate embodiment, the video encoder constitutes two video encoders, a first video encoder producing the first video stream according to the first video specification, and a second video encoder producing the second video stream, which is interspersed for transmission in the transmission channel according to the pockets of “no data” transmission of video stream 1 (as shown in FIG. 4C ). The second video encoder further producing the second video stream according to the second video specification.
[0064] In yet another embodiment, the process of alternating transmission of compressed pictures corresponding to the first video stream and compressed pictures corresponding to the second video stream, results in transmission of a first set of consecutive compressed pictures from different the first video stream when it is the turn to transmit the first video stream, or a second set of consecutive compressed pictures from different the second video stream when it is the turn to transmit the second video stream. For instance, instead of alternating between one compressed picture from the first video stream and one from the second video stream, two consecutive compressed pictures from the second video stream may be transmitted after each transmission of a single compressed picture of the first video stream. Thus, a 1080P-90 Hertz program can be facilitated to 1080P-90 receivers and a 1080P-30 portion of the 1080P-90 program to 1080P-30 receivers. Furthermore, by packetizing every second compressed picture in the second video stream with a third PID value that is different than the first and second PIDs, three corresponding versions of the compressed 1080P-90 program are facilitated respectively to a 1080P-30 receiver, a 1080P-60 receiver, and a 1080P-90 receiver, the latter being able to receive and fulfill the full benefits of the 1080P-90 program.
[0065] In yet another embodiment, the number of consecutive compressed pictures that is transmitted from the first video stream may be grater than one. For instance, if two consecutive compressed pictures from the first video stream are transmitted and three compressed pictures from the second video stream are transmitted after transmission the two from the first video stream, a number of receivers with different processing capabilities may be enabled. If two different PID values are employed, a 1080P-50 receiver will receive a 1080P-50 Program and a 1080P-20 receiver will receive a 1080P-20 corresponding portion. However, if five different PID values are used for the 1080P-50 program, five receivers, each with different processing capability will be capable of receiving a portion of the 1080P-50 program.
Third Video Specification
[0066] Headend 110 may receive from an interface to a different environment, such as from a satellite or a storage device, an already compressed 1080P-60 program—a single video stream encoded according to a third video specification and according to a first stream specification. The first stream specification may be a type of transport stream specification suitable for transmission or a type of program stream specification suitable for storage. The third video specification may comprise of the first video specification, the second video specification, or both the first and second video specifications respectively applied, for example, to every other compressed picture. However, the already compressed 1080P-60 program is received at headend 110 encoded in such a way that it does not facilitate reception some of its portions by receivers with processing capability that are less than those of a 1080P-60 receiver. In other words, it is received without information to inherent signal its different portions to receivers with different processing capabilities.
[0067] Another novel aspect of this invention is that at least one from one or more encoders, one or more multiplexers, or one or more processing entities at the point of transmission at headend 110 , effect packetization of the compressed pictures of the received 1080P-60 program with a plurality of different PIDS, then transmitting the 1080P-60 program as a plurality of identifiable video streams via the first transmission channel. Thus, headend 110 effects proper packetization and prepending of PID values to enable reception of at least a portion of the 1080P-program to receivers with different processing capabilities that are coupled to network 130 .
[0068] The present invention includes methods and systems capable of transmitting compressed video signals according to one or more compression video formats, where compressed video signals correspond to television channels or television programs in any of a plurality of picture formats (i.e., picture spatial resolution and picture rate), including 1080i-60 and 1080P-60 formats. The compressed video signals which correspond to television channels or television programs in any of a plurality of picture formats are received by a plurality of receivers, where each receiver may have a different maximum processing capability. Therefore, the present invention contemplates at least the following combinations for encoding, transmission and reception of video signals. In the following combinations of trio “input/receiver/display,” the input, such as 1080P-60 input in the first combination instance, refers to a compressed video stream that is received at receiver 200 from network 130 via communication interface 242 . The display, such as the 1080P-60 Display in the first combination instance is a television, a display, or a monitor coupled to DHCT 200 via output system 248 . The DHCT 200 provides the compressed video stream corresponding to the “input” in “decoded and reconstructed” form (visible pictures) via output system 248 . The receiver, such as 1080P-60 Receiver in the first combination instance, refers to a receiver, such as DHCT 200 , that has the processing capability specified in the trio.
[0000] 1080P-60 input/1080P-60 Receiver/1080P-60 Display
[0069] In order to process a 1080P-60 compressed video signal, a 1080P-60 capable receiver receives a compressed 1080P-60 video stream via a network interface (or a communication interface). The 1080P-60 compressed video signal is input by storing it in its memory and the receiver decodes with a video decoder (or decompression engine) all the pictures corresponding to the 1080P-60 video signal (or compressed video stream). A 1080P-60 capable display is driven by all the decoded 1080P-60 pictures.
[0000] 1080i-60 Input/1080P-60 Receiver/1080P-60 Display
[0070] In order to process a 1080i-60 compressed video signal, the 1080P-60 capable receiver receives a compressed 1080i-60 video stream via a network interface (or a communication interface). The 1080P-60 compressed video signal is input by storing it in its memory and the receiver decodes with a video decoder (or decompression engine) all the pictures corresponding to the compressed 1080i-60 video signal stored in memory. The 1080P-60 receiver then deinterlaces the decoded 1080i-60 signal with a deinterlacing algorithm based on information in two or more 1080i fields, including a current 1080i field. The deinterlacing algorithm makes decisions based on spatial picture information as well as temporal information. The deinterlacing algorithm can further base decisions on motion estimation or motion detection. A 1080P-60 capable display is driven by all the decoded 1080P-60 pictures.
1080P-60 Input/1080P-60 Receiver/Non-1080P-60 Display
[0071] In order to process a 1080P-60 compressed video signal, the 1080P-60 capable receiver receives a compressed 1080P-60 video stream via a network interface (or a communication interface). When driving a non-1080P-60 display, the receiver outputs a portion of all the decoded 1080P-60 pictures or processes and scales the pictures of the decoded 1080P-60 signal for display. When driving a non-1080P-60 display such as a 1080i-60 display, the 1080P-60 capable receiver could process a 1080P-60 compressed video signal in full (as explained above) and output (or display) a portion of each of the decoded 1080P-60 pictures. The portion may be a temporally-subsampled portion, a spatially-subsampled portion, or a portion resulting from a combination of a temporal-subsampling and spatially-subsampling. Alternatively, when driving a non-1080P-60 capable display, the 1080P60-capable receiver is informed by the user or through a discovery mechanism that the display is not 1080P-60. Consequently, the 1080P-60-capable receiver can behave as if it was a 1080P-30 receiver by not processing the second video stream.
[0000] 1080i-60 Input/1080P-60 Receiver/Non-1080P-60 Display
[0072] When driving a non-1080P-60 display, a 1080P-60 receiver processes a 1080i-60 compressed video signal and outputs the decoded 1080i-60 pictures according to the picture format required to drive the non-1080 display, processing and scaling the pictures of the decoded 1080i-60 signal as required to drive the non-1080P-60 display.
[0000] 1080P-60 Input/1080i-60 Receiver/Non-1080P-60 Display
[0073] In order to process a 1080P-60 compressed video signal, a 1080i-60 capable receiver receives a compressed 1080P-60 video stream via a network interface (or a communication interface). The receiver inputs a first portion of the 1080P-60 compressed video signal by storing it in memory of receiver 200 and the receiver rejects a second and complementary portion of the 1080P compressed video signal by prohibiting it from penetrating any section, portion or buffer of its memory. The receiver 200 decodes with a video decoder (or decompression engine) all the pictures corresponding to the first portion of the 1080P-60 video signal; processing it as if it were a 1080i-60 compressed video signal. A 1080i-60 capable display is driven by the decoded first portion of the 1080P-60 pictures.
[0000] 1080P-60 Input/1080i-60 Receiver/1080P-60 Display—A
[0074] In order to process a 1080P-60 compressed video signal, a 1080i-60 capable receiver receives a compressed 1080P-60 video stream via a network interface (or a communication interface). The receiver inputs a first portion of the 1080P-60 compressed video signal corresponding to a 1080i-60 compressed video signal by storing it in its memory and rejects a second and complementary portion of the 1080P compressed video signal by prohibiting it from penetrating any section, portion or buffer of its memory. The receiver decodes with a video decoder (or decompression engine) all the pictures corresponding to the first portion of the 1080P-60 video signal, processing it as if it were a 1080i-60 compressed video signal. The receiver deinterlaces a decoded 1080i-60 signal with a deinterlacing algorithm based on information in two or more 1080i fields, including a current 1080i field. The deinterlacing algorithm makes decisions based on spatial picture information as well as temporal information. The deinterlacing algorithm can further base decisions on motion estimation or motion detection. A 1080P-60 capable display is driven by all the decoded and deinterlaced 1080i-60 pictures as a 1080P-60 signal.
[0000] 1080P-60 Input/1080i-60 Receiver/1080P-60 Display—B
[0075] In order to process a 1080P-60 compressed video signal, a 1080i-60 capable receiver receives a compressed 1080P-60 video stream via a network interface (or a communication interface). The receiver inputs a first portion of the 1080P-60 compressed video signal corresponding to a 1080i-60 compressed video signal by storing it in its memory and rejects a second and complementary portion of the 1080P-60 compressed video signal by prohibiting it from penetrating any section, portion or buffer of its memory. The receiver decodes with a video decoder (or decompression engine) all the pictures corresponding to the first portion of the 1080P-60 video signal, processing it as if it were a 1080i-60 compressed video signal. In order to drive a 1080P-60 capable display that is capable of receiving a 1080i-60 signal and internal deinterlacing, the display is driven by all the pictures of the decoded 1080i-60 compressed video signal as a 1080i-60 signal. The 1080P-60 display deinterlaces the received 1080i-60 signals according to its deinterlacing capabilities.
Encoding and Transmission
[0076] The encoder produces a 1080P-60 encoded video stream according to a video specification (i.e., MPEG-2 video or MPEG-4 AVC), and assigns a first PID value to packets of every other encoded picture corresponding to the 1080P-60, and assigns a second PID value to every packet of the subsequent picture to the “every other” picture just mentioned, where the second PID value is different from the first PID value. Denoting “every other picture” by N, every subsequent picture is then N+1; and the first PID_value is used for N, while the second PID_value is used for N+1.
[0077] The encoder in one embodiment encodes all pictures according to a single video format, e.g., MPEG-4 AVC, and adheres to the buffer model of the video specification. The encoder in a second embodiment encodes the pictures that correspond to N according to a first video specification and in compliance with the video specification's buffering model, and according to a variable-bit rate model. The encoder further encodes the alternate pictures, every “N+1” picture, according to a second video specification, the second video specification being different from the first video specification. These alternate pictures are encoded according to the syntax of the second video specification, but managed and transferred into a transmission buffer according to the first video specification's buffering model. The encoder further employs in its “encoding loop” a model, or parts thereof, of a receiver's video decoder, including reference pictures, in it's memory.
[0078] Encode 1080P at 60 frames per second, into a single output, ensuring that every other picture (in both decode order and presentation order) is a non-reference picture. Every picture encoded is a progressive frame representing 1/60 th seconds. Now, every other picture can be separated into a new PID. This new PID may be called “PID B”, and the other PID may be called “PID A”. PID B contains only non-reference pictures that can optionally be included in the decoding of PID A. In this separation process, the original picture ordering must be maintained within the multiplex. For example, a picture in one PID must end before the next picture begins in the other PID.
[0079] For backwards-compatibility, the frame rate value in PID A should be set at 30 frames per second; and the temporal references in PID A should be corrected for the separated pictures; and as a convenience, the temporal references in PID B should be set to match those in PID A, such that each picture pair shares a temporal reference number. The 1080P-60 capable decoder will be aware that the frame rate is actually 60 frames per second, and will support the pairs of duplicate temporal references. When decoding both PID A and PID B in combination, the decoder should expect two of every temporal reference number, adjacent in presentation order. Therefore, for example, it can use the temporal reference numbers to detect a missing picture. Picture re-ordering within the decoder may be based on the sequence of picture types received, as normal.
[0080] The following are examples of this scheme demonstrating how a decoder could receive PID A alone, or receive the combination of PID A and PID B. In these examples, the “B”-type pictures represent non-reference frames. Also, these examples are given in decode order, and the numbers represent temporal references (indicating presentation order).
Example 1, IBBBP . . . :
[0081] Before temporal reference number (TRN) correction:
PID A: I3_B1_P7_B5_P11_B9_P15_B13 —
PID B: _B0_B2_B4_B6_B8_B10_B12_B14
[0082] After TRN correction:
PID A: I1_B0_P3_B2_P5_B4_P7_B6 —
PID B: _B0_B1_B2_B3_B4_B5_B6_B7
Example 2, IBP . . . :
[0083] Before TRN correction:
PID A: I1_P3_P5_P7_P9_P11_P13_P15 —
PID B: _B0_B2_B4_B6_B8_B10_B12_B14
[0084] After TRN correction:
PID A: I0_P1_P2_P3_P4_P5_P6_P7 —
PID B: _B0_B1_B2_B3_B4_B5_B6_B7
[0085] In the PMT, PID B can be designated by a new stream_type. A common set of audio streams may serve each case: 1) using only PID A 2) using both PID A and PID B.
[0086] In the above described method of encoding and transmission, the separation of every other frame occurred after encoding. In an alternative embodiment, separation occurs prior to encoding. At one encoder's input, supply every other frame of a 1080P-60 hz signal. Encode this as 1080P-30 hz. Simultaneously, supply another encoding process with the alternate frames, also at 1080P-30 hz. Presentation time stamps (PTSs) shall be generated for every picture, referencing a common clock. The result is two video streams, each being legitimate 1080P-30 hz. A 1080P-60 capable decoder may decode both simultaneously, as a dual-decode operation, to be recombined in the display process. There need be no further correlation between the two PIDs than the commonly referenced PTSs. For example, the group of pictures (GOP) structures, as defined by the video specification (e.g., MPEG-2 video GOP) may be independent, and the buffering may be independent. To recombine the dual 1080P-30 streams into a single 1080P-60 output, the dual-decoder's display process will choose decoded pictures to put on display in order of PTS. If the picture for a particular time interval has not yet been decoded, possibly due to some data corruption or loss, then the previous picture will simply be repeated through that time interval. If any picture is decoded later than its PTS elapses, it is to be discarded. Even though both PIDs may be completely independent, because they reference the same clock, there is no risk that a picture from one PID is sent later than the presentation time of a following picture from the other PID, as long as each PID's buffer is maintained compliantly within the multiplex.
[0087] PID B in the PMT may be designated by a new stream_type, which may be allocated by MPEG, or which may be a user-private stream_type that indicates a privately managed stream. The new stream_type would not be recognized by legacy receivers, so the associated PID B would be ignored. As an additional method of unambiguous identification of the special second PID, the registration descriptor may be used in the ES_descriptor_loop of the PMT to register a unique and private attribute for association with PID B. Any combination of the above methods may be used, as deemed adequate and sensible. A common set of audio streams may serve each case: 1) using only PID A 2) using both PID A and PID B. The methods described above use a separate PID to carry additional information. In those cases, the separate PID can optionally be ignored by the decoder. In another alternative embodiment, a single video PID may be used to carry both the base information and the additional information, while still providing a way to optionally reject the additional information. A separate packetized elementary stream (PES) ID can be used such that a new PMT descriptor, which would be allocated by MPEG, may designate one PES ID for the base layer, and a different PES ID for the additional information, both carried by the same PID. In this way, existing PES IDs may be identified as base, and supplemental, without the need for new PES IDs to be allocated. The decoder that needs only the base layer may discard those PES packets whose ID does not match the ID designated as the base layer in the PMT. The decoder that can use both may simply not reject either. This approach is applicable to both schemes: post-encoding-separation and prior-encoding-separation.
[0088] The foregoing has broadly outlined some of the more pertinent aspects and features of the present invention. These should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by modifying the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims. | Methods and systems for the efficient and non-redundant transmission of a single video program in multiple frame rates, optionally employing a combination of video coding standards, in a way that is backwards-compatible with legacy receivers only supportive of some subsection of frame rates or of some subsection of video coding standards. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of U.S. patent application, Ser. No. 07/642,069, filed Jan. 16, 1991, to be issued on Jun. 23, 1992 as U.S. Pat. No. 5,123,220.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to column assemblies used in the construction of building structures. More particularly, this invention relates to column assemblies having reinforcement rods imbedded within columns and extending from the ends thereof to facilitate connection and alignment of the columns, end to end, during erection.
2. Description of the Background Art
Presently there exists many varieties of construction techniques that employ vertically disposed, floor-height columns which support bearing beams interconnecting adjacent columns, with the bearing beams providing support for the floor above constructed of precast floor slabs, poured-in-place, or the combination of the two.
It is always desirable to erect the column assemblies as precisely vertical as possible while minimizing shoring. In this regard, one technique for minimizing shoring is to extend the reinforcement rods of each column to protrude from their ends and then provide means for aligning the ends via the protruding rods as the columns are stacked vertically one on top of another. In some techniques, the protruding reinforcement rods are aligned by means of an intermediate plate, in others, by slip fitting the rods together. Illustrative examples of such techniques are described in U.S. Pat. No. 976,182, U.S. Pat. No. 1,657,197, U.S. Pat. No. 2,724,261, U.S. Pat. No. 3,613,325, U.S. Pat. No. 3,733,757, U.S. Pat. No. 3,867,805, U.S. Pat. No. 4,081,935, U.S. Pat. No. 4,330,970, U.S. Pat. No. 4,583,336, French Patent 2,387,325 and British Patent 1,045,331.
Of all the above-referenced patents, only U.S. Pat. No. 976,182 employs the use of turnbuckles which threadably engage the aligned ends of the protruding reinforcement rods of columns positioned end to end. Unlike slip-fit sleeves and the other interconnection means shown in the other patents, the turnbuckles taught by U.S. Pat. No. 976,182 provide a means for mechanically interconnecting the rods of adjacent columns stacked one on top of the other. However, the use of turnbuckles for such interconnection requires that the turnbuckles be individually adjusted until the upper column is positioned vertically. Considering the weight of the column, leveling adjustment of the turnbuckles during erection would appear to be difficult since the column would have to remain suspended by a crane as the turnbuckles were threaded onto the rods. Also the total weight of the structure above will have to be carried by the threads of the buckles.
It is an object of this invention to provide an apparatus which overcomes the aforementioned inadequacies of the prior art devices and provides an improvement which is a significant contribution to the advancement of the column assembly art.
Another object of this invention is to provide a column assembly, comprising in combination a first column having a first end and a second end, at least one first threaded rod extending from the second end of said first column, a second column having a first end and a second end, at least one second threaded rod extending from the first end of the second column in axial and contiguous alignment with the first threaded rod defining a space between the second end of said first column and the first end of the second column, and a threaded sleeve threadably interconnecting the first threaded rod and the second threaded rod.
Another object of this invention is to provide a column assembly described hereinabove, wherein a plurality of the first threaded rods extend from the second end of the first column, wherein a corresponding plurality of the second threaded rods extend from the first end of the second column in axial and contiguous alignment with respective first threaded rods, and wherein a corresponding plurality of the threaded sleeves threadably interconnect respective the first threaded rods and the second threaded rods.
Another object of this invention is to provide a column assembly described hereinabove, wherein the first threaded rods extend from the second end of the first column equal distances and wherein the second threaded rods extend from the first end of the second column equal distances.
Another object of this invention is to provide a column assembly described hereinabove, wherein the threaded sleeves comprise a length less than the distance the first threaded rods extend from the second end of the first column or the distance that the second threaded rods extend from the first end of the second column, thereby allowing said threaded sleeves to be threaded fully onto the first threaded rods or the second rods prior to the rods being positioned in axial an contiguous alignment.
Another object of this invention is to provide a column assembly described hereinabove, further comprising grout means filling the space between the second end of the first column and the first end of the second column.
Another object of this invention is to provide a column assembly described hereinabove, wherein the first column further comprises a capital positioned at the second end of the first column, the capital having a surface area greater than the cross-sectional area of the first column defining a ledge for supporting a bearing beam when the columns are positioned vertically.
Another object of this invention is to provide a column assembly described hereinabove, wherein the first column further comprises a plurality of beam anchors cast-in-place at the second end of the first column and corresponding plurality of brackets which removably engage the anchors to protrude from the side of the second end of the first column and provide a support for either precast beams or steel joists.
The foregoing has outlined some of the more pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be obtained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
For the purpose of summarizing this invention, this invention comprises a column assembly having a plurality of floor-height columns which are erected vertically, one on top of the other, to define the floors of the building structure to be constructed. In one embodiment, the upper end of each column comprises a capital for supporting bearing beams which extend from one column assembly to an adjacent column assembly. In another embodiment, the upper end of each column comprises a plurality of anchors cast-in-place and a corresponding plurality of brackets which removably engage into the anchors and provide support for the bearing beams. The bearing beams provide support for a precast slab floor or a cast-in-place floor.
A primary feature of the invention is the manner in which the columns of each column assembly are interconnected. Specifically, each column comprises a plurality of reinforcement rods which are embedded in the column and extend outwardly from the ends thereof. The rods extend precisely equal distances from each end of the column. Each rod is threaded in a precise manner with the thread beginning at the same orientation for each rod such that when the columns are stacked end-to-end, the rods are in perfect axial alignment with the thread of one rod continuously leading into the thread of the contiguous rod to which it is aligned.
The precise cutting and threading of the rods extending from the ends of the columns allow a threaded sleeve to be threaded onto the rods extending from the lower end of the upper column and, after stacking of the upper column end-to-end onto a lower column, the threaded sleeve may be threaded onto the axially aligned and contiguous rods extending from the lower column. A rigid mechanical connection is therefore made between adjacent columns sufficient to support the columns vertically without additional shoring. Most importantly, the preciseness of the length of the rods assures that a precisely, vertically aligned column assembly is achieved. Leveling adjustment is therefore not necessary or minimized.
Another feature of the column assembly of the invention in one embodiment is the use as a capital at the upper end of a lower column for supporting bearing beams which straddle adjacent column assemblies so as to provide support for the laying of precast floor slabs or, alternatively, to provide support for pouring a cast-in-place floor. In another embodiment, a plurality of anchors are cast-in-place into the upper end of the lower column. A corresponding plurality of brackets removably engage into the anchors to protrude outwardly from the sides of the upper end of the column. The brackets therefore provide support for the precast beams or O.W.S.J, alternatively, to provide support for pouring a cast-in-place floor. The brackets may comprise either a removable U-shaped member having an upstanding end which hooks into a corresponding slot in the anchor or a threaded member which threadably engages into a threaded hole in the anchor.
A still additional feature of the column assembly of the invention is the ability to interconnect the adjacent columns through the bearing beams so as to provide a stronger structure. Likewise, the space created between adjacent columns in a column assembly may be filled with grout or other solidifying material to provide added support and structural connection for the adjacent, interconnect columns. Finally, the cast-in-place floor or the precast floor slabs may be tied to the lower end of the upper column so as to provide more rigid support.
The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
FIG. 1 is a front view of the column assembly of the invention;
FIG. 2 is a longitudinal cross-sectional view of the column assembly of the invention employing a precast capital on which is seated bearing beams which support a precast slab floor;
FIG. 2A is a plan view of FIG. 2 taken along lines 2A--2A illustrating the side support precasts;
FIG. 3 is a longitudinal cross-sectional view of the column assembly of the invention employing an integral capital on which is seated bearing beams which support a cast-in-place floor;
FIG. 4 is a front view of two column assemblies of the invention supporting a bearing beam;
FIG. 5 is a longitudinal cross-sectional view of the column assembly of the invention wherein a plurality of anchors are cast-in-place in the upper end of the column permitting a plurality of U-shaped brackets to removably engage therein to further support a precast bearing beam;
FIG. 6 is a top cross-sectional view of the column assembly of FIG. 5;
FIG. 7 is a cross-sectional view along lines 7--7 of FIG. 6;
FIG. 8 is a longitudinal cross-sectional view of the column assembly of the invention employing a plurality of anchors cast-in-place in the upper end of the column for threadably receiving a plurality of threaded brackets to provide support for a steel joist bearing beam; and
FIG. 9 is a top cross-sectional view of FIG. 8.
Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the column assembly 10 of the invention comprises a plurality of columns 12 each having an upper end 12U and a lower end 12L. A plurality of reinforcement rods 14 (e.g. 4) are imbedded in each column 12 throughout the length thereof and extend from the upper end 12U and the lower end 12L. Each reinforcement rod 14 is of equal length such that their upper ends 14U extend from the upper end 12U of each column 12 by equal distances and such that their lower ends 14L extend from the lower end 12L of the column 12 by equal distances. Both the upper and lower ends 14U and 14L of the reinforcement rods 14 are threaded with the same thread. The beginning of the thread of the upper end 14U of each reinforcement rod 14 of a column 12 is aligned with the beginning of the thread of the lower end 14L of the corresponding reinforcement rod 14 of an adjacent column 12 so that when the respective ends 14U and 14L of the reinforcement rods 14 are positioned in axial and contiguous alignment, the threads of the ends 14U and 14L form a continuous, uninterrupted thread allowing a threaded sleeve 18 to threadably interconnect the upper end 14U of the reinforcement rods 14 extending from the upper end 12U of the column 12 with the lower end 14L of the reinforcement rods 14 extending from the lower end 12L of an upper column 12. In this regard, the length of threaded sleeve 18 is preferably less than the distance that the end 14U or 14L of the reinforcement rods 14 extend from the ends 14U and 14L of the column 12 thereby allowing the threaded sleeve 18 to be threaded onto the end 14U or 14L prior to positioning the respective ends 14U and 14L of the reinforcement rods 14 of the adjacent columns 12 in axial and contiguous alignment.
During assembly, a lowermost floor-height column 12 is positioned vertically and embedded or otherwise rigidly supported by foundation 20. A threaded sleeve 18 is threaded all the way onto the lower end 14L of each reinforcement rod 14 that extends from the lower end 12L of the columns 12 to be erected. A column 12 is hoisted, such as by means of a crane, above the lowermost column 12 and then lowered such that the lower ends 14L of the reinforcement rods 14 extending from the lower end 12L of the column 12 are in axial alignment with and resting on the upper ends 14U of the reinforcement rods 14 extending from the upper end 12U of the lowermost column 12. A space 19 between the upper end 12U of the lowermost column 12 and the lower end 12L of the adjacent column 12 is created. The threaded sleeves 18 are then threaded downwardly so as to secure the axially and contiguously aligned ends 14U and 14L of the reinforcement rods 14, thereby rigidly securing the rods 14 together and forming a mechanically sound connection between the two adjacent columns 12 separated by the space 19. The threaded sleeves 18 may be tack-welded to the rods 14 to preclude any further threaded movement along either ends 14U or 14L of the reinforcement rods 14. As described below, space 19 is to be grouted to provide a more solid support.
Additional floor-height columns 12 may be rigidly connected in series so as to extend the column assembly 12 upwardly to the desired height defining the floors of the structure to be constructed. It should be appreciated that the column assembly 12 as thus constructed comprises a self-supporting, rigid structure that does not require shoring of each added column 12 during assembly.
As shown in FIGS. 2 and 3, the upper end 12U of each column 12 may be provided with a capital, generally indicated by numeral 22, for supporting bearing beams, generally indicated by numeral 24, which straddle adjacent column assemblies 10 aligned in a row. Additional bearing beams 24 may be provided for straddling adjacent rows of column assemblies 10. The bearing beams 24 provide support for a precast floor slab (see FIG. 2). Alternatively, the bearing beams 24 allow, with appropriate shoring, the pouring of a cast-in-place floor supported by the bearing beams 24 (see FIG. 3).
More particularly, referring to FIG. 2, in one embodiment, capital 22 comprises a precast capital 26 having a metal top plate 28. Apertures 30 are formed through the precast capital 26 so as to allow the upper ends 14U of the reinforcement rods 14 to extend therethrough. The precast capital 26 comprises a surface area greater than the cross-sectional area of the column 12 so as to over-hang the column 12 and define four ledges 32 around the four sides of the column 12 for supporting the bearing beams 24.
During assembly, the lowermost column 12 is positioned vertically as hereinabove described. The precast capital 26 is lowered onto the upper end 12U of the lowermost column 12 so that the upper ends 14U of the reinforcement rods 14 extend through apertures 30 in the precast capital 26. Another column 12 (with threaded sleeves 18 installed) is lowered into place with its lower ends 14L of the reinforcement rods 14 extending from its lower end 12L positioned in axial and contiguous alignment with the upper ends 14U of the reinforcement rods 14 extending through apertures 30 from the upper end 12U of the lowermost column 12. The threaded sleeves 18 are then threaded onto the upper ends 14U of the reinforcement rods 14 so as to rigidly interconnect the columns 12. Notably, the thickness of the precast capital 26 is dimensioned relative to the distance by which the upper ends 14U of the reinforcement rods 14 extend from the upper end 12U of the lowermost column 12 such that the threaded sleeves 18 additionally function to rigidly secure the precast capital 26 to the upper end 12U of the column 12 as the threaded sleeves 18 are threaded onto the upper ends 14U of the reinforcement rods 14.
Without departing from the spirit and scope of this invention, it is noted that the precast capital 26 may comprise simply the metal top plate 28 without precast. In such event, the thickness of the capital 22 would be appreciably less than the distance by which the upper ends 14U of the reinforcement rods 14 extend from the upper end 12U of the column 12. The reinforcement rods 14U should be correspondingly dimensioned shorter to allow the threaded sleeve 18 to rigidly secure the metal top plate 28 to the upper end 12U of column 12.
As shown in FIG. 2, the ends of the bearing beams 24 are seated on the respective ledges 32 of capital 22. Means are provided for rigidly securing the bearing beams 24 to the ledges 32 of the capital 22. More particularly, the edges of the bearing beams 24 are rigidly secured to the ledges 32 of the capital 22 by means of a threaded fastener 34 which extends through hole 36 in the end of each bearing beam 24 and through an aligned hole 38 in ledge 32. As shown, the threaded fastener 34 may comprise a rod 40 threaded at both ends for receiving a washer 42 and nut 44 at both ends. A recess 46 may be formed in the lower surface of the ledge 32 for receiving the washer and nut 42 and 44 at the rod's 40 lower end. It is noted that a neoprene sheet 48 may be positioned between the ends of the bearing beams 24 and the ledges 32. Also, a dense plastic foam spacer 50 may be provided between the end of the bearing beams 24 and the lower end 12L of the upper column 12.
As mentioned earlier, the bearing beams 24 provide support for a precast floor slab (see FIG. 2) or, alternatively, the bearing beams 24 allow, with appropriate shoring, the pouring of a cast-in-place floor supported by the bearing beams 24 (see FIG. 3).
More specifically, the bearing beams 24 are rigidly connected to opposing ledges 32 formed on opposing sides of the upper 12U of each column 12. As shown in FIG. 2A, a side support precast, generally indicated by numeral 52, is positioned on the two other ledges 32 of the capital 22 to function as a form for pouring grout into the space 19 between the upper end 12U of the lower column 12 and the lower end 12L of the upper column 12. The side support precasts 52 are connected to each other by means of threaded fasteners 54 which pass through space 19 and extend horizontally through holes 56 formed in both the side support precasts 52. Upon tightening, fasteners 54 draw the side support precasts 52 together thereby rigidly clamping the side support precasts 52 about the ends of the bearing beams 24.
The side support precast 52 each comprises at least one pour hole 58 positioned on its superior surface allowing grout 60 (see FIG. 2) to be poured into the space 19 after the side support precast 52 are secured into position. Grout 60 functions to provide added support for the column assembly 10.
After the grout 60 is poured, a plurality of precast floor slabs 62 are positioned on the bearing beams 24 as is conventional in the trade for constructing a floor.
As shown in FIG. 3, in another embodiment of the capital 22, the capital 22 is integrally formed at the upper end 12U of the column 12 to define the four ledges 32 for supporting the bearing beams 24. The ends of the bearing beams 24 are rigidly secured together on opposing sides of the upper column 12 by means of an elongated member 64 which passes through space 19 and extends through angled slots 66 formed through the ends of the bearing beams 24. The elongated member 64 preferably comprises a stranded cable which, after passing through space 19 and angled slots 54, extends along the upper surface of the bearing beams 24.
As illustrated, bearing beams 24 are constructed with protruding anchors 68. Once appropriate shoring is erected, a cast-in-place floor can then be poured as is conventional in the trade. During pouring, the stranded cable 64 and the protruding anchors 68 of the bearing beams 24 are imbedded thereby rigidly securing the bearing beams 24 on opposing sides of the columns 12. However, for added strength, another elongated member 70, such as a stranded cable, may be positioned through a horizontal hole 72 in the lower end 12L of the upper column 12 to extend along the upper surface of the bearing beams 24 to also be imbedded during pouring of the cast-in-place floor.
Without departing from the spirit and scope of this invention, the cast-in-place floor as described hereinabove may alternatively be used in lieu of the precast floor slabs 62 described in connection with the precast capital 26. Finally, it is noted that when employing four bearing beams 24 seated on the four ledges 32 of the capital 22 (ninety degrees from each other) of the column 12, the side support precasts 52 are not needed. However, in order to fill the space 19 with grout for added support, a pour hole 74 must be formed angularly within the lower end 12L of the column 12 allowing grout to be poured therethrough to fill the space 19 or grouted by means of a pressure pump.
Referring now to FIG. 4, a plurality of column assemblies 10 of the invention may be positioned in a row for supporting a bearing beam 80 having holes 82 positioned transversely therethrough in alignment with the upper ends 14U of the reinforcement rods 14 which extend from the upper end 12U of the columns 12. Holes 82 may be formed over-size to facilitate assembly on top of the upper end 12U of the column 12. After assembly, holes 82 may be grouted. A washer plate (not shown) may then be installed over the ends 14U of the rods 14, to provide a base for the threaded sleeves 18. Similar to the above description in regard to capital 22, the length of the upper ends 14U of the rods 14 ma be dimensioned such that the threaded sleeves 18 can be tightened onto the upper ends 14U so as to rigidly secure the bearing beam 80 to the upper end 12U of the column 12. This embodiment of bearing beams 80 may be used to support the floor above, or can be used in combination with the columns 12 and capitals 22 described hereinabove.
Referring now to FIGS. 5-9, the column assembly 10 of the invention may include a plurality of column anchors 110 which are embedded in the sides of the upper end 12U of each of the columns 12. A corresponding plurality of brackets 112 are provided for removably engaging the column anchors 110. The brackets 112 extend outwardly from the sides of the column to be engaged by corresponding beam anchors 114 of precast bearing beams 24 or steel joists 116. Thus, it should be appreciated that these column and beam anchors 110 and 114 and interconnecting brackets 112 function as a substitute for the capital 22.
More particularly, in one embodiment as shown in FIGS. 5-7, the column anchors 110 comprise a right angle member 118 having one side 120 positioned flush with the side of the column 12 and its other side 122 positioned horizontally. A pair of steel side members 124 and 126 are positioned in a spaced-apart manner and welded to the horizontal side 122 of the angle member 118 in an upstanding spaced-apart manner thereby providing a space 128 therebetween. A steel bar 130, equal in width to the space 128 between the side members 124 and 126, is positioned in the uppermost area of the side members 124 and 126 and rigidly welded into position. The bar 130 includes a substantially rectangular notch 132 in its lower surface 134. As shown in FIGS. 5 and 6, the bar 130 preferably extends across the width of the column 12 to thereby interconnect the column anchor 110 on one side of the column 12 with the column anchor 110 on the opposing side of the column 12. Also preferably, two column anchors 110 are positioned on each side of the column 12 with the angle member 118 extending across the side width of the column 12 thereby rigidly interconnecting the two column anchors 110. Without departing from the spirit and scope of this invention, it should be appreciated that the column anchors 110 may be positioned on all four sides of the column 12 with the bars 130 rigidly connected to each other and the angle members 118 rigidly connected to each other. As illustrated, the entire assembly of angle members 118, bars 130 and side members 124 and 126, is cast-in-place in the upper end 12U of the column 12 when the column 12 is being cast; however, the space 128 below the notch 132 in the bar 130 and above the horizontal side 122 of the angle member 118 is kept free of concrete during casting so as to define the space 128 bound on its bottom by the horizontal surface 122 of the angle member 118, on its sides by the side members 124 and 126, and at its rear by concrete wall surface 136 (see FIG. 5).
As noted above, a bracket 112 is provided for removable engagement with each of the column anchors 110 embedded within the upper end 12U of the column 12. As shown in FIG. 5, the bracket 112 comprises a double-hook configuration formed in a U-shape 138. More specifically, the U-shaped bracket 138 comprises a horizontal portion 140 and a pair of upstanding end portions 142 and 144 extending from opposing ends of horizontal portion 140. The thickness of the U-shaped bracket 138 is appreciably less than the distance between the side members 124 and 126 of the column anchor 110 so that the end portion 142 may slidably fit within the space 128 between the side members 124 and 126. The tip of the upstanding end portion 142 is preferably squared off and dimensioned to easily fit into the notch 132 in the bar 130. During assembly, the bracket 138 may be canted relative to the column anchor 110 and its upstanding end portion 142 inserted into the space 128 between the side members 124 and 126 and then pivoted upwardly so that its tip firmly seats or "hooks" into the notch 132 in the bar 130. A space 146 is provided for positioning between the underside of the U-shaped bracket 138 and the horizontal surface 122 of the angle member 118 so as to keep the tip of the upstanding end member 142 in engagement of the notch 132 of the bar 130. Once installed in this manner, the other upstanding end portion 144 of the U-shaped bracket 138 protrudes outwardly and upwardly from the side of the column 12 so as to "hook" the beam anchor 114 cast-in-place in a precast bearing beam 24.
The beam anchor 114 comprises a transversely positioned bar 148 having a width appreciably less than the distance by which the U-shaped bracket 112 extends from the side of the column 12. A pair of longitudinal side members 150 and 152 are rigidly welded to bar 148 in a spaced-apart manner to define a space 154 for receiving the upstanding end portion 144 of the bracket 112 therebetween (see FIG. 7). As best shown in FIG. 6, two beam anchors 114 may be cast-in-place in the end of the beam 24 and the bar 148 may extend across the width of the bearing beam 24 so as to connect one beam anchor 114 with the other. Similarly, each of the paired side members 150 and 152 may be rigidly interconnected by means of transversely extending reinforcement rods 156 or the like. The entire assembly is cast-in-place within the end of the bearing beam 24; however, the space 154 below the bar 148 and the side members 150 and 152 is kept free of concrete so as to provide room for the upstanding end portion 144 of the U-shaped bracket 112 to be inserted therein and "hook" under the bar 148.
During assembly, the columns 12 are erected in the manner described hereinabove. The brackets are installed into the column anchors 110 of each of the columns. The beams 24 are then lowered into position so that the brackets 112 hook onto the bar 148 embedded within the beam 24. In this regard, it is noted that the casting of the column anchors 110 in the column 12 and the casting of the beam anchors 114 in the beam 24 may be such that, when assembled, the top of the column 12 is flush with the top of the beam 24 so as to provide a flat surface permitting a floor to be poured into place.
Referring now to FIGS. 8 and 9, in another embodiment, a column anchor 110 is provided which comprises a generally hollow cylindrical member 150 having internal thread 152 which is rigidly welded to angle member 118. The column anchors 110 may be positioned, as shown, one on each of the four sides of the column 12. All of the column anchors 110 are cast-in-place within the upper end 12U of the column 12.
A threaded bracket 154 is provided having a threaded boss 156 for threadably engaging into the thread 152 of the cylindrical member 150 and having a flat portion 158 extending from the sides of the column 12. A hole or slot 160 is provided in the flat portion 158.
A beam anchor 114 is rigidly welded to the end of a steel truss 162. The beam anchor 114 comprises paired side members 164 and 166 with aligned holes 168. A removable bearing pin 170 is provided for removably engaging through the holes 168 in the opposing side members 164 and 166 of the beam anchor 114 and the hole 160 in the flat portion 158 of the bracket 154.
During assembly, the steel joists 116, having the beam anchors 114 welded to the ends thereof, are positioned between opposing columns 12 and aligned in such a manner that the flat portion 158 of the bracket 154 engages between the side members 164 and 166 of the beam anchor 114. The bearing pin 170 is then inserted through the holes 168 and 160 so as to rigidly secure the steel joist 116 to the column 112. It is noted that a bearing plate 172 may be cast-in-place in the column 12 in alignment with the bottom member 174 of the steel truss 116 to provide additional support for the truss 116. It is also noted that this bottom member 174 may be made slightly telescopic via adjustment screws 176 so that it bears directly against the bearing plate 172.
Once the steel joist 116 is connected to the columns 12 via the brackets 154, a plywood floor 178 may be laid on top of the joists 116 level with the top of the column 12. A concrete floor may then be poured into place on top of the floor 178 and in the space 19 formed between the ends of the columns 12.
The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.
Now that the invention has been described, | A column assembly having a plurality of floor-height columns which are erected vertically, one on top of the other, to define the floors of the building structure to be constructed. Each column comprises a plurality of reinforcement rods which are embedded in the column and extend outwardly from the ends thereof. The rods are cut at precisely equal lengths to extend precisely equal distances from each end of the column. Each rod is threaded in a precise manner with the thread beginning at the same orientation for each rod such that when the columns are stacked end-to-end, the rods are in perfect axial alignment with the thread of one rod continuously leading into the thread of the contiguous rod to which it is aligned. A threaded sleeve is threaded onto the rods extending from the lower end of the upper column and, after stacking of the upper column end-to-end onto a lower column, the threaded sleeve may be threaded onto the axially aligned and contiguous rods extending from the lower column. A rigid mechanical connection is therefore made between adjacent columns sufficient to support the columns vertically without additional shoring. | 4 |
BACKGROUND
Increasingly, the Internet is becoming a forum for conducting business activities, such as online banking and stock trading. Various security protocols may be used to ensure that the business applications associated with the business activities are reliable and secure. Although some security protocols may provide a measure of reliability and security, at least some of the protocols may not provide adequate certification.
SUMMARY
In at least some embodiments, a method comprises calculating a first part of a message authentication function by a first processor, calculating a second part of the message authentication function by a second processor, and combining the first and second parts into the message authentication function by the first or second processor. The message authentication function can be used to authenticate data transmitted between the first processor and a third processor.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of embodiments of the invention, reference will now be made to the accompanying drawings in which:
FIG. 1 shows an exemplary system in accordance with some embodiments of the invention, including a client, a server, and a witness;
FIG. 2 shows an exemplary flow diagram of a communication process between the client and witness to the server of FIG. 1 ; and
FIG. 3 shows an exemplary flow diagram of a communication process from the server to the client and witness of FIG. 1 .
NOTATION AND NOMENCLATURE
Certain terms are used throughout the following description. As one skilled in the art will appreciate, various companies may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. 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 . . . ” Also, the term “couple” or “couples” is intended to mean either an indirect or direct electrical connection. Thus, if a first device couples to a second device, that connection may be through a direct electrical connection, or through an indirect electrical connection via other devices and connections. Unless otherwise explicitly indicated, embodiments discussed herein should be construed as exemplary, and not limiting in scope.
DETAILED DESCRIPTION
The following discussion is directed to various embodiments of the invention. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to intimate that the scope of the disclosure, including the claims, is limited to that embodiment.
In general, the embodiments described herein permit a data communication between a pair of entities (e.g., a server and a client) to be verified. Further, the embodiments provided herein are directed to client-side verification meaning that communications between client and server are encoded in a trustworthy manner, thereby permitting the source of the data as well as the data itself to be authenticated. Although, client-side logic is shown to assist the client in authenticating data to/from the server, similar logic may be used on the server side to provide comparable authentication to the server.
Referring now to FIG. 1 , an electronic witnessing system 100 is shown comprising a server 102 , a client 104 , and a witness 106 . The server 102 , the client 104 , and the witness 106 may represent computer systems capable of independently communicating over a network, such as the Internet. The server 102 , the client 104 , and the witness 106 may comprise processors 116 , 118 , and 120 for executing instructions, non-volatile memory units 122 , 124 , and 126 for storing data, and network interface adapters 128 , 130 , and 132 for establishing network connections, respectively. In addition, server 102 , the client 104 , and the witness 106 may comprise other hardware devices, such as a hard drive, a memory controller, and a keyboard, as desired. The client 104 and witness 106 each may contain executable code 123 and 125 , respectively, stored in a storage medium (e.g., memories 124 , 126 ) and executable by processors 118 , 120 . Such executable code may implement some or all of the functionality described herein.
In accordance with the embodiments of the invention, the electronic witnessing system 100 independently “witnesses” an electronic communication between the client 104 and the server 102 . In this context, the verb “witness” means to authenticate the contents of a communications process and the parties involved in the communications process. As described below, a “witness” (noun) refers to an entity that assists in the verification process. The communication process is generated in response to an application, such as an online banking or stock trading system, that may be running on the server 102 . The witness 106 may generate “evidence” of the electronic communication between the client 104 and the server 102 in the form of verification records that may indicate the authenticity of the communication process.
The client 104 may establish two transmission control protocol (TCP) connections 108 and 110 with the witness 106 and the server 102 , respectively. Data may be exchanged between the client 104 and the witness 106 via the connection 108 and between the client 104 and the server 102 via the connection 110 . In other embodiments, user datagram protocol (UDP) may be used in place of the connections 108 and 110 .
The client 104 may send a request to the witness 106 through the TCP connection 108 requesting a secure sockets layer (SSL) “session” with the server 102 . In general, an SSL session is an established cryptographic-based communications channel between two computer systems. For example, a first computer system may establish an SSL session with a second computer system by performing an SSL “handshake.” During the handshake, cryptographic algorithms, such as triple-DES and RC4, that may be used to encrypt communications during the session may be determined. In addition, the handshake may authenticate either computer's identity and generate a shared secret code between the first and second computers. The identify of the second computer may be authenticated by sending an X.509 certificate from the second computer to the first computer. The certificate may contain the second computer's domain name and a “public key” that is signed by a trusted certificate authority, such as VeriSign. The public key allows the first computer to encrypt messages that may be read only by the second computer. The shared secret code may be generated by encrypting a random number on the first computer using the second computer's public key and sending the encrypted random number to the second computer. The second computer may decrypt the random number to replicate the shared secret code, thereby ensuring that the second computer is indeed the system identified by the certificate. In this way, the client 104 can verify the authenticity of the server 102 .
An SSL session may comprise one or more SSL “connections.” Each SSL connection is layered on a transport protocol, such as TCP. When an SSL connection is created, the session's shared secret code, as previously discussed, may be used to generate symmetric “encryption keys” and message authentication code secrets (“MAC secrets”) that are shared between the first and second computer systems. Each direction (i.e., from the first computer to the second computer and from the second computer to the first computer) of the SSL connection may have an associated MAC secret and encryption key. The encryption key facilitates the encryption and decryption of data between the first and second computer systems, while the MAC secret may be used to generate a message authentication code (MAC), as discussed below.
During an SSL connection, data generated by application and control messages, such as a change in the cryptographic algorithms or strength of the algorithms, may be transferred between the first and second computer systems via SSL “records.” Each record, optionally compressed to decrease size, is encrypted with the agreed upon cryptographic algorithms via the encryption keys. Included within each record is a sequence number that indicates the relative ordering of an SSL record in relation to other SSL records sent during the SSL connection. When an SSL record is received, the record may be decrypted with the encryption keys. The receiver of the SSL record may re-compute the MAC for the record using the receiver's MAC secret code and compare the re-computed MAC with the MAC included in the SSL record. If the MACs are identical, the record is validated. The validated record may be decompressed if necessary. If the MACs are not identical, due to tampering or other inconsistencies, the session is invalidated. Secure file transfer protocol (SFTP) and secure hypertext transfer protocol (HTTPS) are two examples of applications that use SSL. Other similar applications may use SSL as well.
The MAC associated with an a SSL record may be computed from a one way hashing function referred to as a “MAC function.” In general, a one-way hash function, H(m), operates on an arbitrary-length message, m, and returns a fixed-length has value, h, with the following properties: (1) given m, the computation of h may be relatively easy; (2) given h, the computation of m such that H(m)=h may be relatively hard; and (3) given m, it may be relatively hard to find another message m′ such that H(m)=H(m′).
An iterated one-way hash function, such as MD5 and SHA1, may start with a constant initialization vector (IV) and process a message in fixed-sized blocks, such as 512 bits, and may use the result of the current block to derive the IV for the next block. That is,
H c ( m )= H c ( m 1 +m 2 + . . . +m n )= H V i-1 ( m i + . . . +m n ), V i =H V i-1 ( m i ), 1≦ i≦n,V o =C (1)
where H c is the hash function with the constant IV=C, m 1 through m n are the sequence of blocks that m is broken into, “+” denotes concatenation, and H V i is that hash function with V i as the IV.
In accordance with embodiments of the invention, the message authentication function is used to process a record and to generate a MAC that is record specific. Although the embodiments disclosed below use a particular MAC function called HMAC, other MAC function variants, such as an NMAC function, may similarly be used. The HMAC of an SSL 3.0 record may be computed as:
HMAC (secret,seq_num,length,content)= H (secret+pad 2 +H (secret+pad 1 +seq_num+length+content)) (2)
where secret represents the MAC secret; seq_num represents the sequence number of the record; content represents the data content of the record; length represents the length of the record content; H( ) is the one-way hashing function; pad 1 represents the byte 0×36 repeated 36 times; pad 2 represents the byte 0×5c repeated 48 times.
In response to the request for an SSL session from the client 104 , the witness 106 may perform an SSL handshake, as previously described, with the server 102 . While performing the SSL handshake, the witness 106 may record the handshake messages, including the X.509 certificate and the cryptographic algorithms chosen for the session, in non-volatile memory or another storage mechanism, such as a hard drive, in the witness 106 . The generated SSL connection 112 may be operated over the TCP connections 108 and 110 and is “proxied” through the client 104 . The proxy forwards all SSL records sent from the witness 106 to the server 102 . In addition, the proxy forwards all SSL records sent from the server 102 to the witness 106 .
As can be seen from Eq. (2) above, the HMAC is a function, at least in part, on the MAC secret and the record contents. The MAC secret is a data key allowing the computation of the HMAC. In accordance with the embodiments of the invention, the client contains the record contents and the witness contains the data key, e.g., the MAC secret. The client is not permitted to have or otherwise determine the MAC secret, and the witness is not permitted access to the record contents. This aspect by which values that are necessary to compute the HMAC are maintained by separate processors is made possible by decomposing the HMAC into separate parts, at least one part of which is computed by the client and at least another part is computed by the witness. As explained more fully below, the decomposition of the HMAC into the various parts results in the MAC secret being relevant only to the parts that the witness is permitted to compute and the record contents being relevant only to the part that the client is permitted to compute.
The computation of the HMAC may be decomposed into three parts, hereafter referred to as “DeHMAC 1 ,” “DeHMAC 2 ,” and “DeHMAC 3 .” The processor 120 of witness 106 may calculate the DeHMAC 1 and the DeHMAC 3 , while the processor 118 of client 104 may calculate the DeHMAC 2 . By decomposing the computation of the HMAC function, the client 104 and the witness 106 each partakes in at least one component of the HMAC calculation. More specifically, the MAC secret associated with an SSL connection may not be revealed to the client 104 . In addition, the data contents of an SSL record may not be revealed to the witness 106 , thereby creating a mutual dependence between the client 106 and the witness 106 for the generation of the HMAC function that may be needed to carry out SSL communications.
In order to facilitate communication between the client 104 and the server 102 , the witness 106 may compute DeHMAC1 as:
DeHMAC 1 =V 1 =H C (secret,pad 1 ) (3)
and send the DeHMAC 1 and the encryption keys, but not the MAC secret, to the client 104 via a secure channel 114 that may operate over the TCP connection 108 . The process of sending the DeHMAC 1 and the encryption keys may be referred to as a “handover.” Once the handover occurs, the client 104 may start to exchange application data with the server 102 . However, the client 104 is dependent upon the witness 106 for computing part of the HMAC before sending any SSL records to the server 102 . Thus, the client 104 may send SSL records directly to the server 102 only after the witness 106 computes part of the HMAC for a particular SSL record. The secure channel 114 that is used for all messages between the client 104 and the server 102 may be implemented by a secure remote procedure call (SRPC), an additional independent SSL session, or another secure mode of communication.
In the second step, the client 104 , receiving DeHMAC 1 from the witness 106 , may compute DeHMAC 2 as:
DeHMAC 2 =H V 1 (seq_num+length+content) (4)
and sends the DeHMAC 2 to the witness 106 .
In the third step, the witness 106 , receiving DeHMAC 2 from the client 104 , may compute DeHMAC 3 , and thus HMAC, as:
DeHMAC 3 =HMAC=H C (secret+pad 2 +DeHMAC 2) (5)
The above decomposition of the HMAC function may apply to hashing functions, such as MD5, that possess a secret that may be contained in the first block to H( ) with the entire pad 1 . For other hashing functions, such as SHA1, part of the pad 1 may be included in Eq. (4) to produce a decomposition of the HMAC function.
Referring now to FIG. 2 , an exemplary block diagram associated with the transmission of an SSL record from the client 104 to the server 102 is shown. The left side of FIG. 2 may represent actions performed by the client 104 , whereas the right side may represent actions performed by the witness 106 . The transmission of the SSL record may start with the witness 106 sending a control (e.g., a handshake or a change-cipher-spec) message (block 202 ) by creating an SSL record (block 204 ) and computing the MAC (block 206 ) associated with the SSL record. If the handover of encryption keys and the DeHMAC 1 to the client 104 has yet to occur, the SSL record is encrypted by the witness 106 (block 208 ), transferred to the client 104 via the secure channel 114 ( FIG. 1 ), and sent to the server 102 (block 210 ). If the handover has occurred, the SSL record generated in block 204 may be sent to the client 104 via the secure channel 114 and encrypted by the client 104 (block 212 ). The record then may be sent to the server 102 (block 210 ). In addition to sending the control messages (block 202 ), the witness 106 may also send alert messages (block 214 ) in a similar manner. Alert messages may inform the server 102 that the SSL session is closing or the SSL session is being invalidated.
The client 104 may send application data (block 216 ) by creating an SSL record (block 218 ), computing the DeHMAC 2 for the SSL record (block 220 ), and sending the computed DeHMAC 2 to the witness 106 . Based on the DeHMAC 2 , the witness 106 may compute the DeHMAC 2 , which represents the HMAC, (block 222 ) and record the MAC associated with the SSL record (block 224 ). The MAC may be then sent to the client 104 , and the client 104 may record the contents of the SSL record (block 226 ) in non-volatile memory or another permanent storage. The SSL record with the MAC attached then may be encrypted by the client 104 (block 212 ) and sent to the sever (block 210 ). Alert messages, in addition to the application data, may also be sent by the client 104 (block 228 ) to inform the server 102 that the SSL session is closing or the SSL session is being invalidated.
Referring now to FIG. 3 , an exemplary block diagram of a communication from the server 102 to the client 104 is shown. The left side of FIG. 3 may represent actions performed by the client 104 , whereas the right side may represent actions performed by the witness 106 . The transmission may start by the client 104 receiving an encrypted SSL record from the server 102 (block 302 ). Before the handover of encryption keys and the DeHMAC 1 , the record may be sent to and decrypted by the witness 106 (block 304 ) and the MAC for the record may be computed (block 306 ). The computed MAC is then verified against the MAC contained in the SSL record (block 308 ). If inconsistencies are found during the verification, the SSL connection is shutdown by the witness 106 (block 320 ). If no inconsistencies are found and the SSL record is expected application data, the record may be incorporated into the application by the client 104 (block 310 ). If no inconsistencies are found but the record is unexpected application data, the SSL record may undergo error handling in the client 104 (block 312 ). If an error is detected during the handling of unexpected application data (block 312 ), the connection is shutdown (block 316 ). If no error is detected during the handling (block 312 ), the client 104 may update a state variable (e.g., next sequence number to receive), if necessary, and receive the next SSL record (block 302 ). If no inconsistencies are found and the SSL record is a control message, the record is handled by the witness 106 (block 318 ). If the handling procedure (block 318 ) determines that an error has occurred, the SSL connection may be shutdown by the witness 106 (block 320 ), an alert message may be sent to the server 102 (block 322 ), and the SSL connection on the client 104 also may be shutdown (block 316 ). If the error handling procedure (block 318 ) determines that no error has occurred, the state of the witness may be updated, if necessary, (block 324 ) and the state of the client 104 also may be updated, if necessary (block 314 ). The client then may receive the next record (block 302 ).
When the client receives an SSL record (block 302 ) after the handover of encryption keys and the DeHMAC 1 , the record may be decrypted by the client 104 (block 326 ). If application data is found in the decrypted record, the DeHMAC 2 may be computed for the received record by the client 104 (block 328 ). The computed DeHMAC 2 then may be sent to the witness 106 where the DeMAC 3 , and thus the HMAC, may be computed (block 330 ) and a MAC generated for the record. The computed MAC may be verified (block 308 ) and the same procedure as discussed above may result from the verification. Although not specifically shown in FIG. 3 , the recording of the MAC by the witness 106 and the recording of the content of the SSL record also may occur, as previously described.
If a control message, such as an alert message, is found during decryption (block 326 ), the record is sent to the witness 106 where the MAC for the record is computed (block 306 ) and the computed MAC may be verified (block 308 ) as previously discussed.
The sending and receiving of SSL records as described in FIGS. 2 and 3 may continue until the application is terminated, at which time the SSL connection on the server 102 , the client 104 , and the witness 106 may be shutdown.
After the SSL session is shutdown without errors, the witness 106 may digitally sign the recorded server 102 certificate, per-connection MAC secrets, MACs and sequence numbers and send the information to the client 104 as the evidence of the SSL communication. In case of failure by the server 102 , the client 104 , or the witness 106 , throughout any phase of the communication, the evidence may not be sent from the witness 106 to the client 104 .
To verify the evidence as authentic, the SSL records recorded by the client 104 may have a one-to-one correspondence with the MACs recorded by the witness 106 . In addition, if each record contents recorded by the client 104 generates the corresponding recorded MAC using the MAC secret recorded by the witness 106 , the communications may be deemed authentic.
The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications. | A method, and associated apparatus, comprises calculating a first part of a message authentication function by a first processor, calculating a second part of the message authentication function by a second processor, and combining the first and second parts into the message authentication function by the first or second processor. The message authentication function can be used to authenticate data transmitted between the first processor and a third processor. | 7 |
FIELD OF THE INVENTION
The present invention relates generally to new processes for making decals, and more particularly to an electrically conductive decal filled with inorganic insulator material, and herein after referred to as electrically conductive decals Various methods and processes that are used to make these electrically conductive decals filled with inorganic dielectric material are disclosed.
CROSS-REFERENCE
This Patent Application is, related to U.S. patent application Ser. No. 07/665,497, entitled "Novel Processes for Electrically Conductive Decals filled with Organic Insulator Material", and U.S. patent application Ser. No. 07/665,631, entitled "Novel Structures for Electrically Conductive Decals filled with Inorganic Insulator Material", and U.S. patent application Ser. No. 07/665,634, entitled "Novel Structures for Electrically Conductive Decals filled with Organic Insulator Material", which were filed concurrently on Mar. 6, 1991, and which are all assigned to the same assignee as this Patent Application, and the disclosure of all of them is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Marketplace considerations have placed significant demands on packaging for increased circuit densities. New packaging concepts have evolved to meet these requirements utilizing processes that approach the levels of device technology.
Several new packaging methods have been developed to address this need, and one of them is the use of decals.
Decal technology initially relied on utilization of an adhesive that served a dual purpose:
1) bonding of the metallurgy foil and finished images to the carrier throughout the entire process, and
2) complete release of polymer and metallurgy at time of transfer to the substrate.
Early decals were produced from a three-part laminate. The process laminate was composed of a metallurgy layer in the form of a thin metal or alloy foil which was bonded to a polymer carrier with an adhesive. The adhesive also served as a release agent permitting separation from the carrier at time of transfer. Reliability of conductor release was assured because the surface energy of the polymer layer was much less than that of either the conductor or the substrate onto which the decal was transferred. See, for example, U.S. Pat. No. 4,879,156. These early solid conductors were generated from a photolithography and etching process.
Early work rapidly revealed a limitation of such decal systems to reliably achieve adequate feature locations. Movement of the images when compared to glass artwork was noticeable, and was found to emanate from absorption and desorption of process fluids. The film carriers in some cases either expanded or contracted depending upon their placement on the absorption isotherm when they were subjected to process ambients.
Having identified the limitations of organic polymers as carriers, work centered upon identification of material that maintained dimensional integrity throughout the process and could be used as a carrier.
The material selected to replace the unstable polymer was a metal foil, which was not subject to absorption of process liquids or deformation when exposed to elevated process temperatures.
Using such a metal foil in the laminate structure, it was rapidly learned that release of metallurgy from the metal foil carrier could not be accomplished uniformly. This was a result of equal bonding of the release adhesive to both metal surfaces, i.e., the metallurgy layer and the metal foil carrier.
To overcome this characteristic, the surface energy of the metal carrier was reduced to a level much less than that of the decal metallurgy and the substrate accepting the decal. Reliable release of the conductor metallurgy from the metal carrier would then be provided. The desired bonding characteristics were achieved by coating the surface of the carrier foil with a material, such as a polyimide, to restore the release properties of the original system. The metal carrier with a two-layer release agent was found to perform as well as the original carrier with respect to conductor transfer providing improved capability for feature locational accuracy.
Utilization of additive processes provides an alternate method for formation of conductors directly on a metal carrier. Use of plating or lift-off processes in conjunction with photolithographic processes allows for conductor generation in an additive manner. This technique provides a means for attaining increased package densities due to the inherent superior image formation capability of additive processes.
A simplified decal structure was developed enabling direct release of conductors from a metal carrier without the use of release agents. This technique was applicable to conductor generation by either additive or subtractive processes, and allowed for wider range of metals and alloys to be utilized as conductors. This has been discussed in U.S. Pat. No. 4,879,156.
Another packaging method is the intaglio printing process. Images are depressed below the surface of the printing plate such that an impression from the design yields an image in relief, as disclosed in U.S. Pat. No. 4,879,156. This technique can be utilized in packaging processes by etching of the conductor pattern into the surface of the metal carrier to a depth equal to the required thickness of the finished metallurgy followed by plating of the required metallurgy to form the conductors. This technique enables generations of conductors formed in a shape defined by the image recessed into the carrier.
There are several other techniques that have been used for packaging interconnection, such as one disclosed in U.S. Pat. No. 3,541,222, where a connector screen for interconnecting adjacent surfaces of boards or modules is disclosed. The connector screen comprises of conducting connector elements that are separated by a web of nonconducting material.
A connector assembly for a circuit board testing machine is disclosed in U.S. Pat. No. 4,707,657. An electrically insulating material having circuit tracks of an electrically conductive material is arranged on opposite side surfaces. The test points are electrically insulated from each other.
A process to form Multilayered Ceramic (MLC) Substrates, having solid metal conductors, is taught in U.S. Pat. No. 4,753,694. The MLC substrate involves, forming a pattern of solid, nonporous conductors to a backing sheet having a release layer, then transferring the pattern to a ceramic green sheet.
U.S. Pat. No. 4,926,549, discloses a method of producing electrical connection members. A carrier is formed on a first electrically conductive member, holes are etched in portions of the carrier to expose the first electrically conductive member and to form recesses therein. The recesses have a diameter larger than the diameter of the corresponding hole. The respective holes formed in the carrier are filled with a second electrically conductive material, and subsequently, the first electrically conductive member is removed from the carrier, thereby, leaving a carrier having a plurality of an electrically conductive material protruding out of the upper and lower surfaces of the carrier. The carrier having the plurality of electrical conducting protrusion can then be used to connect a semiconductor device to a circuit board.
IBM Technical Disclosure Bulletin, Vol. 27, No. 3, pp. 1404-1405 (Aug. 1984) discloses a process for transferring thin-film conductor patterns to a multilayer ceramic substrate. Conductive patterns are formed on a carrier. The conductive patterns are then completely blanketed by an insulator and holes are made in the insulator to expose the upper surface of the conductive pattern. The holes are then filled with an electrically conductive material and after securely attaching this assembly to a multilayer substrate, the carrier is removed.
One of the problems that has arisen in the earlier work is the formation of gaps at the interface between the vias, such as copper vias, and the insulator sidewalls, such as ceramic sidewalls. This kind of gap allows the infiltration and entrapment of fluids, especially during the post-sinter processing. As a remedy for this problem, polyimide backfilling of the gaps has being practiced. This process has its own inherent drawbacks, such as the lack of a good bond between the polyimide and the copper vias, and the difficulty in fully curing the polyimide which has infiltrated the interior of the substrate. These inherent drawbacks cause defects in the thin film redistribution structures which are subsequently deposited on the top surface of the substrate.
The top surface metallization feature sizes are limited by the present processing techniques. Additionally, via gaps are being generated which is leading to a permeation problem in subsequent processing.
This invention provides a TFR (Thin Film Redistribution) decal structure having studs for via registration. This structure is laminated to the MLC substrate, then co-fired, thus providing "hermeticity." The process of this invention does not generate cracks in the substrates, such as in previous top surface processes. Fine line metallization is also achieved. Additionally, ready alignment of the top surface features to vias is achieved.
In this invention a process is also disclosed which does away with the thin film processing on ceramic substrates and utilizes novel etching techniques and decal structures in order to build the equivalent of thin film redistribution (TFR) prior to sintering and which would also survive the sintering cycle.
