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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 10/685,638, filed Oct. 15, 2003, which application claims the benefit of U.S. Provisional Application No. 60/422,449, filed on Oct. 30, 2002, which applications are both herein incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates generally to a series of novel derivatives of [6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid amide, the synthesis of these compounds and their use in the treatment of inflammatory disease.
[0004] 2. Background Information
[0005] Research spanning the last decade has helped to elucidate the molecular events attending cell-cell interactions in the body, especially those events involved in the movement and activation of cells in the immune system. See generally, Springer, T. Nature, 1990, 346, 425-434. Cell surface proteins, and especially the Cellular Adhesion Molecules (“CAMs”) and “Leukointegrins”, including LFA-1, MAC-1 and gp150.95 (referred to in WHO nomenclature as CD18/CD11a, CD18/CD11b, and CD18/CD11c, respectively) have correspondingly been the subject of pharmaceutical research and development having as its goal the intervention in the processes of leukocyte extravasation to sites of injury and leukocyte movement to distinct targets. For example, it is presently believed that prior to the leukocyte extravasation, which is a mandatory component of the inflammatory response, activation of integrins constitutively expressed on leukocytes occurs and is followed by a tight ligand/receptor interaction between integrins (e.g., LFA-1) and one or several distinct intercellular adhesion molecules (ICAMs) designated ICAM-1, ICAM-2, ICAM-3 or ICAM-4 which are expressed on blood vessel endothelial cell surfaces and on other leukocytes. The interaction of the CAMs with the Leukointegrins is a vital step in the normal functioning of the immune system. Immune processes such as antigen presentation, T-cell mediated cytotoxicity and leukocyte extravasation all require cellular adhesion mediated by ICAMs interacting with the Leukointegrins. See generally Kishimoto, T. K.; Rothlein; R. R. Adv. Pharmacol. 1994, 25, 117-138 and Diamond, M.; Springer, T. Current Biology, 1994, 4, 506-532.
[0006] A group of individuals has been identified which lack the appropriate expression of Leukointegrins, a condition termed “Leukocyte Adhesion Deficiency” (Anderson, D. C.; et al., Fed. Proc. 1985, 44, 2671-2677 and Anderson, D. C.; et al., J. Infect. Dis. 1985, 152, 668-689). These individuals are unable to mount a normal inflammatory and/or immune response(s) due to an inability of their cells to adhere to cellular substrates. These data show that immune reactions are mitigated when lymphocytes are unable to adhere in a normal fashion due to the lack of functional adhesion molecules of the CD 18 family. By virtue of the fact that LAD patients who lack CD 18 cannot mount an inflammatory response, it is believed that antagonism of CD18, CD11/ICAM interactions will also inhibit an inflammatory response.
[0007] It has been demonstrated that the antagonism of the interaction between the CAMs and the Leukointegrins can be realized by agents directed against either component. Specifically, blocking of the CAMs, such as for example ICAM-1, or the Leukointegrins, such as for example LFA-1, by antibodies directed against either or both of these molecules effectively inhibits inflammatory responses. In vitro models of inflammation and immune response inhibited by antibodies to CAMs or Leukointegrins include antigen or mitogen-induced lymphocyte proliferation, homotypic aggregation of lymphocytes, T-cell mediated cytolysis and antigen-specific induced tolerance. The relevance of the in vitro studies are supported by in vivo studies with antibodies directed against ICAM-1 or LFA-1. For example, antibodies directed against LFA-1 can prevent thyroid graft rejection and prolong heart allograft survival in mice (Gorski, A.; Immunology Today, 1994, 15, 251-255). Of greater significance, antibodies directed against ICAM-1 have shown efficacy in vivo as anti-inflammatory agents in human diseases such as renal allograft rejection and rheumatoid arthritis (Rothlein, R. R.; Scharschmidt, L., in: Adhesion Molecules ; Wegner, C. D., Ed.; 1994, 1-38, Cosimi, C. B.; et al., J. Immunol. 1990, 144, 4604-4612 and Kavanaugh, A.; et al., Arthritis Rheum. 1994, 37, 992-1004) and antibodies directed against LFA-1 have demonstrated immunosuppressive effects in bone marrow transplantation and in the prevention of early rejection of renal allografts (Fischer, A.; et al., Lancet, 1989, 2, 1058-1060 and Le Mauff, B.; et al., Transplantation, 1991, 52, 291-295).
[0008] It has also been demonstrated that a recombinant soluble form of ICAM-1 can act as an inhibitor of the ICAM-1 interaction with LFA-1. Soluble ICAM-1 acts as a direct antagonist of CD18,CD11/ICAM-1 interactions on cells and shows inhibitory activity in in vitro models of immune response such as the human mixed lymphocyte response, cytotoxic T cell responses and T cell proliferation from diabetic patients in response to islet cells (Becker, J. C.; et al, J. Immunol. 1993, 151, 7224 and Roep, B. O.; et al., Lancet, 1994, 343, 1590).
[0009] Thus, the prior art has demonstrated that large protein molecules which antagonize the binding of the CAMs to the Leukointegrins have therapeutic potential in mitigating inflammatory and immunological responses often associated with the pathogenesis of many autoimmune or inflammatory diseases. However proteins have significant deficiencies as therapeutic agents, including the inability to be delivered orally and potential immunoreactivity which limits the utility of theses molecules for chronic administration. Furthermore, protein-based therapeutics are generally expensive to produce.
[0010] It follows that small molecules having the similar ability as large protein molecules to directly and selectively antagonize the binding of the CAMs to the Leukointegrins would make preferable therapeutic agents.
[0011] Several small molecules have been described in the literature that affect the interaction of CAMs and Leukointegrins. For example, U.S. Pat. No. 6,355,664 and the corresponding WO 98/39303 disclose a class of small molecule, having a hydantoin core, that are inhibitors of the interaction of LFA-1 and ICAM-1. WO 01/07440 A1 discloses compounds having this same activity that instead have a 6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl core. While the compounds that are described by WO 01/07440 A1 have a more potent inhibitory affect upon the interaction of CAMs and Leukointegrins than do the hydantoins of U.S. Pat. No. 6,355,664 and the corresponding WO9839303, they nevertheless are not ideal therapeutic agents because the rate at which they are metabolized is undesirably high.
[0012] Thus, the problem to be solved by the present invention is to find small molecules that have not only good inhibitory effect upon the interaction of CAMs and Leukointegrins but that also are metabolized at a rate that is not overly rapid.
BRIEF SUMMARY OF THE INVENTION
[0013] The invention comprises a class of derivatives of [6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid amide and methods for making the same. These compounds are useful for the treatment of inflammatory conditions in that they exhibit good inhibitory effect upon the interaction of CAMs and Leukointegrins and are metabolized fairly slowly. Thus, the invention further comprises the use of these compounds for the treatment of inflammatory conditions and pharmaceutical compositions comprising the same as active ingredients.
DETAILED DESCRIPTION OF THE INVENTION
[0014] In its broadest generic aspect, the invention comprises compounds of the formula I
wherein:
R 1 and R 2 are each, independently selected from the group consisting of:
(A) hydrogen, with the proviso that R 1 and R 2 are not both hydrogen atoms; (B) —R 100 , which is: a straight or branched alkyl of 1 to 7 carbon atoms or cycloalkyl of 3 to 6 carbon atoms, which alkyl or cycloalkyl group is mono- or poly substituted with moieties independently selected from the group consisting of:
(i) oxo, (ii) cyano, (iii) halogen, (iv) moieties of the formula —COOR 6 , wherein R 6 is a hydrogen atom, a straight or branched alkyl of 1 to 7 carbon atoms or cycloalkyl of 3 to 6 carbon atoms, (v) moieties of the formula —OR 7 , wherein R 7 is a hydrogen atom, a straight or branched alkyl group of 1 to 7 carbon atoms or an acyl group of the formula —COR 8 wherein R 8 is a straight or branched alkyl group of 1 to 7 carbon atoms, (vi) moieties of the formula —NR 9 R 10 , wherein R 9 and R 10 are each, independently selected from the group consisting of:
(a) hydrogen, (b) straight or branched alkyl of 1 to 7 carbon atoms, (c) acyl of the formula —COR 11 wherein R 11 is a straight or branched alkyl group of 1 to 7 carbon atoms, and (d) groups of the formula —COOR 12 wherein R 12 is a straight or branched alkyl group of 1 to 7 carbon atoms,
or wherein R 9 and R 10 constitute a bridge consisting of 3-5 methylene groups or 2-4 methylene groups and one oxygen atom, such that the groups R 9 and R 10 together with the nitrogen atom between them form a heterocyclic ring, (vii) saturated, heterocyclic groups, consisting of 3 to 5 methylene groups and one oxygen atom, wherein said heterocyclic groups are optionally mono- or disubstituted with moieties that are independently selected from the group consisting of:
(a) oxo and (b) straight or branched alkyl of 1 to 3 carbon atoms; and
(viii) aryl, selected from the class consisting of:
(a) furyl, (b) tetrazolyl and (c) thiophenyl;
(C) aryl, selected from the group consisting of:
(i) biphenyl, (ii) phenyl which is mono- or di-substituted with moieties independently selected from the group consisting of —NH 2 and N-morpholino, and (iii) quinolinyl; and
(D) unsaturated or partially saturated heterocyclic groups consisting of 2 to 3 carbon atoms, 1 to 2 nitrogen atoms, 0 to 1 sulfur atoms and 0 to 1 oxygen atoms wherein said heterocyclic group is optionally mono- or polysubstituted with one or more of the following moieties independently selected from the group consisting of:
(i) oxo and (ii) straight or branched alkyl of 1 to 7 carbon atoms;
or wherein R 1 and R 2 constitute a saturated 3 to 5 methylene group bridge which together with the nitrogen atom between them form a heterocyclic ring, wherein said heterocyclic ring is mono- or disubstituted with moieties independently selected from the group consisting of:
(A) —OH, (B) —COOH and (C) —CONH 2 ;
R 3 is:
(A) aryl selected from the group consisting of pyridyl and pyrimidyl, wherein one or more hydrogen atoms of said aryl group are optionally and independently substituted with moieties selected from the group consisting of:
(i) cyano, (ii) halogen and (iii) groups of the formula —NR 13 R 14 , wherein R 13 and R 14 are each, independently, hydrogen or straight or branched alkyl of 1 to 3 carbon atoms;
(B) trifluoromethoxy or, (C) cyano;
R 4 is straight or branched alkyl of 1 to 3 carbon atoms; R 5a is C 1 or CF 3 ; R 5b is C 1 or CF 3 ; X is an oxygen or a sulfur atom; and Y is an oxygen or a sulfur atom.
[0061] In a preferred generic aspect, the invention comprises compounds of the formula I, wherein:
R 1 and R 2 are each independently selected from the group consisting of:
(A) hydrogen with the proviso that R 1 and R 2 are not both hydrogen atoms; (B) —R 100 , which is: a straight or branched alkyl of 1 to 4 carbon atoms, which alkyl group is mono- or disubstituted with moieties independently selected from the group consisting of:
(i) oxo, (ii) OH, (iii) moieties of the formula —NR 9 R 10 , wherein R 9 and R 10 are each, independently selected from a group consisting of:
(a) hydrogen and (b) methyl,
(iv) tetrazole,
or wherein R 1 and R 2 constitute a saturated 5 methylene group bridge which together with the nitrogen atom between them form a heterocyclic ring, wherein said heterocyclic ring is monosubstituted with COOH; R 3 is:
(A) aryl selected from the group consisting of 3-pyridyl and 5-pyrimidyl wherein said aryl group is monosubstituted with:
(i) cyano or (ii) NH 2 ,
(B) trifluoromethoxy or (C) cyano;
R 4 is a methyl group; R 5a is Cl; R 5b is Cl; X is an oxygen atom and Y is an oxygen atom.
[0084] In a penultimately preferred generic aspect, the invention comprises compounds of the formula I wherein:
R 1 and R 2 are each, independently selected from the group consisting of:
(A) hydrogen with the proviso that R 1 and R 2 are not both hydrogen atoms, or (B) —R 100 , which is: straight or branched alkyl of 1 to 4 carbon atoms, which alkyl group is mono- or disubstituted with moieties independently selected from the group consisting of:
(i) oxo, (ii) OH and (iii) NH 2 ;
R 3 is trifluoromethoxy or cyano; R 4 is a methyl group; R 5a is Cl; R 5b is Cl; X is an oxygen atom; and Y is an oxygen atom.
[0098] It will be appreciated that the compounds of the formula I have at least two chiral centers. In an ultimately preferred generic aspect, the invention includes compounds of formula I with the absolute stereochemistry depicted below in formula I*.
[0099] Specifically preferred compounds of formula I of the invention are those selected from the group consisting of:
({(S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-acetic acid, ({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-acetic acid, (S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide, (S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-ethyl)-amide, (S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid carbamoylmethyl-amide, (S)-1-[(R)-5-[4-(2-Cyano-pyridin-3-yl)-benzyl]-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide, (S)-1-[(R)-5-[4-(2-Cyano-pyridin-3-yl)-benzyl]-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid carbamoylmethyl-amide, (S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (1H-tetrazol-5-ylmethyl)-amide, (S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-trifluoromethoxy-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide, and (S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-trifluoromethoxy-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid carbamoylmethyl-amide.
[0109] The invention also includes pharmaceutically acceptable salts of the compounds of the formula I.
General Synthetic Methods
[0110] Compounds of the invention may be prepared by the general methods described below. Typically, reaction progress may be monitored by thin layer chromatography (TLC) if desired. If desired, intermediates and products may be purified by chromatography on silica gel and/or recrystallization, and characterized by one or more of the following techniques: NMR, mass spectroscopy and melting point. Starting materials and reagents are either commercially available or may be prepared by one skilled in the art using methods described in the chemical literature.
[0111] Compounds of formula I may be prepared from intermediate II. The synthesis of intermediate II is reported by Wu et al., U.S. Non-provisional application Ser. No. 09/604,312 and Frutos et al., U.S. Pat. No. 6,441,183, both incorporated herein by reference.
[0112] Intermediate II may be prepared by the procedure illustrated in Scheme I.
[0113] As illustrated above, intermediate III is deprotonated with a suitable base such as lithium bis(trimethylsilyl)amide at about −20° C. to −30° C., and then alkylated with a substituted benzyl halide, preferably a benzyl bromide (IV) to produce V. Hydrolysis of the trifluoroacetamide group of V, for example by treatment with 40% aqueous benzyltrimethylammonium hydroxide in dioxane/50% NaOH, followed by treatment with acid, such as HCl, provides VI. Treatment of VI with thiocarbonyldiimidazole in the presence of a base such as 4-(N,N-dimethylamino)pyridine (DMAP) provides VII. Treatment of VII with aminoacetaldehyde dimethyacetal and t-butylhydroperoxide solution, followed by treatment of the intermediate acetal with an acid such as p-toluenesulfonic acid provides VIII. Iodination of VIII by treatment with an iodinating agent such as N-iodosuccinamide provides II.
[0114] The method used for preparation of intermediate III, treatment of the amide formed from N-Boc-D-alanine and 3,5-dichloroaniline with trifluoroacetic acid to remove the Boc-group, followed by treatment with pivalaldehyde, and acylation of the resulting imidazolodone with trifluoroacetic anhydride is described in U.S. Pat. No. 6,414,161, cited above, and in the chemical literature (N. Yee, Org Lett., 2000, 2, 2781).
[0115] The synthesis of compounds of formula I from intermediate II is illustrated in Scheme II.
[0116] As illustrated above, treatment of II with a Grignard reagent, such as cyclopentyl magnesium bromide or chloride, followed by treatment of the resulting magnesium salt with SO 2 and then N-chlorosuccinimide provides the sulfonyl chloride IX. Treatment of 1× with the desired amine (X) in the presence of a suitable base such as triethylamine, provides the desired product of formula (I). Intermediates X are either commercially available or readily prepared from commercially available starting materials by methods known in the art. The initial product of formula I may be further modified by methods known in the art to provide additional compounds of the invention. Several examples are provided in the Synthetic Examples section.
[0117] The desired R 3 on formula I compounds may be obtained by selection of the appropriately substituted intermediate IV in Scheme I. Alternately, intermediate VIII having R 3 being Br (VIIIa) may be converted to intermediates having R 3 being CN or an optionally substituted 5-pyrimidyl group as illustrated in Scheme III.
[0118] As illustrated above, the aryl bromide VIIIa is treated with a cyanide salt, preferably CuCN and heated in a suitable solvent such as DMF to provide the cyano-intermediate VIIb. Treatment of VIIIa with a pyrimidine boronate ester such as 5-(4,4,5,5,-tetramethyl-[1,3,2]dioxaborolan-2-yl)-pyrimidine in the presence of a palladium catalyst such as [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium(II).CH 2 Cl 2 (PdCl 2 (dppf).CH 2 Cl 2 ) and a base such as potassium carbonate in a suitable solvent (Suzuki reaction), for example dimethoxyethane, provides the pyrimidine intermediate VIIc. Intermediates VIIb and VIIc may then be converted to desired compounds of formula I by the procedures described in Schemes I and II. The Suzuki reaction to convert R 3 =Br to R 3 =an optionally substituted pyrimidine may also be carried out on a compound of formula I.
[0119] The invention is further described by the following synthetic examples.
SYNTHETIC EXAMPLES
Example 1
Synthesis of (R)-1-(3,5-dichloro-phenyl)-3-methyl-3-(4-trifluoromethoxy-benzyl)-1H-imidazo[1,2-a]imidazol-2-one
[0120]
[0121] Lithium bis(trimethylsilyl)amide (LiHMDS) (38.0 mL, 1 M in THF) was added slowly dropwise over 25 min to a solution of (2S,5R)-2-tert-butyl-3-(3,5-dichloro-phenyl)-5-methyl-1-(2,2,2-trifluoro-acetyl)-imidazolidin-4-one (10.0 g, 25.17 mmol) in 60 mL of THF at −20° C. After stirring at −20° C. for 20 min, a solution of 4-trifluoromethoxybenzyl bromide (6.04 mL, 37.76 mmol) in 30 mL of THF was added dropwise over 20 min. The mixture was stirred at −20° C. for 45 min, warmed to −5° C. over 1 h, and then poured over 50 mL of ice-cold saturated NH 4 Cl solution. The resulting mixture was extracted with two portions of EtOAc (200, 100 mL). The combined organic phases were washed with brine, dried over Na 2 SO 4 , filtered and concentrated. The crude product was triturated with hexanes to afford 12.5 g (87%) of (2R,5R)-2-tert-butyl-3-(3,5-dichloro-phenyl)-5-methyl-1-(2,2,2-trifluoro-acetyl)-5-(4-trifluoromethoxy-benzyl)-imidazolidin-4-one as an off-white solid.
[0122] To a solution of the above imidazolidinone (6.0 g, 10.5 mmol) in 40 mL of dioxane was added 40% aqueous benzyltrimethylammonium hydroxide (6.59 g, 15.75 mmol) at room temperature. As the mixture was warmed to 40° C., 50% aqueous sodium hydroxide (1.68 g, 21.0 mmol) was added slowly dropwise over 5 min. The mixture was stirred at 40° C. for 18 h, then a solution of 6.4 g of conc HCl in 3.3 mL of water was added slowly dropwise over 10 min. The mixture was warmed to 50° C. and stirred for an additional 5 h, then cooled to room temperature and concentrated. 50 mL of toluene was added to the residue, and the biphasic mixture was stirred vigorously as 50% aqueous sodium hydroxide (3.0 g) was added slowly dropwise (pH of the aqueous phase ≧10). The aqueous layer was extracted with two portions of toluene, and the combined organic phases were washed with water and brine, dried over Na 2 SO 4 , filtered and concentrated to afford 4.24 g of (R)-2-amino-N-(3,5-dichloro-phenyl)-2-methyl-3-(4-trifluoromethoxy-phenyl)-propionamide as a light brown oil.
[0123] To a solution of the above propionamide (4.24 g, 10.41 mmol) in 30 mL of THF was added thiocarbonyldiimidazole (2.81 g, 15.77 mmol) and DMAP (0.127 g, 1.04 mmol). The mixture was heated at reflux for 17 h, cooled to room temperature, and concentrated. The orange oily residue was dissolved in 50 mL of toluene and treated slowly dropwise with 20 mL of 5% aqueous HCl solution. After stirring the mixture for 10 min, the aqueous layer was separated and extracted with 30 mL of toluene. The combined organic phases were washed with four 20-mL portions of water and 20 mL of brine, dried over Na 2 SO 4 , filtered and concentrated to provide 4.48 g of (R)-3-(3,5-dichloro-phenyl)-5-methyl-2-thioxo-5-(4-trifluoromethoxy-benzyl)-imidazolidin-4-one as an orange foam.
[0124] To a solution of the above thiohydantoin (4.47 g, 9.95 mmol) and aminoacetaldehyde dimethylacetal (6.50 mL, 59.7 mmol) in 20 mL of MeOH was added 7.69 mL (59.7 mmol, 70% in water) of t-butyl hydroperoxide solution, dropwise over 25 min. During the addition and for about 1 h after, the internal temperature of the mixture was kept below 20° C. with an ice water bath. The mixture was stirred at room temperature for 86 h, and 25 mL of saturated NaHSO 3 solution was added slowly dropwise, maintaining the internal temperature below 20° C. with an ice water bath. The resulting cloudy white mixture was concentrated. To the residue was added EtOAc, and this mixture was concentrated again. The oily residue was partitioned between 30 mL of EtOAc and 20 mL of water, and the aqueous phase was separated and extracted with 20 mL of EtOAc. The combined organic layers were washed with 25 mL of water and brine, dried over Na 2 SO 4 , filtered and concentrated to give 5.21 g of (R)-3-(3,5-dichloro-phenyl)-2-[(E)-2,2-dimethoxy-ethylimino]-5-methyl-5-(4-trifluoromethoxy-benzyl)-imidazolidin-4-one as a thick yellow oil.
[0125] A solution of the above crude acetal (5.20 g, 9.95 mmol) in 30 mL of acetone was treated with p-toluenesulfonic acid (1.89 g, 9.96 mmol). The mixture was heated at reflux for 2 h, then cooled to room temperature and concentrated. The resulting dark orange oil was dissolved in 40 mL of EtOAc and treated carefully with a solution of 2.3 g of NaHCO 3 in 23 mL of water. After gas evolution ceased, the aqueous phase was separated and extracted with two portions of EtOAc. The combined organic layers were washed with saturated NaHCO 3 solution, two portions of water, and brine, dried over Na 2 SO 4 , filtered and concentrated. The oily residue was purified by silica gel chromatography to afford 1.58 g of the title compound as a thick colorless oil (456.2, M+1).
Example 2
Synthesis of (R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-trifluoromethoxy-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl chloride
[0126]
[0127] A solution of (R)-1-(3,5-dichloro-phenyl)-3-methyl-3-(4-trifluoromethoxy-benzyl)-1H-imidazo[1,2-a]imidazol-2-one (Example 1) (1.54 g, 3.38 mmol) in 30 mL of THF was treated with N-iodosuccinimide (0.846 g, 3.76 mmol) and pyridinium p-toluenesulfonate (0.086 g, 0.37 mmol). The mixture was stirred at room temperature for 17 h, then diluted with EtOAc and washed with 10% Na 2 S 2 O 3 solution and water. The combined aqueous layers were extracted with 10 mL of EtOAc. The combined organic phases were washed with 25 mL of brine, dried over Na 2 SO 4 , filtered and concentrated. The crude orange oil was purified by silica gel chromatography to provide 1.27 g (65%) of (R)-1-(3,5-dichloro-phenyl)-5-iodo-3-methyl-3-(4-trifluoromethoxy-benzyl)-1H-imidazo[1,2-a]imidazol-2-one as an off-white oil (582.0, M+1).
[0128] A solution of the above iodide (1.24 g, 2.13 mmol) in 16 mL of THF was cooled at −40° C. as cyclopentyl magnesium chloride (1.17 mL, 2 M in diethyl ether) was added dropwise over 10 min. After stirring at −40° C. for 1 h, SO 2 (g) was added by placing an inlet needle just above the surface of the reaction mixture for 1.5 min. The bright yellow mixture was warmed to −20° C. over 1 h and then stirred at room temperature for 1 h. N 2 (g) was bubbled through the mixture for 20 min followed by concentration and pumping under high vacuum for 12 h. The resulting yellow foam was dissolved in 16 mL of THF and cooled at −20° C. as a solution of N-chlorosuccinimide (0.341 g, 2.56 mmol) in 8 mL of THF was added dropwise over 5 min. After stirring at −20° C. for 1 h, the mixture was poured over ice and extracted with two portions of EtOAc. The combined organic layers were washed with 20 mL of ice-cold brine, dried over Na 2 SO 4 , filtered and concentrated. Purification by silica gel chromatography provided 0.975 g (83%) of the title compound as a thick oil (554.2, M+1).
Example 3
Synthesis of (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-trifluoromethoxy-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide
[0129]
[0130] To a suspension of (S)-2-(2-hydroxy-2-methyl-propylcarbamoyl)-pyrrolidine-1-carboxylic acid tert-butyl ester (see Example 11) (0.190 g, 0.663 mmol) in 1 mL of dioxane was added HCl (2.0 mL, 4 M in dioxane), and the resulting cloudy mixture was stirred at room temperature for 4 h. Concentration of the mixture was followed by addition of CH 2 Cl 2 , and this process was repeated twice. Final pumping under high vacuum for 12 h afforded the deprotected amine HCl salt as a pale yellow oil. This crude amine HCl salt was dissolved in 3 mL of CH 2 Cl 2 and treated with triethylamine (0.200 mL, 1.44 mmol). After stirring at room temperature for 10 min, a solution of (R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-trifluoromethoxy-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl chloride (Example 2) (0.199 g, 0.359 mmol) in 3 mL of CH 2 Cl 2 was added rapidly dropwise via cannula. The reaction mixture was stirred at room temperature for 3 h, then partitioned between 30 mL of CH 2 Cl 2 and 10 mL of water. The organic phase was washed with 10 mL of brine, dried over Na 2 SO 4 , filtered and concentrated. The crude product was purified by silica gel chromatography to give 0.228 g (90%) of the title compound as a white foam (704.0, M+1).
Example 4
Synthesis of (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-trifluoromethoxy-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-ethyl)-amide
[0131]
[0132] To a suspension of (S)-2-(2-hydroxy-ethylcarbamoyl)-pyrrolidine-1-carboxylic acid tert-butyl ester (0.200 g, 0.774 mmol) in 1 mL of dioxane was added HCl (2.0 mL, 4 M in dioxane), and the resulting cloudy mixture was stirred at room temperature for 4 h. Concentration of the mixture was followed by addition of CH 2 Cl 2 . This process was repeated twice and final pumping under high vacuum for 12 h afforded the deprotected amine HCl salt as a white oil. This crude amine HCl salt was dissolved in 3 mL of DMF and treated with triethylamine (0.212 μL, 1.52 mmol). After stirring at room temperature for 10 min, a solution of (R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-trifluoromethoxy-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl chloride (Example 2) (0.211 g, 0.380 mmol) in 4 mL of CH 2 Cl 2 was added rapidly dropwise via cannula. The reaction mixture was stirred at room temperature for 2 h. Following the addition of 75 mL of EtOAc, the organic layer was washed with three portions of water, then brine, dried over Na 2 SO 4 , filtered and concentrated. The crude product was purified by preparative TLC to afford 0.218 g (85%) of the title compound as a white foam (676.1, M+1).
[0133] The following compound was prepared by a procedure analogous to that described above in Example 4:
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-trifluoromethoxy-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid carbamoylmethyl-amide. (689.3, M+1)
[0134]
Example 5
Synthesis of (R)-2-({(S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-propionic acid
[0135]
(R)-3-(4-Bromobenzyl)-1-(3,5-dichlorophenyl)-3-methyl-imidazo[1,2-a]-imidazol-2-one (13.5 g, 29.9 mmol) was dissolved in anhydrous DMF (70 mL) and CuCN (3.22 g, 35.9 mmol) was added. The reaction mixture was heated to 140° C. under argon for 40 h. When the reaction was complete, the solvent was removed under reduced pressure and the residue was diluted with CH 2 Cl 2 . The organic solution was washed four times alternately with 5% aqueous pyridine then water. The organic layer was dried over Na 2 SO 4 and filtered through a diatomaceous earth pad. The filtrate was concentrated and purified by silica gel column chromatography using a mixture of CH 2 Cl 2 -hexane (10:1) as an eluent to afford 9.19 g of (R)-3-(4-cyanobenzyl)-1-(3,5-dichlorophenyl)-3-methyl-imidazo[1,2-a]-imidazol-2-one.
[0137] To a solution of the above product (5 g, 12.6 mmol) in dry CH 2 Cl 2 (50 mL) was added pyridinium p-toluenesulfonate (PPTS, 0.32 g, 1.26 mmol) and then N-iodosuccinimide (NIS, 3.39 g, 15.1 mmol) was added in small portions over a period of 30 min at −20° C. The reaction mixture was stirred at room temperature overnight covered with aluminum foil. The reaction mixture was washed with 10% aqueous sodium bisulfite then water. The organic phase was dried over Na 2 SO 4 and concentrated. The crude product was purified by silica gel column chromatography using a mixture of hexane-EtOAc (4:1) to afford 5.2 g of (R)-3-(4-cyanobenzyl)-1-(3,5-dichlorophenyl)-5-iodo-3-methyl-1-H-imidazo[1,2-a]-imidazol-2-one.
[0138] To a solution of above the above iodide (5.3 g, 10.1 mmol) in anhydrous THF (50 mL) at −40° C., cyclopentylmagnesium bromide (2M in ether, 6.1 mL, 12.2 mmol) was slowly added. The mixture was stirred at −40° C. for 30 min and SO 2 was bubbled into the solution for 1 min. The reaction mixture was stirred at −40° C. for 30 min, and then at room temperature for another 30 min. The solvent was removed under reduced pressure and the resulting residue was dried in vacuo for 2 h. The resulting magnesium sulfonate was dissolved in anhydrous THF and cooled down to −30° C. N-Chlorosuccinimide (NCS, 2.0 g, 15.2 mmol) was added to the solution and the reaction was stirred at −20° C. for 1 h. The reaction mixture was poured into ice water and extracted with EtOAc. The organic phase was dried over Na 2 SO 4 and concentrated. Silica gel column chromatography using a mixture of hexane-EtOAc (5:1) as an eluent afforded 3.0 g of sulfonyl chloride.
[0139] The above sulfonyl chloride (1.0 g, 2.02 mmol) was dissolved in CH 2 Cl 2 (10 mL) and L-proline t-butyl ester (1.03 g, 6.06 mmol) was added to the solution. The reaction mixture was stirred at room temperature for 1 h and diluted with CH 2 Cl 2 (5 mL). The organic solution was washed with 1% HCl, saturated NaHCO 3 and water. The organic phase was dried over Na 2 SO 4 and concentrated. Silica gel column chromatography using a mixture of hexane-EtOAc (1:1) as an eluent afforded 0.56 g of the desired product. This product was then treated with 50% trifluoroacetic acid (TFA) in CH 2 Cl 2 at room temperature for 2 h. The reaction mixture was diluted with CH 2 Cl 2 and washed with water. The organic layer was dried over Na 2 SO 4 and concentrated to afford 0.45 g of the desired carboxylic acid.
[0140] The above carboxylic acid (0.15 g, 0.26 mmol) was dissolved in a mixture of CH 2 Cl 2 -DMF (5 mL-0.1 mL). To this solution, were added D-alanine t-butyl ester (0.07 g, 0.39 mmol) and O-benzotriazole-1-yl-N,N,N′,N′-tetramethyluronium tetrafluoroborate (TBTU, 0.13 g, 0.39 mmol), followed by N,N-diisopropylethylamine (DIPEA, 0.11 mL, 0.65 mmol). The reaction mixture was stirred at room temperature for 2 h and diluted with CH 2 Cl 2 . The solution was washed with 1N HCl and saturated NaHCO 3 . The organic phase was then dried over Na 2 SO 4 and concentrated. The crude product was purified by preparative thin layer chromatography using EtOAc as an eluent to afford the desired product. The resulting compound was then treated with 50% TFA in CH 2 Cl 2 at room temperature for 2 h. The reaction mixture was diluted with CH 2 Cl 2 and washed with water. The organic layer was dried over Na 2 SO 4 and concentrated. The resulting compound was purified by preparative thin layer chromatography using CH 2 Cl 2 -MeOH (95:5) as an eluent to afford 0.119 g of the title compound as a white foam (M+1, 645.2).
[0141] The following compound was made by procedures analogous to those described in the above example:
(S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-acetic acid (631.2, M+1)
[0142]
Example 6
Synthesis of 1-{(S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-piperidine-4-carboxylic acid
[0143]
[0144] To a stirred solution of (S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (see Example 5) (1 eq) in anhydrous CH 2 Cl 2 and O-(7-azabenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HATU) (1.5 eq) was added DIPEA (3 eq) and the mixture was stirred at room temperature for 10 min under nitrogen. Methylisonipecotate (1.5 eq) was added to the reaction mixture and stirred for 2 h at room temperature under nitrogen. The material was purified by column chromatography over silica gel (gradient 10-25% EtOAc in hexane) to provide the methyl ester. The resulting ester (0.140 g, 0.2 mmol) was dissolved in hydrobromic acid in acetic acid (1.0 M) and the reaction was stirred for 4 h. The mixture was concentrated, toluene was added, and the mixture was concentrated again. The resulting residue was chromatographed over silica gel (10% MeOH in methylene chloride) to provide 12 mg of the title compound as a white solid (M+1, 685).
Example 7
(S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid ((S)-2-hydroxy-propyl)-amide
[0145]
[0146] To a stirred solution of (S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (see Example 5) (82 mg, 0.14 mmol) in anhydrous methylene chloride (1 mL) and HATU (82 mg, 0.21 mmol) was added DIPEA (73 μL, 0.42 mmol) and the mixture was stirred for 10 min at room temperature under nitrogen. (S)-1-Amino-propan-2-ol (0.21 mmol) was added and the mixture was stirred for 2 h at room temperature under nitrogen. The material was purified by column chromatography over silica gel to provide 62 mg of the title compound as a white solid (M+1, 631.2).
[0147] The following compounds were made by procedures analogous to those described in the above example:
(S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-1,1-dimethyl-ethyl)-amide
[0148]
(M+1, 645.1); (S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (furan-2-ylmethyl)-amide
[0149]
(M+1, 653.2);
Example 8
Synthesis of (S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (4-hydroxy-phenyl)-amide
[0151]
(S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (see Example 5) (122 mg, 0.2 mmol) was dissolved in methylene chloride (2 mL) under a nitrogen atmosphere. HATU (121 mg, 0.3 mmol) and DIPEA (111 μL, 0.64 mmol) were added. The t-butyldimethylsilyl-(TBDMS-) protected aniline (71 mg, 0.3 mmol) was added and the reaction was stirred overnight. The solvent was evaporated and the resulting residue chromatographed over silica gel (gradient EtOAc/hexanes) to provide a white solid. The white solid was dissolved in methylene chloride (2 mL) and a 1.0 M solution in THF of tetrabutylammonium fluoride (TBAF) (1 mL) was added and the reaction stirred for 3 h. Water and a few drops of 1 N HCl were added and the layers separated. The organic layer was dried over sodium sulfate, filtered, and evaporated. The resulting residue was chromatographed over silica gel (25% EtOAc in methylene chloride) to provide 83 mg of the title compound as a white solid (M+1, 665.2).
[0153] The following compound was made by procedures analogous to those described in the above example:
(S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (3-hydroxy-phenyl)-amide
[0154]
(M+1, 665).
Example 9
Synthesis of (S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid acetyl-amide
[0156]
[0157] To a stirred solution of (R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl chloride (see Example 5) (50 mg, 0.10 mmol) in anhydrous methylene chloride (1 mL) was added 4-dimethylaminopyridine (DMAP) (37 mg, 0.30 mmol). L-Proline amide hydrochloride (69 mg, 0.30 mmol) was added to the mixture and the reaction was stirred for 18 h at room temperature under nitrogen. The reaction was concentrated and the residue was purified by column chromatography over silica gel (gradient elution with 35-50% EtOAc in hexanes) to provide 141 mg of (S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid amide as a white solid.
[0158] (S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid amide (98 mg, 0.17 mmol) was dissolved in acetic anhydride (3 mL, 0.05 M). The reaction was heated to 100° C. for 18 h. The mixture was concentrated, toluene added, and the mixture concentrated again. The residue was chromatographed over silica with a solvent system of 10% MeOH in methylene chloride to provide 19 mg of the title compound as a white solid (M+1, 615).
Example 10
Synthesis of (S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid ((R)-5-oxo-tetrahydro-furan-2-ylmethyl)-amide
[0159]
[0160] (R)-(−)-Dihydro-5-(hydroxymethyl)-2(3H)-furanone (2.0 g, 0.017 mol) was dissolved in CHCl 3 (20 mL) and cooled to 0° C. Pyridine (4.77 g, 0.060 mol) was added to the solution and stirred for 15 min. To this reaction solution, was added 4-nitrobenzenesulfonyl chloride (Nos-Cl) (4.6 g, 0.021 mol) and the reaction mixture was stirred at 0° C. for another 3 h. The reaction mixture was then washed with 1N HCl, saturated NaHCO 3 and water. The organic phase was dried over Na 2 SO 4 and concentrated to afford the Nos-protected intermediate. This intermediate was characterized by 1 H-NMR and then used directly for the next reaction. It was dissolved in MeOH (20 mL) and NaN 3 (5.6 g, 0.086 mol) was added to the solution. This heterogeneous reaction mixture was heated to 62° C. and stirred overnight. TLC indicated the reaction was not complete so the reaction mixture was stirred at 50° C. for 3 more days. The reaction mixture was then concentrated and the resulting residue was diluted with CH 2 Cl 2 , then washed with water to remove any remaining NaN 3 . The organic phase was dried over Na 2 SO 4 and concentrated. The desired (R)-(−)-dihydro-5-(azidoymethyl)-2(3H)-furanone was isolated by silica gel column chromatography using CH 2 Cl 2 as an eluent.
[0161] The above intermediate (0.43 g) was dissolved in MeOH and Pd/C was added to the solution. The reaction mixture was saturated with H 2 and 4N HCl in dioxane was added to the mixture. The reaction mixture was stirred at room temperature for 2 h and then filtered through a diatomaceous earth pad. The filtrate was concentrated under reduced pressure to afford 0.4 g of a mixture of two products (furanone and hydroxy-ester) in hydrochloride salt form.
[0162] To a solution of (S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (see Example 5) (0.1 g, 0.174 mmol) in anhydrous DMF was added the above mixture of amines (0.030 g), followed by TBTU (0.084 g, 0.261 mmol) followed by DIPEA (0.075 mL, 0.435 mmol). The reaction mixture was stirred at room temperature for 30 min. The reaction mixture was then diluted with EtOAc and washed with water (×3), 1N HCl, and saturated NaHCO 3 . The organic phase was dried over Na 2 SO 4 and concentrated. The resulting residue was dissolved in CH 2 Cl 2 and trifluoroacetic acid (1 eq) was added to the solution. The reaction mixture was stirred at room temperature for 3 h and washed with saturated NaHCO 3 and water. The organic phase was dried over Na 2 SO 4 and concentrated. The resulting residue was purified by silica gel preparative thin layer chromatography using CH 2 Cl 2 -MeOH (95:5) as an eluent to afford 0.063 g of the title compound as a white foam (M+1, 671.1).
Example 11
Synthesis of (S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide
[0163]
[0164] A 500 mL 3-necked round bottom flask was fitted with an overhead stirrer, a thermoprobe, and a Claisen head topped with a metering addition funnel and N 2 inlet. Lithium aluminum hydride (8.4 g) was placed in a flask and the flask was cooled in an ice bath. THF (150 mL) was added to the flask under N 2 stream. Gas was evolved and the internal temperature rose to ˜50° C. The addition funnel was charged with 10 mL of acetone cyanohydrin in 50 mL of THF. After the internal temperature cooled to about 5° C., acetone cyanohydrin was added. The rate of addition was set to maintain the temperature below 10° C. The reaction mixture was allowed to gradually warm to room temperature and stir overnight. The reaction mixture was then cooled to about 5° C. and Na 2 SO 4 * 110H 2 O was added in portions to maintain the temperature at about 10° C. After gas evolution and temperature increase stopped, the remaining amount was added and stirred in the ice bath for 30 min. The ice bath was removed and stirring continued overnight. The reaction mixture was filtered and the salts were washed with 200 mL of warm THF (about 50° C.). The filtrate was combined and concentrated to afford 5.6 g of 2-hydroxy-2-methyl-propyl-1-amine.
[0165] A solution mixture of L-Boc-proline (1.5 g, 7 mmol), 2-hydroxy-2-methyl-propyl-1-amine (1.24 g, 13.9 mmol) and HOBt (0.96 g, 7.1 mmol) in anhydrous acetonitrile (35 mL) was cooled down to 0° C. and EDC (1.6 g, 8.4 mmol) was added to the reaction mixture in one portion. The reaction mixture was allowed to warm to room temperature and stirred overnight. The solvent was removed, diluted with CH 2 Cl 2 (30 mL) and washed with 5% citric acid (4×5 mL), saturated NaHCO 3 (4×5 mL) and brine. The organic layer was dried over Mg 2 SO 4 and concentrated to afford 1.5 g of the amide.
[0166] The Boc-protected alcohol (0.31 g, 1.082 mmol) from above was dissolved in CH 2 Cl 2 (5 mL) and 4N HCl in dioxane (5 mL) was added to the reaction solution. The reaction mixture was stirred at room temperature for 3 h and then concentrated under reduced pressure to afford 0.24 g of pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide hydrochloride.
[0167] Pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide hydrochloride (0.241 g, 1.082 mmol) was dissolved in CH 2 Cl 2 and triethylamine (0.206 mL, 1.513 mmol) was added to the solution. The reaction mixture was stirred at room temperature for 10 min. (R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl chloride (see Example 5) (0.3 g, 0.605 mmol) in CH 2 Cl 2 was added to the reaction mixture and stirred for 1 h. DMF (0.5 mL) was then added to the reaction mixture and stirred for another 30 min. The reaction solution was washed with 1N HCl and saturated NaHCO 3 . The organic phase was dried over Na 2 SO 4 and concentrated. The crude product was purified by silica gel preparative thin layer chromatography using CH 2 Cl 2 -MeOH (10:1) as an eluent to afford 0.28 g of the title compound (M+1, 644.98).
Example 12
Synthesis of (S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid carbamoylmethyl-amide
[0168]
[0169] (S)-1-[(R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (see Example 5) (0.25 g, 0.435 mmol) was dissolved in a mixture of CH 2 Cl 2 (10 mL) and DMF (0.2 mL). To this solution, were added glycinamide hydrochloride (0.072 g, 0.653 mmol), TBTU (0.21 g, 0.653 mmol), and DIPEA (0.19 mL, 1.087 mmol). The reaction mixture was stirred at room temperature for 1 h. The reaction mixture was diluted with CH 2 Cl 2 and washed with 1N HCl followed by saturated aq. NaHCO 3 . The organic phase was dried over Na 2 SO 4 and concentrated. The crude product was purified by silica gel preparative thin layer chromatography using CH 2 Cl 2 -MeOH (95:5) as an eluent to afford 0.155 g of the title compound as a white foam (M+1, 630).
Example 13
Synthesis of (S)-1-[(R)-5-(4-cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-ethyl)-amide
[0170]
[0171] A mixture of L-Boc-proline (2.5 g, 11.6 mmol), HOBt (1.6 g, 11.8 mol) and ethanolamine (0.85 g, 13.9 mmol) in CH 3 CN was cooled to 0° C. To this heterogeneous reaction mixture, was added EDC (2.67 g, 13.9 mmol) in one portion. The reaction mixture was allowed to warm to room temperature and stirred overnight. The solvent was then evaporated and the residue was treated with EtOAc (100 mL). This organic solution was washed with 5% citric acid. The aqueous layer was saturated with NaCl and extracted with EtOAc (4×50 mL). The organic phase was combined and washed with saturated NaHCO 3 (10 mL), brine and dried over Na 2 SO 4 . The solution was concentrated and re-dissolved in CH 2 Cl 2 (100 mL) and washed with saturated NaHCO 3 (10 mL) to remove residual HOBt. The organic phase was dried over Na 2 SO 4 and concentrated to afford 2.53 g of the ethanolamine coupled proline derivative as a white solid.
[0172] The above intermediate (2.53 g) was dissolved in CH 2 Cl 2 (30 mL) and 4N HCl in dioxane (7.3 mL) was added to the solution. The reaction solution was stirred at room temperature for 2 h. The reaction solution was bubbled with a strong stream of N 2 for 40 min and then concentrated in vacuo to afford the de-protected proline amine HCl salt as a solidified gummy residue.
[0173] The above amine HCl salt (0.93 g) was dissolved in anhydrous DMF (9 mL) by vigorously stirring at room temperature for 30 min. When all the amine salt was dissolved, triethylamine (1 mL) was added to the solution. (R)-5-(4-Cyano-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl chloride (see Example 5) (1.18 g) in anhydrous DMF (1 mL) was then added to the reaction mixture and stirred at room temperature for 30 min. The reaction mixture was then diluted with EtOAc and washed with water (×2), 1N HCl, saturated NaHCO 3 and brine. The organic phase was then dried over Na 2 SO 4 and concentrated. The residue was purified by silica gel column chromatography using CH 2 Cl 2 and MeOH (gradient 0-5% MeOH) as an eluent to afford 1.18 g of the title compound as a white foam (M+1, 617.2)
Example 14
Synthesis of (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid
[0174]
[0175] Cyclopentylmagnesium bromide (5.2 mL, 2 M solution in Et 2 O) was added to a solution of (R)-3-(4-bromo-benzyl)-1-(3,5-dichloro-phenyl)-5-iodo-3-methyl-1H-imidazo[1,2-a]imidazol-2-one (5.0 g) in Et 2 O (30 mL) at −40° C. and stirred for 15 min. SO 2 was bubbled through the reaction solution for 1 min and the reaction mixture was stirred for an additional 20 min then warmed to room temperature. The precipitate was isolated by filtration, washed with Et 2 O and the remainder of the solvent was removed in vacuo. The resultant salt was dissolved in THF (10 mL) and added dropwise to a solution of N-chlorosuccinimide (0.86 g) in THF (20 mL) at −25° C. The reaction was allowed to slowly warm to room temperature and stirred for 1 h. L-Proline-tert-butyl ester (2.2 g) was added to the reaction solution and stirred for 2 h. The volatiles were removed and the resultant residue was re-dissolved in EtOAc and washed with 1 N HCl, followed by saturated NaHCO 3 and H 2 O. The organic layers were combined, dried (Na 2 SO 4 ), filtered and concentrated. The resultant residue was purified by silica gel chromatography to afford (S)-1-[(R)-5-(4-bromo-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid tert-butyl ester.
[0176] To the above tert-butyl ester (2.0 g) in degassed dimethoxyethane (30 mL) was added 5-(4,4,5,5,-tetramethyl-[1,3,2]dioxaborolan-2-yl)-pyrimidine (1.2 g), K 2 CO 3 (1.61 g), and PdCl 2 (dppf)-CH 2 Cl 2 (0.24 g). The reaction was heated to 95° C. for 24 h then cooled to room temperature and the volatiles were removed. The residue was diluted in CH 2 Cl 2 and washed with H 2 O. The organic layers were combined, dried (Na 2 SO 4 ), filtered and concentrated. The resultant residue was purified by silica gel chromatography to afford (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid tert-butyl ester (1.5 g).
[0177] The above intermediate was dissolved in 50% trifluoroacetic acid-CH 2 Cl 2 (30 mL) at 0° C. and allowed to slowly warm to room temperature. The reaction was allowed to stir for 1 h then concentrated to afford 1.2 g of the title compound.
Example 15
Synthesis of (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-methoxy-ethyl)-amide
[0178]
[0179] TBTU (0.077 g), DIPEA (0.090 mL) and (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (Example 14) (0.10 g) were combined in 5% DMF-CH 2 Cl 2 (4.2 mL) at room temperature. 2-Methoxyethylamine (0.036 g) was then added and the reaction solution was stirred overnight. The reaction was diluted with CH 2 Cl 2 , poured into 1N HCl, and extracted with CH 2 Cl 2 . The organic layers were subsequently extracted with CH 2 Cl 2 from saturated aqueous NaHCO 3 followed by brine. The combined organic phase was dried (MgSO 4 ), filtered, and concentrated. The residue was purified by silica gel chromatography to afford 0.045 g of the title compound (684.2, M+1) as a foam.
[0180] Analogous procedures were employed to prepare the following compounds and utilized standard coupling reagents, such as TBTU, carbonyl diimidazole (CDI), or N-cyclohexylcarbodiimide; tertiary amines, such as Et 3 N or DIPEA; and either the amine or amine hydrochloride:
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-acetylamino-ethyl)-amide (711.2, M+1)
[0181]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-dimethylamino-ethyl)-amide (697.3, M+1)
[0182]
[0183] Acetic acid 2-({(S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-ethyl ester (712.2, M+1)
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide (698.2, M+1)
[0184]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-ethyl)-amide
[0185]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-morpholin-4-yl-ethyl)-amide (739.3, M+1)
[0186]
(R)-1-(3,5-Dichloro-phenyl)-5-[(S)-2-(3-hydroxy-piperidine-1-carbonyl)-pyrrolidine-1-sulfonyl]-3-methyl-3-(4-pyrimidin-5-yl-benzyl)-1H-imidazo[1,2-a]imidazol-2-one (710.3, M+1)
[0187]
[2-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-ethyl]-carbamic acid tert-butyl ester (769.3, M+1)
[0188]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-amino-ethyl)-amide (669.3, M+1)
[0189]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (3-hydroxy-propyl)-amide (684.3, M+1)
[0190]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (furan-2-ylmethyl)-amide (706.2, M+1)
[0191]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2,3-dihydroxy-propyl)-amide (700.2, M+1)
[0192]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-1-methyl-ethyl)-amide (684.2, M+1)
[0193]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid cyanomethyl-amide (665.2, M+1)
[0194]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid ((R)-2-hydroxy-1-methyl-ethyl)-amide (684.3, M+1)
[0195]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid ((S)-1-hydroxymethyl-3-methyl-butyl)-amide (726.2, M+1)
[0196]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid ((R)-1-hydroxymethyl-3-methyl-butyl)-amide (726.2, M+1)
[0197]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-1-hydroxymethyl-ethyl)-amide (700.2, M+1)
[0198]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-amino-phenyl)-amide (717.2, M+1)
[0199]
(S)-1′-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (3-amino-phenyl)-amide (717.2, M+1)
[0200]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (4-amino-phenyl)-amide (717.2, M+1)
[0201]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid biphenyl-4-ylamide (778.2, M+1)
[0202]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid quinolin-6-ylamide (753.2, M+1)
[0203]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (4-morpholin-4-yl-phenyl)-amide (787.2, M+1)
[0204]
(S)-1′-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (1-methyl-4-oxo-4,5-dihydro-1H-imidazol-2-yl)-amide (722.2, M+1)
[0205]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (1,3,5-trimethyl-1H-pyrazol-4-yl)-amide (734.3, M+1)
[0206]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (4-oxo-4,5-dihydro-thiazol-2-yl)-amide (725.2, M+1)
[0207]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid [1,3,4]thiadiazol-2-ylamide (710.1, M+1)
[0208]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-ethyl-2H-pyrazol-3-yl)-amide (720.3, M+1)
[0209]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-1,1-dimethyl-ethyl)-amide (698.1, M+1)
[0210]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid ((S)-2-hydroxy-propyl)-amide (684.0, M+1)
[0211]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid ((R)-2-hydroxy-propyl)-amide (684.0, M+1)
[0212]
(R)-1-(3,5-Dichloro-phenyl)-5-[(S)-2-((R)-3-hydroxy-pyrrolidine-1-carbonyl)-pyrrolidine-1-sulfonyl]-3-methyl-3-(4-pyrimidin-5-yl-benzyl)-1H-imidazo[1,2-a]imidazol-2-one (696.2, M+1)
[0213]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid methylcarbamoylmethyl-amide (697.2, M+1)
[0214]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid ((S)-1-methylcarbamoyl-ethyl)-amide (711.2, M+1)
[0215]
1-{(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-piperidine-4-carboxylic acid amide (737.3, M+1)
[0216]
(R)-1-(3,5-Dichloro-phenyl)-5-[(S)-2-((S)-3-hydroxy-pyrrolidine-1-carbonyl)-pyrrolidine-1-sulfonyl]-3-methyl-3-(4-pyrimidin-5-yl-benzyl)-1H-imidazo[1,2-a]imidazol-2-one (696.2, M+1)
[0217]
1-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-cyclopropanecarboxylic acid methyl ester (724.2, M+1)
[0218]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (4,5-dihydro-oxazol-2-yl)-amide (695.0, M+1)
[0219]
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (1H-tetrazol-5-ylmethyl)-amide (708.0, M+1)
[0220]
Example 16
Synthesis of (R)-2-({(S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-propionic acid
[0221]
[0222] TBTU (0.078 g) and (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (Example 14) (0.10 g) were combined in 7% DMF-CH 2 Cl 2 (3.2 mL) at room temperature. D-Alanine-tert-butyl ester hydrochloride (0.044 g), followed by DIPEA (0.07 mL), was then added and the reaction solution was stirred for 16 h. The reaction was diluted with CH 2 Cl 2 , poured into 1N HCl, and extracted with CH 2 Cl 2 . The organic layers were washed with saturated aqueous NaHCO 3 followed by H 2 O. The combined organic phase was dried (MgSO 4 ), filtered and concentrated. The resultant residue was re-dissolved in either 50% trifluoroacetic acid-CH 2 Cl 2 or 4N HCl-dioxane (5 mL) and stirred at room temperature for 2 h. Following aqueous workup the residue was purified by silica gel chromatography to afford the title compound (0.045 g) as a foam (698.9, M+1).
[0223] Analogous procedures were employed to prepare the following compounds and utilized standard coupling reagents, such as TBTU, CDI, or N-cyclohexylcarbodiimide, and tertiary amines, such as Et 3 N or DIPEA:
(S)-2-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-propionic acid (698.3, M+1)
[0224]
({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-acetic acid (683.9, M+1)
[0225]
({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-methyl-amino)-acetic acid (698.1, M+1)
[0226]
2-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-2-methyl-propionic acid (712.1, M+1)
[0227]
3-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-propionic acid (698.0, M+1)
[0228]
Example 17
Synthesis of 1-{(S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-piperidine-4-carboxylic acid
[0229]
[0230] TBTU (0.12 g), (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (Example 14) (0.15 g) and methyl isonipecotate (0.041 g), followed by DIPEA (0.10 mL), were combined in 1% DMF-CH 2 Cl 2 (10.1 mL) at room temperature and the solution was stirred for 1 h. The reaction was diluted with CH 2 Cl 2 , poured into 1N HCl, and extracted with CH 2 Cl 2 . The combined organic layers were washed with saturated aqueous NaHCO 3 followed by H 2 O. The organic phase was dried (Na 2 SO 4 ), filtered and concentrated. The resultant residue was re-dissolved in 30% HBr—AcOH and heated to 95° C. for 3 h. Following aqueous workup, the organic layer was dried (Na 2 SO 4 ), filtered, concentrated, and the residue was purified by silica gel chromatography to afford the title compound (0.099 g) (738.2, M+1).
[0231] Analogous procedures were employed to prepare the following compounds and utilized standard coupling reagents, such as TBTU, CDI, or N-cyclohexylcarbodiimide; tertiary amines, such as Et 3 N or DIPEA; and an amino acid as either the methyl or ethyl ester.
3-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-4,4,4-trifluoro-butyric acid (766.3, M+1)
[0232]
(S)-2-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-methyl-amino)-3-methyl-butyric acid (740.3, M+1)
[0233]
(1S,2S)-2-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-cyclohexanecarboxylic acid (752.2, M+1)
[0234]
3-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-butyric acid (712.1, M+1);
[0235]
3-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)—methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-2-methyl-propionic acid (712.0, M+1)
[0236]
1-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-cyclopropanecarboxylic acid (710.1, M+1)
[0237]
Example 18
Synthesis of (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-carbamoyl-ethyl)-amide.
[0238]
[0239] TBTU (0.15 g), (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (Example 14) (0.20 g), β-alanine methyl ester (0.067 g) and DIPEA (0.14 mL) were combined in 1% DMF-CH 2 Cl 2 (10.1 mL) at room temperature and the solution was stirred for 1 h. The reaction was diluted with CH 2 Cl 2 , poured into 1N HCl, and extracted with CH 2 Cl 2 . The organic layers were combined and washed with saturated aqueous NaHCO 3 followed by H 2 O. The combined organic phase was dried (Na 2 SO 4 ), filtered and concentrated. The resultant residue was re-dissolved in 2N NH 3 —CH 3 OH (10 mL) and heated to 40-60° C. for 48 h. The volatiles were removed and the residue was purified by silica gel chromatography to afford the title compound (0.021 g) as a foam (697.2, M+1).
Example 19
Synthesis of (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid ((R)-1-carbamoyl-ethyl)-amide
[0240]
[0241] N-Hydroxysuccinimide (0.035 g), followed by 1,3-dicyclohexylcarbodiimide (DCC, 0.064 g), were added to a solution of (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (Example 14) (0.16 g) in CH 2 Cl 2 (20 mL). The reaction was stirred at room temperature for 1 h, then was filtered through a pad of diatomaceous earth, concentrated and re-dissolved in 2N NH 3 —CH 3 OH (10 mL). The solution was stirred at room temperature for 1 h. The volatiles were then removed and the resultant residue was re-dissolved in CH 2 Cl 2 and washed with H 2 O. The combined organic layers were concentrated and the resultant residue was purified by silica gel chromatography to afford the title compound (0.128 g) as a foam (697.2, M+1).
[0242] The following compounds were prepared by procedures analogous to those described in the above example:
[0243] (S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid carbamoylmethyl-methyl-amide (697.3, M+1)
(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (1-carbamoyl-1-methyl-ethyl)-amide (711.2, M+1)
[0244]
Example 20
Synthesis of (S)-2-({(S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-3-hydroxy-propionic acid.
[0245]
[0246] TBTU (0.077 g), DIPEA (0.1 ml), (S)-1-[(R)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (Example 14) (0.075 g) and O-tert-butyl-L-serine tert-butyl ester (0.061 g) were combined in 1:4 DMF-CH 2 Cl 2 (1.2 mL) at room temperature and stirred for 2 h. The reaction was diluted with CH 2 Cl 2 and extracted with 1 N HCl, followed by saturated aqueous NaHCO 3 and brine. The combined organic layers were dried (MgSO 4 ), filtered and concentrated. The resultant residue was purified by silica gel chromatography to afford the desired ester (0.099 g).
[0247] The above ester (0.099 g) was dissolved in 50% trifluoroacetic acid-CH 2 Cl 2 (2 mL) and stirred for 24 h at room temperature. The volatiles were removed and the resultant residue was purified by silica gel chromatography to afford the title compound (0.064 g) as a foam (714.2, M+1).
[0248] The following compound was prepared by procedures analogous to those described for the above example:
(R)-2-({(S)-1-[(R)-7-(3,5-Dichloro-phenyl)-5-methyl-6-oxo-5-(4-pyrimidin-5-yl-benzyl)-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carbonyl}-amino)-3-hydroxy-propionic acid (714.6, M+1)
[0249]
Example 21
Synthesis of (S)-1-[(R)-5-[4-(4-amino-pyrimidin-5-yl)-benzyl]-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide:
[0250]
[0251] To a stirred solution of (R)-5-(4-bromo-benzyl)-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl chloride (see Example 14) (1.5 g) in a mixture of CH 2 Cl 2 (25 mL) and anhydrous DMF (5 mL) was added L-Pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide (0.84 g) followed by N,N-diisopropylethylamine (1.5 mL). The reaction was stirred at room temperature for 2 h then diluted with EtOAc, washed with 1N HCl, H 2 O and brine. The combined organic layers were dried (MgSO 4 ), filtered and concentrated. The residue was purified by silica gel chromatography to afford the desired product (1.58 g).
[0252] To a stirred solution of the above amide (1.2 g) in DMF (80 mL) was added bis(pinacolato)diboron (0.871 g) followed by potassium acetate (0.674 g). The mixture was degassed for 10 min, then PdCl 2 (dppf).CH 2 Cl 2 (0.140 g) was added and the reaction mixture was heated at 80° C. After 36 h, the mixture was cooled to room temperature, diluted with H 2 O, then extracted with EtOAc. The combined organic layers were washed with H 2 O and brine, then dried (MgSO 4 ), filtered and concentrated. The residue was purified by silica gel chromatography to afford the desired boronate (0.586 g).
[0253] The above boronate (0.2 g) was dissolved in DME:H 2 O (5 mL: 1 mL). 2-Amino-3-bromo-pyrimidine (0.070 g) and potassium carbonate (0.092 g) were added and the flask was flushed with N 2 . The mixture was stirred for 20 min, and then PdCl 2 (dppf).CH 2 Cl 2 (0.020 g) was added. The mixture was heated at 80° C. for 2 h, cooled to room temperature and diluted with EtOAc. The mixture was filtered, concentrated and the residue was purified by silica gel chromatography to afford the title compound (0.080 g) as a foam (713.3, M+1)
[0254] The following compounds were prepared by procedures analogous to those described for the above example:
(S)-1-{(R)-7-(3,5-Dichloro-phenyl)-5-[4-(2-fluoro-pyrimidin-5-yl)-benzyl]-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl}-pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide (716.3, M+1)
[0255]
(S)-1-[(R)-5-[4-(4-Amino-pyrimidin-5-yl)-benzyl]-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-ethyl)-amide (685.1, M+1)
[0256]
(S)-1-{(R)-7-(3,5-Dichloro-phenyl)-5-[4-(2-fluoro-pyrimidin-5-yl)-benzyl]-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl}-pyrrolidine-2-carboxylic acid (2-hydroxy-ethyl)-amide (688.0, M+1)
[0257]
(S)-1-[(R)-5-[4-(2-Cyano-pyridin-3-yl)-benzyl]-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid (2-hydroxy-2-methyl-propyl)-amide (722.1, M+1)
[0258]
(S)-1-[(R)-5-[4-(2-Cyano-pyridin-3-yl)-benzyl]-7-(3,5-dichloro-phenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid carbamoylmethyl-amide (707.1, M+1)
[0259]
Description of Biological Properties
[0261] The biological properties of representative compounds of the formula I were investigated by way of the experimental protocol described below.
[heading-0262] Assay to Determine Inhibition of LFA-1 Binding to ICAM-1
[heading-0263] Purpose of Assay:
[0264] This assay protocol is designed to study the direct antagonism, by a test compound, of the interaction of the CAM, ICAM-1 with the Leukointegrin CD18/CD11a (LFA-1).
[heading-0265] Description of Assay Protocol:
[0266] LFA-1 is immunopurified using the TS2/4 antibody from a 20 g pellet of human JY or SKW3 cells, utilizing a protocol previously described (Dustin, M. J.; et al., J. Immunol. 1992, 148, 2654-2660). The LFA-1 is purified from SKW3 lysates by immunoaffinity chromatography on TS2/4 LFA-1 mAb Sepharose and eluted at pH 11.5 in the presence of 2 mM MgCl 2 and 1% octylglucoside. After collection and neutralization of fractions from the TS2/4 column, samples are pooled and precleared with Protein G agarose.
[0267] A soluble form of ICAM-1 is constructed, expressed, purified and characterized as previously described (Marlin, S.; et al., Nature, 1990, 344, 70-72 and see Arruda, A.; et al., Antimicrob. Agents Chemother. 1992, 36, 1186-1192). Briefly, isoleucine 454 which is located at the putative boundary between domain 5 of the ectodomain and the transmembrane domain, is changed to a stop codon using standard oligonucleotide-directed mutagenesis. This construction yields a molecule identical with the first 453 amino acids of membrane bound ICAM-1. An expression vector is created with a hamster dihydrofolate reductase gene, a neomycin-resistance marker, and the coding region of the sICAM-1 construct described above, along with the promoter, splice signals, and polyadenylation signal of the SV40 early region. The recombinant plasmid is transfected into CHO DUX cells using standard calcium phosphate methods. Cells are passaged in selective media (G418) and colonies secreting sICAM-1 are amplified using methotrexate. sICAM-1 is purified from serum-free media using traditional non-affinity chromatographic techniques, including ion exchange and size exclusion chromatography.
[0268] LFA-1 binding to ICAM-1 is monitored by first incubating sICAM-1 at 40 μg/mL in Dulbecco's phosphate buffered saline with calcium and magnesium, additional 2 mM MgCl 2 and 0.1 mM PMSF (Diluting Buffer) in a 96-well plate for 30 min at room temperature. Plates are then blocked by the addition of 2% (w/v) bovine serum albumin in Diluting Buffer for 37° C. for 1 h. Blocking solution is removed from wells, and test compounds are diluted and then added followed by the addition of approximately 25 ng of immunoaffinity purified LFA-1. The LFA-1 is incubated in the presence of test compound and ICAM-1 at 37° C. for 1 h. Wells are washed 3 times with Diluting Buffer. The bound LFA-1 is detected by the addition of a polyclonal antibody directed against a peptide corresponding to the CD 18 cytoplasmic tail in a 1:100 dilution with Diluting Buffer and 1% BSA and allowed to incubate for 45 min at 37° C. Wells are washed 3 times with Diluting Buffer and the bound polyclonal antibody is detected by the addition of a 1:4000 dilution of horse radish peroxidase conjugated to goat immunoglobulin directed against rabbit immunoglobulin. This reagent is allowed to incubate for 20 min at 37° C., wells are washed as above and the substrate for the horse radish peroxidase is added to each well to develop a quantitative colorimetric signal proportional to the amount of LFA-1 bound to sICAM-1. Soluble ICAM-1 (60 μg/mL) is used as a positive control for inhibition of the LFA-1/ICAM-1 interaction. The lack of the addition of LFA-1 to the binding assay is used as a background control for all samples. A dose-response curve is obtained for all test compounds.
[0269] All compounds made in the above examples were tested in this assay and each found to have a K d <10 μM.
[heading-0270] Assay to Determine Metabolism by Human Liver Microsomal Enzymes
[heading-0271] Purpose of Assay:
[0272] This assay protocol is designed to measure the in vitro metabolism of test compounds by human liver microsomal enzymes. The data collected are analyzed to calculate a half-life (t 1/2 , min) for test compounds.
[heading-0273] Description of Assay Protocol:
[0274] The assay is performed in 50 mM potassium phosphate buffer, pH 7.4 and 2.5 mM NADPH. Test samples are dissolved in acetonitrile for a final assay concentration of 1-10 μM. Human liver microsomes are diluted in assay buffer to a final assay concentration of 1 mg protein/mL. A volume of 25 μL compound solution and 50 μL microsome suspension are added to 825 μL assay buffer. The preparation is incubated for 5 min in a 37° C. water bath. The reaction is started by the addition of 100 μL NADPH. Volumes of 80 μL are removed from the incubation mix at 0, 3, 6, 10, 15, 20, 40, and 60 min after the start of the reaction and added to 160 μL acetonitrile. The samples are shaken for 20 sec and then centrifuged for 3 min at 3000 rpm. A 200 μL volume of the supernatant is transferred to 0.25 mm glass fiber filter plates and centrifuged for 5 min at 3000 rpm. Injection volumes of 10 μL are typically added to Zorbax SB C8 HPLC columns with formic acid in water or acetonitrile at a flow rate of 1.5 mL/min. Percent loss of parent compound is calculated from the area under each time point to determine the half-life.
[0275] Compounds made in the above examples were tested in this assay and generally found to have a t 1/2 ≧40 minutes.
[heading-0276] Description of Therapeutic Use
[0277] The novel small molecules of formula I provided by the invention inhibit the ICAM-1/LFA-1 dependent homotypic aggregation of human lymphocytes and human lymphocyte adherence to ICAM-1. These compounds have therapeutic utility in the modulation of immune cell activation/proliferation, e.g., as competitive inhibitors of intercellular ligand/receptor binding reactions involving CAMs and Leukointegrins. To be more specific, the compounds of the invention may be used to treat certain inflammatory conditions, including conditions resulting from a response of the non-specific immune system in a mammal (e.g., adult respiratory distress syndrome, shock, oxygen toxicity, multiple organ injury syndrome secondary to septicemia, multiple organ injury syndrome secondary to trauma, reperfusion injury of tissue due to cardiopulmonary bypass, myocardial infarction or use with thrombolysis agents, acute glomerulonephritis, vasculitis, reactive arthritis, dermatosis with acute inflammatory components, stroke, thermal injury, hemodialysis, leukapheresis, ulcerative colitis, necrotizing enterocolitis and granulocyte transfusion associated syndrome) and conditions resulting from a response of the specific immune system in a mammal (e.g., psoriasis, organ/tissue transplant rejection, graft vs. host reactions and autoimmune diseases including Raynaud's syndrome, autoimmune thyroiditis, dermatitis, multiple sclerosis, rheumatoid arthritis, insulin-dependent diabetes mellitus, uveitis, inflammatory bowel disease including Crohn's disease and ulcerative colitis, and systemic lupus erythematosus). The compounds of the invention may also be used in treating asthma or as an adjunct to minimize toxicity with cytokine therapy in the treatment of cancers. In general these compounds may be employed in the treatment of those diseases currently treatable through steroid therapy.
[0278] Thus, another aspect of the invention is the provision of a method for the treatment or prophylaxis of the above-described conditions through the adminstration of therapeutic or prophylactic amounts of one or more compounds of the formula I.
[0279] In accordance with the method provided by the invention, the novel compounds of formula I may be administered for either a prophylactic or therapeutic purpose either alone or with other immunosuppressive or antiinflammatory agents. When provided prophylactically, the immunosuppressive compound(s) are provided in advance of any inflammatory response or symptom (for example, prior to, at, or shortly after the time of an organ or tissue transplant but in advance of any symptoms of organ rejection). The prophylactic administration of a compound of the formula I serves to prevent or attenuate any subsequent inflammatory response (such as, for example, rejection of a transplanted organ or tissue, etc.). The therapeutic administration of a compound of the formula I serves to attenuate any actual inflammation (such as, for example, the rejection of a transplanted organ or tissue). Thus, in accordance with the invention, a compound of the formula I can be administered either prior to the onset of inflammation (so as to suppress an anticipated inflammation) or after the initiation of inflammation.
[0280] The novel compounds of the formula I may, in accordance with the invention, be administered in single or divided doses by the oral, parenteral or topical routes. A suitable oral dosage for a compound of formula I would be in the range of about 0.1 mg to 10 g per day. In parenteral formulations, a suitable dosage unit may contain from 0.1 to 250 mg of said compounds, whereas for topical administration, formulations containing 0.01 to 1% active ingredient are preferred. It should be understood, however, that the dosage administration from patient to patient will vary and the dosage for any particular patient will depend upon the clinician's judgement, who will use as criteria for fixing a proper dosage the size and condition of the patient as well as the patient's response to the drug.
[0281] When the compounds of the present invention are to be administered by the oral route, they may be administered as medicaments in the form of pharmaceutical preparations which contain them in association with a compatible pharmaceutical carrier material. Such carrier material can be an inert organic or inorganic carrier material suitable for oral administration. Examples of such carrier materials are water, gelatin, talc, starch, magnesium stearate, gum arabic, vegetable oils, polyalkylene-glycols, petroleum jelly and the like.
[0282] The pharmaceutical preparations can be prepared in a conventional manner and finished dosage forms can be solid dosage forms, for example, tablets, dragees, capsules, and the like, or liquid dosage forms, for example solutions, suspensions, emulsions and the like. The pharmaceutical preparations may be subjected to conventional pharmaceutical operations such as sterilization. Further, the pharmaceutical preparations may contain conventional adjuvants such as preservatives, stabilizers, emulsifiers, flavor-improvers, wetting agents, buffers, salts for varying the osmotic pressure and the like. Solid carrier material which can be used include, for example, starch, lactose, mannitol, methyl cellulose, microcrystalline cellulose, talc, silica, dibasic calcium phosphate, and high molecular weight polymers (such as polyethylene glycol).
[0283] For parenteral use, a compound of formula I can be administered in an aqueous or non-aqueous solution, suspension or emulsion in a pharmaceutically acceptable oil or a mixture of liquids, which may contain bacteriostatic agents, antioxidants, preservatives, buffers or other solutes to render the solution isotonic with the blood, thickening agents, suspending agents or other pharmaceutically acceptable additives. Additives of this type include, for example, tartrate, citrate and acetate buffers, ethanol, propylene glycol, polyethylene glycol, complex formers (such as EDTA), antioxidants (such as sodium bisulfite, sodium metabisulfite, and ascorbic acid), high molecular weight polymers (such as liquid polyethylene oxides) for viscosity regulation and polyethylene derivatives of sorbitol anhydrides. Preservatives may also be added if necessary, such as benzoic acid, methyl or propyl paraben, benzalkonium chloride and other quaternary ammonium compounds.
[0284] The compounds of this invention may also be administered as solutions for nasal application and may contain in addition to the compounds of this invention suitable buffers, tonicity adjusters, microbial preservatives, antioxidants and viscosity-increasing agents in an aqueous vehicle. Examples of agents used to increase viscosity are polyvinyl alcohol, cellulose derivatives, polyvinylpyrrolidone, polysorbates or glycerin. Microbial preservatives added may include benzalkonium chloride, thimerosal, chloro-butanol or phenylethyl alcohol.
[0285] Additionally, the compounds provided by the invention can be administered topically or by suppository.
[heading-0286] Formulations
[0287] Compounds of the formula I can be formulated for therapeutic administration in a number of ways. Descriptions of several exemplary formulations are given below.
Example A
[0288]
Capsules or Tablets
Example A-1
Example A-2
Ingredients
Quantity
Ingredients
Quantity
Compound of
250 mg
Compound of formula I
50 mg
formula I
Starch
160 mg
Dicalcium Phosphate
160 mg
Microcrys. Cellulose
90 mg
Microcrys. Cellulose
90 mg
Sodium Starch
10 mg
Stearic acid
5 mg
Glycolate
Magnesium Stearate
2 mg
Sodium Starch Glycolate
10 mg
Fumed colloidal silica
1 mg
Fumed colloidal silica
1 mg
[0289] The compound of formula I is blended into a powder mixture with the premixed excipient materials as identified above with the exception of the lubricant. The lubricant is then blended in and the resulting blend compressed into tablets or filled into hard gelatin capsules.