The decal structure consists of redistribution lines, C4 (Controlled Collapse Chip Connection) pads on top of solid metal studs (acting as electrical interconnects) and EC (Engineering Change) pads. In this process, the only post-sinter processing needed would be to plate Ni and Au with some sort of ball limiting structure for the C4's.
This invention also focuses upon the effort to establish solid conductors that are transferable to substrates as a viable packaging approach.
This invention also describes several unique processing methods associated with the fabrication of solid transferable electrical conductors.
OBJECTS AND SUMMARY OF THE INVENTION
The invention is a novel method for making electrically conductive decals without impacting the structural integrity of the package, or the functionality of the device or devices.
One object of this invention is to make an improved electrically conductive decal.
Another object of this invention is to make an improved electrically conductive decal that has electrical lines, studs, stud caps, C4 pads, EC pads, and the like.
Still another object of this invention is to make a plurality of electrically conductive decals that can be stacked and joined to one another.
Another object is to make an electrically conductive decal that can be secured to a substrate.
Another object of this invention is to provide a hermetically sealed package, once the electrically conductive decal of this invention is secured to a substrate or a module.
Still another object of this invention is to provide an insulating layer with electrical interconnects.
Yet another object of this invention is to provide an electrically conductive decal that can be tested for electrical continuity or structural integrity after the decal has gone through the sintering cycle.
In one aspect this invention comprises, a process for making an electrical connection member, comprising the steps of:
a) forming an electrically conductive substrate comprising a first electrically conductive material and a second electrically conductive material, wherein the first material and the second material sandwich at least a third electrically conductive material therebetween, and wherein the material for the third electrically conductive material is different than the material for the first and second electrically conductive materials,
b) patterning and etching the first electrically conductive material to expose at least a portion of the third electrically conductive material and to form at least one first island of the first electrically conductive material,
c) securing a backing material to the at least one first island,
d) patterning and etching the second electrically conductive material to expose at least a portion of the third electrically conductive material and to form at least one second island of the second electrically conductive material, wherein the at least one second island is opposite the at least one first island,
e) removing the exposed third electrically conductive material,
f) filling the area created by the removal of the exposed third electrically conductive material with an inorganic insulator material, such that at least a portion of the at least one second island is surrounded by the inorganic insulator material, and thereby forming the electrical connection member.
In another aspect, this invention comprises a process for making a multilayered sintered package comprising the steps of:
a) forming an electrically conductive substrate comprising a first electrically conductive material and a second electrically conductive material, wherein the first material and the second material sandwich at least a third electrically conductive material therebetween, and wherein the material for the third electrically conductive material is different than the material for the first and second electrically conductive materials,
b) patterning and etching the first electrically conductive material to expose at least a portion of the third electrically conductive material and to form at least one first island of the first electrically conductive material,
c) securing a backing material to the at least one first island,
d) patterning and etching the second electrically conductive material to expose at least a portion of the third electrically conductive material and to form at least one second island of the second electrically conductive material, wherein the at least one second island is opposite the at least one first island,
e) filling the area created by the removal of the second electrically conductive material with an inorganic insulator material, such that at least a portion of the at least one second island is surrounded by the inorganic insulator material,
f) joining at least a portion of the at least one second island to an electrically conductive member to form a multilayered package,
g) removing the backing material, and
h) sintering the multilayered package until the exposed third electrically conductive material changes into a non-electrically conducting oxide material, and thereby forms the multilayered sintered package.
In yet another aspect, this invention comprises a process for making an electrical connection member, comprising the steps of:
a) forming an electrically conductive substrate comprising a first electrically conductive material and a second electrically conductive material, wherein the first material and the second material sandwich at least a third electrically conductive material therebetween, and wherein the material for the third electrically conductive material is different than the material for the first and second electrically conductive materials,
b) patterning and etching the first electrically conductive material to expose at least a portion of the third electrically conductive material and to form at least one first island of the first electrically conductive material,
c) securing a backing material to the at least one first island,
d) patterning and etching the second electrically conductive material to expose at least a portion of the third electrically conductive material and to form at least one second island of the second electrically conductive material, wherein the at least one second island is opposite the at least one first island,
e) removing the exposed third electrically material to form a third island which is cladded by the at least first island and the at least one second island,
f) filling the area around the first island, the third island, and the second island with an inorganic insulator material, such that at least a portion of the at least one first island and the at least one second island is surrounded by the inorganic insulator material, and thereby forming the electrical connection member.
In still another aspect, this invention comprises a process for making a sintered multilayered device, comprising the steps of:
a) forming an electrically conductive substrate comprising a first electrically conductive material and a second electrically conductive material, wherein the first material and the second material sandwich at least a third electrically conductive material therebetween, and wherein the material for the third electrically conductive material is different than the material for the first and second electrically conductive materials,
b) applying a photoresist on the first and the second electrically conductive material and patterning the photoresist,
c) etching the first electrically conductive material through the patterned photoresist to expose at least a portion of the third electrically conductive material and to form a plurality of first islands from the first electrically conductive material,
d) removing the photoresist from the surface of the first islands,
e) applying a blanket layer of an adhesive over the first islands,
f) adhering a backing material to at least one of the first islands by means of the adhesive,
g) etching the second electrically conductive material through the patterned photoresist to expose at least a portion of the third electrically conductive material and to form a plurality of second islands from the second electrically conductive material, wherein at least one of the second islands is opposite at least one of the first islands,
h) removing the photoresist from the surface of the second islands,
i) removing the exposed third electrically conductive material,
j) filling at least the area created by the removal of the exposed third electrically conductive material with an inorganic insulator material such that at least a portion of one of the second islands is surrounded by the inorganic insulator material,
k) joining at least a portion of one of the second islands to an electrically conductive member to form a multilayered package,
l) removing the backing material and sintering the multilayered package, to form the sintered multilayered device.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:
FIG. 1, illustrates a decal base having an electrically conductive etch-stop layer.
FIG. 2, illustrates the decal base having a resist pattern on both surfaces.
FIG. 3, illustrates the partial etching of the decal base to expose the etch-stop layer on the thin electrical conductor side.
FIG. 4, illustrates the removal of the resist from the upper surface of the thin electrical conductor.
FIG. 5, illustrates the application of an adhesive release agent on the upper surface of the partially etched decal base.
FIG. 6, illustrates the securing of a carrier to the adhesive release agent on the partially etched decal base.
FIG. 7, illustrates the complete etching of the thick electrical conductor side of the decal base.
FIG. 8, illustrates the removal of the photoresist from the surface of the thick electrical conductor.
FIG. 9, shows the etching away of the exposed etch-stop layer.
FIG. 10, illustrates the filling of the area between the thick electrical conductors of the decal base with an inorganic dielectric material.
FIG. 11, illustrates the joining of the decal to a substrate or another layer.
FIG. 12, shows the further processing of the decal of this invention.
FIG. 13, illustrates another embodiment of the completed electrically conductive decal of this invention.
FIG. 14, illustrates the joining of an embodiment of the completed electrically conductive decal of this invention to a pair of electrical devices.
DETAILED DESCRIPTION OF THE INVENTION
This invention describes the structure and various methods of making electrically conductive decals.
The solid circuit patterns discussed in this patent application are referred to as decals, which are defined as pictures, designs or labels printed on specially prepared material to be transferred to another material. These electrically conductive decals will also be referred to as electrical connection members.
Conductive decals are patterns generated in a metallurgy system on a carrier having surface characteristics permitting release of the conductors from the carrier onto a suitable substrate or dielectric, such as a multilayered ceramic (MLC) package. Following pattern transfer, a permanent bond is achieved through controlled sintering of the inorganic substrate, such as a ceramic substrate.
This invention allows the formation of individual decals that can be fabricated for single or several layers of the multilayered ceramic (MLC) package and have been considered as an alternative to thick film conductors in the MLC module.
Another significant advantage of this technique is improvement in fine line capabilities. With this technique, conductors can be reduced in size and an increase in wiring density can be achieved. This technique is capable of providing conductors closer in resolution to that of the underlying artwork. The outcome of this capability is improved potential for increased circuit densities.
Some other advantages of the present invention are:
a) Self-aligned electrical connection member where the metallurgy on both sides of the etch-stop material are aligned and set and will not move.
b) Novel decal structure with built-in etch barrier in order to define stud caps, studs and fine lines by etching.
c) Via caps hermetically seal the substrate so as to prevent the infiltration of fluids during post-sinter process.
d) No post-sinter planarization is necessary.
e) No polyimide backfill is necessary in order to seal vias in glass-ceramic substrates.
f) Pattern-registration to remainder of substrate is made easier due to sprayed sheet, as decal studs only have to capture the bottom vias by 50 percent of stud area, as there are no circuit lines to interface at this surface of the decal.
g) The double-sided photolithography exposure step, insures alignment of studs to TFR pattern.
FIG. 1, illustrates a tri-metallic structure referred to as a work piece or a decal base 5. The decal base 5, is a three metal layer sandwich with the middle layer being an etch barrier or an etch-stop layer 11, surrounded by two electrically conductive metal layers 13 and 15. The etch barrier or etch-stop layer 11, is an electrically conductive material, and it is any material that will allow the preferential etching of the other two metal layers 13 and 15, that are cladding or sandwiching the etch-stop or the third layer 11. The purpose of the etch barrier 11, will be described later in this section. The etch-stop layer 11, should be of sufficient thickness to prevent the permeation of undesirable etchants. Suitable materials for the etch-stop layer are materials that are selected from a group comprising aluminum, chromium, copper, gold, molybdenum, nickel, palladium, platinum, silver, titanium, tungsten or alloys thereof.
The two outside layers of electrically conductive material 13 and 15, may be of the same or different material, depending on the end result that is desired. Suitable materials for the electrically conductive metal layer 13 and 15, are materials that are selected from a group comprising aluminum, copper, gold, iron, molybdenum, nickel, tungsten or alloys thereof. Similarly, the two outside layers 13 and 15, may be of the same or different thickness, again this would depend on how these layers are going to be utilized in the end package. For the purposes of illustration only it is being shown that the metal layer 15, is of a thin material, and the metal layer 13, is of a thicker material, but any variation in the top to bottom thickness can be used to achieve the desired decal profile.
The workpiece or the decal base 5, as seen in FIG. 1, can be made by a number of conventional methods, such as, cladding, coating, evaporation, plating, sputtering, or any other suitable method. The combination of any of these processes may also be employed to build the decal base 5. Any of these methods can further be used to obtain the required conductor thickness. One layer of the decal base 5, could be used as the starting layer (or carrier) so that the other two layers could be formed onto it. Also the etch barrier 11, could be used as the starting point and the outside layers 13 and 15, may be formed simultaneously or sequentially to it. This decal base 5, will provide dimensionally stable structures throughout the process.
FIG. 2, illustrates the decal base 5, having a resist pattern on both surfaces. Once the decal base 5, has been completed, photoresist 17 and 19, is applied to the exposed surfaces of the electrically conductive material 13 and 15. This application of the photoresist 17 and 19, can be done by either a wet or a dry process, for example, by dipping, electrophoresis, lamination, rollercoating, spinning, spraying, or any combination of these processes. The photoresist 17 and 19, may be a negative or positive photoresist depending on photomask used and the end result that is desired.
Two photomasks having desired patterns are aligned to each other and then the decal base 5, having the photoresists 17, and 19, is placed between the aligned photomasks, and the photoresists 17 and 19, are exposed. The photomask may consist of a circuit pattern, or a through-via pattern, or a combination of both, or other electrical features, such as studs and caps. The photoresists 17 and 19, may be exposed simultaneously or sequentially. It is preferred to expose both sides of the decal base 5, at the same time to assure alignment. Similarly, the two sides can be developed simultaneously or sequentially depending on the photoresist combination. The photoresist is developed by any suitable technique, such as, dipping, spraying, etc. The photoresist remaining after developing will define the final images of the circuit pattern and/or studs and caps. As seen in FIG. 2, the photoresist patterns 17, and 19, have holes or open areas 16, and 18, respectively, from where the electrically conductive materials 15 and 13, will be removed during subsequent processing.
FIG. 3, illustrates the partial etching of the decal base 5. The exposed electrically conductive materials 13 and 15, in the imaged decal base 5, is removed by conventional etching processes such as electrolytic, chemical, or dry etching. By using dissimilar metals or metals of varying thicknesses as the electrically conductive materials 13 and 15, the etch-stop layer 11, will be exposed on one side after the partial etch. This is usually the thinner electrically conductive metal side which can contain the circuit patterns and the caps or it is the electrically conductive metal side that is being etched first. The side opposite the side where the etch-stop 11, is exposed is either partially etched through or etched all the way to the etch-stop layer 11. This depends upon the ratio of thicknesses of the two outside electrically conductive layers. The etch-stop layer 11, allows the two outside layers to be processed individually or at the same time. This has the benefit of allowing one to produce patterns of varying densities on the two sides or improve aspect ratio (ratio of image size to thickness) of the image. The first etching of the electrically conductive materials 13 and 15, is stopped when the upper side is etched through the openings 16, and after the etch-stop layer 11, is exposed. This forms openings 21, that define the caps 12, and circuit lines 14. This etched metallurgy is also referred to as islands. The etching material or process that is used should be a suitable etching material or process so as to attack only the desired material and features. As can be seen in FIG. 3, which shows on the upper side of the decal base 5, the defined circuit lines 14, and stud caps 12. The etching of the thin electrically conductive metal layer 15, should continue until there is no material electrically connecting the caps 12, and the circuit lines 14, to each other except through the electrically conductive etch barrier 11. Because simultaneous etching was used, the lower side of the decal base 5, has been exposed to only define openings 23.
FIG. 4, illustrates the removal of the resist 17, from the upper surface of the decal base 5. The photoresist 17, is removed from the upper side by any suitable stripping technique. Again, care should be taken to use a suitable stripping process to attack only the photoresist 17, and not to damage or remove photoresist images 19.
FIG. 5, illustrates the application of an adhesive release agent 25, on the upper surface of the partially etched decal base 5. The upper side could be sprayed with a suitable adhesive release agent 25, such as PMMA (polymethylmethacrylate). The adhesive release agent 25, is applied on the upper surface of the etched decal base 5, using rollercoating, spinning, or spraying techniques, to name a few. The adhesive release agent 25, will conform to the etched surface, such as filling the openings 21, and forming openings 27.
FIG. 6, illustrates the securing of a backing material or a carrier 29, to the adhesive release agent 25, of the partially etched decal base 5. The carrier 29, can be any suitable polymer or metal, as long as it will adhere to the adhesive release agent 25. For example, if a polymer is used as the carrier 29, then a polyester or a polyimide material could be used as the carrier 29. On the other hand, if a metal is used as the carrier 29, then the carrier 29, should be coated with a polymer, such as polyimide, on one or both sides or at least the surface that will contact the adhesive release agent 25, that is already on the decal base, to insure release of the carrier 29, from the decal base 5, during subsequent processing.
A suitable material for a metal carrier 29, is copper. The primary function of the adhesive release agent or layer 25, is to hold the carrier 29, to the partially etched decal base 5, and to allow the carrier 29, to be removed from the decal base 5, in subsequent processing. The carrier 29, serves two purposes, the first is as a mechanical support for the etched decal base 5, and secondly as an etch barrier for one side of the decal base 5, allowing the opposite side of the decal base 5, to be processed further. The only time the carrier 29, is needed as an etch barrier is when similar metals are being used as the electrically conductive metals 13 and 15. The carrier 29, can be secured to the etched workpiece or decal base 5, on the side that the adhesive release agent 25, is on by any suitable means, such as lamination, heat or pressure, etc.
The complete etching of the lower surface of the decal base 5, is now illustrated in FIG. 7. With the photoresist 19, and the carrier 29, protecting the desired images, the decal base 5, is now etched a second time until the bottom surface of the etch-stop layer 11, is exposed. This second etching step creates the openings 33, and forms the studs or interconnections 31. This etched metallurgy is also referred to as islands. This etching of the lower side of the decal base 5, can be done by conventional means, such as, chemical, electrolytic or dry etching.
FIG. 8, illustrates the removal of the photoresist 19, from the decal base 5. This is typically accomplished by wet techniques, such as re-expose and develop or chemical strip, or by dry techniques, such as RIE or ashing.
FIG. 9, shows the final etching of the decal base 5, by etching away the exposed etch-stop layer 11, to form the etch-stop interconnection or island 32, which are also referred to as an electrically conductive island. In some cases the etch-stop material 11, may not have to be removed from the decal base 5, as discussed later in this section. If the etch-stop layer 11, has to be removed, then this can be accomplished by chemical, electrolytic or dry etching. The etch-stop interconnection 32, electrically connects the stud caps 12, to the studs 31. This etching also expands the openings 33, to form openings 35. The removal of the etch-stop layer 11, isolates all the formed electrical interconnects, thus preventing shorting of the via studs 31, and the circuit lines 14.
In some cases the exposed etch-stop material 11, may not have to be removed from the decal base 5, as shown by the dashed line 36, in FIG. 9. This would depend upon what subsequently happens to the exposed etch-stop material 11. For example, certain etch-stop materials interact with the insulator material to form nonconducting oxides during the sintering process and thereby act as an insulator. A good example of this is the use of chromium as an etch-stop material 11, as during the sintering process the exposed etch-stop material would form oxides of chromium, which is an insulator.
FIG. 10, illustrates the filling of the openings 35, in the fully etched decal base 5, with a slurry of an inorganic insulator material 39. The inorganic insulator material 39, must completely surround the etch-stop interconnection or island 32, and should surround at least a portion of either the stud cap 12, or the stud 31, or both, to prevent electrical shorting between neighboring electrical members. The inorganic insulator or dielectric material 39, is normally selected from a group comprising aluminum oxide or ceramic or glass ceramic material. This filling of the openings 35, can be done by rollercoating, spraying, spinning, etc. The thickness of the dielectric material 39, should be no more than the height of the studs 31. During spraying, the slurry is deposited such that it will flow off the top of the studs and "self-clean." The inorganic contamination on the top surface 41, of the via studs 31, will be minimal. The end 41, of the via studs 31, may protrude above the surface 42, of the dielectric or insulator material 39, or it may remain flushed with the surface 42, of the dielectric material 39. This can be accomplished by proper coating techniques, planarization, or by dry etching process.
As discussed earlier, the exposed etch-stop layer 11, does not have to be removed. If the etch-stop layer 11, is left on the pattern, it should be of a material where the exposed etch-stop layer 11, will form a non-electrically conducting oxide during the sintering process. The unexposed etch-stop layer 11, or the etch-stop layer 11, that is between the caps 12, and the studs 31, will form electrically conducting islands, similar to the etch-stop interconnection 32. This is due to the fact that the electrically conducting material for the cap 12, and the stud 31, will diffuse into the etch-stop layer 11, at the interface boundary to form an electrical connection. This left-over etch-stop layer 11, when converted to the oxide, also happens to promote adhesion between the etched metal caps 12, and circuit lines 14, and the insulator material 39, such as a ceramic dielectric material.
A finished decal where the exposed etch-stop layer 11, had been removed, and which is ready to be transferred to the desired substrate is shown in FIG. 10. This completed decal is now ready to be transferred onto an unfired inorganic substrate, such as a ceramic substrate, and the finished structure will provide the metallurgy and interconnection needed for the substrate.
FIG. 11, illustrates the joining of the decal as shown in FIG. 10, to a substrate 45, or another layer 45. The electrically conductive decal or the electrical connection member can be stacked or joined to an unfired inorganic substrate or to another electrically conductive decal and then laminated and sintered. The decal image or features are aligned to images or features of the substrate 45 or the next layer 45, and then joined by applying heat and/or pressure. This electrically conductive decal must be joined to an unfired inorganic layer or substrate 45. The carrier 29, is removed by peeling it off from the decal after the dielectric 39, is joined to the dielectric 43, of the layer or substrate 45, but prior to the sintering cycle. The adhesive release agent 25, that remains on the decal after the carrier 29, has been peeled or removed will be burned-off during the sintering process thus creating surface 52. During this joining process, the stud connection 44, of the layer or substrate 45, bonds with the ends 41, of the decal stud 31, and fuse into each other during the sintering process. After the decal has gone through the sintering cycle, it can be easily tested for electrical continuity or structural integrity to reduce defects in the final product.
FIG. 12, shows the further processing of the electrically conductive decal of this invention. The structure of FIG. 11, which has the decal joined to the layer or substrate 45, is then joined to either another structure 55, fabricated in the same fashion or a stack of layers 55, that are unsintered. If the dielectric in the structure 55, is an inorganic material, such as a ceramic, then the structure 55, must be joined to the unsintered structure of the FIG. 11, and then after this joining, the whole stack is then sintered. During the sintering process the stud connections 51, fuse into the stud caps 12, and the dielectric 59, adheres to the dielectric 39, at the boundary 52. A typical pattern would also include circuit lines 54. If the dielectric in the structure 55, is an organic material, such as a polymer, then the structure 55, must be attached to the fired structure fabricated in FIG. 11. This attachment would be done by a heat and pressure lamination process, where the stud connection 51, would bond to the stud caps 12, and the insulator 59, would adhere to the dielectric 39, at the boundary 52. As shown in FIG. 12, the substrate 55, could also include circuit lines 54.
FIG. 13, illustrates another embodiment of the completed electrically conductive decal or electrical connection member of this invention. The process described earlier concentrated on an electrically conductive decal in which the two electrically conductive metal layers 13 and 15, were not of equal thickness, i.e., one side was thin for circuit patterns 14 and stud caps 12, and the other side was thick for through-via studs 31. As stated earlier that the process of this invention can also be used in situations where the two electrically conductive metal layers 13 and 15, are of equal thickness. The process steps are basically the same as outlined in the preceding paragraphs, the only difference is in the end use of the product. The product could be used as a through-via layer with via studs only, as there would be no circuit patterns on either side of the finished product. As shown in FIG. 13, the dielectric 39, isolates the studs 61, from each other. The studs 31 and 61, may or may not be of the same material and may or may not be of the same height or thickness. The cross-section of a finished unfired electrically conductive decal in which both outside metal layers are of equal thickness is shown in FIG. 13. This product can now be used as a typical interconnection layer to join an unfired circuit pattern to an unfired inorganic substrate or an unfired inorganic substrate to another unfired inorganic substrate. After all the joining, the complete package is sintered to form the final product.
FIG. 14, illustrates the joining of an embodiment of the completed electrical connection member of this invention to a pair of substrates or electrical devices 65 and 75. The substrates 65 and 75, may have stud connections 62 and 72, respectively. Similarly, the substrate 65, may also have circuit lines 64, or the substrate 75, may have circuit lines (not shown). During the joining process the dielectric 39, adheres to the dielectric 69, at the surface 52, and to the dielectric 79, at the surface 42. The completed piece can now be used to connect two circuit layers together, or an unsintered substrate and a circuit layer together, or two unsintered layers together, each on the opposite side of this completed piece.
While the present invention has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention. | The present invention relates generally to new processes for making decals, and more particularly to electrically conductive decals filled with inorganic insulator material. Various methods and processes that are used to make these electrically conductive decals filled with inorganic dielectric material are disclosed. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to tape drives and, more particularly, to flanged tape guides that have an irregular surface to reduce the air bearing between the tape and the surface of the hub.
BACKGROUND OF THE INVENTION
[0002] Information is recorded on and read from a moving magnetic tape with a magnetic read/write head positioned next to the tape. The magnetic “head” may be a single head or, as is common, a series of read/write head elements stacked individually and/or in pairs within the head unit. Data is recorded in tracks on the tape by moving the tape lengthwise past the head. The head elements are selectively activated by electric currents representing the information to be recorded on the tape. The information is read from the tape by moving the tape longitudinally past the head elements so that magnetic flux patterns on the tape create electric signals in the head elements. These signals represent the information stored on the tape.
[0003] Data is recorded on and read from each of the parallel tracks on the tape by positioning the head elements at different locations across the tape. That is, head elements are moved from track to track as necessary to either record or read the desired information. Movement of the magnetic head is controlled by an actuator operatively coupled to some type of servo control circuitry. Tape drive head positioning actuators often include a lead screw driven by a stepper motor, a voice coil motor, or a combination of both. The carriage that supports the head is driven by the actuator along a path perpendicular to the direction the tape travels. The head elements are positioned as close to the center of a track as possible based upon the servo information recorded on the tape.
[0004] FIG. 1 illustrates generally the configuration of a tape drive 10 typical of those used with single spool tape cartridges. Referring to FIG. 1 , a magnetic tape 12 is wound on a single supply spool 14 in tape cartridge 16 . Tape cartridge 16 is inserted into tape drive 10 for read and write operations. Tape 12 passes around a first tape guide 18 , over a magnetic read/write head 20 , around a second tape guide 22 to a take up spool 24 . Head 20 is mounted to a carriage and actuator assembly 26 that positions head 20 over the desired track or tracks on tape 12 . Head 20 engages tape 12 as tape 12 moves across the face of head 20 to record data on tape 12 and to read data from tape 12 . Referring to FIGS. 2 and 3 , roller guide 28 includes disc shaped flanges 30 and an annular hub 32 . Flanges 30 and hub 32 may be machined as a single integral part or as three separate parts bonded together. In either case, flanges 30 function to keep tape 12 at the proper angle as it passes across head 20 . If the tape is presented to the head at too great an angle, then the read and write elements in the head may be misaligned to the data tracks. Flanges 30 are also needed to help keep tape 12 properly packed on take up spool 24 .
[0005] As the tape is pulled over the guides, a film of air is created between the outside surface 34 of hub 32 and tape 12 . This film is often referred to as an air bearing. The air bearing allows the tape to move with low friction very rapidly back and forth between flanges 30 . Consequently, high frequency tape movement can occur when the edge of the tape bumps abruptly against flanges 30 . Read/write head positioning systems have difficulty following such high frequency tape movement. It would be desirable to reduce this air bearing and thereby increase the friction between the tape and the hub to slow the movement of the tape back and forth between the flanges. Slowing the tape in this manner would allow the head positioning system to better follow the tape as it wanders back and forth between the guide flanges.
[0006] One technique that has been used to reduce the air bearing is creating an irregular topography on the surface of the hub. This technique is described in U.S. patent application Ser. No. 09/597,882. In one version of this technique, described in the '882 application, a series of comparatively deep grooves are formed in the surface of the hub to reduce the air bearing. In another version, comparatively high raised areas are formed on the surface of the hub. It has been discovered that these surface topographies can leave imprints on the tape which may, under some conditions, distort or otherwise damage the tape.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a tape guide that has a textured roughness exceeding the flying height of the tape above the surface. This new irregular surface topography reduces the air bearing and allows limited contact between the tape guide and the tape while minimizing tape distortion that can occur with other surface topographies.
[0008] Surface texture is the repetitive or random deviation from the nominal surface that forms the three dimensional topography of the surface. Surface texture includes roughness, waviness, lay and flaws as those terms are defined in the American National Standard ANSI/ASME B46.1-1985 which is incorporated herein by reference. Surface roughness consists of the finer irregularities of the surface texture. Surface roughness, for purposes of this Specification and Claims, is measured and quantified by the Roughness Average R a defined in section 3.9.1 of ANSI/ASME B46.1-1985.
DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a top down plan view of a single spool tape drive.
[0010] FIGS. 2 and 3 are elevation and plan views of a conventional roller tape guide.
[0011] FIG. 4 is an elevation view of a roller tape guide constructed according to one embodiment of the present invention in which a circumferential texture is applied to the surface of the hub.
[0012] FIG. 5 is a detail view of a portion of the roller guide of FIG. 4 showing the texture in more detail.
[0013] FIG. 6 is an elevation view of a roller tape guide constructed according to another embodiment in which a cross hatched texture is applied to the surface of the hub.
[0014] FIG. 7 is a detail view of a portion of the roller guide of FIG. 6 showing the texture in more detail.
[0015] FIG. 8 is an elevation view of a roller tape guide constructed according to another embodiment in which a sputter texture is applied to the surface of the hub.
[0016] FIG. 9 is a detail view of a portion of the roller guide of FIG. 8 showing the texture in more detail.
[0017] FIG. 10 is an elevation view of a roller tape guide constructed according to another embodiment in which a laser texture is applied to the surface of the hub.
[0018] FIG. 11 is a detail view of a portion of the roller guide of FIG. 10 showing the texture in more detail.
[0019] FIG. 12 is an elevation view of a roller tape guide constructed according to another embodiment in which a machined texture is applied to the surface of the hub.
[0020] FIG. 13 is a detail view of a portion of the roller guide of FIG. 12 showing the texture in more detail.
DETAILED DESCRIPTION OF THE INVENTION
[0021] As noted above, FIG. 1 illustrates generally the configuration of a tape drive 10 typical of those used with single spool tape cartridges. Referring again to FIG. 1 , a magnetic tape 12 is wound on a single supply spool 14 in tape cartridge 16 . Tape cartridge 16 is inserted into tape drive 10 for read and write operations. Tape 12 passes around a first tape guide 18 , over a magnetic read/write head 20 , around a second tape guide 22 to a take up spool 24 . Head 20 is mounted to a carriage and actuator assembly 26 that positions head 20 over the desired track or tracks on tape 12 . Head 20 engages tape 12 as tape 12 moves across the face of head 20 to record data on tape 12 and to read data from tape 12 .
[0022] A tape guide constructed according to one embodiment of the present invention is shown in FIGS. 4-5 . Referring to FIGS. 4-5 , each roller guide 38 includes disc shaped flanges 40 and an annular hub 42 . Tape 12 rides on the outer surface 44 of hub 42 . Each flange 40 extends radially past outer surface 44 of hub 42 . When roller guide 38 is installed in tape drive 10 , for example as guides 18 and 22 in FIG. 1 , hub 40 rotates on a fixed pin or axle that extends from the tape drive chassis or other suitable support through the center of hub 40 . Ball bearings or like are preferred to reduce friction and minimize wear between hub 40 and the pin or axle on which it turns. Flanges 40 and hub 42 may be machined as a single integral part or as separate parts bonded together
[0023] A circumferential texture 46 is applied to the outer surface 44 of hub 42 to bleed air from between tape 12 and hub surface 44 . Circumferential texture 46 includes a series of shallow grooves or scratches similar to that achieved by placing sand paper with the desired grit size against a turning roller with no lateral motion.
[0024] In an alternative embodiment shown in FIGS. 6-7 , a cross hatched texture 48 is used. Cross hatched texture 48 includes an array of crossing scratches similar to that achieved by moving sand paper back and forth over a slowly turning roller. In the embodiment shown in FIGS. 8-9 , a sputter texture 50 is applied to hub surface 44 . Sputter texture 50 includes an array of small bumps similar to that achieved by sputter depositing a texture material on to the guide. In FIGS. 10-11 , a laser texture 52 is applied to hub surface 44 . Laser texture 52 includes an array of surface irregularities produced by melting and recrystallizing tiny areas on hub surface 44 similar to that achieved with techniques used to produce laser textured recording disks. In FIGS. 12-13 , a machined texture 54 is applied to hub surface 44 . Machined texture 54 includes a series of ridges or knobs similar to a knurled surface formed at the correct scale to match the desired surface roughness.
[0025] In each of the above described embodiments, the surface texture is designed to allow some contact of the tape with the guide by reducing the air bearing. A texture with a surface roughness exceeding the expected flying height of tape 16 above hub surface 44 is necessary to allow some tape to guide contact. For example, for ½ inch type data storage tapes that have a nominal tape width of 12.65 mm moving at about 4.1 m/s with 1N tension, the tape “flies” on an air bearing about 1.3 microns above the surface of the hub. Hence, for this type of tape and operating configuration, the surface roughness of texture 46 - 54 should be at least 1.3 microns. Although the roughness may be varied as necessary to allow optimum tape to guide contact to achieve the desired damping of lateral movement of the tape, it is expected that textures having a surface roughness of 1-3 microns will have an effect similar to the grooved surface described in the '882 application but without any significant risk of distorting the tape.
[0026] While the invention has been shown and described with reference to the surface textures shown in FIGS. 4-13 , other suitable textures may be possible. It should be understood, therefore, that variations of and modifications to the textures shown and described may be made without departing from the spirit and scope of the invention which is defined in following claims. | A tape guide that has textured surface over which the tape passes. The textured surface has a surface roughness exceeding the flying height of the tape above the surface. This new irregular surface topography reduces the air bearing and allows limited contact between the tape guide and the tape while minimizing tape distortion that can occur with other surface topographies. | 6 |
REFERENCE TO PRIORITY APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 62/190,701, filed Jul. 9, 2015, entitled “Telemedicine And Mobile Health With Human Touch,” U.S. Provisional Application No. 62/190,695, filed Jul. 9, 2015, entitled “Fault Tolerant Identification Check Using Redundant Sensors And Information,” and U.S. Provisional Application No. 62/190,651, filed Jul. 9, 2015, entitled “Advance Radiology Package Containing Pictures Of A Body,” each of which is incorporated herein by reference in its entirety.
FIELD OF THE DISCLOSURE
[0002] The subject matter disclosed herein relates to the field of telemedicine and more particularly relates to a patient and mobile healthcare worker initiated encounter in a telemedicine system.
BACKGROUND OF THE INVENTION
[0003] The conventional US healthcare system is considered by some as inefficient, inconvenient, and often fails to ensure good outcomes to treatment. Typical “fee-for-service” payment models give hospitals and physicians little financial incentive to reduce utilization of healthcare services, and often pay more for low-quality care that is ineffective than for higher-quality or other care that is more effective and can provide a good outcome to treatment. Recent Medicare reports indicate that as few as 5% of Medicare patients drive 40% of Medicare cost, and then next 15% of patients drive the next 40% of Medicare cost. The traditional face-to-face physician office visit is part of the problem due to several reasons.
[0004] One reason is poor care coordination. Patients who are discharged from the hospital or acute nursing facilities have significant confusion about their medications, as they are usually started on new medications, or have dose adjustments to their existing medications and are not provided with adequate information as to the use of these medications. This leads to lack in medication compliance and confusion further exacerbating the complexity of care of these patients. For example, patients taking cardiac medication to control blood pressure may not be informed of recommended changes to their lifestyle such as sitting before standing after laying for an extended period of time to equalize blood pressure and prevent a response which may require further hospitalization and increase costs.
[0005] A second reason is lack of timely health metrics. Intermittent office visits by patients which chronic medical conditions does not provide their physicians any visibility into the day-to-day status of their patients. Further, when patients cannot easily see their physicians, and physicians have no way of knowing the day-to-day condition of their patients, non-acute medical problems can quickly exacerbate, leading to an emergency visit and possible admission to the hospital.
[0006] A third reason is lack of access. It is often difficult for sick patients who need urgent services to coordinate schedules with their physicians, thus leading to increased utilization of emergency services.
[0007] For these and other reasons, global telemedicine (or telehealth) markets are projected to grow at a compound annual growth rate (CAGR) of slightly over 14% from $14 billion in 2014 to $35 billion by 2020. Recently, interest in telehealth has gained momentum due to its many benefits. For example, telehealth systems are especially useful for treating patients located in remote and inaccessible areas, such as many residents of Alaska, who would normally unable to obtain proper medical care in a reasonable amount of time. The benefits of telehealth systems, however, are not limited to remote areas as telehealth systems can also useful for patients with little spare time such as highly-stressed urban professionals who may skip necessary medical care due to workplace time restraints.
[0008] Unfortunately, conventional telehealth systems are modeled upon conventional healthcare systems and do not readily provide, to clinicians treating these patients such as physicians and the like, information that may be necessary for the proper treatment of these patients. For at least this reason, conventional telehealth systems are limited to certain types of medical fields. Further, conventional telehealth systems leave much to be desired due to, among other things, difficulty logging in, mistaken identity, delays, identity theft, service interruptions, and general user inconvenience. Although there have been attempts to overcome these and other disadvantages, these attempts have not been successful.
[0009] All current telemedicine solutions only allow healthcare providers to communicate with the patients without any human touch, and then base all medical decisions on subjective evaluation and history by the patient without any objective data from the patient or diagnostic tests.
[0010] Accordingly, there is a need for a telemedicine system that overcomes these and other disadvantages of conventional telemedicine systems.
SUMMARY OF THE INVENTION
[0011] The present invention is a telemedicine system including a care coordination software platform that allows for patient monitoring at home and connects patients to their medical teams via telemedicine using a Health Insurance Portability and Accountability Act (HIPAA) compliant video portal that is augmented by remote and assisted physical examination, performance of any diagnostic testing including labs and x-rays, and provision of appropriate treatment and prescriptions.
[0012] Home monitoring allows medical teams to have visibility into patients' chronic diseases and allows intervention before these chronic diseases lead to complications. The telemedicine system provides easy access to healthcare providers for non-emergency conditions thus decreasing emergency room (ER) utilization and improving continuity of care. The system (1) provides medical care in a setting of patient's choice without requiring the patient to travel or spend time in waiting rooms; (2) provides treatment based on objective physical examination data and any appropriate diagnostic testing; and (3) provides validation of identity of the patient.
[0013] Patients with chronic diseases who are at high risk for complications are monitored using hardware that collects bio-data like blood pressure, blood sugar, pulse oximetry, weight, heart rate, etc. This data is analyzed by the software and notifications are generated for the medical team if and when the data points breach any parameters thus allowing the medical team to intervene before an addressable problem becomes an acute condition requiring hospitalization and/or ER visits. Healthcare providers are made available via online video encounters to communicate with patients. Allied healthcare workers are dispatched to be in physical proximity to the patient so they can assist in physical examination, and provide objective data including diagnostics. Providers provide appropriate treatments and prescriptions based on examination findings and diagnostics. A software app implementing the telemedicine system verifies identity of the patient by taking an image of driver's license using OCR technology and comparing it to the picture of the patient at the time of the encounter.
[0014] The telemedicine system can interface with proprietary and non-proprietary devices and collects data via wireless technology (e.g., Bluetooth, Wi-Fi, etc.) without manual input by the patient. The system then analyzes the data values automatically against pre-set parameters that are determined by the patient's provider, and are individualized and customizable. The system sends notifications to the care team if the values are outside the set parameters. Now the provider can have a telemedicine encounter with the patients, and send a healthcare worker to the patient's location to obtain more objective data and even assist the provider with an examination by using remote testing equipment. This allows the provider to treat the patient effectively leading to decreased complications.
[0015] Advantages of the telemedicine system of the present invention include: (1) monitoring patients at home without requiring data input from patient; (2) generating notifications for the healthcare team without requiring centralized monitoring stations with personnel thus improving cost structure of such monitoring; (3) connecting patient via video portal with the medical team; (4) verifying the identity of the patient; (5) allowing human interaction with the patient by having an allied health worker collect objective data like vital signs, assist the healthcare provider with an examination using equipment like stethoscope, otoscope, etc., and performing diagnostic testing like labs and x-rays; and (6) providing an accurate method of diagnosing medical conditions, and providing appropriate medical treatments including any prescriptions.
[0016] There is thus provided in accordance with the invention, a method of facilitating a selection of a healthcare provider by a patient, the method comprising generating a graphical user interface that when rendered on a computing device displays at least an option for the patient to request an encounter with a healthcare provider, receiving, on the computing device, a request for the encounter from the patient, sending the request to a server over the internet, in response to the request, the server placing the patient in a waiting room queue, enabling a healthcare provider to select a patient from a pool of available patients in the waiting room queue and sending a notification thereof to the patient, and establishing an encounter directly between assigned healthcare provider and the corresponding patient.
[0017] There is also provided in accordance with the invention, a method of facilitating a selection of a healthcare provider by a patient, the method comprising generating a graphical user interface that when rendered on a computing device displays at least an option for the patient to request either an immediate or scheduled encounter with a healthcare provider, receiving, on the computing device, a request for the immediate or scheduled encounter from the patient, sending the request for an immediate encounter to a server over the internet, in response to the request for an immediate encounter, the server placing the patient in an immediate waiting room queue, enabling a healthcare provider to select a patient from a pool of available patients in the immediate waiting room queue and sending a notification thereof to the patient, in response to the request for a scheduled encounter, generating a graphical user interface that when rendered on a computing device displays at least an option for the patient to select a healthcare provider of their choice, receiving, on the computing device, the healthcare provider selection from the patient, sending the request for a scheduled encounter to the server over the internet, in response to the healthcare provider selection, the server placing the patient in a scheduled waiting room queue associated with the selected healthcare provider, sending a notification to the assigned healthcare provider and the corresponding patient, and establishing an encounter directly between assigned healthcare provider and the corresponding patient.
[0018] There is further provided in accordance with the invention, a method of facilitating a selection of a healthcare provider by a patient, the method comprising generating a graphical user interface that when rendered on a computing device displays at least an option for the patient to request either an immediate or scheduled encounter with a healthcare provider, receiving, on the computing device, a request for the immediate or scheduled encounter from the patient, in response to the request for a scheduled encounter, generating a graphical user interface that when rendered on a computing device displays at least an option for the patient to select a desired specialty type of healthcare provider, receiving, on the computing device, the specialty type selection from the patient, in response to the specialty type selection, generating a graphical user interface that when rendered on a computing device displays at least an option for the patient to select a healthcare provider having the selected specialty type, receiving, on the computing device, the healthcare provider selection from the patient, sending the request for a scheduled encounter to the server over the internet, in response to the healthcare provider selection, the server placing the patient in a scheduled waiting room queue associated with the selected healthcare provider, sending a notification to the assigned healthcare provider and the corresponding patient; and establishing an encounter directly between assigned healthcare provider and the corresponding patient.
[0019] There is also provided in accordance with the invention, a method of initiating an encounter with a healthcare provider by a mobile healthcare worker, the method comprising generating a graphical user interface that when rendered on a computing device displays at least an option for the healthcare worker to request an immediate encounter with a healthcare provider, receiving, on the computing device, a request for the immediate encounter from the healthcare worker, sending the request for the immediate encounter with a healthcare provider to a server computer over the internet, in response to the request for an immediate encounter, the server computer placing the healthcare worker in an immediate waiting room queue, enabling a healthcare provider to select the healthcare worker from the immediate waiting room queue and sending a notification thereof to the healthcare worker, and establishing an encounter directly between the healthcare provider and the corresponding healthcare worker.
[0020] There is further provided in accordance with the invention, a method of initiating an encounter with a healthcare provider by a mobile healthcare worker, the method comprising generating a graphical user interface that when rendered on a computing device displays at least an option for the healthcare worker to request a scheduled encounter with a healthcare provider, receiving, on the computing device, a request for the scheduled encounter from the healthcare worker, in response to the request for a scheduled encounter, generating a graphical user interface that when rendered on a computing device displays at least an option for the healthcare worker to select a desired specialty type of healthcare provider, receiving, on the computing device, the specialty type selection from the healthcare worker, in response to the specialty type selection, generating a graphical user interface that when rendered on a computing device displays at least an option for the healthcare worker to select a healthcare provider having the selected specialty type, receiving, on the computing device, the healthcare provider selection from the healthcare worker, sending the request for a scheduled encounter to a server computer over the internet, in response to the healthcare provider selection, the server computer placing the healthcare worker in a scheduled waiting room queue associated with the selected healthcare provider, sending a notification to the assigned healthcare provider and the corresponding healthcare worker, and establishing an encounter directly between assigned healthcare provider and the corresponding healthcare worker.
[0021] There is also provided in accordance with the invention, a method of initiating an encounter with a healthcare provider by a mobile healthcare worker, the method comprising generating a graphical user interface that when rendered on a healthcare worker computing device displays at least an option for the patient to request either an immediate or scheduled encounter with a healthcare provider, receiving, on the computing device, a request for the immediate or scheduled encounter from the patient, sending the request for an immediate encounter to a server computer over the internet wherein in response to the request for an immediate encounter, the server computer placing the healthcare worker in an immediate waiting room queue, receiving on the computing device a notification of a selection of healthcare worker made by a healthcare provider from a pool of healthcare workers in the immediate waiting room queue, in response to the request for a scheduled encounter, generating a graphical user interface that when rendered on a computing device displays at least an option for the healthcare worker to create an appointment with a healthcare provider of their choice at a desired date and time, receiving, on the computing device, the healthcare provider selection and desired date and time from the healthcare worker, sending the request for a scheduled encounter to the server computer over the internet wherein in response to the request for a scheduled encounter, the server computer creating an appointment for the healthcare worker at the desired date and time, receiving a notification from the server computer in advance of the appointment that the healthcare worker has been placed in a scheduled waiting room queue associated with the previously selected healthcare provider, and establishing an encounter directly between assigned healthcare provider and the corresponding healthcare worker at the appointed date and time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
[0023] FIG. 1 is a block diagram illustrating an example computer processing system or device adapted to implement the telemedicine system of the present invention;
[0024] FIG. 2 is a block diagram illustrating an example tablet/mobile computing device suitable for use with the telemedicine system of the present invention;
[0025] FIG. 3 is a diagram illustrating an example telemedicine system of the present invention;
[0026] FIG. 4 is a diagram illustrating an example encounter between a healthcare provider and a healthcare worker and patient at a remote patient location;
[0027] FIG. 5 is a diagram illustrating an example encounter between a radiological healthcare worker and a patient at a remote patient location;
[0028] FIG. 6 is a flow diagram illustrating an example identity validation method of the present invention;
[0029] FIGS. 7A, 7B, 7C, and 7D are a flow diagram illustrating an example healthcare provider workflow method of the present invention;
[0030] FIG. 8 is a diagram illustrating an example mobile device screenshot of a healthcare provider main landing screen;
[0031] FIGS. 9A, 9B, 9C, and 9D are a flow diagram illustrating an example healthcare worker workflow method of the present invention;
[0032] FIG. 10 is a diagram illustrating an example mobile device screenshot of a healthcare worker main landing screen;
[0033] FIGS. 11A, 11B, 11C, 11D, 11E, and 11F are a flow diagram illustrating an example patient workflow method of the present invention;
[0034] FIG. 12 is a diagram illustrating an example mobile device screenshot of a patient main landing screen;
[0035] FIG. 13 is a diagram illustrating an example immediate waiting room in more detail;
[0036] FIG. 14 is a diagram illustrating an example scheduled waiting room in more detail;
[0037] FIG. 15 is a diagram illustrating an example mobile device screenshot of patient appointment selection;
[0038] FIG. 16 is a diagram illustrating an example mobile device screenshot of patient healthcare provider selection;
[0039] FIG. 17 is a diagram illustrating a first example mobile device screenshot of estimated wait time for the encounter with the healthcare provider;
[0040] FIG. 18 is a diagram illustrating a first example mobile device screenshot indicating the selected healthcare provider type is not available;
[0041] FIG. 19 is a diagram illustrating a second example mobile device screenshot indicating the selected healthcare provider type is not available;
[0042] FIG. 20 is a diagram illustrating a second example mobile device screenshot of estimated wait time for the encounter with the healthcare provider;
[0043] FIG. 21 is a diagram illustrating a third example mobile device screenshot of estimated wait time for the encounter with the healthcare provider;
[0044] FIG. 22 is a diagram illustrating an example mobile device screenshot of a reminder for the encounter with the healthcare provider;
[0045] FIG. 23 is a flow diagram illustrating an example healthcare provider selection method;
[0046] FIG. 24 is a diagram illustrating an example mobile device screenshot of healthcare provider specialty type selection;
[0047] FIG. 25 is a diagram illustrating an example mobile device screenshot of requesting help in choosing a healthcare provider specialty type;
[0048] FIG. 26 is a flow diagram illustrating an example healthcare provider specialty type selection method;
[0049] FIG. 27A is a diagram illustrating a first example mobile device screenshot showing a human body for conveying location of current patient medical issue;
[0050] FIG. 27B is a diagram illustrating a second example mobile device screenshot showing a human body for conveying location of current patient medical issue;
[0051] FIG. 27C is a diagram illustrating a third example mobile device screenshot showing a human body for conveying location of current patient medical issue;
[0052] FIG. 27D is a diagram illustrating a fourth example mobile device screenshot showing a human body for conveying location of current patient medical issue;
[0053] FIG. 27E is a diagram illustrating a fifth example mobile device screenshot showing a human body for conveying location of current patient medical issue;
[0054] FIG. 27F is a diagram illustrating a sixth example mobile device screenshot showing a human body for conveying location of current patient medical issue;
[0055] FIG. 28A is a diagram illustrating a first example mobile device screenshot showing a human body with a list of possible medical issues based on the patient's selection;
[0056] FIG. 28B is a diagram illustrating a second example mobile device screenshot showing a human body with a list of possible medical issues based on the patient's selection;
[0057] FIG. 29 is a diagram illustrating an example mobile device screenshot showing recommended healthcare provider specialty types in accordance with the patient's selections;
[0058] FIG. 30 is a diagram illustrating an example mobile device screenshot of recommended healthcare provider specialty types in accordance with the patient's selections;
[0059] FIG. 31 is a diagram illustrating a screen shot of an example advanced radiology GUI generated in accordance with the present invention;
[0060] FIG. 32 is a flow diagram illustrating a method for performing an encounter in accordance with the present invention;
[0061] FIG. 33 is a diagram illustrating an example CTM invite message generated in accordance with the present invention;
[0062] FIG. 34 is a diagram illustrating an example GUI rendered on an HCP computing device in accordance with the present invention;
[0063] FIG. 35 is a diagram illustrating an example GUI rendered on a computing device of the patient in accordance with the present invention;
[0064] FIG. 36 is a diagram illustrating an example GUI rendered on the computing device of the HCW in accordance with the present invention; and
[0065] FIG. 37 is a diagram illustrating an example GUI rendered on a computing device of the CTM in accordance with the present invention.
DETAILED DESCRIPTION
[0066] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be understood by those skilled in the art, however, that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.
[0067] The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with objects, features, and advantages thereof, may best be understood by reference to the following detailed description when read with the accompanying drawings.
[0068] It will be appreciated that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.
[0069] Because the illustrated embodiments of the present invention may for the most part, be implemented using electronic components and circuits known to those skilled in the art, details will not be explained in any greater extent than that considered necessary, for the understanding and appreciation of the underlying concepts of the present invention and in order not to obfuscate or distract from the teachings of the present invention.
[0070] Any reference in the specification to a method should be applied mutatis mutandis to a system capable of executing the method. Any reference in the specification to a system should be applied mutatis mutandis to a method that may be executed by the system.
[0071] Definitions
[0072] The following definitions apply throughout this document.
[0073] The terms “telemedicine” and “telehealth” are both defined as the use of telecommunication and information technologies to provide clinical health care at a distance. Throughout this document the term telemedicine is used but is meant to incorporate telehealth as well. Telemedicine involves the distribution of health-related services and information. Distribution is via electronic information and telecommunication technologies. It allows long distance patient/clinician contact and care, advice, reminders, education, intervention, monitoring and remote admissions. As well as provider distance-learning; meetings, supervision, and presentations between practitioners; online information and health data management and healthcare system integration. For example, telemedicine can include two healthcare providers or workers discussing a case over video conference; a robotic surgery occurring through remote access; physical therapy done via digital monitoring instruments, live feed and application combinations; tests being forwarded between facilities for interpretation by a higher specialist; home monitoring through continuous sending of patient health data; client to practitioner online conference; or even videophone interpretation during a consult.
[0074] The term “telemedicine system” (or simply “system”) is defined as any system that provides and implements telemedicine or telehealth functionality.
[0075] The term “healthcare provider” (HCP) (or simply “provider”) is defined as any medical practitioner licensed to prescribe drugs and includes but is not limited to a medical doctor (MD), physician, doctor of osteopathic medicine (DO) advanced practice registered nurse, advanced practice provider (APP), podiatrist, veterinarian, etc.
[0076] The term “healthcare worker” (HCW) (or simply “worker”) is defined as any medical practitioner or medical support staff not licensed to prescribe drugs and includes but is not limited to a registered nurse (RN, BSN), licensed practical nurse (LPN), medic (EMT, MA), certified nursing assistant (CNA), radiology technician, proceduralist, pharmacy technician, phlebotomist, medic, psychologist, physician assistant, etc.
[0077] The term “patient” is defined as any person seeking healthcare services. The patient may be ill or injured and in need of treatment or medical assistance.
[0078] The term “care team member” (CTM) is defined as any friend, family, spouse, significant other, partner, etc. selected by the patient to help and aid in the care of the patient.
[0079] The term “sensor” is defined as any sensor or medicals sensor device such as a stethoscope, otoscope, mobile radiological scanning device, blood pressure monitor, blood oxygen sensors, tactile sensors, temperature sensors, pressure sensors, flow sensors, etc. that is capable of interfacing to a network or computing device through wired or wireless means.
[0080] The term “computing device” or “user station” (US) is defined as any general purpose device that has least one processing element, typically a central processing unit (CPU), and some form of memory and can be programmed to carry out a set of arithmetic or logical operations automatically. Examples of computing devices include but are not limited to smartphones (running Android, iOS, etc.), tablet computers (running Android, iOS, etc.), smartwatches (iWatch running watchOS, Samsung Gear, etc.), laptops and desktops (running macOS, Windows, UNIX, Linux, etc.). The computing device may be mobile or non-mobile.
[0081] The term “encounter” is defined as an interaction over a network between a healthcare provider and a patient. The interaction may be, for example, via video only, audio only, video and audio, text session, etc. or combination thereof.
[0082] Note that within the system, user access to various screens, functions, data and workflows are controlled by a set of roles and privileges associated with the particular user's user name. Role based control of access to protected health information (PHI) is a requirement for compliance with HIPAA regulations. Users may have more than one role in the system.
[0083] Computer Embodiment
[0084] As will be appreciated by one skilled in the art, the present invention may be embodied as a system, method, computer program product or any combination thereof. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, the present invention may take the form of a computer program product embodied in any tangible medium of expression having computer usable program code embodied in the medium.
[0085] The invention may be described in the general context of computer-executable instructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. The invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer storage media including memory storage devices.
[0086] Any combination of one or more computer usable or computer readable medium(s) may be utilized. The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), an optical fiber, a portable compact disc read-only memory (CDROM), an optical storage device, a transmission media such as those supporting the Internet or an intranet, or a magnetic storage device. Note that the computer-usable or computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory. In the context of this document, a computer-usable or computer-readable medium may be any medium that can contain or store the program for use by or in connection with the instruction execution system, apparatus, or device.
[0087] Computer program code for carrying out operations of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++, C# or the like, conventional procedural programming languages, such as the “C” programming language, and functional programming languages such as Prolog and Lisp, machine code, assembler or any other suitable programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network using any type of network protocol, including for example a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0088] The present invention is described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented or supported by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0089] These computer program instructions may also be stored in a computer-readable medium that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable medium produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0090] The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0091] The invention is operational with numerous general purpose or special purpose computing system environments or configurations. Examples of well-known computing systems, environments, and/or configurations that may be suitable for use with the invention include, but are not limited to, personal computers, server computers, cloud computing, hand-held or laptop devices, multiprocessor systems, microprocessor, microcontroller or microcomputer based systems, set top boxes, programmable consumer electronics, ASIC or FPGA core, DSP core, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
[0092] A block diagram illustrating an example computer processing system or device adapted to implement the telemedicine system of the present invention is shown in FIG. 1 . The exemplary computer processing system, generally referenced 10 , for implementing the invention comprises a general purpose computing device 11 . Computing device 11 comprises central processing unit (CPU) 12 , host/PIC/cache bridge 20 and main memory 24 .
[0093] The CPU 12 comprises one or more general purpose CPU cores 14 and optionally one or more special purpose cores 16 (e.g., DSP core, floating point, etc.). The one or more general purpose cores execute general purpose opcodes while the special purpose cores execute functions specific to their purpose. The CPU 12 is coupled through the CPU local bus 18 to a host/PCl/cache bridge or chipset 20 . A second level (i.e. L2) cache memory (not shown) may be coupled to a cache controller in the chipset. For some processors, the external cache may comprise an L1 or first level cache. The bridge or chipset 20 couples to main memory 24 via memory bus 20 . The main memory comprises dynamic random access memory (DRAM) or extended data out (EDO) memory, or other types of memory such as ROM, static RAM, flash, and non-volatile static random access memory (NVSRAM), bubble memory, etc.
[0094] The computing device 11 also comprises various system components coupled to the CPU via system bus 26 (e.g., PCI). The host/PCl/cache bridge or chipset 20 interfaces to the system bus 26 , such as peripheral component interconnect (PCI) bus. The system bus 26 may comprise any of several types of well-known bus structures using any of a variety of bus architectures. Example architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Associate (VESA) local bus and Peripheral Component Interconnect (PCI) also known as Mezzanine bus.
[0095] Various components connected to the system bus include, but are not limited to, non-volatile memory (e.g., disk based data storage) 28 , video/graphics adapter 30 connected to display 32 , user input interface (I/F) controller 31 connected to one or more input devices such mouse 34 , tablet 35 , microphone 36 , keyboard 38 and modem 40 , network interface controller 42 , peripheral interface controller 52 connected to one or more external peripherals such as printer 54 and speakers 56 . The network interface controller 42 is coupled to one or more devices, such as data storage 46 , remote computer 48 running one or more remote applications 50 , via a network 44 which may comprise the Internet cloud, a local area network (LAN), wide area network (WAN), storage area network (SAN), etc. A small computer systems interface (SCSI) adapter (not shown) may also be coupled to the system bus. The SCSI adapter can couple to various SCSI devices such as a CD-ROM drive, tape drive, etc.
[0096] The non-volatile memory 28 may include various removable/non-removable, volatile/nonvolatile computer storage media, such as hard disk drives that reads from or writes to non-removable, nonvolatile magnetic media, a magnetic disk drive that reads from or writes to a removable, nonvolatile magnetic disk, an optical disk drive that reads from or writes to a removable, nonvolatile optical disk such as a CD ROM or other optical media. Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like.
[0097] A user may enter commands and information into the computer through input devices connected to the user input interface 31 . Examples of input devices include a keyboard and pointing device, mouse, trackball or touch pad. Other input devices may include a microphone, joystick, game pad, satellite dish, scanner, etc.
[0098] The computer 11 may operate in a networked environment via connections to one or more remote computers, such as a remote computer 48 . The remote computer may comprise a personal computer (PC), server, router, network PC, peer device or other common network node, and typically includes many or all of the elements described supra. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
[0099] When used in a LAN networking environment, the computer 11 is connected to the LAN 44 via network interface 42 . When used in a WAN networking environment, the computer 11 includes a modem 40 or other means for establishing communications over the WAN, such as the Internet. The modem 40 , which may be internal or external, is connected to the system bus 26 via user input interface 31 , or other appropriate mechanism.
[0100] The computing system environment, generally referenced 10 , is an example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Neither should the computing environment be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment.
[0101] In one embodiment, the software adapted to implement the system and methods of the present invention can also reside in the cloud. Cloud computing provides computation, software, data access and storage services that do not require end-user knowledge of the physical location and configuration of the system that delivers the services. Cloud computing encompasses any subscription-based or pay-per-use service and typically involves provisioning of dynamically scalable and often virtualized resources. Cloud computing providers deliver applications via the internet, which can be accessed from a web browser, while the business software and data are stored on servers at a remote location.
[0102] In another embodiment, software adapted to implement the system and methods of the present invention is adapted to reside on a computer readable medium. Computer readable media can be any available media that can be accessed by the computer and capable of storing for later reading by a computer a computer program implementing the method of this invention. Computer readable media includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by a computer. Communication media typically embodies computer readable instructions, data structures, program modules or other data such as a magnetic disk within a disk drive unit. The software adapted to implement the system and methods of the present invention may also reside, in whole or in part, in the static or dynamic main memories or in firmware within the processor of the computer system (i.e. within microcontroller, microprocessor or microcomputer internal memory).
[0103] Other digital computer system configurations can also be employed to implement the system and methods of the present invention, and to the extent that a particular system configuration is capable of implementing the system and methods of this invention, it is equivalent to the representative digital computer system of FIG. 1 and within the spirit and scope of this invention.
[0104] Once they are programmed to perform particular functions pursuant to instructions from program software that implements the system and methods of this invention, such digital computer systems in effect become special purpose computers particular to the method of this invention. The techniques necessary for this are well-known to those skilled in the art of computer systems.
[0105] It is noted that computer programs implementing the system and methods of this invention will commonly be distributed to users on a distribution medium such as floppy disk, CDROM, DVD, flash memory, portable hard disk drive, etc. From there, they will often be copied to a hard disk or a similar intermediate storage medium. When the programs are to be run, they will be loaded either from their distribution medium or their intermediate storage medium into the execution memory of the computer, configuring the computer to act in accordance with the method of this invention. All these operations are well-known to those skilled in the art of computer systems.
[0106] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or by combinations of special purpose hardware and computer instructions.
[0107] The methods described herein may be implemented on one or more processors. The method may store information generated and/or otherwise used by the method in memory for later use. The methods may include one or more steps which may be combined with other steps, separated into sub-steps, and/or skipped depending upon the particular implementation. The method may be performed by embodiments of the present system and may continue to execute after starting.
[0108] Tablet/Mobile Computing Device
[0109] A high-level block diagram illustrating an example tablet/mobile computing device suitable for use with the telemedicine system of the present invention is shown in FIG. 2 . The mobile computing device is preferably a two-way communication device having voice and/or data communication capabilities. In addition, the device optionally has the capability to communicate with other computer systems via the Internet. Note that the mobile device may comprise any suitable wired or wireless device such as multimedia player, mobile communication device, digital still or video camera, cellular phone, smartphone, PDA, PNA, Bluetooth device, tablet computing device such as the iPad, Surface, Nexus, etc. For illustration purposes only, the device is shown as a mobile device, such as a cellular based telephone, smartphone or superphone. Note that this example is not intended to limit the scope of the mechanism as the invention can be implemented in a wide variety of communication devices. It is further appreciated the mobile device shown is intentionally simplified to illustrate only certain components, as the mobile device may comprise other components and subsystems beyond those shown.
[0110] The mobile device, generally referenced 430 , comprises one or more processors 472 which may comprise a baseband processor, CPU, microprocessor, DSP, etc., optionally having both analog and digital portions. The mobile device may comprise a plurality of cellular radios 434 and associated antennas 432 . Radios for the basic cellular link and any number of other wireless standards and Radio Access Technologies (RATs) may be included. Examples include, but are not limited to, LTE 4G, Code Division Multiple Access (CDMA), Personal Communication Services (PCS), Global System for Mobile Communication (GSM)/GPRS/EDGE 3G; WCDMA; WiMAX for providing WiMAX wireless connectivity when within the range of a WiMAX wireless network; Bluetooth for providing Bluetooth wireless connectivity when within the range of a Bluetooth wireless network; WLAN for providing wireless connectivity when in a hot spot or within the range of an ad hoc, infrastructure or mesh based wireless LAN (WLAN) network; near field communications; UWB; GPS receiver for receiving GPS radio signals transmitted from one or more orbiting GPS satellites, FM transceiver provides the user the ability to listen to FM broadcasts as well as the ability to transmit audio over an unused FM station at low power, such as for playback over a car or home stereo system having an FM receiver, digital broadcast television, etc.
[0111] The mobile device may also comprise internal volatile storage 474 (e.g., RAM) and persistent storage 478 (e.g., ROM) and flash memory 476 . Persistent storage also stores applications executable by the processor(s) including the related data files used by those applications to allow device 430 to perform its intended functions. Several optional user-interface interface devices include trackball/thumbwheel which may comprise a depressible thumbwheel/trackball that is used for navigation, selection of menu choices and confirmation of action, keypad/keyboard such as arranged in QWERTY fashion for entering alphanumeric data and a numeric keypad for entering dialing digits and for other controls and inputs (the keyboard may also contain symbol, function and command keys such as a phone send/end key, a menu key and an escape key), headset 496 , earpiece 494 and/or speaker 492 , microphone(s) and associated audio codec or other multimedia codecs, vibrator for alerting a user, one or more cameras and related circuitry 442 , 444 , display(s) 446 and associated display controller 438 and touchscreen control 440 . Serial ports include a USB port (USB 1, 2, 3 or C) 486 and related USB PHY 482 and micro SD port 488 . Other interface connections may include SPI, SDIO, PCI, USB, etc. for providing a serial link to a user's PC or other device. SIM/RUIM card 490 provides the interface to a user's SIM or RUIM card for storing user data such as address book entries, user identification, etc.
[0112] Portable power is provided by the battery 484 coupled to power management circuitry 480 . External power is provided via USB power or an AC/DC adapter connected to the power management circuitry that is operative to manage the charging and discharging of the battery. In addition to a battery and AC/DC external power source, additional optional power sources each with its own power limitations, include: a speaker phone, DC/DC power source, and any bus powered power source (e.g., USB device in bus powered mode).
[0113] Operating system software executed by the processor 472 is preferably stored in persistent storage (i.e. ROM), or flash memory, but may be stored in other types of memory devices. In addition, system software, specific device applications, or parts thereof, may be temporarily loaded into volatile storage, such as random access memory (RAM). Communications signals received by the mobile device may also be stored in the RAM.
[0114] The processor, in addition to its operating system functions, enables execution of software applications on the computing device. A predetermined set of applications that control basic device operations, such as data and voice communications, may be installed during manufacture. Additional applications (or apps) may be downloaded from the Internet and installed in memory for execution on the processor. Alternatively, software may be downloaded via any other suitable protocol, such as SDIO, USB, network server, etc.
[0115] Other components of the mobile device include an accelerometer 448 for detecting motion and orientation of the device, magnetometer 450 for detecting the earth's magnetic field, FM radio 452 and antenna 454 , Bluetooth radio 458 and antenna 456 , Wi-Fi radio 460 including antenna 464 and GPS 466 and antenna 468 .