Example B
[0290]
Parenteral Solutions
Ingredients
Quantity
Compound of formula I
500
mg
PEG 400
40%
by volume
Ethyl Alcohol
5%
by volume
Saline
55%
by volume
[0291] The excipient materials are mixed and then added to one of the compounds of formula I in such volume as is necessary for dissolution. Mixing is continued until the solution is clear. The solution then filtered into the appropriate vials or ampoules and sterilized by autoclaving.
Example C
[0292]
Suspension
Ingredients
Quantity
Compound of formula I
100
mg
Citric acid
1.92
g
Benzalkonium chloride
0.025%
by weight
EDTA
0.1%
by weight
Polyvinylalcohol
10%
by weight
Water
q.s. to 100
mL
[0293] The excipient materials are mixed with the water and thereafter one of the compounds of formula I is added and mixing is continued until the suspension is homogeneous. The suspension is then transferred into the appropriate vials or ampoules.
Example D
[0294]
Topical Formulation
Ingredients
Quantity
Compound of formula I
5% by weight
Tefose 63
13% by weight
Labrafil M 1944 CS
3% by weight
Paraffin Oil
8% by weight
Methylparaben (MP)
0.15% by weight
Propylparaben (PP)
0.05% by weight
Deionized water
q.s. to 100
[0295] The proper amounts of Tefose 63, Labrafil M 1944 CS, Paraffin oil and water are mixed and heated at 75° C. until all components have melted. The mixture is then cooled to 50° C. with continuous stirring. Methylparaben and propylparaben are added with mixing and the mixture is cooled to ambient temperature. The compound of formula I is added to the mixture and blended well.
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Derivatives of 6,7-dihydro-5H-imidazo[1,2-a]imidazole-3-sulfonyl]-pyrrolidine-2-carboxylic acid amide which exhibit good inhibitory effect upon the interaction of CAMs and Leukointegrins and are thus useful in the treatment of inflammatory disease.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a power processor circuit and method for supplying power to generate corona discharge in a corona discharge pollutant destruction corona discharge reactor.
2. Description of the Related Art
Passing a pollutant bearing gas through a corona discharge site is a known method of removing the pollutants from the gas. A general review of this technique is provided in Puchkarev et al., "Toxic Gas Decomposition by Surface Discharge," Proceedings of the 1994 International Conf. on Plasma Science, 6-8 Jun., 1994, Santa Fe, N. Mex., paper No. 1E6, page 88. Corona pollutant destruction has also been proposed for liquids, as disclosed in application Ser. No. 08/295,959, filed Aug. 25, 1994, "Corona Source for Producing Corona Discharge and Fluid Waste Treatment with Corona Discharge," and assigned to Hughes Aircraft Company, now doing business as Hughes Electronics.
In one system, described in Yamamoto et al., "Decomposition of Volatile Organic Compounds by a Packed Bed Reactor and a Pulsed-Corona Plasma Reactor," Non-Thermal Plasma Techniques for Pollution Control, NATO ASI Series Vol. G34 Part B, Ed. by B. M. Penetrante and S. E. Schultheis, Springer-Verlag Berlin Heidelberg, 1993, pages 87-89, brief high voltage pulses of about 120-130 nanoseconds duration are applied to the center conductor of a coaxial corona reactor through which gas is flowing. Each pulse produces a corona discharge that emanates from the center wire and floods the inside volume of the reactor with energetic electrons at about 5-10 keV. A similar system is described in U.S. Pat. No. 4,695,358, in which pulses of positive DC voltage are superimposed upon a DC bias voltage to generate a streamer corona for removing SO x and NO x from a gas stream. These processes have relatively poor energy efficiencies. With the reactor geometries that have been selected, it is necessary to deliver very short pulses to avoid arc breakdown between the electrodes, and consequent damage. The pulse-forming circuit loses approximately half of the power coming from a high voltage supply in a charging resistor, and additional energy is wasted in a double spark gap. Furthermore, the capacitive load of the coaxial corona reactor must be charged; this charging energy is typically much greater than the energy that is actually used in the corona reaction, and simply decays away into heat after each pulse without contributing to the pollutant destruction.
A similar approach, but with a different reactor geometry, is taken in Rosocha et al., "Treatment of Hazardous Organic Wastes Using Silent-Discharge Plasmas," Non-Thermal Plasma Techniques for Pollution Control, NATO ASI Series Vol. G34 Part B, Ed. by B. M. Penetrante and S. E. Schultheis, Springer-Verlag Berlin Heidelberg, 1993, pages 79-80, in which the corona discharge is established between parallel plates. This system also suffers from a poor specific energy due to inefficient pulse formation and non-recovery of reactor charging energy.
A pollutant destruction system using an inductor-capacitor (LC) resonant circuit for corona discharge generation is described in application Ser. No. 08/450,449, filed May 25, 1995, "Gaseous Pollutant Destruction Apparatus and Method Using Self-Resonant Corona Discharge," and assigned to Hughes Aircraft Company, the assignee of the present invention. The application discloses a single stage corona discharge reactor driven by an LC resonator circuit, which is efficient in converting high-voltage pulse energy to corona discharges. High voltage pulses are very effective in destroying hydrocarbons (HC) and carbon monoxide (CO), but do not facilitate the reduction of nitrogen oxides (NO x ) into diatomic nitrogen (N 2 ) and oxygen (O 2 ). Experiments have shown that using high voltages (up to 12 kV) may even produce some additional NO x . On the other hand, low voltage pulses are highly efficient in reducing NO x , but are very poor at oxidizing HC. Therefore, depending on the treatment desired, a wide range of voltages levels and frequencies may be required.
High voltage and high frequency electricity must be supplied to a corona discharge reactor to generate a corona discharge. The voltage required is usually in the range of about 5-20 kV, and the frequency required is usually in the range of about 5 to 15 MHz. A series resonant inverter with a feedback control loop for generating the required waveform is described in U.S. Pat. No. 4,757,432. Spark gap circuits have been used for generating high voltage pulses for corona discharge, and are described in A. Mizuno et al., "NO x Removal Process Using Pulsed Discharge Plasma," IEEE Transactions on Industry Applications, vol. 31, 1995, pages 957-962, and T. Fujii et al., "Pulse Corona Characteristics," IEEE Transactions on Industry Applications, vol. 29, 1993, pages 98-102.
SUMMARY OF THE INVENTION
This invention concerns a power processor circuit for supplying power to generate a corona discharge in a corona discharge pollutant destruction reactor. Several embodiments of the invention utilize discrete solid state field effect transistor (FET) circuits or FET integrated circuits (ICs) to drive high voltage pulses by using direct current (DC) power supplies of only several hundred volts, thereby greatly reducing the volume, weight and cost of the circuits.
In one embodiment, a series resonant inductor-capacitor (LC) circuit is driven by four high power metal-oxide semiconductor field effect transistors (MOSFETs) operating with voltages and currents on the order of 1000 volts and 20 amperes and are connected in a "full bridge" configuration driven by a DC voltage on the order of 900 volts. The LC circuit resonates at about 5-15 MHz. The symmetrically arranged MOSFETs drive the LC resonator, with each MOSFET connected to a driver circuit that comprises multiple parallel stages of FETs. Each FET in the driver circuit is connected to at least one amplification and isolation circuit that receives rectangular pulses from a low-voltage signal source. The isolation circuits used in one embodiment are voltage transformers which isolate currents between the FETs and initial amplifiers. The driver circuit is also isolated from the signal source to protect the signal source from the driver circuit's high voltages and currents. Isolation may be achieved by a remote transmitter/receiver, such as a fiber optic transmitter/receiver link that transmits optical pulse signals from the signal source to the driver circuit but blocks voltages and currents.
In another embodiment, two high power MOSFETs are connected to only one end of a series LC resonator circuit in a "half bridge" configuration and are biased by DC voltages of only about ±200 volts. Each MOSFET is connected to a driver circuit comprising multiple parallel stages of high speed FET IC drivers capable of amplifying high frequency pulses. A low-voltage signal source transmits rectangular pulses to the driver circuits but is electrically isolated from them to avoid damage by high voltages and currents. Isolation may be achieved by a fiber optic transmitter/receiver link, for example, or by other remote transmitter/receiver means. In this driver circuit, no voltage transformers are needed, and in each parallel driver stage, only one high speed driver is connected between the fiber optic receiver and the high power MOSFET.
These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the power stage for one embodiment of the invention that has a full bridge configuration;
FIG. 2 is a schematic diagram of one of the driver circuits in the power processor circuit of FIG. 1;
FIG. 3 is a plot of typical pulses provided to one of the driver circuits;
FIG. 4 is a plot of typical exhaust gas chamber voltages, showing multiple pulses in the time domain;
FIG. 5 is a plot on an expanded time scale of a portion of FIG. 4, showing sinusoidal waves energized by forced resonance within a single pulse;
FIG. 6 is a plot of the typical current flowing across the exhaust gas chamber in the time domain;
FIGS. 7a and 7b are equivalent circuits of a corona discharge reactor respectively without and during a discharge;
FIG. 8 is a schematic diagram of the power stage for another embodiment in which the power processor circuit has a half bridge configuration;
FIG. 9 is a schematic diagram of one of the driver circuits in the power processor circuit of FIG. 3, having a plurality of high speed drivers;
FIG. 10 is a schematic diagram of an alternate embodiment for one of the high speed drivers used in FIG. 4; and
FIG. 11 is a block diagram of an automobile that includes a power processor circuit in accordance with the invention that supplies power for corona discharge to treat engine exhaust gas.
DETAILED DESCRIPTION OF THE INVENTION
The present invention concerns power processor circuits which employ discrete solid state field effect transistors (FETs) or FET integrated circuits (ICs) and relatively low DC voltages to generate high-voltage, high-frequency pulses for corona discharge generation. The circuits drive an LC resonator circuit for corona discharge generation by high power FET amplifiers in a power stage, with each high power FET amplifier driven by a driver circuit, which comprises discrete FETs and/or FET ICs, to feed amplified pulses at an intermediate voltage level to the power stage. The high power amplifier circuits are further provided with appropriate isolation circuits if necessary to prevent large voltages and currents in the high power circuits from damaging a low-voltage signal source, which provides a desired pulse waveform of preferably rectangular shape in the time domain. One advantage of using rectangular pulses is that the duty cycle, which is defined as the ratio of pulse width to pulse repetition period, can be easily adjustable in the low-voltage signal source without changing any components or parameters in the high power circuits.
In one embodiment employing a full bridge configuration, the power stage shown in FIG. 1 comprises four high power FETs 2a, 2b, 2c, 2d having respective gates 4a, 4b, 4c, 4d, drains 6a, 6b, 6c, 6d and sources 8a, 8b, 8c, 8d. The high power FETs 2a, 2b, 2c, 2d are preferably n-channel transistors. It is further preferred that the FETs 2a, 2b, 2c, 2d be metal-oxide semiconductor FETs (MOSFETs) because of their ability to produce high power without breakdown when high voltages are applied to the gates. These high power MOSFETs are preferably of the industry type "DE375X2 102N20". The high power FET gates 4a, 4b, 4c, 4d are connected to respective driver circuits 10a, 10b, 10c, 10d to amplify pulses from an intermediate voltage to a high voltage. An LC resonator circuit 12 is formed by an inductor 14 and a capacitor 16 connected in series, and the inductor 14 is connected in parallel with a corona discharge reactor 18. The resonant frequency f generated by the LC resonator circuit 12 is given by ##EQU1## where L is the inductance of the inductor 14 in henrys, C is the capacitance of the capacitor 16 in farads, and f is the resonant frequency in hertz. To generate a desirable resonant frequency of about 15 MHz for optimal corona discharge, the inductor 14 preferably has an inductance of about 4.5 nH and the capacitor 16 preferably has a capacitance of about 25 pF. Although other resonator configurations such as parallel LC resonator circuits are theoretically possible for generating a resonance, it is preferred that the inductor 14 and the capacitor 16 be connected in series to avoid breakdown at the capacitor.
The four high power FETs 2a, 2b, 2c, 2d are arranged symmetrically about the resonator circuit 12 such that FETs 2a, 2b are connected to one end of the resonator circuit 12 while FETs 2c, 2d are connected to the other end. The FETs 2a, 2c have their drains 6a, 6c connected to a DC voltage source 20 which supplies a bias voltage V+, preferably of about +900 volts. A filter capacitor 22 is connected between the DC voltage source 20 and ground to filter out the DC component of an amplified voltage waveform in which the DC component is generated by the bias voltage V+, so that the DC source 20 is not short-circuited to ground. The sources 8a, 8c of the FETs 2a, 2c are connected to the drains 6b, 6d of the FETs 2b, 2d respectively, while the sources 8b, 8d of the FETs 2b, 2d are grounded. The resonator circuit 12 is connected across the sources 8a, 8c of the FETs 2a, 2c, thereby forming a full bridge circuit.
One embodiment of the driver circuits 10a, 10b, 10c, 10d is shown in FIG. 2. A high power FET 40, which represents one of the FETs 2a, 2b, 2c, 2d, has a gate 42 that is connected to multiple parallel isolation-amplification stages 43a, 43b with intermediate n-channel FETs 44a, 44b, and to multiple parallel isolation-amplification stages 45a, 45b with intermediate p-channel FETs 46a, 46b to provide amplified intermediate-voltage pulses to the gate 42 of the high power FET 40. Resistors 48a, 48b, 50a, 50b of a small resistance, preferably in the range of 1 to 2Ω, are added to drains 52a, 52b, 54a and 54b, respectively. The sources 56a, 56b of the n-channel FETs 44a, 44b are grounded, while the sources 58a, 58b of the p-channel FETs 46a, 46b are connected to a positive bias voltage +V 2 , preferably in the range of 12 to 15 V. Gates 60a, 60b of the n-channel FETs 44a, 44b are connected to the secondary coils of respective 1:1 turns ratio transformers 64a, 64b with the same polarization, while gates 62a, 62b of the p-channel FETs 46a, 46b are connected to the secondary coils of respective 1:1 turns ratio transformers 66a, 66b but with reverse polarization. Resistors 68a, 68b, 70a, 70b of a small resistance, preferably in the range of 5 to 20Ω are, preferably connected between the transformers 64a, 64b, 66a, 66b and the gates 60a, 60b, 62a, 62b, respectively, to dampen possible ringing by the intermediate FETs 44a, 44b, 46a, 46b that could cause undesirable resonance interactions between them. The primary coils of the transformers 64a, 64b, 66a, 66b are connected to respective capacitors 72a, 72b, 74a, 74b to filter out DC components of pulses that are biased by a DC voltage. Although FIG. 2 shows two isolation-amplification stages with n-channel FETs and two stages with p-channel FETs, more stages of the same configuration may be added in parallel if desired to provide amplified pulse signals to the gate 42 of the high power FET 40.
The inputs to all isolation-amplification stages with n-channel FETs are connected to a pair of npn bipolar transistors 76a, 76b, while the inputs to all isolation-amplification stages with p-channel FETs are connected to a pair of pnp bipolar transistors 78a, 78b. Collectors 80a, 82a of the npn transistors 76a, 78a are connected to a bias voltage +V 1 , which preferably has a positive DC voltage in the range of 12 to 15 V. Collectors 80b, 82b of the pnp transistors 76b, 78b are grounded. The emitters 84a, 86a of the npn transistors 76a, 78a are respectively connected to the emitters 84b, 86b of the pnp transistors 76b, 78b to form two nominally identical pairs of bipolar transistors, one pair for n-channel FET isolation-amplification stages and the other for p-channel FET isolation-amplification stages. The connected emitters 84a, 84b feed pulse signals to the n-channel FET stages, while the connected emitters 86a, 86b feed pulse signals to the p-channel FET stages. The bipolar transistor pairs form push-pull switching circuits which provide driving pulses to the isolation-amplification stages.
Bases 88a, 88b of the paired transistors 76a, 76b are connected to a high speed driver 92, and bases 90a, 90b of the paired transistors 78a, 78b are connected to another high speed driver 94. The high speed drivers 92, 94 are ICs that contain a plurality of solid state amplifier circuits capable of fast rise and fall times. They are preferably Elantec High Speed Drivers of the type "EL7104CN" MOSFET ICs. The drivers 92, 94 have respective input pairs 96, 98 and 100, 102, which may be connected directly to receive input pulse signals. In a preferred embodiment that separates the rise and fall of the drive pulses and controls the pulse rise and fall times, thereby retaining a desired pulse shape, diodes 112, 114 directed in opposite directions are respectively connected through resistors 104, 106 to the two inputs 96 and 98 of the driver 92. The resistors 104, 106 are preferably of a small resistance of 5Ω or less. Likewise, a pair of contra-directed diodes 116, 118 are preferably connected through respective resistors 108, 110 to feed input pulse signals to the inputs 100, 102 of the other driver 94. The two pairs of bipolar transistors 76a, 76b and 78a, 78b and their associated drivers 92, 94 along with their pulse-shaping diodes and resistors form preamplifier circuits 101a, 101b, respectively. These preamplifier circuits are isolated from large currents in the intermediate FETs 44a, 44b, 46a, 46b by the transformers 64a, 64b, 66a, 66b.
A signal source 120 generates pulses 200 with a substantially rectangular waveform, as illustrated in FIG. 3. The rectangular pulses generally have a pulse width t and a pulse repetition period T. The duty cycle is defined as t/T, and the pulse repetition rate is defined as 1/T. The signal source 120 need only generate pulses of a low voltage level, on the order of 5 volts, for example. FIG. 2 shows the signal source 120 connected to a transmitter 122, which transmits the pulses to a receiver 124 via a communication link 126. In this configuration, the signal source 120 is isolated by the communication link 126 from the high voltages and currents in the driver circuits to enter the signal source 120 to prevent damaging the signal source. The transmitter 122 and the receiver 124 preferably use fiber optic transmission and reception schemes, and the link 126 is preferably a fiber optic cable which achieves a high level of electrical isolation between the signal source 120 and the remainder of the driver circuit. The transmitter/receiver isolation scheme is required for the driver circuits 10a, 10c in FIG. 1 because they operate at a high DC voltage V+, typically on the order of +900 volts. For the driver circuits 10b, 10d in FIG. 1, which operate at lower voltage levels, the signal source 120 may be connected directly to the diodes 112, 114, 116, 118 in the driver circuit without isolation.
The rectangular pulses 200 in FIG. 3 are amplified by the driver circuits of FIG. 2 and the high power FET transistors 6a, 6b, 6c, 6d in the power stage circuit of FIG. 1. Each of the amplified rectangular pulses excites the LC resonator circuit 12, and causes it to "ring," that is, to generate an oscillating high voltage wave at the resonant frequency of the circuit 12. During the pulse width t, power is continuously supplied to the resonator circuit 12, and forces the voltage amplitude of the resonant sinusoidal wave to increase rapidly to a saturation level. The peak voltage level remains substantially constant thereafter until the pulse is turned off.
FIG. 4 shows a voltage waveform 202 across the corona discharge reactor 18 which results from the LC resonator circuit 12 being forced to resonate by the rectangular voltage pulses shown in FIG. 3. FIG. 5 shows the voltage waveform for one of the pulse periods of FIG. 4 expanded in the time domain, and illustrates the sinusoidal voltage 204 across the corona discharge reactor 18 generated by the forced resonance of a single pulse from the signal source 120. Initially, the amplitude of voltage 204 increases rapidly because of the ringing of the LC resonator circuit 12 forced by the pulse 200, but has not reached the voltage level necessary for corona discharge. There is no discharge within the corona discharge reactor chamber, and the current 208 across the reactor 18 is negligible, as shown in FIG. 6. The electrical characteristic of the corona discharge reactor during this period of no discharge may be represented by an equivalent circuit, shown in FIG. 7a, consisting of a single resistor 212 having a very high impedance. Alternatively, the corona discharge reactor may be regarded simply as an open circuit during the period of no discharge. When the voltage across the corona discharge reactor 18 reaches a certain breakdown level 206, corona discharge occurs, and a large current flows across the reactor 18. Because the voltage reaches the breakdown level 206 very close to the positive and negative peak of each sinusoidal lobe after the initial discharge, the current across the corona discharge reactor 18 appears as positive and negative spikes 210 because of the very short duration of each discharge. When the voltage falls below the breakdown level 206, the current across the reactor 18 rapidly returns to a negligible level.
The electrical characteristic of the corona discharge reactor 18 during discharge may be represented by an equivalent circuit consisting of a pair of Zener diodes 214, 216 connected in series but with opposite polarities as illustrated in FIG. 7b. When either a positive or a negative voltage below breakdown is applied across the equivalent circuit, one of the diodes 214, 216 blocks any significant current flow. When the voltage reaches a breakdown level, current flows through the Zener diode pair 214, 216 as if it were nearly a short circuit.
FIG. 8 shows a preferred embodiment of a power stage circuit in a "half bridge" configuration. Only two high power FETs 300a, 300b are required, and DC bias voltages of only about ±200 V need to be provided. The high power FETs 300a, 300b are preferably n-channel and have gates 302a, 302b, drains 304a, 304b, and sources 306a, 306b, respectively. It is further preferred that the high power FETs 300a, 300b are MOSFETs of industry type "DE375X2 501N40." The gates 302a, 302b of the FETs 300a, 300b are connected to respective driver circuits 308a, 308b, which provide initial amplification for the drive voltage pulses. The drain 304a of the first FET 300a is connected to a DC voltage source V+, which supplies a constant positive DC voltage V+ of preferably about +200 volts. A filter capacitor 314 is connected between V+ and ground to filter out the DC component of an amplified voltage waveform in which the DC component is generated by V+ to prevent V+ from short-circuiting to ground. The source 306b of the second FET 300b is connected to a negative DC voltage source V- of preferably about -200 volts. The source 306a of the first FET 300a and the drain 304b of the second FET 300b are connected together to form one node 322 of a resonator circuit 316, which preferably comprises an inductor 318 and a capacitor 320 connected in series. The opposite node 324 of the LC resonator circuit 316 is grounded. The inductor 318 is connected in parallel with a corona discharge reactor 18.
In a preferred embodiment, the driver circuits 308a, 308b each have a configuration shown in FIG. 9 to amplify relatively low drive voltage pulses to an intermediate voltage level. A high power FET 330, which represents one of the FETs 300a, 300b in FIG. 8, has a gate 332 connected to the driver circuit, which comprises multiple high speed drivers 334a, 334b, . . . 334j connected in parallel with each other. It is preferred that the high speed drivers 334a, 334b, . . . 334j be MOSFET IC devices, preferably Elantec High Speed Drivers of the type "EL7104CN." These high speed drivers 334a, 334b, . . . 334j each have two outputs connected to respective parallel resistors 336a, 336b, . . . 336j, 338a, 338b, . . . 338j of a low resistance, preferably on the order of 2.7Ω. These resistors are connected to the gate 332 of the FET 330, so that amplified voltage pulses from the parallel high speed drivers 334a, 334b, . . . 334j are sent to the gate 332 of the high power FET 330 simultaneously. The high speed drivers 334a, 334b, . . . 334j also have respective inputs connected through respective input resistors 340a, 340b, . . . 340j to receive relatively low voltage pulse signals. In a preferred embodiment that protects a low-voltage signal source 342 from potential damage by high electrical power from the driver circuit, pulses from signal source 342 are delivered by an optical transmitter 344 to an optical receiver 346 via a fiber optic cable 348. The receiver 346 is connected to the input resistors 340a, 340b, . . . 340j to send received pulse signals to the high speed drivers 334a, 334b, . . . 334j. Preferably, the pulses generated by the signal source 342 are of a substantially rectangular shape in the time domain. The signal source 342 need only generate pulses at a low voltage level, on the order of 5 volts, for example. This isolation scheme is used for both driver circuits 308a, 308b in FIG. 8.
In an alternate embodiment shown in FIG. 10, a pair of discrete FETs are used in place of each of the high speed drivers 334a, 334b, . . . 334j of FIG. 9. A p-channel FET 250 and an n-channel FET 252 have gates 254, 256 connected to an input resistor 258 for receiving input pulse signals, and drains 260, 262 connected to respective output resistors 264, 266 for output to the power stage. The source 268 of the p-channel FET 250 is connected to a positive DC voltage +V 1 , while the source 270 of the n-channel FET 252 is grounded. Although this circuit basically performs the equivalent functions of a high speed driver, it is more cumbersome to build and its operation is less reliable than the high speed drivers 334a, 334b, . . . 334j of FIG. 9.
In the preferred embodiment of the "half bridge" circuit of FIG. 8, the amplified rectangular pulses 200 of FIG. 3 force the LC resonator circuit 316 to resonate, thereby generating a voltage across the corona discharge reactor 18 with a wave pattern 202 generally shown in FIG. 4. As in the embodiment of FIG. 1, the amplitude of the voltage wave 204 increases rapidly at the start of each pulse, as shown in FIG. 5, but is not high enough to generate a corona discharge. As shown in FIG. 6, almost no current 208 passes through the corona discharge reactor 18 in the absence of a corona discharge. When the voltage wave reaches a breakdown level 206 close to the peaks, corona discharges are generated and very large currents rapidly flow through the reactor 18, with each breakdown lasting a very short duration corresponding to the current spikes 210 in FIG. 6.
FIG. 11 shows the implementation of a power processor circuit 382 in accordance with the invention in an automobile 390, which has an internal combustion engine 380 that generates a pollutant-bearing exhaust gas. The exhaust gas is transferred through an exhaust conduit 386 to a corona discharge reactor 384, which destroys the pollutants in the exhaust gas by corona discharge. The power processor circuit 382 supplies high voltage pulses to the reactor 384 to enable corona discharge generation. The treated exhaust gas exits the reactor through an outlet conduit 388.
This invention provides a compact power source for corona discharge generation in automotive applications, and is particularly applicable to future electronic catalytic converters which employ corona discharge reactors to meet stringent air quality standards. The circuits embodied in this invention use only solid-state components, which would result in great savings in weight, cost and energy consumption, thereby making them suitable for automobile applications.
While several illustrative embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention as defined in the appended claims.
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A solid-state power processor circuit and method is used to supply power to generate a discharge in a corona discharge pollutant destruction apparatus. The circuit uses field effect transistors (FETs) and integrated circuit devices based upon metal oxide semiconductor field effect transistor (MOSFET) technology to amplify low-voltage pulse signals to high voltage levels. A resonator in the power processor circuit generates sinusoidal oscillation from the high voltage pulses, and provides the high-voltage, high-frequency electrical power necessary for corona discharge.
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BACKGROUND OF THE INVENTION
The present invention relates to a fluororesin composition for a sliding member comprising a fluororesin, a phosphate and a filler composed of glass fiber, glass powder, carbon fiber or carbon powder, and a sliding member comprising the fluororesin composition, which has an excellent sliding property especially under conditions of a low speed and a high load (high surface pressure).
A polytetrafluoroethylene (which is abbreviated as "PTFE" hereinafter), which is one of the fluororesins, is not only excellent in heat resistance and chemical resistance but also has a low friction coefficient with a self-lubricating property, so that it is widely used in various fields as a representative of the so-called engineering plastics such as a material for a sliding member such as bearings and gears, and a molded article such as a tube and a valve. However, its wear resistance is not necessarily sufficient, and the deformation (creep) due to a load is large, so that its use is restricted under a high load or a high temperature.
However, a sliding member consisting of this PTFE is inferior in wear resistance and the creep resistance, so that depending on the use of the sliding member, for example, 1 by blending PTFE with a filler such as graphite, molybdenum disulfide, glass fiber or the like, or 2 by impregnating PTFE in and coating PTFE on a porous sintered metal layer integrally formed on a thin steel plate, the above-mentioned drawbacks are solved.
The sliding member of the above-mentioned embodiment 2 is one so-called as a multi-layer sliding member having a thin wall-thickness of the member itself (usually 1.5 to 3.0 mm) and showing a greatly improved load resistance, so that it is suitable for the use under conditions of low speed and high load.
However, on the other hand, in the case where an with a large grasping force (high surface pressure) and the rotation of the opposite member is smoothly supported with by sliding (in other words, a portion in which a clearance between the sliding member and the opposite member is loose) such as, for example, a hinge portion of various doors or a sliding portion of a ball joint for automobiles, creep and the like of the sliding member itself occurs and as a result it is absolutely impossible to withstand repeated use.
As sliding materials for solving the above-mentioned problems, for example, there have been proposed:
(1) a coated sheet as a bearing material comprising a metal net and a fluoropolymer sintered thereto, where intersectional wires of the metal net themselves are melted to be connected with each other by a thermal operation at intersectional portions (Japanese Patent Publication No. 35107-1978 corresponding to U.S. Pat. No. 3,899,227), and
(2) a sliding member comprising as a base body an expanded metal of stainless steel or a phosphorous bronze alloy provided with regular networks, and a lubricating composition containing a polytetrafluoroethylene as a main component with 5 to 30% by weight of a phenol resin subjected to heat-treatment and/or addition polymerization type polyimide resin as a filler, which is filled in the networks of the base member and coated on the base member (Japanese Patent Application Laid-open (KOKAI) No. 79417/1989).
Moreover, as sliding members containing a fluororesin as a main component, there have been hitherto proposed:
(3) a porous structural article having a tetrafluoroethylene resin coating on one surface such that when an unsintered tetrafluoroethylene resin mixture containing a liquid lubricant is placed on the surface of a porous structural article to be coated in a powder state as it is or having been molded beforehand so as to perform rolling and coating between two rolls, a layer, interposed from the surface of the roll on the side of contacting with its back surface to the surface of the roll, is formed of a material which is soft and is allowed to enter into the surface of the porous structural article, and the resultant layer is rolled (Japanese Patent Publication No. 19053/1964),
(4) a lining foil comprising a metal textile, a fluoroplastic, and a material containing a reinforcing material of inorganic fiber, in which a fluoroplastic filled with glass fiber or other inorganic fiber, preferably polytetrafluoroethylene or fluoroethylenepropylene is rolled, extruded, or pressed in the form of powder, paste, or an unsintered subassembly on the metal textile at a processing temperature of a room temperature or a high temperature, and the obtained product is baked at a temperature not less than the melting point of said used fluorine polymer (Japanese Patent Publication No. 23740/1980),
(5) a sliding bearing member made of an expanded metal having a thickness of 0.3 to 0.9 mm which is a wrought aluminum alloy having an elongation at breakage (δ 5 ) of 8 to 20% and a Brinell hardness (HB) of 35 to 65 and a matrix containing 5 to 25% by volume of lead, 10 to 50% by volume of glass fiber, and 40 to 80% by weight of polytetrafluoroethylene, in which the open portions of the expanded metal are filled with the matrix. The expanded metal is coated with the matrix so that a friction sliding layer composed of the matrix is formed at a thickness of 0.01 to 0.3 mm. The matrix also contains 10 to 50% by volume of zinc sulfide or barium sulfate having a particle size range of 0.1 to 1.0 μm (Japanese Patent Application Laid-open (KOKAI) No. 57919/1988 corresponding to U.S. Pat. No. 4,847,135),
(6) a slide bearing including a rigid backing pad having a face, a metal mesh covering the face of the pad, means fixedly securing the mesh to the pad, and a sheet or low friction bearing material overlaying the mesh and having a portion of its thickness pressed into the mesh to interlock the bearing material with the mesh (U.S. Pat. No. 4,238,137),
(7) a sheet material for sliding surface bearings, consisting of a network of expanded metal coated with a fluorine-containing polymer, having a network of expanded metal, which consists of a wrought aluminum alloy having an elongation at break δ 5 =8 to 20% and a Brinell hardness HB 35 to 65 and which has a coating of a blend of 5 to 25% by volume lead, 10 to 50% by volume glass fibers, and 40 to 80% by volume polytetrafluoroethylene (European Patent No. 40448B), and
(8) a sheet material for sliding surface bearings made of an expanded metal mesh composed of a wrought aluminum alloy having an elongation at break δ 5 =8 to 20% and a Brinell Hardness Number HB of 35 to 65; a primer layer coating the surface of the expanded metal mesh having a thickness of 2 to 10 micrometers; and on the primer layer another layer composed of 10 to 30 wt. % of a filler for improving the thermal conductivity and wear resistance, 10 to 30 wt. % glass fibers and 40 to 80 wt. % polytetrafluoroethylene (PTFE) (U.S. Pat. No. 4,624,887).
Conventionally, in order to improve the wear resistance and the creep resistance previous experiments have added various fillers such as glass fiber, glass beads, carbon fiber, carbon powder and the like.
However, since fillers such as glass fiber and the like are hard, these fillers sometimes damage the opposite member and further the PTFE itself is cut and removed, so that there is a risk of causing abrasive wearing. As a result, depending on the amount of the filler, the wearing amount tends to increase.
Also, the sliding member with a metal network structure as a base member becomes sufficiently intimate with the surface of the opposite member owing to the flexibility generated in its thickness direction. This avoids creep and permits rotation of the opposite member which remains smoothly supported.
Depending on the use of the sliding member, electrical conductivity may be required for the sliding member.
Applicants have found that by adding glass fiber, glass powder, carbon fiber and/or carbon powder as a filler, and a phosphate to a fluororesin such as polytetrafluoroethylene, mixing them homogeneously to obtain a fluororesin composition, pressing and molding it at a normal temperature at 300 to 600 kg/cm 2 , and baking (heating) it under normal pressure at 360° to 380° C., the thus obtained sliding member exhibits a stable performance with a low friction coefficient showing no damage to an opposite member at all during sliding and is electrically conductive.
SUMMARY OF THE INVENTION
In a first aspect of the present invention, there is provided a fluororesin composition for a sliding member comprising a fluororesin, at least one filler selected from the group consisting of glass fiber, glass powder, carbon fiber and carbon powder, and a phosphate.
In a second aspect of the present invention, there is provided a sliding member comprising a metal network structure and the fluororesin composition as defined in the 1st aspect which is filled in networks and coated on the surface of the metal network structure.
In a third aspect of the present invention, there is provided a sliding member comprising a metal network structure and a fluororesin composition comprising a polytetrafluoroethylene, 5 to 30% by weight of carbon fiber as the filler and 0.1 to 15% by weight of a phosphate, which is filled in the networks and coated on the surface of the metal network structure.
In a fourth aspect of the present invention, there is provided a multi-layer sliding member comprising a porous sintered metal layer formed on a steel back plate and the fluororesin composition as defined in the 1st aspect is impregnated in and coated on the porous sintered metal layer.
In a fifth aspect of the present invention, there is provided a multi-layer sliding member comprising the porous sintered metal layer formed on a steel back plate and a fluororesin composition comprising a polytetrafluoroethylene, 5 to 30% by weight of carbon fiber as the filler, and 0.1 to 15% by weight of a phosphate, which is impregnated in and coated on the porous sintered metal layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 4 are figures showing the wear depth in thrust tests of various fluororesin compositions.
FIG. 1 shows wear depth values measured in which various amounts of calcium hydrogenphosphate (anhydrous) are contained in a PTFE (Fluon G 190) which also contains 15% by weight of glass fiber (MFA).
With respect to the fluororesin composition FIG. 2, shows wear values measured in which various amount of glass fiber (MFA) are contained in the same PTFE which also contains 5% by weight of calcium hydrogenphosphate (anhydrous).
FIG. 3 shows wear resistance values measured in which various amounts of calcium pyrophosphate are contained in the same PTFE which also contains 15% by weight of CF (Zyrous) treated at a high temperature.
FIG. 4 shows values measured in which various amounts of CF (Zyrous) treated at a high temperature are contained in the same PTFE which also contains 5% by weight of calcium pyrophosphate.
FIG. 5 is a plan view showing a network structure (expanded metal) as a base member, FIG. 6 is a cross-sectional view taken along the line VI--VI in FIG. 5, and FIG. 7 is a cross-sectional view showing a sliding member.
DETAILED DESCRIPTION OF THE INVENTION
The fluororesin component of the compositions of the present invention can be exemplified as conventionally known PTFE (polytetrafluoroethylene), FEP (tetrafluoroethylene-hexafluoropropylene copolymer), PFA (tetrafluoroethylene-perfluoroalkylether copolymer) and the like. Among them, PTFE is especially preferable. PTFE is a homopolymer of tetrafluoroethylene, which is one kind of fluororesin commercially available under trademarks and trade names such as Argoflon (produced by Montedison S.p.A.), Teflon (produced by E.I. du Pont de Nemours & Company), Fluon (produced by ICI Ltd.), Polyflon (produced by Daikin Industries, Ltd.), Teflon 6CJ and Teflon 6J (produced by Mitsui du Pont Fluorochemical, Co., Ltd.), Fron CD-01, CD-123, CD-076, CD-126, and CD-4 (produced by Asahi Glass Co., Ltd.), and Polyflon F103, F101, F101E, and F201 (produced by Daikin Industries, Ltd.). These resins are capable of compression molding but incapable of ordinary injection molding.
The glass fiber or glass powder to be used as the filler for the fluororesin composition of the present invention includes glass fiber and glass powder which have been usually used in this technical field, namely amorphous silicate glass, borate glass and further includes wollastonite, potassium titanate whiskers and the like.
Glass fibers having a diameter (φ) of 1 to 20 μm are preferable, and especially glass fiber having a diameter of 8 to 12 μm are preferable.
A length (l) of the glass fiber is preferably 20 μm to 1 mm, 50 to 300 μm being especially preferable. In addition, it is preferable to use fibers having an aspect ratio of not less than about 5:1.
Conventional glass powder may be used. The average particle size of the glass powder is preferably in the range of 1 to 50 μm, more preferably 5 to 30 μm.
In addition, carbon fiber (CF) which can be used as a filler for the fluororesin composition of the present invention imparts electrical conductivity to the fluororesin composition. Preferred is pitch type carbon fiber treated at a low temperature (about 1000° to 1500° C.), pitch type carbon fiber treated at a high temperature (about 2000° to 2500° C.), PAN type carbon fiber and phenol type carbon fiber. From the view point of giving a high electrical conductivity to the fluororesin composition, the pitch type carbon fiber treated at a high temperature is more preferable.
The diameter (φ) and fiber length (l) of the carbon fiber are preferably 1 to 20 μm and 30 μm to 3 mm respectively, and especially those having a diameter of about 8 to 12 μm and a length of about 80 to 120 μm are preferable.
A concrete example of the pitch type carbon fiber is Zyrous (trade name) (φ=12 μm, 1=100 μm) produced by Nitto Boseki Co., Ltd. A concrete example of the PAN type carbon fiber is Pyrofil produced by Mitsubishi Rayon Co., Ltd., and a concrete example of the phenol type carbon fiber is Kainol CF16BT produced by Japan Kainol Co., Ltd.
Preferred examples of the carbon powder include Bellpearl C600 (obtained by treating Bellpearl R800 at 600° C.) and Bellpearl C2000 (obtained by treating Bellpearl R800 at 2000° C.) which are spherical phenol resin particles produced by Kanebo Ltd. In addition, pre-calcined coke having an average particle size of 11 to 16 μm is as a preferable carbon powder.
The average particle size of the carbon powder is preferably in a range of 1 to 40 μm, more preferably 5 to 30 μm.
The amount of the filler to be used in the present invention is 1 to 40% by weight, and in order to give suitable wear resistance and creep resistance, in the case of the glass fiber and the glass powder, about 1 to 40% by weight, especially about 5 to 30% by weight are preferable, and in the case of the carbon fiber and the carbon powder, about 1 to 30% by weight, preferably 2 to 20% by weight, especially 5 to 20% by weight are preferable.
Suitable phosphates include metal salts such as tertiary phosphate, secondary phosphate, pyrophosphate, phosphite, metaphosphate and the like and mixtures thereof.
Among them, metal salts of tertiary phosphate, secondary phosphate, and pyrophosphate are preferable. Suitable metals include alkali metal, alkaline earth metal, and transition metal. Among these metal salts, alkali metal and alkaline earth metal are preferable, and especially Li, Ca, Mg, and Ba are more preferable.
Concretely, Li 3 PO 4 , Li 2 HPO 4 , Li 4 P 2 O 7 , Ca 3 (PO 4 ) 2 , Ca 2 P 2 O 7 , and CaHPO 4 (.2H 2 O) are most preferable as the phosphate to be used in the present invention.
Furthermore, hydroxyapatite represented by the formula Ca 10 (PO 4 ) 6 (OH) 2 can be preferably used as the phosphate of the present invention.
A phosphate having an average particle size not more than 20 μm for mixing homogeneously is preferred.
In addition, with respect to those crystal particles having crystal water (water of hydration) in the phosphate, by performing a heat treatment beforehand at a temperature of more than the baking temperature of the fluororesin composition of the present invention, that is at a temperature exceeding a range of about 360° to 380° C., the crystal water is evaporated and as a result evaporation of the crystal water of the phosphate can be prevented during the above-mentioned baking treatment, thereby preventing crack formation in an obtained molded article.
In order to increase the wear resistance, 0.1 to 15% by weight of phosphorous is preferable, especially 3 to 10% by weight is preferable.
The total amount of the filler and the phosphate in the fluororesin composition of the present invention is preferably not to exceed 40.1% by weight.
The phosphate included is not a substance itself inherently having a lubricating property such as, for example, graphite and molybdenum disulfide as it is, however, the phosphate facilitates the film forming property of a lubricating coating of the PTFE resin on the surface of an opposite member (sliding surface) during sliding with the opposite member after blending with the PTFE resin. Owing to the effect of the phosphate, direct contact (sliding) between the hard carbon fiber to be blended with the PTFE resin and the opposite member is prevented, and a disadvantage of the carbon fiber which can damage the opposite member, thereby decreasing the wear resistance of a sliding member, is suppressed. This is an important requirement necessary for the sliding member to be used under dry friction lubrication.
The phosphate to be used in the present invention has a Mohs hardness in a range of 2 to 4, and by interaction of the phosphate with the filler having a Mohs hardness of 4 to 6, the wear of the opposite member or the fluororesin composition itself, which is caused by the filler, can be effectively suppressed.
In the fluororesin composition of the present invention, in addition to the filler such as the glass fiber etc. and the phosphate there can be optionally added and mixed other additives which are known in the art and are used in order to increase the molding property, the wear resistance, the load resistance and the like, for example, molybdenum disulfide and graphite, and other pigments as well as an agent for imparting electrical conductivity and the like.
The fluororesin composition for a sliding member of the present invention can be preferably used as a starting material of a bearing, a cam, a gear, a sliding plate, a liner tube for a flexible shaft and the like.
In another embodiment of the sliding member of the present invention, the network structures which form the base member may be expanded metal or a metal mesh such as a metal network disclosed in Japanese Patent Publication No. 35107 (1978).
FIG. 5 is a plan view showing expanded metal to be used as the base member, and FIG. 6 is a cross-sectional view taken along the line VI--VI in FIG. 5.
In both figures, 1 is expanded metal, 2 is a network, 3 is each side (strand) which forms the network 2, 4 is a connecting portion (bonding portion) of these strands with each other, and t is the thickness of the expanded metal.
The configuration of the network 2 of the expanded metal 1 shown in FIG. 5 is hexagonal, however, the configuration of the network 2 can be rhomboid, rectangular, or other optional polygon, and these also can be used as the base member.
The expanded metal 1 is preferably one having a length of each side of 0.1 to 1.5 mm and a thickness of 0.1 to 1.0 mm.
As metal materials which form the expanded preferred metal are stainless steel, a phosphorous bronze alloy, a bronze alloy and the like.
In addition, the metal mesh is preferably a woven assembled wire mesh which is formed by weaving thin wires of copper, a copper alloy, iron or an iron alloy having a wire diameter of 0.1 to 0.5 mm as the warp and the woof.
In still another embodiment of the sliding member of the present invention, the back plate is composed of a metal thin plate a structural rolled steel thin plate is generally used. However, depending on the use of the sliding member, other steel thin plates or thin plates made of a metal other than steel may be available, or those in which copper plating or the like is applied on these metal thin plates in order to increase the corrosion resistance may be available.
The porous sintered metal layer, which is integrally formed on the back plate, is a copper alloy excellent in friction resistance and wear resistance such as bronze, lead bronze, phosphorous bronze and the like. However, depending on the object and the use, it may be formed from materials other than the copper alloy, for example, an aluminum alloy, iron and the like. The form of particles of the alloy powder is preferably massive or irregular.
Examples of the electrically conductive substance to be used in the sliding member of the present invention include amorphous carbon powder such as coke, anthracite, carbon black, charcoal and the like, graphite carbon powder such as natural graphite, artificial graphite, Kish graphite and the like, copper powder, nickel powder, and soft metal powder such as lead, tin, indium and the like.
Almost all of these conductive substances do not contribute to the increase in the friction and wear resistances, so that special attention is required for the blending ratio.
In the present invention, a range within 0.1 to 10% by weight with respect to the above-mentioned lubricating composition (fluororesin composition) can give a higher conductivity to the lubricating composition without deteriorating the friction and wear resistances.
Next, one example of the production method of the sliding member will be explained.
Preparation of the Lubricating Composition (Fluororesin Composition)
Into PTFE resin powder are blended 1 to 40% by weight of the carbon fiber, 0.1 to 15% by weight of the phosphate and optionally 0.1 to 10% by weight of the conductive substance, and the ingredients are mixed at a temperature not more than the transition point at room temperature (19° C.) of the PTFE resin to obtain a lubricating composition (fluororesin composition).
This mixing is carried out at a temperature not more than the transition point at room temperature (19° C.) of the PTFE resin, whereby preventing fibrous formation of the PTFE resin without applying shearing force to the PTFE resin, and a homogeneous mixture can be obtained.
Production of the Sliding Member
[I] The fluororesin composition obtained by mixing as described above is pressed and molded at an ordinary temperature to produce a green compact.
The molding pressure is preferably in a range of 300 to 800 kg/cm 2 .
The baking (heating) of the obtained green compact is carried out at an ordinary pressure in a range of 360° to 380° C. for 2 to 30 hours depending on the kind, amount and the like of the fluororesin powder, so as to melt the fluororesin powder to fuse the resin mixture with each other.
Mechanical processing can be carried out in such a way that after heating the member is cooled to room temperature, followed by convential machining such as for example a lathe in which a superhard tool is used.
Other ways of producing sliding members of the present invention will be described hereinafter.
[II] (a) To 100 parts by weight of the lubricating composition (fluororesin composition) prepared by the above-mentioned method is blended 15 to 25 parts by weight of a petroleum solvent, and the blend is agitated and mixed to give a wetting property to the lubricating composition (fluororesin composition).
The petroleum solvent may be naphtha, toluene, xylene, an aliphatic solvent, and a mixed aliphatic and naphthenic solvent, such as the commercially available solvent "Exonol" (trade name) produced by Exxon Chemical Co., Ltd. which is a mixed aliphatic and naphthenic solvent.
Also, when the petroleum solvent is blended into the lubricating composition, and agitated and mixed to give a wetting property to the lubricating composition, agitation and mixing are carried out at a temperature not more than the transition point at room temperature (19° C.) of the PTFE resin. Agitation and mixing are carried out at the specified temperature range in order to impart the desired wetting property to the composition and to prevent the PTFE resin from forming fibers as PTFE fibers would reduce the moldability properties of the lubricating composition.
When the blending ratio of the petroleum solvent to the lubricating composition is less than 15 parts by weight, the casting property of the lubricating composition is bad in filling and coating to a base member of a network structure as described hereinafter, and nonuniformity is apt to occur during filling of the base member to networks. In addition, when the blending ratio exceeds 25 parts by weight, the filling and coating operations become difficult to carry out, the uniformity of coating thickness is damaged, and the contacting strength between the lubricating composition and the base member becomes bad.
(b) The lubricating composition (fluororesin composition) to which a wetting property has been imparted is sprayed and supplied to the base member of the network structure, which is subjected to roller application to fill the networks of the base member with the lubricating composition. A uniform coating layer of the lubricating composition is formed on the base layer, followed by maintaining for several minutes in a dry furnace heated to a temperature of 200° to 250° C., whereby the petroleum solvent is evaporated and eliminated.
(c) The base member with the networks and the surface filled and coated with the lubricating composition (fluororesin composition) is introduced into a heating furnace and heated for several minutes or ten-odd minutes at a temperature of 360° to 380° C. to bake the lubricating composition. The baked member is removed from the furnace and thereafter passed through a roller to adjust any nonuniformity of a size, thereby obtaining a sliding member.
The sliding member thus obtained is shown in FIG. 7. In the figure, 5 is the lubricating composition (fluororesin composition) formed by filling the networks 2 of the base member 1 of the network structure (expanded metal) to be the coating layer at the surface. t 1 represents a thickness of the coating layer, and though dependant on the use, the thickness of 0.05 mm to 1.0 mm is usually preferable.
[III] (a') The lubricating composition (fluororesin composition) to which a wetting property has been given is sprayed and supplied on a porous sintered metal layer formed on the back plate, and is rolled with a roller to impregnate the lubricating composition in the sintered layer, whereby a uniform coating layer of the lubricating composition is formed on the surface of the sintered layer. In this step, the lubricating composition is applied at a thickness which is 2 to 2.5 times the resin coating thickness required for the final product. Almost all of the filling of the resin into cavities of the porous sintered metal layer occurs in this step.
(b') The back plate in which the lubricating composition (fluororesin composition) is impregnated in and coated on the porous sintered metal layer is maintained for several minutes in a dry furnace heated to a temperature of 200° to 250° C., thereby the petroleum solvent is evaporated and eliminated, followed by pressing the dried lubricating composition layer with an applied pressure of about 300 to 600 kg/cm 2 by a roller so as to obtain a predetermined thickness.
(c') The back plate provided with the dried lubricating composition layer having been pressed by the roller is introduced into a heating furnace to heat for several minutes or ten-odd minutes at a temperature of 360° to 380° C., thereby baking it. The baked member is removed from the furnace and thereafter passed through the roller again to adjust any nonuniformity of a size.
(d') After the size adjustment, the back plate in which a sliding face layer has been formed is cooled, and then it is optionally passed through a correcting roller so as to correct undulation of the back plate, thereby obtaining a desired multi-layer sliding member.
After cutting the multi-layer sliding member to a suitable size, it can be used as a sliding plate as a planar plate, and in addition, after bending and rounding, it can be used as a cylindrical wound bushing.
As illustrated in examples 1 to 25, by using a suitable amount of the phosphate, in the case of using a hollow cylindrical shaft material (SUS304) as an opposite member at a speed of 11 m/min with a load of 40 kg/cm 2 and a testing period of 8 hrs in a dry state, the wear amount of the sliding member of the present invention is decreased by at least 25%, preferably decreased by 40%, more preferably decreased by 50% as compared with that of a sliding member containing no phosphate.
As clarified by examples 27 to 29 as described hereinafter, the sliding member, in which the fluororesin composition containing the phosphate is filled and coated in the networks and on the surface of the metal network structures, has a friction coefficient not more than 0.20, preferably not more than 0.15 and a wear amount not more than 0.10 mm, preferably not more than 0.08 mm, which is excellent in wear resistance, in the case of using mechanical structural carbon steel (S45C) as an opposite member at a speed of 5 m/min with a load of 100 cm 2 and a testing period of 8 hrs without lubrication.
In addition, as illustrated in examples 30 to 32, the sliding member, in which the fluororesin composition containing the phosphate is formed on a porous sintered metal layer formed on the steel back plate, has a friction coefficient not more than 0.20, preferably not more than 0.15 and a wear amount not more than 30 μm, preferably not more than 25 μm, more preferably not more than 20 μm, which is excellent in wear resistance, in the case of using mechanical structural carbon steel (S45C) as an opposite member at a speed of 11 m/min with a load of 100 kgf/cm 2 and a test period of 8 hrs without lubrication.
Therefore, the lubricating composition, which is filled and coated in the networks and on the surface of the base member of the network structure, can be used without settling of the member in a sliding usage such that it exhibits stable performance with a low friction coefficient with no damage to the opposite member during sliding with the opposite member. The coating composition becomes intimate with the surface of the opposite member due to the flexibility provided in the thickness direction of the base member, grasps the opposite member with great holding force, and smoothly supports rotation and the like of the opposite member.
The lubricating composition which is filled in and coated on the networks and on the surface of the base member has an electrical charge-preventing property because it is conductive, so that no special means are needed to provide conductivity.
The lubricating composition which is impregnated in and coated on the porous sintered metal layer formed on the back plate exhibits stable performance with low friction coefficient and no damage to the opposite member during sliding with the opposite member.
The lubricating composition which is impregnated in and coated on the porous sintered metal layer formed on the back plate has conductivity, so that it can be used for a sliding portion of various equipment requiring change-prevention.
The present invention will be further explained in detail according to examples hereinafter, however, the present invention is not limited to these examples.
EXAMPLES 1 to 25
Various phosphates and fillers were mixed with PTFE in ratios shown in the Table 1. They were homogeneously mixed with a Henshell mixer, and the mixed powder was charged into a mold for molding at a room temperature at a molding pressure of 500 kg/cm 2 , thereby producing a green compact. The green compact was heated under an ordinary pressure at 370° C. for 5 hours to form a molded raw material. The heated member was cooled to a room temperature followed by processing to produce a plate-shaped sliding member sample piece having sides 30 mm×30 mm×thickness 5 mm.
This sample was contacted with sliding against an end face of a hollow cylindrical shaft material (inner diameter 20 mm×outer diameter 25.6 mm, material quality: SUS 304) under the following conditions for a thrust test.
______________________________________Test condition:______________________________________Speed 11 m/minLoad 40 kg/cm.sup.2Period 8 hrLubrication dry______________________________________
The friction coefficient is shown as a changing value 1 to 8 hours after the start of the test.
Results are shown in Table 1.
As shown in Table 1, the fluororesin composition containing the glass fiber or other filler and containing a suitable amount of phosphate according to the present invention, exhibited improved wear resistance.
COMPARATIVE EXAMPLE I
A plate-shaped sliding member was prepared using the same procedures as described in Example 1, except no phosphate was included in the mixture.
The wear amount and friction coefficient of the prepared member are shown in Table 1.
EXAMPLES 26
This example investigated adding various amounts of phosphate and filler and observing how the wear resistance of the fluororesin composition changes. The conditions of the thrust test were the same as described above.
The results are shown in FIGS. 1 to 4. As illustrated in FIGS. 1 and 2, the amounts of glass fiber and phosphate are preferably 1 to 40% by weight and 0.1 to 15% by weight, respectively.
In addition, as shown in FIGS. 3 and 4 the amounts of carbon fiber and phosphate are preferably 1 to 30% by weight and 0.1 to 15% by weight, respectively.
EXAMPLE 27
Base Member
A phosphorous bronze alloy plate having a plate thickness of 0.3 mm was expanded to form an expanded metal having a thickness of 0.43 mm having hexagonal regular networks with each side (strand) of 0.6 mm. This was used as a base member.
In FIG. 5, the length of symbol 3 was 0.6 mm, and in FIG. 6, the thickness of symbol t was 0.43 mm.
Lubricating (Fluororesin) Composition
The PTFE resin used was "Teflon 6CJ" (produced by Mitsui du Pont Fluorochemical Co., Ltd.) having an average particle size not more than 80 μm. Then 65 to 90% by weight of this PTFE resin powder, 5 to 30% by weight of carbon fiber having a diameter of 10 μm and a length of 100 μm ("Zyrous GPMF100JL" produced by Nitto Boseki Co., Ltd.) and 5% by weight of calcium pyrophosphate passing through a 350 mesh seive (Ca 2 P 2 O 7 : produced by Kanto Chemical Co., Ltd.) as a phosphate were introduced into a Henshell mixer, and were mixed at a temperature not more than the transition point at a room temperature of the PTFE resin to obtain various lubricating compositions.
Production Steps
(a) To 100 parts by weight of this lubricating composition was blended 20 parts by weight of an aliphatic and naphthenic mixed solvent ("Exol" produced by Exxon Chemical Co., Ltd.) as a petroleum solvent. The solvent and lubricating composition were mixed at a temperature not more than the transition point of the PTFE resin at room temperature to impart a a wetting property to the lubricating composition.
(b) The lubricating composition to which the wetting property had been given was scattered and applied to a base member of the above-mentioned expanded metal, and was rolled to fill the networks of the base member with the lubricating composition and form a uniform coating layer of the lubricating composition on the surface of the base member. This was followed by heating for 5 minutes in a dry furnace heated to a temperature of 220° C., thereby evaporating and eliminating the petroleum solvent in the lubricating composition.
(c) The base member, in which the networks and the surface were filled and coated with the lubricating composition, was introduced into a heating furnace, and was heated for 10 minutes at a temperature of 360° C. to bake of the lubricating composition, then removed from the furnace.
A thickness of the surface coating layer of the lubricating composition of the sliding member thus obtained was 0.13 mm (a thickness of the symbol t 1 i FIG. 7).
The components of the lubricating composition of the sliding member of this Example 27 are shown in Table 2.
EXAMPLE 28
Base Member
A base member of the same expanded metal as that of Example 27 was used.
Lubricating (Fluororesin) Composition
The PTFE resin used was "Teflon 6CJ" (produced by Mitsui du Pont Fluorochemical Co., Ltd.) having an average particle size not more than 80 μm.[, and] Then 75 to 85% by weight of this PTFE resin powder, 10 to 20% by weight of carbon fiber having a diameter of 10 μm and a length of 100 μm ("Zyrous GPMF100JL" produced by Nitto Boseki Co., Ltd.) and 5% by weight of lithium pyrophosphate passing through a 350 mesh seive (Li 4 P 2 O 7 : produced by Kanto Chemical Co., Ltd.) as a phosphate were introduced into a Henshell mixer, and were mixed at a temperature not more than the transition point at a room temperature of the PTFE resin to obtain various lubricating compositions.
And then, production steps (a), (b), and (c), which were the same as those of Example 27, we used to obtain sliding members.
The components of the lubricating composition of the sliding member of this Example 28 are shown in Table 2.
EXAMPLE 29
Base Member
A base member of the same expanded metal as that of Example 27 was used.
Lubricating (Fluororesin) Composition
The PTFE resin used was "Teflon 6CJ" (produced by Mitsui du Pont Fluorochemical Co., Ltd.) having an average particle size not more than 80 μm.[, and] Then 72 to 87% by weight of this PTFE resin powder, 5 to 20% by weight of carbon fiber having a diameter of 10 μm and a length of 100 μm ("Zyrous GPMF100JL" produced by Nitto Boseki Co., Ltd.), 5% by weight of calcium pyrophosphate passing through a 350 mesh (produced by Kanto Chemical Co., Ltd.) as a phosphate, and 3% by weight of carbon black (CB3750: produced by Mitsubishi Chemical Industries Ltd.) as a conductive substance were introduced into a Henshell mixer, and were mixed at a temperature not more than the transition point at a room temperature of the PTFE resin to obtain various lubricating compositions.
And then, production steps (a), (b), and (c), which were the same as those of Example 27, were used to obtain sliding members.
The components of the lubricating composition of the sliding member of this Example 29 is shown in Table 2.
COMPARATIVE EXAMPLE II
Base Member
A base member of the same expanded metal as that of Example 27 was used.
Lubricating Composition
The PTFE resin used was "Teflon 6CJ" (produced by Mitsui du Pont Fluorochemical Co., Ltd.) having an average particle size not more than 80 μm.[, and] Next 70% by weight of this PTFE resin powder, and 30% by weight of carbon fiber having a diameter of 10 μm and a length of 100 μm were introduced into a Henshell mixer, and were mixed at a temperature not more than the transition point at a room temperature of the PTFE resin to obtain various lubricating compositions.
And then, production steps (a), (b), and (c), which were the same as those of Example 27, were used to obtain sliding member.
The components of the lubricating composition of the sliding member of this Comparative example II is shown in Table 2.
Next, results of tests are described for the friction and wear resistance and the volume resistivity (Ω·cm) of the sliding members obtained by Examples 27 to 29 and Comparative example II.
Friction and Wear Resistance
With respect to the friction and wear resistance, the following sliding conditions were used.
______________________________________(Sliding condition)______________________________________Sliding speed 5 m/minLoad 100 kgf/cm.sup.2Test period 8 hoursLubrication no lubricationCompanion member mechanical structural carbon steel (S45C)______________________________________
A change in the value of the friction coefficient from the start of the test to the end of the test was observed, and the wear amount after 8 hours was measured.
Volume Resistivity
Volume resistivity in a direction perpendicular to each sliding member surface was measured by a four probe resistivity measuring method using a resistivity meter (Lolester AP Mcp-T400 produced by Mitsubishi Petrochemical Co., Ltd.).
The friction and wear resistance and volume resistivity of each sliding member are shown in Table 2. According to the test results in Table 2, the sliding members of Example 27 to Example 28 exhibited stable performance throughout the test period with low friction coefficients and had extremely small wear amounts of the sliding members after the tests.
Although the sliding member of Example 27-vi contained 30% by weight of carbon fiber, no damage was found on the surface of the opposite member after the test. In addition, Values of 10 8 to 10 -3 were measured for volume resistivity.
Sufficiently satisfactory performance was obtained considering the fact that generally, with respect to the charge-preventing effect required for sliding portions of office equipment cabinets, the volume resistivity was not more than 10 8 , and conductivity required following exterior painting after assembling a sliding member to a door hinge, the volume resistivity was not more than 10 3 .
On the other hand, the sliding member of Comparative example II is an excellent material as to charge-preventing effect and conductivity, however, the friction coefficient is high, and with respect to the wear amount, even the base member is invaded, and considerable thin stripe-shaped damage was found on the surface of the opposite member.
In these examples an expanded metal has been used as the base member of the network structure, however, even when a metal mesh, which is formed by weaving metal thin wires as the base member in the warp and the woof is used, the same effect can be obtained.
EXAMPLE 30
The PTFE resin used was "Teflon 6CJ" (produced by Mitsui du Pont Fluorochemical Co., Ltd.) having an average particle size not more than 80 μm.[, and] Next 65 to 90% by weight of this PTFE resin powder, 5 to 30% by weight of CF having a diameter of 12 μm and a length of 100 μm ("Zyrous GPMF100JL" produced by Nitto Boseki Co., Ltd.) and 5% by weight of calcium pyrophosphate passing through a 350 mesh seive (produced by Kanto Chemical Co., Ltd.) as a phosphate were introduced into a Henshell mixer to grind and mix, and with respect to 100 parts by weight of the mixed powder, as a petroleum solvent was blended 20 parts by weight of an aliphatic and naphthenic mixed solvent ("Exol" produced by Exxon Chemical Co., Ltd.), which were mixed at a temperature not more than the transition point at a room temperature of the PTFE resin to obtain wetting of the lubricating compositions.
The wetting lubricating composition was applied to a porous sintered metal layer formed on a steel back plate of a metal thin plate, and was rolled with a roller to obtain a multi-layer plate of a thickness of 1.20 mm. The multi-layer plate was maintained for 5 minutes in a hot air dry furnace heated to a temperature of 200° C. to evaporate and eliminate the solvent, followed by pressing the dry lubricating composition layer with a pressing pressure of 400 kg/cm 2 with a roller to give a thickness of 1.05 mm.
Next, the multi-layer plate was introduced into a heating furnace to heat and bake at a temperature of 370° C. for 10 minutes, followed by pressing with a roller again as needed for size adjustment and correction of undulation of the plate and the like, followed by cutting to obtain a plate-shaped sliding member test piece having sides 30 mm×30 mm×thickness 1.05 mm.
The components of the lubricating composition of the sliding member of this Example 30 are shown in Table 3.
EXAMPLE 31
The PTFE resin used was "Teflon 6CJ" (produced by Mitsui du Pont Fluorochemical Co., Ltd.) having an average particle size of not more than 80 μm.[, and] Next 75 to 82% by weight of this PTFE resin powder, 15% by weight of CF having a diameter of 12 μm and a length of 100 μm and 3 to 10% by weight of lithium pyrophosphate passing through a 350 mesh (produced by Yoneyama Chemical Industries Co., Ltd.) as a phosphate were introduced into a Henshell mixer to grind and mix, and with respect to 100 parts by weight of the mixed powder, as a petroleum solvent was blended 20 parts by weight of an aliphatic and naphthenic mixed solvent ("Exol" produced by Exxon Chemical Co., Ltd.), and were mixed at a temperature not more than the transition point at a room temperature of the PTFE resin to obtain various wetting lubricating compositions.
The same procedures as in Example 30 were used to obtain a plate-shaped sliding member test piece having sides 30 mm×30 mm×thickness 1.05 mm.
The components of the lubricating composition of the sliding member of this Example 31 are shown in Table 3.
EXAMPLE 32
The PTFE resin used was "Teflon 6CJ" (produced by Mitsui du Pont Fluorochemical Co., Ltd.) having an average particle size not more than 80 μm.[and] Next 73 to 88% by weight of this PTFE resin powder 5 to 20% by weight of CF having a diameter of 12 μm and a length of 100 μm, 5% by weight of calcium pyrophosphate passing through a 350 mesh (produced by Kanto Chemical Co., Ltd.) as a phosphate, and 2% by weight of carbon black (produced by Mitsubishi Chemical Industries Ltd.: CB3750, hereinafter referred to as "CB") as a conductive substance were introduced into Henshell mixer to grind and mix, and with respect to 100 parts by weight of the mixed powder, as a petroleum solvent was blended 20 parts by weight of an aliphatic and naphthenic mixed solvent ("Exol" produced by Exxon Chemical Co., Ltd.), and were mixed at a temperature not more than the transition point at a room temperature of the PTFE resin to obtain various wetting lubricating compositions.
Samples we prepared as in Example 30 to obtain a plate-shaped sliding member test piece having sides 30 mm×30 mm×thickness 1.05 mm.
The components of the lubricating composition of the sliding member of this Example 32 are shown in Table 3.
COMPARATIVE EXAMPLE III
The PTFE resin used was "Teflon 6CJ" (produced by Mitsui du Pont Fluorochemical Co., Ltd.) having an average particle size not more than 80 μm[, and] Next 70 to 83% by weight of this PTFE resin powder, 1 30% by weight of CF having a diameter of 12 μm and a length of 100 μm, or 2 15% by weight of CF having a diameter of 12 μm and a length of 100 μm and 2% by weight of CB as a conductive substance were introduced into a Henshell mixer to grind and mix, and with respect to 100 parts by weight of the mixed powder, as a petroleum solvent was blended 20 parts by weight of an aliphatic and naphthenic mixed solvent ("Exol" produced by Exxon Chemical Co., Ltd.), and were mixed at a temperature not more than the transition point at a room temperature of the PTFE resin to obtain wetting lubricating compositions.
Samples were prepared using the procedure of Example 30 to obtain a plate-shaped sliding member test piece having sides 30 mm×30 mm×thickness 1.05 mm.
The components of the lubricating composition of the sliding member of this Comparative example III are shown in Table 3.
Next, friction, wear resistance and volume resistivity (Ω·cm) of the sliding members obtained by the above-mentioned Examples 30 to 32 and Comparative example III were measured.
Friction and Wear Resistance
The following sliding conditions were used to measure friction and wear resistance.
______________________________________(Sliding condition)______________________________________Sliding speed 11 m/minLoad 100 kgf/cmTest period 8 hoursLubrication no lubricationCompanion member mechanical structural carbon steel (S45C)______________________________________
Friction coefficient changed one hour after the start of the test. Wear amount after 8 hours of the test period was measured.
Volume Resistivity
Volume resistivity in a direction perpendicular to each sliding member surface was measured by a four probe resistivity measuring method using a resistivity meter (Lolester AP Mcp-T400 produced by Mitsubishi Petrochemical Co., Ltd.).
Friction, wear resistance and volume resistivity of each sliding member are shown in Table 3.
According to these test results, the sliding members of Example 30 to Example 32 exhibited stable performance through the test period with low friction coefficients and had extremely small amounts wear after the tests.
Although the sliding member of Example 30-vi contained 30% by weight of CF, no damage was found on the surface of the opposite member after the test.
Values of 10 8 to 10 -1 were reported for volume resistivity.
Sufficiently satisfactory performance was attaind considering that generally the conductivity required for sliding portions of office equipment, the volume resistivity is not more than 10 8 .
In contrast, although the sliding members of Comparative example III are very excellent materials with regard to conductivity, friction coefficients were high, and wear amounts also were large, with significant thin stripe-shaped damage observed on the surface of the opposite member.
TABLE 1__________________________________________________________________________Lubricant Wear FrictionEx. No.composition (% by weight) amount (μm) coefficient__________________________________________________________________________ 1 GF (MFB) 15% + Ca-pyrophosphate 24.59 0.11˜0.125% + MoS.sub.2 1% [Ca.sub.2 P.sub.2 O.sub.7 ] 2 GF (MFB) 15% + Ca-pyrophosphate 29.65 0.13˜0.165% + BN 2% [Ca.sub.2 P.sub.2 O.sub.7 ] 3 GF (MFB) 15% + Ca-pyrophosphate 22.70 0.12˜0.135% [Ca.sub.2 P.sub.2 O.sub.7 ] 4 GF (MFA) 15% + Tri Ca-phosphate 18.38 0.14˜0.25% [Ca.sub.3 (PO.sub.4).sub.2 ] 5 GF (MFA) 15% + Al-tripolyphos- 34.27 0.12˜0.22phate 5% [Al.sub.5 (P.sub.3 O.sub.10).sub.3 ] 6 GF (MFA) 15% + Hydroxyapatite 23.96 0.15˜0.215% [Ca.sub.10 (PO.sub.4).sub.6 (OH).sub.2 ] 7 GF (MFA) 15% + Ca-pyrophos- 23.41 0.11˜0.16phate 5% [Ca.sub.2 P.sub.2 O.sub.7 ] 8 GF (MFA) 15% + Li-phosphate 5% 22.72 0.13˜0.16[Li.sub.2 PO.sub.4 ] 9 GF (MFA) 15% + Li-pyrophosphate 26.03 0.1˜0.1155% [Li.sub.4 P.sub.2 O.sub.7 ]10 GF (MFA) 15% + Zn-phosphate 5% 48.65 0.16˜0.2[Zn(PO.sub.4).sub.2 ]11 GF (MFA) 15% + Ca-hydrogen- 22.00 0.1˜0.11phosphate 5% (anhydrous)[CaHPO.sub.4 ]12 GF (MFA) 15% + Ca-phosphate 5% 46.21 0.125˜0.2[CaPHO.sub.3.2H.sub.2 O]13 GF (MFA) 15% + Zn-pyrophos- 43.82 0.12˜0.195phate 5% [Zn.sub.2 P.sub.2 O.sub.7 ]14 GF (MFA) 15% + Mg-phosphate 35.03 0.135˜0.155% [Mg.sub.3 (PO.sub.4).sub.2.8H.sub.2 O]15 GF (MFA) 15% + Mg-hydrogen- 48.27 0.165˜0.21phosphate 5% [MgHPO.sub.4 3H.sub.2 O]16 GF (MFA) 15% + Ca-hydrogen- 22.55 0.11˜0.12phosphate dihydrate 5%[CaHPO.sub.4.2H.sub.2 O]17 CF (low) 15% + ca-pyrophosphate 14.83 0.11˜0.125% [Ca.sub.2 P.sub.2 O.sub.7 ]18 CF (high) 15% + ca-pyrophosphate 13.52 0.10˜0.115% [Ca.sub.2 P.sub.2 O.sub.7 ]19 CF (high) 15% + Ca-hydrogenphos- 13.26 0.11˜0.115phate 5% (anhydrous) [CaHPO.sub.4 ]20 CF (high) 15% + Li-phosphate 5% 14.76 0.11˜0.12[Li.sub.3 PO.sub.4 ]21 Bellpearl C600 15% + ca-pyrophos- 19.06 0.11˜0.125phate 5% [Ca.sub.2 P.sub.2 O.sub.7 ]22 Bellpearl C2000 15% + ca-pyrophos- 20.44 0.105˜0.115phate 5% [Ca.sub.2 P.sub.2 O.sub.7 ]23 Pre-calcined coke 15% + ca-pyro- 19.88 0.11˜0.12phosphate 5% (average particlesize 14 μm) [Ca.sub.2 P.sub.2 O.sub.7 ]24 Kainol CF16BT 15% + Ca-pyro- 29.10 0.105˜0.11phosphate 5% [Ca.sub.2 P.sub.2 O.sub.7 ]25 Pyrofil (PAN type) 15% + Ca-pyro- 12.00 0.11˜0.115phosphate 5% [Ca.sub.2 P.sub.2 O.sub.7 ]__________________________________________________________________________Com. Lubricant Wear FrictionEx. Icomposition (% by weight) amount (μm) coefficient__________________________________________________________________________a GF (MFA) 15% 65.30 0.17˜0.25b GF (MFA) 20% 76.33 0.15˜0.235c CF (low temperature-treated 57.75 0.13˜0.23article) 15%d CF (high temperature-teated 53.50 0.12˜0.24article) 15%e CF (high) 15% + Ca-carbonate 5% 39.88 0.13˜0.24[CaCO.sub.3 ]f CF (high) 15% + Graphite (CSSP) 46.44 0.12˜0.223%g CF (high) 15% + Molybdenum 61.28 0.11˜0.28disulfide (UP-15)h Globular phenol resin 15% 44.27 0.115˜0.18(Bellpearl C600)i Bellpearl C2000 15% 36.74 0.115˜0.19j Pre-calcined coke 15% 51.38 0.105˜0.24(average particle size 14 μm)k Phenol carbon fiber 15% 39.50 0.12˜0.21(Kainol CF16BT)l Pyrofil (PAN type) 15% 79.42 0.13˜0.25__________________________________________________________________________ (Note) GF (MFB): glass fiber (MFB) produced by Asahi Fiber Glass Co., Ltd.: 0 = 13 μm, 1 = 100˜300 μm GF (MFA): glass fiber (MFA) produced by Asahi Fiber Glass Co., Ltd.: 0 = 13 μm, 1 = 30˜100 μm CF: carbon fiber, pitch type, trade name: Zyrous (Nitto Boseki Co., Ltd.) average length = 100 μm, diameter = φ12 μm Low temperaturetreated article: treated at 1000 to 1500° C. High temperaturetreated article: treated at 2000 to 2500° C. Bellpearl C600: Bellpearl R800 is treated at 600° C. Bellpearl C2000: Bellpearl R800 is treated at 2000° C. Balance of the lubricant composition in the table is PTFE.