[0116] In accordance with the invention, the mobile computing device is adapted to implement at least portions of the telemedicine system as hardware, software or as a combination of hardware and software. In one embodiment, implemented as a software task, the program code operative to implement the telemedicine system is executed as one or more tasks running on processor 62 and either (1) stored in one or more memories 474 , 476 , 478 or (2) stored in local memory within the processor 472 itself.
[0117] Telemedicine System of the Present Invention
[0118] The telemedicine system provides for the diagnosis of a medical issue during an encounter with one or more HCPs. One or more users of the system may be located on-site (e.g., office) as well as off-site (e.g., patient's residence). A photo image of a patient wound is acquired by the patient and/or a CTM and uploaded to the system. An HCP views the photo image and can order a medical image, e.g., ultrasound, MRI, x-ray, of the wound and its surrounding areas. The system dispatches an HCW (or HCP) to the patient location to obtain the ordered information using a suitable mobile medical imaging device. The image of the wound is transmitted to an HCP located somewhere else and a diagnosis rendered remotely from the patient. The patient is then informed of the diagnosis during an encounter with the HCP.
[0119] Thus, the present invention provides diagnostics capability with enhanced information acquisition and distribution. This helps pinpoint an area of concern (e.g., a wound or other abnormality) using photo and medical images. Additionally, a HCW (e.g., medical imaging technician (MIT)) can be dispatched to the patient to obtain the medical images. A HCP can select a HCW and dispatch them to the patient's location to obtain vitals and medical images and perform tasks and orders. An HCW closest to the patient may be selected. An HCW closest to the patient, however, may be visiting another patient. In this case, the system selects an HCW that is not the closest but may visit the patient sooner. Thus, the system can employ learning to analyze schedules of HCWs such that it learns how long each HCW and/or groups of HCWs may take to perform their tasks during visits with patients. The system employs scheduling algorithms to select and dispatch an HCW that visits the patient in the shortest amount of time or a desired time as scheduled by the HCP or the patient.
[0120] A diagram illustrating an example telemedicine system of the present invention is shown in FIG. 3 . The system, generally referenced 60 , comprises a wide area network such as the Internet 62 , HIPAA compliant network 92 , Global Positioning System (GPS) 74 , healthcare providers 64 , healthcare workers 66 , patients 68 , care teams 70 , and pharmacy/prescription delivery 72 . The system 60 also comprises mobile access such as via cellular or wireless system 84 for various mobile computing devices such as tablets 86 , smartphones 88 , and desktop/laptop computers 90 . The system also comprises various network capable medical sensor devices such as stethoscopes, otoscopes, mobile radiological scanning devices, blood pressure monitors, etc. For example, sensors 82 communicate over the Internet 62 , sensors 78 communicate via direct connection to tablet computing devices 86 , sensors 76 communicate via wireless connection to smartphone computing devices 88 , and sensors 89 communicate via either wired or wireless connection to a laptop, desktop, or web portal 90 .
[0121] The HIPAA compliant network 92 comprises web services 94 coupled to the Internet and to one or more databases 96 (e.g., SQL, etc.), web app host server 98 and authentication layer 100 which comprises, for example, Google login adapter 102 , Twitter login adapter 104 , and Facebook login adapter 106 . Connected to the network 92 are one or more internal or external services 61 . Examples of services include but are not limited to ePrescription 108 , Picture Archiving and Communication System (PACS) 110 , Google Maps 112 , video/audio collaboration 114 , payment processing 116 , ID validation/processing 118 , and credit card scanning and processing 119 .
[0122] A diagram illustrating an example encounter between a healthcare provider and a healthcare worker and patient at a remote patient location is shown in FIG. 4 . The system may include on-site 120 and off-site 122 locations which communicates with each other via a network 124 such as the Internet. The on-site location 120 can be situated at a non-mobile location of a provider such as in an office, a clinic, a hospital, and the like in which at least one US may be located for establishing communication between the US of a HCP 126 and/or associates 128 (e.g., HCPs, HCW, etc.) and a patient 134 , one or more HCWs 136 , and/or one or more CTMs 132 situated at the off-site location 122 (i.e. which may be remote from the on-site location) during an encounter (e.g., a video session). During the encounter, the system may acquire video information of parties to the encounter such as the HCP 126 and/or the associates 128 and the HCW 136 , the patient 134 , and/or the CTMs 132 and may transmit this video information to one or more other parties of the encounter and may thereafter render the transmitted video information in real time, as shown on the HCP computing device 127 and the HCW computing device 137 . Accordingly, the system may establish at least one communication channel 130 to transmit the video information in real time.
[0123] In one embodiment, the at least one communication channel 130 may also transmit information related to the patient such as vitals, biometric information, etc. For example, one or more sensors 138 may acquire information such as vitals of the patient, medical images of the patient, etc., and may form corresponding sensor information which may be transmitted to the on-site portion 120 for further analysis and rendering on a device of the system for the convenience of the HCP 126 . For example, a tactile glove sensor 138 is shown being used by the worker to examine the patient. Touch based feedback information detected by the glove is transmitted to the provider over link 139 where the provider can experience in real time what the worker feels at the patient location. Accordingly, the HCP 126 may effectively remotely touch the patient 134 via the HCW 136 and the one or more sensors 138 .
[0124] Accordingly, the system may render information acquired by the sensors such as medical image information (e.g., from an MRI, X-ray, CT scan, and/or an ultrasound), blood test results, drug test results, acquired signals (e.g., ECGs, etc.), etc. on a rendering device of the HCP 126 for further analysis. The system may further provide an interface for the HCW 136 to enter analysis information regarding the patient 134 such as notes regarding the condition of the patient 134 such as the physiological and/or psychological condition of the patient 134 and may transmit this information to the HCP 126 for further analysis. The system may then transmit this information to the HCW 136 for further analysis as may be desired.
[0125] A computing system including a software application to integrate and/or combine image information obtained from one or more image acquisition devices such as cameras with radiology artifacts will now be described. A diagram illustrating an example encounter between a radiological healthcare worker and a patient at a remote patient location is shown in FIG. 5 . The system, generally referenced 690 , comprises part of an enhanced radiology platform of the telemedicine system constructed in accordance with the present invention. In one embodiment, the system comprises at least one controller 715 , memory 710 , USs 692 , at least one medical imager 700 , analyzer 706 , reconstructor 708 , registration block 711 , user interface (UI) 712 , and an enhanced radiology block 713 .
[0126] In one embodiment, the controller 715 controls the overall operation of the system and may obtain US image information from an USs 692 of a patient and medical image information from the reconstructor 708 .
[0127] The USs 692 may include a camera or other image capture device for capturing an image of the user. For example, the USs may comprise a smartphone, personal digital assistant (PDA), camera phone 694 , a 2D camera 698 or 3D camera 696 , and the like. The camera may capture still as well as video images. The USs may include a microphone to capture audio information concurrently with the image information. The images may have any desired definition (e.g., standard, high definition (HD), 4K, etc.) and may be black and white and/or color as may be acquired by the camera. The USs transmit the captured image information to the controller 715 for further analysis. One or more of the USs may belong to the patient and/or a CTM assigned to the patient. Accordingly, these images may be referred to as patient acquired images.
[0128] In one embodiment, the medical imager 700 includes one or more medical imagers and may be configured to acquire medical image information such as an X-ray imager 701 , CT-scanner 704 , MM scanner 702 , and ultrasound scanner 703 . The medical imager may also comprise fluorescence-detecting cameras, catheter acquired images, and/or other medical imaging devices or medical scanning devices such as an electrocardiograph (ECG) or the like (not shown). The acquired medical image information can be provided in raw format or processed (e.g., reconstructed) format to the controller 715 for further processing such as for reconstruction, display, and/or storage. For the sake of clarity, these images may be referred to as medical images in the current example as opposed to the images captured by the USs 692 .
[0129] In one embodiment, the reconstructor 708 is under control of the controller 715 and operative to obtain the medical image information acquired by the medical imager 700 (e.g., directly from the medical imager 700 or via the controller 715 ) and may reconstruct this information to form reconstructed medical image information and provide this information to the controller 715 for further processing. The reconstructed medical image information is rendered on the UI 712 of the system such as on a display 714 .
[0130] In one embodiment, the memory 710 comprises any suitable memory such as a local and/or a distributed memory. The memory may store information generated or otherwise acquired by the system as well as operating instructions, user information, and/or other information such as firmware, etc.
[0131] In one embodiment, the UI 712 is under control of the controller 715 and includes any suitable UI which renders information such as enhanced radiology information, image information, reconstructed image information, and the like. The UI may include the display 714 , a speaker, a haptic device, and/or a user input device such as a touchscreen display, a keyboard, a mouse, a microphone, a touchpad, a stylus, and/or any other device with which a user may enter information.
[0132] Once the medical image information, and/or the reconstructed medical image information is acquired, it can be attached to a radiology package linked to a patient and stored in association with patient information (PAI) for the corresponding patient. The patient radiology package may further include information related to an identification of an issue for which the patient sought treatment (e.g., right knee pain, etc.) and which issue and/or any information associated therewith may be date stamped. The system can generate a graphical user interface (GUI) with which the user may interact to store desired image information (e.g., from any source) in the patient radiology package.
[0133] In one embodiment, the analyzer 706 is under control of the controller 715 and is operative to obtain the image information acquired by one or more of the USs 692 and perform image analysis on the image information using any suitable method to detect any abnormalities such as a skin rash or discoloration, limb deformation, a bulge, swelling, other visual signs, etc. and form corresponding analysis information which can include information related to the abnormalities such as, a location of the abnormalities (e.g., in relation to an image and in relation to a patient), a description of the abnormalities (e.g., rash, bruise, cut, etc.), etc. Similarly, the analyzer 706 may analyze the reconstructed medical image information to detect abnormalities and mark them for later analysis. For example, when abnormalities are detected within an image (e.g., in the image information or the reconstructed medical image information), the analyzer 706 marks these abnormalities for further processing as may be desired. In another embodiment, the analyzer 706 uses highlighting or the like to delineate detected abnormal areas to mark these areas.
[0134] In another embodiment, the analyzer 706 determines or otherwise receives a description of the part of the patient that is being analyzed and/or marked (e.g., as abnormal) such as right arm, lower abdomen, left knee, etc. Accordingly, the analyzer 706 performs image analysis upon a corresponding image to determine the location of an abnormal area/region and mark this abnormal area/region and store this information in association with the corresponding image (e.g., image information or reconstructed medical image information). The analyzer may provide an interface (e.g., a GUI) with which the user can interface to mark any desired abnormal or other areas and store this information in association with the corresponding image (e.g., image information or reconstructed medical image information). The system can further include metadata which indicates whether the abnormal area/region was marked by a user and/or the system (e.g., automatically) and, if marked by a user include an identification of the user.
[0135] Thus, the analyzer 706 can mark any detected abnormal areas/regions within a region-of-interest (ROI) as may be determined by the analyzer 706 and/or a user. Accordingly, the system can render the image for a user to highlight the ROI or the system may determine a ROI within the image.
[0136] The analyzer 706 and/or user may further determine landmarks within the image information and/or medical image information and mark these landmarks for further analysis. These landmarks may then be stored in association with the corresponding image information and/or medical image information.
[0137] In one embodiment, the registration block 711 includes a software application and/or registers (i.e. links) one or more images obtained by one or more of the USs 692 (e.g., the image information) and/or one or more of the medical imagers 700 (e.g., the medical image information or reconstructed medical image information which may be collectively referred to as medical images for the sake of clarity) with each other and forms corresponding image registration information. For example, if a user (e.g., an HCP, a HCW, the patient, and/or a CTM) takes a picture of a patient's knee with an abnormality such as scaring on it (e.g., an image acquired by the USs 692 ), and an MRI image of this knee is available (e.g., a medical image), these images may be registered, when possible with each other. Similarly, images from the same or different imaging devices such as the USs 692 and the medical imagers 700 may be registered (i.e. linked) with each other provided that they are taken of the same or a substantially similar region-of-interest (ROI). For example, all images taken of a portion of an anatomy of a patient for an encounter (e.g., left knee pain, etc.) may be linked with each other. The registration portion 711 checks that the patient is the same patient and that the images were acquired substantially concurrently with each other such as within a certain time period (e.g., hours, a day, etc.) and/or for the same or similar ROI as may be set by system and/or user settings. The time period may be set by the system and/or user (e.g., three days, etc.).
[0138] The registration portion 711 can also obtain and/or detect landmarks within the image information and/or the medical image information which may aid in the linking process which may be performed automatically and/or semi-automatically (e.g., with at least some input from a user such as a provider or worker. The registration block 711 then forms image registration information that may be used to link the acquired image information.
[0139] In another embodiment, an initial encounter for an issue (e.g., left knee pain) may be considered a main encounter and may be assigned an identification that may be given a start date of the initial encounter for this issue (e.g., left knee pain March 4 , 2016 ) and all subsequent encounters for this issue may be associated with the main encounter identification. Thus, the system may separate multiple encounters for different issues so that images for these separate encounters may not have to be registered unless requested by a user such as a HCP. For example, if a patient has several encounters for left knee pain, and other encounters for a sore throat, images obtained for these separate issues may not have to be registered with each other. They may, however, be registered for the same issue.
[0140] After generating the image registration information and linking it with the corresponding images, registration block 711 may provide the image registration information to the controller 715 which stores this information in the corresponding patient radiology package in the memory of the system such as memory 710 for later use.
[0141] In one embodiment, the enhanced radiology block 713 is under control of the controller 715 and provides an interface with which a user may interact with the system to render information that was stored in the patient radiology package such as the image information (e.g., acquired by the cameras of the USs 692 ) and the reconstructed medical image information (e.g., acquired by the medical imagers 700 ) as well as related information such as image registration information, abnormalities, etc.
[0142] A flow diagram illustrating an example fault tolerant identity validation method of the present invention is shown in FIG. 6 . In one embodiment, the method is implemented using one or more controllers, processors, shift registers, logic gates, computers, etc. of the system, etc. operating in accordance with the present system. The method may then store information generated and/or otherwise used by the method in a memory of the system for later use, if desired. The method may include one or more of the following steps or actions. Further, one or more steps of the method may be combined with other steps, separated into sub-steps, and/or skipped depending upon system settings.
[0143] The system first acquires information from one or more sensors 721 (step 720 ). The one or more sensors 721 generate corresponding sensor data which may be received by a multiplexer 722 which outputs corresponding validity sensor information (VSI) in any suitable format. The multiplexer 722 further obtains information from external sources such as from a service provider of the US and includes this information from the VSI as desired.
[0144] The sensors 721 can be divided into multiple types, namely biometric, virtual, and physical type sensors. For example, biometric type sensors acquire biometric information from a user and generate corresponding information such as image information (e.g., facial information such as a facial image obtained by a camera sensor of the system for use with facial recognition software and which is considered a facial image sample), audio information (e.g., a voice sample obtained by a microphone sensor of the system for use with voice recognition), fingerprint information (e.g., obtained by a fingerprint reader sensor of the system for use with fingerprint recognition and which is considered a fingerprint sample), which information may be stored in a corresponding format such as an image format (e.g., JPEG, etc.), audio format (e.g., MP3/MP4, etc.), and fingerprint format, respectively.
[0145] The virtual type sensors capture virtual information such as user station identification (USID) (e.g., a unique user device ID and/or service provider recognition information, cell phone ID (e.g., SSID), cell phone number, etc.), user name/password information, and/or location tagging information (e.g., obtained from a node at which a user is accessing the Internet, Internet service provider (ISP) ID, etc.). The physical type sensors obtain information such as location information (e.g., obtained from a location sensor such as a GPS sensor, etc.). At least one of the sensors is operative to determine the user/name password information and/or location tagging information and provide this information to multiplexer 722 .
[0146] User name/password information is obtained via any suitable login such as a user manually logging in to the system using, for example, a text entry area to enter the user's ID and corresponding password. Accordingly, the system can generate a GUI including a request to enter a user ID (e.g., a name, an email address, a telephone, number, etc.) and password and renders the GUI on the US for input by the user.
[0147] With regard to acquisition of the sensor information, the sensor information may be acquired from a user actively or passively. For example, with respect to passive acquisition of the sensor information, it is envisioned that a user may enter his/her fingerprint when requested or the fingerprint of the user may be obtained when the user touches the screen such as during a screen unlock process in which the user touches the screen to unlock the screen. Fingerprint data can also be acquired when a user selects a selection item (e.g., a menu item) which is rendered on a touchscreen display of the US. The menu item may be related to any GUI rendered by the US. Similarly, the system can detect the face of a user when the user uses his/her US and generates corresponding facial (image) information. The sensor information may include information which identifies the type of sensor information (e.g., fingerprint, facial recognition, audio, etc.).
[0148] Conversely, with regard to active acquisition of validity sensor information (VSI), the system can generate and render a request for the user to enter information for the VSI such as an image of the user's face, a fingerprint, etc. Accordingly, the user enters the desired information (or portions thereof) by selecting a menu item to activate a camera of the US to capture a facial image of the user, or by placing a finger over a fingerprint reader of the system, etc.
[0149] Note that some the sensor information may be required. For example, sensor information which may identify an account of a user (e.g., user ID, name, biometric information, etc.). Further, for accounts not yet established, sensor information may require a name to be entered. Other identifying information may be obtained (as may be set by system settings, etc.) such as date of birth, social security number, etc.) which may be used to validate a user and/or to initialize an account of the user.
[0150] The system can also provide the user with options to select which sensor information to acquire. For example, a user may select to enter facial recognition, fingerprint, and location information, while a different user may select to enter facial, voice, and location information. These settings can be set in user setting information (USI) for later use by the system. Accordingly, at login, the system obtains USI for the user (e.g., via identifying US of the user). The USI can be analyzed to select sensor information to acquire for the user. Thus, it may be desirable to select different types of sensors to use to acquire the sensor information. For example, when at a home registered to a user, location tagging information is entered (which the system recognizes as belonging to a registered location of the user) for at least part of the sensor information. When the user is travelling, however, a voice sample for at least part of the sensor information is preferred rather than the location tagging information which will not be recognized as belonging to an account of the user. Further, depending upon the type of sensor used, the system can generate a query to obtain the sensor information. For example, if an ISP ID of the US of a user is desired, the system generates a query to request this information and submits this information to the ISP or accesses this information from the memory of the US.
[0151] Table 1 below shows login information selection data which includes login information selections for two registered users (e.g., user A and user B) of the system. Each user has corresponding login information selections.
[0000]
TABLE 1
Login Information Selection Data
Sensor Information
(Minimum No. Samples = 3_)
User A
User B
Account Name
Yes
Yes
Audio Sample
Yes
Yes
Facial Image Sample
Yes
Yes
Fingerprint Sample
Yes
No
Iris Sample
No
Yes
Location Tagging
No
No
.
.
.
.
.
.
.
.
.
Service Provider
No
No
[0152] As indicated in Table 1, User A desires to use sensor information for login such as an account name, audio sample, facial image sample, and fingerprint sample for logging in, whereas user B, wants to use an account name, audio sample, facial image sample, and iris sample. The system sets a minimum number of samples required for the login between one and five, e.g., three. In addition, one or more of the selections and/or groups of selections may be mandatory. For example, is may be required to enter a user name to reduce processing. A user, however, may enter a fingerprint and the system may identify the user based upon the fingerprint by searching a fingerprint library and finding a match.
[0153] Each user can set and reset information within the login information matrix. For example, a user may set or reset one or more selections within the login information matrix. The login information matrix, however, may be blocked from being set/reset by a user. Further, the system may employ a default logon information matrix as may be desired.
[0154] Sensor information may be stored in the multiplexer (mux) 722 prior to output. The mux then outputs the sensor information as the VSI to the binary searcher 724 . in one embodiment, location tagging is achieved by determining a location of the us and generating corresponding location information which is then included within the VSI with, for example, the image, audio, or finger print information, etc., as desired.
[0155] The system then performs a binary search on the validity of the sensor data included within the VSI (step 724 ). The binary searcher receives the VSI and identifies the sensor information contained therein using any suitable method. For example, for biometric information such as an image, voice, and fingerprint information, this information may be extracted from the VSI and identified (e.g., by type) using any suitable method such as by identifying a format of the information. For example, the binary searcher can identify image information as a facial image sample, audio information as a voice sample, and fingerprint information as a fingerprint sample of the user.
[0156] The binary searcher then obtains validation information to validate at least a portion of the sensor information extracted from the VSI. This validation information can be obtained from user account information stored in association with an account of the user and/or the system can identify a user based upon a match of the sensor information against stored validation information (e.g., a match of a name of the sensor information with a corresponding name stored in the user account information, a match of a fingerprint sample of the sensor information with a fingerprint sample stored in the user account information, etc.). Once at least some of the sensor information is matched with corresponding stored validation information of a user, a partial identification of a user may be established and the system then attempts to match the remaining sensor information of this user with corresponding validation information for this user.
[0157] Thus, for example, if the system obtains a fingerprint sample from the user, the system matches this fingerprint sample to a fingerprint sample within the verification information and at least partially identifies the user. Thereafter, the system, depending upon system settings, obtains verification information for this user from the memory of the system and attempts to match the remaining sensor information with corresponding information within the verification information. Thus, the system obtains verification information for a particular user or identifies a user based upon verification information for a plurality of users and, if a match is found (e.g., the user is at least partially identified), the system obtains further verification information for this user to more fully identify them.
[0158] The system compares the sensor information within the VSI to determine whether it matches corresponding verification information stored in the memory of the system. For example, assuming an image (facial) and fingerprint information of the user are acquired (and included within the VSI), the system compares this information with corresponding image and fingerprint information for the user that is stored in VSI memory and determines whether there is a match. The sensor information as well as the verification information can be passively or actively acquired. For example, the system can passively obtain facial image information as sensor information and then employs facial recognition methods to determine whether the acquired facial image information matches the corresponding facial image information for the user. The system then stores results of the determination(s). For example, assuming that the user name, facial image information, and fingerprint sample were matched with corresponding verification information, the system stores the results. If, however, the user name matched the verification information but the facial image information and fingerprint sample did not match corresponding verification information for the user name, the system also stores results of this determination. The user can then be given another opportunity to get their ID validated.
[0159] Thus, the binary searcher determines whether the sensor information matches corresponding validity information. If the sensor information matches the corresponding validity information, the sensor information and/or results of the determination are input to the weighted average adaptive filter (step 741 ). Otherwise, the user is not identified and is given another opportunity to get validated. For example, the user may have incorrectly entered a user name, etc.
[0160] Note that the system may identify a user even when all the sensor information is not input and/or not matched with corresponding validity information. For example, if it is determined that some sensor information which matches the corresponding validity information is greater than a threshold value such as N Thresh (where N Thresh is an integer set by the system and/or a user), the process determines that the sensor information matches the corresponding validity information.
[0161] In the event that the user is not identified, which, may occur when the user enters an incorrect user name, or does not enter a fingerprint sample correctly, or is not registered, the system informs the user (e.g., notifying the user that a fingerprint match was not made, user ID is incorrect, etc.). The user is given an opportunity to correct the sensor information. For example, if the sensor information for the user does not match any verification information for any accounts of a user, the system may determine that the user is not a registered user, and may inform (e.g., by displaying a message) the user that the user has not been recognized as a registered user and may provide the user with an opportunity to correct and/or reenter the sensor information. Accordingly, the system repeats step 720 .
[0162] The weighed adaptive filter (step 741 ) obtains the sensor information from the binary searcher and results of the determinations for the identified user. The system then pulls validity search information (VSI) from any suitable information source such as from public 728 and/or private 729 records databases for the identified user via network 725 (such as the Internet). For example, the VSI may include information such as licenses (e.g., drivers and other licenses), a passport, banking account(s), criminal records, and service provider(s) of/for the identified user and/or the US the user is communicating with. The system forms the VSI such that the VSI includes information fields which correspond with information fields of the sensor information. For example, if the sensor information includes a facial image information field, the system includes a corresponding facial image information field and generates a corresponding query to obtain the VSI from any suitable source such as public and/or private records databases.
[0163] The system determines whether fields of the VSI match corresponding fields of the sensor information and generates corresponding matching information (MI) which indicates whether a match has been found. The MI can be a binary number whether or not the sensor information matches the VSI (e.g., “1” or yes, or “0” or no) and/or may be normalized to a likelihood of a fit (e.g., 0 to 1, where “0” indicates no likelihood of a fit (i.e. no match) and “1” indicates a full fit (i.e. a match). For clarity sake, it is assumed that the MI is a binary number (e.g., “1”=match and “0”=no match). Accordingly, the system employs well known statistical algorithms which analyze the sensor information and VSI to determine a likelihood of a match (e.g., a fit) and generate the corresponding MI.
[0164] In one embodiment, the system applies a weight to the MI. For example, the result of a name match (e.g., name MI) has a weight of 10*MI, while the result of a location may have a weight of one, wherein higher weights may indicate greater importance and vice versa. Thus, a weight of one can be assigned to matches of lowest importance and a weight of 10 may be assigned to those of greatest importance. The system may determine weights from a weight table which include weights for various information fields such as a weight for a name field (e.g., 10) and a weight for an address field (e.g., one), etc. The system can obtain the weight table from memory and determine corresponding weights for matches in accordance with the weight table.
[0165] In one embodiment, the databases and/or queries are based upon a group and/or subgroup that the identified user is a member of, such as, a patient, HCP, HCW, CTM, and/or subgroup thereof. The system further includes an unregistered users group which may include unregistered users who may be attempting to register as a member of another group of the system (e.g., an HCP, patient group, etc.). For example, if the identified user is identified as a provider, the system may determine that the identified user is a member of the HCP group and physician subgroup. The system then obtains information related to this group and subgroup (e.g., searching terms) and further obtains locations (e.g., databases, websites, etc.) from which to search. The system obtains search terms using any suitable method such as by employing a table look up method to obtain desired search terms. For example, assuming the identified user is a provider (e.g., of the HCP group and physician subgroup), the system obtains search information for the group and subgroup from a search information table (SIT) stored in memory.
[0166] Table 2 below shows a portion of a SIT for a HCP group and its subgroups (e.g., physicians, PAs, and NPs). Other groups may have similar SITs with information fields which can vary by group and/or subgroup. The SIT can be learned and/or modified by the system or modified by a user.
[0000]
TABLE 2
Search Information Table (SIT)
Group
Search Information Fields
HCP
(for validation search
Check
Databases and Location
Subgroup
information (VSI))
Fields
Public
Private
Physician
name, address, profession,
registration
State:
Insurance Co.
license no. date of
end date
CA: If MD:
A:
licensure, additional
dated after
xww.mbc.ca.gov/Breeze/License_Verification.aspx
xyz.123
qualification, status,
current date
CA: If DO:
Insurance Co.
registration end date,
xww.breeze.ca.gov/datamart/searchByName.do
B- . . .
medical school, and
. . .
degree date
NY: xww.nys.op . . .
NJ: xww.nj . . .
. . .
PA
name, address, profession,
registration
www.xyz123.com
Ins. Co. ABC
license no. date of
end date
licensure, additional
dated after
qualification, status,
current date
registration end date,
medical school, and
degree date
NP
name, address, profession,
registration
www.xyz123.com
Ins. Co. ABC
license no. date of
end date
licensure, additional
dated after
qualification, status,
current date
registration end date,
medical school, and
degree date
[0167] As shown in Table 2, the system identifies a group/subgroup of the identified user (e.g., a physician subgroup of the HCP group). The system then generates a query in accordance with the search information field for the current group and subgroup (e.g., in the current example, the query is formed to obtain: name, address, profession, license no., date of licensure, additional qualification, status, registration end date, medical school, and degree date). The search query is submitted to the corresponding information source(s) (e.g., databases) for the current group and subgroup as listed in Table 2.
[0168] The sources (e.g., databases) to search may be determined in accordance with a geographical region of the user (e.g., Michigan, etc.). For example, assuming that the identified user has a residence or business address in Michigan, the system performs a search in databases corresponding with this state such as the Michigan Licensing and Regulatory Affairs website and/or in neighboring states such as in Ohio, Indiana, Wisconsin, etc. This may save system resources. Accordingly, each state, territory, and/or region may have corresponding search locations associated therewith and is listed in the SIT.
[0169] Thus, in one embodiment, the search includes terms which correspond with the search information fields of the SIT and can be further narrowed to search databases in accordance with an identified geographic region associated with the user. Assuming that the user is identified as being licensed to practice their profession in the state of Michigan, then information from this state may be obtained. One or more private databases (such as insurance company databases, private databases, etc.) are queried for the same or similar information or information that cannot be obtained (or is difficult to be obtained) from public sources (e.g., public database) or vice versa. Accordingly, the system transmits a search query to request the information from a desired source (e.g., a private and/or public database) which corresponds with the search information fields. The system receives a response to the query and generates corresponding the VSI.
[0170] Note that sources may include a list of search addresses for searching each group and/or subgroup. Further, the search addresses may be geographically dependent upon geographic location. Thus, for example, if the user is licensed in the Michigan, the search may query for information related to that state such as the Licensing and Regulatory Affairs website, Michigan Department of Motor Vehicles website (e.g., for license information, etc.), etc., public utility service providers (e.g., for phone and/or Internet service related records such as for address) and banks (e.g., for banking related records such as address) operating within the identified users geographic region (e.g., Michigan area). This can save time and system resources. A search can be widened to cover other geographic areas such as when an insufficient number of records (e.g., a number of records below a record threshold) are obtained through a narrowed geographic region search and/or when information falls below a quality or reliability threshold.
[0171] The system can obtain driver license information (e.g., including name, address, license number, and biometric information which may include a facial image and/or a fingerprint(s) of the licensee) or non-driver ID for the identified user from any suitable identification source (e.g., database) such as an insurance company database, a state motor vehicle department database, a health insurance provider, etc. Similarly, passport information can be obtained for the user from an immigration database (e.g., provided by a state or federal immigration department) which may include similar information as that discussed above with respect to a driver license. Lastly, banking information related to bank accounts, credit cards, mortgages, and rental property can be obtained from any suitable banking database.
[0172] Assuming that the sensor information includes a user name, facial image information and fingerprint sample, the system can then query any suitable source to obtain at least corresponding information such as driver license information (e.g., a driver license database, an insurance database, etc.) and generate corresponding VSI. The information included in the sensor information, such as the user name, facial image information and fingerprint sample is compared with the corresponding information (e.g., user name, facial image information and fingerprint sample, respectively) from the driver license information for the identified user in order to determine whether a match (or substantial match) is found as well as to generate corresponding MI which indicates whether the compared information matches. In other words, the matching information (MI) is generated to indicate a degree of confidence (e.g., probability of match) in the match. The MI may be normalized as well.
[0173] In one embodiment, the system obtains similar information fields and compares them to determine a match (or a substantial match) and generates the corresponding MI. For example, the system queries several databases for an address of the identified user. The system then compares results of these comparisons (e.g., residence address, professional address, insurance carrier, social security number, etc.) and determines whether a match (or a substantial match) is found. The MI includes information related to results of a comparison as well as the compared information, the sources, and corresponding time stamps (e.g., indicating time of the search query). Thus, for example, if several databases are queried for an address of the identified user and these addresses are determined not to match, the MI includes results of the comparison, a flag to indicate fields which did not match, sources and of the information that was compared (e.g., address 1 obtained from insurance sources A and address 2 obtained from insurance source B, on Jan. 1, 2017).
[0174] In one embodiment, the MI is generated using any suitable format and stored in memory and associated with the identified user for later use. the MI includes a format identifier, e.g., a certain number of bits may indicate the information contained therein.
[0175] The VSI is then searched for terms which are not permitted for a user depending upon the group and subgroup of the identified user. For example, with reference to Table 2, the check fields indicate one or more fields which should be compared with a threshold value. For example, the registration status (e.g., active, registered, or current (hereinafter these terms may be collectively referred to as active unless the context indicates otherwise)) may indicate an active registration while other terms such as expired, deceased, suspended, revoked, inactive, surrendered, and rescinded (hereinafter these terms may be collectively referred to as inactive unless the context indicates otherwise) may indicate an inactive registration status of the identified user. Thus, if it is determined that the registration of the identified user matches any acceptable term such as active, registered, or current (although other terms are also envisioned), the system generates the MI to so indicate. For example, the system generates the MI to include a corresponding indication of confidence, e.g., one. Similarly, if the system determines (e.g., using any suitable method such as a free-form text search method, etc.) that the registration status of the identified user is not active (e.g., which may occur when the registration status of the identified user matches any undesirable term such as any of the terms such as not-registered, not current, deceased, suspended, revoked, inactive, surrendered, or rescinded (although other terms are also envisioned)), the system generates the MI to indicate such (e.g., a zero to indicate a low degree of confidence) and may flag this MI to draw attention during later processing. One or more fields of the MI may then be weighted as described supra.
[0176] Although the identified user may have an MI which is assigned a low value to indicate a low degree of confidence, the user may still be permitted to perform certain tasks. For example, with regard to information such as registration status, if this status is determined to be not active (e.g., inactive), the system may allow the identified user to register but may not allow them to practice until the registration status is changed to an acceptable status such as active. Thus, during each login, the system determines a use for the login such as to register, to review or change/update information, and/or to conduct an encounter with a patient, for HCPs. Each of these uses may have different accessibility rules associated therewith. Further, each type of user (e.g., HCP, HCW, patient, etc.) may have different accessibility rules associated therewith. For example, a patient may register and/or update patient information (PAI) absent certain information such as payment information but may not conduct an encounter nor perform tasks which may result in an immediate or scheduled appointment. These accessibility rules may be defined in an accessibility table and may be stored in memory.
[0177] In one embodiment, information is obtained that is used to automatically tune filter gains. For example, the process employs a learning function to learn about current risks with regard to identity fraud and updates system settings accordingly. For example, if it is determined that a certain database was hacked, this source is removed from querying and/or may a lower weight is assigned to information obtained from this source. If it is determined that a source of information (e.g., license information and facial image information etc.) was determined to be hacked, the system removes this source from querying to enhance reliability and security.
[0178] Once the filtering is complete (step 741 ), the it is checked whether user identity is sufficiently validated (step 743 ). If it is determined that the ID check of the user is valid, the process continues to authorization (step 736 ). Otherwise, validation using human assistance is performed (step 745 ).
[0179] An ID check of the identified user may be found to be validated when an MI score for one or more required fields either separately and/or combined, depending upon system settings, is equal to or greater than one or more corresponding thresholds such as a corresponding MI Threshold value (MI Thresh ). For example, a combined score for all or select MI fields is calculated and compared to a corresponding MI Threshold value (MI Thresh ). If the total MI score for each of the corresponding MI field(s) is greater than or equal to MI Thresh , the ID check of the identified user is validated. Otherwise, the ID check of the identified user does not pass. Depending on the implementation, the fields may be chosen by the system (e.g., as required fields with other fields considered non-required fields). The system may then ignore the MI field(s) which are not selected (at least until selected) when for example, determining a combined score, etc. as described infra.
[0180] In one embodiment, the MI threshold value(s) (MI Thresh ) are set to an integer (or other value) in accordance with predetermined system settings (e.g., a default setting, etc.) or are set to a value equal to a number of fields in a corresponding MI.
[0181] When checking a plurality of fields of the MI and assuming the number of fields in MI is equal to F MI , then the value of a corresponding MI threshold value MI Thresh is set equal to a CF Thresh *F MI
[0182] , where CF Thresh is a confidence factor that, in the present example, may be assumed to be equal to 1 for high confidence and may be set to lower values for a lower confidence factor. Thus, in the present example, MI Thresh =1 and assuming that CF Thresh =1, then if the MI has 6 normalized fields (e.g., MI=0, 0.5, 0, 1, 1, 1), MI Thresh =F MI =6 and if the MI has 9 normalized fields (e.g., MI=1, 0, 1, 0, 1, 1, 1, 0, 0), an MI threshold is set to 9 . Thus, for the above example of MI=(0, 0.5, 0, 1, 1, 1), MI Thresh =F MI =6, then the total score of MI=0+0.5+0+1+1+1=3.5 obtained is less than MI Thresh =6 resulting in a no go. Thus, it is determined that the MI score for each of the MI fields is not greater than or equal to MI Thresh and thus the ID check of the user does not pass.
[0183] In one embodiment, the MI fields are divided into two or more groups such as selected (e.g., required) and non-required field groups each of which may include at least one field. For example, using the above example, of MI=(0, 0.5, 0, 1, 1, 1), the first three fields for the selected field group are selected and the other fields ignored. Thus, a temporary MI′=(0, 0.5, 0) is processed as described supra. This is done for one or more groups of fields within the original MI. Other values may be set such as CF Thresh , F MI , and/or MI Thresh as discussed supra and the ID check decision made using MI′ for MI as discussed supra.
[0184] In one embodiment, human assisted validation is performed (step 745 ). A GUI that includes one or more portions of the sensor information, the VSI, and the MI is rendered on a display to inform an operator of information related to the identified user such as name, facial information (used during a video conference) and/or other information. For example, the GUI may include information related to fields of the MI that were below a threshold confidence factor. If a user's address was incorrect, this is flagged and similar fields of information (e.g., all addresses in the current example) on record for the identified user is included in the GUI for the convenience of the operator.
[0185] If the identified user moved from one address to another, this is brought to the attention of the operator. Similarly, if the identified user is a physician with an inactive license status, this information is flagged and included in the GUI. A communication channel may be established between the operator and the identified user so that text, audio, and/or video information may be exchanged. The GUI may further include available information fields and sources of information so the operator can quickly and conveniently confirm information. The GUI may include an override, which overrides selected information (e.g., overrideable information which may be predefined and stored memory) such as address information, facial image information, etc. Thus, if the user changes address due to a move and/or shaves his beard to change facial characteristics, the system provides a method to override. Other information such as license status (e.g., if not active) may be non-overrideable unless authorized by a user with the proper authorization. Thus, during the conversation with the identified user, the operator may request additional information from the user and/or databases and be provided with an option to pass an ID check of the user. Further, the operator may update and/or override information related to the identified user and the system stores these updates in memory. Accordingly, when the identified user attempts to login at a future date, the override information is checked to avoid repeating the failure of the ID check for the same reason(s).
[0186] Once identity is validated, users are then authorized to interact with the system (step 736 ). At this point, the identified user is considered to have passed the ID check. A GUI notifies the user that they have passed the ID check and are authorized to use the system in accordance with system rights information (SRI) for the user. The SRI may set forth rights (e.g., authorizations, etc.) for each user in accordance with group and/or subgroup settings for a group and/or subgroup to which the identified user belongs and/or individual settings as may be stored in PAI. The SRI is stored in memory in any suitable format. The SRI sets forth rights and privileges of the identified user during at least the present session and/or future sessions. Accordingly, the system determines a group to which associate the present user such as: a provider, worker, patient group 738 , taxi driver/realtor group 740 , home service group 742 , care team group 744 , and/or an identification of other personnel group 746 , and sets system rights information (SRI) accordingly for the user's particular group and/or subgroup.
[0187] Healthcare Provider Workflow
[0188] A flow diagram illustrating an example healthcare provider workflow method of the present invention is shown in FIGS. 7A, 7B, 7C, and 7D . First, a landing screen is displayed on the provider's computing device (step 140 ). The provider then selects to either register (step 142 ) as a new provider or login (step 156 ) as a previously registered provider. To log in, the provider selects one of three options. The first option is to log in from a new device (step 158 ). The provider enters their full email and password (step 164 ) and input a code generated by the system that is sent to the provider's computing device such as a smartphone or tablet (step 170 ). The second option is to log in more than seven days from the last login (step 160 ). The provider must enter their full email and password (step 166 ). If they forgot their password (step 172 ), they must input a code generated by the system that is sent to the provider's computing device such as a smartphone or tablet (step 170 ). The third option is to log in less than seven days from the last login (step 162 ). In this case, the provider is prompted to enter a code or to scan their fingerprint (step 168 ). If they forgot their code (step 174 ), they must enter their full email and password (step 166 ) and continue with step 172 .
[0189] To register (step 142 ) with the system, the provider enters demographic information (e.g., name, home address, work address, gender, ID number such as social security number (SSN), date of birth, etc. (step 144 ). The provider then enters license information (e.g., driver's, Drug Enforcement Agency (DEA) number, state licenses, etc.) (step 146 ) and practice profile information (e.g., email, work phone number, home phone number, cellphone number, login ID, profile photo, screen name, employee ID, spoken languages, insurance plans accepted, group practice name, national provider ID (NPI), etc.) (step 148 ). Once the ID and licenses of the provider have been validated and verified, the system sends an email or text message to the new user. The provider then enters the code(s) received (step 150 ). A passcode and/or touch ID on mobile devices is created for easy access. The provider then enters a password or the system generates one and the provider confirms (step 152 ).
[0190] Note that during the registration process, the provider's identify is validated and verified. This can be achieved using any number of techniques and processes such as input a code sent via email, inputting a code sent via test messaging, facial recognition from a picture, fingerprint, touch ID, using data retrieved from public, private, criminal and government databases, e.g., driver license information.
[0191] Note also that a new healthcare provider account can be created manually or automatically. The provider or other staff member can perform a manual creation. Alternatively, the account can be created by an automatic load from an external system (e.g., EPIC or other practice management system).
[0192] Once registration or login is complete, the provider is placed on the waiting room landing screen 154 such as shown in FIG. 8 . Via example screen 260 , the provider can call emergency services such as 911 ( 262 ), see their photo 264 and name 266 , enter the waiting room 268 , receive and send messages 270 , view and edit patient charts 272 , see and edit calendars 274 , edit their account 276 , contact system administration 278 and log out from the system 279 .
[0193] Appointments previously made with a patient can be canceled (step 176 ). When an appointment is canceled, a message is sent to the patient with an option to reschedule (step 186 ).
[0194] The provider can enter a patient's medical chart (step 178 ) and add, delete and edit the patient's record. The provider can also generate orders or tasks to be performed by one or more healthcare workers at the patient's location, for example (step 188 ). Once generated, the provider assigns one or more orders or tasks to a healthcare worker (step 190 ).
[0195] In one embodiment, a provider or worker can generate a clinical report that can include any or all of the following related to the encounter: summary, clinical notes, medications prescribed, patient instructions, images, medical and social history, and medications and allergies.
[0196] The provider can also initiate a patient visit (i.e. encounter) whereby a healthcare worker may be dispatched to the patient's location (step 180 ). The system calculates and displays the estimated time of arrival (ETA) to the patient's location of those healthcare workers within a certain radius thereof (step 192 ). The provider then starts an encounter with the patient (step 194 ). Note that the encounter is typically a video encounter but can take other forms, e.g., text session, etc.). The provider can record and enter any document notes into the patient's record.
[0197] In one embodiment, the data elements captured during an encounter include any or all of the following: date, provider name, reason for the encounter (e.g., complaint), primary diagnosis, clinical notes, images, medication(s) prescribed, patient instructions, and signature date.
[0198] At this point, the provider can activate a healthcare worker (step 198 ) whereby the worker is dispatched to the patient location. The provider can also issue any number of orders and/or tasks to be performed by the worker (step 206 ).
[0199] The provider can write one or more prescriptions at any time during the encounter (step 200 ). The prescriptions may be processed and sent to a pharmacy using a third party software tool such as MDToolbox-Rx as described in more detail infra.
[0200] Any assessments and plans are recorded by the provider into the patient record (step 202 ). Any diagnosis is also recorded into the patient record (step 208 ). Once the diagnosis is records, the provider electronically signs the patient's chart (step 210 ).
[0201] During the encounter (step 204 ), the provider can request the worker who is at the patient's location to perform a physical examination of the patient possibly using any type of sensor, perform any procedures on the patient, etc. In essence, the worker with the patient acts as the eyes, ears and touch of the provider.
[0202] The provider is also provided with messaging services (step 218 ) including composing and reading messages. When composing a message (step 220 ), the provider selects a recipient from a directory of recipients (step 226 ) and the system sends the message (step 228 ). Saved messages can be accessed (step 222 ) and are shown within selected folders (step 230 ). An inbox (step 224 ) holds both received patient related messages (step 232 ) as well as personal messages (step 244 ). Personal messages are moved to a personal folder (step 246 ), while patient related messages are displayed along with the patient's chart (step 234 ). From there, the provider can reply to the message (step 236 ), forward the message (step 238 ) or view the chart (step 240 ) and optionally add a note thereto (step 242 ).
[0203] The provider can also access account information (step 247 ) including demographic information (step 248 ) that can be edited (step 254 ), license information (step 250 ) that can be edited (step 256 ) and practice profile information (step 252 ) that can be edited (step 258 ).
[0204] In one embodiment, after providing feedback (step 212 ), the provider is taken back to the waiting room landing screen (step 154 ).
[0205] At any point during an encounter, the provider may decide that medication is required for the treatment of the patient. The system provides the capability for the provider to write any number of electronic prescriptions before terminating the encounter or discharging the patient. In one embodiment, prescription writing is handled using third party software tools such as MDToolbox-Rx. Alternatively, prescription writing can be implemented entirely within the system platform.
[0206] During the encounter, the provider reviews and records key facts about the patient's other medications and drug allergies and indicates whether medication history has been verified before prescribing. Information collected during encounters is recorded in the patient medical record.
[0207] Before prescribing any medications during an encounter, the provider the system displays one or more screens that include current medications and allergies. Information about current medications and allergies is also transmitted to the third party tool (e.g., MDToolbox-Rx) to check for contraindications. The provider then selects drugs, doses, selected pharmacy, etc. The system or the third party tool transmits the prescription(s) to the selected pharmacy. If successful, information related to the prescription is returned to the system for storing in a database. Once stored, this information can be viewed by providers, workers and patients. Note that renewals are handled in similar fashion to new prescriptions. Providers can optionally include prescription information with patient discharge instructions.
[0208] Healthcare Worker Workflow
[0209] A flow diagram illustrating an example healthcare worker workflow method of the present invention is shown in FIGS. 9A, 9B, 9C, and 9D . First, a landing screen is displayed on the worker's computing device (step 280 ). The worker then selects to either register (step 282 ) as a new worker or login (step 292 ) as a previously registered worker. To log in, the worker selects one of three options. The first option is to log in from a new device (step 294 ). The worker enters their full email and password (step 300 ) and input a code generated by the system that is sent to the worker's computing device such as a smartphone or tablet (step 302 ). The second option is to log in more than seven days from the last login (step 296 ). The worker must enter their full email and password (step 306 ). If they forgot their password (step 308 ), they must input a code generated by the system that is sent to the worker's computing device such as a smartphone or tablet (step 302 ). The third option is to log in less than seven days from the last login (step 298 ). In this case, the worker is prompted to enter a code or to scan their fingerprint (step 310 ). If they forgot their code (step 312 ), they must enter their full email and password (step 306 ) and continue with step 308 .
[0210] To register with the system (step 282 ), the worker enters demographic information (e.g., name, home address, work address, gender, ID number such as social security number (SSN), date of birth, etc. (step 284 ). The provider then enters practice profile information (e.g., email, clinical credentials (e.g., RN, CNA, EMT, MA, etc.), license information (e.g., driver's, state licenses, etc.), work phone number, home phone number, cellphone number, login ID, employee ID, profile photo, screen name, spoken languages, insurance plans accepted, group practice name, national provider ID (NPI), etc.) (step 286 ). Once the ID and clinical credentials of the worker have been validated and verified, the system sends an email or text message to the new user. The worker then enters the code(s) received in the email or text message (step 288 ). A passcode and/or touch ID on mobile devices is created for easy access. The worker then enters a password or the system generates one and the worker confirms (step 290 ).
[0211] Note that during the registration process, the worker's identify is validated and verified as described supra. Note also that a new healthcare worker account can be created manually or automatically as described supra.
[0212] Once registration or login is complete, the worker is placed on the patients assigned landing screen 304 such as shown in FIG. 10 . Via example screen 410 , the worker can call emergency services such as 911 ( 412 ), see their photo 414 and name 416 , enter the waiting room 418 , receive and send messages 420 , view and edit patient charts 422 , see and edit calendars 424 , edit their account 426 , contact system administration 428 and log out from the system 429 .
[0213] In addition, once logged into the system, the worker's location is tracked by GPS in their mobile computing device or other means. This enables the time to the patient's location to be estimated so the closest worker can be dispatched to the patient. Knowledge of the location of the worker also permits the tracking of resources in the field.
[0214] The worker can view the capitated patients list (step 314 ). Note that capitation is a payment arrangement for healthcare providers that pays a provider a set amount for each enrolled patient assigned to them, per period of time, whether or not that patient seeks care. The worker can then add a patient (step 316 ), edit a patient (step 318 ) or view a patient (step 320 ). To add a patient, the worker enters the patient data (step 322 ), insurance information (step 324 ), and patient history, medications, etc. (step 326 ). An appointment can then be scheduled with the patient (step 328 ) and any iHealth collection parameters configured (e.g., blood pressure, sleep trackers, glucometers, scales, pulse oximeters, etc.) (step 330 ).
[0215] For patients that are assigned to the worker by a provider, the worker has the option of either accepting (step 332 ) or declining (step 333 ) the assignment. If the worker declines the assignment, a message is sent to the patient and the provider (step 335 ). If the worker accepts the assignment, the system calculates and displays the ETA to the location of the patient based on the current location of the worker (step 334 ). The worker is displayed an optimum travel route to the patient along with the ETA. The worker can communicate with the patient and/or provider via messaging. One or more messages may be automatically generated and sent to the patient and/or the provider indicating the current location and en route status information of the worker.
[0216] A notification of the arrival of the worker at the patient location is generated upon arrival (step 336 ). The worker then enters the patient chart for viewing and editing (step 338 ) and also views any worker orders or tasks entered by the provider (step 340 ). Optionally, the patient's identity may be verified before the visit proceeds further. The worker then performs any orders or tasks assigned by the provider and enters results into the patient chart (step 342 ). Examples include obtaining lab samples, dropping off medications, taking x-rays, repairing a laceration, etc.
[0217] During the encounter, the provider can request the worker who at the patient's location to perform a physical examination of the patient possibly using any type of sensor (e.g., stethoscope, otoscope, etc.), perform any procedures on the patient, etc. In essence, the worker acts as the eyes, ears and touch of the provider.
[0218] The worker can start an encounter with the provider or reconnect the patient with the provider (e.g., video) (step 344 ), enter notes into the chart (step 348 ) and complete the encounter (step 350 ). The worker can also compose and send messages to other workers, providers or other patients assigned to the worker (step 346 ).
[0219] In addition, the worker has access to one or more calendars (step 354 ) where they can set their availability (step 356 ) and enter dates/times, etc. (step 358 ).
[0220] Workers can also view charts for patients assigned to them (step 360 ) as well as any information contained in one or more folders (step 362 ).
[0221] The worker is also provided with messaging services (step 364 ) including composing and reading messages. When composing a message (step 366 ), the worker selects a recipient from a directory of recipients (step 368 ) and the system sends the message (step 370 ). Saved messages can be accessed (step 372 ) and are shown within selected folders (step 374 ). An inbox (step 376 ) holds both received patient related messages (step 378 ) as well as personal messages (step 390 ). Personal messages are moved to a personal folder (step 392 ), while patient related messages are displayed along with the patient's chart (step 380 ). From there, the worker can reply to the message (step 382 ), forward the message (step 384 ) or view the chart (step 386 ) and optionally add a note thereto (step 388 ).
[0222] The worker can also access account information (step 394 ) including demographic information (step 396 ) that can be edited (step 400 ) and professional profile information (step 398 ) that can be edited (step 402 ).
[0223] In one embodiment, after providing feedback (step 352 ), the worker is taken back to the patients assigned landing screen (step 304 ).
[0224] Once the encounter and visit are complete, the worker indicates this in the system. The worker then becomes active again and can be assigned to another patient. Note that in one embodiment, the worker can be assigned another patient during a visit with a patient. The worker can accept or decline each new patient assignment while engaged in another appointment. The worker can view their patient queue at any time.
[0225] Note that in one embodiment, in-field workers can initiate an encounter with a provider. Patients may have a planned visit by the healthcare worker or be located in a facility such as a nursing home, assisted living center, etc. where the worker is already present. In this case, if the healthcare worker determines that the patient needs to be evaluated by the provider, the worker can connect with the provider either through either an immediate or scheduled appointment using the mechanisms described supra. The worker can then assist the provider with a more thorough examination using any number of sensors such as a stethoscope, otoscope, blood pressure monitor, etc. During the encounter, the provider can direct the worker to take any lab or other tests that may help with a more complete encounter.
[0226] Patient Workflow
[0227] A flow diagram illustrating an example patient workflow method of the present invention is shown in FIGS. 11A, 11B, 11C, 11D, 11E, and 11F . First, a landing screen is displayed on the patient's computing device (step 500 ). The patient then selects to either register (step 502 ) as a new patient or login (step 522 ) as a previously registered patient. To log in, the patient selects one of three options. The first option is to log in from a new device (step 522 ). The patient enters their full email and password (step 530 ) and inputs a code generated by the system that is sent to the patient's computing device such as a smartphone or tablet (step 532 ). The second option is to log in more than seven days from the last login (step 526 ). The patient enters their full email and password (step 534 ). If they forgot their password (step 536 ), they must input a code generated by the system that is sent to the worker's computing device such as a smartphone or tablet (step 532 ). The third option is to log in less than seven days from the last login (step 528 ). In this case, the patient is prompted to enter a code or to scan their fingerprint (step 538 ). If they forgot their code (step 540 ), they must enter their full email and password (step 534 ) and continue with step 536 .
[0228] To register (step 502 ) with the system, the patient enters demographic information (e.g., name, home address, work address, gender, ID number such as social security number (SSN), date of birth, etc. (step 504 ). The system sends an email or text message to the new patient. The patient then enters the code(s) received in the email or text message (step 506 ). A passcode and/or touch ID on mobile devices is created for easy access. The worker then enters a password or the system generates one and the patient confirms (step 508 ). The patient then enters profile information (e.g., login ID or username, email, license information (e.g., driver's, etc.), work phone number, home phone number, cellphone number, profile photo, screen name, spoken languages, etc.) (step 286 ).
[0229] The patient then enters payment information such as primary and secondary insurance, including insurance company, policy number, member number, front and back insurance ID photos, etc. (step 512 ). Medical history information is then entered (step 514 ) followed by current medication, any allergies, social history (e.g., drugs, smoking), etc. (step 516 ).
[0230] Physician and care team information is then entered, e.g., care team member names (i.e. family, friends, etc.), contact phone numbers, relation to the patient, etc. (step 518 ). Care team members have a registered account with the system to permit them to access information on the patient they are linked to. When logged in, they have the ability to toggle between their own account and that of their ‘patient.’ They have access to that patient's data based on what is shared, e.g., full access or choose which features they are given access to. For example, patients can share and edit appointments, share patient instructions (e.g., discharge instructions), share and edit medications and allergies, medical history, allow communications with the medical team, share disease management data, permit reception of notifications, view test results, pay bills, view and edit registration and join video encounters.
[0231] Note that accounts for minors can also be created and setup. Minor accounts can be linked to a legal guardian or parent's account. Note also that during the registration process, the patient's identify is validated and verified as described supra. Note further that a new patient account can be created manually or automatically as described supra.
[0232] Once registration or login is complete, the patient is placed on the appointments landing screen 520 such as shown in FIG. 12 . Via example screen 660 , the patient can call emergency services such as 911 ( 662 ), see their photo 664 and name 666 , view and make appointments 668 , view their medical chart 670 , view and edit their medical history 672 , view and edit their profile 674 , create a minor account 676 , receive and send messages 678 , contact system administration 680 and log out from the system 684 .
[0233] Using the system, patients can make appointments with providers (step 542 ). In one embodiment, two types of appointments are possible: immediate appointments and scheduled appointments. To make an immediate appointment (step 544 ), the location of the patient is first acquired (step 546 ). It is then checked whether the patient's location is within a worker's network area (step 548 ). If it is not, then the patient is alerted that only an encounter (e.g., video) is available and that a worker cannot be dispatched to their location (step 588 ).
[0234] If the location is within a worker's network area, the patient is then verified against criminal records databases (step 550 ) as it is not desired to send a worker to a patient that may be high risk. If the patient is high risk, then the patient is alerted that only an encounter (e.g., video) is available (step 588 ). If the patient is not high risk, it is then determined whether the patient is using insurance as payment (step 554 ). If so, it is checked whether the insurance information is on file and whether it needs updating (step 556 ). If the information is not on file or needs updating, then the patient is offered the option to update their insurance information (step 560 ). If the information is on file and no updating is needed, patient eligibility is checked with their insurance (step 590 ). If they are active/eligible (step 592 ), consent is obtained from the patient to charge their credit card for any copayment and deductible charges (step 594 ). If they are not active or not eligible, the method continues with credit card payment step 558 .
[0235] Once consent is obtained, the patient is then presented with a list of provider specialty types (step 596 ). The patient then selects a provider specialty type (step 598 ). If a provider of the selected type is available (step 600 ), then the estimated wait time is calculated and displayed to the patient (step 602 ). If the wait time is less than a threshold (step 606 ), the patient is notified to wait (step 608 ), the patient is placed in the immediate waiting room (step 610 ) and the patient is returned to the appointment landing page (step 520 ). When the provider is ready, the patient receives a notification to enter the encounter (e.g., video) for their appointment.
[0236] If the patient is not using insurance as payment (step 554 ), then it is checked whether the patient is using a credit card as payment (step 558 ). If not, the appointment process is canceled and the patient is returned to the appointment landing page (step 520 ). Otherwise, the patient is presented with a list of provider specialty types (step 596 ) and the method continues as described supra.
[0237] If a provider of the selected specialty type is not available (step 600 ), the patient is offered the option of selecting a different type (step 604 ). If they choose not to, then the patient is offered the option of making a scheduled appointment and continues with step 616 . If they want to choose another type, the method continues with step 596 .
[0238] If the wait time is greater than or equal to the threshold (step 606 ), then the system asks the patient if they want to wait in the immediate waiting room (step 612 ). If so, the method continues with step 608 . Otherwise, the patient is asked if they want to be alerted a predetermined time before the estimated availability (step 614 ). If so, they are placed in the immediate waiting room (step 610 ) and they are notified before the appointment. Otherwise, the patient is given the option to make a scheduled appointment (step 616 ). If they choose not to, the method returns to the appointment landing page (step 520 ). If they do, the method continues with making a scheduled appointment (step 564 ).
[0239] To make a scheduled appointment, the patient is first presented with a list of provider specialty types (step 566 ). The patient selects a provider type (step 568 ) and the system checks whether the patient is paying with insurance or credit card (step 570 ). The system then displays a list of providers in accordance with the patient's insurance and type selection (step 572 ). Alternatively, the patient is given the option to view all providers including those that do not accept the patient's insurance.
[0240] A list of available dates/times that provider or multiple providers is available is then displayed (step 574 ). If an appointment is available at the date/time selected by the patient (step 576 ), an appointment is made (step 634 ). Appointment details are then sent via email or other means to the patient (step 640 ). In addition, notifications and reminders are sent to the patient at certain time before the appointment, such as one day, one hour, and five minutes (step 642 ). The patient then returns to the appointment landing page (step 520 ).
[0241] If the desired appointment is not available (step 576 ), then a list of alternative affiliated providers of the selected type are displayed to the patient (step 578 ). If no provider is found (step 620 ), the method continues with step 626 which displays a list of non-affiliated providers and/or providers that do not accept the patient's insurance. If at least one provider is found, the available appointment dates/times are displayed to the patient (step 622 ). If an appointment at the desired date/time is available (step 624 ), the appointment is made and the method continues with step 634 . Otherwise, a list of non-affiliated providers of the selected type are displayed to the patient (step 626 ). If no provider is found (step 628 ), the method continues with step 636 where the option to make an immediate appointment is offered to the patient. If the patient chooses not to make and immediate appointment, then the patient returns to the appointment landing page and continues with step 520 . If the patient wishes to make and immediate appointment, the method continues with step 544 . If at least one provider is found (step 628 ), the available appointment dates/times are displayed to the patient (step 630 ). If an appointment at the desired date/time is available (step 632 ), the appointment is made and the method continues with step 634 . At the time of the appointment, the patient is sent a link and/or notification to enter the encounter room (e.g., video) for the appointment when the chosen provider is ready.
[0242] As described supra, the patient can create accounts for minors (step 580 ). The patient enters the minor's name, relationship, date of birth, etc. (step 582 ).
[0243] Patients can view past appointments (step 584 ). Folders containing prior patient visits are displayed to the patient (step 586 ).
[0244] The patient can also access profile information (step 644 ) including demographic information that can be edited (step 646 ), payment information that can be edited (step 648 ), and provider/caregiver/care team information that can be edited (step 650 ).
[0245] Patients can also view and update their medical history and those of minors linked to them (step 652 ). Screens are presented to the patient to edit medical history information (step 654 ). This includes editing medical information (step 656 ), editing social history, allergy information (step 658 ), and editing medical history information (step 659 ).
[0246] Immediate and Scheduled Waiting Rooms
[0247] A diagram illustrating an example immediate waiting room in more detail is shown in FIG. 13 . The immediate waiting room, generally referenced 970 , comprises an input queue 972 , patient queue 973 , provider queue 975 , output queue 977 and storage and assignment controller 978 . In operation, patients 971 entering the immediate waiting room are first placed in the input queue 972 . Depending on the state where they are located, they are then placed in a state queue 974 corresponding to their particular state. The patients in each state queue are then fed to the queue 976 of a provider in that state. The output queue then feeds patients 979 to the individual providers. The storage and assignment controller 978 is operative to assign patients in each state to the next available provider in that state for an immediate encounter. In this manner, patients do not choose their provider, but rather are assigned to the next available provider in that state.
[0248] A diagram illustrating an example scheduled waiting room in more detail is shown in FIG. 14 . The scheduled waiting room, generally referenced 960 , comprises an input queue 962 , provider queue 963 , output queue 965 and storage and assignment controller 966 . In operation, patients 961 entering the scheduled waiting room are first placed in the input queue 962 . Depending on the particular provider they scheduled with, they are then placed in a provider queue 964 corresponding to the selected provider. The patients in each provider are then fed to the output queue which then feeds patients 967 to the individual providers. The storage and assignment controller 966 is operative to assign patients to their chosen provider for a scheduled encounter. In this manner, patients choose their provider and an encounter occurs at the patient scheduled date/time.
[0249] A diagram illustrating an example mobile device screenshot of patient appointment selection is shown in FIG. 15 . In one embodiment, the appointment selection screen includes a GUI 910 including selection items 912 for selecting an appointment type such as, an immediate-type appointment (ITA) 914 and a scheduled type appointment (STA) 916 which may be selected by the patient in accordance with methods described in more detail supra.
[0250] Accordingly, the system generates content which informs the patient to, for example, select an immediate appointment or to schedule an appointment at a later time, and may include graphics and/or text suitable to inform a user and/or receive a selection of a desired appointment type from the patient.
[0251] In addition, a help and/or guidance button is provided for selection by the user. Guidance selection items such as a back arrow 919 and/or a question mark help icon “?” 918 are provided to assist navigation of displays by a user. If the help icon “?” is selected, the system retrieves assistance information from memory corresponding to the current screen and renders it on the display. For clarity sake, guidance, help, and/or other selection items may not be shown in subsequent screen capture drawings.
[0252] A diagram illustrating an example mobile device screenshot of patient healthcare provider selection is shown in FIG. 16 . The GUI screenshot, generally referenced 920 , is displayed on the UI of a US of the patient. In one embodiment, the GUI comprises a list of modified physician type information (PTI) 922 , and an area 924 for a current patient to enter information such as text (e.g., using a text entry area) which is recognized as the patient enters it. The system determines and renders autocompletion data based upon information in the PTI 922 for the convenience of the user. For example, if the user enters the letters PE, the system highlights (and/or changes the order of) a matching physician type such as “Pediatrician” for the convenience of the user. Thus, the system places “Pediatrician” at the top of the list and/or autocompletes the entry in the search box.
[0253] The patient then selects a physician specialty type (or types) using any suitable method such as by selecting a menu item, entering text and/or a voice command, etc. and the system enters this information as a selected physician type.
[0254] The PTI is stored in memory and includes information related to physicians such as names, qualifications, licensure (e.g., state, term, current license status, medical school, residency, etc.), patient acceptance, patient age range, and practice type (e.g., cardiology, ob/gyn, etc.).
[0255] A diagram illustrating a first example mobile device screenshot of estimated wait time for the encounter with the healthcare provider is shown in FIG. 17 . In one embodiment, the screenshot of a GUI, generally referenced 930 , comprises an estimated wait time (E WT ) 932 . The GUI is rendered on a rendering device such as computing device of a user. The E WT is calculated by the system and updated in real time. The GUI may also comprise advertisement information generated by or obtained by the system such as information related to an advertisement which may be directed to the patient. For example, knowing that the patient is a diabetic (e.g., determined through analysis of the PAI), the system displays an advertisement (e.g., advertisement information) for diabetes treatment and/or medication from a third party. The duration of the advertisement is determined so that the advertisement fits within a time period (e.g., one minute) of the wait notification. For example, the GUI can be updated in real time to include the updated E WT and a directed message 934 (e.g., “Use abc product to cure xyz condition,” “Use X123 face cream to rejuvenate face,” etc.) which may include still, audio, and/or video content. The system at this time can further provide a user with a selection item 936 for more information about the product or service advertised 934 . For example, if the directed message is a medication, the system provides the selection item 936 for the user to receive information about and/or obtain a free sample of, the directed medication.
[0256] A diagram illustrating a first example mobile device screenshot indicating the selected healthcare provider type is not available is shown in FIG. 18 . In one embodiment, a screenshot of a GUI, generally referenced 940 , comprises text indicating that the desired provider specialty type is unavailable for an immediate type appointment 942 ; an option to select another provider type 944 ; and buttons for responding either “yes” or “no” by the patient or a CTM 946 .