TABLE 2__________________________________________________________________________Lubricating composition(% by weight) Wear Volume Carbon Phosphate Conductive amount resistiv-PTFE fiber coefficient substance Friction (mm) ity (Ω · cm)__________________________________________________________________________Ex. 27 i 90 5 Ca.sub.2 P.sub.2 O.sub.7 5 -- 0.06˜0.08 0.07 1 × 10.sup.8 ii 85 10 Ca.sub.2 P.sub.2 O.sub.7 5 -- 0.07˜0.10 0.06 1.4 × 10.sup.6 iii 80 15 Ca.sub.2 P.sub.2 O.sub.7 5 -- 0.07˜0.10 0.04 3.2 × 10 iv 75 20 Ca.sub.2 P.sub.2 O.sub.7 5 -- 0.09˜0.10 0.02 4.5 × 10.sup.-2 v 70 25 Ca.sub.2 P.sub.2 O.sub.7 5 -- 0.10˜0.12 0.07 9.8 × 10.sup.-3 vi 65 30 Ca.sub.2 P.sub.2 O.sub.7 5 -- 0.11˜0.14 0.08 9.3 × 10.sup.-3Ex. 28 i 85 10 Li.sub.4 P.sub.2 O.sub.7 5 -- 0.08˜0.10 0.07 1.4 × 10.sup.6 ii 80 15 Li.sub.4 P.sub.2 O.sub.7 5 -- 0.07˜0.10 0.04 3.0 × 10 iii 75 20 Li.sub.4 P.sub.2 O.sub.7 5 -- 0.08˜0.11 0.02 4.7 × 10.sup.-2Ex. 29 i 87 5 Ca.sub.2 P.sub.2 O.sub.7 5 Carbon 0.07˜0.09 0.08 1 × 10 black 3 ii 82 10 Ca.sub.2 P.sub.2 O.sub.7 5 Carbon 0.07˜0.10 0.07 5.6 × 10.sup.-1 black 3 iii 77 15 Ca.sub.2 P.sub.2 O.sub.7 5 Carbon 0.08˜0.10 0.05 4.3 × 10.sup.-2 black 3 iv 72 20 Ca.sub.2 P.sub.2 O.sub.7 5 Carbon 0.10˜0.11 0.02 9.6 × 10.sup.-3 black 3* 70 30 -- -- 0.28˜0.35 0.23 8.7 × 10.sup.-3__________________________________________________________________________ *Comparative example II
TABLE 3__________________________________________________________________________Lubricating composi- wear Volumetion, % by weight Friction amount resistivityPTFE CF Phosphate CB coefficient μm Ω · cm__________________________________________________________________________Ex. 30 i 90 5 5 -- 0.10˜0.11 14 4.1 × 10.sup.8 ii 85 10 5 -- 0.09˜0.11 12 1.1 × 10.sup.5 iii 80 15 5 -- 0.10˜0.11 8 1.2 × 10.sup.3 iv 75 20 5 -- 0.10˜0.11 5 5.5 × 10.sup.1 v 70 25 5 -- 0.11˜0.13 15 6.3 × 10.sup.0 vi 65 30 5 -- 0.12˜0.15 20 8.8 × 10.sup.-1Ex. 31 i 82 15 8 -- 0.10˜0.12 12 5.5 × 10.sup.2 ii 80 15 5 -- 0.10˜0.11 7 7.4 × 10.sup.2 iii 75 15 10 -- 0.12˜0.14 18 8.2 × 10.sup.2Ex. 32 i 88 5 5 2 0.09˜0.11 18 7.6 × 10.sup.3 ii 83 10 5 2 0.10˜0.11 9 1.4 × 10.sup.2 iii 78 15 5 2 0.10˜0.11 6 8.1 × 10.sup.0 iv 73 20 5 2 0.11˜0.12 8 1.5 × 10.sup.0* i 70 30 -- -- 0.20˜0.33 65 8.6 × 10.sup.-1 ii 83 15 -- 2 0.22˜0.88 96 8.2 × 10.sup.1__________________________________________________________________________ *Comparative example III
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Disclosed herein are a fluororesin composition for a sliding member comprising a fluororesin, at least one of fillers selected from the group consisting of glass fiber, glass powder, carbon fiber and carbon powder, and a phosphate, and a sliding member thereof.
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BACKGROUND OF THE INVENTION
This invention relates to a spin size and thermosetting aid for pitch fibers.
In order to convert pitch fibers into carbon fibers it is necessary to first thermoset them before they can be carbonized to produce the desired final product. Generally, such fibers are spun and further processed into carbon in the form of multifilament yarn or tow. Because of the exothermic nature of pitch oxidation, however, hot spots often develop in the multifilament bundle during thermosetting which cause the fibers to melt or soften before they become infusibilized. As a result of this, deformation of the individual filaments occurs along with exudation of molten pitch through the filament surfaces which causes them to stick together at various points of contact along the length of the yarn or tow. This deformation and sticking of the fibers in turn causes the yarn or tow to become stiff and brittle and to suffer a loss of flexibility and tensile strength. As a result, such yarn or tow cannot be further processed without breaking a large number of filaments.
Spin sizes are conventionally applied to pitch fiber yarn or tow immediately following spinning in order to maintain the integrity of the yarn or tow, to provide lubricity at the filament-to-filament interfaces, and to impart abrasion resistance to the filament bundle. However, while such sizes improve the handleability of the yarn or tow prior to thermosetting, they often are of no value, or only of limited value, during thermosetting. Thus, for example, while mixtures of plain water and glycerol impart good handling properties to as-spun pitch fiber yarn or tow, such yarn or tow is still subject to the same disadvantages encountered during thermosetting of unsized yarn or tow, i.e., melting and sticking of the fibers often occurs which causes a reduction of the flexibility and tensile strength of the fiber bundle.
One attempt to overcome the sticking problem encountered during thermosetting is disclosed in U.S.S.R. Pat. No. 168,848. The approach to the problem suggested in that reference is to fan the filaments with coal dust prior to thermosetting. However, not only is this method dirty and inconvenient, but it is also very difficult to apply a uniform layer of particles to the filaments by this technique. Furthermore, because coal has a high inorganic impurity content, significant pitting of the fiber surfaces occurs during oxidation which is accompanied by a concomitant reduction in the strength of the fibers after carbonization.
A similar attempt to surmount the sticking problem and at the same time accelerate oxidation of pitch fibers is disclosed in U.S. Pat. No. 3,997,654 wherein it is suggested that the fibers be dusted with activated carbon which has been impregnated with an oxidizing agent. However, this procedure appears to suffer from the same disadvantages as the process of U.S.S.R. Pat. No. 168,848. Furthermore, because of the hardness and large size of the particles employed (60 microns), this procedure does not provide sufficient separation of the filament bundle to allow maximum contact of the oxidizing gas with the fiber surfaces or provide sufficient lubricity between the fibers to prevent physical damage to the fiber surfaces.
SUMMARY OF THE INVENTION
The present invention provides a method of treating a multifilament bundle of pitch fibers, such as yarn or tow, to prepare such multifilament bundle for further processing which comprises applying to the fibers thereof an aqueous finishing composition comprising a dispersion of graphite or carbon black in water in which is dissolved a first compound comprising a water-soluble oxidizing agent and a separate second compound comprising a water-soluble surfactant.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The aqueous dispersion employed to treat a multifilament bundle of pitch fibers according to the present invention serves as both a size for the bundle and as an effective thermosetting aid during the infusibilization step which must be conducted before the fibers can be carbonized to produce the desired product. Because the graphite or carbon black particles are applied as a finely-divided dispersion, more effective penetration of these particles between the filaments of the bundle is achieved. As a result of this increased pentration of the particles, greater lubricity is provided between the filaments which helps prevent physical damage to the fiber surfaces during subsequent processing. In addition, the separation of the fiber bundle caused by the infiltration of these minute particles between the filaments allows improved penetration of the oxidizing gas into the bundle during thermosetting, which helps reduce oxidation time and the exothermic excursion and filament fusion which ordinarily occurs at that time. As noted previously, such fusion reduces the flexibility and tensile strength of the yarn or tow.
Either finely-divided graphite or carbon black can be employed in the dispersions employed in the present invention. Materials such as activated carbon and coal are undesirable because they are abrasive and contain a high amount of inorganic impurities (usually several percent) which is known to cause pitting of the fiber surfaces during oxidation and a concomitant loss of fiber strength. For this reason, it is preferable to use graphite or carbon black as they are softer, more slippery materials and are available in a relatively pure state compared to other carbonaceous materials. For best results, the graphite or carbon black should contain less than 0.5 percent by weight of inorganic impurities. This inorganic impurity content is usually measured by determining the ash content of such materials.
Any form of carbon black, e.g., gas blacks, furnace combustion blacks, furnace thermal blacks, lampblacks, may be employed in the dispersions of the present invention. Likewise, any form of graphite, either natural or synthetic, can be employed. In order to allow maximum penetration of such particles between the filaments of the fiber bundle, they should be no greater than 15 microns in size. Preferably, they have a size of from 0.3 micron to 5 microns. Because of the small size of these particles, they readily infiltrate the fiber bundle and uniformly coat the filaments. When the fiber bundle is further processed, these soft and slippery particles readily slide over each other and over the filaments so that the fibers are less subject to breakage and damage. Furthermore, the separation of the fiber bundle caused by the infiltration of these minute particles between the filaments facilitates permeation of the oxidizing gas into the bundle during thermosetting. This increased permeation of oxygen into the fiber bundle reduces the oxidation time and allows the fibers to be processed at greatly increased speeds. Ordinarily, unless filament packing in the fiber bundle is kept low and the oxidation process is very gradual, an exotherm excursion occurs during oxidation which causes fusion of the filaments to occur. Because of the separation of the fiber bundle caused by the infiltration of the graphite or carbon black particles between the filaments, however, the filament surfaces are brought into contact with the oxidizing gas to a greater extent during oxidation and such heat excursion is prevented. As a result, the fibers can be more rapidly oxidized without the fusion and filament sticking which formerly occurred. Thus, throughput speeds of at least 1.5 times that formerly attained without the use of such dispersions are now possible without loss of fiber properties. As a result, production capacity and the economics of the process have been greatly improved.
By adjusting the concentration and wetting characteristics of the dispersion employed in the present invention, it is possible to control the amount of graphite or carbon black which is deposited on the pitch fiber bundle. Generally, the dispersion contains from about 0.1 part by weight to about 10 parts by weight of graphite or carbon black per 100 parts by weight of mixture, preferably from 1 part by weight to 6 parts by weight of graphite or carbon black per 100 parts by weight of mixture.
Any water-soluble compound which is capable of functioning as an oxidizing agent at the temperature at which thermosetting is effected can be employed as a thermosetting aid in the aqueous dispersions employed in the present invention, provided such compound does not cause the suspension to flocculate. Because the compounds employed are water soluble, their physical presence on the fiber surfaces during thermosetting is assured. Oxidation and infusibilization of the fibers is thereby enhanced during thermosetting, allowing the fibers to be processed at greatly increased speeds. Suitable oxidizing agents include peroxygenated compounds, for example, peroxides, persulfates, pyrosulfates, and perchlorates. Among the compunds which can be employed are sodium peroxide, potassium peroxide, sodium persulfate, potassium persulfate, sodium pyrosulfate, potassium pyrosulfate, sodium perchlorate, potassium perchlorate, and magnesium perchlorate. Sulfates, sulfites, bisuflites, sulfamates, and nitrates are also suitable, including, for example, sodium sulfate, potassium sulfate, sodium sulfite, potassium sulfite, sodium bisulfite, potassium bisulfite, sodium sulfamate, potassium sulfamate, sodium nitrate, and potassium nitrate. However, because such salts leave residues on the fibers and may cause pitting of the fiber surfaces during oxidation, it is preferred to use the corresponding ammonium salts or such compounds as hydrogen peroxide and sulfamic acid. Certain oxidizing agents which also act as a surfactant are not employed, however, because a surfactant is otherwise provided in the dispersion.
Any water-soluble surfactant can be employed in the aqueous dispersions employed in the present invention, provided such surfactant does not cause the suspension to flocculate. Anionic and nonionic surfactants are preferred for this reason. Such surfactants serve to increase wetting of the fibers by the dispersion by reducing the surface tension of the water, thereby promoting the distribution of the graphite or carbon black throughout the fiber bundle. As a result, oxidation and infusibilization of the fibers during thermosetting is enhanced and the fibers can be processed at greatly increased speeds. Suitable surfactants include tetramethyl sodium oleate, tetramethyl sodium laurate, sodium laruate, and the like. However, because such salts leave resiudes on the fibers and may cause pitting of the fiber surfaces during oxidation, it is preferred to use the corresponding ammonium salts. Certain surfactants which also act as an oxidizing agent are not employed because an oxidizing agent is otherwise provided in the dispersion.
Generally, an amount of surfactant is employed which will impart a surface tension of less than about 50 dynes/cm. to the dispersion, preferably less than about 40 dynes/cm. The amount of oxidizing agent employed should not exceed an amount which will destroy the stability of such dispersion. Generally, from about 0.1 part by weight to about 2.0 parts by weight, preferably from about 0.2 part by weight to about 0.8 part by weight, per 100 parts by weight of mixture are satisfactory. If necessary, a suitable dispersing agent may be employed to facilitate dispersion of the graphite or carbon black in the water and maintenance of the dispersion. Suitable stabilizers, film formers, etc., may also be employed if desired.
After the dispersion has been formed, it is applied to the fibers by an convenient means, such as by spraying, brushing, rolling, or simply by immersing the fibers in the dispersion. A convenient means of applying the dispersion to the fibers is to pass the fibers over a sizing wheel which rotates in a bath of the dispersion and is coated with the dispersion. This, preferably, is done as the fibers emerge from the spinnerette. By controlling the size and speed of the wheel it is possible to control the amount of the dispersion which is applied to the fibers. In any event, the fibers should be allowed to absorb a sufficient amount of the suspension to provide from about 0.1 gram of the dispersion to about 1.5 grams of the dispersion per gram of fiber.
The fibers treated in this manner are then thermoset in a conventional manner by heating in an oxygen-containing atmosphere, such as pure oxygen or air. Drying of the fibers is not necessary and the fibers can be thermoset while still wet if desired. Such thermosetting, of course, must be carried out at a temperature below the temperature at which the fibers soften or distort. Because the thermosetting action of the oxidizing agent employed usually commences at a temperature below 200° C. where the rate of oxidation is ordinarily quite slow, infusibilization can usually be effected at lower temperatures than are normally required, or in shorter periods of time than are normally required. While the time required to oxidize the fibers to the desired degree will vary with such factors as the particular oxidizing atmosphere, the temperature employed, the diameter of the fibers, and the particular pitch from which the fibers were prepared, at any given temperature such time is usually less than two-thirds of the time required when the fibers are not treated with the dispersions of the present invention.
The thermoset fibers may then be carbonized in a conventional manner by heating them in an inert atmosphere to a temperature sufficiently elevated to remove hydrogen and other carbonizable by-products and produce a substantially all-carbon fiber. Fibers having a carbon content greater than about 98 percent by weight can generally be produced by heating to a temperature in excess of about 1000° C., and at temperatures in excess of about 1500° C. the fibers are completely carbonized. Generally, carbonization times of from about 2 seconds to about 1 minute are sufficient.
If desired, the carbonized fibers may be further heated in an inert atmosphere to a graphitization temperature, e.g., from about 2500° C. to about 3300° C.
Pitch fibers suitable for use in the present invention can be prepared in accordance with well-known techniques. Preferably, the fibers employed are prepared from mesophase pitch as described in U.S. Pat. No. 4,005,183.
While the invention has been described with reference to pitch fiber yarn or tow, it should be apparent that fibers of other carbonizable organic polymeric materials, such as homopolymers and interpolymers or acrylonitrile, can be treated in a similar manner.
The following examples are set forth for purposes of illustration so that those skilled in the art may better understand this invention. It should be understood, however, that they are exemplary only, and should not be construed as limiting this invention in any manner. Tensile strength and pull strength properties referred to in the examples and throughout the specification were determined as described below unless otherwise specified.
TENSILE STRENGTH
Tensile strength was determined on an Instron testing machine at a cross-head speed of 0.02 cm/min. All measurements were made on 10-inch length unidirectional fiber-epoxy composites.
PULL STRENGTH
Pull strength was determined on Mechanical Force Gage Model D-20-T, manufactured by Hunter Spring Co., Hatfield, Pa., a division of Ametak Inc. The filament or filament bundle to be tested is passed over a pulley which is attached by means of a spring to a gauge designed to record the force in pounds exerted on the pulley. Both ends of the filament or filament bundle are then wrapped around a mandrel which is suspended from the pulley by means of the filament or filament bundle. Typically, a distance of from about 3 to 12 inches is provided between the pulley and the mandrel. Tension is then exerted on the filament or filament bundle by pulling down on the mandrel until the yarn breaks. The total force in pounds required to break the filament or filament bundle is recorded on the gauge. This force is designated as the pull strength of the filament or filament bundle.
EXAMPLE 1
Continuous pitch filaments were spun through two 1000 hole hot melt spinnerettes from a 322° C. softening point mesophase pitch having a mesophase content of 77 percent. The capillary holes of the spinnerette were 4 mils in diameter and 8 mils in length. As the filaments emerged from the spinnerette, they were combined into a single bundle which was drawn down over a sizing wheel which rotated in a bath containing a suspension of carbon black flour in and aqueous solution of ammonium persulfate and ammonium laurate. The fibers were spread over the slowly rotating wheel as they were brought into contact with it and were thoroughly wetted by and uniformly coated with the suspension by this procedure. The coated fibers were then collimated into a yarn by means of a gathering wheel having a "V" slot, and subsequently drawn down to a diameter of about 14 microns by means of two godet wheels.
The suspension employed to coat the fibers contained 3.6 parts by weight of carbon black, 0.8 part by weight of ammonium persulfate, and 0.4 part by weight of ammonium laurate per 100 parts by weight of mixture. The carbon black particles present in the suspension had an average size of 0.5 micron. The composition was prepared by admixing (a) 3.2 parts by weight of an aqueous solution containing 25 parts by weight of ammonium persulfate in 75 parts by weight of water with (b) 20 parts by weight of an aqueous solution containing 2 parts by weight of ammonium laurate in 98 parts by weight of water, and (c) 6.4 parts by weight of "Dylon"* DS insulating carbon coating (a commercially available suspension of 56 parts of weight of amorphous carbon in 44 parts by weight of water), and then adjusting the pH of the mixture to 10 by means of ammonium hydroxide to give 100 parts of mixture.
The fibers treated in this manner were then thermoset by transporting them through a 40-foot long forced air convection furnace at a speed of 6 inches per minute. The furnace contained eight zones, each 5 feet in length, and the fibers were gradually heated from 175° C. in the first or entrance zone to 380° C. in the eighth or exit zone while air was passed through the furnace at a velocity of 4 feet/minute. Total residence time in the furnace was 80 minutes. The fibers produced in this manner were totally infusible. A 3-inch length of the thermoset fibers had a pull strength of 5.1 lbs. and a 12-inch length had a pull strength of 3.1 lbs. (By 3-inch and 12-inch lengths is meant the distance between the pulley and the mandrel of the Mechanical Force Gage employed in the determination.)
The thermoset fibers were then wound on a roller and carbonized by heating them in a nitrogen atmosphere at at temperature of about 2200° C. for 3 seconds. After carbonization, the fibers had a strand tensile strength of 302,000 psi.
EXAMPLE 2
The procedure of Example 1 was repeated employing a colloidal suspension of graphite flour in an aqueous solution of ammonium persulfate and ammonium laurate. The suspension contained 3.6 parts by weight of graphite, 0.8 part by weight of ammonium persulfate, and 0.4 part by weight of ammonium laurate per 100 parts by weight of mixture. The graphite particles present had an average size of 1 micron. This composition was prepared by admixing (a) 3.2 parts by weight of an aqueous solution containing 25 parts by weight of ammonium persulfate in 75 parts by weight of water with (b) 20 parts by weight of an aqueous solution containing 2 parts by weight of ammonium laurate in 98 parts by weight of water, and (c) 16.4 parts by weight of "Aquadag"* micro-graphite colloid in aqueous suspension (a commercially available colloidal suspension of 22 parts by weight of graphite in 78 parts by weight of water), and then adjusting the pH of the mixture to 9.7 by means of ammonium hydroxide to give 100 parts of mixture.
After thermosetting, a 3-inch length of the fibers had a pull strength of 4.7 lbs. and a 12-inch length had a pull strength of 3.8 lbs.
When the procedure was repeated eliminating the ammonium persulfate from the colloidal suspension employed to treat the fibers, a 3-inch length of the thermoset fibers had a pull strength of 2.4 lbs. and a 12-inch length has a pull strength of 1.8 lbs.
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A method of treating a multifilament bundle of pitch fibers, such as yarn or tow, to prepare such multifilament bundle for further processing which comprises applying to the fibers thereof an aqueous finishing composition comprising a dispersion of graphite or carbon black in water in which is dissolved a water-soluble oxidizing agent and a water-soluble surfactant. The finishing composition serves as both a size for the fiber bundle and as a thermosetting aid during infusibilization of the fibers.
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BACKGROUND OF THE INVENTION
This application is a continuation-in-part of application Ser. No. 08/195,119 entitled Safety Delineators, now U.S. Pat. No. 5,560,732 and filed on Feb. 10, 1994.
This application relates to traffic safety delineators, and more particularly to an improved vertical panel which is fixedly mounted to a traffic safety delineator having a conical structure, thereby having a unique capability of being easily stacked and transported.
Traffic safety delineators are extensively used at the present time to mark potential driving hazards, such as construction zones, potholes, etc., as well as to channelize traffic past such hazards. They are often used, as well, on sidewalks, bicycle paths, parking lots, indoor shopping malls, and the like to alert passersby to potential dangers, whatever the mode of transportation.
Vertical panels are well known in the prior art for use as barrel delineators when lack of space is an issue, being typically mounted on metallic stands and the like. They are most usually fabricated of polyethylene sheeting and have a minimum frontal surface area of 270 square inches as required by U.S. government standards, the frontal surface comprising alternating contrasting stripes (typically orange and white contrasting stripes) arranged in a diagonal pattern. This configuration has been shown to assist motorists in guiding their vehicles through the demarcated zone.
Traffic safety delineators having a conical structure are particularly widely used, and are commonly referred to as traffic safety cones. Although they may comprise only a freestanding conical body portion, they more typically include an integral weighted base as well, in order that the body portion may be stably supported in the wind gusts which are typically generated by high speed traffic, as well as by natural weather patterns. Prior art bases are typically fabricated of a solid material, such as rubber or plastic, in order to provide adequate weight to anchor the delineator body, which is typically molded of a resilient plastic.
Both traffic safety cones and vertical panels are designed to be temporary and portable, so are frequently lifted and transported from place to place, either within a single which permits a comfortable full hand grip of the cone.
SUMMARY OF THE INVENTION
The present invention solves the aforementioned problems of the prior art by providing a safety delineator having a conical body portion to which is attached one or more vertical panels. A new and improved handle feature permits easy and comfortable full hand gripping of the delineator and also prevents sticking and jamming together of a plurality of the delineators when they are stacked. The delineators may be stacked with the vertical panels attached thereto, since each vertical panel is particularly designed to wrap around the conical body portion to which it is attached as another vertical delineator slides over it.
More particularly, a safety delineator is provided which comprises a body portion having a top end and a base end, wherein the base end includes a horizontal support element for supporting the body portion in an upstanding position. A handle, which is adapted to permit convenient generally full hand gripping of the safety delineator, is integrally molded with the body portion and comprises a shaft portion axially oriented and extending axially upwardly from the body portion top end. A knob portion extends axially upwardly from the shaft portion. Preferably the handle is at least three inches long and the shaft portion has a sufficient length to permit all of the fingers of an average adult hand to be wrapped thereabout. One or more vertical panels are preferably fixedly attached to the body portion.
In another aspect of the invention, a safety delineator is provided which comprises a conical body portion constructed of a resilient plastic material and having a top end and a base end. The base end includes a horizontal support element for supporting the body portion in an upstanding position and one or more vertical panels fixedly attached to the body portion. Each vertical panel is preferably attached to its corresponding conical body using one or more mechanical fasteners, such as metal tubular rivets (plastic push rivets could be used as well), and is generally rectangular in shape, having two upper corners and two lower corners. The two upper corners of the vertical panel preferably have a rounded configuration to facilitate wrapping of the vertical panel about the circumference of the body portion to which it is attached when another delineator is stacked thereatop in a nesting fashion construction site as the construction project progresses, or between different sites. Thus, it is important that the temporary markers be easy and convenient to pick up. Unfortunately, however, neither prior art cones nor vertical panels typically provide means for being conveniently gripped, and are usually just lifted by attempting to grab some portion of the body portion of the cone or vertical panel itself. Both the cone and the vertical panel can be quite heavy and awkward to pick up, particularly with the supporting structure attached.
Several prior art designs have been developed to attempt to provide a handle for picking up traffic safety cones and the like. For example, a traffic safety cone having a bail handle, like that of a pail, extending from the top thereof is known in the prior art. Also, traffic safety cones and tubes are presently available which have a T-top handle extending from the top thereof Such a handle may be used to carry the tube or cone by grasping the T-top with one's fingers. However, neither type of handle is fully satisfactory in providing a convenient means for easily grasping and picking up a delineator, since they do not permit a comfortable, full hand grip, and tend to pinch and cramp the user's fingers over time.
Another problem with traffic safety cones results from the common practice of stacking the cones when storing or transporting them. Obviously, stacking the cones is advantageous because of the space which is saved and because of the increased number of cones which may be transported at one time. However, as one cone is dropped downwardly over another one in a stacking relationship, they tend to stick and jam together, because of the interfering contact between their respective sidewalls. This problem is aggravated in warm weather, when the cone sidewall material tends to expand and increase the interfering contact. Once jammed, they can be very difficult to separate, and the tedious process of doing so can be labor intensive and result in downtime and frustration for the construction crew.
Because of their non-uniform construction and typically metallic supporting stands, vertical panels are even more difficult to transport and store. Since they are not stackable, they tend to be stowed singly in a storage yard or truck in a somewhat haphazard manner, wasting space and increasing clutter.
What is needed, therefore, is a vertical panel having a supporting structure which permits convenient stacking of a plurality of vertical panels, as well as a handle for providing a convenient means for gripping the vertical panel, in order to transport it to a new location. Furthermore, an improved traffic safety cone is needed, including a contoured gripping means
In yet another aspect of the invention, a method of storing or transporting a plurality of vertical panel delineators, wherein each delineator comprises a conical body portion having at least one vertical panel attached thereto, is disclosed. The method comprises the steps of standing a first one of said delineators in an upright position and stacking a second one of the delineators over the first delineator in a nesting fashion such that the vertical panel attached to the first delineators wraps about the conical body portion thereof as the second delineator slides over the first vertical panel.
The invention, together with additional features and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying illustrative drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view illustrating a conical safety delineator (traffic safety cone) having vertical panels attached thereto, constructed in accordance with the present invention;
FIG. 2 is a fragmentary view, partially in cross-section, of the top handle portion of the delineator illustrated in FIG. 1;
FIG. 3 is a cross-sectional view taken along lines 3--3 of FIG. 2;
FIG. 4 is a cross-sectional view taken along lines 4--4 of FIG. 1, illustrating a preferred means for attaching the vertical panels to the conical safety delineator; and
FIG. 5 is a cross-sectional view illustrating two stacked conical safety delineators of the type shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, FIG. 1 illustrates a vertical panel delineator 10 constructed in accordance with the invention. The delineator 10 comprises a highway safety cone 12 having a conical body portion 14, which includes a top end 16 and a base end 18. The conical body portion 14 has a minimum diameter at the top end 16 and expands conically to a maximum diameter at the bottom end 18. At the bottom end, a lip portion 20 (FIG. 5) flares outwardly to form a horizontal support base for the cone body 14, and to provide a means for assembling the cone 12 to a weighted support base (gravity anchor) 22. The illustrated support base 22 is constructed of a solid dense material, preferably rubber, but could also comprise a hollow plastic ballasted member, as is discussed in the co-pending parent application 08/195,119 entitled Safety Delineators, now U.S. Pat. No. 5,560,732 and filed on Feb. 10, 1994. Both such bases are available commercially from the assignee of the present application. The cone body 14 itself, between the top end 16 and the lip portion 20, is conventional in construction and is preferably fabricated of a resilient plastic using known molding techniques.
An advantageous and important feature of the invention is the addition of a handle 24 to the cone 12, which enables a user to quickly and easily grip the cone in order to transport it between locations. The handle 24 is preferably molded to be integral with the cone body 14, extending upwardly from the top end 16, and is configured to generally resemble a doorknob. In its preferred configuration, the handle includes a first transition fillet 26, a necked down generally cylindrical shaft portion 28, and a generally hemispherical knob portion 30. The first fillet 26 transitions the handle 24 between the diameter of the top end 16 (approximately 4 inches in the preferred embodiment) and that of the cylindrical shaft 28. The diameter of the shaft 28 is small enough to be comfortably gripped by the hand of an average adult (approximately 11/4 inches in the preferred embodiment). A second transition fillet 32 (FIG. 2) transitions the handle 24 between the diameter of the shaft 28 and the diameter of the knob 30, which in the preferred embodiment is about 23/4 inches. The purpose of the knob is primarily to prevent a user's hand from slipping off of the end of the shaft 28. Of course, the actual configuration and dimensions of the handle 24 may be varied in accordance with particular design and manufacturing considerations, as long as it functions to permit easy and convenient gripping of the cone.
Preferably, the handle shaft portion 28 includes a plurality of spaced circumferential ribs 34 (FIGS. 1 and 2), which primarily function to improve a user's grip on the shaft by preventing slipping of his or her hand thereon. In the preferred embodiment, they are blended out at the mold parting line for ease of fabrication (not shown). Any number of ribs may be employed, but they may also be eliminated if desired, or replaced by an alternate non-skid surface, such as rubberized tape or the like.
Still another desirable feature is the employment of a plurality of circumferentially spaced stiffeners 36, best seen in FIG. 3, of which there are preferably four, although a different number may be used. The stiffeners 36, which are molded protrusions, extend axially through the first transition fillet 26, functioning to reinforce it and to prevent it from buckling because of downward pressure on the handle 24, which is commonly applied in the ordinary course of utilizing the cone 12.
A key feature of the present invention is the use of the safety cone 12 as a convenient platform for supporting one or more vertical panels 38. The vertical panels 38 are conventional, in that they are rectangular in configuration, preferably fabricated of polyethylene sheeting or some other flexible, weather-resistant material, and preferably have a minimum frontal surface area of 270 square inches, in order to meet current governmental regulations. In a preferred embodiment, they are approximately 8 inches in width and 36 inches in length. The frontal surface of each panel 38 (only one of which is shown) has a plurality of alternating contrasting stripes 40 and 42, which are preferably orange and white, respectively. Each vertical panel 38 is preferably attached to the body portion 14 of the safety cone 12 using metal tubular rivets 44 (best seen in FIG. 4), in combination with low profile washers 45 (FIG. 4). Alternatively, plastic push rivets could be utilized. The tubular rivet is pushed through a corresponding hole 46 in the body portion 14, as well as through the vertical panel 38. Once fully through both pieces, the washer 45 secures the attachment, the head 50 of the rivet being flush with the vertical panel 38. In the preferred embodiment, four such tubular rivets 44 are employed to secure each vertical panel 38. Of course a different number of rivets could be employed if desired, or other known fastening means could be alternatively utilized.
The use of the safety cone 12 as a standardized supporting platform for the vertical panels 38 greatly increases the versatility and functionality of the vertical panels. The cone 12, when used in combination with the weighted support base 22, easily withstands gusts caused by high speed traffic and prevailing weather conditions to remain in position. Furthermore, because of the handle 24 on the cone 12, the vertical panels 38 are conveniently carried by a worker for placement in a desired location. The cones 12 are more durable and lighter than the supporting platforms typically used for vertical panels in the prior art, many of which are metallic, because of their resilient plastic construction. Finally, and perhaps most significantly, the use of standardized cones 12 as platforms for the vertical panels 38 enables the panels 38 to be much more easily transported and stored, because of their stacking ability.
As discussed above in the Background of the Invention portion of the specification, safety cones of the type herein disclosed, as well as many other types of traffic safety delineators and channelizers, are typically stacked for compact storage and for ease of transportability between locations. However, the prior art cones generally available in the prior art tend to stick and jam together when stacked, thereby making it difficult to separate them for use. This invention solves that problem because of the unique handle configuration at the top of each cone 12, which makes the cones self-spacing. Thus, when two or more cones are stacked together, as shown in FIG. 5, the top of the knob portion 30 of the lower cone abuts the interior surface 52 of the transition fillet 26 of the upper cone, thereby creating a stop which prevents further relative stacking motion between the two cones, i.e. further collapsing of the upper cone onto the lower one. Advantageously, the relative stacking motion is stopped by the abutment of the lower cone knob 30 on the upper cone interior surface 52 before the upper cone has descended onto the lower cone sufficiently to create a jamming or sticking problem.
As illustrated in the drawing, the cones 12 may be stacked with the vertical panels 38 attached thereto; i.e. the vertical panel delineators 10 may be stacked without removing the vertical panels. This is possible because the vertical panels 38 are made of a flexible material (preferably polyethylene sheeting), so that as the upper cone 12 descends onto the lower one during the stacking process, the vertical panel 38 on the lower cone merely rolls about the circumference of the lower cone, as illustrated, so that substantially all of the reverse side of the vertical panel contacts the circumferential surface of the cone. In other words, the vertical panel 38 wraps around the cone as the upper cone slides over it. In order to enhance this "rolling" or "wrapping" action, the two upper corners 54 and 56 of each vertical panel 38 are preferably rounded. The rounding of the corners 54 and 56 causes them to better engage the inner surface of the upper cone as it descends, so that they "plow in", thereby enhancing the desired "rolling" or "wrapping" action. Thus, even when the vertical panels are attached, the stacked delineators do not stick and are rotatable about one another.
Accordingly, although exemplary embodiments of the invention have been shown and described, it is to be understood that all the terms used herein are descriptive rather than limiting, and that many changes, modifications, and substitutions may be made by one having ordinary skill in the art without departing from the spirit and scope of the invention.
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A safety delineator is provided which includes a conical body portion to which is attached one or more vertical panels. A new and improved handle feature permits easy and comfortable full hand gripping of the delineator and also prevents sticking and jamming together of a plurality of the delineators when they are stacked. The delineators may be stacked without removing the vertical panels, since each vertical panel is particularly designed to wrap around the conical body portion to which it is attached as another vertical delineator slides over it.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for monitoring the supply of substitution fluid for an apparatus for extracorporeal blood treatment with an extracorporeal blood circuit, which comprises a first chamber of a dialyzer or filter divided by a membrane into the first chamber and a second chamber, and a fluid system which comprises the second chamber of the dialyzer or filter. Moreover, the present invention relates to a device for monitoring the supply of substitution fluid for an apparatus for extracorporeal blood treatment as well as an extracorporeal blood treatment apparatus with a monitoring device for the supply of substitution fluid.
BACKGROUND
[0002] Various methods for extracorporeal blood treatment or cleaning are used to remove substances usually eliminated with urine and for fluid withdrawal. In hemodialysis, the patient's blood is cleaned outside the body in a dialyzer. The dialyzer comprises a blood chamber and a dialyzing fluid chamber, which are separated by a semipermeable membrane. During the treatment, the patient's blood flows through the blood chamber. In order to clean the blood effectively from substances usually eliminated with urine, fresh dialyzing fluid flows continuously through the dialyzing fluid chamber.
[0003] Whereas the transport of the lower-molecular weight substances through the membrane of the dialyzer is essentially determined by the concentration differences (diffusion) between the dialyzing fluid and the blood in the case of hemodialysis (HD), substances dissolved in the plasma water, in particular higher-molecular weight substances, are effectively removed by a high fluid flow (convection) through the membrane of the dialyzer in the case of hemofiltration (HF). In hemofiltration, the dialyzer functions as a filter. Hemodiafiltration (HDF) is a combination of the two processes.
[0004] In hemo(dia)filtration, part of the serum drawn off through the membrane of the dialyzer is replaced by a sterile substitution fluid, which is generally fed to the extracorporeal blood circuit either upstream of the dialyzer or downstream of the dialyzer. The supply of substitution fluid upstream of the dialyzer is also referred to as pre-dilution and the supply downstream of the dialyzer as post-dilution.
[0005] Apparatuses for hemo(dia)filtration are known, wherein the dialyzing fluid is prepared online from fresh water and dialyzing fluid concentrate and the substitution fluid is prepared online from the dialyzing fluid.
[0006] In the known hemo(dia)filtration apparatuses, the substitution fluid (substituate) is fed to the extracorporeal blood circuit from the fluid system of the machine via a substituate supply line. With pre-dilution, the substituate line leads to a connection point on the arterial blood line upstream of the dialyzer or filter, whereas with post-dilution the substituate line leads to a connection point on the venous blood line downstream of the dialyzer or filter. The substituate line comprises for example a connector with which it may be connected either to the venous or arterial blood line. In order to interrupt the fluid supply, a clamp or suchlike is provided on the substituate line. A hemo(dia)filtration apparatus of this kind is known for example from European Patent Publication No. EP 0 189 561.
[0007] The effectiveness of the blood treatment depends on whether the substitution fluid is fed to the extracorporeal blood circuit upstream or downstream of the dialyzer or filter. A knowledge of the mode of treatment, i.e., pre- or post-dilution, is therefore important.