[0257] A diagram illustrating a second example mobile device screenshot indicating the selected healthcare provider type is not available is shown in FIG. 19 . In one embodiment, a screenshot of a GUI, generally referenced 950 , comprises text indicating that the selected physician specialty type is unavailable for an immediate appointment 952 ; an option to make a scheduled appointment (STA) 954 ; and buttons for responding either “yes” or “no” by the patient or CTM 956 .
[0258] A diagram illustrating a second example mobile device screenshot of estimated wait time for the encounter with the healthcare provider is shown in FIG. 20 . In one embodiment, a screenshot of a GUI, generally referenced 960 , comprises text 962 informing the patient that the estimated wait time is ‘X’ minutes 964 (e.g., estimated wait time (E WT )); an option to wait in the immediate waiting room 966 ; and buttons for responding either “yes” or “no” 968 . Note that the estimated wait time (E WT ) may be updated in real time.
[0259] A diagram illustrating a third example mobile device screenshot of estimated wait time for the encounter with the healthcare provider is shown in FIG. 21 . In one embodiment, a screenshot of a GUI, generally referenced 970 , comprises text 971 informing the patient that the estimated wait time is ‘X’ minutes 972 (e.g., estimated wait time (E WT )); an option to be alerted a predetermined time (PT W ) before their encounter with the provider 974 ; buttons for responding either “yes” or “no” 976 ; and a slider for the user to adjust the predetermined time (PT W ) time to a desired value between minimum and maximum values 978 . Note that the estimated wait time (E WT ) may be updated in real time.
[0260] A diagram illustrating an example mobile device screenshot of a reminder for the encounter with the healthcare provider is shown in FIG. 22 . In one embodiment, a screenshot of a GUI, generally referenced 980 , comprises a notification 982 informing the patient of a wait time (X WT ) 984 using any suitable language such as: “The doctor will be with you shortly. You will be informed of your upcoming session in about “X WT ” minutes.” Where X WT is the estimated wait time (E WT ) less the predetermined time (PT W ); X WT =E WT −PT W .
[0261] The GUI also comprises selection items 986 to select one or more notification methods, e.g., email, telephone (e.g., a voice call), simple message service (SMS), social media such as Facebook™, twitter™, etc., and a default notification method. An option may be provided to change the predetermined time (PT W ) with the estimated wait time (E WT ) updated accordingly. The PT W may be set to a default value or may be based upon a system wait time.
[0262] The notification mechanism may be set to a default (e.g., SMS message, voice call, etc.) or may be set in accordance with settings stored in the PAI (e.g., alert by SMS and email), etc.
[0263] A flow diagram illustrating an example healthcare provider selection method is shown in FIG. 23 . First, the patient information (PAI) related to the corresponding patient is obtained (step 750 ). The PAI is obtained from memory and may include one or more of: user identification information (e.g., 67 year old male, date of birth 24 Dec. 1948, etc.), previous medical history (e.g., diabetic, allergies, etc.), previous medical charts, biometric data (6′5″ tall, 250 lbs., blue eyes, blood type O, fingerprint information, gender, etc.), medication history (e.g., past and current medications prescription and non-prescription), dosage, insurance carrier information (e.g., Medicare™, Oxford™ supplemental, etc.), insurance account information (e.g., account no. 123456789, effective date, expiration date, etc.), credit card information, desired system settings, etc.
[0264] A physician specialty type-selection (PTS) request is then rendered on a computing device (step 752 ). For example, the PTS may be rendered on the display and/or speaker of the computing device shown in FIG. 24 . The GUI 760 comprises an option to select a physician type manually 762 or automatically (e.g., by the system) 764 .
[0265] The system waits until a response is received from the patient (step 754 ). The response may be received via any suitable user input device such as via a display (e.g., a touchscreen) or microphone. If the patient selects manual selection (step 756 ), the patient manually chooses a provider specialty type (step 758 ). If the patient selects automatic selection (step 756 ), the system executes an automatic type selection process (step 759 ), described in more detail infra.
[0266] A diagram illustrating an example mobile device screenshot of healthcare provider specialty type selection is shown in FIG. 24 . The PTS screen shot 760 is rendered on a computing device of the patient. The PTS request comprises one or more menu items such as “Manual” selection item 762 and “Automatic” selection item 764 for selection by the patient to request physician specialty type manually or automatically, respectively.
[0267] A diagram illustrating an example mobile device screenshot of requesting help in choosing a healthcare provider specialty type is shown in FIG. 25 . The GUI 770 prompts the patient whether they would like help in selecting a healthcare provider specialty type. displays asks The GUI also comprises one or more menu items such as “no” selection item 772 and “yes” selection item 774 for selection by the patient. In this embodiment, the patient provides information regarding a current medical issue (CMI) for which the patient seeks treatment to permit a recommendation of provider to be generated.
[0268] A flow diagram illustrating an example healthcare provider specialty type selection method is shown in FIG. 26 . First, a human form (HF) is generated and rendered on the computing device of the patient such as shown in FIG. 27A . The HF may be generated as a 2D or 3D human form and is shown as a 2D HF for clarity sake. It is also assumed that the HF may be represented as a human male or female form as may be selected from memory. For example, a user may initially set a desired shape and/or color of the HF to customize the experience in accordance with patient preferences. In one embodiment, the HF represents the actual anatomy and/or gender of the patient. The system obtains the PAI of the patient and determines their gender from the PAI.
[0269] For example, the PAI of the patient is obtained that indicates the patient is female and lost her left leg below the knee due to complications from diabetes. Thereafter, the HF is configured to represent a female without a left leg below the knee or with the left leg being de-highlighted below the left knee to more closely reflect the anatomy of the patient. The HF may be generated using one or more actual images of the patient obtained in real time and/or from memory (e.g., PAI).
[0270] Another selection area is displayed whereby the patient can search for a description of a current medical issue (CMI) and/or may enter one or more search terms. This may be used to select CMIs which are difficult to depict graphically and/or select such as psychological issues, depression, etc. Thus, whether to display the HF is optional for the patient. If no HF is to be rendered, a selection area with a list of medical issues and/or corresponding physician types is displayed for selection by a user.
[0271] Instructions are rendered (step 782 ) to permit the patient to select at least one location on the HF which corresponds with areas in which the patient is experiencing the current medical issue (CMI) and for which the patient is seeking treatment (e.g., during an encounter with an HCP). This at least one location may correspond with the ROI. These instructions are referred to as request instructions (RIs).
[0272] The RIs may be set/reset by the system and/or the user and may be stored in memory for later use. The RI may be obtained from memory and may be generated in accordance with the PAI. For example, if the PAI indicates that the patient prefers a certain language, e.g., Spanish, then the request is provided in Spanish.
[0273] It is then determined whether the patient wants to manipulate a view of the HF (step 784 ). If so, the view of the HF is manipulated in accordance with the patients input (step 786 ). Otherwise, the method continues with step 788 . The system determines that the patient wants to manipulate the HF when any manipulation command for changing the view of the HF is detected. Manipulation commands may include, for example, pan, tilt, rotate, and/or zoom (in/out) commands. The manipulation commands may be sensed using the user interface (UI) (e.g., keyboards (hard or soft), touchscreen sensors, accelerometers, gyroscopes, orientation sensors, etc., mice, stylus, touchpads, etc.) of the computing device.
[0274] Thus, the HF may be manipulated so that a desired area of the HF is displayed and an ROI selected (step 788 ). At least one ROI is selected at which the patient is experiencing the current medical issue (CMI). The ROI may be selected using the built in UI features of the computing device (e.g., touch, click, etc.). Once selected, the patient can move or delete the selected ROI and select a new one. Note that a plurality of ROIs may be selected.
[0275] The ROIs may correspond with the gender of the patient. Thus, the ROI corresponds with the male anatomy for male patients and corresponds with the female anatomy for female patients. Analysis of the PAI can be used to automatically determine the patient's gender. The ROI is then configured to correspond with a patient's gender. The ROI may also correspond with other information in the PAI such as current medical history of the patient (e.g., diabetes, heart condition, etc.), age, etc. For example, if the patient is under a threshold age (e.g., 18, etc.), the ROI may be different from the ROI for a person above the threshold age. In other words, the system may select and render baby, juvenile, young adult, middle aged, and older adult HFs depending upon an age of the patient.
[0276] Several examples of selecting ROIs will now be described. If the patient is having abdominal pain in the right lower quadrant (e.g., pain in the right lower quadrant (RLQ) is area at which the patient experiences the CMI), the RLQ of the abdomen of the HF may be selected as a ROI. Similarly, if the patient is having knee pain, the corresponding knee may be selected as a ROI. In a similar fashion, if the patient is having back pain in the left lower quadrant of the back, then this area may be selected as a ROI.
[0277] Once the patient has selected one or more ROIs (step 790 ), an area of the HF associated with the selected at least one ROI is determined (step 792 ). Note that it can be determined that the patient has selected at least one ROI when an ROI remains stationary for a threshold period of time, e.g., four seconds.
[0278] The area may have a corresponding coordinate or coordinates or boundary relative to coordinates of the HF. For clarity sake, it is assumed that the area of the HF associated with the selected ROI defines an anatomical region of a human such as a shoulder, a foot, a right lower quarter abdomen, etc. which has a well-defined boundary.
[0279] For example, the HF may be divided into corresponding anatomic regions of a human using any well-known mapping technique such as a 2D or 3D coordinate mapping method, etc. These regions are divided into sub-regions and may be layered. For example, the head may be divided into a right or left temple, a right or left ear, a right or left inner ear, lips, an upper or lower jaw, a chin, left or right eyes, behind left or right eyes, individual teeth, tonsils, throat, left or right inner cheek, mucosa of the mouth, etc. Similarly, a limb such as a right foot may be divided into muscles, skin, bones, such as a tibia, a fibula, femur, joints such as the hip, knee, or ankle, digits such as toes and joints thereof, etc. With regard to layering, if a user selects the abdomen, the upper layer may be skin while lower (i.e. inner) layers) may be mapped to organs within the corresponding area and/or layer of the abdomen, etc.
[0280] Each of the regions may be subdivided into sub-regions. One or more of the regions and/or sub-regions may superpose or otherwise overlap other regions or sub-regions. The area of the HF associated with the selected ROI may be scaled in accordance with a scale of the HF. Further, the regions and/or sub-regions may be scaled relative to the HF. For clarity sake, each region or sub-region is referred to by its anatomical name rather than by coordinates as described infra.
[0281] Once the area of the ROI is determined, ROI information (ROII) corresponding to the area of the HF associated with the selected ROI is obtained (step 794 ). The area may be referred to using a corresponding anatomical name such as a shoulder, a chest, a head, a right or left leg, abdomen, etc. or using absolute coordinates of the HF. It is understood that the ROII may be mapped to the corresponding areas of the HF using any suitable method such as by regions and/or by absolute coordinates (e.g., in 2D or 3D) and this mapping (e.g., which may be known as ROII mapping) is stored in memory for further analysis.
[0282] As an example, Table 3 below illustrates exemplary ROII for areas of a genderless adult
[0283] HF using anatomical areas. Note that ROII may be specific for gender, age, medical history (e.g., diabetes, heart condition, crones, Lyme disease, etc.), geographic region, etc. Thus, the ROII may be selected based, at least in part, upon PAI. ROII may be tailored to patients. For example, ROII may be specific to gender (e.g., there may be an ROII table for males which may be different from ROII tables for females), age (e.g., ROII tables for adults may differ from ROII tables for children, and infants), medical condition (e.g., ROII for diabetics may differ from ROII for non-diabetics, etc.), etc. In one embodiment, a learning engine is used to learn ROII based upon historical patient evaluations and/or diagnosis.
[0000]
TABLE 3
ROI Information (ROII) Table (Genderless, Adult)
ROII (selections)
Main
Sub-Selections
Area
Selection
. . .
Condition(s)
Physician Type
of HF
Selections 1
Selections M
Medical
Primary
Tertiary
(selected)
(highest order)
Selections 2
(lowest order)
Issue(s)
(highest order)
Secondary
(lowest order)
Abdomen
Rash/Cuts
. . .
Dermal
GP
Internist
Dermatologist
(right
(external)
lower
Lump
Constant Size
. . .
Tumor
Internist
Gastroenterologist
GP
quarter
when
(RLQ))
straining
Increases in
. . .
Hernia
GP
Hernia
Surgeon
size when
Specialist
straining
Pain
Constant/
. . .
N/A
Internist
Surgeon
Gastroenterologist
Intermittent
Increases
. . .
Sprain/
Hernia
Surgeon
Gastroenterologist
when
Hernia
Specialist
coughing,
lifting, or
standing
Bloating
. . .
. . .
GP
Internist
Gastroenterologist
Eye(s)
All
. . .
Optometrist
Internist
Knee
Pain
. . .
Orthopedist
Internist
Swelling
. . .
Orthopedist
Internist
Rash/Cuts
. . .
Internist
Dermatologist
Noise
. . .
Orthopedist
Internist
Shoulder
Pain
. . .
Internist
Orthopedist
Swelling
. . .
Internist
Orthopedist
Rash/Cuts
. . .
Internist
Orthopedist
Other
. . .
Internist
Orthopedist
Skin
Simple
. . .
GP
Dermatologist
Cuts/Bruises
Redness,
. . .
Dermatologist
Internist
Rash, Itch and
all other skin
conditions
Neck/Throat
Pain/Infection
. . .
Internist
GP
Ear-Nose-
Throat
(ENT)
specialist
Lump
. . .
GP
Surgeon
Chest
Cold
. . .
Internist
Cardiologist
Pain/Shortness
. . .
Cardiologist
Internist
of Breath
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
Other
Fainting
. . .
Internist
Internist
GP
Fear/Anxiety
Psychologist
Internist
GP
Depression
. . .
Psychologist
Internist
GP
[0284] As indicated in Table 3, each anatomical area of the HF has corresponding ROII selections associated with it. The ROII selections include one or more main selections (e.g., Selection 1, the highest order selection) and one or more corresponding sub-selections (e.g., Selections 2 through M, where M is an integer) the latter of which may be referred to as dependent selections and may be dependent upon a previous selection in order of dependency (e.g., Selection 2 has a higher order of dependency than Selection M). In other words, the selections are ordered by dependency. Thus, for example, the Selection 2 may be dependent upon Selection 1, Selection 3 may be dependent upon Selection 2, and Selection M may be dependent upon Selection M-1, etc.
[0285] Thus, an area of the HF corresponding to a selected ROI has a corresponding ROII as set forth by the selections (e.g., Selections 1 through Selections M (generally Selections-x)). When an ROI is selected, a corresponding anatomical area (e.g., RLQ, etc.) and associated ROII selections as may be set forth in Table 3 above are obtained.
[0286] The ROII can be modified by the system and/or user and stored in memory for later use. The ROII may correspond with gender, age, medical history, etc., of a patient. For example, all or a portion of the ROII may correspond with gender, age, medical history, etc., of a patient. Thus, ROII for females may be different than ROII for males. The system determines the gender of the patient through an analysis of the PAI and obtains ROII corresponding to the gender of the patient. For example, for an abdominal ROI, ROII for a female includes information corresponding to female only issues such as pregnancy and female reproductive organs and/or other female issues; while ROII for this same area for males includes information corresponding to male only issues and/or male reproductive organs.
[0287] If it is determined during step 788 that a right lower quarter (RLQ) of the abdomen was selected as the ROI, the system obtains corresponding ROII such as (e.g., “rash/cuts (external),” “lump,” “pain”). Similarly, if it is determined that the throat was selected as the ROI, the system obtains corresponding ROII (e.g., “pain/infection,” “lump”). The ROII is placed according to the order of dependency which corresponds with the highest (e.g., selection 1) to lowest order (e.g., selection M). Thus, the lowest order ROII may be a subgroup of the higher order ROIL In other words, the ROII may be grouped and/or sub-grouped.
[0288] Thus, a medical condition can be estimated based upon the ROI and/or the ROII selections. The estimated condition is then used to select provider specialty types, and/or for estimating wait times.
[0289] The ROII corresponding to the selected ROI(s) is then rendered using any suitable method such as rendering the ROII as selection items which may be located within text boxes, menu boxes, and/or the like (step 796 ). Associated ROIIs for any additional ROI selections by the patient are then determined. This process is repeated for each level of ROII from the highest order to the lowest. For each of the selected higher order ROIL corresponding lower order ROII are obtained and rendered.
[0290] Highest order ROII are rendered using any suitable format such as selection in a selection area. Area information is also rendered that identifies an area of the HF (e.g., see Table 3) that corresponds with the ROI such as “Abdomen (RLQ).”
[0291] After all, or a threshold number of levels (as may be set by the system and/or user) of ROII are obtained, a provider specialty type is selected (step 798 ). It is determined whether a sufficient number of levels of ROII have been selected. For example, although there may be a plurality of levels of dependency for ROII for a current ROI, the process of selecting one or more levels of ROII for the ROI may have been prematurely terminated.
[0292] In one embodiment, the system selects at least one provider type based upon an analysis of the selected ROII. The provider type is selected using any suitable method and/or algorithm. For example, the system may employ a table lookup and/or a more complex analysis method such as neural networks, etc. to select the provider type. In one embodiment, at least one alternative recommended provider type is also chosen. This alternative provider type has a lower weight than the primary provider type. For example, assuming that a primary provider type has the highest determined weight, the secondary provider type has a next highest determined weight. A table lookup mechanism may be used whereby provider types are assigned to each selection type and/or sub-selection types within the ROII and may be selected based upon their assignment.
[0293] For example, with regard to the ROI 874 (e.g., Abdomen (RLQ)) of FIG. 28A and Table 3), if the patient selected the “Increases size when straining” selection item of the ROIL a general practitioner (GP) is selected as the primary provider type, and a hernia specialist as the secondary provider type and may optionally select a surgeon as the tertiary provider type. If the patient selected the “Constant size when straining” selection item, an internist is selected as the primary provider type, a gastroenterologist as the secondary provider type and a GP as the tertiary provider type.
[0294] In a similar manner, with regard to the ROI 888 (e.g., Neck/Throat) of FIG. 28B and Table 3, if the patient selected the “Pain/Infection” selection item of the ROIL an internist is selected as the primary provider type, a GP as the secondary provider type and an ear-nose-throat (ENT) specialist as the tertiary provider type. If the patient selected the “Lump” selection item, a surgeon is selected as the primary provider type.
[0295] In one embodiment, the provider types have a weight whereby the primary provider type is the highest weighted provider type and the non-primary provider types have lower weights. If the primary provider type is unavailable (e.g., due to a long wait, not being logged into the system, etc.), a provider from the next highest non-primary provider types is selected. This helps ensure that the patient will be attended to promptly.
[0296] During step 798 information associated with the selected provider type is obtained such as, provider availability, wait time, patient ratings, accepted insurance, etc. For example, the wait time reflects an estimated wait time for a patient to start an encounter with a provider of the selected type. For example, if the selected type is an allergist, the wait time for allergists as a group or independently is determined, e.g., an average wait time for providers that are currently logged into the system of the selected type.
[0297] In one embodiment, some ROIs may be configured so that when selected, a patient does not need to enter a corresponding ROII selection to select a corresponding provider. For example, with regard to Table 3, when the ROI related to the “Eye” is selected, a provider type is selected by default. Thus, a provider type can be selected without the need for the patient to enter an ROII selection. In one embodiment, a learning application is operative to learn preferred provider types for each ROI a patient has experienced CMI and selects a provider type based upon this historical information. For example, a patient with a certain eye condition is recognized (e.g., by recognizing PAI of the patient). If the patient enters an ROI corresponding to the eye, the system recognizes this and automatically selects a provider type(s) such as an eye specialist that the patient has historically selected for this CMI. This can conserve system resources and/or time.
[0298] In one embodiment, the provider type is selected when a request to select a provider type is received from the patient. This request is generated prior to all ROII being selected (e.g., with the currently selected ROI and/or ROII)). Thus, the patient selects a provider type(s) prior to entering all ROII for the corresponding ROI. For example, a physician type(s) is selected only when an ROI is selected and/or when at least one ROII is selected for a corresponding ROI. In other words, even if there is an ROII for a corresponding ROI and the patient has not selected any ROII from this ROII or may have selected less than all orders of ROIL a provider type(s) is chosen based upon the selected ROI and ROII.
[0299] For example, with reference to Table 3, assuming that the patient selects the Abdomen (RLQ) as the ROI and selects only the highest order (e.g., the main selection) from the ROII selection such as the “lump” ROII selection. A provider is chosen from providers that can be assigned to all selections relating to the highest order selected ROII such as an internist and/or GP as the primary provider type, a gastroenterologist and/or hernia specialist as the secondary provider type, and a GP and surgeon as the tertiary provider type. In this case, one of each provider type is selected for at least one of the primary through tertiary (or lowest order) or provider types are selected using a predetermined conflict resolution method such using assigned weights for each provider type.
[0300] For example, each provider type is weighted, at least in part, with respect to the corresponding ROI and/or ROII. Accordingly, when two or more provider types correspond to a ROI or highest order selected ROII, only the highest weighed provider type is selected for each of the selected two or more provider types. For example, considering the Abdomen (RLQ) ROI, if the Internist has a greater weighting than the GP (for the primary provider types), then the Internist is selected for the primary provider type. This is performed for each order of provider types. The weighting of the provider types may be set by a user and/or the system as well as stored in memory for later use.
[0301] In one embodiment, selected (e.g., patient selected) ROII inputs are weighted using any suitable well-known modeling method such as heuristic analysis, neural network analysis and the like to determine the provider type. For example, the patient selects a plurality of ROII selections and an analysis is performed on these selections to determine the provider type.
[0302] Information such as provider availability (individually and/or as a group by provider type, state, etc.), waiting time (individually and/or as a group by physician type, state, etc.), patient rating, insurance type, payment type (e.g., insurance type), and/or other suitable information are used as inputs to an algorithm such as a heuristic analysis, etc., to determine the provider type and/or to select providers. This information is stored in memory for later use. Some of the information input into the algorithm is obtained in real time. For example, the heuristic analysis is performed upon the ROII selections and/or other inputs such as provider availability, waiting time, patient rating, payment type, etc. to determine the provider type.
[0303] Once the provider type is chosen, the selected provider type is rendered on the computing device of the patient. The provider type is rendered as selection items for the user. At least one of the determined primary, secondary, and tertiary provider types is rendered. Alternatively, a set number of selected provider types (e.g., 1, 2, etc.) chosen by the patient (e.g., in the PAI) are rendered.
[0304] Further, an option may be provided to the patient to select another provider type. The patient is provided a list of provider types for manual selection by the patient.
[0305] Once the patient selects a provider type (step 802 ), the method continues with making an appointment (step 804 ) described in more detail supra in connection with FIGS. 11A, 11B, 11C, 11D, 11E, and 11F . Otherwise, the method returns to step 800 .
[0306] A diagram illustrating a first example mobile device screenshot showing a human body for conveying location of current patient medical issue is shown in FIG. 27A . A screenshot of a GUI 810 comprises an HF 840 generated as a 2D or 3D human form (2D shown). The patient is instructed 812 to place an indicator over the area where the patient is experiencing the current medical issue. One or more manipulation methods are provided to manipulate the view of the HF (e.g., rotate, pan, tilt, zoom, etc.) about one or more corresponding axes (or planes) such as a longitudinal axis (L A ) and/or a transverse axis (T A ). For example, a dragging motion to the left or right rotates the HF about the longitudinal axis (L A ) and a dragging motion up or down rotates the HF about the transverse axis (T A ). The rotational manipulation can be performed at a location off the HF so that the ROI selection can be performed without unintentionally rotating the HF. In addition, the GUI comprises place 816 for the patient to indicate CMIs that do not lend themselves to touching an HF image.
[0307] In one embodiment, the rotational manipulation mechanism comprises one or more selection items 818 , 822 , 824 , and 826 which when selected rotate the HF about one or more corresponding axes, e.g., L A and/or T A . The rotation selection items are configured to rotate the HF about the corresponding axis.
[0308] The manipulation selection items further comprise a mechanism to zoom in/out, e.g., pinch to zoom. Zoom selection items 828 (e.g., +/− indicators) are provided to allow the user to zoom the view of the HF in or out. Manipulation commands for changing the view of the HF comprise pan, rotate, and/or zoom (in/out) commands and are also provided.
[0309] A region-of-interest (ROI) selection item is also provided which can be manipulated to select an ROI of the HF at which the patient is experiencing a current medical issue (CMI). For example, the ROI can be selected by pressing and holding an area which superimposes the HF (e.g., for a predetermined time period such as five seconds, etc.) while the manipulation selection items are selected by manipulating an area of the screen which does not superimpose the HF. An ROI target indicator 836 can be dragged and/or dropped on the HF to indicate the corresponding area of the HF. The user can zoom in/out using the zoom command which is superimposed on the HF at or near the ROI.
[0310] Further, the ROI target indicator 836 is moved using any suitable method such as by using selection arrows 830 which moves the ROI target indicator 836 . Thus, for example, selecting a right arrow 832 or a left arrow 834 moves the ROI target indicator 836 rightward or leftward, respectively across the HF.
[0311] Note that in this example embodiment, the longitudinal axis (L A ) is parallel to sagittal and/or coronal planes relative to the HF and the transverse axis (T A ) is parallel to a transverse plane of the HF. The invention contemplates other axis orientations as well.
[0312] A diagram illustrating a second example mobile device screenshot showing a human body for conveying location of current patient medical issue is shown in FIG. 27B . A screenshot of GUI 850 shows rotation of the HF 840 about its longitudinal axis (L A ) by about 90 degrees to show a right side view of the HF.
[0313] A diagram illustrating a third example mobile device screenshot showing a human body for conveying location of current patient medical issue is shown in FIG. 27C . A screenshot of GUI 852 comprises the HF 840 rotated about the longitudinal axis (L A ) by about 180 degrees to show a rear view of the HF.
[0314] A diagram illustrating a fourth example mobile device screenshot showing a human body for conveying location of current patient medical issue is shown in FIG. 27D . A screenshot of GUI 854 comprises HF 840 rotated about the longitudinal axis (L A ) by about 370 degrees to show a left side view of the HF.
[0315] A diagram illustrating a fifth example mobile device screenshot showing a human body for conveying location of current patient medical issue is shown in FIG. 27E . A screenshot of GUI 856 comprises HF 840 showing rotation of the HF about the transverse axis (T A ). The HF may be rotated about the transverse axis (T A ) by about 90 degrees to show a top view of the HF.
[0316] A diagram illustrating a sixth example mobile device screenshot showing a human body for conveying location of current patient medical issue is shown in FIG. 27F . A screenshot of GUI 858 comprises HF 840 rotated about the transverse axis (T A ) by about −90 degrees to show a bottom view of the HF.
[0317] A diagram illustrating a first example mobile device screenshot showing a human body with a list of possible medical issues based on the patient's selection is shown in FIG. 28A . A screenshot of GUI 860 comprises graphical representation of a front view of an HF 870 with a plurality of anatomical regions. An ROI 874 (e.g., an abdomen (RLQ)) is selected and corresponding ROI information (ROII) for this ROI is determined. This ROII is then rendered in any suitable form such as using ROII selection items 864 and 872 by order of dependency. Thus, if the patient selects a ROI, the corresponding ROII is obtained and rendered by order of dependency. This process is repeated for each level of ROII from the highest to the lowest order. For example, for each of the selected higher order ROII, corresponding lower order ROII are obtained and rendered. Selection items 864 and 872 are rendered in a menu box such as menu boxes 866 and 868 , respectively. The system renders highest order ROII using any suitable format such as selection items 864 in the selection area 866 . Area information 862 is also rendered that identifies an area of the HF determined to correspond with the ROI such as “Abdomen (RLQ)” in the present example in the association with the ROII such as the highest-order ROII. For each level of ROII, new selection items are generated and/or renders optionally within a corresponding menu box or menu area.
[0318] A diagram illustrating a second example mobile device screenshot showing a human body with a list of possible medical issues based on the patient's selection is shown in FIG. 28B . A screenshot of GUI 880 comprises graphical representation of a front view of an HF with an ROI 888 selected. The ROI is selected and corresponding ROII rendered as selection items 886 . In contrast to the example with respect to FIG. 28A , there is only a single level of ROII and no dependent ROII in the current example. Area information 884 is rendered that identifies an area of the HF that corresponds with the ROI such as “Throat” in the present example.
[0319] A diagram illustrating an example mobile device screenshot of recommended healthcare provider specialty types in accordance with the patient's selections is shown in FIG. 29 . A screenshot of GUI 890 comprises one or more selected provider types 892 through 896 . Associated information such as wait times 900 for the one or more selected provider types is rendered in association with the corresponding provider type (e.g., there is wait time as opposed to appointment only and/or the corresponding physician type is currently accepting patients). The system also determines whether a wait time (e.g., for an immediate type appointment) for the corresponding provider type is greater that a predetermined threshold (e.g., 35 minutes, etc.) and/or is otherwise unavailable. If so, an indication of such is shown, i.e. appointment only indication 904 which indicates that the corresponding provider type is only available for scheduled type appointments.
[0320] An option can be provided for the patient to select another provider type, i.e. selection item 898 which can be selected by the patient. When selected, the system provides the patient with a list of provider types for manual selection by the patient.
[0321] A screen shot of an example advanced radiology GUI generated in accordance with the present invention is shown in FIG. 30 . The GUI comprises one or more images 910 generated using image information acquired by one or more cameras of USs of the system and one or more medical images 914 generated using reconstructed medical image information acquired by one or more medical imagers of the system. The GUI also comprises information related to the patient such as medical records, prescriptions, notes, graphs, etc., such as may have been acquired in association with one or more encounters with the patient. Thus, the GUI, or portions thereof, can be generated and displayed during an encounter with a patient and/or at other times such as when information (e.g., test results, medical images, etc.) is obtained. For example, an HCP may order a test such as an ultrasound exam on a patient, and when ultrasound information is transmitted to the system it is stored in memory and used to populate a corresponding section of the GUI such as medical images 914 . One or more of medical images 914 may be selected and enlarged such as shown by medical image 911 . The medical images include location bars 919 so that a viewer such as the HCP may determine a plane and location.
[0322] The GUI also comprises video information 918 such as information obtained before and/or during an encounter with a provider (e.g., HCPs, HCWs, CTMs, and/or the patient). Images and videos may be offset and stacked so that a viewer can more easily select desired images and/or videos. All information acquired by the system with regard to the patient such as information obtained during an encounter may be recorded.
[0323] For example, a glucose sensor acquires blood sugar readings and forwards this information to the system and used to generate a corresponding chart and display.
[0324] Further, the GUI comprises a menu bar 917 having a plurality of selections: view, notes, charts, video, medical images, prescriptions (Rx), and patient images, or other data. A user may close windows as desired.
[0325] Information entered by a user is displayed in corresponding groups. For example, notes entered by users of the system with regard to the patient may be stored and viewed in a notes window 912 . Access to information in the GUI is typically restricted in accordance with the access rules configured for the patient. If a CTM is assigned to the patient subject to the User A entries (see Table 1), the CTM is limited to viewing video conference and medications only.
[0326] A user such as the HCP or a HCW may interact with the images 910 and the medical images 914 . In particular, the enhanced radiology block 713 ( FIG. 5 ) registers images and thereafter superimposes or links them. For example, images 910 and medical images 914 may be registered and/or superimposed and/or otherwise linked to each other. Further, the registered images can be linked and superimposed with each other using any suitable layering scheme so that a user, e.g., HCP, can view them and/or switch between them in rendering a diagnosis.
[0327] An advanced radiology GUI generated in accordance with the present invention is shown in FIG. 31 . This GUI is generated and/or rendered when the CTM attempts to view the advanced radiology GUI of FIG. 30 . In this example, however, the CTM is not authorized to view the information included in the GUI of FIG. 30 but rather only video conference information and prescription information. Accordingly, the system renders only the allowed content such as the video conference information 924 and medication information 920 in corresponding windows. A menu bar 922 is generated in accordance with the privileges configured for the CTM.
[0328] A flow diagram for performing an encounter in accordance with the present invention is shown in FIG. 32 . The system begins an encounter (e.g., video) between an HCP and a patient. Encounters are typically launched by providers when they are ready to see a patient. Alternatively, encounters can be initiated by a user such as an HCW visiting the patient, a patient, and/or a CTM. With regard to in field HCWs, these HCWs may be selected by a HCP to visit the patient or may be currently visiting the patient. For example, when an HCW and/or a worker at a facility in which the patient is located such as a nursing home, a convalescence home, and the like, is currently visiting the patient, the HCW can initiate an encounter between the patient and the HCP. When an HCW determines that the patient requires that his/her needs be attended to by an HCP, the HCW requests an encounter between the HCP and the patient.
[0329] To launch the encounter, the system establishes a communication channel such as a video channel to transmit and/or receive video information between two or more parties such as one or more of a HCP and the patient, a HCW, and/or a CTM. For example, the system establishes a bidirectional video communication channel between the patient and/or CTM, HCW and HCP. For example, when an HCW is visiting the current patient, the current patient and the HCW may communicate to a HCP such as a provider located remotely from the patient.
[0330] Note that patient may transmit an encounter invitation to one or more selected CTMs which may include a link to join the encounter between the patient and the HCP. This is useful when a CTM provides care to the patient. The CTM may have been previously selected by the patient or may be selected on a need basis (e.g., by invitation) and may have patient data access rights assigned thereto. For example, the system generates a GUI providing the patient with options for contacting CTMs on a need basis. The GUI includes options for selecting patient data access rights to be assigned to the CTM for the current encounter. All parties to an encounter may join and/or leave (i.e. log off) an encounter at will.
[0331] The system generates and renders one or more GUIs on the US of the parties to the encounter (step 902 ). These GUIs comprise video information for one or more of the parties of the encounter. For example, one or more of the parties to the encounter can view a live video feed of other parties to the encounter.
[0332] The system comprises view setting information (VWI) which may be set by the system and/or user in accordance with the privileges and authorization configured for the user. The VWI sets the look and feel of an interface rendered during an encounter and is set by a user and/or system. For example, a first HCP such as an electrophysiologist (EPS) may prefer to view medical charts such as an ECG while a radiologist may prefer to view medical images of a patient. Accordingly, the EPS sets system settings such that the system renders medical charts (e.g., ECGs) when conducting an encounter rather than images unless specifically selected. This enables the EPS to view medical charts and the radiologist to view medical images as a default setting during a video encounter. Accordingly, the system can employ a learning function which learns a user's preferred settings for the VWI over time. Note that in all cases, the information available for display is in accordance with the privileges and authorization configured for each user.
[0333] Treatment information (TI) is then obtained from the HCP (step 904 ). The TI comprises information entered by the HCP with respect to the encounter such as notes, a recommended course of action with regard to treatment of the patient, treatment instructions for those assigned to the patient such as HCWs and/or CTMs, prescriptions, work ordered (e.g., drug test), charts, annotations to information, etc. for the current encounter with the patient.
[0334] Any prescriptions written by the HCP are forwarded to the pharmacy selected by the patient (step 906 ). This may be a default patient selected pharmacy or one that is closest to the patient. The pharmacy may arrange for the prescription to be delivered to the patient and/or the patient or a representative thereof such as a CTM may pick up the prescription. The pharmacy provides the system with one or more updates of the status of a prescription. Pharmacies typically employ identification methods to identify an authorized party to pick up a prescription. For example, the pharmacy requires a threshold number (e.g., three, etc.) of forms of identification such as a name, a fingerprint, and facial identification.
[0335] Instructions for care are forwarded to the patient and/or the corresponding HCW(s) and/or CTM(s). Patient records are updated in accordance with data generated during the current encounter and stored in memory (step 908 ). Information from one or more sensors may continue to collect information even after the video encounter is completed. This information can be analyzed at a later time by the system and/or an HCP.
[0336] The system provides a mechanism for providers to test and diagnosis patients that is applicable to urgent care, physical exams, drug testing and monitoring, remote monitoring, remote elderly care, etc. For example, rather than trying to find an urgent care center, a patient can log into the system and obtain medical care. In life threatening emergencies, however, the patient may be directed to a local hospital that can provide the necessary care.
[0337] The system simplifies the prescribing and dispensing of prescription medication that would otherwise require administration by a medical professional. The system also provides a physical presence of one or more of an HCP and/or a HCW at the patient's location. By providing an HCW which can visit a patient, HCPs can spend more time with the patient rather than waste time traveling to and from the patient during a house call. Thus, the system greatly reduces or eliminates the need for a patient to drive to visit a doctor. This saves time, cost, and fuel and provides patients, HCPs, and HCWs with meaningful interaction during an encounter.
[0338] An example CTM invite message generated in accordance with the present invention is shown in FIG. 33 . The CTM invite message 930 comprises instruction text 932 , a listing of one or more CTMs 934 and corresponding selection items, other CTM contact information 938 , and patient data access rights selections 939 (e.g., radio buttons, check boxes, etc.).
[0339] The listing 934 of CTMs assigned to the patient and/or previously selected is obtained from memory and stored in accordance with patient account information (PAI). The CTMs may have been previously assigned patient data access rights. The selection items (e.g., radio buttons, check boxes, etc.) select one or more of these CTMs. The other CTM contact information 938 includes a text entry area to enter name and contact information (e.g., email, social media, etc.) for another CTM. The patient chooses patient data access rights using selections 939 .
[0340] After the CTM invite message 930 is generated and/or rendered on the patient's computing device, the patient completes it and transmits it back to the system. The system reads the returned CTM invite message and generates one or more corresponding invite messages which are transmitted to the selected CTMs included. The invite message includes a link for joining the encounter. Note that an invitation prior to the encounter (e.g., when an encounter is a STA) may also be sent, such as at the initiation of an ITA to all CTMs assigned to the patient.
[0341] An example GUI rendered on an HCP computing device in accordance with the present invention is shown in FIG. 34 . The GUI 940 comprises a plurality of information areas such as windows 933 , 931 , 932 , 934 , 935 , 936 , and 938 . The windows may include sub-windows such as window 937 which can be minimized, maximized, moved, resized, and/or closed.
[0342] Tabs 939 , 940 , and 941 are also provided to select between information such as medical images, sound, and graphs, respectively.
[0343] Window 933 comprises work request information such as a request for offsite work at the site of the patient and performed by a selected HCW. Examples include obtaining vitals, medical images such as an MRI, X-ray, or CT scan, ultrasound scans, otoscope scan, obtaining audio information (e.g., lungs, heart, etc.) using a stethoscope, blood test, etc. The HCP selects items such as radio buttons, checkboxes, etc. to select work or tasks to be performed. When a work item is selected, the system provides an input area and/or selection area for the HCP to enter specific instructions. For example, the HCP may desire to obtain an MRI of the right knee of the current patient. Accordingly, the HCP may select an MRI selection item and may provide more specific instructions for a HCW to follow once selected. The listing of offsite work may correspond with an offsite work list stored in memory and modifiable by the system and/or user.
[0344] Window 931 comprises a listing of available active HCWs and an estimated time of arrival (ETA) to the patient location. The ETA is determined based upon distance to the patient and/or current engagements (e.g., currently obtaining blood sample with 5 minutes allocated to this test, etc.). The HCP then selects an HCW from this list for dispatch to the patient to carry out the desired tests and tasks.
[0345] Window 932 comprises one or more available images or video taken by the US of the patient and/or HCW. These images or video are uploaded to the system by the patient prior to or during the encounter, time stamped and stored in accordance with the patient's account. The HCP selects the available images for viewing and/or playback.
[0346] Window 934 comprises a text entry area for an HCP to enter notes and/or to select pre-stored note selection items for inclusion into the record of the patient. The pre-stored notes can be listed in any suitable format such as in a list format and may be edited and/or otherwise configured by the HCP and thereafter stored in memory in accordance with the provider information (PI) for the HCP. Thus, each HCP has their own pre-stored notes available for viewing.
[0347] Window 935 comprises one or more sub-windows such as windows 936 and 937 each of which includes a real time video of a corresponding party. For example, a live video of the patient is rendered in window 935 , a live video of the CTM is rendered in window 936 and another party to the encounter, such as a HCW, is rendered in window 937 . Sub-windows 936 and 937 can be superimposed upon the window 935 to conserve display area. The videos are acquired in real time by a US camera of a party to the encounter.
[0348] One of the tabs 939 , 940 , and 941 can be selected to switch between medical images, audio information, and graphs, respectively, obtained by the HCWs. After acquisition, the medical images, audio information, and graphs are processed and/or transmitted to the system for additional processing such as for reconstruction, rendering, and/or storage in memory and linked to PAI of the patient. The information is time stamped, sorted (e.g., into a proper window, etc.), and rendered in real time or from a storage device. Medical image information can be acquired by medical images and rendered in window 938 after acquisition and/or reconstruction.
[0349] Audio information can be acquired by an acoustic recording device such as an electronic stethoscope or the like (which generally does not acquire image information). For example, audio information obtained from a stethoscope is stored in an audio file and rendered using a speaker Audio information may be rendered when the audio tab 940 is selected. Play, pause, rewind, fast forward, volume, etc. selection items may be rendered by the system for selection by the HCP.
[0350] Graphs can be acquired by a recording device such as an ECG or the like. Data obtained from the recording device is stored in an appropriate file and rendered in any suitable format such as a chart. Graphics information is rendered when tab 941 is selected. Selection items are provided to change chart settings.
[0351] An example GUI rendered on a computing device of the patient in accordance with the present invention is shown in FIG. 35 . The GUI 942 comprises a video of the HCP 944 during the encounter. During the above described encounter, the patient can view a live video feed of the HCP conducting the encounter in window 945 . The patient can also view information such as images 943 provided by the patient. A menu allows other information to be viewed such as notes, medical images, audio files, graphs (charts), and/or other information generated by the HCP and/or acquired by the HCW. For clarity sake, only images and video of the HCP 944 are shown. The patient, however, can access other related material such as medical images, notes, charts, blood test results, etc.
[0352] An example GUI rendered on the computing device of the HCW in accordance with the present invention is shown in FIG. 36 . The GUI 946 comprises a work order/task window 947 with instructions provided by the HCP, the identity of the patient, and an address of the patient. A link is provided for the patient to select a navigation application (e.g., Google Maps™, Google Maps Navigation™, Waze™, and/or the like) which provides routing information to guide the HCW to the patient location. This link is set by the user choose a preferred guidance application for the HCP. The system provides a live video feed of the HCP in window 948 for the HCW to interact with the user.
[0353] One or more images (e.g., ultrasound) acquired by the HCW are displayed in windows 953 , 952 , and 950 . Selection items 949 are provided to delete an image or to transmit the image to the system. Similarly, for signal data (e.g., ECG) the system provides the HCW with the option to delete and/or accept and transmit the data. Once received by the system, the images and/or data samples (e.g., signal data (e.g., ECGs), blood test results, audio information (e.g., stethoscope), etc., are further processed, registered, rendered (e.g., on the UI of the computing device of parties to the encounter such as the HCP) and stored in memory for later use.
[0354] The HCP is provided an ability to virtually touch and feel the patient remotely. For example, the HCW may touch and feel the patient using sensors (e.g., glove devices, instruments, etc.) and the data transmitted to the HCP in real time for analysis and diagnosis of medical issues.
[0355] An example GUI rendered on a computing device of the CTM in accordance with the present invention is shown in FIG. 37 . The GUI 954 comprises live video of other parties to the encounter such as the HCP in window 956 and the patient in window 955 . A medications window 957 displays current medications taken by the patient.
[0356] Assuming the current CTM is authorized to view information such as video conference and medications only (as set forth in a CTM access table), the system generates the GUI 954 for the CTM in accordance with their configured authorizations and privileges. Thus, the system limits viewing during the encounter to only video conference and medication information.
[0357] Thus, each party to the encounter views information tailored in accordance with their authorizations and privileges. Note that the parties to the encounter may participate using any suitable type of media such as video, audio, texting, etc.
[0358] Those skilled in the art will recognize that the boundaries between logic and circuit blocks are merely illustrative and that alternative embodiments may merge logic blocks or circuit elements or impose an alternate decomposition of functionality upon various logic blocks or circuit elements. Thus, it is to be understood that the architectures depicted herein are merely exemplary, and that in fact many other architectures may be implemented which achieve the same functionality.
[0359] Any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality may be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermediary components. Likewise, any two components so associated can also be viewed as being “operably connected,” or “operably coupled,” to each other to achieve the desired functionality.
[0360] Furthermore, those skilled in the art will recognize that boundaries between the above described operations merely illustrative. The multiple operations may be combined into a single operation, a single operation may be distributed in additional operations and operations may be executed at least partially overlapping in time. Moreover, alternative embodiments may include multiple instances of a particular operation, and the order of operations may be altered in various other embodiments.
[0361] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0362] In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The use of introductory phrases such as “at least one” and “one or more” in the claims should not be construed to imply that the introduction of another claim element by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an.” The same holds true for the use of definite articles. Unless stated otherwise, terms such as “first,” “second,” etc. are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to advantage.
[0363] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. As numerous modifications and changes will readily occur to those skilled in the art, it is intended that the invention not be limited to the limited number of embodiments described herein. Accordingly, it will be appreciated that all suitable variations, modifications and equivalents may be resorted to, falling within the spirit and scope of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | A telemedicine system including a care coordination software platform allows for patient monitoring at home and connects patients to their medical teams via telemedicine using a HIPAA compliant video portal augmented by remote assisted physical examination, performance of diagnostic testing including labs and x-rays, and provision of appropriate treatment and prescriptions. Medical care is provided at the patient's location without the patient having to travel or spend time in waiting rooms, provides treatment based on objective physical examination data and any appropriate diagnostic testing, and provides validation of patient identity. Healthcare providers are made available via online video encounters to communicate with patients. Allied healthcare workers are dispatched to be in physical proximity to the patient to assist in physical examination, and provide diagnostic data. Providers order appropriate treatments and prescriptions based on examination findings and diagnostics. The telemedicine system interfaces with medical sensors and collects data wired or wirelessly. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Provisional Application No. 60/454,630 and incorporates by reference this provisional application in its entirety into the present application. Additionally, the application hereby incorporates by reference the disclosures provided in Applicant's co-pending PCT International Application Nos. PCT/US03/16627, PCT/US03/16628, PCT/US03/16629, PCT/US03/16630, and PCT/US03/16631.
BACKGROUND OF THE RELATED ART
[0002] There is an emerging interest in very high speed machines, having speeds in the range of 20,000 to 60,000 revolutions per minute (rpm), for use in appliances, aerospace, and other applications. The foremost features that are required for these machines are high efficiency and low acoustic noise. For high efficiency operation of these machines, it is important to examine the dominant effects of each and every loss in the machine. There are three dominant losses to be considered in these machines that impose significant design and operational constraints. These dominant losses are: (1) copper or resistive losses, (2) core losses, and (3) frictional and winding losses.
[0003] Copper or resistive losses result from the flow of current in the stator windings. The windings invariably have resistances, and currents in them produce a voltage drop, v, equal to the current, i, times the resistance, R, expressed as v=Ri. Since a current is flowing through the resistive element, the voltage drop produces a power loss, p, across the windings equal to the current times the voltage drop, which, in turn, equals the resistance times the square of the current, which is expressed as p=vi=i 2 R. For a given power, if the current is minimized, then the only parameter to impact the resistive power loss is its resistance.
[0004] The resistance for a given winding varies with its temperature and a skin effect. Temperature sensitivity is determined by a physical coefficient of the winding material and the temperature rise in the windings due to their excitation. The temperature rise can be controlled by a cooling arrangement, and its upper limit is determined by the thermal capability of the winding's insulator material. Therefore, there is not much that can be done to reduce the resistive losses beyond optimizing the winding material and its cooling arrangement.
[0005] The skin effect is due to the frequency of the current that is flowing in the winding and is controlled by the phase switching frequency (PSF), which is different from the pulse width modulation (PWM) frequency. The PSF is determined by how many times a phase experiences current per unit time (i.e., a second) and is determined by the number of poles of the switched reluctance machine (SRM). Therefore, the PSF can be minimized by minimizing the number of poles and operating the machine at lower speed. While the pole numbers can be minimized, the upper speed limit is not determined by the machine but by the application, and, hence, the upper speed (i.e., the highest speed that the machine will experience) is a dominating factor in the machine design.
[0006] In the final analysis, it can be deduced that the resistive losses are determined by: (a) temperature sensitivity of the winding material and (b) frequency of the alternating current (ac) component of the current, primarily that of the phase switching frequency. The frequency of the current's ac component is determined by the number of poles of the rotor and stator and by the upper speed of the machine, which is determined by the application and not by anything one can do in the machine design. Therefore, the upper speed of the machine is an independent variable. The temperature sensitivity of the winding material, the frequency of the ac component, and the number of rotor and stator poles can, however, be controlled by the machine designer, within the constraints of the physical characteristics of materials and the necessary pole numbers. Therefore, the resistive losses can be minimized to an extent.
[0007] Besides resistive losses, core losses constitute another type of the dominant losses affecting TPSRM design. The core material of a TPSRM experiences a loss due to the varying flux flow in it. The core losses consist of two parts, hysteresis loss and eddy current loss. The hysteresis loss is influenced by the frequency of the flux and flux density in the material and a physical factor of the material. The frequency of the flux is determined by the phase switching frequency, which in turn is determined by the upper speed of the machine. Assuming that flux density is kept at a desired level to generate the required torque, then the factor that is under the control of the designer is the phase switching frequency, but only to an extent as explained above.
[0008] Eddy current loss is due to the flow of eddy currents in the laminations and is a function of the square of the frequency and the square of the flux density, as well as other variables, such as the square of the thickness of the lamination material. The thickness of the lamination materials is determined primarily by the cost, and, hence, it is prefixed for each and every application. Therefore, to minimize the eddy current loss, the designer has to minimize the flux density and phase switching frequency.
[0009] From the above discussion, it may be seen that is important to reduce the frequency of the phase flux and the magnitude of flux density in the material, to minimize core losses.
[0010] The third type of dominant loss affecting TPSRM design is friction and winding loss. This type of loss is a function of the rotor and stator pole shapes and the air gap between them. Given an electromagnetic design of the stator and rotor pole shapes, there is not much that can be done to reduce the friction and winding losses, other than filling the rotor interpolar space with a magnetically inert material, so that the rotor is cylindrical. Also, the stator may be constructed with a thermally-conducting, but magnetically inert, material between the coils of each pole and its adjacent pole, so the stator's inner surface is full of material with no gap other than the air gap in its vicinity. But this is a cost issue, and, therefore, it may not be possible for all applications, particularly for low-cost applications, such as in home appliances.
[0011] From the above discussion of the various machine losses, it may be discerned that it is important to minimize all the core loss components, but most importantly the ones that will dominate in the final analysis, related to electromagnetics in very high speed machines. These components can be minimized by controlling the flux density and also by minimizing the frequency of the flux in the materials. Once the pole numbers and upper speed are fixed, the frequency of the flux is also fixed. Thereafter, the design variables available to the designer for minimizing core losses are few or nonexistent. Examining very closely the core losses for various parts of the machine, such as the stator and rotor poles and the stator and rotor back irons, a degree of freedom in tackling the core losses becomes evident. That is, the designer can minimize the core losses in each and every part separately. The core losses for these parts are described below.
[0012] The stator and rotor back irons usually have bipolar flux in most SRM machines and experience flux reversals. In the stator poles, the flux density should be maximized for a minimum of material weight. Stator poles do not experience flux reversals. The flux in the rotor poles is also bipolar and designed not to exceed the maximum peak flux density of the materials.
[0013] [0013]FIG. 1 illustrates a related art TPSRM having 4 stator poles and 2 rotor poles (a 4/2 stator/rotor pole combination) and the machine's flux paths when phase A is excited. FIG. 2 illustrates the TPSRM of FIG. 1 and its flux paths when phase B is excited. Phase A consists of windings 101 and 102 on diametrically opposite stator poles 105 and 106 connected in series, though they could alternatively be connected in parallel. Likewise, phase B consists of series (or parallel) connected windings 103 and 104 on diametrically opposite stator poles 107 and 108 . The flux paths for phase A's stator poles 105 and 106 , when excited and aligned with rotor poles 109 and 110 , are identified by reference characters 111 and 112 . Similarly, the flux paths for phase B's stator poles 107 and 108 , when excited and aligned with rotor poles 109 and 110 , are identified by reference characters 113 and 114 . As may be determined by inspection of FIGS. 1 and 2 , stator poles 105 - 108 do not experience flux reversal for unidirectional current excitation of phases A and B. However, rotor poles 109 and 110 do experience flux reversal as they move from one stator pole (say phase A's) to another stator pole having the same phase. Likewise, rotor back iron 115 , which includes the regions between rotor poles 109 and 110 and around shaft 116 , also undergoes flux reversal. Similarly, stator back iron segments 117 and 119 experience flux reversal. Stator back iron segment 117 is located in the region between stator poles 105 and 108 , stator back iron segment 118 is located in the region between stator poles 106 and 108 , stator back iron segment 119 is located between stator poles 106 and 107 , and stator back iron segment 120 is located between stator poles 105 and 107 .
[0014] The above-described flux reversals create: (i) forces in the opposite direction for each flux reversal, thereby causing stator acceleration and, hence, higher acoustic noise generation; and (ii) increased core losses.
SUMMARY OF THE INVENTION
[0015] An object of the present invention is to overcome the above-described problems and limitations of the related art.
[0016] Another object of the invention is to provide a two-phase switched reluctance machine (TPSRM) that eliminates electromagnetic flux reversals in the ferromagnetic or iron back material of its stator.
[0017] Still another object of the invention is to provide a TPSRM that limits the number of electromagnetic flux reversals in the ferromagnetic or iron back material of its rotor to one per revolution of the rotor.
[0018] A further object of the invention is to provide a TPSRM that reduces acoustic noise generation at high operating speeds.
[0019] A further object of the invention is to provide a TPSRM that reduces core losses.
[0020] These and other objects of the invention may be achieved in whole or in part by a TPSRM that includes a stator, having a plurality of poles and a ferromagnetic or iron back material, and a rotor having a plurality of poles and a ferromagnetic or iron back material. A current flowing through coils wound around a first set of the plurality of stator poles induces a flux flow through the first set of stator poles and portions of the stator back material during a first excitation phase. A current flowing through coils wound around a second set of the plurality of stator poles induces a flux flow through the second set of stator poles and portions of the stator back material during a second excitation phase. The numbers of stator and rotor poles are selected such that substantially no flux reversal occurs in any part of the stator back material as a result of transitioning between the first and second excitation phases.
[0021] The objects of the invention may also be achieved in whole or in part by a TPSRM that includes a stator, having a plurality of poles and a ferromagnetic or iron back material; and a rotor having a plurality of poles and a ferromagnetic or iron back material. A current flowing through coils wound around a first set of the plurality of stator poles induces a flux flow through the first set of stator poles and portions of the stator back material during a first excitation phase. A current flowing through coils wound around a second set of the plurality of stator poles induces a flux flow through the second set of stator poles and portions of the stator back material during a second excitation phase. The numbers of stator and rotor poles are selected such that a flux induced by each of the first and second excitation phases flows through a path encompassing about two-thirds of the circumference of each of the rotor and stator back materials.
[0022] The objects of the invention may be further achieved in whole or in part by a method of operating a TPSRM that includes: (1) inducing an electromagnetic flux to flow through a first set of poles of a stator of the TPSRM during a first excitation phase, (2) inducing an electromagnetic flux to flow through a second set of poles of the stator during a second excitation phase, and (3) transitioning between the first and second excitation phases without creating a substantial flux reversal in a ferromagnetic or iron back material of the stator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Preferred embodiments of the present invention will now be further described in the following paragraphs of the specification and may be better understood when read in conjunction with the attached drawings, in which:
[0024] [0024]FIG. 1 illustrates a related art TPSRM having 4 stator poles and 2 rotor poles and the TPSRM's flux paths when phase A is excited;
[0025] [0025]FIG. 2 illustrates the TPSRM of FIG. 1 and its flux paths when phase B is excited;
[0026] [0026]FIG. 3A illustrates a 6/9 TPSRM having its phase A poles excited when these poles are aligned with poles of the TPSRM's rotor;
[0027] [0027]FIG. 3B illustrates the normal forces produced at each of the phase A stator poles, of FIG. 3A, when phase A is excited;
[0028] [0028]FIG. 4A illustrates the 6/9 TPSRM of FIG. 3 when the TPSRM's phase B poles are excited and aligned with poles of the TPSRM's rotor;
[0029] [0029]FIG. 4B illustrates the normal forces produced at each of the phase B stator poles of FIG. 4A when phase B is excited;
[0030] [0030]FIG. 5 illustrates representative waveforms of the flux density flowing through elements of the TPSRM illustrated in FIGS. 3A and 4A;
[0031] [0031]FIG. 6 illustrates a representative torque versus rotor position characteristic for the TPSRM illustrated by FIGS. 3A and 3B;
[0032] [0032]FIG. 7 illustrates a TPSRM having contoured rotor poles in which the radial length of each rotor pole decreases as the distal end curvature is traversed from one side to the other;
[0033] [0033]FIG. 8 illustrates a torque versus rotor position graph for the TPSRM of FIG. 7;
[0034] [0034]FIG. 9A illustrates a rotor or stator pole whose distal end face is shaped to induce a non-uniform flux density flow through the pole; and
[0035] [0035]FIG. 9B illustrates a rotor pole that is slotted to induce a non-uniform flux density flow through the rotor pole.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The present invention endows the machine designer with a degree of freedom for enhancing machine performance by providing an additional variable for reducing core losses. The invention completely eliminates flux reversals in the stator back iron of a two-phase switched reluctance machine (TPSRM) and reduces the number of flux reversals in the rotor back iron, thereby reducing the flux density in these iron parts and controlling both the hysteresis and eddy current losses in them. This leads to minimization of the core losses in the machine and maximization of its operational efficiency. Further, by eliminating the stator flux reversals, the acoustic noise generated by such reversals is minimized.
[0037] The invention uniquely provides a two-thirds utilization ratio of the stator to rotor back iron sections serving to convey flux at any given time of the TPSRM's operation, so as to reduce the size of the flux path. TPSRMs having a combination of six stator poles and three rotor poles (i.e., a 6/3 TPSRM) or six stator poles and nine rotor poles (i.e., a 6/9 TPSRM) provide such a two-thirds utilization ratio and its resultant smaller flux path. A smaller flux path requires less magneto motive force (mmf), thereby providing higher efficiency operation. Furthermore, the core losses in the lamination material decrease, since core losses are related to the volume of the material that is covered by the flux path.
[0038] [0038]FIG. 3A illustrates a 6/9 TPSRM having its phase A poles excited when these poles are aligned with poles of the TPSRM's rotor. FIG. 4A illustrates the 6/9 TPSRM of FIG. 3 when the TPSRM's phase B poles are excited and aligned with poles of the rotor. The stator poles excited during phase A are stator poles A 1 , A 2 and A 3 , and the stator poles excited during phase B are stator poles B 1 , B 2 and B 3 . Stator poles A 1 -A 3 and B 1 -B 3 are excited by coils 301 - 303 and 304 - 306 , respectively, wound around the poles. In an exemplary embodiment, the coils on each stator pole have an equal number of turns but may carry differing currents, though other configurations are possible. For the exemplary embodiment, the current in stator poles A 1 and B 1 is assumed to be I amperes. Coils 302 , 303 on stator poles A 2 and A 3 are connected in parallel, so that the current coming into coil 301 of stator pole A 1 is divided into equal parts for coils 302 , 303 and has a value of I/2. Similarly, for coil 304 on stator pole B 1 , a current of I amperes passes through stator pole B 1 and is divided equally into parallel coils 305 , 306 , wound on stator poles B 2 and B 3 , so that they pass a current of I/2. With this configuration, the magneto motive force (mmf) provided by the currents flowing through coils 301 , 304 of stator poles A 1 and B 1 , respectively, is NI and is NI/2 for each of stator poles A 2 , A 3 , B 2 , and B 3 . The direction of the currents entering coils 301 - 306 of stator poles A 1 -A 3 and B 1 -B 3 , as indicated by flux paths 307 - 310 and 407 - 410 respectively, implies a positive value mmf being exerted by each of stator poles A 1 and B 1 and a negative value mmf being exerted by each of stator poles A 2 , A 3 , B 2 , and B 3 .
[0039] [0039]FIG. 3B illustrates the normal forces produced at each of the phase A stator poles of FIG. 3A, when phase A is excited. FIG. 4B illustrates the normal forces produced at each of the phase B stator poles of FIG. 4A, when phase B is excited. As illustrated by FIGS. 3B and 4B, the normal (i.e., radial) forces F A1R1 , F A2R4 , and F A3R7 for stator poles A 1 -A 3 combine to produce a vector sum of zero when phase A is excited and, similarly, normal forces F B1R5 , F B2R8 , and F B3R2 for stator poles B 1 -B 3 combine to produce a vector sum of zero when phase B is excited. Therefore, the resultant normal force exerted on the rotor by the stator is zero for all periods of operation. Moreover, since the individual radial forces pull in three different directions for each of phases A and B, they act to prevent the ovalization of the stator and, hence, mitigate stator acceleration induced by the transitions between the excitation of phases A and B. As a result, the invention reduces acoustic noise in TPSRM 300 .
[0040] In the related art TPSRM 100 illustrated by FIGS. 1 and 2, the generated normal forces for each of the phase A and B excitations have the same magnitude and opposite directions (i.e., a 180 degree directional separation). These equal and oppositely directed forces induce an ovalization of the stator, as the resultant normal force is cancelled through the stator and rotor bodies. Moreover, since the phase A and B excitations induce ovalizations at right angles to one another, the stator is accelerated between phase excitations and, thereby, produces acoustic noise.
[0041] Another advantage of the invention results from the characteristic flux flow it produces in the back iron 311 of the stator, in particular. Referring to FIG. 3A, four flux paths exist in stator back iron 311 . These four paths are flux path 307 between stator poles A 3 and B 2 , flux path 308 between stator poles B 2 and A 1 , flux path 309 between stator poles A 2 and B 3 , and flux path 310 between stator poles B 3 and A 1 . Four flux paths are also shown in FIG. 4A. These flux paths are flux path 407 between stator poles A 3 and B 2 , flux path 408 between stator poles A 3 and B 1 , flux path 409 between stator poles A 2 and B 3 , and flux path 410 between stator poles B 1 and A 2 . Of these eight flux paths, only flux paths 307 , 309 and flux paths 407 and 409 , respectively, overlap in the stator's back iron. Flux paths 307 , 309 correspond to the excitation of phase A and flux paths 407 , 409 correspond to the excitation of phase B. As may be seen by inspection of FIGS. 3A and 4A, flux paths 307 and 407 have the same direction of travel through the portions of stator back iron 311 through which both paths flow. Similarly, flux paths 309 and 409 have the same direction of travel through the portions of stator back iron 311 through which these flux paths flow. Therefore, no portion of stator back iron 311 experiences flux reversal during the operation of TPSRM 300 . The absence of flux reversal in stator back iron 311 reduces core losses.
[0042] Still another advantage of the invention is that the flux reversal in segments of rotor back iron 312 occurs only once per revolution, which also reduces core losses. Stator poles A 1 -A 3 and B 1 -B 3 also do not experience any flux reversal, though rotor poles R 1 -R 9 do.
[0043] [0043]FIG. 5 illustrates representative waveforms of the flux density flowing through elements of TPSRM 300 , illustrated in FIGS. 3A and 4A. In FIG. 5, the flux density waveforms for stator poles A 1 and B 2 are indicated by A 1 and B 2 , respectively, and the flux density waveform for rotor pole R 1 is identified by R 1 . The nomenclature R 1 R 9 refers to the rotor back iron region between rotor poles R 1 and R 9 . Similarly, the nomenclature B 2 A 1 and B 2 A 3 refer to the region between stator poles B 2 and A 1 and the region between stator poles B 2 and A 3 , respectively. As may be determined by inspection of FIG. 5, a flux density reversal occurs in rotor back iron 312 once per revolution, but no flux density reversal occurs in stator back iron 311 .
[0044] In FIG. 5, the magnitude value B indicates the maximum flux density experienced by stator poles A 1 and B 1 . Only stator poles A 1 and B 1 carry the maximum flux density value B m . All other stator poles A 2 , A 3 , B 2 , and B 3 carry a maximum flux density of B m /2. As a result, all stator poles other than A 1 and B 1 can be half the size of stator poles A 1 and B 1 , as each carries only half the flux of these poles. A considerable cost saving and weight reduction can be achieved with this arrangement. This may matter in aerospace applications where weight and volume minimization are critical factors in the selection of an electric machine.
[0045] The present invention eliminates flux reversals in the stator back iron and reduces or minimizes flux reversals in the rotor back iron. The stator back iron is defined for this invention as being all iron or ferromagnetic components in the stator, except the stator pole components, that convey the flux flowing through the rotor and stator. Because there are no flux reversals in the stator back iron, the hysteresis and eddy current losses in the iron decrease significantly, thus enhancing the efficiency of the machine.
[0046] In the rotor back iron (i.e., the back iron between adjacent rotor poles), the flux reversal occurs only once per rotor revolution, which is much less than occurs in conventional machines. For example, in a conventional 6/4 SRM, flux reversal in the rotor back iron may occur six times per rotor revolution, as described in Chapter 3 of Switched Reluctance Motor Drives, by R. Krishnan, CRC Press, 2001, which is hereby incorporated in its entirety into this specification. Four flux reversals occur in one revolution of the rotor in a conventional three-phase 12/8 machine.