[0008] European Patent Publication No. EP 1 348 458 A1 describes a method and a device for monitoring the supply of substitution fluid for an extracorporeal blood treatment apparatus. The propagation time of the pressure waves of a substituate pump disposed in the substituate line is measured in order to detect the supply of substitution fluid upstream or downstream of the dialyzer or filter. The supply of substituate upstream or downstream of the dialyzer or filter is detected on the basis of the propagation measurement. The known method requires the use of a substituate pump generating pressure waves.
[0009] There is known from German Patent Publication DE 10 2004 023 080 Al a device for monitoring the supply of substitution fluid, wherein the supply of substituate upstream or downstream of the dialyzer or filter is detected on the basis of the change in the pressure, for example on the basis of a sudden pressure rise and/or pressure drop after the substituate pump is switched off or switched on. The known method requires the use of a substituate pump generating pressure waves.
[0010] A goal of example embodiments of the present invention is to provide a method for monitoring the supply of substitution fluid, which permits the detection of pre- or post-dilution with a high degree of reliability. Moreover, it is a goal of example embodiments of the present invention to provide a device for monitoring the supply of substitution fluid, with which the pre- and post-dilution may be reliably detected. A further goal of example embodiments of the present invention is to create an extracorporeal blood treatment apparatus with such a monitoring device.
SUMMARY
[0011] The method according to example embodiments of the present invention and the device according to example embodiments of the present invention for the detection of pre- or post-dilution is based on the measurement and monitoring of the density of the blood or a blood constituent in the extracorporeal circuit. When there is a change in substitution rate Q S at which substitution fluid is fed to the blood in the extracorporeal circuit, and/or blood flow rate Q B at which blood is fed to the first chamber of the dialyzer or filter and/or flow rate Q M at which fluid is withdrawn from the blood via the membrane of the dialyzer or filter, the density of the blood or the blood constituent in the extracorporeal blood circuit changes. It has been shown that the amount and/or the direction of the change, i.e., an increase or reduction in the density by a specific value, depends on whether the substitution fluid is fed to the blood upstream or downstream of the dialyzer or filter. It is then concluded that there is a pre-dilution or post-dilution on the basis of the change in the density of the blood or the blood constituent. Change in density is also understood in this sense to mean the change in concentration of a blood constituent such as for example hemoglobin.
[0012] The method according to example embodiments of the present invention and the device according to example embodiments of the present invention in principle require only the single change in substitution rate Q S and/or blood flow rate Q B and/or flow rate Q M at which fluid is withdrawn from the blood via the membrane of the dialyzer or filter. Since the pre- or post-dilution is to be monitored during the blood treatment, which is preferably to be carried out at specific fluid rates Q S , Q B and/or Q M , a preferred embodiment makes provision, after the reduction or increase in at least one of the three fluid rates by a preset amount for a preset time interval, which should be as short as possible, for an increase or reduction again after the lapse of the preset time interval by a preset amount, which in particular corresponds to the amount by which the corresponding fluid rate or the fluid rates has or have been previously reduced or increased, so that the blood treatment may be continued at the same fluid rates. Flow rate Q M withdrawn from the blood is reduced or increased preferably simultaneously in the same time interval preferably by the same amount and, after the lapse of the preset time interval, preferably increased or reduced again by the same amount as substitution rate Q S .
[0013] When mention is made below of a change in the flow rate, this may also be understood to mean a reduction in the flow rate by an amount such that the flow rate is zero, i.e., the flow is interrupted.
[0014] The amount by which a flow rate is reduced or increased is in principle irrelevant for the detection of pre- or post-dilution. The decisive factor, however, is that a change in the density can be detected selectively for pre- and post-dilution with sufficient reliability.
[0015] The method according to example embodiments of the present invention and the device according to example embodiments of the present invention provide different embodiments, which differ from one another by the point of the extracorporeal blood circuit at which the density of the blood or the blood constituent is measured.
[0016] A pre- or post-dilution may be detected by a measurement of the density downstream of the point of the extracorporeal blood circuit at which substitution fluid is fed to the blood circuit in the case of a pre-dilution and upstream of the first chamber of the dialyzer or filter. It is also possible to detect a pre- or post-dilution by a measurement of the density downstream of the first chamber of the dialyzer or filter and upstream of the point of the blood circuit at which substitution fluid is fed to the blood circuit in the case of post-dilution. The density may also be detected by a measurement downstream of the point of the blood circuit at which substitution fluid is fed to the blood circuit in the case of post-dilution. It may be decisive that the density is measured immediately after the change in the respective flow rate, since a change in the density may be detected only within a specific time interval, depending on the measurement position. The reason is that, in these cases, the density may reassume its original value after the lapse of this time interval.
[0017] It has been shown that the change in substitution rate Q S , with a simultaneous change in flow rate Q M at which fluid is removed from the blood via the membrane of the dialyzer or filter, leads to notably different changes in the density at different points of the extracorporeal circuit. For example, the density may increase or decrease depending on a pre- or post-dilution.
[0018] In a first example embodiment, substitution rate Q S is reduced by a preset amount and the density is measured in the blood circuit downstream of the point of the blood circuit at which substitution fluid is fed to the blood circuit in the case of pre-dilution and upstream of the first chamber of the dialyzer or filter. The density of the blood or blood constituent before the reduction in substitution rate Q S and after the reduction in substitution rate Q S are then compared with one another, it being concluded that there is a supply of substitution fluid upstream of the dialyzer or filter if the density after the reduction of the substitution rate has increased by a preset amount. If the density of the blood after the reduction in the substitution rate has not increased by a preset amount, it is concluded on the other hand that there is a supply of substitution fluid downstream of the dialyzer or filter.
[0019] The method according to the invention and the device according to the invention do not in principle require the measurement of the density of the blood both before and after the reduction in the substitution rate. It may, in principle, be sufficient to measure the density only after the reduction in the substitution rate, in order to compare the measured value with a characteristic threshold value.
[0020] A particularly preferred example embodiment with a particularly significant change in the density of the blood provides for a measurement of the density of the blood or blood constituent in the blood circuit downstream of the point of the blood circuit at which substitution fluid is fed to the blood circuit in the case of post-dilution. After a comparison of the density before and after the reduction in substitution rate Q S and preferably a simultaneous reduction in flow rate Q M , it is concluded that there is a supply of substitution fluid upstream of the dialyzer or filter if the density after the reduction in substitution rate Q S has diminished by a preset amount. It is concluded that there is a supply of substitution fluid downstream of the dialyzer or filter if the density after the reduction in substitution rate Q S has increased by a preset amount.
[0021] The increase in the density of the blood or the blood constituent in the case of post-dilution is due to the fact that, immediately after the reduction in substitution rate Q S at which the substitution fluid is fed to the blood and the simultaneous reduction in fluid rate Q M at which fluid is withdrawn from the blood via the membrane of the dialyzer or filter, a corresponding quantity of fluid has also been withdrawn via the membrane from the blood now flowing out of the dialyzer. The blood flowing out of the dialyzer or filter is thus thickened immediately after the reduction in rates Q S and Q M . A reduction in the quantity of the substitution fluid fed to the blood after the passage through the dialyzer (post-dilution) therefore leads directly to an increase in the density of the blood or the blood constituent in the blood circuit downstream of the dialyzer. When, on the other hand, rates Q S and Q M are reduced in the case of pre-dilution, the blood present in the dialyzer or filter has already been diluted by the previous inflow of substitution fluid. Since the filtration in the dialyzer corresponding to the substituate flow is reduced or does not take place, the density of the blood flowing back to the patient diminishes. It is therefore concluded that there is a supply of substitution fluid upstream of the dialyzer or filter (pre-dilution) if the density of the blood or the blood constituent, after the reduction in substitution rate Q S , has diminished by a preset amount or diminished by an amount which is greater than the preset threshold value.
[0022] On the basis of the increase or reduction in the density of the blood or blood constituent after the reduction in substitution rate Q S , it is therefore possible to conclude with a high degree of reliability that there is a post- or pre-dilution. The increase or decrease in the density should however exceed a preset threshold value, in order for it to be possible to distinguish reliably between a change in the density of the blood due to a change in the flow rates and general density fluctuations of the blood.
[0023] An increase in substitution rate Q S at which fluid is withdrawn from the blood is also possible instead of a reduction in substitution rate Q S . In this example embodiment, the density may be measured downstream of the point of the blood circuit at which substitution fluid is fed to the blood circuit in the case of pre-dilution and upstream of the first chamber of the dialyzer or filter. It is concluded that there is a supply of substitution fluid upstream of the dialyzer (pre-dilution) or filter if the density after the increase in the substitution rate has diminished by a preset amount, and it is concluded that there is a supply of substitution fluid downstream of the dialyzer or filter (post-dilution) if the density after the increase in the substitution rate has not diminished by a preset amount.
[0024] In this example embodiment, the density of the blood or the blood constituent in the blood circuit may alternatively also be measured downstream of the point of the blood circuit at which substitution fluid is fed to the blood circuit in the case of post-dilution. It can be concluded that there is a supply of substitution fluid upstream of the dialyzer or filter, preferably with a simultaneous increase in flow rate Q M , if the density after the increase in substitution rate Q S has increased by a preset amount, and it is concluded that there is a supply of substitution fluid downstream of the dialyzer or filter if the density after the reduction in substitution rate Q S has diminished by a preset amount.
[0025] As the density of the blood, it is possible to measure both the physical density or mass density, which describes a mass distribution, as well as the optical density of the blood, which is a measure of the attenuation of radiation (for example light) in a medium, i.e., the blood.
[0026] For the method according to the invention, consideration may be given in particular to all measurement methods with which a measurement of the physical or optical density of the blood or one of its constituents is possible. For the measurement of the change in the density, a first example embodiment provides for a measurement of the propagation speed of ultrasound in the blood along a measuring distance, while an alternative example embodiment provides for the measurement of the attenuation of light in the blood along a measuring distance. The measurement equipment required for this is generally known to the person skilled in the art. Moreover, optical detectors for the detection of blood and ultrasound measuring distances for the detection of air are in any case generally present in the known dialysis apparatuses.
[0027] In a further particularly preferred example embodiment, a signal signaling the operational state of pre-dilution is generated when a pre-dilution is detected, whereas a signal signaling the operational state of post-dilution is generated when a post-dilution is detected. The signal for the pre- or post-dilution may control further devices provided in the blood treatment apparatus. For example, an intervention in the blood treatment may be made.
[0028] The device according to the invention for monitoring the supply of substitution fluid may be a component of a blood treatment apparatus or form a separate unit. Since the components required for the monitoring device are generally in any case present in the known blood treatment apparatuses, an integration into the blood treatment apparatuses is appropriate. The corresponding sensors for the density measurement may for example be used. A microprocessor control is also available. The outlay on equipment is therefore small.
[0029] The monitoring device according to the present invention comprises a control unit for controlling the substitution apparatus and the ultrafiltration apparatus for withdrawing ultrafiltrate via the dialyzer membrane, in such a way that corresponding flow rates Q S and Q M may be adjusted for the measurement. A measuring unit is used to measure the density of the blood or the blood constituent and an evaluation unit is used to detect the pre- or post-dilution on the basis of the density measurement.
[0030] The method according to the present invention and the apparatus according to the present invention may give the user not only an indication of the type of treatment, i.e., pre- or post-dilution, but also deviations between the actual and the desired type of treatment. Moreover, automatic documentation or an automatic limitation of the input parameters is possible. With the method according to the present invention and the apparatus according to the present invention, it is also possible to control other operational parameters of the blood treatment apparatus depending on the respective operational state.
[0031] Not only the change in the corresponding flow rates, but also other parameters have an influence on the duration of the change in density. For example, the volume of the blood chamber of the dialyzer and the volume of the hose line sections following the blood chamber have an influence on the duration of the change in density. In this respect, the volume of a partial section of the extracorporeal blood circuit may also be deduced using the density measurement. The level of the change in density depends on the enclosed volume of blood.
[0032] Example embodiments of the method according to the invention and of the blood treatment apparatus according to the invention are described in greater detail below by reference to the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 shows an extracorporeal blood treatment apparatus with a device for monitoring the supply of substitution fluid, in particular for detecting pre- and post-dilution, in a very simplified schematic representation.
[0034] FIG. 2A and 2B show the time-related course of the density in the case of pre-dilution and post-dilution with a reduction in substitution rate Q s and flow rate QM, at which fluid is withdrawn from the blood via the membrane of the dialyzer or filter, by the same amount.
[0035] FIG. 3A and 3B show the time-related course of the density in the case of pre-dilution and post-dilution with an increase in substitution rate Q s and flow rate Q M , at which fluid is withdrawn from the blood via the membrane of the dialyzer or filter, by the same amount.
[0036] FIG. 4A and 4B show the time-related course of the density in the case of pre-dilution and post-dilution with an increase in the blood flow rate.
DETAILED DESCRIPTION
[0037] FIG. 1 shows, in a schematic representation, only the main components of a blood treatment apparatus that are relevant for the monitoring of the pre- or post-dilution. The present blood treatment apparatus is a hemo(dia)filtration apparatus, which comprises a dialyzer 1 , which is divided by a semi-permeable membrane 2 into a first chamber 3 , through which blood flows and which is referred to in the following as the blood chamber, and a second chamber 4 , through which dialyzing fluid flows and which is referred to in the following as the dialyzing fluid chamber. First chamber 3 is incorporated in an extracorporeal blood circuit 5 A, while second chamber 4 is incorporated in dialyzing fluid system 5 B of the hemo(dia)filtration apparatus.
[0038] Extracorporeal blood circuit 5 A comprises an arterial blood line 6 , which leads to inlet 3 a of blood chamber 3 , and a venous blood line 7 , which leads away from outlet 3 b of blood chamber 3 of dialyzer 1 . The patient's blood is conveyed through blood chamber 3 of dialyzer 1 by an arterial blood pump 8 , in particular a roller pump, which is disposed on arterial blood line 6 . The blood pump feeds blood to blood chamber 3 of the dialyzer at a specific blood flow rate Q b . Blood lines 6 , 7 and dialyzer 3 form a disposable intended for one-off use, which is inserted into the dialysis apparatus for the dialysis treatment. An air separator (drip chamber) may be incorporated into the arterial and venous blood line in order to eliminate air bubbles.
[0039] The fresh dialyzing fluid is made available in a dialyzing fluid source 9 . A dialyzing fluid supply line 10 leads from dialyzing fluid source 9 to an inlet 4 a of dialyzing fluid chamber 4 of dialyzer 1 . A dialyzing fluid discharge line 11 leads from outlet 4 b of dialyzing fluid chamber 4 to a drain 12 . A first dialyzing fluid pump 13 is incorporated in dialyzing fluid supply line 10 and a second dialyzing fluid pump 14 is incorporated in dialyzing fluid discharge line 11 . First dialyzing fluid pump 13 conveys dialyzing fluid from the dialyzing fluid source at a specific dialyzing fluid supply rate Q di to inlet 4 a of dialyzing fluid chamber 4 , while second dialyzing fluid pump 14 conveys dialyzing fluid at a specific dialyzing fluid flow rate Q do from outlet 4 b of dialyzing fluid chamber 4 to drain 12 .
[0040] During the dialysis treatment, dialyzing fluid may be fed from dialyzing fluid system 5 B as a substitution fluid to extracorporeal blood circuit 5 A via a substitution fluid line 15 , which branches off from dialyzing fluid supply line 10 upstream of first dialyzing fluid pump 13 .
[0041] Substitution fluid line 15 comprises two line sections 15 a and 15 b , one line section 15 a leading to arterial blood line 6 and the other line section 15 b leading to venous blood line 7 .
[0042] The substitution fluid is conveyed by means of a substituate pump 16 , in particular a roller pump, into which substitution fluid line 15 is inserted. A sterile filter 17 divided into two chambers 17 a , 17 b is incorporated into substitution fluid line 15 upstream of the substituate pump. The substituate pump together with the respective lines and the sterile filter form the substitution device of the dialysis apparatus. In order to pinch off the two line sections 15 a , 15 b of substitution fluid line 15 , shut-off elements, for example hose clamps, may be provided, which however are not represented for the sake of better clarity.
[0043] Blood pump 8 , first and second dialyzing fluid pumps 13 and 14 and substituate pump 16 are connected via control lines 8 ′, 13 ′, 14 ′, 16 ′ to a central control and computing unit 18 , from which the pumps are controlled taking account of the preset treatment parameters.
[0044] Blood pump 8 as well as first and second dialyzing fluid pumps 13 and 14 are operated in order to operate the hemo(dia)filtration apparatus as a hemodialysis apparatus, dialyzing fluid flowing through dialyzing fluid chamber 4 of dialyzer 1 . Substituate pump 16 is operated in order to operate the hemo(dia)filtration apparatus as a hemodiafiltration apparatus, so that sterile dialyzing fluid flows as a substitution fluid via sterile filter 17 optionally to arterial admission point 19 downstream of pump 8 and upstream of blood chamber 3 (pre-dilution) or to venous admission point 20 downstream of the blood chamber (post-dilution). Operation of the hemo(dia)filtration apparatus solely as a hemofiltration apparatus is however also possible, if first dialyzing fluid pump 13 is not operated and therefore the inflow of dialyzing fluid into the dialyzing fluid chamber of the dialyzer is interrupted.
[0045] The device for monitoring the supply of substitution fluid comprises a control unit which, in the present example of embodiment, is part of central control and computing unit 18 of the blood treatment apparatus. Moreover, the device for detecting pre- and post-dilution comprises a measuring unit 21 A for measuring the density of the blood or a blood constituent, which flows out of blood chamber 3 of dialyzer 2 via a venous blood line 7 back to the patient. Measuring unit 21 A measures the density of the blood in venous blood line 7 downstream of venous admission point 20 , at which substitution fluid flows into venous blood line 7 during the substitution.
[0046] Venous measuring unit 21 A comprises an ultrasound transmitter 21 A′ and an ultrasound receiver 21 A″, which are disposed along a measuring distance. The measuring distance may for example run through a venous drip chamber (not shown) or through a section of the venous blood line following the drip chamber. Such ultrasound measuring devices for measuring the density of media are known to the person skilled in the art. The measuring devices are based on the measurement of the propagation speed of ultrasound waves, which are transmitted by transmitter 21 A′ and received by receiver 21 A″. Alternatively, a measuring unit for measuring the attenuation of light may be used to measure the blood instead of an ultrasound measuring device, said measuring unit comprising, instead of the ultrasound transmitter and receiver, a light source disposed on one side of the measuring distance and a light sensor disposed on the other side of the measuring distance.
[0047] The device for detecting pre- or post-dilution further comprises an evaluation unit 22 , which is connected via a data line 23 to central control and computing unit 18 . Evaluation unit 22 receives the measured values of measuring unit 21 A via a further data line 24 .
[0048] The structure and the mode of functioning of the device for detecting a pre- and post- dilution are explained in detail below.
[0049] During the extracorporeal blood treatment, central control and computing unit 18 controls blood pump 8 in such a way that blood flows into blood chamber 3 of the dialyzer at blood flow rate Q b , and controls first and second dialyzing fluid pumps 13 , 14 in such a way that dialyzing fluid flows into dialyzing fluid chamber 4 at dialyzing fluid rate Q di and dialyzing fluid flows out of dialyzing fluid chamber 4 at dialyzing fluid rate Q do . Substituate pump 16 is controlled by control unit 18 in such a way that substitution fluid is fed to the blood optionally upstream and/or downstream of the blood chamber at substitution rate Q S .
[0050] For the monitoring of pre- or post-dilution, control unit 18 controls substituate pump 16 in such a way that its delivery rate is preferably reduced by a preset amount only for a preset time interval or substituate pump 16 is stopped. At the same time, control unit 18 controls first and second dialyzing fluid pumps 13 and 14 in such a way that flow rate Q M at which fluid is withdrawn from the blood via membrane 2 of the dialyzer or filter, whereby Q M =Q do −Q di , is simultaneously reduced within the same time interval by the same amount as the substitution rate has been reduced. The effect of this is that less fluid (ultrafiltrate) is removed from the blood via membrane 2 of dialyzer 1 . Before and after the changing of the delivery rates or stopping of the pumps involved, measuring unit 21 A measures the density of the blood or the blood constituent downstream of venous admission point 20 .
[0051] It is also possible for substitution rate Q S and flow rate Q M , at which fluid is withdrawn from the blood via the membrane of the dialyzer or filter, to be adjusted to a value of zero. This may be achieved, for example, by the fact that the dialyzer or filter is switched into a bypass operation, so that Q di is then also equal to zero. If there was previously a net ultrafiltration rate which has made a contribution to Q M , flow rates Q S and Q M in this case are not reduced by the same amount, since Q M was greater than the net ultrafiltration amount.
[0052] Evaluation unit 22 comprises a comparison device 22 A, which compares the value for the density of the blood or the blood constituent measured before the change in the delivery rates of the pumps with the value for the density measured immediately after the change in the delivery rates. The measurement of the density takes place within a specific time interval after the change in the flow rates, since the original values are re-established after the lapse of the time interval. The time interval should in any event be shorter than the length of the density change (rectangular function), empirical values being usable. It should be noted that the flow rate changes in the mentioned examples—Q S and Q M change by the same amount—lead only to a time-limited change in the density. On the basis of the change in the density, the evaluation unit then detects whether a dilution is taking place and ascertains whether a pre-dilution or post-dilution is present.
[0053] The operational states established by evaluation unit 22 are displayed on a display unit 25 , which is connected via a data line 26 to evaluation unit 22 . Furthermore, the evaluation unit generates two control signals, which on the one hand signal the operational state of pre-dilution and on the other hand the operational state of post-dilution. Both control signals are received by control unit 22 via data line 23 , which may undertake an intervention into the machine control depending on the respective operational state of pre- or post-dilution.
[0054] In the case of post-dilution, evaluation unit 22 ascertains a short-time increase in the density of the blood at the measurement point. This is due to the fact that the blood has thickened after the passage through blood chamber 3 of dialyzer 1 , since fluid (ultrafiltrate) has been withdrawn from the blood via membrane 2 of dialyzer 1 . Since the already thickened blood in post-dilution is no longer diluted sufficiently with substitution fluid, the density of the blood or the blood constituent increases downstream of the dialyzer for a specific time period. The delivery rates need to be changed only for a short time for the measurement, i.e., the original delivery rates may be re-established after the measurement has taken place, as a result of which an opposite—again time-limited—behaviour of the density change occurs.
[0055] In the case of pre-dilution, on the other hand, the blood flowing into blood chamber 3 is diluted by the inflow of substitution fluid upstream of the blood chamber. Immediately after the time at which the delivery rates of the pumps are reduced, still diluted blood first enters into the blood chamber, from which, however, sufficient fluid is no longer withdrawn via the dialyzer membrane after the reduction in the delivery rates. Consequently, the density of the blood emerging from the blood chamber and flowing back to the patient diminishes. The reduction in the density is again measured with measuring unit 21 A, evaluation unit 22 establishing the operational state of pre-dilution.
[0056] Comparison device 22 A of evaluation unit 22 calculates the difference between the two measured values of the density before and immediately after the change in the delivery rates. If the amount of the difference is greater than a preset threshold value, i.e., the values measured before and after the change in the substitution rate differ markedly from one another, evaluation unit 22 establishes that a dilution is taking place. Moreover, the evaluation unit ascertains whether an increase or decrease in the density is taking place, i.e., whether the difference between the measured values is positive or negative.
[0057] In the case of an increase in the density by an amount which is greater than a preset threshold value, the evaluation unit then ascertains the operational state of post-dilution. If the density has diminished by an amount whose magnitude is greater than a preset threshold value, the evaluation unit then ascertains the operational state of pre-dilution.
[0058] FIGS. 2A and 2B show the time-related course of the density of the blood in the case of pre-dilution ( FIG. 2A ) and post-dilution ( FIG. 2B ), substitution rate Q S on the one hand diminishing by a preset amount ΔQ S <0 and flow rate Q M at which fluid is withdrawn from the blood diminishing simultaneously by the same amount.
[0059] The graphs of FIGS. 2A and 2B denoted by A show the time-related course of the density in the case of pre- or post-dilution, when the change in density is measured by measuring unit 21 A downstream of venous admission point 20 , as is described by reference to FIG. 1 .
[0060] Alternative embodiments, however, also provide for a measurement of the change in density upstream of venous admission point 20 and downstream of blood chamber 3 or downstream of arterial admission point 19 and upstream of blood chamber 3 of dialyzer 1 . Two further alternative measuring units are provided for this purpose, which are denoted in FIG. 1 by 21 B and 21 C. Measuring unit 21 B measures the density upstream of venous admission point 20 and downstream of blood chamber 3 , while measuring unit 21 C measures the density downstream of arterial admission point 19 and upstream of blood chamber 3 .
[0061] The graphs of FIGS. 2A and 2B denoted by B show the time-related course of the density in the case of pre- ( FIG. 2A ) or post-dilution ( FIG. 2B ), when the change in density is measured with measuring unit 21 B, while graphs C show the time-related course of the change in density when the density is measured with measuring unit 21 C.
[0062] It is shown that a variation in substitution rate Q S , with a simultaneous change in Q M , also leads to a change in the density of the blood upstream of venous admission point 20 and downstream of blood chamber 3 . The density of the blood diminishes both in the case of pre- and post-dilution, the original value for the density being re-established in the case of pre-dilution, in contrast with post-dilution.
[0063] It may also be seen that a variation in substitution rate Q S also leads to a change in the density of the blood downstream of arterial admission point 19 and upstream of blood chamber 3 . The density of the blood increases in the case of pre-dilution, whereas with post-dilution it neither increases nor decreases, i.e. it remains the same.
[0064] Alternative embodiments of the invention provide for a measurement of the change in density with measuring units 21 B or 21 C, the evaluation unit concluding that there is a pre- or post-dilution on the basis of the nature of the change in density, which is shown in FIGS. 2A and 2B . Suitable devices with which the signals may be evaluated are known to the person skilled in the art. These devices may comprise comparators, timers etc.
[0065] It is also possible to combine the aforementioned measuring methods with one another, so that a pre- or post-dilution may be detected on the basis of two or three measurements at different measurement points. For example, it may be concluded that there is a pre- or post-dilution if a change in the signals characteristic of a pre- or post-dilution is detected at least in two measurements at different measurement points.
[0066] FIGS. 3A (pre-dilution) and 3 B (post-dilution) show the time-related course of the density of the blood or of a blood constituent, which is measured with measuring units 21 A, 21 B and 21 C, when on the one hand substituate rate Q S is increased by a preset amount and simultaneously the flow rate at which fluid is withdrawn from the blood via membrane 2 is increased by the same amount. The graphs are again denoted, similar to FIG. 2A and 2B , by A, B and C.
[0067] It may be seen that an increase in substitution rate Q S , with a simultaneous change in Q M , leads to a change in the density at all three measurements points in the case of pre-dilution. In contrast to a reduction in the rate, the consequence of an increase in Q S and Q M downstream of venous admission point 20 in the case of a pre-dilution is not to a reduction, but rather to an increase in the density and leads in the case of a post-dilution not to an increase, but rather a reduction in the density (graph A). The density increases upstream of venous admission point 20 and downstream of blood chamber 3 both for the pre- as well as the post-dilution, the original value for the density being re-established (graph B) in the case of pre-dilution, in contrast with post-dilution. The density in the case of pre-dilution diminishes downstream of arterial admission point 19 and upstream of blood chamber 3 , whereas in the case of post-dilution it neither increases nor decreases, i.e. it remains the same (graph C).
[0068] In an alternative embodiment, control unit 18 and evaluation unit 22 are designed in such a way that substitution rate Q S and flow rate Q M are reduced and it is concluded that there is a pre- or post-dilution on the basis of the change in the density, as is described by reference to FIGS. 3A and 3B .
[0069] In a further example of embodiment, it is not substitution rate Q S or flow rate Q M , but rather blood flow rate Q b that is changed ( FIGS. 4A and 4B ). Control unit 18 controls blood pump 8 in this embodiment in such a way that blood flow rate Q b is increased by a preset amount ΔQ b . Graphs A, B, C again show the time-related course of the density of the blood or the blood constituent, which is measured with the three measuring units 21 A, 21 B, and 21 C. It may be seen that, with measuring units 21 A and 21 B, a pre- or post-dilution may be detected only with a more precise quantitative evaluation of the change in density. The evaluation unit therefore preferably evaluates the measured values of measuring unit 21 C, with which the density downstream of arterial admission point 19 and upstream of blood chamber 3 of the dialyzer is measured. Evaluation unit 22 ascertains a pre-dilution if the density has increased by a preset amount and it ascertains a post-dilution if the density has not increased by a preset amount, i.e. has remained the same. It is of course also conceivable for blood flow rate Q B to be reduced by a preset amount. The measurements then run in each case in the opposite direction.
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An apparatus and a method for monitoring the supply of replacement fluid during an extracorporeal treatment of blood is disclosed. Detection of the supply of replacement fluid upstream or downstream of the dialyser or filter is based on a measurement of the optical or physical density of the blood or of a constituent of blood in the extracorporeal circulation. To detect pre- or post-dilution, the blood flow rate and/or the replacement rate and/or the flow rate of the fluid removed from the blood through the dialyser membrane is altered, and the density of the blood or of the constituent of blood is measured upstream and/or downstream of the dialyser. Additionally, an apparatus for treating blood with an apparatus for monitoring the supply of replacement fluid is disclosed.
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CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a method of construction of an artificial island.
BRIEF DESCRIPTION OF THE INVENTION
Along the coastlines of the United States and other countries, barrier islands protect the mainland and wetlands from damage caused by storms. In locations where no barrier islands exist, shore erosion is a serious problem. To reduce the impact of storms on the shoreline wetlands, the instant invention is a method of making artificial barrier islands. The method consists of driving a series of piles in the shape of the island, attaching a number of wire mesh sections, to form a fence around the perimeter of the piles, connecting the tops of the piles with cables, and then filling the formed enclosure with rock, reworked concrete or suitable fill material. Once the fill material has reached the water surface, it can be covered with suitable soil and vegetation to create the island. When complete, the piles and mesh are hidden below the surface and the formed island takes on a natural appearance.
In this way, the artificial island acts as a barrier to storms, thus protecting the shoreline wetlands. Moreover, the artificial island creates an ideal habitat for birds, fish and amphibians. It is estimated that one island protects 10 times the amount of shoreline that lies behind it in certain applications.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional view of he invention.
FIG. 2 is a diagrammatic plan view of the invention showing the plan of cross ties.
FIG. 3 is a side view of a portion of a typical island fence section.
FIG. 4 is a detail side view of a typical pile.
FIG. 5 is a plan view of a typical pile.
FIG. 6 is a perspective view of a typical pile.
FIG. 7 is a plan environmental view of a typical shoreline with wetlands, showing the placement of the invention is open water in from of the shore.
FIG. 8 is an environmental view of a series of islands formed using the invention.
FIG. 9 is a side detail view of an alternative embodiment, in which the invention is used to form an artificial reef.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a side view of the island is presented showing the interior and exterior structure. FIG. 1 shows an assembled island 1 . The island has a number of piles 2 formed about a perimeter; see also below. The piles are driven into the sub bottom 100 . A mesh fence 3 is attached to the piles, as discussed below. The fence extends from below the muckline (when present) 101 to the top surface of the water 102 , (see FIG. 3 ). In FIG. 1, the mesh is only partially shown to allow the inner components to be shown. The combination of piles and fencing forms a “corral” structure (see FIG. 2) to hold the island components in place.
The island components are placed within the “corral” structure. Extending from the muckline to a point near the surface of the water is a mass of riprap material 5 . Above the riprap is a layer of geotextile fabric 16 that is used to retain the cover soil 6 .
Above the geotextile fabric 16 is a layer of cover fill 6 . The cover fill extends above the water line for a specific distance to form the portion of the island that is visible. This cover may then be planted with indigenous vegetation 7 to prevent erosion and to create habitat for wildlife (birds, reptiles and amphibians).
FIG. 2 is a plan view of the basic “corral” structure. Note that the piles are tied together by cables (stainless steel cables for marine environment) 8 , which are discussed below. The cables 8 extend around the perimeter of the island 1 as shown and they run across the center of the island to anchor opposite pilings as shown. The details of the cables and their connections are discussed below.
FIG. 3 is a side detail view showing three piles and two mesh sections. The piles 2 can be made of steel, wood or concrete, depending on the location and site-specific design considerations. Although all of the piles may be made of the same material, it is also possible to alternate piles of different materials. For example, concrete piles can be alternated with wooden piles or steel point bearing piles. The mesh fence 3 is made of a wire mesh. In the preferred embodiment, the fence 3 is made of stainless steel welded wire mesh that is reinforced with stainless steel cables 8 for marine environment. Wire mesh of 8 gauge is preferred but mesh strength is calculated for site-specific environments. The mesh is attached to the piles using a clip system that is described below.
FIG. 4 is a detail side view of a typical pile 3 . A stainless steel “T”-rail 10 is installed in two sides (see FIG. 5 ). The “T”-rail 10 is used to secure the wire mesh 3 with stainless steel clips 11 (see also FIG. 6 ). A header 12 is formed onto the pile. The header is used to secure clamps for the stainless steel cable ties 5 .
FIG. 5 is a plan view of a typical pile 2 . FIG. 6 is a perspective view of a typical pile. In these views, the stainless steel “T”-rails 10 are clearly shown. The wire mesh 3 is shown extending out from the pile laterally. Behind the wire mesh is a layer of riprap material 5 . Note the shackles 15 that are connected to the header 12 . Note also the stainless steel cables 5 that extend out from the shackles to connect to other piles (see FIG. 2 ). Note also that FIG. 6 shows the stainless steel clips 11 that secure the mesh 3 to the piles 2 .
As discussed below, the artificial islands are intended to be positioned in water in front of or adjacent to wetland areas. FIG. 7 is a plan environmental view of a typical shoreline 110 with wetlands 111 , showing the placement of the invention 1 is open water 112 in front of the shore. The islands are arraigned in a line to act as shoreline protection and a barrier for storm surges. The water depth can vary from 5 feet to a maximum of about 45 feet. The minimum water depth is limited by the draft of the barges needed for the construction of the island.
FIG. 8 is an environmental view of a series of islands formed using the invention. Here three islands 1 are shown in water 112 . In this way, a row of several islands can be built to minimize damage from storms.
A typical island is formed as follows:
Typically, all work is done from a barge. First, a set of piles is positioned in the shape of the island. The piles can be made of concrete, steel or wood, using well know techniques. The shape of the island is dependent on a number of factors and is always site-specific. Factors such as water depths and currents (speed and direction) as well as wind velocity and storm surge are site specific and will determine the purpose of the island (such as protecting eroding shoreline or wetlands). The environmental processes shall determine the exact shape of the island. These factors are commonly used to design structures such as bridges and other in-water structures and their calculations are well within the scope of ordinary skill in the art.
Once the piles are positioned, they are driven into the bottom at a sufficient depth to meet the design conditions. The length of the piles depends on the depth of the water and subsurface conditions. In the preferred embodiment, the maximum water depth is 45 feet. However, the island can be built in shallower water as needed. Note also that the depth of the water determines the distance of the island from the mainland. The piles are driven so that their tops are at the water surface level (usually measured at low tide for marine environments). Spacing of the piles also depends on the design factors. For example, a spacing of 30 feet between piles is a typical measure. However, this spacing will change with the conditions and is, again, entirely site-specific.
The size of the island depends on the intended use and site-specific conditions. The minimum diameter of the island is calculated, but is also dependent upon the water depth. Typically, the diameter of the island shall be three times the depth of the water. Thus, for a 30-foot water depth, the island diameter should be considered to be at least 90 feet. Using the rule above provides an adequate base to make a stable island.
Once the piles are set, wire mesh is attached to the piles. This mesh runs around the perimeter, forming a corral-like structure. In the preferred embodiment, the wire mesh is stainless steel welded wire mesh, but mesh made of other materials can be used. The wire mesh is pushed down into the bottom, to the level of the sub bottom. It then extends up to the top of the piles, as shown.
Once the “corral” is formed, the tops of the piles are tied together using cables that form tiebacks. The tiebacks are shown in FIGS. 2 and 5. In FIG. 2, a top view of the corral structure is shown. Note how the tiebacks run to piles that are positioned opposite of each other. The tiebacks hold the piles in a vertical position when the island is formed. They keep the piles from splaying out as the “corral” is filled.
Once the “corral” structure is complete, it is filled with riprap material (rock is preferred). The riprap material is delivered on barges. Typically, riprap material is added until it is almost to the surface of the water. The “rock” is then covered with a geotextile mat that extends up to the top of the screen mesh. This matting retains the cover soil in the corral and provides a base for natural vegetation. At that point, soils can be added to build up the island above the surface of the water as desired. Alterations and design considerations for marine environments shall include tidal actions, storm surge and wave frequency.
Finally, the soil is planted with vegetation suitable for the location.
FIG. 9 shows another embodiment of the invention. Here, the piles 20 are set to a height below the surface of the water 120 . For example, the tops of the piles might be 8 feet below the surface at low tide. The “corral” is formed in the same way as discussed above using the wire mesh 21 . “Rock” 22 is placed in the structure to the top of the piles 20 , however no top cover is used. This structure forms an artificial reef, which acts as a breakwater.