[0047] [0047]FIG. 6 illustrates a representative torque versus rotor position characteristic for the TPSRM illustrated by FIGS. 3A and 3B. As may be seen by inspection of FIG. 6, there are rotor positions for which the torque 601 , 602 produced by each of phases A and B is zero. To produce a non-zero torque at all rotor positions, the rotor poles can be slotted, contoured, air-gap stepped, etc.
[0048] [0048]FIG. 7 illustrates a TPSRM having contoured rotor poles in which the radial length of each rotor pole decreases as the distal end curvature is traversed from one side to the other. FIG. 8 illustrates a torque versus rotor position graph for the TPSRM of FIG. 7. The torque for phase A is identified by reference character 801 and that for phase B is identified by reference character 802 . The contouring of rotor pole 701 provides a non-uniform air gap across the pole face. As a result, the combined torque generated by TPSRM 700 has a non-zero value, considering both phases of the machine, at all times. This feature is crucial for supporting a self-starting capability for TPSRM 700 in both rotational directions of the shaft.
[0049] The present invention provides a force distribution similar to that of three phase ac machines, by distributing a stator current distribution among three windings. The three windings may constitute one phase of the SRM, as illustrated in FIGS. 3A and 4A. Alternatively, the SRM may have multiples of three windings in a phase with other combinations of total stator and rotor poles. The rationale for such a force distribution is that the normal forces are cancelled and uniformly distributed about the circle of rotation. Furthermore, the tangential forces can be distributed over two thirds of the periphery as opposed to only half the periphery, such as occurs where only two diametrically opposite poles contribute to the entire tangential force.
[0050] [0050]FIG. 9A illustrates a rotor or stator pole whose distal end face is shaped to induce a non-uniform flux density flow through the pole. FIG. 9B illustrates a rotor pole that is slotted to induce a non-uniform flux density flow through the rotor pole. In FIG. 9A, rotor or stator pole 900 is shaped so that its distal end face has a non-uniform radius from the rotational axis of the rotor. In FIG. 9B, slots 911 are formed in rotor pole 910 . With stator pole shaping or rotor pole shaping or slotting, or some combination thereof, the present invention can operate in both the clockwise and counter-clockwise directions with full four-quadrant capability, thereby providing a bidirectional start and run capability using only two phases.
[0051] The embodiment of the invention illustrated in FIGS. 3A and 4A is only one of many embodiments of the invention. Other embodiments may have different combinations of stator and rotor poles, such as the combinations of 6/3, 6/15, etc. The invention completely eliminates flux reversals in the stator back iron and reduces or minimizes the flux reversals in the rotor back iron to one reversal for each rotor revolution.
[0052] There are many advantages to having zero flux reversals in the stator back iron. These include: (1) reduced core losses and, hence, higher operating efficiency of the machine, (2) reduced vibration in the stator back iron and, hence, lower acoustic noise generated in the machine, and (3) a lower amount of required excitation, since there is no flux reversal in the machine, and hence higher operating efficiency.
[0053] Similarly there are advantages to having only one flux reversal per revolution in the rotor back iron of the machine. These advantages include reduced core losses, reduced excitation requirements, and reduced vibration induced by the rotor.
[0054] The present invention includes the unique pole combination of 6/9 for the stator and rotor with concentric windings for a two phase switched reluctance machine and its derivatives using the same principle of no flux reversals in the stator back iron. The stator poles may have differing numbers of winding turns around each pole of one phase of the machine, so as to distribute the normal and tangential forces as desired. Also, the winding currents on each pole can be controlled independently of other winding currents, thereby individually controlling the normal force around the periphery of the machine to produce a frictionless SRM. Furthermore, the TPSRM may be operated with the power converter topologies, described in Applicant's co-pending applications, that use either one controllable switch or two controllable switches for the control of currents and voltages in the windings of the machine for the two phases of the machine.
[0055] The foregoing description illustrates and describes the present invention. However, the disclosure shows and describes only the preferred embodiments of the invention, but it is to be understood that the invention is capable of use in various other combinations, modifications, and environments. Also, the invention is capable of change or modification, within the scope of the inventive concept, as expressed herein, that is commensurate with the above teachings and the skill or knowledge of one skilled in the relevant art.
[0056] The embodiments described herein are further intended to explain best modes known of practicing the invention and to enable others skilled in the art to utilize the invention in these and other embodiments, with the various modifications that may be required by the particular applications or uses of the invention. Accordingly, the description is not intended to limit the invention to the form disclosed herein. | A TPSRM may include a stator, having a plurality of poles and a ferromagnetic or iron back material, and a rotor having a plurality of poles and a ferromagnetic or iron back material. A current flowing through coils wound around a first set of the plurality of stator poles induces a flux flow through the first set of stator poles and portions of the stator back material during a first excitation phase. A current flowing through coils wound around a second set of the plurality of stator poles induces a flux flow through the second set of stator poles and portions of the stator back material during a second excitation phase. The numbers of stator and rotor poles for this TPSRM are selected such that substantially no flux reversal occurs in any part of the stator back material as a result of transitioning between the first and second excitation phases. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to drilling devices and more particularly to a roof bolt hole groover which cuts grooves simultaneously as the hole is drilled.
2. Description of the Prior Art
In mining, it is often necessary to bolt together a discontinuous rock mass in order to provide a safe mine roof. This is normally accomplished by roof bolting. There are two popular methods of roof bolting, namely point-anchored (or tensioned) and full-length anchored (or nontensioned) bolting. A point-anchored bolt is a bolt anchored at the extreme end located in a roof bolt hole drilled into the rock mass and having a bearing plate connected at the other end of the bolt located at the collar of the hole. On the other hand, a full-length anchor bolt is a bolt grouted with resin or the like throughout the roof bolt hole.
With present devices a roof bolt hole is drilled into a rock mass and a smooth bore hole surface results. The anchoring capacity of the full-length anchor bolt, usually a resin bolt if resin is used, can be enhanced by making the roof bolt hole surface rough. Therefore, rifling tools were developed to scratch or groove the roof bolt hole surface. The roof drilling operation using such a rifling tool required two steps: first step being to drill a hole in the rock mass and the second step to cut rifle grooves in the bore hole surface. The groove inervals and depth are not easily controllable with the presently used rifling tools.
The present invention ameliorates the aforementioned problems of the prior devices by providing a roof bolt hole groover which cuts grooves in the wall hole surface simultaneously as the hole is being drilled.
SUMMARY OF THE INVENTION
Accordingly, it is one object of the present invention to provide a novel roof bolt hole groover which simultaneously grooves the hole as it is being drilled.
It is another object of the present invention to provide a roof bolt hole groover which enables easy control of the interval and depth of the grooves.
It is yet another object of the present invention to provide a novel roof bolt hole grover which is easily connectable to conventional rotary percusive drill units and the like.
In order to accomplish the aforesaid objects, the present invention in one embodiment provides a bolt hole groover comprising a pair of grooving bits pivotally connected to a drill rod and protruding radially therethrough near the connection for the groove drill bit, a connecting rod connected to the pair of grooving bits which causes the grooving bits to move arcuately as the connecting rod reciprocates, and a gear box conversion means operably connected to the rotating portion of the rotary drill unit and the connecting rod, which converts the rotational movement of the rotary drill unit into reciprocating movement in order to cause reciprocating movement of the connecting rod. Simple adjustments of the gear box conversion means and the length of the grooving bits can be made to control the depth and interval of the grooves.
BRIEF DESCRIPTION OF THE 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 plan view of a first embodiment of the present invention;
FIG. 2 is a partial cross-sectional view of FIG. 1;
FIG. 3 is a partial top view of FIG. 1;
FIG. 4 is a partial view illustrating a connection of the connecting rod 12 to the sliding lever 22 of FIG. 1;
FIG. 5 is a plan view of a second embodiment of the present invention with the gear box portion shown in cross section;
FIG. 6 is a partial plan view of a third embodiment of the present invention showing the gear box portion in cross section;
FIG. 7 is a partial plan view of a fourth embodiment of the present invention with the gear box portion shown in cross section;
FIG. 8 is a partial plan view of a fifth embodiment of the present invention with the gear box portion shown in cross section.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, and more particularly to FIG. 1 thereof, a novel roof hole groover is illustrated. The roof hole groover 3 comprises a gear box and housing 4 connected to the rotary drill unit 2 by way of bolts or other means well-known in the art. Gear box and housing 4 includes a drive shaft 6 which connects to the rotary drive portion 5 of the rotary drill unit 2. A hollow drill rod 8 is connected by conventional means to the drive shaft 6 and rotates whenever the rotary drill unit 2 is operated. Drill rod 8 also is designed to receive a drill bit 10 connected thereto by conventional means and also houses groove bits 14 and 16 which are pivotally connected thereto by way of pins 18 and 20. The proximal ends of the groove bits 14 and 16 are pivotally connected to a connecting rod 12 which in turn is connected to a lever 22 which reciprocates in response to rotational movement of the drive shaft 6.
One possible connection of the connecting rod 12 to the lever 22 is illustrated in FIG. 4. In that embodiment, the connecting rod 12 has an L-shaped member 24 connected thereto by conventional means, while the lever 22 has a wedge-shaped portion 26 which is connected thereto by way of a nut and bolt 28 or other suitable means and a stopper portion 30 which can be made integral with the lever 22. Therefore, as the lever 22 reciprocates downwardly, the wedge-shaped portion 26 engages with the L-shaped portion 24 and pulls the connecting rod 12 downwardly, thus causing the distal ends of the groove bits 14 and 16 to swivel upwardly. When the lever 22 reciprocates upwardly, the stopper portion 30 contacts the L-shaped portion 24 and forces the connecting rod 12 upwardly, thus causing the distal ends of the groove bits 14 and 16 to swivel downwardly. It can be appreciated by referring to FIG. 1 that, as the distal ends of the groove bits 14 and 16 swing upwardly, the depth of the grooves is increased, whereas, when the distal ends of the groove bits 14 and 16 swing downwardly, the depth of the grooves is decreased.
Referring now to FIGS. 2 and 3, the operation of the gear box 4 which causes the lever 22 to reciprocate can be easily understood. The drive shaft 6 includes a grooved portion 34 which slidably receives the lever 22. The lower end of the lever 22 has the upper end of a second lever 36 pivotally connected thereto by way of a connector pin 38. The other end of the second lever 36 is connected to a helical gear 42 mounted on a gearshaft 46 by way of connecting pin 40 offset from the center of the gear 42 and the gearshaft 46. The gearshaft 46 is mounted to the drive gearshaft 6. Also mounted to the gearshaft 6 are supports 50 and 52 of a worm gear 47. The threads 48 of the worm gear 47 are intermeshed with the teeth 44 of the helical gear 42. The lower end of the worm gear 47 is connected to a spur gear 56 by any conventional means well-known in the art. The periphery of the gear box housing 4 includes the female gear 60 which has inwardly facing teeth 58. The female gear 60 can be bolted to the rotary drill unit 2 by way of bolts 62. The teeth 56 of the spur gear 54 intermesh with the teeth 58 of the female gear 60.
In operation, the rotary drive portion 5 of the rotary drill unit 2 causes the drive shaft 6 to rotate. As the drive shaft 6 rotates, the spur gear 54 rotates as it follows the path of the female gear 60. The rotation of the spur gear 54 in turn causes the worm gear 47 to rotate. The rotation of the worm gear 47 causes the helical gear 42 to rotate and causes the upper end of the second lever 36 to move upwardly and downwardly as the lower end rotates about an offcenter portion of the helical gear 42. As the upper end of the second lever 36 moves upwardly and downwardly, the lever 22 is also caused to reciprocate. The reciprocating motion of the lever 22, as explained previously in the discussion of FIGS. 1 and 4, ultimately causes arcuate movement of the groove bits 14 and 16 to effect the desired grooves in the hole being drilled.
Referring now to FIG. 5, a second embodiment of the present invention is illustrated. In this example, the drill rod 8 is connected directly to the rotary drill unit 2 and includes the drill bit 10 with the groove bits 14 and 16 protruding therefrom. However, in this example a connecting rod 112 has a forked end 114 operably connected to the pin 118 in order to effect the arcuate movement of the distal ends of the groove bits 14 and 16. Also attached to the rotary drill unit 2 on the bottom side is the drive shaft 6 with a spur gear 78 attached thereto. The teeth of the spur gear 78 are intermeshed with the teeth of a second spur gear 80 which has its shaft 82 rotatably mounted to a support 84. The second spur gear 80 also has connected offcenter therefrom a connecting pin 86. The connecting pin 86 is connected by any means well-known in the art to one end of a flexible connector 70 such as a steel wire rope. The other end of the flexible connector 70 is connected to the lower end of the connecting rod 112 by way of a ball joint 87. The upper end of the flexible connector 70 also includes a spring 72 and stopper 74 arrangement to bias the flexible connector 70 upwardly. Flexible connector 70 is forced to change its direction approximately 90° by a guide bar 76 which is connected to the gear box housing 4.
In the above embodiment, when the first spur gear 78 rotates in response to the rotation of the shaft 5 of the rotary drill unit 2, the second spur gear 80 is also caused to rotate, which moves the connecting pin 86 about the center point thereof, ultimately causing horizontal reciprocating motion of the lower portion of the flexible connector 70. The horizontal reciprocating motion of the flexible connector 70 is transferred to vertical reciprocating motion by way of the guide bar 76 and causes the distal ends of the groove bits 14 and 16 to move arcuately in response thereto. The ball joint 87 is used in this embodiment to prevent the flexible connector 70 from rotating with the connecting rod 112, which would render the device inoperative.
Referring now to FIG. 6, a third embodiment of the gear box portion of the invention is illustrated. In this embodiment the spur gear 78 is connected to the drive shaft 6, and the drive shaft 6 rotates in response to the rotary movement of the rotary drill unit 2. The teeth of the spur gear 78 are intermeshed with the teeth of a second spur gear 90 which has a shaft 92 connected to the support 94. A first bevel gear 93 is concentric to and rotates with the second spur gear 90. A second bevel gear 96 has its teeth intermeshed with the teeth of the first bevel gear 90, and the second bevel gear shaft 98 is rotatably mounted to the shaft 92 of the first bevel gear 90. The second bevel gear 96 has a connecting pin 100 one end of which is connected offcenter on its surface facing the lever 22. The other end of the connecting pin 100 pivotally connected to the lower end of the lever 22. Therefore, when the spur gear 78 rotates, the first bevel gear 93 is caused to rotate, which in turn causes the second bevel gear 96 to rotate and the connecting pin 100 to rotate about the center thereof of the second bevel gear 96. The rotation of the connecting pin 100 causes reciprocating movement of the lever 22 in order to drive the groove bits 14 and 16 as in the previous embodiments.
Referring now to FIG. 7, a fourth embodiment of the gear box 4 of the present invention is illustrated. In this embodiment, a worm gear 120 is shown connected to the drive shaft 6, which rotates in response to the rotary drill unit 2. The threads 122 of the worm gear 120 are intermeshed with the threads 126 of a heclical gear 124 which is rotatably mounted to the gear box housing 4. The helical gear 124 also includes a patterned groove 128 in the planar surface thereof. A pivoting lever 130 is connected to the gear box 4 by way of a pin 132. One end of the pivoting lever 130 carries a groove follower 134 which is slidably mounted on the lever 130 to permit lost motion therebetween and which slides within the groove 128 in the helical gear 124. The linkage between the groove follower 134 and the helical gear 124 causes the other end of the pivoting lever 130 to move arcuately about the pivot pin 132. Again, this ultimately results in the reciprocating movement of the lever 22.
Referring now to FIG. 8, a fifth embodiment of the present invention is illustrated wherein a bevel gear 136 is connected to the drive shaft 6 of the gear box 4. The teeth of the bevel gear 136 are intermeshed with the teeth of a second bevel gear 138 which has a shaft 140 connected to the housing 4 by way of a support 142. The second bevel gear 138 has a connecting pin 146 connected offcenter on its surface facing the first bevel gear 136. The connecting pin 146 rotates about the center of the second bevel gear 138 as the second bevel gear 138 rotates in response to rotation of the first bevel gear 136. The lever 22 is pivotally connected to the connecting pin 146 and reciprocates in response to the rotational movement of the second bevel gear 138. Therefore, the operation of the groove bits 14 and 16 is again effected as previously described.
It should be noted that, with the embodiment illustrated in FIG. 1, the groove bits 14 and 16 groove the drill hole surface as they swing upwardly. This is the preferred method, as it prevents jamming of the groove bits 14 and 16 while drilling is in process. However, it is possible to shape the groove bits 14 16 so that they groove the drill hole surface as they swing downwardly.
Obviously, numerous (additional) 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. | A hole groover comprising a pair of grooving bits radially protruding from the surface of a drill rod and connected to swivel upwardly and downwardly near the end of the drill rod where the drill bit is connected. A connecting rod is connected to the inside ends of the groove bits and causes arcuate movement of the grooving bits as it reciprocates. The hole groover further includes a gear box which is connectable to a rotary drilling unit which converts rotational movement of the rotary drill until to reciprocating movement of a lever. The lever is connected to the connecting rod which causes movement of the grooving bits. The device is readily adaptable to be connected to most rotary drill units and the depth and intervals of the grooves can be easily controlled by adjusting the length of the grooving bits and the gear ratios. The device enables grooves to be cut in a wall hole surface, concurrently with the drilling of the hole. | 4 |
BACKGROUND
[0001] Today users are frequently presented with complex tasks as they employ software applications (and associated user interfaces) on their devices to go about their different activities. Guided activity floorplans, or wizards, can assist users in completing such tasks. Although guided activity floorplans are meant to streamline complex tasks, there are circumstances under which they can actually increase the complexity for users.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] The embodiments are illustrated by way of examples and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. The embodiments may be best understood from the following detailed description taken in conjunction with the accompanying drawings.
[0003] FIG. 1 presents various steps of an illustrative task.
[0004] FIG. 2 depicts aspects of one particular positioning option (horizontal) for an illustrative anchored information bar.
[0005] FIG. 3 depicts aspects of one particular positioning option (horizontal) for an illustrative anchored information bar.
[0006] FIG. 4 depicts aspects of one particular positioning option (vertical) for an illustrative anchored information bar.
[0007] FIG. 5 depicts aspects of device type and orientation particulars.
[0008] FIG. 6 depicts aspects of device type and orientation particulars.
[0009] FIG. 7 depicts aspects of an illustrative additional service.
[0010] FIG. 8 is a block diagram illustrating an exemplary computer system, according to an embodiment.
[0011] Like reference symbols in the various drawings indicate like elements
DETAILED DESCRIPTION
[0012] Embodiments of techniques for guiding user activities are described herein. In the following description, numerous specific details are set forth to provide a thorough understanding of the embodiments. One skilled in the relevant art will recognize, however, that the embodiments can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail.
[0013] Reference throughout this specification to “one embodiment”, “this embodiment,” and similar phrases, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one of the one or more embodiments. Thus, the appearances of these phrases in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0014] In the discussion below, ‘device’ refers to a logical and/or a physical unit adapted for a specific purpose. For example, a device may be at least one of a mechanical and/or an electronic unit. Device encompasses, but is not limited to, a communication device, a computing device, a handheld device, and a mobile device such as an enterprise digital assistant (EDA), a personal digital assistant (PDA), a tablet computer, a smartphone, a smartwatch, a desktop computer, a laptop computer, and the like. A device can perform one or more tasks. A device includes a computing system comprising electronics (e.g., sensors) and software. A device is uniquely identifiable through its computing system. A device may access internet services such as World Wide Web (WWW) or electronic mails (E-mails), and exchange information with another device or a server by using wired or wireless communication technologies, such as Bluetooth, Wi-Fi, Universal Serial Bus (USB), infrared, wireless connectivity, and the like. A device may offer one or more Graphical User Interfaces (GUIs) to allow, support, facilitate, enable, etc. users to among other things complete various tasks.
[0015] As a user employs a device to complete, pursue, etc. different activities, guided activity floorplans, or wizards can assist users in completing complex, complicated, infrequently performed, etc. tasks consisting of multiple steps. Such tasks may include for example creating a purchase order, generating a sales order, posting a financial transaction, submitting a request, configuring a system component, etc. See for example FIG. 1 .
[0016] Depending upon the options, choices, etc. that may be selected by a user in a particular step of a task, the task may branch out into different flows with inter alia varying sub-steps, dependencies, decision points, etc.
[0017] Although guided activity floorplans are meant to streamline complex tasks, there are circumstances when they might actually increase the complexity for users. Such a situation could arise when for example a user needs to consider a piece of information from an earlier step in any of the subsequent steps. A user could try to retain the information (if for example they have any prior knowledge of the task and the guided activity), but this would among other things increase the cognitive load for the user. The user could also go back a couple of steps, but this would slow them down and decrease their efficiency and satisfaction. Designers could also repeat the piece of information in each step where it's necessary but this would unnecessarily clutter the screen.
[0018] By introducing an anchored information bar that inter alia presents sequentially the selected options from each previous step in a task, various of the challenges noted above may be obviated and among other things a user's work efficiency may be increased, the cognitive workload for the user may be decreased, the frequency of user errors may be reduced, user satisfaction may be increased or improved, etc.
[0019] An anchored information bar may appear anywhere on a display and the placement, orientation, size, content, etc. of the bar may be dynamically adjusted based on any number of criteria including for example device orientation, the nature (complexity, etc.) of a task, screen or display density, user actions or selections, etc.
[0020] For example, an anchored information bar may appear below task steps that are listed on top of the screen (horizontal positioning). See for example FIG. 2 and FIG. 3 .
[0021] Alternatively, an anchored information bar may appear on the left or right side of the screen (vertical positioning). See for example FIG. 4 .
[0022] A particular positioning option (such as for example horizontal, vertical, etc.) may offer among other things different capabilities, etc. For example, a vertical positioning option may support the display, presentation, etc. of more detailed (e.g., step) information (see for example FIG. 4 ).
[0023] The positioning options noted above are illustrative only and it will be readily apparent to one of ordinary skill in the relevant art that numerous other positioning options are easily possible.
[0024] The particulars of an anchored information bar may be managed by a user. For example:
[0025] 1) A bar may be enabled (switched on) or disabled (switched off) by a user via any number of means including for example a control (such as a button, etc.) that may be presented on a display. See for example the ‘Show Selections’ control in FIG. 2 and the ‘Hide Selections’ control in FIG. 3 .
[0026] 2) A bar may be customized by a user in any number of ways including for example any combination of one or more of colors, fonts, skins, etc.
[0027] 3) The location, positioning, placement, etc. of a bar may be ‘locked’ by a user to for example any combination of one or more of inter alia vertical, horizontal, top, bottom, left, right, etc.
[0028] The management options noted above are illustrative only and it will be readily apparent to one of ordinary skill in the relevant art that numerous other management options are easily possible.
[0029] The elements of an anchored information bar may be generated, created, etc. based on possibly among other things the particular steps in a task, previously completed steps, a current step, upcoming steps, configuration information, etc. and may be dynamically adjusted, updated, etc. as for example a user iterates through the steps in a task.
[0030] The particulars of an anchored information bar may be dynamically adjusted, altered, etc. based on for example changes that a user may make to the orientation of a device (e.g., shifting from a portrait orientation to a landscape orientation), the type of device that a user may employ at any given time (and shift between as they go about their activities), etc. See for example FIG. 5 and FIG. 6 (where for simplicity of exposition hypothetical measures, quantifiers, etc. are presented).
[0031] An anchored information bar may include among other things any number of additional items such as for example tips or hints, advertising, alerts, factoids, etc. Such items may for example be context sensitive or specific.
[0032] An anchored information bar may among other things provide visual clues, indicators, cues, etc. to distinguish between for example completed steps, visited but incomplete steps, unvisited steps, etc. in a task.
[0033] An anchored information bar may among other things offer any number of features, functions, capabilities, lookup, etc. For example, various what-if, forecast, calculation, estimation, etc. services (which may for example comprise one or more screens or displays, may accept and respond to user input, etc.) may be offered at any step of a task. See for example FIG. 7 .
[0034] At any given time multiple anchored information bars may be active, visible to a user, in use, etc. Within such a plurality of anchored information bars each anchored information bar may operate independently, interoperate with aspects of one or more other anchored information bars, etc.
[0035] FIG. 8 is a block diagram of an exemplary computer system 800 . The computer system 800 includes a processor 805 that executes software instructions or code stored on a computer readable storage medium 855 to perform the above-described activities. The processor 805 can include a plurality of cores. The computer system 800 includes a media reader 840 to read the instructions from the computer readable storage medium 855 and store the instructions in storage 810 or in random access memory (RAM) 815 . The storage 810 provides a large space for keeping static data where at least some instructions could be stored for later execution. According to some embodiments, such as some in-memory computing system embodiments, the RAM 815 can have sufficient storage capacity to store much of the data required for processing in the RAM 815 instead of in the storage 810 . In some embodiments, the data required for processing may be stored in the RAM 815 . The stored instructions may be further compiled to generate other representations of the instructions and dynamically stored in the RAM 815 . The processor 805 reads instructions from the RAM 815 and performs actions as instructed. According to one embodiment, the computer system 800 further includes an output device 825 (e.g., a display) to provide at least some of the results of the execution as output including, but not limited to, visual information to users and an input device 830 to provide a user or another device with means for entering data and/or otherwise interact with the computer system 800 . The output devices 825 and input devices 830 may be joined by one or more additional peripherals to further expand the capabilities of the computer system 800 . A network communicator 835 may be provided to connect the computer system 800 to a network 850 and in turn to other devices connected to the network 850 including other clients, servers, data stores, and interfaces, for instance. The modules of the computer system 800 are interconnected via a bus 845 . Computer system 800 includes a data source interface 820 to access data source 860 . The data source 860 can be accessed via one or more abstraction layers implemented in hardware or software. For example, the data source 860 may be accessed by network 850 . In some embodiments the data source 860 may be accessed via an abstraction layer, such as, a semantic layer.
[0036] Computer system 800 may include, support, service, etc. among other things:
[0037] 1) One or more application, web, data, etc. servers which may comprise any combination of one or more of cloud-based and/or on-premise resources and which may be exposed, accessed, etc. via one or more networks.
[0038] 2) One or more databases which may comprise any combination of one or more of a relational database, a multi-dimensional database, an in-memory facility, an object database, an eXtendable Markup Language (XML) document, flat files, or any other data storage system that supports structured and/or unstructured data. Such databases may be distributed among several different entities.
[0039] 3) One or more devices such as for example any combination of one or more of a desktop computer, a notebook computer, a laptop computer, a tablet, a smartphone, a smartwatch, etc.
[0040] 4) One or more administrators who may among other things engage in various management, control, configuration, support, etc. activities.
[0041] Various of the system element, component, etc. exchanges or interactions that were presented above may incorporate aspects of inter alia one or more Application Programming Interfaces (APIs), one or more standards-based artifacts (such as for example JSON, XML, etc.), one or more custom artifacts, etc.
[0042] In the above description, numerous specific details are set forth to provide a thorough understanding of embodiments. One skilled in the relevant art will recognize, however, that the one or more embodiments can be practiced without one or more of the specific details or with other methods, components, techniques, etc. In other instances, well-known operations or structures are not shown or described in details.
[0043] Although the processes illustrated and described herein include series of steps, it will be appreciated that the different embodiments are not limited by the illustrated ordering of steps, as some steps may occur in different orders, some concurrently with other steps apart from that shown and described herein. In addition, not all illustrated steps may be required to implement a methodology in accordance with the one or more embodiments. Moreover, it will be appreciated that the processes may be implemented in association with the apparatus and systems illustrated and described herein as well as in association with other systems not illustrated.
[0044] The above descriptions and illustrations of embodiments, including what is described in the Abstract, is not intended to be exhaustive or to limit the one or more embodiments to the precise forms disclosed. While specific embodiments of, and examples for, the embodiment are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the embodiments, as those skilled in the relevant art will recognize. These modifications can be made to the embodiments in light of the above detailed description. Rather, the scope of the one or more embodiments is to be determined by the following claims, which are to be interpreted in accordance with established doctrines of claim construction.
[0045] The foregoing diagrams represent logical architectures for describing processes according to some embodiments, and actual implementations may include more or different components arranged in other manners. Other topologies may be used in conjunction with other embodiments. Moreover, each system described herein may be implemented by any number of devices in communication via any number of other public and/or private networks. Two or more of such computing devices may be located remote from one another and may communicate with one another via any known manner of network(s) and/or a dedicated connection. Each device may comprise any number of hardware and/or software elements suitable to provide the functions described herein as well as any other functions.
[0046] All systems and processes discussed herein may be embodied in program code stored on one or more non-transitory computer-readable media. Such media may include, for example, a floppy disk, a CD-ROM, a DVD-ROM, a Flash drive, magnetic tape, and solid state Random Access Memory (RAM) or Read Only Memory (ROM) storage units. Embodiments are therefore not limited to any specific combination of hardware and software. | Methods and systems that facilitate the generation, presentation, and adaptation of an anchored information bar, associated with a guided activity floorplan or wizard, in support of assisting users as they complete the different steps of a complex task as the user employs software applications (and associated user interfaces) on their devices to go about their different activities. | 6 |
This is a continuation-in-part of two U.S. patent application Ser. Nos. 07/714,381, filed Jun. 11, 1991, now pending and being a continuation-in-part of Ser. No. 07/550,515, filed Jul. 10, 1990, now pending
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an air emission control system for removing volatile organic compounds (VOCs) and other objectionable contaminants from an emitted gas stream which is generated from a water treatment means. Specifically the improved air emission control system of this invention relates to collecting, dehumidifying, bypassing, diluting, monitoring, purifying recycling and reusing the emitted gas stream, and also relates to feeding an inert gas , upon demand, for reducing oxygen content of said emitted gas stream, in turn, for preventing a gas purification contactor from being ignited and/or exploded due to oxidation of carbonaceous substances inside said gas purification contactor. A complete water treatment and gas emission control system is developed by applying the air emission control system to either single stage water treatment or multiple stage water treatment. The present invention which causes no air pollution is a low cost and highly efficient alternative to present site remediation and water treatment technologies.
About 70 percent of potable water in the U.S.A. is supplied by groundwater.
Groundwater contamination, which is a national major concern, is about 71 percent caused by industrial accidents (chemical spills, tank leaks, etc.), 16 percent caused by railroad or truck's chemical accidents, and 13 percent caused by leachates from lagoons or dumpsites.
The primary reasons for treating groundwater are: potable use (39 percent), clean-up of aquifer to prevent spread of contamination (48 percent), and industrial and commercial use (13 percent). In any case, the potentially hazardous VOCs must be removed. Timely clean-up of aquifer to prevent spread of contamination is extremely important because the damage can be beyond repair if the spread of contamination is too wide.
Toxic organic compounds commonly found in groundwater include, but will not be limited to, the following: carbon tetrachloride, chloroform, dibromo chloro propane, DDD, DDE, DDT, CIS-1,2 dichloro ethylene, dichloro pentadiene, diisopropyl ether, tertiary methyl butyl ether, diisopropyl methyl phosphonate, 1,3-dichloro propene, dichloro ethyl ether, dichloro isopropyl ether, benzene, acetone, ethyl acrylate, trichloro trifloro ethane, methylene chloride, phenol, orthochloro phenol, tetrachloro ethylene, trichloro ethylene, 1,1-trichloro ethane, vinylidiene chloride, toluene, xylene, EDB and others.
Conventional water treatment means for groundwater purification is an air stripping tower in which a groundwater containing toxic volatile organic compounds is introduced to the top of said air stripping tower forming a swarm of downward water droplets, while a bulk volume of air is introduced to the bottom of said air stripping tower forming an upward counter current air stream. In other words, water droplets enter the air phase (gas phase) for removing volatile organic compounds from said water droplets by air stripping action. An emitted gas stream containing toxic volatile organic compounds and other volatile contaminants is formed, and exits from the top of said air stripping tower. This emitted gas stream must be properly treated in order to prevent air pollution. An air stripping tower water effluent containing negligible concentration of volatile organic compounds is also formed . Although the efficiency of an air stripping tower for removing volatile organic compounds from a contaminated groundwater is high, disposal of its emitted gas stream containing toxic volatile organic compounds generally is a problem.
Conventional water treatment means for treating wastewater is a biological activated sludge process plant in which an aeration basin having a mixed liquor and suspended microorganisms is used for removing organics from wastewater by biochemical reactions in the presence of air bubbles, microorganisms and nutrients. Due to physical action of air bubbling, an emitted gas stream containing odorous, toxic, volatile organic compounds is also generated over the top of said aeration basin. Air emission control at activated sludge process plants is now an important environmental engineering task.
Recently several dissolved air flotation plants and dispersed air flotation plants are developed. These modern water treatment meanses utilize flotation technology for either water purification or wastewater treatment. Since air bubbles must be generated for removing volatile, surface-active, oily and/or suspended contaminants from a water stream, an emitted gas stream containing these contaminants is also formed over the top of a flotation plant, in turn, causing air pollution.
The method and apparatus of this invention have been developed specifically for air pollution control at air stripping towers, activated sludge process plants, dissolved air flotation plants, dispersed air flotation plants and other similar plants that generate gas bubbles and/or emitted gas streams.
In addition to treating the contaminated ground water, commercial, industrial or municipal wastewaters containing VOCs and other toxic volatile contaminants can all be efficiently treated by the process system of the present invention.
2. Description of the Prior Art
Conventional technologies for groundwater treatment include: air stripping without air emission control, granular activated carbon, chemical oxidation, and biological processes. Air stripping without air emission control is not acceptable in many states.
Granular activated carbon contactor is technically feasible for either water purification or air emission control, but may be economically unfeasible when it is used alone. Lawrence K. Wang et al (U.S. Pat. No. 5,122,165, Jun. 16, 1992) and Orest Hrycyk et al (U.S. Pat. No. 5,122,166, Jun. 16, 1992) have developed two physical-chemical processes for groundwater treatment both processes using a liquid phase granular activated carbon contactor for water purification and using a gas phase granular activated carbon contactor for air emission control. A biological process for groundwater treatment with air emission control has also been developed by Lawrence K. Wang et al (U.S. patent application Ser. No. 550,515, filed Jul. 10, 1990, now pending).
The above three inventions (U.S. Pat. Nos. 5,122,165 and 5,122,166; and U.S. patent application Ser. No. 550,515, filed Jul. 10, 1990) relate to efficient and cost-effective groundwater purification systems aiming at clean-up of aquifer to prevent spread of VOCs contamination in the environment. The purified groundwater can be discharged to a recharging well; while the purified gas is recycled to the system for gas stripping, thus eliminating a gas emission problem. The above three inventions consider the affordability, performance, governmental acceptance, air pollution prevention and simplified operation.
The present invention, however, relates to an improved air emission control system that can be used in conjunction with the above three inventions (U.S. Pat. Nos. 5,122,165 and 5,122,166; and U.S. patent application Ser. No. 550,515, filed Jul. 10, 1990) as well as with other prior art systems described by O'Brien and Fisher (Water Engineering & Management, May 1983), O'Brien and Stenzel (Public Works, December 1984), Stenzel and Gupta (Journal of the Air Pollution Control Association, December 1985), Krofta (U.S. Pat. Nos. 2,874,842, 3,182,799, 4,022,696, 4,184,967, 4,377,485, 4,626,345, and 4,931,175), Ying et al (U.S. Pat. Nos. 4,623,464, and 4,755,296), Copa et al (U.S. Pat. No. 4,810,386), Meidl (U.S. Pat. No. 4,857,198), Irvine et al (U.S. Pat. No. 5,126,050) and Wang et al (U.S. Pat. No. 5,069,783).
The prior art air pollution control systems for removing volatile organic compounds from an emitted gas stream include gas incineration and gas phase granular activated carbon adsorption. Gas incineration is efficient but extremely expensive. Granular activated carbon adsorption is affordable, but frequently causes combustion at carbon beds or even explosion due to interactions of carbon, volatile organic compounds, and oxygen during a rising temperature at carbon beds.
Prior art concerning treatment of a gas effluent from multistep liquid treatment systems has been reviewed. Carnahan et al merely treat a gas effluent in a reactor tank with chlorine, in accordance with their U.S. Pat. No. 4,919,814. Irvine et al suggests such gas effluent being treated by carbon adsorption followed by membrane separation in accordance with their U.S. Pat. No. 5,126,050 (Col. 11, lines 36-41). U.S. Pat. No. 4,894,162, awarded to Cournoyer et al in January 1990, suggests such gas effluent being treated by venturi dilution and collection in a tank where microorganism action purifies the gas. Anderson's U.S. Pat. No. 4,391,704 suggests venturi dilution, treatment with chlorine or ozone and adsorption. Meidl's U.S Pat. No. 4,857,198 suggests initial separate gas stripping followed by recycling of such gas effluent back to the treatment system containing biological solids and powdered adsorbent. A publication by Waltrip et al (Journal WPCF, Vol. 57, No. 10, 1985) suggests primarily treatment of such gas effluent in a scrubber.
The method and apparatus of this invention, however, relates to an air emission control system comprising a gas piping system, at least one gas mover, at least one gas dilution unit, a demister, a monitoring unit, at least one gas bypass unit, a gas purification contactor, a recycling unit, at least one gas sampling unit, and an inert gas source for preventing possible combustion or explosion to be occurred inside the gas purification contactor. Said gas purification contactor of this invention is packed with virgin granular activated carbon, virgin fibrous activated carbon, ion exchange resins, polymeric adsorbent, base treated activated carbon, aluminate treated activated carbon, base treated polymeric adsorbent, aluminate treated polymeric adsorbent, reticulated foam, fiberglass screen, fibrous activated carbon screen, coalescing filter screen, membrane filter media, or combinations thereof for removal of volatile contaminants from a gas effluent emitted from multistep liquid treatment systems.
SUMMARY OF THE INVENTION
In accordance with the present invention, an improved process method for removing volatile contaminants from an emitted gas stream comprises the following steps:
(a) providing an enclosure and a gas piping system to collect said emitted gas stream from a water treatment means,
(b) operating at least one low pressure and low volume gas mover to move said emitted gas stream from said water treatment means through said enclosure and said gas piping system to a dehumidifying means comprising at least a demister pad for removing water droplets from said emitted gas stream,
(c) monitoring the emitted gas stream with a flow meter, a vacuum/pressure gauge, and a humidity meter for measuring gas flow, vacuum/pressure, and humidity, respectively,
(d) sampling the emitted gas stream which has been dehumidified at an inlet sampling port for determining gas quality of said emitted gas stream which has been dehumidified,
(e) providing a first bypass means comprising a first bypass line, and a first gas dilution means for bypassing, diluting and discharging said emitted gas stream which has been dehumidified if air emission standards are met,
(f) diluting oxygen concentration of said emitted gas stream which has been dehumidified with at least one inert gas from an inert gas source, thereby producing an inert gas diluted gas stream, which causes no ignition nor explosion inside a gas purification contactor at downstream,
(g) treating said inert gas diluted gas stream with said gas purification contactor, thereby producing a contactor effluent,
(h) sampling the contactor effluent at an outlet sampling port for determining gas quality of said contactor effluent, in turn, determining the efficiency of said gas purification contactor in removing volatile contaminants,
(i) discharging said contactor effluent to an ambient air environment through a second bypass means comprising a second bypass line and a second gas dilution means, if gas quality of said contactor effluent meets said air emission standards,
(j) recycling said contactor effluent to said water treatment means for treating water, in turn, generating additional emitted gas stream, and
(k) providing a make-up gas to said water treatment means from a make-up gas source for treating water.
Still in accordance with the present invention, an air emission control apparatus for treating an emitted gas stream containing high concentrations of volatile contaminants comprises the following in combination:
(a) an enclosure and a gas piping system for collecting said emitted gas stream from a water treatment means,
(b) a dehumidifying means comprising at least a demister pad directly or indirectly connected to said enclosure and said gas piping system for removing humidity from said emitted gas stream,
(c) at least a gas mover directly or indirectly connected to said enclosure for moving said emitted gas stream,
(d) a monitoring means directly or indirectly connected to said gas mover for monitoring said emitted gas stream, said monitoring means further comprising a flow meter, a vacuum/pressure gauge, and a humidity meter for measuring gas flow rate, vacuum/pressure and humidity, respectively, of said emitted gas stream,
(e) an inlet sampling port directly or indirectly connected to said monitoring means and said gas mover for sampling and analyzing said emitted gas stream,
(f) a first bypass means connected to said gas piping system and said inlet sampling port at upstream of a gas purification contactor for bypassing said emitted gas stream when gas quality of said emitted gas stream meets air emission standards; said first bypass means further comprising a first bypass line, and a first gas dilution means for diluting said emitted gas stream with air before being discharged into an ambient air environment,
(g) an inert gas source connected to said gas piping system at upstream of said gas purification contactor for supplying at least one inert gas to said gas purification contactor, in turn for preventing ignition and explosion inside said gas purification contactor,
(h) said gas purification contactor connected to said gas piping system and said inert gas source for purifying said emitted gas stream, thereby producing a contactor effluent; said gas purification contactor further comprising a purifying agent,
(i) an outlet sampling port connected to said gas piping system at downstream of said gas purification contactor for sampling and analyzing said contactor effluent,
(j) a second bypass means connected to said gas piping system and said gas purification contactor for discharging said contactor effluent when gas quality of said contactor effluent meets air emission standards; said second bypass means further comprising a second bypass line and a second gas dilution means for diluting said contactor effluent with air before being discharged into said ambient air environment,
(k) a recycle pipe line connected to upstream of said water treatment means, but downstream of said second bypass line, said outlet sampling port and said gas purification contactor for recycling said contactor effluent to said water treatment means for reuse in treating water, in turn, producing additional emitted gas stream, and
(l) a make-up gas source directly or indirectly connected to said water treatment means for supplying additional gas upon demand for treating water.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a flow diagram of the present invention when applied to water treatment.
FIG. 2 is a schematic diagram of the present invention when a single stage system is applied to groundwater purification or wastewater treatment considering gas emission control.
FIG. 3 is a schematic diagram of the present invention when a two stage system is applied to water treatment or wastewater treatment considering gas emission control.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, an air emission control apparatus for treating an emitted gas stream containing high concentrations of volatile contaminants comprises the following in combination shown in FIGS. 1 and 2:
(a) an enclosure 12 and a gas piping system 13 for collecting said emitted gas stream 14 from a water treatment means 3,
(b) a dehumidifying means comprising at least a demister pad 16 directly or indirectly connected to said enclosure 12 and said gas piping system 13 for removing humidity from said emitted gas stream 14,
(c) at least a gas mover 15 directly or indirectly connected to said enclosure 12 for moving said emitted gas stream 14,
(d) a monitoring means 71 (FIG. 1) directly or indirectly connected to said gas mover 15 for monitoring said emitted gas stream 14; said monitoring means 71 further comprising a flow meter 40, a vacuum/pressure gauge 41, and a humidity meter 42 for measuring gas flow rate, vacuum/pressure and humidity, respectively, of said emitted gas stream 14,
(e) an inlet sampling port 17 directly or indirectly connected to said monitoring means 71 and said gas mover 15 for sampling and analyzing said emitted gas stream 14,
(f) a first bypass means 45A directly or indirectly connected to said gas piping system 13 and said inlet sampling port 17 at upstream of a gas purification contactor 18 for bypassing said emitted gas stream 14 when gas quality of said emitted gas stream 14 meets air emission standards; said first bypass means 70A (shown in FIG. 1) further comprising a first bypass line 45A, and a first gas dilution means 46A for diluting said emitted gas stream 14 with air 44A,
(g) an inert gas source 60 connected to said gas piping system 13 before being discharged into an ambient air environment stem 13 at upstream of said gas purification contactor 18 for supplying at least one inert gas to said gas purification contactor 18, in turn for preventing ignition and explosion inside said gas purification contactor 18,
(h) said gas purification contactor 18 connected to said gas piping system 13 and said inert gas source 60 for purifying said emitted gas stream 14, thereby producing a contactor effluent 18E; said gas purification contactor 18 further comprising a purifying agent,
(i) an outlet sampling port 19 connected to said gas piping system 13 at downstream of said gas purification contactor 18 for sampling and analyzing said contactor effluent 18E,
(j) a second bypass means 70B (shown in FIG. 1) connected to said gas piping system 13 and said gas purification contactor 18 for discharging said contactor effluent 18E when gas quality of said contactor effluent 18E meets air emission standards; said second bypass means 70B further comprising a second bypass line 45B and a second gas dilution means 46B for diluting said contactor effluent 18E with air 48 before being discharged into said ambient air environment 44B,
(k) a recycle pipe line 9 directly or indirectly connected to said water treatment means 3 and said second bypass line 45B, said outlet sampling port 19 and said gas purification contactor 18 for recycling said contactor effluent 18E to said water treatment means 3 for reuse in treating water, in turn, producing additional emitted gas stream 14, and
(l) a make-up gas source 50 directly or indirectly connected to said water treatment means 3 for supplying additional gas upon demand for treating water 2.
A complete water treatment and gas emission control system shown in FIG. 2 is presented below as a typical example. An influent pump 1 feeds a contaminated water 2 to an enclosed water treatment means 3, which is seeded/fed with microorganisms 30 and/or chemical 31 and is equipped with a sparger system 4, a vacuum breaker 5, a water inlet 6, a water outlet 7 with trap 8, a gas inlet recycle pipe line 9 to said sparger system 4, a gas outlet 10 to a gas recycle system, a manhole with cover 11, and an enclosure 12.
The water treatment means 3 shown in FIG. 2 is constructed to provide sufficient gas head space for holding an emitted gas stream 14 above water 53 in said water treatment means 3. Gas bubbles generated from the sparger system 4 passing through water 53 inside said water treatment means 3 entrains volatile organic compounds (VOCs) and other volatile contaminants from water phase 53 into gas phase becoming an emitted gas stream 14. The remaining VOCs and other organic contaminants are removed by the microorganisms 30 and/or chemical 31 in the water phase 53 inside said water treatment means 3.
Said chemical 31 include inorganic chemical, organic chemical, powdered activated carbon , peat moss and enzymes. The microorganisms 30 include aerobic, facultative and enzymatic (enzyme producing) microorganisms which may be fed to said water treatment means 3 for aerobic biological treatment. Anaerobic and facultative microorganisms may be seeded to said water treatment means 3 for anaerobic biological treatment when entire liquid treatment and gas emission control system shown in FIG. 2 is full of inert gas(es) from an inert gas source 60.
The emitted gas stream 14 from said water treatment means 3, shown in FIGS. 1 and 2 containing VOCs is sucked by a gas mover 15, and passes through the gas outlet 10 and a dehumidifying means such as a demister pad 16 or equivalent to remove water droplets from said emitted gas stream 14. The preferred gas mover 15 shown in FIGS. 1 and 2 is of low pressure (5 to 15 psi) and low volume (500 to 1500 scfm) type.
The dehumidified gas from said demister pad 16 or an equivalent dehumidifying means is monitored by a monitoring means 71 comprising a flow meter 40, a vacuum/pressure gauge 41, and is sampled at an inlet sampling port 17. Said dehumidified gas from said demister pad 16 or said equivalent dehumidifying means can be either bypassed through a bypass line 45A, or purified by a gas purification contactor 18 specifically designed for gas emission control, thereby producing a contactor effluent 18E., as shown in FIGS. 1 and 2. The contactor effluent 18E is sampled at an outlet sampling port 19, and is either partially or totally bypassed through a second bypass line 45B, or recycled to the water treatment means 3 via the gas inlet recycle pipe 9 and the sparger system 4 for continuous water purification for a plurality of times, as shown in FIG. 2.
The heart of this invention is the inert gas source 60 (FIGS. 1 and 2) which supplies at least one inert gas upon demand to said gas purification contactor 18, in order to dilute oxygen concentration in said emitted gas stream 14.
In case said purifying agent in said gas purification contactor 18 is granular activated carbon or fibrous activated carbon, the temperature of said granular or fibrous activated carbon gradually increase due to adsorption of volatile organic compounds onto said granular or fibrous activated carbon. At an elevated temperature with sufficient oxygen content, the volatile organic compounds and said granular or fibrous activated carbon may be ignited causing explosion and equipment damage. The inert gas source 60 of this invention is the solution to this ignition and explosion problem. After the oxygen content in said emitted gas stream 14 is significantly diluted by said inert gas, ignition or explosion at said gas purification contactor 18 can then be avoided.
The inert gas source 60 of this invention is selected from the group comprising nitrogen, helium, carbon dioxide, or combination thereof, which are commercially available in liquid cylinder form.
Alternatively the inert gas source 60 can be either a pressure swing adsorption (PSA) system or a vacuum swing adsorption (VSA) system. The former (PSA) applies pressure, while the latter (VSA) applies vacuum for moving an air stream containing oxygen, nitrogen, carbon dioxide, etc. Pelletized adsorbents, call molecular sieves, show a preference, at a given temperature and pressure, for nitrogen, carbon dioxide and hydrocarbons in air. When operating a PSA system, the pelletized adsorbent is contained in multiple adsorption vessels through which the influent pressurized air flows. Nitrogen, carbon dioxide and trace amount of hydrocarbons are adsorbed by the pelletized adsorbent. The non adsorbed gas, oxygen, passes through until the pelletized adsorbent becomes saturated. The air flow is then switched to the next vessel and the pelletized adsorbent is regenerated by depressurization, releasing the trapped nitrogen and other trace gases. Each of the vessels is pressurized and depressurized sequentially to produce a continuous stream of inert nitrogen and a continuous steam of oxygen.
The oxygen produced from said PSA system is a byproduct which can also be used in said water treatment means 3 if aerobic biological treatment is intended; while the nitrogen produced from the same PSA system is to be used as the inert gas source 60 of this invention. The inert gas source 60 supplies inert gas for preventing said gas purification contactor 18 from being ignited or exploded, and also for operating said water treatment means 3 for anaerobic biological treatment, upon demand.
The monitoring means comprises a flow meter 40, a vacuum/pressure gauge 41 and a humidity meter 42 (or combinations thereof) for measuring gas flow rate, vacuum/pressure and humidity, respectively, of said emitted gas stream 14, as shown in FIG. 2.
The first bypass line 45A comprises a first gas dilution means 46A for diluting the emitted gas stream 16E (FIG. 1) with air 48, and discharging it 16E to an ambient air environment 44A, under the condition that governmental air emission standards can be met. If said air emission standards can not be met, said emitted gas stream 16E (FIG. 1) should not be bypassed, instead, should be forwarded to said gas purification contactor 18 for purification.
The second bypass line 45B comprises a second gas dilution means 46B for diluting the contactor effluent 18E with air 48, and discharging it 18E with air 48, and discharging it 18E to the ambient air environment 44B, under the condition that governmental air emission standards can be met. Said outlet sampling port 19 is for gas quality control and assurance. Said second bypass line 45B is required if recirculation of the contactor effluent 18E to the water treatment means 3 through said recycle pipe line 9 is not intended or interrupted.
A make-up gas source 50 connected to said water treatment means 3 is for supplying additional gas upon demand. As a typical example, a make-up gas source 50 can be either air or oxygen if said water treatment means 3 is an aerobic biological treatment plant in which microorganisms require oxygen for their biochemical reactions.
In case that said water treatment means 3 is an air stripping unit, a dissolved gas flotation plant, a dispersed gas flotation plant, a foam separation plant, a froth flotation plant, a non-biological reactor, an anaerobic biological plant, or a physical-chemical plant, each involving generation of gas bubbles and an emitted gas stream, entire water treatment means 3 and entire gas emission control apparatus shown in FIG. 1 can be filled with one or more inert gases. The bubbles in said water treatment means 3 are inert gas bubbles, such as nitrogen, helium, carbon dioxide, or combinations of. The emitted gas stream 14 as well as the contactor effluent 18E contain mainly inert gas. Besides, the contactor effluent 18E is continuously recycled to said water treatment means 3 for generation of more inert gas bubbles. Under this process condition, both said first bypass line 45A and said second bypass line 45B can be idled or disconnected. Only small volume of inert gas is required to be the make-up gas source 50.
The purified water 53 in said water treatment means 3 shown in FIG. 2 flows through the water outlet 7 and a trap 8 and is further treated by a clarifier 20, a filter 21 and a disinfection unit 22. The plant effluent 23 is further treated or discharged to the environment. The sludge from said clarifier 20 is either partially recycled via a sludge recycle line 25 to the water treatment means 3, or partially/totally discharged as waste sludges 24.
Entire said water treatment means 3 and its gas emission control system (FIG. 1) comprising said enclosure 12, gas piping system 13, dehumidifying means such as demister pad 16, gas mover 15, gas purification contactor 18, inlet sampling port 17, outlet sampling port 19, bypass means 70A and 70B (FIG. 1), and monitoring means 71, sampling ports 17 and 19, inert gas source 60 and recycle line 9 are completely enclosed, thus eliminating gas emissions or secondary air pollution.
The present invention is specific for removal of volatile contaminants including volatile organic compounds (VOCs). VOCs are removed by gas purification contactor 18 in the gas phase rather than water phase. The remaining organic compounds are removed by the microorganisms 30 and/or chemical 31 in said water treatment means 3. Removal of VOCs by conventional granular activated carbon (GAC) filter in water phase is hindered by the other organic and inorganic compounds competing for adsorption sites on the GAC. Consequently, more VOCs are removed by the present invention's gas purification contactor 18 in the gas phase than that removed by conventional GAC filter in the water phase. The gas purification contactor 18 of this invention contains a purifying agent; while the filter means 21 of this invention contains a filter media. Both said purifying agent and said filter media are selected from a group comprising granular activated carbon, polymeric adsorbent, activated alumina, ion exchange resin, manganese dioxide, magnesium oxide, fibrous activated carbon, membrane filter media, fiberglass filter media, coalescing filter media, or combinations thereof. All filter media to be adopted by this invention are insoluble, and further comprise sand, coal, diatomaceous earth, calcium carbonate, or combinations thereof. Said purifying agent further comprise calcium chloride, sodium carbonate, lime, potassium carbonate, or combinations thereof, for further removing humidity and/or adjusting pH inside said gas purification contactor 18.
The size of said water treatment means 3 shown in FIG. 2 is altered to adjust the hydraulic residence time to conform to different influent flow rates.
In normal operation, the water treatment means 3 shown in FIG. 2 is under slightly negative pressure and is provided sufficient gas head space above the level of water 53 in said water treatment means 3.
The sparger system 4 is located at bottom of said water treatment means 3, shown in FIG. 2. The low pressure and low volume gas mover 15 provides energy for gas recirculation and gas bubbling through water phase containing influent water 2, chemical 31 and/or microorganisms 30. The gas bubbles passing through said water phase 13 and entraining (VOCs) from water phase 53 into gas phase becoming said emitted gas stream 14 inside said water treatment means 3, shown in FIG. 2 is a physical reaction, termed gas stripping. The remaining VOCs and other organic contaminants in said water phase 53 are removed by biochemical reactions of microorganisms 30 and/or by physical chemical reactions of chemical 31.
The emitted gas stream 14 containing VOCs exits said water treatment means 3 (See FIG. 2) and passes through a dehumidifying means such as a demister pad 16 to remove water droplets before entering said gas purification contactor 18 for adsorbing VOCs onto said purifying agent from said emitted gas stream 14 in high efficiency.
The trap 8 of said water outlet 7 prevents external air intrusion into said water treatment means 3, shown in FIG. 2. Partial recycling of the sludge produced from said clarifier 20 is for maintaining a constant population of microorganisms 30 in said water treatment means 3 under the condition that the water treatment means is operated for either aerobic biological treatment, or anaerobic biological treatment, in the presence of appropriate microorganisms and dissolved gases in water phase 53. The partially discharged waste sludges 24 include excess microorganisms and/or spent chemical flocs.
The inlet sampling port 17 and the outlet sampling port 19 at upstream and downstream, respectively, of the gas purification contactor 18 determine the present invention's efficiency for VOCs reduction.
When the purifying agent in said gas purification contactor 18 is exhausted, the spent purifying agent is replaced with virgin purifying agent, chemically treated purifying agent, and/or regenerated purifying agent.
The microorganisms 30 inside said water treatment means 3 are mixed with the chemical 31, upon demand, for improvement of water or wastewater treatment efficiency. Alternatively said chemical 31 can be fed to said water treatment means 3 without said microorganisms 30
The present invention is applied to groundwater decontamination as well as treatment of industrial, commercial or municipal wastewater, in which the water treatment means 3 generates said emitted gas stream 14.
The gas emission control apparatus (comprising all process units shown in FIG. 1 excluding said water treatment means 3) of the present invention is easily adjusted for treating said emitted gas stream 14 from various water treatment means 3 including conventional air stripping towers similar to that were described in the literature (R. P. O'Brien and J. L. Fisher, Water/Engineering & Management, May 1983; R. P. O'Brien and M. H. Stenzel, Public Works, December 1984; M. H. Stenzel and U. S. Gupta, Journal of the Air Pollution Control Association, December 1985) and in the prior art, such as the U.S. Patents cited in this invention.
A complete water treatment and gas emission control apparatus (comprising all process units shown in FIG. 1 including said water treatment means 3) is easily mobilized and demobilized because of its modular construction and its feasibility of being skid mounted, truck mounted, train mounted, boat mounted, or combinations thereof, for enhancing mobility.
For specific gas emission control, the purifying agent in said gas purification contactor 18 is totally or partially packed with said purifying agent, such as granular activated carbon (GAC), activated alumina, ion exchange resin, polymeric adsorbent, manganese oxide, sodium carbonate, membrane media, lime, fibrous activated carbon, calcium chloride, reticulated foam, lime, calcium chloride, calcite, dolomite, fiberglass media, coalescing filter media, membrane filter media, potassium carbonate, calcium carbonate, or combinations thereof, and can be chemically regenerated or treated by base (sodium hydroxide, potassium hydroxide, calcium hydroxide, or combinations thereof), aluminate (sodium aluminate, potassium aluminate, or both), chromium compound (potassium dichromate, sodium dichromate, or both), or manganese compound (potassium permanganate, sodium permanganate, or both).
The clarifier 20 of the present invention shown in FIG. 2 is either a sedimentation clarifier or a flotation clarifier. The filter 21 of the present invention shown in FIG. 2 is a single media filter, a multi-media filter, a diatomaceous earth (DE) filter, a cartridge filter, a granular activated carbon (GAC) filter, a micro filter, an ultra filter, or combinations thereof. The disinfection unit 22 of the present invention also shown in FIG. 2 is ultraviolet (UV) using UV light, chlorination using chlorine, ozonation using ozone, or combinations thereof.
While the invention has been described and illustrated with reference to a specific embodiment thereof, it will be understood that the modification and variations thereof will occur to those skilled in the art, and that the following examples and the appended claims are intended to cover such modifications and variations which are within the scope and spirit of this invention.
For example, the flow meter 40, vacuum/pressure gauge 41, humidity meter 42, or combinations thereof, shown in FIG. 1, can be idled or disconnected.
Alternatively, a foam collector-breaker 51, shown in FIG. 1, can be added to the gas emission control system of this invention for collecting and breaking surface active foam present in said emitted gas stream 14. Said foam collector-breaker 51 is to be connected directly or indirectly to said enclosure 12.
Alternatively, a scrubber means 52 can be added to the gas emission control system (FIG. 1) of this invention for removing volatile inorganic compounds (VICs) present in said emitted gas stream 14. Said scrubber means 52 is a wet scrubber, a dry scrubber, or both, directly or indirectly connected to said dehumidifying means comprising said demister pad 16. For the preferred embodiments of this invention, a wet scrubber 52 shall be installed at upstream of said demister pad 16; while a dry scrubber 52 shall be installed at downstream of said demister pad 16, as shown in FIG. 1.
Still the inert gas source 60 can be installed at either downstream or upstream of said gas mover 15, as shown in FIGS. 1 and 2. If said inert gas source 60 is located at downstream or pressure side of said gas mover 15, a venturi feeder 60V is needed for feeding inert gas into said gas piping system 13. If said inert gas source 60 is located at upstream or suction side of said gas mover 15, a venturi feeder 60V is not needed.
Still alternatively the make-up gas source 50 can be directly connected to said water treatment means 3, or connected at upstream or suction side of said gas mover 15, as shown in FIGS. 1 and 2.
The complete water treatment and gas emission control system of this invention shown in FIGS. 1 and 2 is a single stage system, and can be operated under various environmental or process conditions. Specifically the water phase 53 inside said water treatment means 3 shown in FIG. 2, can have, at least, the following eight process conditions for a single stage water treatment system:
(a) Condition A: aerobic condition, without chemical 31, without microorganisms 30;
(b) Condition B: aerobic condition, with chemical 31, without microorganisms 30;
(c) Condition C: aerobic condition, without chemical 31, with microorganisms 30;
(d) Condition D: aerobic condition, with chemical 31, with microorganisms 30;
(e) Condition E anaerobic condition, without chemical 31, without microorganisms 30;
(f) Condition F: anaerobic condition, with chemical 31, without microorganisms 30;
(g) Condition G: anaerobic condition, without chemical 31, with microorganisms 30; and
(h) Condition H: anaerobic condition, with chemical 31, with microorganisms 30.
A multiple stage water treatment system having multiple sets of process units shown in FIGS. 1 and 2 (except said filter 21 and said disinfection unit 22) is also covered by this invention. Various combinations of the above eight process conditions (Conditions A to H) are available for said multiple stage water treatment. FIG. 3 shows a two stage water treatment system of this invention having two sets of process units (i.e. The process units shown in FIGS. 1 and 2 are duplicated) except said filter 21 and said disinfection unit 22. The water phase 53 inside said two water treatment meanses 3 shown in FIG. 3 for a two-stage system can have many operating environmental and process conditions, namely various combinations of the eight Conditions A, B, C, D, E, F, G, and H identified in the last paragraph. For example, the combination of Conditions C and G for the first and the second, respectively, of the water treatment means 3 shown in FIG. 3 is an efficient aerobic/anoxic two-stage biological treatment system suitable for treating water contaminated by industrial pollutants.
The combination of Conditions B and C (or D) identified above is an efficient two-stage physicochemical & biological treatment system, which is also represented by FIG. 3.
The complete water treatment and gas emission control system of this invention can be expanded to more than two stages.
A three-stage system of this invention (not shown), for instance, has been proven to be an efficient biological treatment system for carbonaceous oxidation in the first stage (Condition C or D), nitrification in the second stage (Condition C or D), and denitrification in the third stage (Condition G or H). The theory, principles, and chemical reactions of carbonaceous oxidation, nitrification, and denitrification are reported in the literature by Lawrence K. Wang et al (Journal of Environmental Science, Volume 21, pages 23-28, December 1978).
The gas emission control system of this invention (all process units shown in FIG. 1 except said water treatment means 3) is always needed in the first stage, but may or may not be needed in the later stages.
The sparger system 4 (FIGS. 2 and 3) of this invention is a porous tube diffusion means, a porous plate diffusion means, nozzle diffusion means, an induced gas diffusion means, a diaphragm diffusion means, a jet gas diffusion means, a mechanical diffusion means, or combinations thereof.
Common reactive purifying agent packed inside said gas purification contactor 18 (FIGS. 1, 2, and 3) includes, at least, virgin granular activated carbon, virgin fibrous activated carbon, virgin polymeric adsorbent, base treated granular activated carbon, base treated fibrous activated carbon, base treated polymeric adsorbent, aluminate treated granular activated carbon, aluminate treated fibrous activated carbon, aluminate treated polymeric adsorbent, or combinations thereof. All base treated said purifying agent are impregnated with base; while all aluminate treated said purifying agent are impregnated with aluminate. Said base includes sodium hydroxide, potassium hydroxide, calcium hydroxide, or combinations thereof. Said aluminate includes sodium aluminate, potassium aluminate, or both. Both base treated purifying agent and the aluminate treated purifying agent of this invention are used for removing odorous contaminants from an emitted gas stream 14. Special chromium impregnated granular activated carbon, chromium impregnated fibrous activated carbon, chromium impregnated polymeric adsorbent, manganese impregnated granular activated carbon, manganese impregnated fibrous activated carbon, manganese impregnated polymeric adsorbent or combinations thereof, can be used as the purifying agent in the gas purification contactor 18 of this invention for removing formaldehyde gas and hydrocarbon gases from said emitted gas stream 14.
Said chromium comprises potassium dichromate, sodium dichromate, or both. Said manganese comprises potassium permanganate, sodium permanganate, or both.
The water treatment step of said water treatment means 3 comprises a continuous process steps described previously, and shown in FIG. 2, and a batch process steps described in the following paragraph.
The batch process steps for operating the water treatment means 3 of this invention comprise the following steps in sequence:
(a) pumping and discharging the contaminated water 2 into a water treatment means 3 until said water treatment means 3 reaches its full capacity, which is termed a Filling Phase; said Filling Phase further comprising a Static Filling Phase, a Mixed Filling Phase, a Reacting Filling Phase, or combinations thereof, depending on simultaneously feeding or subsequently feeding gas bubbles, microorganisms 30 and/or chemical 31 into said water treatment means 3; Said Static Filling Phase further representing a specific operating time period during which gas bubbles, microorganisms 30 and/or chemical 31 are not simultaneously fed to said water treatment means 3 together with said contaminated water 2; Said Mixed Filling Phase further representing a specific operating time period during which microorganisms 30 and/or chemical 31 are simultaneously fed to said water treatment means together with said contaminated water under a mixing condition; Said Reacting Filling Phase further representing a specific operating time period during which gas bubbles, microorganisms 30 and/or chemical 31 are fed into said water treatment means 3 together with said contaminated water 2 under another mixing condition,
(b) stopping to feed microorganisms 30 and/or chemical 31 but still feeding gas bubbles into said water treatment means 3 for removing contaminants from said contaminated water 2 and producing a water effluent and an emitted gas stream 14; simultaneously collecting, transporting, dehumidifying, monitoring, and purifying the emitted gas stream 14 and producing a gaseous contactor effluent 18E; recycling said contactor effluent 18E to said water treatment means 3 for continuously generating gas bubbles for reuse; Step b being a Reacting Phase,
(c) stopping to feed gas bubbles to said water treatment means 3 allowing insoluble sludge in the water effluent to separate by density difference without turbulence, thereby producing a clarified effluent and a separated sludge; said density difference being either sedimentation clarification or flotation clarification; Step c being a Separating Phase,
(d) discharging the clarified effluent from said water treatment means 3; filtering, disinfecting, discharging, or combinations thereof, said clarified effluent; Step d being Effluent Discharging Phase,
(e) totally or partially discharging the separated sludge from said water treatment means 3; Step e being Sludge Wasting Phase, (f) allowing said water treatment means 3 to remain idle until said water treatment means 3 is to be filled again; Step f being an Idling Phase which is used when there is more than one said water treatment means 3, and the lowest idling time being zero, and
(g) repeating the batch process cycle from steps a to f for a plurality of times for treating said contaminated water 2 while simultaneously collecting, transporting, monitoring, dehumidifying purifying recycling and reusing the emitted gas stream 14.
Said sedimentation clarification is a process method by which insoluble suspended solids and settleable solids settle to the bottom of said water treatment means 3 by gravity because the densities of said insoluble suspended solids and said settleable solids are higher than that of water. Said flotation clarification is a process method by which said insoluble suspended solids and said settleable solids float to a water surface inside said water treatment means 3 by rising gas bubbles with diameter smaller than 80 microns because the combined density of said fine gas bubbles, said insoluble suspended solids and said settleable solids are lower than that of water. Fine gas bubbles are produced by a gas dissolving and bubble generating means described by the U. S. Pat. Nos. 5,049,320 (Sep. 17, 1991) and 5,167,806 (Dec. 1, 1992) of Lawrence K. Wang et al, or commercially available means for producing fine gas bubbles. | The present invention relates to an air emission control system for removing volatile organic compounds (VOCs) and other objectionable contaminants from an emitted gas stream which is generated from a water treatment means. Specifically the improved air emission control system of this invention relates to collecting, dehumidifying, bypassing, diluting, monitoring, purifying recycling and reusing the emitted gas stream, and also relates to feeding an inert gas, upon demand, for reducing oxygen content of said emitted gas stream, in turn, for preventing a gas purification contactor from being ignited and/or exploded due to oxidation of carbonaceous substances inside said gas purification contactor. A complete water treatment and gas emission control system is developed by applying the air emission control system to either single stage water treatment or multiple stage water treatment. The present invention which causes no air pollution is a low cost and highly efficient alternative to present site remediation and water treatment technologies. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of Korean Patent Application No. 10-2014-0065894, filed on May 30, 2014, which is hereby incorporated by reference as if fully set forth herein.
TECHNICAL FIELD
The present disclosure relates to a laundry treatment apparatus.
BACKGROUND
Generally, a laundry treatment apparatus can include an apparatus adapted to wash laundry, an apparatus adapted to dry laundry, and an apparatus adapted to perform both washing and drying of laundry.
A front-loading laundry treatment apparatus (also called a drum washing machine) is designed to allow laundry to be put into the apparatus from the front of the apparatus and has an introduction port through which laundry can be put into the apparatus. Since the front-loading laundry treatment apparatus has an introduction port positioned at a level lower than a user's waist, use of the apparatus may be inconvenient in that a user has to stoop in order to put laundry into the apparatus or takes laundry out of the apparatus.
In order to eliminate such inconvenience, among conventional laundry treatment apparatuses, a laundry treatment apparatus in which a support platform is additionally provided at a front-loading laundry treatment apparatus has been proposed.
Such a support platform is intended to raise the height of an introduction port and not for performing a function of laundry treatment such as washing or drying of laundry.
SUMMARY
An object of the present disclosure may be to provide a laundry treatment apparatus which is detachably coupled to another laundry treatment apparatus to perform washing or/and drying of laundry.
Another object of the present disclosure may be to provide a laundry treatment apparatus which is constructed to enable washing water to be easily supplied to or discharged from an accommodation unit retractably provided at a cabinet to accommodate laundry.
A further object of the present disclosure may be to provide a laundry treatment apparatus capable of condensing moisture discharged from the accommodation unit and returning the condensed water to the accommodation unit.
Still another object of the present disclosure may be to provide a laundry treatment apparatus capable of preventing washing water from remaining in a discharge unit serving to discharge washing water contained in an accommodation unit.
Yet another object of the present disclosure may be to provide a laundry treatment apparatus including means for circulating washing water in an accommodation unit.
According to one aspect, a laundry treatment apparatus includes a cabinet having an open surface, a drawer that includes a drawer body provided in the cabinet and configured to be retracted out of the cabinet through the open surface and a drawer panel provided at the drawer body and configured to close the open surface based on the drawer body being retracted within the cabinet, an accommodation unit provided within the drawer body and defining a space for receiving washing water, a discharge unit configured to discharge washing water from the accommodation unit to the outside of the accommodation unit, a water discharge channel configured to guide discharged washing water in the discharge unit to the outside of the cabinet, and a residual water discharge unit configured to provide an alternative path for discharging washing water in the discharge unit to the outside of the cabinet, wherein at least a portion of the residual water discharge unit is exposed to and accessible from the outside of the cabinet based on the drawer body being withdrawn from the cabinet, and wherein the entire residual water discharge unit is covered by the cabinet based on the drawer body being retracted within the cabinet.
Implementations according to this aspect may include one or more of the following features. For example, the water discharge channel may be inclined such that washing water in the water discharge channel moves back toward the discharge unit based on the discharge unit being turned off. The residual water discharge unit may include a residual water discharge tube communicating with the discharge unit and extending toward the drawer panel from the discharge unit. The residual water discharge tube may have a free end detachably provided at the drawer. The free end of the residual water discharge tube may include an opening and closing device that is configured to open and close the residual water discharge tube. The laundry treatment apparatus may further include a fixed body provided at the drawer, the fixed body including a receiving portion for receiving the residual water discharge tube to thereby releasably attach a free end of the discharge tube to the drawer. The fixed body may define a through hole for receiving the residual water discharge tube. The fixed body may be positioned closer to a front side of the drawer than a rear side of the drawer. The laundry treatment apparatus may further include a water discharge tube support provided at the drawer body and configured to support the residual water discharge tube such that the residual water discharge tube does not contact an inner surface of the cabinet. The drawer body may include an introduction opening, and the accommodation unit may include a tub provided in the drawer body and configured to receive washing water, a drum rotatably provided in the tub, and a tub cover defining a tub introduction port that provides a passage from the introduction opening to the drum, wherein the fixed body may be positioned along a side surface of the drawer body at a location between the drawer panel and a portion of the introduction opening closest to the drawer panel.
Further according to this aspect, the discharge unit may include a housing fixed to the drawer body and configured to communicate with the accommodation unit, the housing defining a space for receiving washing water, a first housing water discharge part that provides a fluidic connection between the housing and the water discharge channel, a second housing water discharge part that provides a fluidic connection between the housing and the residual water discharge unit, and an impeller configured to transfer washing water in the housing to the water discharge channel. The laundry treatment apparatus may further include a guider including a first body rotatably coupled to the cabinet, and a second body rotatably coupled to the first body and the drawer body to connect the first body to the drawer body, wherein the water discharge channel is provided at the guider. The water discharge channel may include a second channel provided at the first body, a first water discharge pipe providing a fluidic connection between the second channel and the first housing water discharge part, and a second water discharge pipe configured to guide washing water in the second channel to the outside of the cabinet. The first water discharge pipe may be inclined such that washing water remaining in the first water discharge pipe is recovered to the first housing water discharge part based on the impeller being turned off. The first housing water discharge part may be inclined such that washing water remaining in the first water discharge pipe is recovered to the first housing water discharge part based on the impeller being turned off. The laundry treatment apparatus may further include a supply unit connected to a water supply source, a first channel provided at the first body, a connecting pipe providing a fluidic connection between the first channel and the supply unit, and a water supply pipe supported by the second body and configured to guide washing water in the first channel to the accommodation unit. The laundry treatment apparatus may further include a first valve connected to a first water supply source, a second valve connected to the second water supply source and configured to supply washing water of a temperature different from that of the first water supply source, a first channel provided in the first body, a first connecting pipe providing a fluidic connection between the first channel and the first valve, a second connecting pipe providing a fluidic connection between the first channel and the second valve, and a water supply pipe supported by the second body and configured to guide washing water in the first channel to the accommodation unit.
Additional advantages, objects, and features of the disclosure will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the disclosure. The objectives and other advantages of the disclosure may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description of the present disclosure are exemplary and explanatory and are intended to provide further explanation of the disclosure as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the disclosure and are incorporated as a part of this application, illustrate implementations of the disclosure and together with the description serve to explain the principle of the disclosure. In the drawings:
FIG. 1 is a perspective view showing an example laundry treatment apparatus according to the present disclosure;
FIG. 2 is an exploded perspective view of the laundry treatment apparatus of FIG. 1 ;
FIGS. 3A and 3B are views showing an drawer, a tub, and a door of the laundry treatment apparatus according to the present disclosure;
FIGS. 4A, 4B, and 4C are views showing an example tub cover of the laundry treatment apparatus according to the present disclosure;
FIGS. 5A and 5B are cross-sectional views showing an example recovery unit of the laundry treatment apparatus according to the present disclosure;
FIGS. 6, 7, 8A, 8B, and 8C are various views showing an example guider of the laundry treatment apparatus according to the present disclosure; and
FIGS. 9 and 10 are plan views showing an example operation of the guider.
DETAILED DESCRIPTION
Reference will now be made in detail to the implementations of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
Hereinafter, the present disclosure will be described in connection with a laundry treatment apparatus including both a first treatment apparatus T and a second treatment apparatus L.
The first treatment apparatus T according to the present disclosure may include a first treatment apparatus cabinet 1 defining an exterior appearance, a first treatment apparatus tub disposed in the first treatment apparatus cabinet 1 to contain washing water therein, a first treatment apparatus drum rotatably disposed in the first treatment apparatus tub to contain laundry, a first treatment apparatus water supply unit for supplying washing water to the first treatment apparatus tub, and a first treatment apparatus water discharge unit for discharging washing water contained in the first treatment apparatus tub to the outside of the first treatment apparatus cabinet 1 .
The first treatment apparatus cabinet 1 includes a first treatment apparatus introduction port through which laundry is put into the cabinet 1 or taken out of the cabinet 1 . The first treatment apparatus introduction port is opened and closed by a first treatment apparatus door 11 hinged to the first treatment apparatus cabinet 1 .
The first treatment apparatus tub includes a first treatment apparatus tub introduction port communicating with the first treatment apparatus introduction port, and thus a user can put laundry into the first treatment apparatus drum upon opening of the first treatment apparatus door 11 .
When the first treatment apparatus T is designed to also perform a function of drying of laundry, the first treatment apparatus cabinet 1 has to be provided therein with a hot air supply unit for supplying hot air to the first treatment apparatus tub.
The hot air supply unit may include a circulation duct for circulating air in the first treatment apparatus tub, and a heat exchange unit disposed at the circulation duct to dehumidify and heat the air discharged from the first treatment apparatus tub.
Alternatively, the hot air supply unit may also include a discharge duct for discharging air in the first treatment apparatus tub to the outside of the first treatment apparatus cabinet 1 , a supply duct for supplying air from outside the first treatment apparatus cabinet 1 to the first treatment apparatus tub, and a heat exchange unit disposed at the supply duct.
Unlike the above construction, if the first treatment apparatus T is designed to perform a function of drying of laundry, the first treatment apparatus may not need the first treatment apparatus tub. In this case, the hot air supply unit has to supply hot air to the first treatment apparatus drum provided in the first treatment apparatus cabinet 1 .
The second treatment apparatus L incorporated in the laundry treatment apparatus according to the present disclosure includes a cabinet 2 detachably provided at the first treatment apparatus cabinet 1 , a drawer 3 disposed in the cabinet 2 to be retractable therefrom, and an accommodation unit 4 , 5 disposed in the drawer 3 and serving as a treatment space of laundry.
The cabinet 2 , which defines an exterior appearance of the second treatment apparatus L, may support the first treatment apparatus cabinet 1 . Unlike the cabinet shown in FIG. 1 , the cabinet 2 provided at the second treatment apparatus may be detachably provided at an upper surface or a side surface of the first treatment apparatus cabinet 1 .
However, since a height of the first treatment apparatus door 11 is increased when the second treatment apparatus L is positioned under the first treatment apparatus T, it is convenient for a user to put laundry into the treatment apparatus or to take laundry out of the treatment apparatus.
The cabinet 2 includes an open surface 21 such that the drawer 3 is withdrawn from the cabinet 2 through the open surface 21 or is accommodated in the cabinet 2 . When the second treatment apparatus L is provided at a bottom surface of the first treatment apparatus T, the open surface 21 may be disposed at a side (a front side of the first treatment apparatus T) at which the first treatment apparatus door 11 is positioned.
As shown in FIG. 2 , the drawer 3 includes a drawer body 31 having an open upper surface, and a drawer cover 35 disposed at the open upper surface of the drawer body 31 .
The drawer body 31 may be configured to have a hexahedral shape having a hollow cavity defined therein. The drawer cover 35 is fixed to the drawer body 31 to define the upper surface of the drawer body 31 .
The drawer body 31 is provided at a front surface thereof with a drawer panel 33 . The drawer panel 33 may include a handle. In this case, a user can draw the drawer body 31 disposed in the cabinet 2 from the cabinet 2 using the handle.
The drawer panel 33 may include a control panel 331 for controlling operation of the second treatment apparatus L. The control panel 331 serves to allow a user to input control commands for control of units for supplying washing water to the accommodation unit 4 , 5 and discharging the washing water from the accommodation unit 4 , 5 , a unit for rotating laundry, units for supplying steam or hot air to laundry and the like.
The control panel 331 may also serve to allow a user to check control commands input by a user and to display an execution state of the control commands input by the user.
The drawer cover 35 may be provided with an introduction opening 353 formed through the drawer cover 35 to communicate the inside of the drawer body 31 with the outside of the drawer body 31 , and a water supply opening 355 formed through the drawer cover 35 to guide washing water to the accommodation unit 4 , 5 .
The accommodation unit 4 , 5 provided in the drawer 3 may include a tub 4 provided in the drawer body 31 to provide a space for containing laundry, and a drum 5 rotatably provided in the tub 4 to contain laundry.
The tub 4 may include a tub body 41 having a space for containing washing water and having an open upper surface, and a tub cover 43 fixed to the upper surface of the tub body 41 . The drum 5 may be configured to have a cylindrical shape having an open upper surface.
As shown in FIGS. 3A and 3B , the drum 5 may be rotatable in the tub body 41 by means of a driving unit provided outside the tub body 41 . The driving unit may include a stator M 1 fixed to the tub body 41 to generate a rotating magnetic field, a rotor M 2 which is rotated by the rotating magnetic field, and a driving shaft M 3 extending through the tub body 41 and connecting the drum 5 to the rotor M 2 .
The drum 5 includes drum through holes 51 formed at an outer circumferential surface thereof to communicate the inside of the drum 5 with the inside of the tub body 41 .
The tub body 41 is held in the drawer body 31 by means of tub supports D.
Each of the tub supports D may include a drawer connecting portion D 1 , a tub connecting portion D 3 , and a rod D 5 connecting the tub connecting portion D 3 to the drawer connecting portion D 1 .
Here, the drawer body 31 may be provided with a first bracket 311 for supporting the drawer connecting portion D 1 , and the tub body 41 may be provided at an outer circumferential surface thereof with a second bracket 411 supported by the tub connecting portion D 3 .
The first bracket 311 may be provided at the drawer body 31 , and the second bracket 411 may protrude toward the inner surface of the drawer body 31 from the outer circumferential surface of the tub body 41 .
The tub cover 43 includes a cover body 431 defining an upper surface of the tub body 41 , and a tub introduction port 435 formed through the cover body 431 to communicate the introduction opening 353 with the drum 5 .
The tub introduction port 435 is provided with a door 49 hinged to the cover body 431 .
The door 49 is coupled to the cover body 431 by means of a hinge. The introduction opening 353 is positioned over the tub introduction port 435 . The door 49 or the tub introduction port 435 has a smaller size than that of the introduction opening 353 . Accordingly, even though the tub introduction port 435 is positioned below the drawer cover 35 , the tub introduction port 435 may be opened and closed by the door 49 .
Particularly, the outer circumferential surface of the door may be spaced apart from the inner circumferential surface of the introduction opening 353 by predetermined distances X 1 and X 2 in order to avoid a problem that the door 49 cannot be opened because of interference between the door 49 and the introduction opening 353 caused by geometric tolerance or positional tolerance.
Furthermore, when the outer circumferential surface of the door 49 is spaced apart from the inner circumferential surface of the introduction opening 353 by a predetermined interval, it is possible to also prevent breakage of the door due to vibration of the tub.
The door 49 may be provided with a door handle 493 which detachably secures the door 49 to the drawer cover 35 or the cover body 431 .
The door 49 may be provided with a sealing unit 495 for preventing washing water from leaking through the tub introduction port 435 .
The sealing unit 495 may include a sealing body 496 fixed to a lower surface of the door 49 , which is fitted in the tub introduction port 435 upon closing the tub introduction port 435 , and first and second protrusions 497 and 498 protruding from the sealing body 496 .
The first protrusion 497 protrudes toward the inner circumferential surface of the tub introduction port 435 from the outer circumferential surface of the sealing body 496 . The first protrusion 497 may have a length sufficient to contact the inner circumferential surface of the tub introduction port 435 when the tub introduction port 435 is closed by the door 49 .
The first protrusion 497 may include two or more protrusions provided at the sealing body 496 . The two or more first protrusions 497 may be spaced apart from each other by a predetermined interval.
The second protrusion 498 may protrude from the outer circumferential surface of the sealing body 496 so as to close the tub introduction port 435 when the tub introduction port 435 is closed by the door 49 . In other words, the second protrusion 498 must have a length sufficient to contact the upper surface of the cover body 431 when the tub introduction port 435 is closed by the door 49 .
Although the sealing unit 495 may be made of any materials so long as it can seal the tub introduction port 435 when the tub introduction port 435 is closed by the door 49 , as an example, the sealing unit 495 may be made of an elastic material such as rubber.
As shown in FIGS. 4A-4C , the cover body 431 , which defines the upper surface of the tub body 41 , includes a fitting rib 439 fitted in the inner circumferential surface of the tub body 41 . The fitting rib 439 may be provided with an inclined portion 4391 for guiding washing water in the tub body 31 into the drum 5 .
The drum 5 disposed in the tub body 41 is configured to have a cylindrical shape having an open upper surface. The drum 5 includes drum through holes 51 which are formed at an outer circumferential surface thereof to communicate the inside of the drum 5 with the inside of the tub body 41 .
In this implementation, when the drum 5 rotates, washing water contained in the tub body 41 may rise to the tub cover 43 from the bottom surface of the tub body 41 while rotating along the inner circumferential surface of the tub body 41 . At this time, the inclined portion 4391 serves to guide washing water having moved to the tub cover 43 from the bottom surface of the tub body 41 , toward the upper surface of the drum 5 .
When the washing water is again supplied to the drum 5 through the upper surface of the drum 5 , washing water can strike laundry contained in the drum 5 . Consequently, the present disclosure can improve washing performance by virtue of the inclined portion 4391 .
The cover body 431 includes a through hole 438 which is disposed under the water supply opening 355 formed at the drawer 3 to guide washing water introduced to the water supply opening 355 to the drum 5 .
Since the tub 4 is fixedly disposed in the drawer 3 , the through hole 438 is theoretically considered to be fixed under the water supply opening 355 (it is considered that relative movement between the through hole and the water supply hole does not occur). Accordingly, it is also possible to supply washing water, which is introduced into the water supply opening 355 through a pipe connected between the through hole 438 and the water supply opening 355 , to the tub 4 .
However, the pipe connected between the through hole 438 and the water supply opening 355 may vibrate when vibration generated during rotation of the drum 5 is transmitted to the tub body 41 . In this case, problems that durability of the pipe is deteriorated or a structure for attenuating vibration of the pipe has to be adopted should be considered. Accordingly, it may be the case that washing water is supplied to the tub 4 by positioning the through hole 438 under the water supply opening 355 without using an intermediate member connected between the through hole 438 and the water supply opening 355 .
Meanwhile, under the condition that there is no pipe connected between the through hole 438 and the water supply opening 355 , when hot water is supplied to the tub body 41 or steam is supplied to the tub body 41 from a steam generation device, there is a problem that moisture (water, steam, mist, etc.) in the tub 41 is discharged into the cabinet 2 through the through hole 438 .
Specifically, when moisture in the tub 41 is discharged in to the cabinet 2 through the through hole 438 , washing performance may be deteriorated and devices (electronic devices) disposed in the cabinet 2 may fail or corrode. Accordingly, the laundry treatment apparatus according to the present disclosure may further include a recovery unit for minimizing moisture or heat that is discharged from the tub 41 into the cabinet 2 through the through hole 438 .
As shown in FIGS. 5A and 5B , the recovery unit 45 incorporated in the laundry treatment apparatus according to the present disclosure may include a first recovery part 451 provided at the drawer cover 35 and contacting moisture discharged from the through hole 438 , and a second recovery part 453 for guiding moisture supplied from the first recovery part 451 to the through hole 438 .
The second recovery part 453 may include a recovery body 454 protruding toward the first recovery part 451 from the upper surface of the tub cover 43 , and a body through hole 456 formed through the recovery body 454 and communicating with the through hole 438 .
The first recovery part 451 may be configured to have any shape so long as it can guide moisture discharged from the through hole 438 to the second recovery part 453 .
Specifically, the first recovery part 451 according to the present disclosure may be configured into a flat or curved board shape protruding toward the second recovery part 453 from the drawer cover 35 , and may also be configured into a hollow bar shape having an open surface facing the second recovery part 453 .
When the first recovery part 451 is configured into the hollow bar shape, the hollow bar may be variously configured. FIGS. 5A and 5B illustrate an implementation in which the hollow bar is configured into a cylindrical shape.
When the first recovery part 451 is configured into the flat board, the first recovery part 451 may be positioned in the body through hole 456 .
In other words, when the first recovery part 451 includes a plurality of boards, the plurality of boards have to be positioned in a space which is defined by projection of the through hole 456 to the drawer cover 35 (through hole projection space) in order to supply moisture (water or condensed water) fallen toward the second recovery part 453 from the plurality of boards to the through hole 438 through the body through hole 456 .
Meanwhile, when the first recovery part 451 includes a plurality of hollow bars, the hollow bars have to be positioned in the through hole projection space.
Specifically, when the plurality of hollow bars are arranged to have the same center, the hollow bar having the largest surface area has to be positioned in the through hole projection space. However, when the plurality of hollow bars are not arranged to have the same center, the space defined by the plurality of hollow bars has to be positioned in the through hole projection space.
The first recovery part 451 may not interfere with the water supply opening 355 regardless of the shape of the first recovery part 451 . Furthermore, the free ends of the first recovery part 451 may not interfere with the free end of the recovery body 454 .
This prevents a problem that the first recovery part 451 collides with the recovery body 454 owing to vibration transmitted to the tub body 41 during rotation of the drum 5 and thus the first recovery part 451 or the second recovery part 453 is broken.
The first recovery part 451 may be made of any materials so long as the first recovery part 451 is able to prevent water discharged from the tub 4 from spreading in the drawer 3 (for guiding water discharged from the tub 4 to the second recovery part).
When the first recovery part 451 is meant to condense moisture discharged from the tub 4 (exchanging heat with moisture discharged from the tub 4 ) and guiding the condensed water to the second recovery part, the first recovery part 451 may be made of a metal material. In this case, the second recovery part 453 may be made of an elastic material.
The recovery unit 45 according to the present disclosure may further include the following components in order to increase recovered amount and condensed amount of moisture.
Specifically, the tub cover 43 may further include a reception recess 437 formed at the cover body 431 to be concave and at which the through hole 438 is positioned. The second recovery part 453 may further include a body flange 455 protruding from an outer surface of the recovery body 454 and positioned over the reception recess 437 , and a flange through hole 457 formed through the body flange 455 .
Here, the first recovery part 451 may be positioned in a space which is defined by projection of the body flange 455 to the drawer cover 35 (flange projection space).
In other words, when the first recovery part 451 is in the form of a board, the first recovery part 451 may protrude toward the recovery body 454 from the drawer cover 35 such that the first recovery part 451 is positioned in the flange projection space.
Alternatively, when the first recovery part 451 is in the form of a plurality of hollow bars, the plurality of hollow bars should be positioned in the flange projection space.
Even if the plurality of hollow bars are arranged so as not to have the same center, it is not a problem if a range defined by connection of hollow bars positioned at the periphery is positioned in the flange projection space.
However, when the plurality of hollow bars are in the form of cylinders having the same center, the hollow bar having the greatest diameter may be positioned in the flange projection space positioned outside the through hole projection space and the hollow bar having the smallest diameter may be positioned in the through hole projection space.
If the plurality of hollow bars have the same center but do not have the cylindrical shape, the hollow bar having the greatest surface area has to be positioned in the flange projection space and the hollow bar having the smallest surface area has to be positioned in the through hole projection space.
In conclusion, regardless of shape of the plurality of hollow bars, the hollow bar having the greatest surface area may be configured to be smaller than that of the flange projection space but larger than that of the through hole projection space. Furthermore, the hollow bar having the greatest surface area may be configured to have a smaller surface area than that of the through hole projection space.
When the first recovery part 451 is in the form of a plurality of hollow bars having the same center, the centers of the respective hollow bars may be positioned at the water supply opening 355 . In this case, distances between the respective hollow bars may be regular or irregular.
Since the first recovery part 451 is held by the drawer cover 35 and the drawer cover 35 can continuously exchange heat with outside air, the surface temperature of the first recovery part 451 can be maintained to be lower than the temperature of air discharged from the through hole 438 .
Furthermore, when the first recovery part 451 is provided near the water supply opening 355 , the first recovery part 451 may further decrease in surface temperature by directly exchanging heat with cool water supplied through the water supply opening 355 or outside air introduced through an area around the water supply opening 355 , thus improving cooling performance of the first recovery part 451 .
The recovery unit 45 has to further include a recovery hole 47 for guiding moisture introduced into the reception recess 437 through the flange through hole 457 to the through hole 438 .
When the reception recess 437 is provided with a support pipe 4381 that protrudes toward the first recovery part 451 to support a lower surface of the recovery body 454 , the recovery hole 47 may be formed through the support pipe 4381 . However, when the recovery body 454 is directly fixed to a circumferential surface of the through hole 438 , the recovery hole 47 has to be formed through the recovery body 454 .
In any case, the inner surface of the reception recess 437 may be inclined such that condensed water in the reception recess 437 flows toward the recovery hole 47 .
Although the present disclosure has been described in connection with an implementation in which the recovery unit 45 includes both the first recovery part 451 and the second recovery part 453 , the recovery unit 45 may include only the first recovery part 451 positioned over the through hole 438 .
The reason is because steam discharged from the through hole 438 will be condensed on a surface of the first recovery part 451 and then introduced into the through hole 438 by gravity, and water discharged from the through hole 438 will come into contact with the surface of the first recovery part 451 and then will be introduced into the through hole 438 by gravity.
For coupling of the tub cover 43 to the tub body 41 , the tub cover 43 may further include a first fitting groove 432 having a larger diameter than that of the fitting rib 439 , and a second fitting groove 433 positioned between the first fitting groove 432 and the fitting rib 439 .
In this case, the upper end of the tub body 41 may be fitted in the second fitting groove 433 and a fitting member 413 , 415 provided at an outer circumferential surface of the tub body 41 may be fitted in the first fitting groove 432 .
The fitting member may include a first fitting member body 413 protruding from the outer circumferential surface of the tub body 41 outward, and a second fitting member body 415 protruding toward the tub cover 43 from the first body 413 and fitted in the second fitting groove 433 .
In addition, the tub cover 43 may further include a fitting groove partition 434 for discriminating the first fitting groove 432 from the second fitting groove 433 . The fitting groove partition 434 is fitted in a groove formed between the second fitting member body 415 and the outer circumferential surface of the tub body 41 .
Thanks to the above coupling structure between the tub body 41 and the tub cover 43 , the present disclosure can minimize washing water or steam outwardly leaking through between the tub body 41 and the tub cover 43 from the tub body 41 .
Unlike the above structure, the fitting member 413 , 415 according to the present disclosure may be positioned in the tub body 41 . In other words, the second fitting member body 415 may have a smaller diameter than that of the tub body 41 .
In this case, the second fitting member body 415 may be fitted in the second fitting groove 433 and the upper end of the tub body 41 may be fitted in the first fitting groove 432 .
The laundry treatment apparatus according to the present disclosure, which is constructed as described above, supplies washing water into the tub body 41 through a water supply channel, and discharges the washing water in the tub body 41 to the outside of the cabinet 2 through a water discharge channel.
The water discharge channel has to be constructed to connect a discharge unit F ( FIG. 6 ) fixed to the drawer 3 to a rear panel 23 , and the water supply channel has to be constructed to connect the water supply opening 355 provided at the drawer 3 to a water supply source positioned outside the cabinet 2 through a supply unit S ( FIG. 7 ).
Accordingly, if the water supply channel and the water discharge channel merely include a pipe connecting the supply unit S to the water supply opening 355 and a pipe connecting the water discharge unit F to the rear panel 23 , respectively, there may be a risk of the water supply channel or the water discharge channel becoming entangled or broken when the drawer 3 is withdrawn from the cabinet 2 or is pushed into the cabinet 2 .
In order to avoid such risk, the laundry treatment apparatus 100 according to the present disclosure may further include a guider 6 which is provided in the cabinet 2 not only to serve as a water supply channel or a water discharge channel but also to guide movement of the water supply channel and the water discharge channel.
Hereinafter, the supply unit S and the discharge unit F are first described and then the guider 6 , the water supply channel and the water discharge channel are described.
As shown in FIG. 6 , the discharge unit F may include a pump fixed to the drawer body 31 . The pump may include a housing F 1 fixed to the drawer body 31 to contain washing water, and a motor F 2 for rotating an impeller disposed in the housing F 1 .
The housing F 1 is connected to the tub body via a housing introduction part F 3 and connected to the water discharge channel via a first housing water discharge part F 4 . Accordingly, when the impeller is rotated by the motor F 2 , washing water contained in the tub body 41 is introduced into the housing F 1 through the housing introduction part F 3 and then introduced into the water discharge channel through the first housing water discharge part F 4 .
As shown in FIG. 7 , the supply unit S may include a first valve V 1 connected to a first water supply source (washing water supply source of a first temperature), and a second valve V 2 connected to a second water supply source (washing water supply source of a second temperature) for supplying washing water having a temperature different from the temperature of washing water supplied from the first water supply source. However, when there is only one water supply source provided outside the cabinet 2 to supply washing water, the supply unit S may include only one valve.
As shown in FIG. 6 , the guider 6 according to the present disclosure may include a support 61 secured in the cabinet 2 , a first body 63 rotatably connected to the support 61 , and a second body 65 connecting the first body 63 to the drawer cover 35 .
The support 61 may include a support body 611 fixed to the cabinet 2 , a discharge pipe 615 provided at the support body 611 and extending through the rear panel 23 , and a shaft support 613 supporting the first body 63 .
The support body 611 may be secured to the rear panel 23 of the cabinet 2 . In this case, the first valve V 1 and the second valve V 2 may be fixed to the support body 611 .
The discharge pipe 615 serves to discharge washing water introduced to the water discharge channel to the outside of the cabinet 2 . The shaft support 613 may be fixed to an outer surface of the discharge pipe 615 (see FIG. 8 ) so as to minimize a size of the support 61 .
As shown in FIGS. 8A and 8B , the first body 63 may include a base 631 defining a first channel 71 (body water supply pipe) connected to the supply unit S and a second channel 81 (body water discharge pipe) connected to the discharge unit F, a cover 635 provided on the base 631 to close the first channel 71 and the second channel 81 , and a first shaft 637 for rotatably connecting the base 631 to the shaft support 613 .
The first channel 71 and the second channel 81 are discrete channels which are isolated from each other by a partition 633 . The base 631 and the cover 635 may be coupled to each other through thermal fusion so as to prevent fluid present in the first channel 71 and the second channel 81 from leaking to the outside of the first body 63 .
The first channel 71 includes a first inlet 632 communicating with a first connecting pipe 73 which is opened and closed by the first valve V 1 , and a second inlet 634 communicating with a second connecting pipe 75 which is opened and closed by the second valve V 2 . Washing water having been introduced to the first channel 71 is discharged to the water supply pipe 77 through a first channel outlet 636 .
As described above, the water supply channel according to the present disclosure includes the first channel 71 provided in the first body 63 , the first and second connecting pipes 73 and 75 connected between the first channel 71 and the respective power supply sources and controlled to be opened and closed by the first and second valves V 1 and V 2 , respectively, and the water supply pipe 77 connected between the first channel outlet 636 and the water supply opening 355 and supported by the second body 65 .
Washing water supplied from the water supply sources is introduced into the first channel 71 through the first and second connecting pipes 73 and 75 which are opened and closed by the first and second valves V 1 and V 2 , and the washing water in the first channel 71 is supplied to the water supply opening 355 formed at the drawer cover 35 through the first channel outlet and the water supply 77 . The water supply pipe 77 may be secured to the water supply opening 355 formed at the drawer cover 35 by means of a fixing portion 771 .
The second channel 81 is provided with a second channel inlet 638 and a second channel outlet 639 . The second channel inlet 638 and the first housing water discharge part F 4 are connected to each other through a first water discharge pipe 83 , and the second channel outlet 639 and the discharge pipe 615 are connected to each other through a second water discharge pipe 85 .
Accordingly, the water discharge channel according to the present disclosure includes the second channel 81 defined in the first body 63 , the first water discharge pipe 83 connected between the second channel 81 and the housing F 1 , and the second water discharge pipe 85 connected between the second channel 81 and the discharge pipe 615 .
The second body 65 of the guider 6 is rotatably connected to the first body 63 through a second shaft 651 and rotatably connected to the drawer cover 35 through a third shaft 653 .
The second body 65 is provided with a first flange 656 and a second flange 657 which define a reception space 655 accommodating the water supply pipe 77 .
The first flange 656 is longitudinally provided along the second body 65 and protrudes toward the upper surface of the cabinet 2 from a side surface of the second body 65 . The second flange 657 is longitudinally provided along the second body 65 to face the first flange 656 .
A water supply pipe attachment 659 , which is detachably provided at the water supply pipe 77 to hold the water supply pipe 77 in the reception space 655 , may be provided at at least one of the first flange 656 and the second flange 657 .
Since the discharge pipe 615 provided at the support 61 includes a drainpipe F 7 which is connected between the discharge pipe 615 and a sewage outlet to discharge washing water supplied through the water discharge channel, washing water in the tub body 41 may be discharged by the siphon effect upon activation of the motor F 2 .
When the siphon effect occurs, it may be advantageous if washing water does not remain in the tub body 41 or the water discharge channel. However, bad smell generated from the sewage outlet may be introduced into the tub body 41 through the drainpipe F 7 . Furthermore, when washing water is supplied to the tub body 41 before completion of discharge of washing water, there is a risk that even washing water introduced to the tub body 41 may be discharged.
Accordingly, the present disclosure may further include a communication pipe 79 for preventing the siphon effect by the water discharge channel.
The communication pipe 79 may be configured in any shape so long as it can communicate the inside of the water discharge channel with the outside of the water discharge channel. In other words, the communication pipe 79 according to the present disclosure may be constructed to be connected between the water supply channel and the water discharge channel, and may be constructed to communicate the water supply channel with the inside of the drawer.
The communication pipe 79 may be constructed to connect one of the second channel 81 , the first water discharge pipe 83 and the second water discharge pipe 85 to the water supply pipe 77 or the water supply opening 355 . The drawings illustrate an implementation in which the communication pipe 70 is connected between the water supply pipe 77 and the second channel inlet 638 and is supported by the second body 65 .
In order to support the communication pipe 79 , the second flange 657 provided at the second body 65 may further include a communication pipe attachment 658 for detachably holding the communication pipe 79 outside the reception space 655 .
In order to ensure that washing water supplied to the tub body 41 is not discharged to the outside of the tub body 41 through the water discharge channel even though the motor F 2 provided at the discharge unit F is not operated, the discharge pipe 615 has to be positioned at a higher level than the maximum level of washing water contained in the tub body 41 (the first water discharge pipe 83 defining the water discharge channel is positioned below the guider 6 including the second channel 81 ).
Under the above condition, when operation of the impeller is halted by deactivation of the motor F 2 of the discharge unit F, air in the tub body 41 is introduced into the water discharge channel through the communication pipe 79 , thus blocking the siphon effect. Consequently, washing water present at a position lower than the position at which the communication pipe 79 is connected to the first water discharge pipe 83 will remain in the first water discharge pipe 83 .
When washing water remains in the first water discharge pipe 83 , it is possible to introduction of foul odor generated from a sewage outlet into the tub body 41 but there is a risk of the first water discharge pipe 83 is rupturing upon freezing in winter. Accordingly, there is a need to discharge even washing water in the first water discharge pipe 83 . To this end, the present disclosure may include a residual water discharge unit 9 if desired.
As shown in FIG. 7 , the residual water discharge unit 9 may include a residual water discharge tube 91 which communicates with the housing F 1 of the discharge unit F and is exposed to the outside of the cabinet 2 when the drawer 3 is withdrawn from the cabinet 2 .
A fixed end of the residual water discharge tube 91 may communicate with the housing F 1 through the second housing water discharge part F 5 , and a free end of the residual water pipe 91 may be detachably held on the drawer body 31 . The free end of the residual water discharge tube 91 may be provided with a water discharge pipe opening and closing device 911 for opening and closing the residual water discharge tube 91 . In some cases, the closing device 911 may be integrated in the drawer body 31 or the drawer panel 33 .
In order to hold the free end of the residual water discharge tube 91 on the drawer body 31 , the residual water discharge unit 9 may further include a water discharge pipe attachment 93 provided at the drawer body 31 .
The water discharge pipe attachment 93 is provided at the drawer body 31 such that it is positioned in the rear of the drawer panel 33 (near the open surface 21 ).
Specifically, the water discharge pipe attachment 93 may include a fixed body 931 fixed to the drawer body 31 to be positioned between the rear surface of the drawer panel 33 and the introduction opening 353 , a fixed body through hole 933 formed through the fixed body 931 , and an entrance 935 formed at the fixed body 931 such that the fixed body through hole 933 communicates with the outside of the fixed body 931 . The fixed body through hole 933 and the entrance 935 form a receiving portion for receiving the residual water discharge tube to thereby releasably attach a free end of the discharge tube to the drawer.
The fixed body through hole 933 has a diameter equal to or larger than that of the residual water discharge tube 91 , and the entrance 935 has a width smaller than the diameter of the residual water discharge tube 91 .
As a result, a user can fit the residual water discharge tube 91 into the fixed body through hole 933 through the entrance 935 , or can take the residual water discharge tube 91 out of the fixed body 931 .
In order to prevent the residual water discharge tube 91 from becoming entangled in the cabinet or interfering with components provided in the cabinet 2 when the drawer 3 is withdrawn from the cabinet 2 , the drawer body 31 may further include a water discharge tube support 313 for preventing the residual water discharge tube 91 from contacting the inner surface of the cabinet 2 . FIG. 7 illustrates an implementation in which the water discharge tube support 313 is provided at a lower position of the drawer body 31 .
In order to more efficiently discharge washing water remaining in the first water discharge pipe and the housing F 1 through the residual water discharge tube 91 , the first water discharge pipe 83 may be positioned such that a distance between the bottom surface of the drawer body 31 and the first water discharge pipe decreases toward the housing F 1 of the water discharge unit F. In other words, the first water discharge pipe 83 may be downwardly inclined toward the housing F 1 of the water discharge unit F.
The laundry treatment apparatus 100 according to the present disclosure may further include a water discharge pipe holder 95 adapted to hold the first water discharge pipe 83 at a location on the drawer body 31 higher than the first housing water discharge part F 4 of the housing F 1 such that the first water discharge pipe 83 is partially inclined downwardly toward the first housing water discharge part F 4 of the housing F 1 .
The effects obtained by the inclined first water discharge pipe 83 may, of course, be obtained by inclining the first housing water discharge part F 4 of the housing F 1 such that a distance between the bottom surface of the drawer body 31 and the first housing water discharge part F 4 increases in a direction away from the housing F 1 .
Although not shown in the drawings, the laundry treatment apparatus according to the present disclosure may further include a hot air supply device for supplying hot air to the tub 4 to dry laundry contained in the drum 5 . The hot air supply device may be provided at any of the first treatment apparatus T and the second treatment apparatus L.
Hereinafter, operation of the laundry treatment apparatus according to the present disclosure will be described with reference to FIGS. 9 and 10 .
As shown in FIG. 9 , the drawer 3 is positioned in the cabinet 2 before laundry is put into the second treatment apparatus L.
In order to put laundry into the accommodation unit 4 , 5 provided in the drawer 3 , a user has to withdraw the drawer body 31 from the cabinet 2 using the drawer panel 33 .
As shown in FIG. 10 , when the drawer body 31 is withdrawn from the cabinet 2 , the first body 63 is rotated in a drawing direction of the drawer body 31 about the first shaft 637 while the second body 65 maintains the state in which the first body 63 is connected to the drawer cover 35 through the second shaft 651 and the third shaft 653 .
The first channel 71 that forms the water supply channel is provided at the first body 63 , and the water supply pipe 77 connected between the first channel 71 and the water supply opening provided at the drawer cover 35 is supported by the second body 65 . Therefore, the present disclosure can prevent the water supply channel from becoming entangled or caught by components provided in the cabinet 2 and thus broken.
In addition, since the second channel 81 that forms the water discharge channel is provided at the first body 63 and the first water discharge pipe 83 connected between the second channel 81 and the discharge unit F is positioned below the guider 6 , it is also possible to prevent the water discharge channel from becoming entangled or broken when the drawer 3 is withdrawn from the cabinet 2 .
However, since the rotation center of the first body 63 and the rotation center of the second water discharge pipe 85 are different from each other as shown in FIG. 10 , the second water discharge pipe 85 according to the present disclosure may be made of an elastic material (such as rubber) or may be constructed into a bellows structure capable of extending and contracting in a longitudinal direction.
When the drawer body 31 is withdrawn from the cabinet 2 , the introduction opening 353 formed at the drawer cover 35 is exposed to the outside. As a result, a user can put laundry into the drum 5 positioned below the tub introduction port 435 by rotating the door 49 disposed in the introduction opening 353 to open the tub introduction port 435 .
When laundry is put into the drum 5 , a user closes the tub introduction port 435 by the door 49 and pushes the drawer 3 into the cabinet 2 as shown in FIG. 9 .
At this point, since the first body 63 of the guider 6 is rotated in the same direction as the moving direction of the drawer 3 (counterclockwise direction) about the first shaft 637 and the second body 65 is rotated toward the first body 63 by the second shaft 651 and the third shaft 653 , it is possible to possible to prevent the water supply channel and the water discharge channel according to the present disclosure from breaking due to components provided in the cabinet 2 , by virtue of the guider 6 .
When a user inputs a control command for washing through the control panel 331 in the state in which the drawer 3 is disposed in the cabinet 2 , the respective valves V 1 and V 2 provided at the supply unit S open one of connecting pipes 73 and 75 connected between the respective valves and the first channel 71 .
Specifically, if only a first temperature washing water is required, a control unit controls the first valve V 1 to open only the first connecting pipe 73 . In addition, if only a second temperature washing water is required, the control unit controls the second valve V 2 to open only the second connecting pipe 75 .
In any case, washing water from the water supply source is supplied to the first channel 71 provided at the first body 63 , and the washing water supplied to the first channel 71 is supplied to the drum 5 through the water supply pipe 77 supported by the second body 65 , the water supply opening 355 provided at the drawer cover 35 and the through hole 438 formed at the tub cover 43 .
Upon completion of supply of the washing water, the driving unit rotates the drum 5 . When the drum 5 rotates, washing water in the tub body 41 can rotate in the tub body 41 , together with the drum.
When washing water is rotated in the tub body 41 by the drum 5 , the washing water in the tub body 41 can move toward the tub cover 43 from the bottom surface of the tub body 41 . However, since the tub cover 43 is provided with the inclined portion 4391 , the present disclosure can again introduce washing water into the drum 5 through the open upper surface of the drum 5 .
Upon completion of washing, the control unit discharges washing water contained in the tub body 41 .
More specifically, the control unit supplies power to the motor F 2 provided at the discharge unit F to transfer washing water in the tub body 41 to the first water discharge pipe 83 . The washing water introduced to the first water discharge pipe 83 flows to a sewage outlet through the second channel 81 provided at the first body 63 , the second water discharge pipe 85 , the discharge pipe 615 and the drainpipe F 7 .
Since the first water discharge pipe 83 is connected to the water supply pipe 77 through the communication pipe 79 and the water supply pipe 77 communicates with the drawer body 31 through the water supply opening 355 , when the control unit stops supply of power to the motor F 2 , air is supplied to the first water discharge pipe 83 , thus eliminating siphon effect. Consequently, the washing water that is flowing to the second channel 81 through the first water discharge pipe 83 remains in the first water discharge pipe 83 .
Furthermore, since the first water discharge pipe 83 according to the present disclosure is constructed to enable residual water in the first water discharge pipe 83 to be moved to the discharge unit F, almost all of the residual water in the first water discharge pipe 83 will be contained in the housing F 1 of the discharge unit F.
If washing water is contained in the housing F 1 , it is possible to prevent introduction of foul odor generated from a sewage outlet into the tub body 41 through the water discharge channel and to prevent breakage of the first water discharge pipe 83 in the case of decrease in outside temperature of the laundry treatment apparatus.
Furthermore, according to the present disclosure, since the residual water discharge tube 91 is connected to the housing F 1 , even residual water in the housing F 1 can be discharged if desired. However, in order to discharge residual water in the housing F 1 , a user has to withdraw the drawer 3 from the cabinet 2 .
As shown in FIG. 10 , since the free end of the residual water discharge tube 91 is exposed to the outside of the cabinet 2 when the drawer 3 is withdrawn from the cabinet 2 , a user can discharge residual water in the housing F 1 by separating the residual water discharge tube 91 from the water discharge pipe attachment 93 and then opening the water discharge pipe opening and closing device 911 .
Furthermore, when washing water supplied for laundry washing is hot water or steam is supplied to laundry after washing of laundry, moisture (vapor or steam of hot water) supplied into the tub body 41 can be discharged to the outside of the tub body 41 through the through hole 438 .
The moisture, which has been discharged to the outside of the tub body 41 through the through hole 438 , is condensed on a surface of the first recovery part 451 provided over the through hole 438 and then falls to the secondary recovery part 453 . Therefore, the present disclosure can minimize that leakage of moisture in the tub body 41 into the drawer 3 or the cabinet 2 .
Although the present disclosure has been described in connection with the above implementation in which the first channel 71 forming the water supply channel and the second channel 81 forming the water discharge channel are provided in the first body 63 of the guider, structures of the water supply channel and the water discharge channel are not limited thereto. In other words, the water discharge channel may be supported by the outer surface of the guider while the first channel 71 maintains the same construction as described above.
Here, the water discharge channel may be formed by a single pipe connected between the housing F 1 of the discharge unit F and the discharge pipe 615 , and may be detachably held on the outer surface of the first body 63 .
Although the present disclosure has been described in connection with an implementation in which the second treatment apparatus L is detachably mounted on the first treatment apparatus T (the cabinet 1 of the first treatment apparatus and the cabinet 2 of the second treatment apparatus are separated from each other), the second treatment apparatus may be integrally formed with the first treatment apparatus T.
In this case, the drawer 3 of the second treatment apparatus L has to be constructed to be retractable from the cabinet of the first treatment apparatus (the cabinet 2 of the second treatment apparatus is omitted), and components of the second treatment apparatus L, which are fixed to or rotatably coupled to the cabinet 2 of the second treatment apparatus, have to be provided at the cabinet 1 of the first treatment apparatus.
As described above, the present disclosure can provide a laundry treatment apparatus which is detachably coupled to another laundry treatment apparatus to perform both functions of washing and drying of laundry.
Furthermore, the present disclosure can provide a laundry treatment apparatus which is constructed to enable washing water to be easily supplied to or discharged from an accommodation unit retractably provided at a cabinet to accommodate laundry.
In addition, the present disclosure can provide a laundry treatment apparatus capable of condensing moisture discharged from the accommodation unit and returning the condensed water to the accommodation unit.
Furthermore, the present disclosure can provide a laundry treatment apparatus capable of preventing washing water from remaining in a discharge unit serving to discharge washing water contained in an accommodation unit.
In addition, the present disclosure can provide a laundry treatment apparatus including means for circulating washing water in an accommodation unit.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the spirit or scope of the disclosures. Thus, it is intended that the present disclosure covers the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents. | A laundry treatment apparatus includes a cabinet, a drawer with a drawer body and a drawer panel, an accommodation unit in the drawer body and defining a space for receiving washing water, a discharge unit for discharging washing water from the accommodation unit to the outside of the accommodation unit, a water discharge channel for guiding discharged washing water in the discharge unit to the outside of the cabinet, and a residual water discharge unit that provides an alternative path for discharging washing water in the discharge unit to the outside of the cabinet, wherein at least a portion of the residual water discharge unit is exposed to and accessible from the outside of the cabinet based on the drawer body being withdrawn from the cabinet, and wherein the entire residual water discharge unit is covered by the cabinet based on the drawer body being retracted within the cabinet. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Priority of U.S. Provisional Patent Application Ser. No. 60/824,005, filed Aug. 30, 2006, incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to marine platforms such as oil and gas well drilling platforms. More particularly, the present invention relates to an improved method and apparatus for elevating the deck area of a fixed marine platform to better protect equipment that is located on the deck area from storms (e.g. hurricanes) that generate heightened wave action.
2. General Background of the Invention
There are many fixed platforms located in the oil and gas well drilling areas off the United States coast such as in the Gulf of Mexico. Such marine platforms typically employ an undersea support structure that is commonly referred to as a jacket. These jackets can be many hundreds of feet tall, being sized to extend between the seabed and the water surface area. Jackets are typically constructed of a truss like network of typically cylindrically shaped pipe, conduit or tubing that is welded together. The jackets can be secured to the seabed using pilings that are driven into the seabed. The jacket is then secured to the piling. The part of the offshore marine platform that extends above the jacket and above the water surface is typically manufactured on shore and placed upon the jacket using known lifting equipment such as a derrick barge. This upper portion is the working part of the platform that is inhabited by workers.
Marine platforms can be used to perform any number of functions that are associated typically with the oil and gas well drilling and production industry. Such platforms can be used to drill for oil and gas. Such platforms can also be used to produce wells that have been drilled. These fixed platforms typically provide a deck area that can be crowded with extensive equipment that is used for the drilling and/or production of oil and gas.
When storms strike the Gulf of Mexico and other areas, offshore marine platforms are put at risk. While the jacket and platform are typically designed to resist hurricane force wind and wave action, equipment located on the deck of the marine platform can easily be damaged if hurricane generated wave action reaches the deck area.
An additional consequence of wave action reaching the platform deck is catastrophic platform collapse, which happened in several instances during recent storms in the United States Gulf of Mexico.
BRIEF SUMMARY OF THE INVENTION
The present invention solves these prior art problems and shortcomings by providing a method and apparatus for elevating the deck area of an existing marine platform so that equipment that occupies the deck can be further distanced from the water surface. The method of the present invention this provides more clearance, more freeboard and more protection to deck area equipment during severe storms such as hurricanes.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIG. 1 is a schematic, elevation view of a fixed marine platform;
FIG. 2 is a perspective view illustrating a method step of the present invention;
FIG. 3 is a perspective view illustrating a method step of the present invention;
FIG. 4 is a perspective view illustrating a method step of the present invention, placement of the upper and lower bushing sleeves;
FIG. 5 is a partial perspective view of the preferred embodiment of the apparatus of the present invention illustrating placement of the upper and lower bushing sleeves;
FIG. 6 is a partial perspective view of the preferred embodiment of the apparatus of the present invention illustrating a method step of the present invention;
FIG. 7 is a partial perspective view of the preferred embodiment of the apparatus of the present invention illustrating one of the extension sleeve guides;
FIG. 8 is a sectional view taken along lines 8 - 8 of FIG. 7 ;
FIG. 9 is a partial elevation view of the preferred embodiment of the apparatus of the present invention illustrating placement of the extension sleeve guides;
FIG. 10 is a partial elevation view of the preferred embodiment of the apparatus of the present invention showing positions of the leg cuts;
FIG. 11 is a partial perspective exploded view of the preferred embodiment of the apparatus of the present invention;
FIG. 12 is a partial perspective view of the preferred embodiment of the apparatus of the present invention illustrating the method of the present invention, placement of the upper ring;
FIG. 13 is a partial elevation view of the preferred embodiment of the apparatus of the present invention illustrating placement of the upper ring;
FIG. 14 is a partial perspective exploded view of the preferred embodiment of the apparatus of the present invention illustrating placement of the hydraulic pistons;
FIG. 15 is a partial perspective view of the preferred embodiment of the apparatus of the present invention illustrating placement of the hydraulic pistons;
FIG. 16 is a fragmentary elevation view illustrating the method of the present invention, namely the step of completing the leg cuts;
FIG. 17 is a fragmentary perspective of the preferred embodiment of the apparatus of the present invention illustrating extension of the leg with the hydraulics pistons;
FIG. 18 is a partial perspective view of the method and apparatus of the present invention, showing the method step of closing the sleeve openings; and
FIG. 19 is an elevation view of the preferred embodiment of the apparatus of the present invention illustrating the marine platform after its deck area has been elevated using the method and apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a marine platform deck elevating system 10 that is shown generally in FIGS. 14-15 and 17 and in method steps that are illustrated in FIGS. 2-18 .
In FIG. 1 , a fixed marine platform 11 is shown having a deck 16 that is positioned at an elevation 18 that is elevated above the water surface 12 a distance H 1 that is indicated by the numeral 19 in FIG. 1 . The numeral 19 and the dimension line H 1 represent the existing clearance above water. It is necessary to protect equipment that is contained on the deck 16 from storm generated wave action. In the Gulf of Mexico, hurricanes can generate a storm surge and wave action that puts equipment and/or personnel located on deck 16 at peril. If a deck is not located at a safe elevation, it must be elevated. FIG. 1 illustrates a typical fixed platform 11 having a plurality of legs 14 that support the deck 16 . Diagonal braces 17 can extend between legs 14 and deck 16 as shown in FIG. 1 . The platform 11 can include other structure such as for example horizontal beams or members and/or additional vertical or diagonal members.
Legs 14 can be of a constant diameter or can include tapered sections 13 , wherein the diameter of the upper leg section 15 A is less than the diameter of the lower leg section 15 B. Leg 14 can thus include a number of different leg sections such as a lower, larger diameter leg section 15 B, a tapered leg section 13 , and an upper, smaller diameter leg section 15 A that is positioned above the tapered section 13 . The method and apparatus of the present invention can be used to elevate the deck 16 to a new elevation 20 (see FIG. 19 ) that is higher than the previous, existing deck elevation 18 of FIG. 1 . The method and apparatus of the present invention thus provides a new clearance 21 above water surface 12 (also shown by the arrow H 2 in FIG. 19 ).
FIGS. 2 and 3 illustrate an initial method step of the present invention, namely the placement of lower bushing sleeve 24 . The lower bushing sleeve 24 can be comprised of a pair of half sleeve sections 22 , 23 as shown in FIGS. 2-3 . The sections 22 , 23 can be joined with welds 26 as shown in FIGS. 3-4 . Arrows 25 in FIG. 2 schematically illustrate the placement of sleeve sections 22 , 23 upon leg 14 at a position below tapered section 13 as shown.
In FIGS. 4-6 , upper bushing sleeve 29 can also be comprised of a pair of sleeve half sections. The sleeve sections 27 , 28 each provide an opening 35 or 36 that is receptive of a pin 50 as will be explained more fully hereinafter. Weld ring sections 30 , 31 can be used to attach the sleeve sections 27 , 28 to tapered section 13 . As with the lower bushing sleeve 24 , one or more welds 37 can be used to join the sleeve sections 27 , 28 to each other. Arrows 33 in FIG. 4 illustrate the placement of sleeve sections 27 , 28 upon tapered section 13 . Arrows 34 in FIG. 4 illustrate the attachment of weld ring 32 to the assembly of sleeve sections 27 , 28 and to tapered section 13 .
In FIGS. 6-9 and 11 , a plurality of extension sleeve guides 38 are shown. These extension sleeve guides 38 are attached to the platform 11 leg 14 at a position that is above upper bushing sleeve 29 . The extension sleeve guides 38 can extend from tapered section 13 to smaller diameter leg section 15 A as shown in FIGS. 6 and 9 . Arrows 39 illustrate placement of extension sleeve guides 38 to leg 14 . Each extension sleeve 38 can be comprised of flanges 40 and webs 41 . The web 41 actually contacts the leg 14 and can be shaped to conform to the shapes of tapered section 13 and smaller diameter leg section 15 A as shown in FIGS. 7 and 9 (see DIM “A”, FIG. 7 ).
In FIGS. 10-15 , an extension sleeve 44 can be comprised of a pair of extension sleeve sections 45 , 46 . Each extension sleeve section 45 , 46 has slots 47 , 48 that can be used to complete a cut through the leg 14 after the sleeve sections 45 , 46 have been attached to leg 14 and guides 38 .
Before attachment of the sleeve sections 45 , 46 four cuts are made through leg 14 as shown in FIG. 10 . The cuts 42 , 43 do not extend 360 degrees around the leg 14 , but rather extend only a partial distance as shown in FIG. 10 . Though partial cuts 42 , 43 are made, enough of the leg 14 remains to structurally support the platform 11 and its deck 16 considering the use of sleeve 44 and the method of the present invention disclosed herein.
After the sleeve sections 45 , 46 have been installed, a cut can be made to encircle the leg 14 thus severing it in two parts. In order to complete the cut, slots are provided in the sleeve sections 45 , 46 . In FIG. 11 , the sleeve section 45 has slot 47 . In FIG. 11 , the sleeve section 46 has slot 48 .
After installing the upper bushing sleeve 29 , circular cut openings 49 are made through the leg 14 at the openings 35 , 36 in the sleeve sections 27 , 28 . These cut openings 49 enable pin 50 to be placed through the openings 67 , 68 in sleeve sections 45 , 46 respectively as well as through the openings 49 in upper bushing sleeve 29 . Pin 50 prevents uplift from damaging the platform 11 should a storm produce excess wave action before the method of the present invention can be completed.
Each of the sleeve sections 45 , 46 provides lugs to which hydraulic pistons can be attached. Sleeve section 45 provides a plurality of lugs 51 . Sleeve section 46 provides a plurality of lugs 52 . Each of the lugs provides an opening for enabling a pinned connection to be made between the lugs 51 , 52 and the hydraulic pistons 64 . Lugs 51 provide openings 53 . Lugs 52 provide openings 54 . In the preferred method and apparatus, four pairs of lugs 51 , 52 are thus provided to the extension sleeve 44 . Each pair of lugs 51 , 52 can be spaced circumferentially about sleeve 44 , about 90 degrees apart.
A ring 55 is positioned above extension sleeve 44 as shown in FIGS. 12-15 and 17 - 19 . Ring 55 is used to form a connection between the leg 14 and the hydraulic piston 64 . Ring 55 can be formed of a pair of ring sections 56 , 57 that are attached to the smaller diameter leg section 15 A as shown in FIGS. 12 and 13 . Each of the ring sections 56 , 57 provides a plurality of lugs 58 , 59 . The ring section 56 has lugs 58 . The ring section 57 has lugs 59 . Each lug 58 , 59 has a lug opening 60 that enables a pinned connection to be made between a lug 58 or 59 and a piston 64 . Each ring section 56 , 57 can be formed of arcuate generally horizontal plate sections and vertical plate sections. Each of the ring sections 56 , 57 thus provide an upper arcuate plate section 61 and a lower arcuate plate section 62 . Vertical plate sections 63 span between the upper and lower arcuate plate sections 61 , 62 .
Hydraulic pistons 64 are provided for elevating that portion of the leg 14 that is above the cuts that are made through the leg 14 (see FIGS. 10 and 16 ). Preferably three (3) or four (4) pistons can be used, but as few as two (2) rams can be used or more, such as many as eight (8) could be used for example.
Each hydraulic piston 64 can be comprised of a cylinder 65 and an extensible push rod 66 . Each end portion of hydraulic piston 64 provides an opening 69 on cylinder 65 that enables a pinned connection to be formed between each end of hydraulic piston 64 and lugs 51 , 52 or 58 , 59 . The upper end portion of each hydraulic piston 64 attaches with a pinned connection to a lug 58 or 59 that is a part of ring 55 . The lower end portion of each hydraulic piston 64 forms a pinned connection with the lugs 51 , 52 of extension sleeve 44 as shown in FIGS. 14-15 . Arrows 74 in FIG. 14 illustrate assembly of pistons 64 to lugs 51 , 52 , 58 , 59 .
Once the hydraulic pistons 64 have been installed to the position shown in FIG. 15 , a cut can be completed for severing leg 14 . This can be seen in more detail in FIGS. 10 , 15 - 16 wherein the previously formed cuts 42 , 43 are shown. Notice that uncut portions 70 (DIM “B”, FIG. 16 ) of leg 14 align with the slots 47 or 48 of sleeve sections 45 , 46 . The leg 14 can thus be cut 360 degrees by cutting the previously uncut section 70 at slot 47 or 48 , indicated by phantom lines as cut 73 in FIG. 16 . The three hundred sixty degree cut ( 42 , 43 , 73 ) is made after the extension sleeve 14 , hydraulic pistons 64 and ring 55 form a structural support of the leg 14 above and below the cuts 42 , 43 . In order to then elevate the smaller diameter leg section 15 A relative to the larger diameter leg section 15 B below tapered section 13 , each hydraulic piston 64 can be activated as illustrated by arrows 72 in FIG. 17 .
Once elevated, the various openings and slots in sleeve 44 can be covered for corrosion protection using a plurality of curved cover plate sections 71 . To complete the repair, the sleeves 44 can be welded to the leg 14 and using shims as necessary between sleeve 44 and leg 14 , tapered section 13 or sections 15 A, 15 B. While the method disclosed herein contemplates that the elevation process would preferably take place as one jacking operation. The invention should not be so restricted. The method of the present invention contemplates a method wherein the jacking process could be subdivided into several smaller (or shorter) jacking elevations. The legs 14 would be pinned off at an intermediate point and the jacks moved to a second set of lugs. Arrow 75 in FIG. 17 shows the distance that the upper leg section 15 A is elevated.
The following is a list of parts and materials suitable for use in the present invention.
PARTS LIST
Part Number
Description
10
marine platform deck elevating
system
11
platform
12
water surface
13
tapered section
14
leg
15A
smaller diameter leg section
15B
larger diameter leg section
16
deck
17
diagonal brace
18
existing deck elevation
19
existing clearance above water
20
new deck elevation
21
new clearance above water
22
sleeve section
23
sleeve section
24
lower bushing sleeve
25
arrow
26
weld
27
sleeve section
28
sleeve section
29
upper bushing sleeve
30
weld ring section
31
weld ring section
32
weld ring
33
arrow
34
arrow
35
opening
36
opening
37
weld
38
extension sleeve guide
39
arrow
40
flange
41
web
42
cut
43
cut
44
extension sleeve
45
extension sleeve section
46
extension sleeve section
47
slot
48
slot
49
drilled opening
50
support pin
51
lug
52
lug
53
opening
54
opening
55
ring
56
ring section
57
ring section
58
lug
59
lug
60
lug opening
61
upper arcuate plate section
62
lower arcuate plate section
63
vertical plate section
64
hydraulic piston
65
cylinder
66
pushrod
67
opening
68
opening
69
opening
70
uncut portion
71
cover plate
72
arrows
73
cut
74
arrow
75
arrow
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | A method of elevating the deck area of a marine platform (e.g. oil and gas well drilling or production platform) utilizes a specially configured sleeve support to support the platform legs so that they can be cut. Once cut, jacks elevate the platform above the cuts. The sleeve support is then connected (e.g. welded) to the platform leg and becomes part of the structural support for the platform. | 4 |
BACKGROUND OF THE INVENTION
The invention generally relates to a method and apparatus for applying a treatment medium to a textile web in which the web is resiliently pressed against a stationary surface as the web is passed through a gap.
A method of this nature and a device of this kind are disclosed in DE-OS 33 15 770. In this patent the gap is closed on one side by a protruding application bar that forms an opposing face in which a slot is arranged that extends over the web and from which the treatment medium can be squeezed out. Opposite the slot an oblong cushion is arranged, which extends transversely over the width of the web. The cushion rests against a fixed support on the side facing away from the slot. The cushion is covered by a glide foil, which is fastened on the edge opposing the machine direction. The web is pulled through between the opposing face and the glide foil, with the treatment medium, which flows from the slot into the web, being pressed into the web. Since the cushion extends over the entire width of the Web, and since the pressure in the cushion propagates uniformly, the pressure exerted on the web is uniform over the entire width.