An example of a typical construction follows: To make an island in approximately 30-35 feet of water, fifteen of 70 foot concrete “I” piles are used (note: pile depth is site specific). The piles are driven into the bottom until they extend up from the bottom 30-35 feet, until that are at the level of the low tide. The piles are spaced approximately 30 feet apart forming a shell with a perimeter of approximately 440 feet (this configuration is shown in FIG. 2 ). Next, 8 ga. stainless steel welded wire mesh is attached to the piles. The mesh is approximately 35-40 feet in height. The mesh is pushed down into the muck layer. A series of stainless steel cables is suspended between the piles in a pattern as shown in FIG. 2 . Once the cables are secure, barges loaded with riprap material are positioned and the material is dumped into the enclosure. The riprap is laid to a point approximately 1 foot above the water surface. The rock is then covered with a geotextile mat that extends above the top of the screen mesh. Then quantities of fill dirt are added as cover material until the cover material extends to design height, (in this case approximately 5 feet above the high tide mark). Finally, a number of indigenous plants and trees are added to the island to form a vegetative cover to prevent erosion.
The present disclosure should not be construed in any limited sense other than that limited by the scope of the claims having regard to the teachings herein and the prior art being apparent with the preferred form of the invention disclosed herein and which reveals details of structure of a preferred form necessary for a better understanding of the invention and may be subject to change by skilled persons within the scope of the invention without departing from the concept thereof.
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A method of making artificial barrier islands or break waters. The method consists of driving a series of piles in the shape of the island, attaching a number of wire mesh sections, to form a fence around the perimeter of the piles, connecting the tops of the piles with cables, and then filling the formed enclosure with riprap (rock) material. Once the rock has reached the water surface, it is covered with suitable soil and vegetation to create the island. The piles and mesh are hidden below the water surface and the formed island takes on a natural appearance. In this way, the artificial island is a barrier to storms, thus protecting the shoreline and wetlands from erosion. Moreover, the artificial island creates an ideal habitat for birds, fish, reptiles and amphibians. In certain environments one island can protect approximately 10 times the amount of shoreline that lies behind it.
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RELATED APPLICATIONS
[0001] This application is the US National Phase of PCT/KR2012/009114, filed on Nov. 1, 2012, under 35 U.S.C. 371 and claims priority to Korean Patent Application Nos. 10-2011-0114084, filed on Nov. 3, 2011 and 10-2012-0122774, filed on Nov. 1, 2012 in the Korean Intellectual Property Office, the entire disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an integrated terminal for an advanced metering infrastructure (AMI) system based on a home network for a smart grid and a method of controlling the same, and more particularly, to an apparatus for providing various types of information regarding energy use, such as energy usage, rate information, and the like, through a single device configured of a combination of the existing energy service interface (ESI) and an in home display (IHD), while observing ZigBee smart energy profile (SEP) that is a wireless communication standard for interlocking an AMI with a home network and a device language message specification (DLMS) that is a communication standard of an electronic power meter system.
[0004] 2. Description of the Related Art
[0005] A smart grid means an intelligent power network and is a next-generation, power network capable of optimizing an energy use by enabling a power supplier and a power consumer to transmit and receive information associated with electricity use in real time, as an intelligent power network that is a combination of an energy network with a communication network by integrating the existing power network with an information communication technology. The smart grid based power network is being developed to cope with a change in production and consumption in real time and in order to implement a smart grid, there is a need to effectively monitor power consumption.
[0006] The AMI is a system that can implement bidirectional information exchange between a power consumer and a power producer based on a smart meter, wherein the smart meter based on the AMI provides a basis for optimizing a supply and demand of power by providing a bidirectional information providing function, a home network interlocking function, a power control function, and the like.
[0007] FIG. 1 is a diagram illustrating a structure of a power monitoring system within a home of the AMI system that is suggested in a standard system of the ZigBee SEP.
[0008] As illustrated in FIG. 1 , the AMI system includes an AMI related upper system 10 of an electric power company based on a meter data management system (MDMS), a communication system connecting an electric power company that is a subject of power production and/or a supplier with a smart meter in a home 30 that in a power consumer, and a smart meter 20 serving as a gateway between an outside and an inside of the home 30 .
[0009] The upper system 10 includes a data concentration unit (DCU) 11 that collects and stores poser consumption information for each home from the smart meter 20 of each home or transmits the collected information to an automated data collection system (ADCS) 12 in real time, the ADCS 12 that collects various types of power consumption information collected through the DCU 11 , and a meter data management system (MDMS) 13 that performs processes such as calculation of a power rate for each home, and the like, by performing various types of processes based on various rate information such as progressive rate information for each power consumption unit, and the like, in addition to various types of power consumption information for each home, power production and supply information of a power producer, rate information from the industry that is collected through the DCU 11 and the ADCS 12 , and the like.
[0010] A home appliance (HA) 33 may be a general home appliance, such as a TV, a refrigerator, a washing machine, an air conditioner, and the like, and the home appliances 33 for a smart grid need to have a smart function.
[0011] The smart meter 20 is an apparatus for bidirectional communication between a power supplier and a user while monitoring power consumption in real time.
[0012] For the communication, between the upper systems, an Internet network (TCP/IP) power line communication (PLC), and the like, are used and for communication between the smart meter 20 and the ESI 31 , ZigBee communication that is one of the general short range communication types may be used. Alternatively, the communication between the smart meter 20 and the DCU 11 is performed by using the device language message specification (DLMS) that is a communication standard of the smart meter and is a protocol for communication between the smart meter 20 and the DCU 11 .
[0013] ZigBee is a protocol that can be used to build a low power and low scale wireless network. Meanwhile, a media access control (MAC) and a physical layer are regulated as a standard in IEEE 802.15.4 that is an international standard and a standard of an upper layer in regulated in conjunction with ZigBee Alliance.
[0014] Further, the communication between the AMI and a home may be performed through an energy service interface (ESI) 31 . In addition, the home is provided with an IHD 32 that displays power consumption information, a rate, carbon emission information, and the like, of various home appliances 33 within a home.
[0015] The communication between the ESI 31 and the smart meter 20 is performed by the ZigBee SEP.
[0016] Various types of information such as power consumption information, rate information, and the like, of various home appliances 33 within a home are displayed in the IHD 32 via the ESI 31 and the total power consumption information, the rate information, and the like, within a home are transmitted to the IHD 32 via the ESI 31 from the upper system 10 and are displayed.
[0017] However, the foregoing existing scheme performs all the communications between the smart meter 20 serving as a gateway and the ESI 31 and between the IHD 32 and the home appliances 33 via the ESI 31 and as a result, a communication system is complicated and the definition of interlocking function and role is not clear.
[0018] In particular, in the network configuration of the ZigBee SEP, the IHD 32 cannot search the detailed information of the home appliances 33 that participate in the network and the ESI 31 has a control right of the home appliances 33 , such that only the simple information such as power consumption information, and the like, can be searched. Further, it is uncertain whether the interlocking between the ESI 31 of the ZigBee SEP and the upper system 10 is defined.
[0019] Further, an upgrade of a firmware is not defined in the ZigBee SEP and therefore, the implementation of the function cannot secure compatibility of standards and a remote firmware upgrade requires high reliability but it is difficult for the RF characteristic and the communication mechanism of ZigBee to meet the request.
[0020] The system of the related art has problems in that communication capacity is insufficient and the reliability of communication is limited, due to a limitation of the ZigBee communication.
[0021] Recently, some of the smart devices that are manufactured by makers of the home appliances 33 are not based on the ZigBee SEP, but instead home appliances performing communications based on WiFi have appeared. In this case, the system of the related art cannot cope with the WiFi based home appliances.
SUMMARY OF THE INVENTION
[0022] The present invention has been made in an effort to solve the above problems of the related art by configuring a network among a smart meter, an upper system, and home appliances by a terminal in which ESI and IHD functions are integrated into one unit, while observing ZigBee SEP that is a communication standard of an international standard and a DLMS that is a communication standard of the smart meter.
[0023] Another object of the present invention is to provide an integrated terminal that can be applied to other communication types of home appliances other than ZigBee SEP.
[0024] In order to accomplish the foregoing object, according to an aspect of the present invention, there is provided an integrated terminal that is connected between an upper system of an advanced metering infrastructure (AMI) system and a plurality of home appliances, respectively, within a home as a power consumer by a predetermined communication unit, the integrated terminal including: a communication module between upper systems serving as an interface for communication with an upper system; a communication module between home appliances serving as an interface for communication with the plurality of home appliances; and a display unit which displays the information received from the upper systems by the communication module between the upper systems, and displays information received from each home appliance by the communication module between the home appliances.
[0025] According to another aspect of the present invention, there is provided a method for controlling an integrated terminal that is connected between an upper system of an AMI system and a plurality of home appliances, respectively, within a home as a power consumer by a predetermined communication unit, the method including: (a) configuring a communication network between a plurality of home appliances within the home as a power consumer and a smart meter; (b) waiting after the step (a); (c) during the waiting in step (b), determining whether a connection/disconnection of home appliances is requested due to the installation or removal of home appliances and if it is determined that the connection/disconnection is requested, returning to the step (a) to reconfigure the communication network, including the home appliances that are additionally connected or disconnected; (d) during the waiting in step (b), determining whether a control of the home appliances is requested and if it is determined that the control of the home appliances is requested, controlling the corresponding home appliances, and (e) in the waiting in step (b), checking data to be displayed on a display device to determine whether the checked data is valid data and if it is determined that the checked data is valid data, displaying the corresponding data on the display device.
[0026] According do the foregoing configuration, the exemplary embodiment of the present invention con simplify the communication system that interconnects between the upper system and the lower system, immediately process the user request, and facilitate an upgrade (firmware upgrade) of the integrated terminal within a home from the upper system, thereby solving the lack of communication capacity and the reliability of communication due to the ZigBee communication that is the existing system.
[0027] Further, the exemplary embodiments of the present invention can perform communication with home appliances using, for example, WiFi based communications in addition to the ZigBee SEP of the related art, thereby being applicable for various communication types of home appliances.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The above objects, features and advantages of the present invention will become more apparent to those skilled in the related art in conjunction with the accompanying drawings. In the drawings;
[0029] FIG. 1 is a diagram illustrating a structure of a power monitoring system of an AMI system that is suggested in a standard system of ZigBee SEP of the related art;
[0030] FIG. 2 is a diagram illustrating a structure of a power monitoring system of an AMI system according to an exemplary embodiment of the present invention;
[0031] FIG. 3 is a functional block diagram illustrating a configuration of an integrated terminal according to an exemplary embodiment of the present invention; and
[0032] FIG. 4 is a flow chart illustrating an operation of the integrated terminal according to the exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.
[0034] FIG. 2 is a diagram illustrating an overall structure of a power monitoring system of an AMI system according to an exemplary embodiment of the present invention.
[0035] First, as illustrated in FIG. 2 , an upper system of an AMI system is the same as the related art, and therefore, like components are denoted by reference numerals of FIG. 1 and a detailed description thereof will be omitted. However, in FIG. 2 , an IHD server 14 and a mobile server 15 are added in an upper system 10 , but the IHD server 14 is a server that performs a lower function of an MDMS 13 as a server that holds data for displaying information of an integrated terminal 35 performing an IHD function and a mobile server 15 is a server than performs a service using a smart phone, which is not directly associated with the present invention.
[0036] In the present specification, the term ‘upper system’ means a system of an upper side, that is, a power supplier side above a smart meter and an integrated terminal, based on the smart meter according to an exemplary embodiment of the present invention and the integrated terminal to be described below and the term ‘lower system’ means a system of a home appliance side within a home that is a lower side, that is, a power consumer below a smart meter and an integrated terminal.
[0037] According to the exemplary embodiment of the present invention, improved parts of the related art are that ESI 31 and IHD 32 functions are integrated in an integrated terminal 35 and the integrated terminal 35 is connected to a DCU 11 by a power line communication (PLC) while being connected to an ADCS 12 and the MDMS 13 via an Internet network.
[0038] That is, the integrated terminal 35 in which the ESI 31 and IHD 32 functions are integrated is connected to the DCU 11 by the power line communication and thus, thereby the integrated terminal 35 may optionally communicate with the upper system 10 via the DCU 11 and/or the Internet network.
[0039] Here, the connection between the integrated terminal 35 and the system 10 may depend on a short range communication network such as WiFi, or the like, within a home 30 and may be directly connected to the Internet network within the home 30 .
[0040] Further, a home appliance 33 having a smart function among home appliances within the home 30 can be communicably connected directly to the integrated terminal 35 and a home appliance 37 that does not have a smart function can be communicably connected to the integrated terminal 35 via a smart plug.
[0041] The integrated terminal 35 according to the exemplary embodiment of the present invention performs both of an interface function for communication between the upper system 10 and the IHD 32 and an interface function for communication between the home appliance 36 ( 37 ) that is the ESI 31 function of the related art and the IHD 32 and further performs both of the IHD 32 function of the related art and the ESI 31 function directly controlling the home appliance 36 ( 37 ).
[0042] Next, the integrated terminal 35 according to the exemplary embodiment of the present invention will be described with reference to FIG. 3 . FIG. 3 is a functional block diagram illustrating a configuration of an integrated terminal according to an exemplary embodiment of the present invention.
[0043] As described above, the integrated terminal 35 includes a data request unit 352 that can be communicably connected to the upper system of the AMI system via the Internet or the power line communication, communicably connected to the home appliances 36 ( 37 ) that are the lower system by ZigBee SEP or WiFi, and periodically requests necessary data to the upper system 10 according to a user request through a user interface 351 or a time set in an embedded program, a data receiving unit 353 that receives data requested by the data request unit 352 from the upper system 10 , a command/data request unit 354 that transmits a command for periodically controlling the home appliances 36 ( 37 ) that is the lower system according to the user request through the user interface 351 or the time set in the embedded program or requests data necessary for the home appliances 36 ( 37 ), and a command/data receiving unit 355 that receives data requested by the command/data requesting unit 354 frost the home appliances 36 ( 37 ).
[0044] As the request data that is requested to the upper system 10 by the data request unit 352 , there may be, for example, power consumption information (LP) accumulating data 352 - 1 per a unit time, power consumption statistical information data 352 - 2 , past LP data 352 - 3 , power consumption comparison data 352 - 4 , rate data for each step (progressive rate data) 352 - 5 , other data 352 - 5 , and the like. The data corresponding to the request data as the data received 1 from the upper system 10 by the data receiving unit 353 according to the request by the data request unit 352 is data 353 - 1 to 353 - 6 that is accumulated in the MDMS 13 or the ADCS 12 of the upper system 10 .
[0045] Further, as the command controlling the home appliances 36 ( 37 ) by the command/data request unit 354 , there may be a command 354 - 1 that turns on or off each home appliance connected to, for example, the smart plug 37 or a command 354 - 1 that turns on or off each home appliance 36 having a smart function.
[0046] Further, as the request data requested to the home appliances 36 ( 37 ) by the command/data request unit 354 , there may be, for example, LP data 354 - 2 for each home appliance 36 ( 37 ), current state date 354 - 3 indicating whether each home appliance 36 ( 37 ) is in a current operating state or a stop state, other data 354 - 4 such as data indicating carbon emission information for each home appliance 36 ( 37 ), and the like. The data received from the home appliances 36 ( 37 ) by the command/data receiving unit 355 is data 355 - 1 to 355 - 4 received from each home appliance 36 ( 37 ) as data corresponding to the request data requested by the command/data request unit 354 .
[0047] As described above, the data request to the upper system 10 or the home appliances 36 ( 37 ) by the data request unit 352 or the command/data request unit 354 by the integrated terminal 35 may be periodically performed in a unit of several minutes, for example, 15 minutes, and the like, according to the case in which there is the user request through the user interface 351 or the embedded program.
[0048] Further, the integrated terminal 35 includes a display device 359 and each data received from the home appliances 36 ( 37 ) of the upper system 10 or the lower system is displayed on the display device 359 and thus, is provided for visual confirmation by a user.
[0049] The data request unit 352 and the data receiving unit 353 correspond to a communication module between the upper systems according to the exemplary embodiment of the present invention, the command/data request unit 354 and the command/data receiving unit 355 correspond to the communication module between the home appliances, and the display device 359 corresponds to a display unit.
[0050] Further, in addition to the foregoing functions, the integrated terminal 35 may further include an open auto demand request (Open ADR) processing unit 356 , a home appliance power consumption information collection unit 357 , and a smart meter power consumption information collection unit 358 .
[0051] The Open ADR is a system that stops the use of the home appliances by directly controlling the home appliances 36 ( 37 ) within each home via the integrated terminal 35 in the upper system 10 by, for example, a previous contract between a power supplier and a consumer, for example, when reserved power is insufficient due to a peak of power demand and prevents the occurrence of a power outage in the overall transmission network or distribution network.
[0052] The Open ADR processing unit 356 perforce a function of stopping an operation of all or a part of the home appliances 36 ( 37 ) by the control from the upper system 10 when a necessity of the Open ADR is generated.
[0053] The home appliance power consumption information collection unit 357 performs a function of collecting the power consumption information for each home appliance 36 ( 37 ) or for each predetermined period of all the home appliances 36 ( 37 ) within the home 30 and transmitting the collected power consumption information to the upper system 10 .
[0054] The smart meter power consumption information collection unit 358 performs a function of collecting the power consumption information for each home that is held by the smart meters 20 of each home 30 through the DCU 11 or the upper system 10 .
[0055] Further, the integrated terminal 35 includes a database (DB) and may store the power consumption information for a predetermined period and the power consumption information for each home that are collected by the house appliance power consumption information collection unit 357 and the smart meter power consumption information collection unit 358 in the DB within the integrated terminal 35 . In this case, the power consumption information for each predetermined period of the home appliances 36 ( 37 ) stored in the DB and the power consumption information for each home held by the smart meter 20 may be displayed by a user request, and the like.
[0056] Unlike the data request unit 352 to the command/data receiving unit 355 , the Open ADR processing unit 356 , the home appliance power consumption information collection unit 357 , and the smart meter power consumption information collection unit 358 controls each home appliance 36 ( 37 ) by the direct control of the upper system 10 or collects the desired information from each home appliance 36 ( 37 ) and the smart meter 20 .
[0057] Next, an operation of the integrated terminal 35 according to the exemplary embodiment of the present invention to perform the integrated function of the ESI and the IHD based on the ZigBee SEP will be described with reference to FIG. 4 . FIG. 4 is a flow chart illustrating an operation of the integrated terminal according to the exemplary embodiment of the present invention.
[0058] First, when a network connected to the upper system 10 is configured simultaneously with the initialization of the system, in step S 1 , the integrated terminal 35 configures, for example, the ZigBee SEP communication network with the lower home appliances 36 ( 37 ) and smart meter ( 20 ), and the like, and then, proceeds to step S 2 and waits.
[0059] Next, during the waiting of step S 2 , it is determined whether the connection/disconnection of the home appliances are additionally requested to the communication network built in step S 1 by, for example, the installation or removal of the home appliances, and the like (step S 3 ). As the determination result, if it is determined that the connection/disconnection is requested from the home appliances (Yes in step S 3 ), the operation returns to step S 1 to reconfigure the communication network including the home appliances that are additionally connected or disconnected. If it is determined that there is no connection/disconnection request (No in step S 3 ), the operation returns to step S 2 and waits.
[0060] Further, during the waiting in step S 2 , it is determined whether there are the control of the home appliances and the collection request of the power consumption information according to the request from a user or a predetermined period in the embedded program as described above (step S 4 ). As the determination result, if it is determined that there are the control of the home appliances and the collection request of the power consumption information (Yes in step S 4 ), the operation proceeds to step S 5 to control the corresponding home appliances or collect the power consumption information and then, the operation proceeds to step S 8 to display the results on the display device 359 of the integrated terminal 35 and then, returns to step S 2 and waits. If it is determined that there is no control of the home appliances or collection request of the power consumption information (No in step S 4 ), the operation returns to step S 2 and waits.
[0061] In addition, during the waiting of step S 2 , the integrated terminal 35 continuously checks the data to be displayed on the display device 359 (step S 6 ) and in step S 7 , it is determined whether the checked data is valid data. As the determination result, if it is determined that the checked data is valid data (Yes in step S 7 ), the operation proceeds to step S 8 to display the corresponding data on the display device 359 and returns to step S 2 and waits. If it is determined that the checked data is not valid data (No in step S 7 ), the operation returns to step S 2 and waits.
[0062] The integrated terminal 35 performs a routine as described above to achieve the function of the integrated terminal 35 .
[0063] Further, as illustrated in FIG. 4 , according to the integrated terminal on the present invention, the ESI function of the related art marked by symbol a, the IHD function of the related art marked by symbol b, and a function of integrating the ESI and the IHD of the related art marked by symbol c are performed by a single apparatus.
[0064] As described above, the exemplary embodiment of the present invention configures the network between the smart meter and the home appliances by the integrated terminal in which the ESI and IHD functions of the related art are integrated into one to collect or provide the information and the data through the communication with the home appliances that are the lower system while collecting or providing the information and the data through the communication with the upper system and the user can control the operation of the home appliances by the integrated terminal according to the exemplary embodiment of the present invention or the upper system can directly control the home appliances within each home as a power consumer by the integrated terminal.
[0065] Therefore, according to the present invention, it is possible to simplify the communication system that interconnects between the upper system and the lower system, immediately process the user request, and facilitate an upgrade (firmware upgrade) of the smart function of the integrated terminal within a home from the upper system, thereby solving the lack of communication capacity and the reliability of communication due to the ZigBee communication that is the existing system.
[0066] Further, the exemplary embodiments of the present invention can perform the communication with home appliances using, for example, WiFi based communications in addition to the ZigBee SEP of the related art, thereby being applicable for various communication types of home appliances.
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An integrated terminal for an advanced metering infrastructure (AMI) system based on a home network for a smart grid and a method of controlling the same are disclosed. The integrated terminal is connected between an upper system 10 of an AMI system and a plurality of home appliances 36, respectively, within a home as a power consumer by a predetermined communication unit. The integrated terminal includes a communication module between upper systems serving as an interface for communication with an upper systems 10, a communication module between home appliances 36 serving as an interface for communication with the plurality of home appliances, and a display unit which displays the information received from the upper systems by the communication module between the upper systems, and displays information received from each home appliance by the communication module between the home appliances.
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FIELD OF THE INVENTION
[0001] The present invention relates to a mounting apparatus for a power train of a vehicle adapted to control the displacement of the power train and increase dynamic rigidity and vibration insulation of each mount, thereby improving a ride comfort and the Noise, Vibration, and Harshness (NVH) function of the vehicle.
BACKGROUND OF THE INVENTION
[0002] A power train mounting apparatus that supports the power train and insulates noise and vibration thereof is generally formed by a principal axis of inertia of three to four support points or a center of gravity of three support points.
[0003] For light automobiles, the center of gravity or principal axis of inertia of three support points is typically used. However, as the center of gravity requires a sub-frame, crossmember, or center member, the principal axis of inertia of three support points has mainly been adopted in recent vehicles for reducing the weight and improving the rate of fuel consumption thereby.
[0004] The principal axis of inertia of three support points has two main mounts, such as an engine and transmission mounts, at the vehicle body. A third mount (roll mount or roll rod) is at the crossmember.
[0005] In case of the center of gravity of three support points, all mounts are located underneath the engine, and thus, it is difficult to restrict engine roll. Hence, the Noise, Vibration, and Harshness (NVH) function and vehicle ride are inferior to that of the principal axis of inertia of three support points.
[0006] However, a drawback of the principal axis of inertia of three support points is that one mount is conventionally a roll rod that controls the displacement of engine roll; therefore, a relatively large displacement of the engine occurs in the vertical direction thereof.
[0007] Accordingly, a liquid filled hydraulic mount is added either to the engine mount or transmission mount for preventing the deterioration of the vehicle ride.
[0008] The liquid filled hydraulic mount, however, is heavy in weight and high in manufacturing cost such that the price load could fall heavily on the drivers of light vehicles.
SUMMARY OF THE INVENTION
[0009] Embodiments of the present invention help control the displacement of a power train and increase dynamic rigidity and vibration insulation of each mount, thereby improving the ride comfort and the Noise, Vibration, and Harshness (NVH) function of the vehicle.
[0010] A power train mounting apparatus of a vehicle according to one embodiment of the present invention includes an engine mount supportively connecting an engine and side member therebetween in an engine compartment. A transmission mount supportively connects a transmission and side member therebetween. A roll mount supportively connects a crossmember and the joint of the engine and transmission therebetween.
[0011] The engine mount is constituted by an upper and lower brackets, a bridge-type insulator contacting the lower bracket, and an inner pipe fixed to the insulator.
[0012] The transmission mount is constituted by an outer pipe, a bridge-type insulator contacting the outer pipe, and an inner pipe fixed to the insulator.
[0013] The roll mount is constituted by bushing-type mounts placed at both ends of the roll mount, and a roll rod that connects the bushing-type mounts therebetween.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a better understanding of the nature and objects of the present invention, reference should be made to the following detailed description with the accompanying drawings, in which:
[0015] FIG. 1 a schematic view of a power train mounting apparatus according to an embodiment of the present invention;
[0016] FIGS. 2 to 3 illustrate an engine mount of FIG. 1 ;
[0017] FIGS. 4 to 5 illustrate a transmission mount of FIG. 1 ; and
[0018] FIG. 6 illustrates a rear roll mount of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring to FIG. 1 , a preferred embodiment of the present invention includes an engine 1 and transmission 5 that attach at three places to a left and right side members 3 L and 3 R of the vehicle body and a rear crossmember 7 in an engine compartment.
[0020] An engine mount 10 is located between engine 1 and left side member 3 L, a transmission mount 20 is located between transmission 5 and right side member 3 R, and a roll mount 30 is placed between rear crossmember 7 and the joint of engine 1 and transmission 5 .
[0021] Engine mount 10 , as shown in FIG. 2 , is composed of an upper and lower brackets 11 and 12 , bridge-type insulator 13 , and support bracket assembly 14 . Upper and lower brackets 11 and 12 couple to each other at both ends thereof, and bridge-type insulator 13 is fixed via vulcanization between upper and lower brackets 11 and 12 . Support bracket assembly 14 attaches engine mount 10 to left side member 3 L.
[0022] With reference to FIGS. 3 a and 3 b , the middle portions of upper and lower brackets 11 and 12 of engine mount 10 are convexly curved in flat sheet shapes. Each end of upper and lower brackets 11 and 12 are coupled to each other by means of spot welding.
[0023] The bottom of bridge-type insulator 13 fastens via vulcanization to lower bracket 12 . The insulator is equipped at the center thereof with an inner pipe 15 via vulcanization. When upper bracket 11 couples to lower bracket 12 , upper bracket 11 presses bridge-type insulator 13 for a pre-compression.
[0024] Support bracket assembly 14 coupled on left side member 3 L supports engine mount 10 via a bolt (‘B’ in FIG. 2 ) penetrating inner pipe 15 .
[0025] Bridge-type insulator 13 includes a primary damper 13 a having inner pipe 15 at the center thereof and a plurality of split ends. Each end of primary damper 13 a couples or contacts with upper and lower brackets 11 and 12 . A supplementary damper 13 b is distanced from primary damper 13 a and secures at the bottom thereof to lower bracket 12 .
[0026] An unexplained reference numeral 16 is an engine mounting bracket fixing engine mount 10 to engine 1 .
[0027] As the pre-loaded insulator is fixed via vulcanization between the assembly of upper and lower brackets 11 and 12 , the displacement of insulator 13 is minimized when the load is applied to engine mount 10 during engine operation.
[0028] Further, a gap between upper and lower brackets 11 and 12 and insulator 13 is minimized so that a large displacement of engine 1 can effectively be controlled and a comfortable vehicle ride is provided thereby.
[0029] Furthermore, engine mount 10 increases in damping value during a large displacement of engine 1 by the pre-compressed insulator; therefore, engine mount 10 may preferably substitute for an existed liquid filled engine mount.
[0030] Consequently, engine mount 10 improves the ride comfort by minimizing the displacement thereof in place of the costly liquid filled engine mount.
[0031] In reference to FIGS. 4 and 5 , transmission mount 20 is constituted by an outer pipe 21 , bridge-type insulator 22 , and inner pipes 23 . Outer pipe 21 is in the shape of a cylinder, bridge-type insulator 22 is situated via vulcanization in outer pipe 21 , and inner pipes 23 are fixed via vulcanization at the center of the insulator in the lateral direction of the vehicle.
[0032] A side member mounting bracket 24 coupled at the outside of outer pipe 21 is disposed on right side member 3 R in the engine compartment.
[0033] Bridge-type insulator 22 includes a primary damper 22 a and supplementary damper 22 b . Primary damper 22 a has inner pipes 23 at the center thereof and a plurality of split ends. Each end of primary damper 22 a couples or contacts outer pipe 21 . Supplementary damper 22 b is distanced from primary damper 22 a and couples at the bottom thereof to outer pipe 21 .
[0034] An unexplained reference numeral 25 is a transmission mounting bracket fixing transmission mount 20 to transmission 5 .
[0035] Bolts (‘B’ in FIG. 4 ) passing through transmission mounting bracket 25 and inner pipes 23 of bridge-type insulator 22 support transmission mount 20 by connecting right side member 3 R and transmission 5 .
[0036] As for transmission mount 20 , when the external force of compression is applied in the anteroposterior direction of bridge-type insulator 22 due to vehicle acceleration and engine roll, the force is absorbed by primary damper 22 a of bridge-type insulator 22 to thereby reduce the noise upon acceleration by a gradual variation of the spring characteristic value.
[0037] Referring now to FIG. 6 , roll mount 30 connects rear crossmember 7 and the joint of engine 1 and transmission 5 . Roll mount 30 includes bushing-type mounts 31 at both ends of roll mount 30 , and a roll rod 32 connecting the bushing-type mounts therebetween.
[0038] Each bushing-type mount 31 has a cylindrical outer pipe 31 a , and bushing-type insulators 31 b fixed by means of vulcanization in the outer pipe. An inner pipe 31 c is fixed at the center of the insulator by means of vulcanization in the lateral direction of the vehicle.
[0039] Unexplained reference numerals 33 are crossmember mounting brackets that fix bushing-type mounts 31 to rear crossmember 7 and the joint of engine 1 and transmission 5 , respectively.
[0040] As for roll mount 30 , when the external force of compression is applied in the anteroposterior direction of bushing-type mount 31 due to vehicle acceleration and engine roll, the force is absorbed by bushing-shaped insulator 31 b installed sideways in the vehicle. Thus, the noise is lessened by a gradual variation of the spring characteristic value.
[0041] As apparent from the foregoing, there is an advantage in that a power train mounting apparatus according to the present invention fixes the engine and transmission to the side members and crossmember in the engine compartment by using a preloaded engine mount, transmission mount, and roll mount, thereby effectively coping with the large displacement of the engine during engine operation. The load displacement in the anteroposterior direction of the vehicle is also effectively dampened, thus improving the ride comfort.
[0042] Moreover, the liquid filled engine mount is substituted by an ordinary rubber engine mount that is preloaded or changed in installation direction thereof, contributing to a minimization of the manufacturing cost.
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A power train mounting apparatus for a vehicle is disclosed to improve the vehicle riding by properly restricting the displacement of the power train. The dynamic rigidity and vibration insulation in relation to an engine mount and transmission mount are also increased, thus improving the Noise, Vibration, and Harshness (NVH) function of the vehicle.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Reference is made to commonly assigned, co-pending U.S. Patent Applications:
[0002] Ser. No. ______ by Bernel et al., (Docket 81820) filed of even date herewith entitled “Ink Jet Recording Element”;
[0003] Ser. No. ______ by Bermel et al., (Docket 82109) filed of even date herewith entitled “Ink Jet Recording Element”;
[0004] Ser. No. ______ by Bermel et al., (Docket 82110) filed of even date herewith entitled “Ink Jet Recording Element”;
[0005] Ser. No. ______ by Bermel et al., (Docket 82111) filed of even date herewith entitled “Ink Jet Recording Element”;
[0006] Ser. No. ______ by Bermel et al., (Docket 82133) filed of even date herewith entitled “Ink Jet Printing Method”;
[0007] Ser. No. ______ by Bermel et al., (Docket 82134) filed of even date herewith entitled “Ink Jet Printing Method”;
[0008] Ser. No. ______ by Bermel et al., (Docket 82138) filed of even date herewith entitled “Ink Jet Printing Method”;
[0009] Ser. No. ______ by Lawrence et al., (Docket 81815) filed of even date herewith entitled “Ink Jet Printing Method”;
[0010] Ser. No. ______ by Lawrence et al., (Docket 81817) filed of even date herewith entitled “Ink Jet Printing Method”;
[0011] Ser. No. ______ by Lawrence et al., (Docket 81818) filed of even date herewith entitled “Ink Jet Printing Method”;
[0012] Ser. No. ______ by Lawrence et al., (Docket 81821) filed of even date herewith entitled “Ink Jet Printing Method”;
[0013] Ser. No. ______ by Lawrence et al., (Docket 81893) filed of even date herewith entitled “Ink Jet Printing Method”;
[0014] Ser. No. ______ by Lawrence et al., (Docket 81894) filed of even date herewith entitled “Ink Jet Printing Method”; and
[0015] Ser. No. ______ by Lawrence et al., (Docket 81983) filed of even date herewith entitled “Ink Jet Printing Method”.
FIELD OF THE INVENTION
[0016] The present invention relates to a method for using a porous ink jet recording element.
BACKGROUND OF THE INVENTION
[0017] In a typical ink jet recording or printing system, ink droplets are ejected from a nozzle at high speed towards a recording element or medium to produce an image on the medium. The ink droplets, or recording liquid, generally comprise a recording agent, such as a dye or pigment, and a large amount of solvent. The solvent, or carrier liquid, typically is made up of water and an organic material such as a monohydric alcohol, a polyhydric alcohol or mixtures thereof.
[0018] An ink jet recording element typically comprises a support having on at least one surface thereof an ink-receiving or image-receiving layer, and includes those intended for reflection viewing, which have an opaque support, and those intended for viewing by transmitted light, which have a transparent support.
[0019] An important characteristic of ink jet recording elements is their need to dry quickly after printing. To this end, porous recording elements have been developed which provide nearly instantaneous drying as long as they have sufficient thickness and pore volume to effectively contain the liquid ink. For example, a porous recording element can be manufactured by cast coating, in which a particulate-containing coating is applied to a support and is dried in contact with a polished smooth surface.
[0020] When a porous recording element is manufactured, it is difficult to co-optimize the image-receiving layer surface appearance and ink drying times. Good image-receiving layer surface appearance is obtained when it is virtually crack-free. A crack-free surface appearance can be obtained merely by adding more binder to the image-receiving layer. However, adding more binder increases dry time since the binder fills the pores in the image-receiving layer. Therefore, it is difficult to obtain an image-receiving layer which has a crack-free surface yet is fast-drying.
[0021] Another problem encountered with a recording element is ink coalescence which occurs when adjacent ink dots coalesce which leads to nonuniform density.
[0022] U.S. Pat. 6,037,050 and EP 888,904 relate to an ink jet recording element wherein an ink absorption layer comprises inorganic particles such as silica and a poly (vinyl alcohol) binder that is crosslinked with a hardener. However, there is no disclosure in these references that the crosslinker should be present in an amount greater than 10%, based on the binder.
[0023] It is an object of this invention to provide a method for using a porous ink jet recording element that exhibits good overall appearance without cracking and has an excellent dry time and reduced ink coalescence.
SUMMARY OF THE INVENTION
[0024] These and other objects are achieved in accordance with the invention which comprises an ink jet printing method comprising the steps of:
[0025] A) providing an ink jet printer that is responsive to digital data signals;
[0026] B) loading the printer with an ink jet recording element comprising a support having thereon a porous image-receiving layer comprising particles, a poly (vinyl alcohol) binder and a crosslinking agent, the particles having a primary particle size of from about 7 to about 40 nm in diameter which may be aggregated up to about 300 nm, and the crosslinking agent being present in an amount of at least about 20 weight % of the poly(vinyl alcohol) binder;
[0027] C) loading the printer with an ink jet ink composition; and
[0028] D) printing on the image-receiving layer using the ink jet ink composition in response to the digital data signals.
[0029] By use of the process of the invention, a porous ink jet recording element is obtained that exhibits good overall appearance without cracking and has an excellent dry time and reduced ink coalescence.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Examples of particles useful in the invention include alumina, boehmite, clay, calcium carbonate, titanium dioxide, calcined clay, aluminosilicates, silica, barium sulfate, or polymeric beads. The particles may be porous or nonporous. In a preferred embodiment of the invention, the particles are metallic oxides, preferably fumed. While many types of inorganic and organic particles are manufactured by various methods and commercially available for an image-receiving layer, porosity of the ink-receiving layer is necessary in order to obtain very fast ink drying. The pores formed between the particles must be sufficiently large and interconnected so that the printing ink passes quickly through the layer and away from the outer surface to give the impression of fast drying. At the same time, the particles must be arranged in such a way so that the pores formed between them are sufficiently small that they do not scatter visible light.
[0031] The particles may be in the form of primary particles, or in the form of secondary aggregated particles. The aggregates are comprised of smaller primary particles about 7 to about 40 nm in diameter, and being aggregated up to about 300 nm in diameter. The pores in a dried coating of such aggregates fall within the range necessary to ensure low optical scatter yet sufficient ink solvent uptake.
[0032] Any fumed metallic oxide particles may be used in the invention. Examples of such particles include fumed alumina, silica, titania, cationic silica, antimony (III) oxide, chromium (III) oxide, iron (III) oxide, germanium (IV) oxide, vanadium (V) oxide, or tungsten (VI) oxide. Preferred examples of fumed metallic oxides which may be used in the invention include silica and alumina fumed oxides. Fumed oxides are available in dry form or as dispersions of the aggregates mentioned above.