A further device is disclosed in FRP 13 81 081. This patent teaches the formation of a vertical narrow treatment trough, which is filled to a certain height with the treatment medium, and through which the web is led in a downward direction. At the lower end of the treatment trough the sides of the treatment trough parallel to the web adjoin the web on s both sides and are pressed against each other by opposing pressure tubes which act from the outside against the lower portions of the sides. In this patent the opposing face is thus also resiliently elastic, and feed of the treatment medium does not take place at the opposing face, but rather at the height of the fill level in the trough through which the web passes. In the first embodiment the web is pulled between the opposing face and the glide foil and in the second embodiment between the sides of the trough that are pressed against each other. It must, therefore, have a certain tensile strength. In addition, and integral to the function of the known devices, the treatment medium is to some extent pressed or massaged into the web. Thus, web must be able, to some extent, to absorb the treatment medium. Textile webs such as woven fabrics and especially those fabrics With pile are primarily of interest. Fabrics with thicker fleece having sufficient tensile strength can, however, also be processed according to this method. No restrictions regarding the web type exist otherwise.
The apparatus disclosed in DE-OS 33 15 770 has proven useful not only in the dyeing of carpeting, but also in the dyeing of flat woven materials. On some occasions, however, it has been observed that the application of the treatment medium is very sensitive to the pressure exerted on the web when it passes the slot. If the pressure rises in a particular site, the web in this location receives noticeably less treatment medium. This effect can be observed especially when materials with pile are used because the volume of the pile is reduced by compression and volume, which could absorb the liquid is eliminated in the process because the material is compressed, is no longer as absorbent as before. The two effects, thus, overlap and relatively slight pressure differences result, for example, in readily noticeable differences in shade and saturation of color when liquid treatment media are used. This leads to problems in the uniformity of dyeing especially at the edges of the web where uniformity of pressure sometimes cannot completely be ensured and where, furthermore, the web for reasons of structure and selvedge absorbs the liquid dye differently than in the web middle even if the pressure is uniform.
The invention, therefore, is directed to the problem of, on the one hand, ensuring treatment which is uniform over the web even if absorption of the treatment medium by the web varies, and on the other hand, advantageously utilizing the recognized sensitivity of the method to differences in pressure for the purposed of imprinting patterns on the web.
SUMMARY OF THE INVENTION
The invention solves this problem by providing a method and apparatus in which the web is pressed against the opposing face with a non-uniform pressure. The resilient pressure exerted in the slot on the web is thus no longer necessarily uniform over the entire width of the web, but can intentionally be non-uniform. This is done for the purpose of ensuring on the web, which may absorb the treatment medium unevenly, nevertheless uniform application of the pressure fluid over the width of the web and, thus, achievement of uniformity of treatment through appropriately adjusted pressure control. This is a significant aspect of the invention.
On the other hand, by varying the pressure control different imprinting results can be achieved over the surface of the web of the fabric. For example, dyeing can appear graded or veiled, as it is intended for some materials influenced by fashion and also for carpeting. The specific pressure, the non-uniformity of which varies depending on the pattern, can vary spatially, that is in the direction transverse to the web, and also temporally on passing the slot such that, broadwise in one and the same location in different regions along the web, differences in the shade and saturation of color can exist.
The apparatus of the invention employs various means for pressing the web non-uniformly that may comprise resilient pressing elements. Where the best possible uniformity of treatment over the width of the web is a concern, provision of a first pressure in the center of the web and a second pressure at the web edges has in many instances been found to be sufficient. Both edge regions may be acted upon independent of the center region which is treated uniformly.
The means for pressing the web with a non-uniform pressure may comprise an oblong cushion extending over the width of the web. By "cushion" what is meant is a hollow body with flexible walls which is filled with a fluid medium to an internal pressure that is uniform over its entire length. The cushion transmits this internal pressure essentially uniformly to the web when placed against it.
A configuration of this general nature is disclosed in DE-OS 33 15 770 in which the cushion extends over the entire width of the web. According to the invention, the cushion is subdivided into several sections forming individual cushions adjacent to each other, which can be filled with fluid medium independent of each other such that in each individual section an essentially uniform pressure can be exerted. However, adjacent sections may be adjusted to exert differing pressures. To be a "cushion" in this sense, the internal pressure must be propagated uniformly over the entire extent of each section.
However, other types of resilient pressure elements are disclosed per se in FRP 13 81 081, in particular, resilient elements which can be compressed and have some degree of inherent stability, such as thick-walled tubing, cylindrical or rod-shaped elastomer sections or similar elements. When such elements are compressed in one location, other locations s sufficiently transversely spaced to the web remain substantially unaffected.
A "cushion" can have non-rigid walls and fulfill its function in the presence of internal pressure. Without this internal pressure it Would collapse upon itself and could not function as a resilient pressure element. The pressing elements according to FRP 1381081 do not collapse even in the absence of internal pressure because of their inherent stability. It is, however, also possible, to use pressing elements which combine both properties, for example, relatively stable tubing having internal pressure. Filling the tubing with fluid medium yields a pressure component Which is uniform over the width of the web and, in addition, because of its inherent rigidity is able upon compression to exert varying forces at different locations transverse to the web.
The means for pressing may not be subdivided into separately actuatable sections, but rather may be a continuous member acted upon by separately actuatable additional pressing elements, from which originate the varying pressures exerted on the web. The pressing means may act directly upon the continuous member. However, in some cases this may cause problems at the transitions of the effective regions of the distinct pressure elements because of the occurrence of pressure stages in these locations. For this reason a bar or plate may be provided for bridging the above-mentioned pressure stages such that no change of pressure can occur at short transition distances transverse to the web. Over larger transition distances, however, the bar or the plate should still be resilient such that it can compress the pressing element in different regions transverse to the web and thereby generate different pressure effects in the web. Other advantageous embodiments are disclosed herein.
The drawing schematically represents several embodiments of the invention discussed below.
BRIEF DESCRIPTION OF THE DRAWINGS
FlG. 1 shows a cross section along line I--I of FIG. 2 in a longitudinal plane perpendicular to the web of a carpet dyeing facility constructed according to the invention.
FIG. 2 is a cross sectional view along line II--II in FIG. 1.
FlG. 3 shows a cross section according to FIG. 1 of a modified embodiment along line III--III in FIG. 4.
FIG. 4 is a cross sectional view along line IV--IV in FIG. 3.
FIG. 5 shows a cross sectional view according to FIG. 1 of a third embodiment.
FIG. 6 represents a partial section along line VI--VI in FIG. 5.
FIG. 7 is a view corresponding to FIG. 1 of a fourth embodiment.
FIG. 8 shows a partial section along line VIII--VIII in FIG. 7.
FIG. 9 represents a section corresponding to FIG. 1 of a fifth embodiment along line IX--IX in FIG. 10.
FlG. 10 is a sectional view along line X--X in FIG. 9 in reduced scale.
FIG. 11 shows a section corresponding to FIG. 1 along line XI--XI in FIG. 12 of a sixth embodiment.
FIG. 12 shows a cross sectional view along line XII--XII in FIG. 11 in reduced scale.
FIG. 13 shows schematically a cross section in a transverse plane perpendicular to the web of two further embodiments of the invention
DETAILED DESCRIPTION
In the device labeled 10 in FIGS. 1 and 2, the web 1 is a carpet web, which, in a manner clearly apparent in the drawing, is led with the pile 1' facing upward over guide rollers 2, 3 which are parallel to each other and placed at approximately equal levels.
Between the guide rollers 2, 3 an application bar 4 is located in contact with the web 1 that is disposed transverse and parallel to the Web. Bar 4 forms on the side facing the web 1 an opposing face 5 acting as a glide surface. Application bar 4 may be formed from a longitudinal segment of thick-walled tubing of synthetic material. Opposing face 5 has a circular cylindrical convex shape.
The web 1 rests against the opposing face 5 in the encircling region indicated by the arrow 6. Approximately in the center of the wrapping region 6 a slot 8 forming an interior chamber is provided in the application bar 4. The slot extends approximately perpendicular to the opposing face 5 and terminates in the latter. Slot 8 extends continuously over the length of the application bar 4, i.e., the width of the web 1.
Close to the base of the slot 8 are ports of feed channels 9 disposed perpendicular to slot 8. A number of channels 9, for example twenty or fifty, are distributed over the length of the slot. The feed channels 9 are formed by transverse bores, which extend from an offset 14 in the opposing face 5 and are sealed to the outside with plugs 11. Each individual feed channel 9 is connected to a connecting channel 12, which leads approximately radially to the concave inside face of the application bar 4 and there connects to one of the feed ducts 13, which are evenly supplied with liquid treatment medium, for example, liquid dye, by a distributor.
During operation of the device 10, the treatment medium is supplied via the feed ducts 13, the connecting channels 12 and the feed channels 9 to the slot at sites distributed over its entire length. Supply takes place at right angles to the slot 8 such that the treatment medium, before flowing out of the slot 8 into the web 1, can be diverted and thereby made more uniform. The flow width can be adjusted to the width of the web 1 by sliding the element 26 which fills the cross section of slot 8 and seals it to the outside.
On the side of the web 1 opposing the slot 8, a resilient pressing element 20 is provided. The resilient pressing element 20 comprises an oblong cushion 15 provided in the center region of the web 1 that extends transverse to the web, as well as further cushions 16 17, 18 arranged next to each other, i.e., in the adjoining edge regions. Each cushion 15, 16, 17, 18 has, in a manner clearly evident in FIG. 2, its own connection and can accordingly be provided with its own individual internal pressure by having a fluid medium pumped into it, for example compressed air.
The resilient support element 20 is located on the side facing away from the web 1. Between the resilient pressing element 20 and the web 1 a fixed flexible glide foil 21 is arranged, which in the running direction of the web 1 shown in FIG. 1, i.e. parallel to the web, is fastened with its left edge at 22 on the support 19. The application bar 4 with the opposing face 5 on the one hand, as well as the resilient pressing element 20 and the glide foil 21, define a gap 25 through which the web 1 is pulled. The resilient pressing element 20 presses the glide foil 21 and the web 1 against the opposing face 5. The specific pressure to which the web 1 is subjected in the gap 25 can be selectively varied by variably inflating the cushions 15, 16, 17, 18.
In the device 30 shown in FIG. 3 and 4, the application bar 4 with the slot 28 forms the opposing face 5. Bar 24 comprises a stationary carrier extending over the width of the web 1. On the underside of support 29 that faces the web 1 a resilient pressing element 40 is provided in the form of several separately inflatable cushions of equal width arranged over the width of the web immediately adjacent to each other. Between the cushions 35 and the web 1 a glide foil 31 is provided, which is fastened at the sides of the carrier 29 in a manner evident in FIG. 3 such that the resilient unit comprising the cushion 35 and the glide foil 31 does not vibrate when the web 1 is pulled through the gap 25.
The resilient pressing elements 20, 40 in FIGS. 1 to 4 comprise distinct cushions, which, similar to balloons, can be inflated with a fluid medium and do not need to possess any utilizable inherent stability until filled. In the device 50 of FIGS. 5 and 6 and pressing element 60 is in the form of tubing 44 that extends over the width of the web. Tubing 44 has inherent stability, that is, even without being filled with a fluid medium, it has resistance to being compressed which increases with the degree of deformation in its transverse direction.
In the device 50 as in the device 30 an application bar 24 with a slot 28 extending over the width of the web 1 is provided. The slot 28 is closed at its ends by adjustable elements 26 and in this way enables adjustment of the application width to the width of the Web 1. Above the Web 1 a support 39 in the form of a carrier is provided, which extends transversely over the web. The carrier has a chamber 32 open at the bottom. The chamber 32 is defined in the longitudinal direction of the web by posts 33, 34 which extend perpendicular to the web 1 and between which a plate 38, extending continuously over the width of the web 1, is adjustably guided in the direction perpendicular to the web 1.
Plate 38 has, on the side facing the web 1, a continuous T-groove 42 into which fits a T-shaped longitudinal projection provided on the tubular hollow section 44 that forms the resilient pressing element 60.
The tubular hollow section 44 rests, in a manner evident in FIG. 5, against the inside of the glide foil 41 fastened to the sides of the carrier 39, and presses the glide foil 41 against the web 1 and the web 1 against the port edges of the slot 28.
The plate 38 is supported by pressure elements 45, 46, 47 formed as inflatable hollow bodies and arranged between a stationary carrier 48, which extends parallel to the web 1 and connects the posts 33, 34, and the upper side of the plate 38. The pressure elements 45, 46, 47 can be separately pressurized to cause the plate 38 to bend in the manner shown in FIG. 6 if the pressure in the pressure element 45 spanning the center region of the web 1 is somewhat less than the pressures in the separate pressure elements 46, 47 in the region closer to the edges. The rigidity of plate 38 is such that at the marginal areas between the pressure elements 45, 46, 47 no deformation stages occur. However, over a greater area the plate can bend in the indicated manner via differences in pressure in the pressure elements 45, 46, 47. Bending of the plate 38 is transmitted to the resilient pressing element 60 such that in areas where element 60 is compressed more strongly, particularly at the edges of plate 38, more pressure is transferred to the glide foil 41 and the web 1 than in the center.
In the embodiments of FIGS. 1 to 6 supply of the treatment medium takes place through the gap 8, 28 in the opposing face 5, which was formed by a rigid part. In the design 70 according to FIGS. 7 and 8, in contrast, supply of treatment medium does not occur in the gap 25 and the opposing face is also resilient. As is evident in FIG. 7, a narrow vertical trough 52 is formed by two glide foils 51, located opposite each other in the indicated manner, through which the web 1 is guided vertically from above and which is sealed at both edges of the web 1 in an appropriate manner. The glide foils 51 are inclined toward each other and are disposed on a respective side adjacent to the web 1 in the gap 25. In this area, resilient pressing elements 80 in the form of inflatable cushions 55, 59 act upon the outside of the glide foils 51. The cushions are arranged in channel-like recesses 56 of carriers 57, 58 extending transverse over the width of the web 1. On the left-hand side of FIG. 7 a carrier 57 is shown, which, for example, may be formed as a massive element of synthetic material or, as shown on the right-hand side of the web 1, carrier 58 may be constructed from sheet metal.
The web 1 on passing through the trough 52 takes liquid, which, in the gap 25 by means of the pressure of the resilient pressing element 80 transmitted by glide foils 51 to the web, is pressed into and worked into the fabric.
The resilient pressing element 80 of the device 70 is subdivided over the width of the web 1 into several inflatable elastic hollow bodies 55, 59. Outside the hollow body 55 disposed in the center only one additional hollow body 59 is provided at each edge, which covers only approximately 10% of the total width. Pressurizing the hollow body 59 to a different pressure than hollow body 55 suffices to compensate for uneven edges that sometimes are encountered during treatment of the web 1.
The device 90 in FIG. 9 combines the features of device 70 of FIG. 7 and device 50 of FIG. 5. A trough 52 is provided between glide foils 61 extending essentially vertically. The trough is filled with treatment medium and the web 1 is led vertically into the trough from above. On both sides of the web 1, the glide foils 61 rest against the opposing sides of bars 62 that face each other and extend in the direction transverse to the web 1. The bars 62 have mutually opposing channels 63 in which resilient pressing elements 100 are arranged that are formed as thick-walled tubing 64. The tubing 64 extends over the width of the web 1 and has, because of the rigidity of its sides, resistance to being compressed. In addition, in the illustrated embodiment tubes 64 are adjustably filled with air under pressure such that pressure remains uniform over the length of the tubing 64 due to the interaction of the air pressure and the additional pressure generated by local compression and deformation of the tubing 64.
The bars 62 are guided by bolts 65 carried by stays 68 that extend parallel to the web 1. Stays 68 comprise part of supports 69 formed as carriers extending transversely over the width of the Web such that they can shift perpendicular to the web 1 relative to each other. The stationary carriers 68 are arranged outside the bars 62, and between the stays 68 and the bars 62 pressure elements 67 are located that comprise pressure tubing. The pressure tubing is subdivided by crimped connections 71 into a center section 72 and two outer sections 73. Each section 72, 73 can be filled separately with a fluid medium. By setting the pressure in the individual sections 72, 73, the bar 62 is bent somewhat causing the tubing 64 to become compressed to varying degrees over its length and thereby transmit correspondingly varying forces to the glide foil 61 and the web 1.
Device 110 in FIGS. 11 and 12 differs from device 90 only in that the resilient pressing elements 120 are formed by a thick-walled tubing 74 of rubber, which may be open at its ends. Massive cylindrical sections of rubber may also be employed. These resilient pressing elements act only through their inherent resistance against being compressed and have no internal pressure that remains uniform over the width.
The device 130 in FlG. 13 illustrates that the pressure elements may also have a tubular shape or resemble balloons. The web 1 is pressed against the opposing face 75 by a resilient pressing element 140 and moves perpendicularly to the web. The pressing element 140 itself has a resistance against deformation, i.e., the pressure it exerts against the web 1 increases, the more it is compressed together.
In the left bottom half of FIG. 13 pressure elements 85 in the form of pneumatic cylinders or mechanical spindle devices are provided that are arranged on a fixed support 79 and act upon a plate 38, Which corresponds to plate 38 described in FIG. 5. The plate 38 experiences bending and increasingly deforms the resilient pressing element 140 in the direction of the web center. The pressure exerted on the web 1 behaves in a similar manner. The pressure elements 85 are independently actuatable.
The pressure elements 95 in the right bottom half of FIG. 13 act, by way of pressure plates 86, directly upon the resilient pressing element 140. | A liquid, foam or paste treatment medium is applied to a textile or similar web as the web is led through a gap in which the web is pressed resiliently against an opposing face in an area extending over the width of the web with non-uniform pressure by, for example, several adjacent cushions that are independently inflatable. The non-uniform pressure serves primarily to achieve uniform treatment, in particular, uniform coloring, despite the non-uniform conditions existing over the web width. The non-uniform pressure may also be used for imprinting patterns on the web. | 3 |
This application is a 371 of PCT/GB02/02616 filed May 30, 2002.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims priority from PCT/GB02/02616, filed on May 30, 2002, which is based on and claims priority from British Application 0113861.9 filed on Jun. 7, 2001, the entire disclosure of each of the aforementioned applications are each herein incorporated by reference in their entirety.
1. Field of the Invention
The present invention relates to a collapsible scaffolding tower.
2. Background of the Invention
It is known to form a scaffolding tower from similar rigid frames that are designed to slot into one another. Each frame is formed of tubular steel with two upright poles, or uprights, two horizontal bars and additional struts to maintain the rigidity of the frame. The uprights have different diameters at their upper and lower ends so that the bottom of one frame can be fitted over the top of another. To assemble the tower, two frames are positioned at the sides of the tower, and then frames at the front and rear of the tower are joined to the side frames. The process is then repeated by placing two further frames at the sides of the tower and joining them to the front and rear frames.
When collapsed, such towers are very bulky and when erected they are rickety because they rely on a good fit between the individual frames to give the tower its rigidity.
GB 1,311,569, shows collapsible scaffolding made up folding sections that slot into one another. The scaffolding when collapsed consists of several separate sections and is not therefore very compact nor easy to transport.
GB 988,270 discloses an extension frame having telescopically collapsible legs. However, the extension frame needs to rest on the base frame, not on the ground, and it provides only one extendible section. GB 988,270 also shows a complex collapsible scaffolding that is formed of a base frame, an extension frame and various bracing elements. Once again, the use of separate frames makes the structure bulky when collapsed.
WO95/027836 discloses a scaffolding which without being dismantled can be reduced in height to one tenth of its operational height for storage and transportation. The scaffolding has platforms with hinged uprights that can be folded to a horizontal position beneath the platforms in a concertina-like manner. The scaffolding cannot be erected simply and indeed this operation requires a separate hoist or crane.
Accordingly, what is needed is to overcome the shortcomings of the prior art and to provide a scaffolding tower that is compact when collapsed, that is easy to erect and that is sturdy when assembled.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a collapsible scaffolding tower having four uprights arranged in two pairs, wherein each of the uprights is formed of three or more telescopically collapsible sections and a respective rigid horizontal bar extends between each pair of sections of the uprights to form two telescopically collapsible ladder structures which rest directly on the ground when the tower is in use and wherein a support platform is provided having opposite ends each removably resting on a rigid horizontal bar of a respective one of the two ladder structures.
While it would be possible to interconnect two collapsible ladder structures using detachable cross members to form a rigid tower, such a tower would need at least two people to assemble it. To permit single-handed assembly, it is preferred for the lowermost sections of the two collapsible ladder structures to be permanently connected to one another by a folding or collapsible structure that allows the two ladder structures to move towards and away from one another while remaining essentially parallel to one another.
Such a collapsible structure may comprise a lazy tongues or trellis-like system of pivoted bars to connect the ladder structures to one another, but it is preferred to use a folded gate formed of two leaves which are pivoted about vertical axes to one another and to respective ones of the sections of the uprights of the two ladder structures.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described further, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a first embodiment of the invention in its extended position,
FIG. 2 shows a front view of a gate structure of the preferred embodiment when in the extended position,
FIG. 3 shows a side view of a first embodiment when attached to a ladder,
FIG. 4 shows an alternative perspective view to that of FIG. 1 , and
FIG. 5 shows a perspective view of a second embodiment of the present invention when in its extended position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a scaffolding tower 10 , two opposing sides of which each consist of a telescopic ladder structure 12 and 14 . The remaining opposing sides of the tower are formed by a collapsible gate 18 (see FIG. 2 ) and a cross brace 34 . The rungs 20 b of the telescopic ladder structures 12 , 14 support a platform 36 similar to those which can be found on conventional scaffolding towers.
The telescopic ladder structures 12 , 14 have stiles 16 formed of telescopically collapsible tubular sections 16 a , 16 b and 16 c . Each section supports a rung 20 a , 20 b and 20 c . When extended, the tubular sections lock into each other, by means of spring-loaded pins (not shown), thereby preventing the stiles 16 from collapsing when in use. Further security can be attained by providing an additional pin, which can be manually inserted in a hole through any two aligned telescoping sections 16 a , 16 b or 16 c . When collapsed, the three rungs 20 a , 20 b and 20 c lie adjacent one another. This allows the sides of the tower when extended to be approximately three times their collapsed height.
FIG. 2 shows the third side of the tower which is formed by joining the two opposing ladder structures to each other on one side by a gate 18 having two gate leaves 24 and 26 .
The gate leaves 24 , 26 are formed from an open frame, and hinged to each other about a vertical axis. The remaining vertical edges of the gate 18 are hingedly attached to the lowest section 16 a of the telescopic stile 16 of the respective ladder structure. This arrangement positions both ladder structure ends of the tower approximately upright enabling construction to be carried out by one person.
In the preferred embodiment, the leaves of the gate are symmetrical about the hinge 44 joining them and trapezium in shape. As a result, the ladder structures do not lie exactly parallel to one another but form a more sturdy A-frame. The hinges still allow the leaves to fold inwards when collapsed, about the centre hinge 44 .
A support bar 28 is positioned just above the foot of each ladder structure between its stiles 16 , in line with the lower edge of the collapsible gate 18 , thereby adding to the rigidity of the structure. Rigidity is still further increased by the provision of bracing rods 30 and 32 which extend diagonally between the support bar 28 and rung 20 a on each ladder structure. The tensioned crossed arrangement resists racking in either direction.
The fourth and final side of the tower 10 is formed by the insertion of a cross brace 34 parallel to the gate 18 spanning either between the vertical stiles 16 of the ladder structures 12 , 14 or between the support rungs 28 . The cross brace 34 is secured to either of these using conventional methods such as threaded clamps.
This completes the first level of the tower 10 . The second and third rungs 20 b and 20 c of telescopic ladder structures 12 , 14 define the second and third levels when the ladder structures are extended to full height. Platform 36 for providing a support floor for a user of the tower, is supported on rung 20 b and locked thereto using suitable means. This will further increase structural rigidity of the tower.
FIG. 3 shows a ladder 46 secured to the tower to allow easy access to the platform. The ladder 46 may itself be collapsible for ease of transportation. To aid with assembly, a ladder 46 may be secured to either of rungs 20 a . This provides stability whilst enabling the user to reach high enough to insert the platform boards.
Though the A-frame structure is not prone to racking, its rigidity is improved further by the inclusion of telescopic tension rods 38 and 40 . These are similar in function to bracing rods 30 and 32 . The telescopic nature of the rods 38 and 40 , allows them to also retract in a direction required for the tower 10 to collapse when not in use. This feature is not a requirement of bracing rods 30 and 32 since they span a distance which remains constant regardless of the configuration of the tower. The telescopic tension rods 38 and 40 diagonally span from support bar 28 of one ladder structure to rung 20 b of the opposing ladder structure. The telescopic tension rods 38 , 40 can employ spring loaded locking pins, similar to those used in the telescopic stiles 16 of the ladder structures 12 , 14 . These would give the rods strength in both tension and compression but would make the tower more difficult to collapse. In place of pins, one could use spring biased pawl-like members to prevent the rods from being extended without interfering with their collapse. It should be noted that for the tower to be totally collapsible, the telescopic tensioning rods 38 , 40 must each comprise at least two sections. Alternatively, the telescopic tension rods 38 , 40 may be replaced with fixed support rods which would require attachment each time the tower is erected.
For safety as well as rigidity, a support bar 42 , is secured between rungs 20 c of the opposing ladder structures 12 , 14 . This completes the erected tower but further reinforcements can be employed.
For the purposes of collapsing the tower 10 , support bar 42 , platform 36 and cross brace 34 must all be removed. It is then necessary to retract the telescopic stiles 16 , by releasing the spring loaded pins and pulling the upper rungs 20 b and 20 c in a downwards direction.
At this stage the partially collapsed tower appears similar to a child's play pen. The final stage of collapsing requires that the collapsible gate 18 is bent about its hinge 24 , towards the now partially retracted telescopic tension rods 38 , 40 . When viewed from above, the tower at this point would appear M-shaped. The gate 18 is then fully folded and the ladder structures 12 , 14 brought together, at the same time the telescopic tension rods will be in their fully retracted position. This final position is very space efficient and makes for ease of storage and transportation.
FIG. 5 shows a second embodiment intended for use primarily as a conventional scaffolding tower again with the advantage that it may be collapsed and easily erected by one person.
Tower 50 is similar in construction to the previous embodiment, the main difference being that the ladder structures which form the sides of the tower 50 are parallel. To aid in construction the present embodiment uses a collapsible gate 56 similar to that described with reference to the previous embodiment.
The second embodiment further differs by employing two platforms 58 . These may have a cut-out 60 formed therein, enabling a ladder to be placed between the platforms to allow ascent on to the upper level.
The embodiment of FIG. 5 also employs support rungs 62 similar to support rungs 28 . Racking in two directions is reduced by telescopic braces 64 and 66 which are attached between each of the rungs of the telescopic ladder structures 52 and 54 . The braces 64 and 66 are formed of telescoped sections that can collapse one inside the other but a catch or other abutment prevents their extension beyond a certain point. Because they cannot be extended beyond a certain point, they act in the same way as taut wires to prevent racking but because they can be collapsed they do not interfere with the collapsing of the scaffolding.
Racking in the direction parallel to the width of the tower is further reduced by longer telescopic braces 68 and 70 which stretch between the rungs of adjacent levels of the opposing ladder structures. These may be replaced by rigid removable braces, but this arrangement would not be as easily erected or collapsed. | A collapsible scaffolding tower having four uprights arranged in two pairs, wherein each of the uprights is formed of three or more telescopically collapsible sections and rigid horizontal bars extend between the sections of the uprights in each pair to form two telescopically collapsible ladder structures, which rest directly on the ground when the tower is in use. | 4 |
This is a continuation-in-part of application Ser. No. 365,780 filed Jun. 14, 1989, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the provision of a safety arrangement for preventing articles from being accidentally or unintentionally displaced from an overhead bin for hand luggage, that is to be found in the passenger cabin of an aircraft.
An overhead luggage bin in an aircraft cabin is well known; but is shape, the working interrelationships of its elemental parts and its location present certain problems, some of which interact. For example, the bin must be large and strong and yet be light in weight, and it is usually to be constructed of flame or fire resistant materials. Its closure door means should open outwardly and upwardly and the full storage space should be capable of being exposed. The door opens upwardly so that space for movement of passengers and crew within the cabin is not impinged upon.
The actual construction of such overhead bins varies and is adapted to conform with structural requirements and the overall internal configuration of the cabin of the aircraft in which it is installed. In one typical form of such a luggage bin, the bin has such a construction that its interior has the shape of a generally rectangular box. The essential feature of such a bin is its shelf like strongly made floor. From this, side and rear wall panels extend upwardly. These side and rear panels need not extend upwardly over the full height of the luggage space defined within the bin. Such a bin will often, but not always, possess a roof panel. Where there is no roof panel, the roof of the cabin of the aircraft may serve also as the roof of the luggage bin; and in this case, the front door panel which lifts to open, may be hinged at or towards its upper generally horizontal edge to a structural part of the body or structure of the aircraft. Where the bin has a roof panel the main bin door may be hinged to a frontal part of such roof panel; or, alternatively, the upwardly and outwardly opening closure door means may be hinged to side walls of the luggage bin. At least the floor panel and the closure door means when closed, will be firmly attached to, or firmly relative to, the body or structure of the aircraft cabin.
These bins are often up to seven feet wide, and they are usually at least 30 inches wide; and as a result their frontal access openings are corresponding large and wide. Considering a typical overhead bin whose access opening has a height of 20 inches and a width of 60 inches it needs to be mentioned that this bin will be disposed above the cabin seating and the bin floor will be located some 60 inches above the cabin floor. A person operating the catch means of the main bin door to lift this door to open it will have a line of sight extending to the bin opening over a distance of about 20 inches. The field of view will extend over about 30°, and an arc of say 24 inches will be subtended. Thus on opening the main bin door, the person will have a field of view extending over less than half of the full width of the bin opening. The span of a human hand is six to nine inches and this is a small fraction of the full width of the bin opening.
Accordingly, even if the passenger or crew member, who is opening the bin, has both hands free, the full width of the opening can be covered and viewed, only if speed and dexterity of hand and eye are employed. And accordingly, when the front door panel of such a bin is opened by being raised, there is a risk in that heavy articles such as cameras, brief cases or even bottles are liable to fall out inadvertently, and this may cause injury to a passenger seated or standing nearby. A particularly dangerous situation occurs when the bin is fully loaded with a variety of heavy articles. Loading will not have been effected systematically. On the contrary, heavy objects will be randomly located and may have been inserted on top of other objects; and they may be liable to slide and fall out as soon as the main closure door of the bin is opened.
SUMMARY OF THE INVENTION
The invention is concerned with the provision of improved utility and safety in an overhead luggage bin of the type which has an opening whose width is greater than say 80 centimeters or about 31 inches. Typically the frontal openings of such bins have heights of 50 cm, or about 20 inches, or more and they may have widths of 50 to 70 inches. This frontal access opening will be closable by a single primary bin door with its own "slam shut" latching means located at its lower edge and this main door will open outwardly and upwardly and it will be spring assisted during its opening movement.
According to this invention, in its broadest aspect, there is provided an aircraft cabin luggage bin having wall panel means fixed to structure of the aircraft cabin and defining a load carrying interior having the general shape of a box; said box having a laterally elongate frontal access opening and a front door panel which is openable to uncover, and closable to cover, said opening; said door panel having an upper generally horizontal edge and being hinged at a location adjacent its said upper edge; and in which said front door panel lifts, on opening to uncover said frontal access opening of the bin, pivoting outwardly and upwardly about its hinge; and said luggage bin being characterized in that there is provided behind the upwardly and outwardly pivoting front door panel of such a bin, visor means comprising a plurality of hinged, upwardly and outwardly pivoting transparent visors, each of which has catch means which require to be released before the visor can be raised: said visor means constituting a temporary physical barrier, which masks at least the lower half of the access opening which is uncovered when the front closure door panel of the bin is opened.
The invention is based upon the appreciation that utility and safety will be promoted if the following considerations can be satisfied, in the circumstances when, the bin is full of articles, and the main bin door is opened. Firstly, it will assist if there remains some temporary physical barrier to prevent objects from falling out. Secondly, it will assist if it is possible to view at least the uppermost article disposed behind the temporary physical barrier, and also, it will assist if the means constituting the temporary physical barrier, are removable, but not all at once by one hand. The provision of multiple, separately movable and separately latchable transparent visor means meets these requirements and will be helpful in preventing accidents. If these visor means nest neatly behind the main bin doors, both when opened and when closed, the loss of usable space is minimised.
The invention is particularly applicable to bins with wide front openings, that is those whose width is greater than say 40 inches. Accordingly, in a preferred embodiment of this invention there is provided an aircraft cabin luggage bin defining a load carrying interior having the general shape of a box and with a front door panel which lifts to open to uncover a frontal access opening of the bin, the front panel being hinged at a location adjacent its upper generally horizontal edge, and characterized in that there is provided behind the upwardly and outwardly pivoting front door panel of such a bin, auxiliary visor means which has the following characteristics in combination.
a) said visor means is constituted by a plurality of hinged part-visors located side by side to extend over substantially the full width of the opening uncovered by the lift-up front door panel of the bin, said part-visors being openable and closable separately of one another and said part visors pivoting upwardly and outwardly to open;
b) each part-visor has catch means which require to be released by hand, before the visor can be raised, each said catch means being self-latching when the visor is closing;
c) each part-visor is formed, over the major part of its area, of material which is transparent and enables objects stowed away behind each said part-visor to be seen; and
d) and each said part-visor is assisted by spring means during its upward and outward movement towards its fully open position.
Such a multi-visor system is well suited to one handed operation, both in opening and closing. When opening, one hand is used first to open the main door of the bin; then to operate the release catch; then to raise on part-visor assisted by the spring means. The other hand is free to prevent objects from falling out. At first other part-visors which extend over the remainder of the width of the bin opening, are latched shut to prevent other objects falling out. When closing the bin, each part visor may be closed in turn to pen objects in sections of the bin. Or the main door of the bin may be shut and this will also effect closure and latching of all the auxiliary part-visors.
Visor widths will be within the range 15 to 32 inches and preferably within the range 24 to 30 inches. It is not necessary for each visor to mask the full height of each bin opening--for example, the height of each part-visor, in its mid region may be some 14 inches, while the height of bin opening might be 20 inches. What is necessary is that the visor means, when latched closed, must mask at least the lower half of each bin opening. Any gap unmasked by the visor means in the upper part of each bin opening, has a number of possible functions. Thus weight may be saved. Or, clearance room may be provided so that the visor will open past an obstruction, such as for example, to enable the visor as it opens, to clear the frontal edge of the bin roof.
The visors may be hinged close to the hinge axes of the main bin doors. In bins for some aircraft the two hinge systems may pivot aligned axes. But an important preferred feature is that each part visor nests with the main door in both open and closed conditions.
In one particular application, use is made of an existing fixture, this being the casing for the main door hinges. Alternatively, separate new bracket work may be provided and fixed to existing structure on a bin or on some other wall component (of the aircraft cabin) to support the hinges of each part visor.
Different arrangements may be required for bins with unusual configurations. Each bin will always have a bottom and sides, but it will not necessarily have side and back walls of full height, nor a top or roof wall of a full depth; indeed there may be no roof panel. However there will usually be some sort of framework bridging the top of the main door opening of each bin, and the auxiliary visor means provided according to this invention may be hinged to this; or if the bin has side walls, these may be used to mount the hinges of the part visors.
It is essential that each part-visor has its own "slam shut" self-latching catch which must be deliberately manipulated if the visor is to be opened, for example, by squeezing with finger and thumb or by turning. Preferably slam shutting of the main door also effects slam shutting and self-latching of the visor doors (at least if the bin is empty, or, when partly full, if there is no hindrance to the closing of the visors).
Advantageously each part-visor is comprised of a generally rectangular frame of lightweight composition plastics material resistant to combustion, this frame defining "see-through" openings, and with transparency of the part-visor being achieved by means of reticulated or net-like material which covers said openings.
In one preferred aspect of the invention there is provided an overhead storage bin for aircraft comprising a generally rectangular box-like body including interconnected floor, side and rear walls adapted to be mounted within the cabin of an aircraft to receive and retain passenger articles therewithin, said body defining a laterally elongate generally rectangular, access opening; closure means for said frontal access opening of said bin including a primary front door panel pivotally mounted on a generally horizontal axis for pivotal movement from a generally vertical closed position, outwardly and upwardly to a generally horizontal open position; and said closure means further including generally transparent visor means hingedly mounted to pivot about an axis which is parallel and close to the pivot axis of said primary door panel, said visor means providing visual access to the interior of said bin when said primary door panel is in the open position; said visor means being movable between open and closed positions to provide and deny physical access to the interior of said bin, and retention means on each of said bin and said closure means for cooperatively retaining said closure means in the closed position; and wherein said visor means is constituted by a plurality of hinged part-visors located side by side to extend over substantially the full width of the opening uncovered by the lift-up front door panel of the bin, said part-visors being openable and closable separately of one another and said part visors pivoting upwardly and outwardly to open.
Although a luggage bin provided with such auxiliary visor means may be part of original equipment in an aircraft, this invention is particularly concerned with the provision of such auxiliary visor means capable of and suitable for being fitted to an existing luggage bin fitted in the cabin of an aircraft, for the purpose of improving the utility and safety thereof.
Accordingly, in another preferred aspect of this invention, there is provided for use in conjunction with a previously installed aircraft overhead storage bin, said bin including a generally rectangular box-like body and a pivotally mounted access door which lifts to open, the combination comprising generally transparent visor means hingedly affixed to said storage bin and movable about said hinge between open and closed positions, said visor means being positioned internally of said bin adjacent said access door and configured to complement the interior shape of said door when said door and said visor are in each of the open and closed positions; each of said door and visor means including independent latching means operable to retain said door and said visor means in closed position; and wherein said visor means is constituted by a plurality of hinged part-visors located side by side to extend over substantially the full width of the opening uncovered by the lift-up front door panel of the bin, said part-visors being openable and closable separately of one another and said part visors pivoting upwardly and outwardly to open.
Preferably, there are included also, means associated with each of said door and said visor, to retain each of them in an open position in generally complementary association whereby, when both said door and said visor are in the open position, they may be simultaneously moved to the closed and latched position in a single action by the closure of the door.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by way of example with reference to the accompanying diagrammatic drawings in which
FIGS. 1A, 1B and 1C show a luggage bin of the kind being discussed, in three different operative conditions.
FIG. 2 is a frontal view of a luggage bin in the condition when its main door has been fully opened.
FIG. 3 is cross-sectional side view showing schematically the opening and closing movements of frontal access opening closure means for a luggage bin according to a further exemplary embodiment.
FIGS. 4 and 5 show examples of door helper spring mechanisms.
FIGS. 6 and 7 show one example of a "slam shut" door latching mechanism; FIG. 6 being a cross sectional plan view taken on the line VI--VI of FIG. 7; and FIG. 7 being A cross sectional side view taken on the line VII--VII of FIG. 6.
FIG. 8 shows a hairpin spring.
FIG. 9 is a frontal view of a latch release mechanism operable by finger and thumb.
FIG. 10 is a perspective view of a visor means according to the invention fitted to an existing luggage bin.
FIG. 11 is a perspective view showing hinge work for the visor of FIG. 10.
FIG. 12 is a side view of part of the hinge work shown in FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 to 3, there is shown a luggage bin generally designated 200 which will be fixed in an overhead location for example above seating in an aircraft cabin. The actual construction of such an overhead bin varies and is adapted to conform with structural requirements and the overall internal configuration of the cabin of the aircraft in which it is installed. In the typical form of such a luggage bin 200 as illustrated diagrammatically, the bin has such a construction that its interior has the shape of a generally rectangular box with a frontal access opening 210 closable by a single main front door 100.
The essential feature of such a bin is its shelf like strongly made floor 201 from which extend upwardly, side panels 202 and a rear panel 203. These side and rear panels need extend upwardly over the full height of the luggage space defined within the bin, but in the case with the bin shown in FIG. 3 of the drawings, these side and rear panels are shown extending to full extent. Such a bin will often, but not always posses a roof panel. Such a roof panel is indicated at 205 in FIGS. 1 to 3. Where there is no roof panel, the roof of the cabin of the aircraft may serve also as the roof of the luggage bin; and in this case, the front door panel 100, which lifts to open, may be hinged at or towards its upper generally horizontal edge to a structural part of the body or structure of aircraft. Where the bin has a roof panel such as indicated at 205, the main bin door 100 may be hinged to a frontal part of such roof panel as shown in FIG. 3; or, alternatively, and as shown in FIG. 2, the upwardly and outwardly opening main closure door 100 may be hinged to side panel means of the luggage bin. At least the floor panel and the closure door means when closed, will be firmly attached to, or firmly relative to, the body or structure of the aircraft cabin.
These bins are often up to seven feet wide, and they are usually at least 30 inches wide; and as a result their frontal access openings 210 are correspondingly large and wide. Considering a typical overhead bin whose access opening has a height of 20 inches and a width of 60 inches it needs to be mentioned that this bin will be disposed above the cabin seating and the bin floor 201 will be located some 60 inches above the cabin floor.
A person operating the catch means (generally designated 110 in FIGS. 1 to 3) of the main bin door 100 to lift this door to open it will have a line of sight extending to the bin opening over a distance of about 20 inches. The field of view will extend over about 30°, and an arc of say 24 inches will be subtended. Thus on opening the main bin door, the person will have a field of view extending over less than half of the full width of the bin opening. The span of human hand is six to nine inches and this is small fraction of the full width of the bin opening.
Accordingly, even if the passenger or crew member, who is opening the bin, has both hands free, the full width of the opening 210 can be covered and viewed, only if speed and dexterity of hand and eye are employed. And accordingly, when the front door panel 100 of such a bin is opened by being raised, there is a risk in that heavy articles such as cameras, brief cases or even bottles are liable to fall out inadvertently, and this may cause injury to a passenger seated or standing nearby. A particularly dangerous situation occurs when the bin is fully loaded with a variety of heavy articles. Loading will not have been effected systematically. On the contrary, heavy objects will be randomly located and may have been inserted on top of other objects; and they may be liable to slide and fall out as soon as the main closure door of the bin is opened.
The invention is concerned with the provision of improved utility and safety in an overhead luggage bin of the type which has an opening 210 whose width is greater than say 80 centimeters or about 31 inches. Typically the frontal openings 210 of such bins 200 have heights of 50 cm, or about 20 inches, or more and they may have widths of 50 to 70 inches. This frontal access opening 210 will be closable by a single primary bin door 100 with its own "slam shut" self-latching means 100 located at its lower edge and engaging cooperating "keep" means affixed to the bin floor 201, and this main door 100 will open outwardly and upwardly and it will be spring assisted during its opening movement.
According to this invention, in one of its broadest aspects, there is provided behind the upwardly and outwardly pivoting front door panel 100 of such a bin 200, a plurality of upwardly and outwardly pivoting transparent visor means generally designated 120 in FIGS. 1 to 3, each of which has catch means generally designated 130, which require to be released before the visor means can be raised, said visor means 120 constituting a temporary physical barrier making at least the lower half of the bin opening 210 which is uncovered when the main bin closure door 100 is opened. Transparency may be achieved by rendering a major part of the visor means of reticulated or net-like material 10.
The invention is based upon the appreciation that utility and safety will be promoted if the following considerations can be satisfied, in the circumstances when, the bin is full of articles, and the main bin door is opened. Firstly, it will assist if there remains some temporary physical barrier to prevent objects from falling out. Secondly, it will assist if it possible to view at least the uppermost article disposed behind the temporary physical barrier, and also, it will assist if the means constituting the temporary physical barrier, are easily removable, but not all at once by one hand. The provision of multiple, separately movable and separately latchable transparent visor means meets these requirements and will be helpful in presenting accidents. If these visor means nest neatly behind the main bin doors, both when opened and when closed, the loss of usable space is minimised.
The invention is particularly applicable to bins with wide front openings, that is those whose width is greater than say 40 inches. Accordingly, and as shown in particular in FIG. 2, the visor means is constituted by a plurality of hinged part-visors located side by side to extend over substantially the full width of the opening 210 uncovered by the lift-up front main door panel 100 of the bin, said part-visors being openable and closable separately of one another and said part visors pivoting upwardly and outwardly to open. Each part-visor has catch means 130 which require to be released by hand, before the visor can be raised, each said catch means is self-latching when the visor is closing.
Each part-visor is formed, over the major part of its area, of net like material 10 which is transparent and enables objects stowed away behind each said part-visor to be seen. And each part-visor is assisted by spring means during its upward and outward movement towards its fully open position, such spring means being indicated diagrammatically at 150 in FIG. 3. In this drawing 160 generally designates further spring means arranged to assist the upward and outward opening movement of the main door panel 100.
For the spring means 150 or 160, resilient extensible telescopic struts, examples of which are shown in FIGS. 4 and 5 may be employed.
Such a multi-visor system is well suited to one handed operation, both in opening and closing. When opening, one hand is used first to open the main door 100 of the bin; then to operate the release catch 130 of the visor means; then to raise one part-visor assisted by the spring means 150. The other hand is free to prevent objects from falling out. At first, any other part-visors which extend over the remainder of the width of the bin opening, are latched shut to prevent other objects falling out. When closing the bin, each part visor may be closed in turn to pen objects in sections of the bin. Or the main door 100 of the bin may be shut and this will also effect closure and latching of all the auxiliary part-visors.
Visor widths will be within the range 15 to 32 inches and preferably within the range 24 to 30 inches. As shown in FIG. 2, it is not necessary for each visor to mask the full height of each bin opening--for example, the height of each part-visor, in its mid region may be some 14 inches, while the height of bin opening might be 20 inches. What is necessary is that the auxiliary visor means, when latched closed, must mask at least the lower half off the each bin opening. Any gap unmasked by the visor means in the upper part of each pin opening, has a number of possible functions. Thus weight may be saved. Or, clearance room may be provided so that the visor will open past an obstruction, such as for example, to enable the visor as it opens, to clear the frontal edge of the bin roof.
As is shown in FIG. 3, the visors may be hinged at or close to the hinge axes of the main bin door, in FIG. 3 there is a common pivot axis indicated at 140. In bins for some aircraft the two hinges systems may pivot about aligned axes.
But an important preferred feature is that each visor nest with the main door in both open nd closed conditions. Thus, the visors are advantageously so shaped that the configuration of their external surfaces compliments the configuration of the internal surface of the main door 100, as is shown in FIGS. 1 and 3.
Each visor or part-visor preferably comprises a generally rectangular frame of light-weight composite plastics material resistant to combustion. This frame defines "see-through" openings, occupied by a transparent material such as netting which is also of material resistant to combustion. Polypropylene may be employed as the transparent netting.
It will be noted from FIGS. 1B and 1C, that when the front door panel 100 of the bin is opened, the two part-visors remain closed side by side at first. In this condition the contents of the bin can be seen through the net like areas of the visors. Each part-visor can only be raised and opened following a deliberate unlatching of its catch 130. The visor is closed, with its catch 130 being self-latching to become engaged behind a keep 134 in the bin floor 201, and such closing of the visor may be effected by fully lowering the bin door panel 100.
Referring to FIG. 4 there is shown here a resilient extensible telescopic strut (which may serve as the spring means 150 or 160 of FIG. 3), with a piston rod 41 slidable within the cylinder 42 and moving against the resistance of a coil spring 43. The strut has fixing eyes 44 at its opposite ends.
The resilient extensible telescopic strut of FIG. 5 is broadly the same except that the coil spring is replaced by a bag 45 containing a gas under pressure housed within an outer casing 46. Oil 47 transmits forces between the gas bag 45 and the piston rod 41 (moving in cylinder 42) by way of a transfer port 48. 49 denotes an end cap which together with appropriate seals, retains the oil and guides the piston rod.
The lock and keep shown diagrammatically in FIGS. 6 and 7, comprises firstly a latch plate 61 secured by screws 62 to a floor panel 63 of a luggage bin. Upstanding from plate 61 are two keep posts 64. 120 represents a visor, which adjacent to its lower edge is fitted with manually operable latching means as generally designated 130 in FIG. 1.
The latch 130 has two locking pawls 65 which engage behind the keep posts 64 in the latched condition, the pawls being carried on scissor arms 66 pivoted on a post 67 fixed in a lock barrel 68. The barrel 68 extends through an aperture in the visor and is secured by circlips 69 in this location. The barrel houses the arms 66 and has slots to accommodate the pawls 65, and it has further apertures to accommodate protruding end cups 70, one on each of the arms 66. The cups 70 have covers 71, shown also in FIG. 9 where there is also shown a cap 72 for the outer end of the lock barrel 68. The covers 71 are squeezable by finger and thumb to close the scissor arms 66 to disengage the pawls 65 from latching engagement with posts 64. A hairpin spring 73, shown also in FIG. 8, surrounds pivot posts 67 and urges apart arms 66. A coil spring 74, supplementing the spring 73, extends between the two cups 70.
When the visor 120 is slammed shut the latching pawls 65 are shaped to ride over the keep posts 64, with the scissor arms 66 closing against the bias of the springs 73 and 74. As soon as the pawls 65 pass behind the keep posts, the scissor arms 66, biased by the springs, diverge and the pawls "self-latch" behind the keep posts, from which they can then only be disengaged by deliberate manipulation, the covers 71 requiring finger and thumb pressure.
Other types of known latching means can be employed, the version shown in FIGS. 6 to 9 being purely by way of example. For example a turn and pull mechanism, similar to that of a household door lock can be employed if it will self latch when pushed shut.
Referring now to FIGS. 10 to 12, the visor 120 there shown, is one of a pair of visors fitted to a bin 200, which exists prefitted by means not shown, to structure defining an aircraft cabin. This bin 200 will have the outwardly and upwardly opening main door 100 shown in FIG. 12. The main door 100 of FIG. 12 is hingedly connected by brackets and pivots not shown, either to the roof panel 205 or to the slide panel 202 of the bin, and the main door is arranged to pivot upwardly to clear the frontal edge 205A of the roof panel 205 as it rises, and then the upper region of the main door panel will move through a path such as that indicated at B in FIG. 12 until it is disposed in rear of the frontal edge 205A of roof panel 205. In this condition the door 100 will be fully open nd disposed generally horizontally; whereas it its closed positions it will be disposed generally vertically; this being the position shown in FIG. 12.
The visor 120, is carried by an outer carrier linkage 171 and an inner carrier linkage 172. At their ends the linkages 171 and 172 are pivotally connected to plates 173 bolted to the bin roof panel 205, and a torque tube 174 interconnects the inner ends of the linkages. Each linkage 171 and 172 comprises two links pivotally connected together by pivot pins 175. At their outer ends the linkages are connected to the visor 120 by hinge pivots 176.
Also hingedly carried on the outer bracket 173 is a link 177 which depends from a pivot pin 178. Carried at the distal end of link 177, by means of pivot pin 179 is a fulcrum arm 180 which has an outer arm portion 181 connected to the visor 120 by a pivot pin 182. A telescopically extensible spring strut 150 acts by pivot pin 183 on a short arm 184 of the fulcrum 180, the opposite end of the strut being pivotally anchored to the bin side wall 202 by means not shown. The strut is spring biased to extend telescopically as is the strut of FIG. 5.
130 again represents latching means for the visor and these will be operative to engage a keep plate 61 secured to the floor panel 63 of the bin 200, the mechanisms being analogous to those described and shown with reference to FIGS. 6 to 9.
As is shown in FIG. 11, the inner and outer linkages 171 and 172, with their hinge plates 173, the arm 180, the strut 150 and the keep plate 61 can all be affixed to the bin, prior to the visor 120 being installed (by pivotally connecting it by pins 176 and 182). Thus the visor is installable in an existing luggage bin already fitted in an aircraft cabin.
It will be noted that the external shape of visor 120 conforms closely to the internal shape of the main door 100, as shown in FIG. 12. This is what is termed "nesting" in this description. The linkage supporting the visor is such that when the visor open it follows a path, such as that indicated at A in FIG. 12, and when fully open it will still be nested with the main door 100.
When the main door is closed by being pulled down, it takes the visor 120 with it, against the bias of the spring strut 150, until the latch 130 self engages the keep plate 61 to hold the visor 120 in closed condition. The torque tube 174 ensures that the inner and outer linkages 171 and 172 operate in harmony. | The invention relates to overhead luggage bins in the cabins of aircraft, the bin being either pre-existing or equipment to be newly fitted. Such bins have horizontally elongate frontal access openings. The invention provides that behind the main front door panel which closes such an opening there is provided transparent visor means which masks at least the lower part of the access opening while enabling objects within the bin to be seen. An essential feature is that the visor means are constituted by multiple part-visor located side by side, each of which are self latching on closure of the visor means, the part-visors being individually openable on unlocking of the latching means. This arrangement reduces the risk of heavy objects falling from the bin in that it militates against inadvertant simultaneous uncovering by one person, of the whole lateral width and extent of the frontal access opening of the bin. | 1 |
BACKGROUND OF THE INVENTION
Technical Field
This invention relates to digital image processing systems, and, more particularly, to systems for automatically controlling the steering of a vehicle.
Discussion
The technical literature suggests the desirability of a control system for automatically controlling the steering of a vehicle. Representative examples of some known approaches are disclosed in European Patent Application Nos. EP 0 354 56 A2 filed Aug. 9, 1989 and EP 0 361 914 A2 filed Sep. 28, 1989, both assigned to Honda Giken Kogyo Kabushiki Kaisha, Japanese Application No. 62-97935 and European Patent Application No. EP 0 304 042 A2 filed Aug. 17, 1988 assigned to Kabushiki Kaisha Toshiba. Briefly, these documents disclose the general concept of using a video input device, such as a camera, that is mounted to the vehicle and a computer processor for processing the image data and providing control signals to mechanisms for controlling the steering of the vehicle.
Generally, the prior art approaches do not appear to be cost effective. As a result, their implementation in a vehicle affordable by the ordinary consumer is not very practical. One reason for the expense is that most of these techniques process the video input data in a very complex manner. For example, the EP '914 application utilizes a Hough transform to analyze the image data. The use of transforms of these types are relatively sophisticated and difficult to analyze thereby requiring expensive computer equipment to perform the analysis since an exceedingly large amount of data is required in order to perform these transforms.
Most of the known systems continuously analyze all of the video input data and the majority of their algorithm parameters are either fixed or predetermined. As a result, the processor is given the enormous task of isolating those smaller areas of interest that contain meaningful image data points. The prior art systems also generally require an extensive manual tuning effort for each specific traffic scene and condition. Even so, there is no high degree of probability that the processor has correctly detected the actual lane boundary lines that are often used as criteria for controlling the vehicle steering. This is because there is no good preset criteria for initiating the processing of the image data associated only with relevant road features. As a result, the processor's power and resources are often wasted in processing image data from scenes which do not actually contain the lane boundary lines. In addition, the prior art approaches do not generally embody any mechanisms which allow the driver of the vehicle to operate the automatic steering control system only when traffic conditions are proper and safe.
SUMMARY OF THE INVENTION
In accordance with the preferred embodiment of the present invention, a system is provided for automatically steering a vehicle. Included is a sensor which is mounted to the vehicle and generates position information about the road in front of the vehicle. The vehicle contains a cruise control system that has a switch for initiating vehicle speed control. The invention advantageously utilizes the actuation of the cruise control switch to initiate the processing of the sensor information and to provide automatic steering control of the vehicle under safe traffic and road conditions. A programmable processor provides signal processing and analyzes the information, while a steering controller controls the steering of the vehicle as a function of the analysis by the processor.
BRIEF DESCRIPTION OF THE DRAWINGS
The various advantages of the present invention will become apparent to those skilled in the art by reading the following specification and by reference to the drawings in which:
FIG. 1 is a schematic diagram of a vehicle equipped with an automatic vehicle steering system in accordance with the present invention;
FIGS. 2A-2B are schematic diagrams which illustrate detection of the lane in the road in front of the vehicle;
FIG. 3 is a block diagram which illustrates the system configuration in accordance with the present invention;
FIGS. 4A-4C are pictures which illustrate the operation of the present invention;
FIG. 5 is a flow diagram which illustrates the processing steps;
FIG. 6 is a schematic diagram illustrating the detection and prediction of the lane boundaries in the road in front of the vehicle;
FIGS. 7A-7C are continued schematic diagrams illustrating the detection and prediction of the lane in the road;
FIG. 8 is a continued schematic diagram illustrating the detection and prediction of the lane in the road;
FIG. 9 is a flow chart diagram which illustrates the lane detection algorithm in accordance with the present invention;
FIG. 10 is a flow chart diagram which illustrates the operation of the lane detection algorithm; and
FIG. 11 is a flow chart diagram which further illustrates the operation of the lane detection algorithm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1, a vehicle 10 is shown therein which illustrates the essential components of the automatic vehicle steering system in accordance with the present invention. An image input device 12 is mounted to the front portion of the vehicle 10 at a location near the rear view mirror assembly. Such a device may be a video camera of the conventional or infrared kind and is used to monitor the road geometry and traffic condition in front of the vehicle 10 by providing a plurality of frames of video images of the road. Image input device 12 may be mounted in combination with the rear view mirror assembly or separate therefrom or at any other location which adequately monitors the road in front of the vehicle 10.
An image digitization electronics and processing unit 14 is shown mounted under the hood of the vehicle 10. The processing unit 14 may be one of several standard off the shelf programmable processors capable of providing image processing. Image digitization and electronics and processing unit 14 is made up of both hardware and software. The hardware is connected to image input device 12 and contains all the signal conditioning electronics. Included in the hardware are image digitizing frame grabbers for converting each frame of the analog video images to digital signals or pulses, and computer processors for providing digital image processing. The software provides control for the image input device 12, image processing for lane detection and a predictor for improving the efficiency of the image processing function by providing for the necessary search area.
A steering control actuator 16 is mounted on the vehicle 10. Steering control actuator 16 may be either hydraulic or electric and controls the steering angle of the wheels, subject to the manual steering override by the driver, so that the vehicle is at the desired position within the lane in the road when the automatic vehicle steering system is engaged.
Steering actuator electronics and control unit 18 is also mounted to the vehicle 10. Steering actuator control unit 18 drives the steering control actuator 16 so that the vehicle motion follows the desired path provided from the output of the image digitization electronics and processing unit 14.
Wheel angle and driver steer sensors 20 are mounted to the vehicle 10. The wheel angle sensor measures the steering wheel angle. The driver steer sensor measures the driver force applied to the steering wheel to detect driver effort in controlling the steering wheel. The detection of a significant driver steer will temporarily disengage the steering control actuator 16 so that the automatic vehicle steering function is overridden by conventional driver steering.
A conventional cruise control system 22 is employed to provide automatic vehicle speed control of the vehicle 10. A manually actuable cruise control switch 26 is mounted inside the vehicle 10 for engaging the cruise control system 22. It is generally assumed that the cruise control system 22 is engaged when the vehicle is under proper and safe traffic and road conditions.
An automatic steering switch 24 is also mounted to the interior of the vehicle 10. Automatic steering switch 24 allows the driver to engage the automatic vehicle steering system. In order to engage the automatic vehicle steering system to steer the vehicle 10, the system requires that both the cruise control switch 26 and automatic steering switch 24 be engaged. Cruise control switch 26 and automatic steering switch 24 can also be configured such that with the cruise control system 22 disengaged, engagement of the automatic steering switch 24 will also simultaneously engage the cruise control switch 22 which also engages the cruise control system 22, thereby providing engagement of the automatic vehicle steering system. On the other hand, when the cruise control system 22 or switch 26 is disengaged, the automatic steering switch 24 and the automatic steering control function are both disengaged.
Two additional system components are included, whose location in the vehicle 10 are irrelevant. The first being a sensor and vehicle system interface 64 which includes a standard vehicle speed sensor added to the standard vehicle equipment, a vehicle power supply interface and a standard vehicle cruise system interface. The vehicle speed sensor may be used for steering control purposes to modify controller response time thereby enhancing the operation of the automatic vehicle steering system. The vehicle power supply and cruise control interface may be necessary to connect the video cruising system to the standard vehicle equipment to ensure that both systems operate properly.
The second is a driver interface and warning information center 54 which may consist of audio, visual and other sensory interactions. Such devices may inform the driver about performance of the automatic vehicle steering system to enable the driver to make proper judgment on the safety of the driving situation.
In operation, the driver, while driving the vehicle 10 on a road having lanes such as a freeway, may engage the automatic vehicle steering system. During normal weather and driving conditions, the driver is required to have engaged both the cruise control switch 26 and automatic steering switch 24. With the cruise control system 22 engaged, the driver may engage the automatic steering switch 24 to engage the automatic vehicle steering system. With the cruise control system 22 disengaged, the system may be configured so that engagement of the automatic steering switch will further cause engagement of the cruise control switch 26 to thereby allow engagement of the automatic steering system. By requiring engagement of the cruise control system 22, the system may assume that the vehicle is under proper and safe traffic road conditions.
Engagement of the automatic vehicle steering system initiates the video input device 12. Video input device 12 generates a continuous plurality of frames of video images of the road in front of the vehicle 10. The image digitization electronics and processing unit 14 receives and analyzes the frames of the video images. In doing so, processing unit 14 converts the analog inputs from each frame to a plurality of digital signals. Processing unit 14 then analyzes the digital signals and attempts to detect the lane boundaries on both sides of the vehicle 10. Furthermore, processing unit 14 analyzes the path and determines the proper directional response needed to maintain the vehicle 10 in the desired position within the lane.
The automatic vehicle steering system utilizes the processed data to lock on to the lane and steer the vehicle 10 in a desired position therein. In doing so, the processing unit 14 provides a directional control response to steering actuator control unit 18 which in turn directs steering control actuator 16 to steer the vehicle in the desired direction. Wheel angle and driver steer sensors 20 measure the steering wheel angle and furthermore measure and detect driver effort to override the automatic vehicle steering system. The detection of a significant driver steer by the driver steer sensor will result in temporary disengagement of the steering control actuator 16 thereby temporarily disengage the automatic vehicle steering system. This may occur, for example, when the driver of the vehicle 10 changes lanes. Once in the new lane the automatic vehicle steering system will be re-engaged to provide steering within the new lane provided the driver is no longer manually overriding the automatic steering of the vehicle 10.
FIGS. 2A and 2B illustrate the basic geometry involved for providing images of the road for the automatic vehicle steering system. Vehicle 10 is shown within the lane of a road 28 having a left lane boundary 34 and a right lane boundary 36. Image input device 12 monitors the road geometry and provides a plurality of frames of video images of the road in front of the vehicle 10 such as frame 66.
FIG. 3 illustrates the system configuration for the automatic vehicle steering system. Video input device 12 provides continuous frames of the road in front of the vehicle 10 to image processor 14. Image processor 14 performs lane identification 42 within the area specified by the search area predictor 40 and furthermore, a lane centering algorithm 44. Search area predictor 40 provides the necessary search area in an efficient manner. The response signal from lane centering algorithm 44 is provided to steering controller 18, which in turn controls steering actuator 16. Steering actuator 16 adjusts the angle of the wheels 60 of vehicle 10 to direct the vehicle 10 in the desired direction.
Wheel angle and driver steer sensors 20 measure the wheel angle and detect conventional driver steering. Wheel angle and driver steer sensors 20 are adapted to provide a signal to search area predictor 40. The image processor 14 receives this signal and uses the wheel angle signal to check for a consistent steering angle sufficient to allow for the initiation of the system. The wheel angle signal further provides the image processor 14 with vehicle turning information. As such, the processor 14 is able to use this information to provide for a better prediction of the lane position. The wheel angle and driver steer sensors 20 are further adapted to provide a driver steer signal to steering controller 18 to disengage steering actuator 16 when the driver manually operates the steering wheel 32 while the automatic vehicle steering system is engaged. A wheel angle signal is also provided to steering controller 18. Steering controller 18 is further adapted to receive inputs from steering wheel 32 and steering actuator 16. Furthermore, steering controller 18 is adapted to provide signals to a warning system 54.
Cruise control switch 26 engages the cruise control system 22 which is adapted to control vehicle speed 38 by controlling throttle control 58 which in turn controls the throttle 60. The cruise control switch 26, vehicle speed 38, automatic steering switch 24 and steering wheel 32 are adapted to receive driver inputs 46. Automatic steering switch 24 is further adapted to receive cruise control inputs from cruise control switch 26. Automatic steering switch 24 in turn communicates with steering wheel 32. Cruise control switch 26 further communicates with pedal positions 56 which in turn controls throttle control 58.
FIGS. 4A-4C are photographs which illustrate the operation of the automatic vehicle steering system. FIGS. 4A-4C illustrate operation of the vehicle 10 within the lane boundaries of the road. The automatic steering system maintains the vehicle 10 at the desired location within the lane, under normal traffic conditions. FIG. 4C illustrates the vehicle 10 changing lanes, whereby the automatic vehicle steering system is temporarily disengaged as long as the driver manually operates the steering. Once in the desired position of the new lane the driver may discontinue manual steering which re-engages the automatic vehicle steering system.
The flow chart in FIG. 5 illustrates the processing steps performed by the automatic vehicle steering system. The driver of the vehicle 10 initially turns on the cruise control switch 26 to engage the cruise control system 22 or turns the automatic steering switch 24 to engage both the cruise control system 22 and automatic vehicle steering system. With the cruise control system 22 engaged and the automatic vehicle steering disengaged or not ready to operate, the vehicle maintains speed control in the cruise control mode unless the cruise control system 22 is disengaged. Cruise control system 22 may be disengaged by conventional techniques such as applying the brakes or disengaging the cruise control switch 26 or may be temporarily disengaged while manually depressing the throttle control 58. With the cruise control system 22 and the automatic vehicle steering switch 24 both engaged, the vehicle 10 locks on to the lane and operates in the speed and steering cruise control mode until being disengaged.
The automatic vehicle steering system may be disengaged in several ways. The driver may disengage the vehicle steering system by turning off either the cruise control switch 26 or the automatic steering switch 24. Depressing the brake pedal will further disengage the system. Temporary disengagement will result from manual driver steer. When the driver depresses the throttle control 58 the cruise control system 22 will be temporarily overridden, however, the automatic vehicle steering system will continue to steer the vehicle.
When the driver engages the automatic vehicle steering system, the system initially undergoes an initialization process. Audio and video information is provided to the driver of the vehicle 10 which indicates whether the system is ready. During automatic vehicle steering system initialization, all that is required of the driver is that he maintain the vehicle in the desired position between the lane boundaries of the road.
FIGS. 6-11 illustrate how processing unit 14 operates to analyze the frames of road images and predict the path of the lane in the road in front of the vehicle 10. Processing unit 14 receives a continuous series of frames of the road in front of the vehicle 10 from image input device 12. Image input device 12 provides frames of images at a rate of thirty frames per second, capable of providing an adequate response for vehicles travelling at normal highway speeds. For higher speeds, the system may require a higher rate of frame speed.
The processing unit 14 includes image digitizing frame grabbers for receiving each analog input frame from image input device 12 and converting each frame to a plurality of digital signals. Processing unit 14 includes computer processors for providing digital processing to analyze the digital information provided by the image digitizing frame grabbers. Processing unit 14 is further equipped with software for controlling the image input device, image processing for lane detection and a predictor to improve the efficiency of the image processing function.
In order to locate the lane boundaries in the image of a road scene, the processing unit 14 first detects all edge points in the image. In doing so, there are certain assumptions that are made in order to simplify the problem. For an automatic vehicle steering system we first assume low curvature lane boundaries. In addition, we assume that in most situations a pair of boundaries exist. Finally, it is assumed that the ground is locally level and the images are taken while the car is in the lane of the road. This letter assumption is usually correct because the driver is likely to engage the cruise control switch 22 and/or steering control switch only when the car is travelling between one lane boundaries and the car is usually travelling in a straight line. Under these assumptions, the location of the lane in the image can be predicted by the predictor 40 based on lane curvature, vehicle dynamics and steering inputs.
Two main lane boundaries are modeled close to the vehicle using two parallel line segments. The first line segment being the tangent to the current left lane boundary 34 and the second being tangent to the current right lane boundary 36. Due to the projective geometry of the image, these two convergent lines must converge at a point in the image called a vanishing point 84.
The best two convergent lines are essentially chosen from a set of candidates. Here, however, we will use two intersection points 86 and 88, that is, where the left convergent line 78 and the right convergent line 80 each cross the chosen search area 82 as shown in FIG. 7. The use of two intersection points rather than one vanishing point allows for the ability to follow the lane in situations where one side of a lane boundary is less prominent than the other or is completely missing.
Since the location of the intersection points does not change much between two continuous frames, an assumption is made that its location in the current frame will be close to that in the previous frame. This fact allows for combining road edge detection and intersection point determination in one step.
To select the two best intersection points, the algorithm collects evidence supporting each candidate from the image. The supporting evidence, coming from the pixel level local computation, includes the strength and direction of edge points and length of line segments. Functions are provided to measure the support of each of the evidence and combine them in the performance measure that gives confidence in an intersection point. The intersection point having the highest confidence is selected and the corresponding convergent line is considered as the image of the lane boundary. FIG. 8 illustrates the characteristics of such an image. Shown therein are edge responses and associated orientation of several line samples. It is desirable to obtain the data that provides a strong edge response in addition to a consistent orientation such as line 90. The overall response is then used to calculate the intersection point for that boundary line within a chosen search area 82.
FIG. 6 illustrates a left convergent line 78 and a right convergent line 80 as both pass through the chosen search area 82 to obtain the left convergent line intersection point 86 and the right convergent line intersection point 88. Left and right convergent lines 78 and 80 cross at the point known as the vanishing point 84. It is most desirable to obtain the intersection of intersection points 86 and 88 or vanishing point 84 within the search area 82. In order to do so, the system employ a predictor to continuously adjust the search area as shown in FIG. 7. The predictor determines the area in which to search. Upon system initialization, the predictor initially searches a large area. As the predictor locates the intersection points it is able to adjust to that location and search a smaller area, thereby enabling the system to operate faster and more efficiently. Upon initialization the predictor could be adjusted to monitor a narrower area based on various assumptions or cover a proportioned area (i.e., monitor every second or third Pixel) in order to speed up the initialization process. The resulting intersection point 88 found within the search area 82 provides the desired vehicle direction.
Algorithm software flow chart diagrams are provided on FIGS. 9 through 11. The processor 14 receives an image input. The gradient magnitude and gradient direction of the image data is computed. The intersection point is then hypothesized based on the search area as shown in FIG. 10, wherein (X1, X2) specifies a one-dimensional search area in the image and m is the number of hypothesized intersection points within the one dimensional area. Then, the software then collects support for each hypothesized intersection point as shown in FIG. 11. {(ipx(k), ipy), k=0, 1, . . .} represents the set of image coordinates of the hypothesized intersection point. M(i, j) is the gradient magnitude at pixel location (i, j) in the image, and xwidth and ywidth are the horizontal and vertical size of the one below the one-dimensional search area respectively. In addition, the right and left intersection point and convergent lines are then selected and the search area is updated prior to receiving the next image input.
In view of the foregoing, it can be appreciated that the present invention enables the user to achieve a system for automatically steering a vehicle within the lines of a road. Thus, while this invention has been described in connection with a particular example thereof, no limitation is intended thereby except as defined by the following claims. This is because the skilled practitioner will realize that other modifications can be made without departing from the spirit of this invention after studying the specification and drawings. | An automatic vehicle steering system is provided for automatically steering a vehicle along a lane in a road. A video sensor is included for generating a plurality of frames of video images of the road. A computer processor analyzes the frames to determine the lane boundaries of the road and the position of the vehicle. The system advantageously utilizes engagement of a cruise control switch and a steering control switch to initiate processing of the image data and automatic steering of the vehicle. In such manner, the reliability and efficiency of the system is increased while at the same time minimizing complexity and cost. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to scaffolding systems and in particular, to toeboard systems used to provide perimeter protection about a raised working surface.
BACKGROUND OF THE INVENTION
[0002] One of the main purposes of scaffolding is to provide a safe raised working surface used during the construction, repair or maintenance of a structure. Once the raised platform reaches a certain height, it is recommended or required that the working surface have a toeboard or restraint system to reduce the possibility of tools or material on the work platform accidentally being forced off the platform. As can be appreciated, many tools and/or materials can present a serious hazard if they fall from a platform and strike a person on the ground or on any lower work surface.
[0003] Many toeboard systems are merely of a wooden two by six fabricated construction while other toeboard systems are specifically designed to engage and be received in slots of upright members of the scaffolding system. Such integrated systems have not been readily accepted, probably due to the difficulty in using the system and the substantial increase in cost in manufacture of the uprights.
[0004] The present invention provides a toeboard system which is easy to use and takes advantage of the existing features of the common scaffolding systems for effective securement of the toeboard to the scaffolding system.
SUMMARY OF THE INVENTION
[0005] A toeboard for a raised working platform according to the present invention comprises an elongate member with connectors at opposite ends thereof with these connectors extending in line with and beyond the elongate body member. Each connector has two adjacent fingers at the free end thereof and the fingers extend in a manner to intersect with a longitudinal axis of the elongate member. The connectors at opposite ends of the elongate member have an opposite orientation with the fingers one connector orientated in a first direction and the fingers of the opposite connector orientated in a direction 180 degrees to the first direction.
[0006] According to an aspect of the invention, the outermost finger of each connector is offset relative to the adjacent finger of the connector such that the outermost finger is located to one side of the other finger.
[0007] According to a further aspect of the invention the elongate body is made of a metal and is generally L-shaped in cross section. This L-shape is defined by an upright portion and a foot portion.
[0008] In yet a further aspect of the invention, the connector is a metal plate secured to the upright portion on the side thereof above the foot portion.
[0009] In yet a further aspect of the invention, each connector terminates within a height dimension of the upright portion.
[0010] In yet a further aspect of the invention, the outermost finger is shorter than the inner finger.
[0011] In yet a further aspect of the invention, the elongate body has a series of securing holes spaced in the length thereof and these securing holes are used for engaging the toeboard during lifting thereof.
[0012] The present invention is also directed to a toeboard system used to provide perimeter protection about a working platform. The toeboard system comprises a series of connected toeboards where each toeboard comprises an elongate body member with connectors at opposite ends thereof. Each connector extends in line with and beyond the elongate body member with two adjacent fingers at the free end thereof. These fingers extend in a manner to intersect with the longitudinal axis of the respective elongate member. The connectors at opposite ends of each elongate body have an opposite orientation with the fingers of one connector orientated in a first direction and the fingers at the opposite connector orientated in the opposite direction. Each toeboard is connected to adjacent toeboards due to engagement of the connectors of adjacent toeboards.
[0013] In yet a further aspect of the invention, the toeboards of the system are connected one to the other such that cooperating connectors of the toeboard are interengaged and the interengaged connectors are positioned in a gap between a wedge member and upright support member of the scaffolding system.
[0014] In yet a further aspect of the invention, the toeboard system has the toeboards connecting in an end to end manner using the outermost fingers of the connector and the innermost fingers are used for connection of toe boards at an intercept angle one to the other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Preferred embodiments of the invention are shown in the drawings, wherein:
[0016] FIG. 1 is a perspective view of the scaffolding system with two defined working surfaces;
[0017] FIG. 2 is a perspective view of a toeboard used as part of the toeboard system;
[0018] FIG. 3 is a top view of a toeboard;
[0019] FIG. 4 is a side view of the toeboard;
[0020] FIG. 5 is a partial perspective view showing connection of two toeboards at a scaffold support member where the toeboards are aligned one with the other;
[0021] FIG. 6 shows the connection of two toeboards at a right angle corner;
[0022] FIG. 7 is a partial perspective view showing the right angled toeboards and the upright support standard;
[0023] FIG. 8 is a view of a corner connection similar to FIG. 7 ;
[0024] FIG. 9 is a partial perspective view of the toeboard system with an additional safety gate as part of the scaffolding system;
[0025] FIG. 10 is a perspective view of a safety gate and a connected swinging toeboard; and
[0026] FIG. 11 is a perspective view of a swinging portion of the safety gates;
[0027] FIG. 12 a is a perspective view of an “L” shaped securing bracket; and
[0028] FIG. 12 b is a perspective view of an alternate securing bracket.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Scaffolding systems such as the system 2 shown in FIG. 1 , are used for the construction, repair and maintenance of buildings, bridges or other structures which are accessed by means of a raised work surface 10 .
[0030] The specific scaffolding system 2 shown in the Figures, is formed by connecting a series of standards 4 to form the upright members of the scaffolding system and these standards are connected one to another by a series of horizontal ledgers 6 . Diagonal bracing can also be provided. The raised work surface 10 is defined by the manufactured planks 12 which extend to and are supported by the ledgers 6 . The standards 4 include a series of rosettes 8 which are at fixed positions on the standards 4 for connecting with the ledgers 6 . As shown in FIG. 7 , the ledger 6 has a connector 9 which is positioned either side of the rosette 8 and a wedge connector 11 passes through one of the series of ports 15 in the rosette to secure the ledger 6 to the standard 4. Each ledger is connected to a rosette in a similar manner. The wedge 11 is spaced slightly outwardly of the standard 4 and the toeboards will advantageously make use of the gap between the wedge 11 and the standard 4 for securing of the toeboard about the perimeter of the work surface 10 .
[0031] Details of the toeboard are shown in FIG. 2 . The toeboard 20 has a connector 28 at one end thereof and an oppositely orientated connector 30 at the opposite end of the toeboard. The elongate body of the toeboard is defined by the upright portion 54 in combination with the foot portion 56 and the reinforcing channel 58 . The elongate body has a generally L-shaped cross section and is preferably made of metal. Each of the connectors 28 and 30 are secured to the upright portion 54 using rivets or other fasteners 50 .
[0032] The connectors 28 and 30 are the same connector but have opposite orientations. Each connector has a connecting plate 34 used to secure the connector to the upright portion 54 and an outer finger 36 and an inner finger 38 positioned beyond the upright portion 54 . The outer finger 36 is slightly offset from the plate by means of the bend 44 as shown in FIG. 2 . The outer finger 36 and the inner finger 38 have a slot 40 therebetween which is used to secur two toeboards in an end to end manner as shown in FIG. 1 . Inner finger 38 cooperates with the connecting plate 34 to define a further connecting slot 42 . This slot is used for connecting toeboards in a perpendicular manner or in an intersecting manner.
[0033] As shown in FIG. 1 , toeboard 20 is of a longer length than the toeboard 22 . The scaffolding system 2 has one dimension for positioning standards 4 and in a direction perpendicular the first direction, the standards are positioned at a different spacing. Scaffolding systems of the type shown in FIG. 1 have standard modular dimensions. Two different spacings are used and two different sized toeboards are used. With the toeboard as shown in FIG. 2 , the only difference between the long toeboards and the short toeboards is the length of the elongate body portion. The connectors will be the same. The toeboards will be of a length such that the space between the two securing slots 40 of a toeboard are such that they will align with the center of the upright standards. Typically, the modular spacing in length and width are multiples. For example, the width could be one third or one half of the length of the module.
[0034] As shown in FIG. 5 , the outer slots 40 are used to connect the two toeboards such that these toeboards connect generally on the center of the standard 4. The connecting plates due to the offset and due to the opposite orientation of the connecting plates interconnect and form an overlapping non pivotting finger type connection. In addition the plates are trapped between the standard 4 and the wedge 11 of the ledger 6 . With this arrangement, the toeboards are connected one to the other and the elongate body portions of the connected toeboards are positioned either side of the standard 4. Each foot of the toeboard overlaps with the working surface 10 and is partially supported on this surface. Any gap between the work plank 12 and the ledger which would be parallel to this plank, is covered by means of the foot portion 56 .
[0035] FIG. 6 shows the connection of the toeboards at an end of the work surface 10 . As can be appreciated from a review of FIG. 6 , the connection point of the toeboard is at an inner edge of the standard 4 and is not on a centerline as would be the case with respect to FIG. 5 . For this inside connection, the inner fingers 38 are used and the connecting slot 42 . With this arrangement, the outer finger 36 of each of the connecting brackets extends across the face of the standard 4 and is trapped between a wedge 11 and the standard 4 as shown in FIG. 7 .
[0036] FIG. 8 also shows how on one side of the standard 4 wedge 11 a traps the connecting bracket between the wedge and the standard 4 and the other connecting plate is trapped between wedge 11 b and the standard 4. Thus, the system for mechanically securing the ledgers 6 to the rosettes is also used to retain the connecting plates of the toeboards adjacent the standard.
[0037] Although the system has been described with respect to the two securing slots with the outer slots used for end to end connection and the inner slots used for an angled connection, there may be circumstances where the spacing between the standard is slightly off or there may be slight damage to one of the toeboards or combination thereof such that the connection is made by means of the other slot. In all cases, the overall length of the toeboards and connector for their respective insertion between spacing of the standards is such that the toeboards are of a slightly greater length to effect overlapping with these standards.
[0038] FIGS. 9, 10 and 11 show a specialized standard 4a and a safety gate 80 . The standard 4a includes a lower securing connector 70 for fastening of the standard to the ledger 6 . As can be appreciated, the standard 4A is to the outside of the connected ledger 6 and the ledger 6 directly thereabove. The standard 4a includes a saddle type bracket 82 which sits on the upper ledger 6 . Immediately above the saddle bracket 82 , the special ledger 4 a has a bend 84 which merges with a further upright portion 86 . The bend 84 brings upright portion 86 in line with the other standards. The safety bracket 80 includes standard wedge connectors 88 for securing of the safety gate to the rosettes 8 .
[0039] The opposite side of the safety gate 80 is connected to the corner standard 4 using the rosettes 8 thereof and connectors 88 of the safety gate. The toeboard 22 is connected in a slot 83 of the saddle bracket 82 . This slot 83 will either take the bottom edge of the connector or the innermost finger of the connector. The safety gate 80 has two L-shaped brackets 90 extending between the connectors 88 with each bracket 90 having a fixed stopped plate 92 secured thereto. The safety gate is defined by two swinging portions 94 and 96 . Each of these swinging portions swing inwardly and cannot swing outwardly as they are stopped by the plates 92 . The gates have a spring loaded pivot arrangement with the brackets 90 such that they are biased to the closed position as shown. The swing gate is also reversible by rotating the gate 180 degrees to allow opening in the opposite direction. This ability for opposite orientation is required as the work platform could be to the opposite side.
[0040] Extending downwardly from each of the swinging portions 94 and 96 are two tubular members 98 which support a swinging toeboard 104 . The height of the swinging toeboards 104 is determined by the extent that members 98 extend downwardly from the respective swinging portions 94 and 96 . Each of the downwardly extending members 98 have a series of holes 120 cooperating with ports 122 in tube slots 108 of each swinging portion 94 and 96 such that these members can be secured close to the working surface 10 but slightly thereabove to allow inward swinging movement. With the gate in the closed position, the toeboards 104 form a perimeter block below the safety gate.
[0041] FIG. 10 shows a pin and latch member 126 which passes through ports 122 in square uprights 128 of each swinging portion and through an appropriate hole 120 in tubular members 98 . The lower portion of the square tubes 128 are shown in FIG. 10 as being transparent, such that the adjustable securement of tube members 98 is more easily understood. In this way, the toeboard 104 is easily adjusted in height and is free to swing over the working surface 10 . Ports 122 are also provided on the upper ends of square uprights 128 as each swing portion is reversible in a vertical plane. The connectors 88 can also be rotated 180 degrees such that the captured latch wedge 130 will engage a rosette by being driven downwardly.
[0042] The hinge of each swinging portion 94 or 96 is defined by the tube member 132 and 134 fixed to the stop plate 92 and an axle rod 136 captured at either end by the swinging portion. This axle rod 136 passes through the tube members 132 and 134 and forms a hinge therewith. A helical spring 138 is sleeved on the axle rod 136 in the gap between the tube members 132 and 134 . End 140 of the helical spring is secured to the swinging portion 96 and spring end 142 is secured to the stop plate 92 .
[0043] FIGS. 12 a and 12 b show two arrangements for fastening of the swinging portions 94 or 96 to an upright of a scaffolding system. FIG. 12 a shows the ‘L’ shaped bracket 90 securable to the stop plate 92 of FIG. 11 using the bolt and net fasteners 150 . This bracket includes the rotatable captured wedge connectors 88 . FIG. 12 b shows a clamp connector 160 having two clamp members 162 of a traditional design mechanically secured to the plate extension 164 . Plate extension 164 has two ports 166 for receiving bolt and nut fasteners 150 . Each arrangement of FIGS. 12 a and 12 b secure to the stop plate 92 shown in FIG. 11 .
[0044] Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims. | A toeboard for a raised working platform advantageously cooperates with known construction systems to simplify securement and allow efficient setup. Each toeboard has connectors at either end of an elongate body member. Each connector has two fingers extending in a manner to intersect with a longitudinal axis of the elongate member. The connectors at opposite ends of the elongate body have an opposite orientation of said fingers where the fingers of one connector are 180 degrees out of alignment with the fingers of the other connector. This arrangement allows toeboards to connect easily in an end to end manner as well as in a perpendicular manner. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a fabric composite of three or more layers of structural fibers, wherein at least one of the layers is biased. The fabric is further characterized in that the layers are comprised of parallel fibers but there are no "holding" or "secondary" stitches in the horizontal direction, the entire composite being maintained by stitching in the vertical direction only. The invention also relates to the process and apparatus for making this fabric composite.
2. Background of the Prior Art
Structural fabrics have a wide variety of industrial applications wherever high strength is required, but weight must be kept to a minimum. In particular, the aerospace, marine and automobile industries frequently employ structural fabric composites comprised of many layers of structural fibers saturated with a cross-linked and hardened resin as high strength materials. Structural fibers are intended to refer generally to fibers referred to as fiberglass, E-glass, S-glass, boron fibers, carbon fibers and related fibers, which can be characterized as having extremely high Young's modulus. However, fibers of lower modulus but high strength application, such as nylon, may be structural. In general, structural fibers should be distinguished from common household and apparel fabric fibers, where strength is not critical. The layers of these composites are usually biased in directions to maximize the strength of the overall products, frequently in the directions of strongest applied tension or strain.
By biased, it is intended to mean that the structural fibers of any particular layer are substantially oriented at an angle of other than 0° or 90° to the major axes as the fabric composite (i.e., longitudinal and lateral centerlines).
It has long been known that woven fibers are generally inappropriate for extremely high strength requirements, as the fibers themselves, and the stress applied, tend to create weak or break points where the fibers overlap in the weaving, destroying the integrity of the product and rendering the fabric relatively useless.
Accordingly, in order to achieve composites of three or more layers, which are not interwoven, it has been necessary to produce individual layers of parallel structural fibers maintained in that parallel array by "holding" or secondary fibers or layers held in place by resin, transport those individual layers to the molding site, and then "lay-up" the layers, manually rotating succeeding layers in the desired direction or bias, and thereafter saturating the produced "lay-up" with the resin and appropriately thereafter molding the layers into a single composite.
The above-described process has a number of obvious drawbacks. One is the necessity to produce individual, or "uni" layers at the textile manufacturing plant, and thereafter go through the ardous hand labor task of correctly orienting each individual layer at the molding site, which may be many miles distant from the original textile plant.
Additionally, it has been discovered that these type of "lay-up" composites or laminates, when subjected to constant high stress, for example, as in an airplane wing surface or edge, have a tendency to develop cracks or gaps between the layers of fabric, where there is only the resin to hold the fabric together. Once a flaw does appear, it quickly spreads between the layers, rapidly producing complete failure of the composite. At the same time, these lay-ups exhibit extremely low resistance to shearing forces, applied across the laminate, as there is nothing but the resin to hold the layers in vertical array. Once again, a small flaw rapidly results in complete failure of the composite.
There are some methods known to produce non-woven fabrics of more than one layer, wherein at least one of the layers is biased at an angle other than 0 or 90°. One exemplary process is disclosed in Japanese Patent No. 45-33874, Oct. 30, 1970. A similar process is described in U.S. Pat. No. 2,890,579, to Mauersberger. Essentially, these processes consist of directing fibers through a rapidly oscillating weft lay down carriage, which oscillates between two advancing rows of hooks which engage the fibrous strands, and advances the strands, in parallel array into a stitching machine. However, at most, these processes can produce 2-layer fabrics and accordingly do not completely overcome the aforementioned disadvantages. Additionally, these processes are necessarily limited to forming fabrics wherein the orientation of the fibers of one layer is necessarily the opposite of the orientation of the fibers of the opposing layer, due to the oscillation of the lay down carriage.
An alternative method for making multi-layer composites of more than 2 layers, wherein the layers may each by biased individually, is disclosed in U.S. patent application Ser. No. 210,852 filed Nov. 26, 1980. That process consists of directing formed "uni" layers as described above through nip rollers oriented, with respect to a stitching machine, at an angle thereto, so that the fibers "slide" or slip across, resulting in a bias to the fabric equal to the angle of the nip rollers. However, this process has the drawback of including in the final composite the horizontal "holding" or "secondary" yarns which maintain the fibers in parallel array prior to and during biasing. These same secondary fibers add no strength to the final composite, as they exist only within the layers of parallel fibers, and are, in any event, generally not as strong as the structural fibers of the individual layers. At the same time, however, they add substantial weight to the overall laminate, sometimes making up as much to 5 to 7% of the total weight of the fabric. If it were possible to eliminate these horizontal threads, without jeopardizing the parallel array of the structural fibers in each layer, this weight reduction would have substantial impact, particularly on fuel efficiency, in light of the industries in which these composites are employed. Furthermore, this process includes 2 distinct discontinuous steps--1, formation of the uni-layer; 2, vertical stitching.
Accordingly, it is one object of this invention to provide a fabric comprised of three layers of parallel structural fibers, wherein at least one of the layers is biased, the layers being maintained by vertical stitching only, with no horizontal holding threads being present in the composite.
It is another object of this invention to provide a continuous process and apparatus whereby the abovedescribed fabric may be made.
It is yet another object of this invention to provide a fabric, and an apparatus and process for its manufacture, which may suitably be saturated with a resin and yet, upon curing, exhibit substantial resistance to inter-layer crack propagation and shear forces.
These and other objects that will become apparent may be better understood by reference to the detailed description provided below.
SUMMARY OF THE INVENTION
The fabric composite of this invention is comprised of at least three layers of parallel structural fibers, wherein the fibers of at least one layer are oriented at an acute angle to the longitudinal center line of the fabric, i.e., the layer is biased, the fibers being held in parallel array, and the layers being held in vertical array, solely by vertical stitching through the layers. This unitary fabric may be saturated with a resin, which may be subsequently cured, and exhibits substantial crack propagation resistance and interlaminar shear strength. The fabric further comprises such layers stitched to other materials in a stitch-bonded laminate, such as nonwoven mats, paper, etc.
This fabric may be formed using an apparatus which consists of two or more weft lay down carriage mechanisms each aligned with a vertical stitching machine. The lay down carriage mechanisms all lay athwart a means for advancing the fibers delivered therefrom into the stitching machine. At least one of the lay down carriages is oriented at an angle to the fiber advancing means and stitching machine, such that, when fibers are laid down in parallel array by each of the lay down carriages, the fibers from each are deposited on the fibers of the immediately previously laid down carriage mechanism and are advanced into the stitching machine, the fibers from the angled lay down carriages are parallel biased with respect to the major axes of the fabric. In the stitching machine, a vertical stitch is passed between the fibers of each layer through the layers, sufficient to maintain the layers in vertical array and the fibers within each layer in parallel array.
After stitching, the fabric may be stored on a take up roll or cut to a suitable length. When desired, the fabric may be saturated with resin, which is subsequently cured, producing the strong but lightweight composite of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are overhead views of the apparatus of this invention, the arrows indicating the direction of fiber/fabric advancement.
FIG. 3 is an exploded view of the fabric of this invention.
FIG. 4 is a close-up of the stitching employed in this invention.
FIGS. 5 and 6 are isolated representatives of the patterns of vertical stitching that may be practiced with this invention.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus, process and composite of this invention resides in the discovery that weft insertion lay-down carriages, or simply "lay down carriages", which are widely used in the art to produce a layer of parallel or crossing over fibers in the weft direction in a fabric which incorporates warp fibers and/or matting which are subsequently stitched together in the stitching machine to which the lay down carriage is attached, may be separated from that machine. Separated, they may be oriented or angled with respect to the face of the stitching machine such that the fibers are laid down in a parallel array, but at an angle equal to the angle of the lay down carriage, such that, when the fibers enter the stitching machine, they are oriented at an angle to the longitudinal center line of the fabric being formed, thus creating a biased layer.
Lay down carriages are widely used and recognized in the art, and no attempt to describe one in detail is made herein. However, a particularly preferred lay down carriage is fully disclosed in U.S. patent application Ser. No. 377,211, filed May 11, 1982, the entire content of which, including the drawings thereof, is incorporated herein by reference. Briefly stated, that lay down carriage is comprised of a frame through which the eventual weft fibers may be led and a "presser bar" apparatus mounted on the frame in a fashion allowing free rotation of the presser bar apparatus. The frame rapidly traverses the width of the stitching machine or weft carriage support, oscillating back and forth between the ends thereof, being driven by a drive train whose speed is synchronized with the speed of the machine. The presser bar apparatus slidably engages a cam mechanism which is mounted on the knitting machine or weft carriage support at a slight angle to the horizontal. The engagement is preferably off-center of the presser bar. As the frame and presser bar apparatus completes a traverse of the width of the knitting machine, the fibers being led through the lay down carriage are depressed by the lower end of the presser bar apparatus being forced downward because of the engagement with the cam.
At the point of maximum depression, the fibers are engaged by a means for advancing the fibers into the knitting machine, generally an endless belt of hooks or needles. The presser bar frame then shuttles to the other side of the knitting machine, where the same operation takes place. By carefully coordinating the speed of the lay down carriage with the knitting machine, and the means for advancing the fibers toward the stitching machine, substantially parallel rows of structural fibers can be laid down at high speed. These fibers are then united with any other layers being inputted to the stitching machine by the vertical stitching effected thereby. However, as noted, this is but one of a number of lay down carriage mechanisms, any of which would be suitable for use in the current invention.
Turning now to the drawings described above, FIG. 1 is an illustration of the apparatus of this invention in its simplest form. A stitching machine 100 is employed, which may be any conventional stitching or knitting machine, and is preferably a compound needle warp knitting machine.
Distant from the knitting machine is a first lay down carriage 102, which is aligned with the knitting machine and is parallel thereto. The fibers supplied by warp lay down carriage 102 will eventually become the bottom-most layer of the fabric to be stitched through in warp knitting machine 100. Situated between stitching machine 100 and lay down carriage 102 is a second lay down carriage 104, together with the associated framework 105. Carriage 104 is "aligned with" knitting machine 100 and first carriage 102, in that the ends 101 of carriage 104 are along the line formed by the ends 101, 103 of stitching machine 100 and lay down carriage 102. However, carriage 104 is oriented at an acute angle with respect to carriage 102 and stitching machine 100.
Passing along the ends of each of carriages 102 and 104 and into stitching machine 100 is a means for advancing fibers delivered by the lay down carriages into the stitching machine. In a preferred embodiment, as illustrated in FIG. 1, this advancing means is comprised of endless belts of hooks 106 and 108.
Of course, those of ordinary skill will recognize that, in order to maintain the alignment of carriage 104 with carriage 102 and knitting machine 100, but maintain the angled orientation thereof, it will be necessary for carriage 104 to have a traverse longer than that of 102. However, this can conveniently be provided for in interchangeable parts by mounting the framework of each of carriages 102 and 104 on extendable sleeves attached to the vertical posts of the framework. Thereby, the carriage traverses can be shortened or lengthened, as needed. Alternatively, carriages of predetermined length for the various desired angles can be built.
In operation of the apparatus of FIG. 1, weft fibers 110 from carriage 102 are laid down in parallel array and transferred to the advancing rows of hooks 106 and 108. As these fibers are carried toward stitching machine 100, they pass under carriage 104.
Carriage 104 lays down a series of parallel fibers 112 on top of the fibers 110 from carriage 102, however, these fibers 112, due to the orientation of carriage 104, are aligned at an angle or bias to the alignment of fibers 110 of the first layer. It will be recognized that the hooks of belts 106 and 108 must be of sufficient height to engage and retain at least two layers of fibers.
As the two layers of parallel fibers are advanced into the stitching machine 100, they are stitched together in a vertical direction. Generally, the number of needles used in this stitching will be determined by the requirements of the fabric application, however, this figure can range from one needle per every two inches up to about eighteen needles per inch. A preferred range is 2-12 needles per inch.
In conventional knitting machines, these needles will penetrate the fabric in a vertical direction a number of times per inch of length. Generally, each needle will penetrate about 4-12 times per inch.
As illustrated in FIG. 4, this stitching 114 binds all layers together in the vertical direction. Also as illustrated each stitch binds a plurality of fibers together in each layer, maintaining this parallel alignment.
The stitched-together unitary fabric exiting stitching machine 100 may now be stored on a take-up roll (not illustrated) or cut to convenient lengths, etc. It will be recognized that this fabric is comprised of a first layer of parallel fibers, and a second layer of parallel fibers thereon, wherein the fibers of the second layer are aligned at an acute angle to the fibers of the first layer. Although it may be possible to form two-layer fabrics of this type through other, more difficult methods, it is believed that the method of this invention has never been so employed. Certainly, the three or more layer fabrics of this invention are not known, and are the unique product of this process. These fibers, and the fabric itself, are held together by vertical stitching 114. As illustrated in FIG. 5, this vertical stitch pattern may be achieved by stitching across the length of the fabric, advancing the fabric slightly and then stitching back across to the original starting point. (For the sake of clarity the fibers of the fabric have been omitted in FIGS. 5 and 6; to clearly show the pattern formed by stitching). Alternatively, stitching may be constant while the fabric is advanced, in which case a zigzag pattern of stitching will occur as illustrated in FIG. 6. Of course, myriad other stitch patterns will occur to those of skill in the art and are suitable for use in this invention.
The fibers 110 of the first layer and 112 of the second layer may be of any material sufficient to meet the end use of the fabric. Among preferred fibers are those formed from glass, Kevlar®, graphite, carbon, polyester and nylon. The fibers of one layer may be the same as or different from the fibers of another layer. Each layer may incorporate more than one type of fiber, depending on end application.
As the threads used for vertical stitching 114, most natural and virtually all manmade fibers may be used. Among preferred species there are glass, kevlar, graphite, polyester and nylon. A particularly preferred embodiment, of exceedingly high strength, is a multi-layer fabric wherein the fibers of each layer are comprised of graphite, and the vertical stitching is similarly comprised of graphite threads.
An alternative preferred embodiment of the apparatus of FIG. 1 is illustrated in FIG. 2, wherein an additional lay down carriage 116 has been provided beyond carriage 102, having an orientation opposite from that of carriage 104 for providing a third layer of fibers 117, such that a three-layer fabric, comprised of two biased layers sandwiching a center, unbiased layer may be formed. The operation of the apparatus of FIG. 2 is identical to that of FIG. 1, and similar materials may be employed. It will be recognized that the number of lay-down carriages employed, and the number of layers of fibers provided, will be limited only by the space available for the apparatus, the length of the means for advancing the fibers into the stitching machine and the capacity of the stitching machine to "stitch through" in a vertical direction, the increasing number of layers. Of these three limiting factors, the only one not easily overcome is the capability of the stitching machine to stitch through only so many layers. Frequently, composites of up to 54 layers, wherein the top and bottom 27 layers are mirror images, are necessary. Accordingly, the stitching machine should have the necessary stitch through capacity.
A typical fabric produced by the apparatus of FIG. 2 is illustrated in FIG. 3. This fabric consists of a first layer of biased fibers 118. These are the fibers laid down by carriage 104.
Directly underneath those fibers is a layer of parallel, unbiased fibers 120, which is comprised of the fibers laid down by carriage 102.
Underneath the layer of parallel fibers 120 is a third layer of parallel, biased fibers 122, which are biased at an angle which is the negative of the bias angle of fibers 118.
Of course, the angle of bias of fibers 118 and 122 can be any angle, and is determined by the angle of orientation of their respective lay down carriages. However, in a particularly preferred embodiment, the angle of orientation of one of the outer sides is +45°, the angle of orientation of the remaining outer side is -45°. An alternative preferred embodiment, particularly for tubular elements is one wherein the outer layers are biased at plus and minus one angle of 55°-60°. However, additional applications will occur to those with skill in the requiring different orientations. Moreover, it must be stressed that, particularly in fabrics of three or more layers, randomly selected adjacent layers need not be mirror images of each other, or even mirror images across a central, unbiased layer. In general, angles which are whole number multiples at 15° are preferred.
These layers are bound together in a fabric that may be transported to the desired molding spot, stored, or otherwise handled without destroying the layers and the orientation by virtue of vertical stitching 114. As noted above, the pattern of the stitching formed will depend on the nature of the operation of stitching machine 100, and as is illustrated, in FIG. 3, a "ratchet" type of stitching wherein the machine stitches across the length of the fabric, advances the fabric and stitches back may be employed.
An alternative embodiment of a fabric that may be made with the apparatus of FIG. 2 that has particularly valuable torsional resistance characteristics is one wherein the center, unbiased layer is comprised of fibers having approximately twice the weight of the fibers in the exterior layers. The biased, exterior layers are again orientated at angles of + and -45°.
It is to be critically observed that both the vertical relationship of the layers, and the parallality of the fibers within each layer is maintained solely by threads stitched in the vertical direction. There are no secondary or holding threads in the horizontal direction other than the structural fibers provided by the lay down carriages. In this respect, the fabric of this invention 4 is importantly different from the fabric addressed in U.S. patent application Ser. No. 279,649 filed July 2, 1981. This elimination of the horizontal threads, which add little or no strength to the fabric can save as much as 2 to 3 or even 5-7% of the overall weight of the fabric. A savings of this type, as applied to, e.g., airplanes, represents substantial fuel economy.
Upon completion of the stitched fabric, it may be transported to the molding location, wherein the fabric is saturated with a conventional resin. Although the fabric of this invention is compatible with most resins, and compatability will be further determined by the nature of the fiber employed, exemplary resins that may be used include epoxy resins, vinyl ester resins and polyester resins. The fabric is saturated with the resin which is subsequently cured. Upon curing, a strong, extremely lightweight composite is formed. The strength of the composite is due principally to the parallel structural fibers present in the layers of that composite, and its vertical stitching. Where fibers such as glass are employed, the resin may constitute 45-70% of the composite, on a weight basis. Where graphite is employed, this figure may be 25-50%.
Articles of proprietary interest comprised of multiple layers of parallel structural fibers, wherein the fibers of some of the layers are oriented at a bias, the layers being held together by vertical stitching, the entire fabric being saturated with a resin which is subsequently cured, have been subjected to stress testing. In this testing, a flaw is deliberately introduced into the sample tested, and stress is thereafter applied. In repeated tests, the multi-layer bias composites of this invention demonstrated excellent resistance to the crack propagation phenomena described above, i.e., resistance to the spreading of cracks between layers, in the resin, or layer separation. In fact, the performance of these articles has been superior to conventional metal articles, such as those fabricated from aluminum. The tests have established, simultaneously, that the composites of this invention exhibit excellent shear strength and shearing force resistance, such that the multi-layer aspect of the article does not present a liability as compared with conventional single layer articles constructed of metals and similar materials.
Although the invention has been disclosed, above, with regard to particular and preferred embodiments, these are advanced for illustrative purposes only, and are not intended to limit the scope of this invention. Specifically stitch distances, stitching amounts, fiber and thread materials and angles of orientation have been identified. variations on these and other parameters will occur to those of ordinary skill in the art, without the exercise of inventive faculty. These variations remain within the invention as claimed below. | Non-woven, multi-layer biased structural fabric is disclosed, which is comprised of at least three layers of parallel structural fibers, with no secondary yarns or fibers in the plane of the layers to hold said fibers in parallel relationship. Both the vertical relationship of the layers and the parallelity of the fibers within each layer is maintained by vertical stitching. The fabric may be made into a structural composite by saturation and subsequent curing with a curable, crosslinking resin. An apparatus and method for forming that fabric and composite is also disclosed, which is comprised of aligned weft lay down carriages arranged sequentially and further aligned with a stitching machine. A means for advancing the fibers from each weft lay down carriage into the stitching machine passes along the weft carriages. As each layer is laid down on top of the previous layer, it is engaged by the advancing means and so brought into the stitching machine, where the layers are vertically stitched through. At least one of the weft carriages is oriented with respect to the stitching machine, so that the fibers laid down thereby comprise a biased layer. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to the handling of thinned substrates mounted to rigid carriers for support. Specifically, the invention describes a cassette fixture that holds the film frames affixed to the thinned substrates with bonded support carriers. More specifically, the cassette fixture is designed in a manner and with materials of construction to allow immersion into liquid chemistry to facilitate debonding (removal) of the rigid carriers. In particular, the immersion liquid is of a specific chemistry, such that it may penetrate and effect removal of the adhesive that bonds the thinned substrate to the carrier but does not adversely affect the tape that is present on the film frame. The value and importance of a cassette fixture to support film frames designed to be immersed into a chemical liquid allows a batch process arrangement to occur for the removal of the rigid carriers from thin electronic devices such as semiconductors, microelectromechanical systems (MEMS), solar, displays, and other thin solid materials which must be supported during their manufacturing. Batch removal processes aid manufacturing by increasing throughput without significant burdens of additional equipment or cost.
BACKGROUND OF THE INVENTION
[0002] Electronic devices face continued pressure to design and produce their configurations in a further state of miniaturization, ergonomically pleasing shapes, and a reduced weight. To achieve these goals, substrates must be thinned to 100 um (microns) and less, making them extremely fragile and difficult to handle with existing equipment. To prevent breakage, cracking, or otherwise chipping and stressing these fragile substrates, it becomes necessary to always keep them temporarily supported by an external platform, being a rigid carrier or a membrane. During microelectronic manufacturing, the thinned substrates are temporarily supported by rigid carriers, as these provide the most secure and reliable media to conduct high-resolution processes. These carrier substrates may be composed of sapphire, quartz, certain glasses, or silicon and exist in thicknesses from 0.5-1.5 mm (millimeters=500-1,500 um). The device substrate is commonly affixed to the carrier by an adhesive that offers sufficient adhesive force and quality to withstand the manufacturing process, while also allowing the thinned substrate to be removed at the completion of work without damaging to its integrity.
[0003] Common tape adhesives exist which offer temporary support to the device substrate either alone or used as an interface to the carrier. These materials are commonly used for dicing operations, including high-volume photodegradative delamination practices (i.e. pick-and-place). However, tape adhesives are reserved only for the end of the process where dicing occurs. Most tape adhesives are not used in upstream microelectronic processes as their properties do not meet the needs for fabrication, including rigidity and uniformity, thermal and chemical resistance, and outgassing (weight loss). These shortcomings in adhesive tapes result in loss of adhesion, gas bubbles lodged in-between the device substrate and carrier, or produce unwanted gaseous by-products of degradation, which will adversely interact, with the processes of vacuum deposition or etching to produce inferior results.
[0004] In the example where thinned substrates include semiconductor wafers, the device wafer is commonly removed from a carrier support, cleaned, and mounted to a film frame containing tape adhesive, allowing the dicing process to proceed. Carrier removal is conducted with robotic assisted complex tooling. Tooling is designed according to the type of adhesive chosen. At the time of this invention, there are no less than six (6) adhesive materials on the market. The majority of these adhesives require a single wafer tooling configuration whereby the tool handles one wafer at a time.
[0005] Single wafer processes that use thermoplastic adhesives may utilize thermomechanical demounting as taught in U.S. Pat. No. 6,792,991 B2, Thallner, and 2007/0155129 (2007), Thallner. Device wafer separation is achieved by heating the mounted stack to a temperature above the melting point of the thermoplastic adhesive while simultaneously applying a shear force in a manner designed to separate the mounted surfaces. Cleaning with a selected organic solvent typically follows to ensure residual adhesive is cleaned from the substrate.
[0006] Another single-wafer tooling practice for removing carrier supports is described in U.S. Patent Application Nos. 2009/0017248 A1 (2009), Larson et al., 2009/0017323 A1 (2009), Webb et al., and in the International Application WO 2008/008931 A1 (2008), Webb et al. The adhesive described is a bilayer system composed of a photothermal conversion layer and a curable acrylate. The applications cite the use of a laser irradiation device which allows rapid demount of the external support carrier and is followed by a mechanical peeling practice of the curable acrylate from the thinned substrate.
[0007] Additional laser ablative carrier demounting practices are described in U.S. Pat. No. 6,036,809, Kelly, et.al, U.S. Pat. Nos. 7,867,876B2, and 7,932,614B2, Codding, et.al. Laser ablative tooling is non-trivial, in that it requires exacting focus of an optical device of a specific wavelength and to do this onto an interface between the work unit and the carrier substrate. The laser's focus does this while it or the substrate is being shifted in continual motion moving rapidly across the substrate. It is well known to those familiar with the art of coatings and planarization efforts that irregularities will exist in materials applied over the surface of the work unit. The adhesives used for these practices vary between rubber, silicone, polyimide, acrylic, and the like. The laser transmits through an optically clear carrier substrate and focuses onto the interfacial region where the adhesive meets the carrier, causing a significant and immediate rise in temperature to burning of that material to destroy its adhesion to the carrier. There is a micro area of impact that absorbs this temperature rise and fall during contact. The laser continues to move to the next location in an apparent smooth fashion until the entire surface of the substrate has been exposed and thereupon the release of the work unit is expected. The impacts of this process is realized later when irregularities are observed as micro-cracks, fissures, and residue that is burnt onto surfaces which cannot be removed. Laser ablative processes, although a common practice for debonding delicate substrates, remains a subject of much discussion when considered for high volume manufacturing.
[0008] These and other carrier debonding (removal) practices are discussed in U.S. Patent Application No. 2009/0218560A1, Flaim, et.al, where the author consolidates the practice of wafer and carrier separation into four approaches. These include 1) chemical, 2) photodecomposition (laser ablation), 3) thermomechanical, and 4) thermal decomposition. Although the author mentions drawbacks in each mechanism, they refrain from classifying them as single-wafer or batch processing according to their respective tooling configuration. Of these four processes, only chemical penetration is considered as a batch mechanism. In such processes, wafers may be populated into a cassette or holder and immersed into a chemical liquid for a designated time to allow penetration into the adhesive, emulsification, and removal to allow carrier debonding. As mentioned in U.S. Patent Application No. 2009/0218560A1, Flaim, et.al, chemical debonding may require hours to complete. At the time of this document writing, common throughput for single wafer processes may vary between 8-12 wafers per hour (wph). In the case of a conventional chemical debond, cassettes of between 12-25 wafers are used and may last up to four (4) hours. For a bath size of >100 liters as common for most fabrication facilities in Asia, this volume can accommodate up to 4 cassettes at a time, providing throughputs between 12-25 wph, exceeding that for single wafer processes (i.e. 12-25 wafers per cassette ×4 cassettes=48-100 wafers/4 hrs=12-25 wph). Without being bound to variations of the art of batch processing, this option is needed in fabrication to offer lower cost options for debonding carrier substrates. Therefore, it is a desire to consider batch wafer processing as a viable and cost effective practice for thin substrate debonding from carriers.
[0009] Batch debonding processes are described in U.S. Pat. No. 6,076,585, Klingbeil, et.al, and U.S. Pat. No. 6,491,083 B2, De, et.al, where a fixture holding thinned gallium arsenide (GaAs) wafers are removed from sapphire carriers using an immersion chemical practice. In both of these inventions, the fixture is designed to operate with the wafers held horizontally. The fixture has steps machined within it and requires a perforated carrier substrate that is slightly larger in diameter than the device wafer, such that during the debonding operation, the separation of the two substrates occurs by one item landing upon the fixture step while the wafer separates and falls to a lower level of support. Carrier substrates that are machined to be larger in diameter than the work unit and which have perforations can be costly. For example, enlarged perforated sapphire substrates are a common choice for GaAs work unit wafers, however, these can cost $1,000 or more for each piece. In the case of silicon substrates of diameters at 12″ or 18″, carrier wafers are chosen to be dummy type (i.e. same size, shape, and composition of the work unit without the electronic purity). Oversized perforated carriers are cost prohibitive for silicon processes as their cost can fall between factors of 10-100 ×that of conventional dummy sized wafers. It is a desire to avoid fixtures that require oversized perforated carriers and instead use fixtures that accept dummy wafers as carriers for thin wafer handling as a means to minimize process costs.
[0010] A batch demounting process is also described in U.S. Pat. Nos. 6,601,592 B1 and 6,752,160, Zhengming Chen, where two fixture cassettes work in conjunction with each other in a manner that allows separation of the device wafer from carrier substrates. The inventions describe the batch process separation between device wafer and carrier as conducted such that the top fixture cassette is populated with the mounted wafers whereby during liquid immersion, the chemistry penetrates the adhesive contact to release the two substrates. The top fixture cassette is constructed in a manner to allow only the device wafer pass downwards to the lower fixture cassette during gravity assisted separation, retaining the carrier substrate. The inventions require the sized of the carrier substrate and device wafer to be different, either the device wafer to exhibit a flat edge (i.e. wafer flat) or the carrier substrate to be oversized as compared to the device wafer. In either case, when the process commences and the fixture cassettes are arranged vertically, the oversize carrier is held back within the above fixture cassette while the device wafer travels from the top to the bottom cassette. Device wafers with a flat location were at one-time popular for reasons of reference location when handling and transferring from one process to another. The wafer flat is less desirable as it eliminates valuable device manufacturing realty on the wafer and reduces the number of devices built upon a substrate. Conversely, oversized carrier wafers are cost prohibitive as described earlier in this document. Further and most important, these inventions describe fixture design that requires the device wafer to be separated and released from the carrier substrate and move freely from one fixture cassette to another during liquid chemical immersion processing. It is commonly understood in the practice of thin wafer handling, that at anytime during this work, the device wafer should always be supported and never left to move freely. Consistent device wafer support would minimize irregular bending, vibration, and edge contact that would generate cracks, chipping, and other flaws within a thin wafer. It is a desire to avoid fixtures that require device wafer flat designs or oversized carriers and to avoid fixtures that promote a batch processing practice which allows the device wafer to move freely and subject itself to cracks, flaws, or other signs of breakage.
[0011] A unique carrier formation and process for separation from the device wafer is described in the International Publication No. WO 210/107851 A2 (International Application No. PCT/US210/027560), Moore, et al, where a carrier substrate is manufactured (formed) directly onto the device wafer in a manner sufficient to support grinding and backside processing and when complete, the materials used to form the carrier are designed to break down in a liquid chemistry cleaning process. Carrier supports which are removed by chemical breakdown during a special cleans process require a special fixture to allow the device wafer to remain in tact and without damage. These batch clean designs and would require a fixture that would support multiple device wafers during carrier removal. It is a desire to use fixture designs that promote a batch processing practice which allow the device wafer to be held secure while the carrier is allowed to be chemically broken down by a chemical fluid or otherwise be removed.
[0012] For these reasons and others not mentioned, it is a desire to perform batch process separation (debonding) of carriers from device wafers in a manner that accepts low-cost dummy wafers as carriers and maintains support of the device wafer throughout the process.
SUMMARY OF THE INVENTION
[0013] This invention is directed to a method and apparatus for a non-manual method of demounting semiconductor substrates from their support substrates simultaneously and efficiently without damaging the semiconductor substrates.
[0014] A preferred version of the process of separating one or more semiconductor substrates from one or more support substrates having features of the present invention comprises the following steps. The first step comprises providing an apparatus having: (a) a top cassette having a plurality of vertical slots, and one or more small bars for stopping the support substrate from exiting the top cassette; and (b) a bottom cassette having a plurality of vertical slots. The next step comprises vertically inserting the semiconductor substrate into the slot of the top cassette while the semiconductor substrate is coupled to the support substrate, wherein the surfaces of each semiconductor substrate is positioned approximately parallel to a force of gravity during the inserting step. Then, the supporting step comprises supporting the support substrate above the small bars in the top cassette. Next, the introducing step comprises introducing the apparatus to a dissolving agent to separate the semiconductor substrate from the support substrate, wherein the first surface of each semiconductor substrate is positioned approximately parallel to the force of gravity during the introducing step, and wherein the force of gravity moves the semiconductor substrate from the top cassette towards the bottom cassette. The next step comprises removing the top cassette from the apparatus. This is followed by the exposing step that comprises exposing the apparatus to a cleaning agent to clean the semiconductor substrate. Next step comprises drying the semiconductor substrate after the cleaning step.
[0015] In another embodiment of the present invention, the providing step further comprises a basket in which the bottom cassette and the top cassette are placed.
[0016] In yet another embodiment of the present invention, the providing step further comprises providing the bottom cassette having a first wall, a second wall substantially parallel to the first wall and coupled to the first wall, a large bar embedded inside the first wall; and a large bar embedded inside the second wall, such that a distance between the two bars is shorter than a greatest surface length of the semiconductor substrate.
[0017] In yet still another embodiment of the present invention, the providing step further comprises providing the bottom cassette having a tapered end such that the semiconductor substrate is stopped from exiting the bottom cassette through the tapered end.
[0018] In another embodiment of the present invention, the providing step further comprises providing the support substrate that is optically transparent.
[0019] In still embodiment of the present invention, the providing step further comprises providing the support substrate having one or more via holes.
[0020] In another embodiment of the present invention, the inserting step further comprises preventing the small bars from contacting the semiconductor substrate.
[0021] In yet another embodiment of the present invention, the moving step further comprises moving the semiconductor substrate towards the bottom cassette without removing the semiconductor substrate from the apparatus.
[0022] In yet still another embodiment of the present invention, the introducing step further comprises exposing the semiconductor substrate to a chemical to release the semiconductor substrate from the support substrate.
[0023] In still another embodiment of the present invention, the introducing step further comprises heating the semiconductor substrate to release the semiconductor substrate from the support substrate.
[0024] In another embodiment of the present invention, the introducing step further comprises subjecting the apparatus to an ultrasonic treatment to release the semiconductor substrate from the support substrate.
[0025] A preferred version of the apparatus of separating one or more semiconductor substrates from one or more support substrates having features of the present invention comprises a top cassette having one or more small bars for stopping the support substrate inside the top cassette, and a bottom cassette for receiving the semiconductor substrate.
[0026] In another embodiment of the present invention, the bottom cassette has one or more large bars such that the semiconductor substrate remains inside the bottom cassette after being received.
[0027] In yet another embodiment of the present invention, the bottom cassette has one or more tapered ends such that the semiconductor substrate remains inside the bottom cassette after being received.
[0028] In yet still another embodiment of the present invention, the apparatus further comprises a basket in which the bottom cassette and the top cassette are placed.
[0029] In still another embodiment of the present invention, the apparatus further comprises the top cassette and the bottom cassette having a first wall, a second wall being substantially parallel to the first wall and coupled to the first wall, a plurality of tabs extending from each wall towards the other wall, wherein the plurality of tabs have approximately equal lengths and are substantially coplanar with each other.
[0030] In another embodiment of the present invention, the apparatus further comprises: (a) the top cassette having one or more top pins extending from a bottom surface of the first wall, and one or more top pin apertures on a bottom surface of the second wall; (b) the bottom cassette having one or more bottom pins extending from a top surface of the second wall, and one or more bottom pin apertures on a top surface of the first wall. The top pin on the top cassette is inserted into the bottom pin aperture on the bottom cassette. The bottom pin on the bottom cassette is inserted into the top pin aperture on the top cassette. The plurality of tabs on the top cassette is substantially aligned with the plurality of tabs on the bottom cassette. The top cassette and the bottom cassette are attached in vertical alignment.
[0031] In yet another embodiment of the present invention, the apparatus further comprises the bottom cassette having the first wall and the second wall made of metal coated with tetrafluoroethylene polymer fiber.
[0032] In yet still another embodiment of the present invention, the small bar is made of a material containing tetrafluoroethylene polymer fiber.
[0033] In still another embodiment of the present invention, a first small bar is embedded within an aperture on the first wall and a second small bar is embedded within an aperture on the second wall, such that a distance between the two small bars is shorter than a greatest surface length of the supporting substrate but longer than a greatest surface length of the semiconductor substrate.
[0034] Another preferred version of the apparatus of separating one or more semiconductor substrates from one or more support substrates having features of the present invention comprises a top cassette and a bottom cassette. Each cassette has a first wall, a second wall being substantially parallel to the first wall and coupled to the first wall, a first interior surface on the first wall facing towards the second wall, a second interior surface on the second wall facing towards the first wall. Each cassette also has a plurality of tabs extending from the first interior surface towards the second interior surface, where the tabs have approximately equal lengths and are substantially coplanar with each other. It also has a plurality of tabs extending from the second interior surface towards the first interior surface, where the tabs have approximately equal lengths and are substantially coplanar with each other. The top cassette has one or more small bars made of a material containing tetrafluoroethylene polymer fiber along the interior surface of at least one wall for stopping the support substrate inside the top cassette from dropping into the bottom cassette. The bottom cassette for receiving the semiconductor substrate has a stopping means to hold the semiconductor substrate within said bottom cassette after being received. The top cassette is capable of receiving the semiconductor substrate, and the support substrate is coupled to the semiconductor substrate in a manner whereby a first surface of the semiconductor substrate is positioned substantially parallel to a force of gravity. The top cassette is attached to the bottom cassette, such that the plurality of tabs on the top cassette is substantially aligned with the plurality of tabs on the bottom cassette, such that the top cassette and the bottom cassette are attached in vertical alignment.
[0035] In another embodiment of the present invention, the apparatus further comprises the top cassette further comprising one or more top pins extending from a bottom surface of the first wall, and one or more top pin apertures on a bottom surface of the second wall. The apparatus also has the bottom cassette further comprising one or more bottom pins extending from a top surface of the second wall, and one or more bottom pin apertures on a top surface of the first wall. The top pin on the top cassette is inserted into the bottom pin aperture on the bottom cassette and the bottom pin on the bottom cassette is inserted into the top pin aperture on the top cassette, such that the top cassette and the bottom cassette are attached in vertical alignment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] FIG. 1 outlines a fixture that supports multiple device wafers during the removal of affixed carrier substrates by a batch design process whereby the fixture is allowed to be submerged into a liquid chemistry.
[0037] FIG. 2 illustrates the support mechanism for device wafers that are intended to be populated into the batch processing fixture identified in FIG. 1 . In FIG. 2 , the support mechanism is identified as a film frame, which comprises both the film frame ring 101 and tape 102 . The tape 102 has affixed to its tacky surface the bonded stack of the thinned device wafer 103 (not shown) and carrier 104 . Those skilled in the art and practitioners in the field recognize that the film frame 101 containing adhesive tape 102 is a specific tool designed to support thin device wafer 103 , commonly during dicing practices.
[0038] FIG. 3 illustrates a side view of film frame in FIG. 2 , showing the film frame ring 101 , tape 102 (not shown), affixed thinned device wafer 103 , and carrier 104 .
[0039] FIG. 4 illustrates the removal of the carrier 104 from the thinned device wafer 103 that remains bonded to the tacky adhesive tape 102 (not shown) held by the film frame ring 101 . The removal of carrier 104 from the device wafer 103 that is affixed to film frame 101 via adhesive tape 102 (not shown) occurs within the fixture of the present invention shown in FIG. 1 .
[0040] For simplicity and clarity of illustration, the drawings are not necessarily drawn to scale. Furthermore, the same reference numbers in different figures denote the same elements.
DETAILED DESCRIPTION OF THE DRAWINGS
[0041] The following describes in detail one embodiment of the invention and several variations of that embodiment. This discussion should not be construed, however, as limiting the invention to those particular embodiments. Practitioners skilled in the art will recognize numerous other possible embodiments as well as the ones specifically described. For a definition of the complete scope of the invention, the reader is directed to the appended claims.
[0042] This invention allows a highly efficient, high capacity batch demounting process for separating carrier support substrates from thinned semiconductor substrates in contrast to a single semiconductor substrate separation process (i.e. single wafer process). The invention may be manufactured of a range of materials that their choice is dependent upon the material's compatibility with the liquid chemical. For example, aluminum may be a common and inexpensive metal of choice for accepting film frame rings, however, aluminum is not compatible with many alkaline reagents without proper inhibition of metal corrosion or is not compatible with halogenated acids. Alternatively, stainless may be a better choice, however, this choice is more concerned with the type of halogenated acid and concentration. Teflon™ (a trade name for Du Pont's polytetrafluoroethylene resin) may be a better choice for compatibility, however, the weight of the cassette may become excessive, as Teflon™ has a density of 2.2 g/cm 3 . Other related materials to Teflon™ perfluoroalkoxy (PFA) and fluorinated ethylene propylene (FEP). Teflon™, PFA, and FEP are all related and are thermoplastics, however, they differ in their melting temperatures of >300 C, 300 C, and 260 C, respectively. PFA is considered superior to the others based upon it being used as a coating, such as on aluminum or stainless.
[0043] During the batch processing of carrier removal, it is expected that carriers will be removed by a variety of means. The method of removal will be determined by the bonding configuration and type of carrier chosen. In the case of carrier breakdown and dissolution, the tool will be one that can accept any breakdown products, solids, particles, or other materials used in the composite manufacture. Alternatively, where the carrier is simply removed by sliding away from the device wafer surface, it is desired for that unit to simply fall by gravity from the invention fixture, leaving behind the device wafer affixed to the film frame tape. Collections of the carrier substrates are a secondary consideration to this invention practice. The carrier substrates are thick ceramic species and are more robust in form as compared to the thinned device wafer. A common approach may be the collection to be conducted using baskets or other similar arrangement. The efficiency and smoothness in processing such carrier removal and the collection of such substrates is not a limiting factor of the batch process. It shall be assumed that this invention and the varying embodiments described are not restricted by the collection and recycling of the carrier substrates. One who is familiar with the art shall offer various means of conducting carrier collection by manual or automated means dependent upon the sophistication and cost of the tool that is desired.
[0044] Once the invention fixture is populated with film frame rings containing affixed device wafer stack containing carrier substrates, the fixture can then be sent to the liquid chemistry to be used for carrier removal. The liquid chemistry operates in a variety of means onto the carrier substrate from adhesion reduction at the bondline location between the carrier and device wafer or works to breakdown the carrier substrate. The invention fixture sidewalls hold the film frame rings in place and upon release of the adhesive that affixes the carrier to the device wafer, the carrier substrates to fall by gravity through the openings of the fixture and continue until they are completely free from the fixture invention. As mentioned, there may optionally be a basket, which collects the carrier substrates below to minimize their falling into the tank bottom.
[0045] For film frames which have affixed device wafer stacks containing carrier substrates with a combined thickness of more than twenty five mils=625 um (i.e. 1 mil=0.001 mili inch=25 um) the number of loaded frames per single invention fixture can vary depending upon the construction size of the fixture. General industry standard cassette practice for loading of substrates is approximately twenty-five (25), however, the size of the device wafer cassette may not be the same dimensions of the invention fixture that is desired to hold film frames. The thinned device wafers may be GaAs semiconductor substrates, Si semiconductor substrates, or ceramic substrates for RF and microwave. They may be physically thinned by a grinder, a lapper machine, or a polisher machine, and may as well be chemically thinned by an acid. The semiconductor substrate size can range from one inch to sixteen inches in diameter, and they can be of various shapes, including, but not limited to, circles and rectangles. The carrier substrates can be made of any material that is chemically resistant. Examples include semiconductor substrates, ceramic substrates, sapphire, and glass or quartz substrates. The carrier substrate size can also range from one inch to sixteen inches in diameter, and they can also be physically thinned by a grinder, lapper machine, polisher machine, or they can be thinned by dissolving chemicals. If there is backside alignment through the use of infrared light wave, the support substrates should be optically transparent to allow the infrared light wave to penetrate them. Sapphire and glass carrier substrates are commonly used as support substrates because they are chemically resistant and optically transparent.
[0046] The device wafer substrates are mounted onto the carrier substrates using an adhesive material such as a wax, a wax mixed with solvents or other chemicals, or a film that temporarily grips the device wafer to the carrier substrate. The adhesive for mounting the semiconductor substrates onto the support substrates can be of any material that can coat and bond these substrates and withstand the chemical and thermal demands of the process. Removing the carrier substrates from the device wafers may involve a variety of means already mentioned here with a suitable cleaning liquid to remove debris and adhesive material during the separation process.
[0047] FIG. 1 outlines the invention fixture that is shown to contain multiple film frame rings 101 with tape 102 identified in FIG. 2 . The invention fixture in FIG. 1 requires the insertion of frame rings 101 in FIG. 2 with affixed device wafer 103 and carrier substrate 104 shown in FIG. 3 . The device wafers 103 in FIG. 3 are coupled to one or more carrier substrates 104 in FIG. 3 and affixed onto tape 102 in FIG. 2 by contacting tape 102 in FIG. 2 to device wafer 103 in FIG. 3 . The tape 102 in FIG. 2 is mounted onto frames 101 in FIG. 2 and populated into the slots of the invention fixture shown in FIG. 1 . The device wafers can be made of any material, such as silicon, ceramic, glass, or quartz. Therefore, hereinafter it is understood that the term device wafer can include both semiconducting and non-semiconducting substrates. The device wafers 103 in FIG. 3 are coupled to the carrier substrates 104 in FIG. 3 by an adhesive such as a wax, a wax mixed with chemicals or solvent, or a film gripping material.
[0048] During the batch process, the invention fixture in FIG. 1 with inserted frame rings 101 in FIG. 2 with affixed device wafers 103 in FIG. 3 and carrier substrates 104 shown in FIG. 3 , the liquid chemical works upon the adhesive between device wafers 103 in FIG. 3 and carrier substrates 104 in FIG. 3 , until the adhesive is broken down and allows the carrier substrates 104 in FIG. 3 to begin to separate and fall by gravity away from the device wafers 103 in FIG. 4 allowing carrier substrates 104 shown in FIG. 4 to become fully removed or separated. The invention fixture shown in FIG. 1 allows one or more carrier substrates 104 in FIG. 4 to be separated from device wafers 103 shown in FIG. 4 . The invention fixture allows multiples of carrier substrates to be separated and removed in a simultaneous fashion. This practice is described as batch processing where a batch or multiple of the carrier substrates of interest can be acted upon simultaneously.
[0049] Various embodiments of this batch processing for carrier substrate removal from device wafers is presented here using an invention fixture desired to hold film frames with affixed device wafers. The invention fixture and its use in batch process carrier substrate removal is not limited by the embodiments presented and shall apply to variations not mentioned here. | The invention describes the ability to conduct multiple carrier substrate removal practices simultaneously. The fixture design is slotted in a manner to hold film frame rings and has the bottom region open without interference to the passage of the released carrier substrate. Slots in the fixture are arranged on two sides at top and bottom to support the film frame, however, the distance between the slots and the area of the open region is sufficient to allow the carrier substrate to travel downwards under gravity force, once it has been released from the device wafer. The method describes a batch process whereby a fixture design supports multiple film frames with taped adhered device wafers enable exposure to a chemical medium that either acts upon the interface between the device wafer and carrier substrate or digests the carrier substrate in a manner that results in removal. | 8 |
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