[0033] The process for fuming metallic oxides is well known in the art. For example, reference may be made to Technical Bulletin Pigments, no. 56, Highly Dispersed Metallic Oxides Produced by the AEROSIL® Process, by Degussa AG., 1995.
[0034] Any poly (vinyl alcohol) may be used in the invention. In a preferred embodiment, the poly(vinyl alcohol) has an average viscosity greater than about 20 cp when employed in a 4% aqueous solids solution at 20° C. Specific examples of such poly(vinyl alcohols) which may be used in the invention include the following:
TABLE 1 Poly(vinyl alcohol) Average Viscosity @ 4% (cp) PVA-A Gohsenol ® GH-17 30 1 PVA-B Gohsenol ® GH-23 52 1 PVA-C Gohsenol ® N300 27.5 1 PVA-D Elvanol ® 52-22 23.52 2
[0035] The amount of poly(vinyl alcohol) binder used should be sufficient to impart cohesive strength to the image-receiving layer, but as small as possible so that the interconnected pore structure formed by the aggregates is not filled in by the binder. In a preferred embodiment of the invention, the weight ratio of the binder to the particles is from about 1:20 to about 1:5.
[0036] The image-receiving layer may also contain a mordant. Examples of mordants which may be used include water-soluble cationic polymers, metal salts, water-insoluble cationic polymeric particles in the form of a latex, water dispersible polymer, beads, or core/shell particles wherein the core is organic or inorganic and the shell in either case is a cationic polymer. Such particles can be products of addition or condensation polymerization, or a combination of both. They can be linear, branched, hyper-branched, grafted, random, blocked, or can have other polymer microstructures well known to those in the art. They also can be partially crosslinked. Examples of core/shell particles useful in the invention are disclosed and claimed in U.S. patent application Ser. No. ______, of Lawrence et al., Ink Jet Printing Method, filed of even date herewith, Docket 81894HEC, the disclosure of which is hereby incorporated by reference. Examples of water dispersible particles useful in the invention are disclosed and claimed in U.S. patent application Ser. No. ______, of Lawrence et al., Ink Jet Printing Method, filed of even date herewith, Docket 81815HEC; and U.S. patent application Ser. No. ______, of Lawrence et al., Ink Jet Printing Method, filed of even date herewith, Docket 81817HEC, the disclosures of which are hereby incorporated by reference.
[0037] Examples of crosslinkers which may be used in the invention include carbodiimides, polyfunctional aziridines, aldehydes, isocyanates, epoxides, polyvalent metal cations, acetals, ketals, etc. In a preferred embodiment of the invention, the crosslinker is an aldehyde, an acetal or a ketal. In a more preferred embodiment, the crosslinker is 2,3-dihydroxy-1,4-dioxane.
[0038] As noted above, the amount of crosslinking agent is present in an amount of at least about 20 weight % of the poly(vinyl alcohol) binder. This amount is far beyond a typical amount of crosslinking agent for poly(vinyl alcohol). For example, in Paper Coating Additives, Robert J. Kane, TAPPI PRESS, Atlanta Ga., 1995, page 96, it is disclosed that a typical aldehyde crosslinker, glyoxal, is used at about 10% by weight relative to the poly(vinyl alcohol). In a preferred embodiment of the invention, the crosslinking agent is present in an amount of at least about 40 weight %, more preferably about 50 weight %, of the poly(vinyl alcohol) binder.
[0039] Since the image-receiving layer is a porous layer comprising particles, the void volume must be sufficient to absorb all of the printing ink. For example, if a porous layer has 60 volume % open pores, in order to instantly absorb 32 cc/m 2 of ink, it must have a physical thickness of at least about 54 μm.
[0040] The support for the ink jet recording element used in the invention can be any of those usually used for ink jet receivers, such as resin-coated paper, paper, polyesters, or microporous materials such as polyethylene polymer-containing material sold by PPG Industries, Inc., Pittsburgh, Pa. under the trade name of Teslin®, Tyvek® synthetic paper (DuPont Corp.), and OPPalyte® films (Mobil Chemical Co.) and other composite films listed in U.S. Pat. 5,244,861. Opaque supports include plain paper, coated paper, synthetic paper, photographic paper support, melt-extrusion-coated paper, and laminated paper, such as biaxially oriented support laminates. Biaxially oriented support laminates are described in U.S. Pat Nos. 5,853,965; 5,866,282; 5,874,205; 5,888,643; 5,888,681; 5,888,683; and 5,888,714, the disclosures of which are hereby incorporated by reference. These biaxially oriented supports include a paper base and a biaxially oriented polyolefin sheet, typically polypropylene, laminated to one or both sides of the paper base. Transparent supports include glass, cellulose derivatives, e.g., a cellulose ester, cellulose triacetate, cellulose diacetate, cellulose acetate propionate, cellulose acetate butyrate; polyesters, such as poly (ethylene terephthalate), poly (ethylene naphthalate), poly (1,4-cyclohexanedimethylene terephthalate), poly (butylene terephthalate), and copolymers thereof; polyimides; polyamides; polycarbonates; polystyrene; polyolefins, such as polyethylene or polypropylene; polysulfones; polyacrylates; polyetherimides; and mixtures thereof. The papers listed above include a broad range of papers, from high end papers, such as photographic paper to low end papers, such as newsprint. In a preferred embodiment, polyethylene-coated paper is employed.
[0041] The support used in the invention may have a thickness of from about 50 to about 500 μm, preferably from about 75 to 300 μm. Antioxidants, antistatic agents, plasticizers and other known additives may be incorporated into the support, if desired.
[0042] In order to improve the adhesion of the ink-receiving layer to the support, the surface of the support may be subjected to a corona-discharge treatment prior to applying the image-receiving layer.
[0043] Coating compositions employed in the invention may be applied by any number of well known techniques, including dip-coating, wound-wire rod coating, doctor blade coating, gravure and reverse-roll coating, slide coating, bead coating, extrusion coating, curtain coating and the like. Known coating and drying methods are described in further detail in Research Disclosure no. 308119, published Dec. 1989, pages 1007 to 1008. Slide coating is preferred, in which the base layers and overcoat may be simultaneously applied. After coating, the layers are generally dried by simple evaporation, which may be accelerated by known techniques such as convection heating.
[0044] To improve colorant fade, UV absorbers, radical quenchers or antioxidants may also be added to the image-receiving layer as is well known in the art. Other additives include pH modifiers, adhesion promoters, rheology modifiers, surfactants, biocides, lubricants, dyes, optical brighteners, matte agents, antistatic agents, etc. In order to obtain adequate coatability, additives known to those familiar with such art such as surfactants, defoamers, alcohol and the like may be used. A common level for coating aids is 0.01 to 0.30% active coating aid based on the total solution weight. These coating aids can be nonionic, anionic, cationic or amphoteric. Specific examples are described in MCCUTCHEON's Volume 1: Emulsifiers and Detergents, 1995, North American Edition.
[0045] The coating composition can be coated either from water or organic solvents, however water is preferred. The total solids content should be selected to yield a useful coating thickness in the most economical way, and for particulate coating formulations, solids contents from 10-40% are typical.
[0046] Ink jet inks used to image the recording elements used in the present invention are well-known in the art. The ink compositions used in ink jet printing typically are liquid compositions comprising a solvent or carrier liquid, dyes or pigments, humectants, organic solvents, detergents, thickeners, preservatives, and the like. The solvent or carrier liquid can be solely water or can be water mixed with other water-miscible solvents such as polyhydric alcohols. Inks in which organic materials such as polyhydric alcohols are the predominant carrier or solvent liquid may also be used. Particularly useful are mixed solvents of water and polyhydric alcohols. The dyes used in such compositions are typically water-soluble direct or acid type dyes. Such liquid compositions have been described extensively in the prior art including, for example, U.S. Pat. Nos. 4,381,946; 4,239,543 and 4,781,758, the disclosures of which are hereby incorporated by reference.
[0047] The following example is provided to illustrate the invention.
EXAMPLE
Element 1 of the Invention
[0048] A coating solution was prepared by combining fumed alumina (Cab-O-Sperse® PG003, Cabot Corp.), PVA-B and crosslinker 2,3-dihydroxy-1,4-dioxane (Clariant Corp.) in a ratio of 88:10:2 to give an aqueous coating formulation of 30% solids by weight, so that the crosslinking agent is present in an amount of 20 weight % of the poly(vinyl alcohol) binder.
[0049] The layer was bead-coated at 40° C. on polyethylene-coated paper base which had been previously subjected to corona discharge treatment. The coating was then dried at 60° C. by forced air to yield a recording element with a thickness of 40 μm.
Element 2 of the Invention
[0050] This element was prepared the same as Element 1 except that the ratio of components was 87:10:3 to give an aqueous coating formulation of 30% solids by weight, so that the crosslinking agent is present in an amount of 30 weight % of the poly (vinyl alcohol) binder.
Element 3 of the Invention
[0051] This element was prepared the same as Element 1 except that the ratio of components was 86:10:4 to give an aqueous coating formulation of 30% solids by weight, so that the crosslinking agent is present in an amount of 40 weight % of the poly (vinyl alcohol) binder.
Comparative Element C-1
[0052] This element was prepared the same as Element 1 except that PVA-D was used instead of PVA-B, and the ratio of components was 84:15:1 to give an aqueous coating formulation of 30% solids by weight, so that the crosslinking agent is present in an amount of 6.6 weight % of the poly (vinyl alcohol) binder.
Comparative Element C-2
[0053] This element was prepared the same as Element 1 except that PVA-D was used instead of PVA-B, and the ratio of components was 86.5:12.5:1 to give an aqueous coating formulation of 30% solids by weight, so that the crosslinking agent is present in an amount of 8 weight % of the poly (vinyl alcohol) binder.
Comparative Element C-3
[0054] This element was prepared the same as Element 1 except that PVA-D was used instead of PVA-B, and the ratio of components was 89:10:1 to give an aqueous coating formulation of 30% solids by weight, so that the crosslinking agent is present in an amount of 10 weight % of the poly (vinyl alcohol) binder.
Coating Quality
[0055] The above dried coatings were visually evaluated for cracking with the following results:
TABLE 2 Recording Element Cracking 1 None 2 None 3 None C-1 None C-2 None C-3 Some
[0056] The above results show that neither any of the recording elements of the invention nor two comparative elements exhibited any cracking.
Dry Time
[0057] Test images of cyan, magenta, yellow, red, green, blue and black bars, each 1.1 cm by 13.5 cm, were printed on the above elements using an Epson Stylus® Photo 870 using inks with catalogue number T008201. Immediately after ejection from the printer, a piece of bond paper was placed over the printed image and rolled with a smooth, heavy weight. Then the bond paper was separated from the printed image. Ink transferred to the bond paper if the recording element was not dry. The length of the bar imaged on the bond paper was measured and is proportional to the dry time. Dry times corresponding to a length of about 40 cm or less are acceptable.
TABLE 3 Proportional Dry Time Recording Element (cm) 1 6 2 2 3 6 C-1 91 C-2 91 C-3 65
[0058] The above results show that the elements employed in the invention had much better dry times than all the comparative elements.
Coalescence
[0059] A test image of a green patch was printed on each of the above elements using an Epson Stylus® Photo 870 using inks with catalogue number T008201. Coalescence of the ink on the patches was visually rated as follows:
[0060] 1=None
[0061] 2=Slight
[0062] 3=Moderate
[0063] 4=Severe
[0064] The following results were obtained:
TABLE 4 Recording Element Coalescence 1 3 2 2 3 1 C-1 4 C-2 4 C-3 4
[0065] The above results show that the recording elements employed in the invention had much less coalescence than the comparative elements.
[0066] Although the invention has been described in detail with reference to certain preferred embodiments for the purpose of illustration, it is to be understood that variations and modifications can be made by those skilled in the art without departing from the spirit and scope of the invention.
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An ink jet printing method comprising the steps of: A) providing an ink jet printer that is responsive to digital data signals; B) loading the printer with an ink jet recording element comprising a support having thereon a porous image-receiving layer comprising particles, a poly (vinyl alcohol) binder and a crosslinking agent, the particles having a primary particle size of from about 7 to about 40 nm in diameter which may be aggregated up to about 300 nm, and the crosslinking agent being present in an amount of at least about 20 weight % of the poly (vinyl alcohol) binder; C) loading the printer with an ink jet ink composition; and D) printing on the image-receiving layer using the ink jet ink composition in response to the digital data signals.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part application and claims the benefit under 35 U.S.C. §120 of U.S. Non-Provisional patent application Ser. No. 11/162,747, filed Sep. 21, 2005, by Walter Jarck, and entitled “A System and Method for the Manufacture of Reconsolidated or Reconstituted Wood Products”, now U.S. Pat. No. 7,537,031, and U.S. Non-Provisional patent application Ser. No. 11/162,748, filed Sep. 21, 2005, by Walter Jarck, and entitled “Systems and Methods for the Production of Steam-Pressed Long Fiber Reconsolidated Wood Products”, now U.S. Pat. No. 7,537,669, both of which claim the benefit of U.S. Provisional Patent Application No. 60/612,075, filed Sep. 22, 2004, by Walter Jarck, and entitled “Method and Apparatus for the Manufacture of Reconsolidated or Reconstituted Wood Products”, all of which are incorporated herein by reference as if set forth herein in their entirety. This application claims the further benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/012,564, filed Dec. 10, 2007, and entitled “A System and Method for the Separation of Bast Fibers”, which is also incorporated herein by reference as if set forth herein in its entirety.
TECHNICAL FIELD
The present invention relates to an improved method and apparatus for the separation of bast and core fibers from bast plants.
BACKGROUND
The present invention relates generally to the timber products industry, and particularly to methods and apparatus for the separation of bast fibers. Fibers and other materials from plants such as kenaf, flax, hemp, sisal, jute, ramie, bamboo, and even banana and cotton stalks, can be successfully used to create a wide range of products. These alternative plants are commonly referred to as “bast plants,” or dicotyledonous plants, which are flowering plants with net-veined leaves.
Bast plants are comprised of two primary fibrous elements: the outer fiber, similar to bark or skin, referred to as “bast,” and the inner fiber, referred to as “core.” Both of these elements can be used for different and varying purposes, and to create a wide range of products. The core from the bast plants may be used to make paper, polyesters and other fabrics, or to create reconstituted or reconsolidated paneling and wood products, or it can even be burned as fuel. The bast of the bast plants may be used to make rope, yarn, or burlap, or to manufacture lightweight and burnable materials, preferably including car parts such as dashboards, door panels, seat linings and seat backs.
Bast plants are preferable for use for many reasons. First, as mentioned, the bast and core can both be used to create a variety of different products. Second, many bast plants have phenomenal growth rates, typically reaching a harvestable height of 12-18 feet in approximately 150 growing days, whereas other organic materials such as pine or other timber generally cannot be harvested for 7-40 years. Because bast plants grow so quickly, they are a vastly renewable resource. Also, bast plants typically contain low amounts of lignin, which is the resin that binds cellulose fibers in plants and trees together. Lower amounts of lignin makes it easier to separate the core during processing, and makes it easier to further process the core at a later time as compared to other organic materials. Additionally, bast plants characteristically yield 3-5 times more usable material per acre than pine and other timbers. Bast and core are also very lightweight, thus making them easier to transport and store as compared to heavier fibers and timber.
However, current manufacturing processes are unequipped to effectively process bast plants. The bast and core are both useful for different purposes and to create different products, but the compositions of the bast and core are such that the two components must be separated from each other to be processed effectively and efficiently. Also, this separation must be accomplished without damaging or altering the biological makeup of either component.
An inherent property of a bast plant is that the bast is extremely difficult to separate from the core. Most previous processes separated the bast from the core by a human labor process called “retting,” which essentially involves soaking the bast plant for a long period of time and then hand-peeling or chopping the bast off of the core of the plant. This retting process is not only tedious and time consuming, but also inefficient as it prevents large amounts of bast fiber from being processed quickly and effectively because each bast plant must be individually peeled. Because of this long felt, but unresolved problem, industry has previously avoided the widespread use of bast plants.
Therefore, it is an aim of the present invention to provide a method and apparatus that effectively and efficiently separates bast fibers.
BRIEF SUMMARY OF THE DISCLOSURE
The present invention relates to a system and method for the separation of bast fibers.
An embodiment of the present invention comprises a method for the separation of bast fibers. The method comprises the steps of soaking the bast fiber stalks in a hot water bath for a short period of time to loosen and soften the bast from the core. If the stalks are freshly-harvested, meaning they have been cultivated within approximately two weeks prior to processing, then the stalks may not require soaking in the hot water bath. The method further comprises the step of respectively feeding each stalk or a plurality of stalks into a plurality of scrim stations either sequentially or in groupings of a predetermined amount, each scrim station comprising a plurality of sets of scrim rolls for effectively separating the bast fibers from the core fibers of the stalk, and for softening of the outer bast of the stalk. Further, the scrim roll sets are configured to comprise a top scrim roll and a bottom scrim roll. The method further comprises the step of operating the last scrim roll set in the line of scrim stations at a speed moderately faster than the speed of the previous sets such that the previous scrim roll sets effectively hold the stalk in place while the last scrim roll set strips the bast from the core.
An aspect within the present embodiment comprises the step of respectively scanning each stalk in order to acquire data in regard to the diameter of a large and a small end of the stalk. Next, at a cutting station, the first and the second end of the stalks are cut at a predetermined angle of cut in order to enhance subsequent stalk scrim processing, the angle of cut being variable in a range greater than 15° and less than 60°.
A further aspect within the present embodiment comprises the step of feeding the stalks through a flailing station prior to soaking the stalks in the hot water bath, wherein any limbs, branches, leaves or stubs are removed from the stalks. This flailing station may comprise two opposing rollers with flailing instruments attached thereto. If the bast plants are freshly-harvested, then flailing is necessary to remove unwanted branches and limbs, and leave only the bast stalks for processing. If the plants are not freshly-harvested, then the flailing step may be unnecessary because the limbs and branches will break off easily during the scrimming process.
A yet further aspect within the present embodiment comprises the step of feeding the stalks through a stalk incisor prior to sending the stalks through the scrim stations to produce longitudinal cuts or slices along the length of the stalks before the stalks are scrimmed. The stalk incisor may be similar in configuration to a “spike” roll, or may comprise rollers with blades aligned around the circumference of the rollers perpendicularly to the axis of the rollers. The longitudinal cuts help initiate and control the width of splits within a stalk, and improve the quality of subsequently produced scrim stalk material.
A still further aspect within the present invention comprises the step of cutting the stalks via a post-processing cutting station after the stalks are scrimmed, wherein the stalk material is cut to predetermined and desired lengths.
Another embodiment of the present invention comprises a system for the separation of bast fibers. The system comprises a hot water bath for soaking a plurality of stalks, wherein the stalks are soaked for a short period of time to soften and loosen the bast from the core. If the stalks are freshly-harvested, then soaking may be unnecessary. The system further comprises a plurality of scrim stations, each scrim station comprising a plurality of sets of scrim rolls for crushing and refined cutting of the stalk, softening of the bast of the stalk, and separating the bast from the core of the stalk, the scrim sets being configured to comprise a top scrim roll and a bottom scrim roll.
A stalk scanning device is also included for scanning each stalk in order to acquire data in regard to the diameter of a large and a small end of the stalk. Additionally, the first and the second end of the stalks are cut at a predetermined angle of cut in order to enhance stalk scrim processing, the angle of cut being variable in a range greater than 15° and less than 60°.
The system further comprises a final scrim roll set in the line of scrim stations that operates at a speed moderately faster than the speed of the previous sets such that the previous scrim roll sets effectively hold the stalk in place while the last scrim roll set strips the bast from the core of the stalk.
A further aspect of the present embodiment comprises a flailing station, wherein any limbs, branches or stubs are removed from the stalks. This flailing station may comprise two opposing rollers with flailing instruments attached thereto. If the bast plants are freshly-harvested, then flailing is necessary to remove unwanted branches, leaves and limbs, and leave only the bast stalks for processing. If the plants are not freshly-harvested, then the flailing device may be unnecessary because the limbs and branches will break off easily during the scrimming process.
A yet further aspect of the present embodiment comprises a stalk incisor for producing longitudinal cuts or slices along the length of the stalks before the stalks are scrimmed. The stalk incisor may be similar in configuration to a “spike” roll, or may comprise rollers with blades aligned around the circumference of the rollers perpendicularly to the axis of the rollers. The longitudinal cuts help initiate and control the width of splits within a stalk, and improve the quality of subsequently produced scrim stalk material.
A still further aspect within the present embodiment comprises a post-processing cutting station, wherein the stalk material is cut to predetermined and desired lengths after it exits the scrimming stations.
Another aspect of the present invention comprises a computer program product that includes a computer readable medium that is usable by a control unit processor. The medium having stored thereon a sequence of instructions that when executed by a control unit processor causes the control unit processor to execute the step of scanning a stalk in order to acquire data in regard to the diameter of a large and a small end of the stalk. The computer program product further determines the optimum spacing between a top scrim roll and a bottom scrim of a plurality of scrim roll sets based upon the acquired diameter of the large and small ends of the scanned stalk. The computer program product further comprises the step of dynamically adjusting the spacing between the top scrim roll and the bottom scrim roll of the scrim roll sets based upon the determined optimum spacing of each scrim roll set. The computer program product further comprises the step of dynamically adjusting the speed at which the scrim rolls turn, including the last, faster-spinning scrim roll set, based upon the acquired diameter of the large and small ends of the scanned stalk.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate one or more embodiments of the invention and, together with the written description, serve to explain the principles of the invention. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment, and wherein:
FIG. 1 is a diagram illustrating a production line system for the separation of bast fibers that may be implemented in embodiments of the present invention.
FIGS. 2A-2J are diagrams illustrating profiles of scrim rolls that may be implemented in scrimming stations that are utilized within embodiments of the present invention.
DETAILED DESCRIPTION
One or more exemplary embodiments of the invention are described below, the disclosed embodiments are intended to be illustrative only since numerous modifications and variations therein will be apparent to those of ordinary skill in the art. Further, all embodiments of the present invention may either be implemented, assisted or controlled via computerized control systems, wherein the computerized control systems can be a conventional personal computer system. The computing systems further include user interfaces that operate in accordance with conventional windowing graphical user interface (GUI) paradigms.
The computerized control systems can further comprise additional hardware and software elements of the types generally included in conventional personal computers, such as a processor, a main memory, a disk storage device such as a hard disk drive, input/output interfaces, an image scanner, a mouse, a keyboard and a removable read/write storage device such as a drive that uses a CD-ROM or a floppy disk.
The software elements of the computerized control system are executable in the main memory, but as persons skilled in the art will understand, the software elements may not in actuality reside in its entirety in the main memory. The computerized control systems can further comprise other hardware and software elements of the types conventionally included in personal computers, such as an operating system.
The stalks or stems utilized within aspects of the present invention are preferably freshly harvested. Freshly-harvested stalks are defined as those which have been cultivated within 2 weeks prior to processing. Accordingly, the stalks must be promptly used or, in the event the stalks are not promptly used, liberally sprinkled with water in order to prevent the stalks from drying out. The stalks come preferably from bast fiber plants, namely kenaf, flax, hemp, sisal, jute, ramie, bamboo, banana plants, cotton plants, and the like. Stalks that are used within aspects of the present invention should preferably have a first and second end with the large-end diameters of the stalks being in the range of about 0.25 to 4 inches and the length of the stalks being in the range of about 10 to 20 feet, although as one having ordinary skill in the art will understand, the stalks may be larger or smaller than those described.
For bast plants, effective removal of the outer fiber (“bast”) from the inner fiber (“core”) is critical for satisfactory processing of either the bast or core materials. The separation of the bast from core is extremely difficult, and has effectively prevented the previous use of bast fibers in industry. Previous attempts at separating the core from the bast have used either chemical processes that alter the makeup of the plant, or crude mechanical processes that damage or affect the fibrous materials. Thus, the effective separation of the bast from the core is an essential and novel feature within aspects of the present invention.
The quality of any resultant product made from the bast or core is predicated upon the quality of the scrim stalk material that is produced via the stalk processing line. An important step in producing quality scrim stalk material, and in the removal of the bast from the core, is the initial conditioning of the stalks by immersing them in a hot water bath prior to the stalks being scrimmed. If the stalks are freshly-harvested, then immersing the stalks in the hot water bath may not be necessary. But, if the stalks are not freshly-harvested, and are thus dried out, then soaking the stalks may be necessary. Although freshly-harvested stalks are preferable, even if they are not freshly-harvested, stalks that are heated in a water bath for a short period of time result in satisfactory scrim material. The hot water bath softens and moistens the bast plants which allows the bast to be removed from the core more cleanly and easily. Because the bast is cleanly removed, the use of the hot water bath results in uninjured bast and core fibers, both of which are highly desired.
It is important within aspects of the present invention that conditioned stalks not be soggy or over saturated from the soaking or conditioning process; preferably conditioned stalks need to retain some degree of crispness so that they split easily into stalk length strands. Conditioned stalks should be quickly processed through the present system. The over conditioning of a stalk can result in knots within the stalk that become too soft to separate from the strands of the crushed and scrimmed material of the stalk.
Aspects of the present invention are initially described in reference to FIG. 1 . FIG. 1 illustrates an overall processing line system 100 that may be implemented within embodiments of the present invention. The specific stations and processing areas within the process line system 100 can be configured as desired. As shown, the preferred system 100 of FIG. 1 comprises a flailing station 2 , a hot water bath 3 , a stalk incisor 10 , scrim roll stations 25 a - 25 g , a post-processing cutting station 27 , and a dryer 35 .
As shown in FIG. 1 in an aspect of the present invention, stalks and processed stalk materials are transported throughout the system 100 from station to station via a conveyor transport system 7 . The speed and direction of the conveyor transport system is controlled and directed via a computer control system.
The preferred embodiment of the system 100 comprises a flailing station 2 , wherein limbs, branches and stubs are removed from the stalks. This flailing station 2 may comprise two opposing rollers with flailing instruments attached thereto. The flailing instruments may comprise soft wire brushes, rubber fingers, or any other pliable, semi-rigid members capable of removing the leaves and limbs from the bast stalks without interfering with or damaging the bast fibers. The two opposing rollers spin as the stalks are fed between them, and the flailing instruments detach limbs, leaves, stubs, and any other unwanted materials from the bast stalks. If the bast plants are freshly-harvested, then flailing is necessary to remove unwanted branches and limbs, and leave only the bast stalks for processing. If the plants are not freshly-harvested, then the flailing step may be unnecessary because the limbs and branches will break off easily during the scrimming process.
After the flailing station 2 , the dried stalks are transported to the hot water bath 3 , wherein the bast stalks are soaked for a short period of time to soften and loosen the outer bark from the inner fibers. If the stalks are freshly-harvested, then soaking the stalks may be unnecessary. The temperature of the water comprising the hot water bath should be in the range of 110-150° F. so that the stalks will soften and soak up the water more quickly. The stalks are soaked for different lengths of time depending on the size of each stalk. Stalks that are 1″ or less in diameter generally only need to be soaked for approximately half an hour to reach optimal moisture content and temperature. Stalks that are larger than 3″ in diameter generally should be soaked for 1.5 hours or longer, depending on the size of the stalk. Bast stalks between these size ranges should be soaked for time periods greater than half an hour but less than 1.5 hours, depending on the size of the stalk. Regardless of the size of the diameter of the stalk, optimum temperature and moisture content is reached when the inner temperature of the stalk is approximately 120° F. The soak in the hot water bath 3 enables the stalks to be processed more easily and efficiently.
Upon removal from the hot water bath 3 , conditioned stalks are deposited upon the conveyor transport system 7 , wherein the conveyor transport system 7 transports the stalks to the stalk incisor 10 prior to entering the first scrimming station 25 . Before the stalks are cut via the stalk incisor 10 , the stalks are scanned by a stalk-scanning device (not shown) in order to acquire measurement data in regard to the diameter of a large and a small end of each stalk. This data will aid in setting the distance between the rollers included in the stalk incisor 10 and scrimming stations 25 .
In an additional aspect of the present invention, as shown in FIG. 1 , a stalk incisor 10 is utilized to produce longitudinal cuts or slices along the length of the stalks before the stalks are scrimmed. The stalk incisor 10 may be similar in configuration to a “spike” roll, or may comprise rollers with blades aligned around the circumference of the rollers perpendicularly to the axis of the rollers. The longitudinal cuts help initiate and control the width of splits within a stalk, and improve the quality of subsequently produced scrim stalk material.
Further aspects of the present invention provide for a cutting station (not shown) wherein the first and the second end of the stalks are cut at a predetermined angle of cut in order to enhance the subsequent stalk scrimming process. The angle of cut of the stalk ends is preferably variable in a range greater than about 15° and less than about 60°.
As mentioned above, aspects of the present invention comprise a plurality of scrim stations 25 a - 25 g ; each scrim station 25 a - 25 g comprises pluralities of sets of scrimming rolls for the crushing and refined cutting of the bast stalk. As will be understood, a scrim station 25 a - 25 g may comprise only one scrim roll set, or many scrim roll sets. Within aspects of the present invention, a scrimming set comprises a top scrim roll and a bottom scrim roll. The primary objective of the scrimming stations 25 a - 25 g is to effectuate the separation of the bast fiber from the core fiber of the stalk. Another objective is to produce a group of separately defined, but not discrete, strands in which most of the strands are the length of the stalk and evenly separated from each other so as to produce a mat with a consistent basis weight. FIG. 1 illustrates a set of seven stalk scrimming stations 25 a - 25 g . As will be understood by one having ordinary skill in the art, other embodiments of the present invention may comprise as many or as few scrim stations 25 a - 25 n as needed to provide the desired texture and consistency of a specific scrim stalk material. Further, as illustrated in FIGS. 2A-2J , the scrim rolls can comprise varied sizes and spacing between the top and bottom rolls, as well as varying surfaces and textures on the rolls.
It has been observed in previous stalk material processing operations that oscillating scrim rolls can do considerable damage to processed scrim stalk material, therefore, the traditional oscillating scrim rolls have been replaced within aspects of the present invention with stationary adjustable fluted scrim rolls. The majority of the scrim rolls used within aspects of the present invention comprise fluted grooves that appear similar to ruffles in appearance. The fluted grooves of respective scrim roll sets comprise specific pitches, wherein the pitch of a flute is determined by the angle formed by two adjacent sides of a protruding flute segment. The last set of scrim rolls may comprise simply a rough surface or texture, or smaller, axially-aligned grooves, rather than fluted grooves, depending on the freshness of the stalk.
As illustrated in the scrim roll profiles of FIGS. 2A-2H , the pitch of a flute and the flute depth of a scrim roll profile vary as the stalk proceeds through a plurality of scrim roll stations 25 a - 25 g . In particular, the pitch distance—or the distance between two flute groove sides—determines the size of the scrim flute elements, while the depth of the flutes determines the amount of separation between the scrim elements. The pitch distance, and the depth and the angle the flute grooves make with the shaft are all important considerations in achieving consistent scrim quality.
As the stalk material is passed through each scrim station 25 a - 25 g , the distance or space gap between each consecutive scrim roll set becomes progressively smaller, thus resulting in a finely crushed stalk material mat or scrim stalk material mat. This specific design assists in reducing the diameter of the scrim in a series of consecutive stages without reducing the strength of the scrim fiber strands. The design of the profiles on each of the respective scrimming stations is different (as illustrated in FIGS. 2A-2G ).
In the preferred embodiment of the present invention, the number of scrimming roll sets actually used for a particular bundle of bast stalks typically depends upon the freshness and size of the stalks. For instance, fresher stalks which have been harvested within 2 weeks of processing may only require the use of two or three scrim roll sets to become sufficiently separated, whereas older stalks that have been stored for a long period of time may require processing through several scrim roll sets. The number of scrim roll sets used, whether it is as few as two, or many more than two, can be varied by the system user at his or her discretion.
Within further aspects of the present invention, as illustrated in FIG. 2H , alternative scrim roll profiles may be implemented at any scrim roll station within the system 100 . As seen in FIG. 2H , the flute depth of a scrim roll can be reduced, while the pitch distance remains the same. As shown in FIG. 2H , either filling the flute groove with a durable substance or not machining the flute groove to its entire depth at the manufacture of the scrim roll can reduce the flute depth of a scrim roll. The scrim roll configuration of FIG. 2H assists in clearing processed scrim from a scrim roll set and thus can be implemented on a scrimming line in the instances where there is constant trouble within a production process from the strands of the scrim becoming lodged within the scrim rolls during the scrimming process.
An aspect of the present invention is a final stalk scrimming set (which would be included within scrimming station 25 g in the present embodiment) that has an outer roll surface different than the fluted design present in the other scrim roll sets. A shown in FIG. 2I , this final roll set may include small ridges 210 axially aligned along the scrim roll, as compared to the flutes of the other sets shown in FIGS. 2A-2H , which are aligned perpendicular to the axis of the scrim rolls. Alternatively, as shown in FIG. 2J , the final scrim roll set may simply comprise a rough or coarse outer surface 220 , or any other similar surface. As previously mentioned, the purpose of these alternative outer surfaces is to strip the bast from the core of the stalks, thus separating these two discrete elements for use. In some embodiments, as few as two scrim roll sets are used; one set comprising scrimming rolls with a fluted design, and a final set comprising rolls with an alternative outer surface. As will be understood, the number of scrim roll sets and scrim roll stations 25 a - 25 g may be varied by a system operator.
Within further aspects of the present invention, the last scrim roll set should be rotated at a faster speed than the earlier scrim roll sets in the process such that the last scrim roll set strips the bast from the core while the earlier sets effectively hold the stalks in place. The bast is separated because the rough surfaces, either 210 or 220 or some other coarse surface, are spinning against the outer bast fiber faster than the stalk is moving through the scrimming station, and thus the bast is removed from the stalk as it moves through the last scrim roll set. This last scrim roll set is operated in a range of approximately 5% to 15% faster than previous scrim roll sets to easily and gently rub the bast fiber off of the core material. Preferably, this last scrim roll set should be operated at a speed approximately 10% faster than the earlier scrim roll sets, but as one having ordinary skill in the art will understand, any number of speeds may be used to accomplish the separating function. Bast and core fibers comprise different compositions and properties, and thus these two elements will be clearly and discretely defined after exiting the final scrim roll set.
As mentioned above, an objective of the scrimming stations 25 a - 25 g is to produce a group of separately defined, but not discrete, strands in which most of the strands are the original length of the stalk in addition to being evenly separated from each other, and to subsequently remove and separate the outer bast from the inner core of the bast plant. This aspect of the present invention is enhanced by the ability to dynamically control the spacing between a discrete scrim roll set, and the speed at which the scrim roll set is operating. This feature is accomplished by utilizing the stalk diameter data that was obtained at the stalk scanning station to determine the optimum spacing between the top and bottom scrim roll of a scrimming roll set. Once the optimum spacing is established for a respective scrim roll set, the scrim roll set can be configured to the established optimum spacing by either a manual means or via a computerized control system within aspects of the present invention.
In some instances, as stalks are being processed at the scrimming stations 25 a - 25 g the leading edges of some stalks may have a tendency to produce larger scrim stalk material than is desired. Aspects of the present invention provide a solution to this particular problem. Specifically, prior to entering a predetermined scrim station 25 a - 25 g the scrim stalk material is rotated 180°, which provides an appropriate remedy to this particular problem. This orientation changing feature places larger scrim stalk material on the back sides of the remaining scrim station 25 a - 25 g roll sets and thus results in a more homogeneous scrim stalk material mat. Within further aspects of the present invention, the scrim stalk material can be separated into predetermined mat bundle sizes at pre-specified scrimming stations 25 a - 25 g situated upon the stalk processing line.
Within aspects of the present invention, after the stalk material exits the scrimming stations 25 a - 25 g , it will progress through a post-processing cutting station 27 wherein the stalk material is cut to predetermined and desired lengths. The post-processing cutting station 27 preferably comprises two opposing rollers with axially-aligned blades that slice the scrim stalk material into smaller lengths, but may comprise any mechanism for the cutting of the scrim stalk material, such as a guillotine-type cutter. The scrim stalk material may be cut into lengths as short or as long as the user desires, depending on the spacing of the blades on the rollers of the post-processing cutting station 27 . Alternatively, the post-processing cutting station 27 may be omitted if the user desires longer, uncut, stalk-length material.
Once the scrim stalk material has exited the scrimming stations 25 a - 25 g , the scrim stalk material is transported to a first drying station 35 (see FIG. 1 ). Within aspects of the present invention, wet scrim stalk material is dried at the drying station 35 using a simple air drying mechanism. In one embodiment of the present invention, the air used for drying should be at a temperature in the range of 180° to 280° F. The residual moisture content range for the dried scrim stalk material is preferably in the range of 5% to 20%, but as will be understood by one having ordinary skill in the art, the moisture content may be outside of this range.
After the scrim stalk material is sufficiently dried, it is gathered and baled for use. Because both the bast and core have not yet been mechanically damaged or chemically altered, they may be used in numerous applications. The bast may be further processed into lightweight materials, preferably including car parts such as dashboards, door panels, and seat backs and linings. The core may be processed into polyesters or other synthetics, or may be used in any application requiring a strong and durable composite material. In one aspect of the present invention, the core may be further processed into reconsolidated or reconstituted wood products.
A further embodiment of the present invention comprises a method for the separation of bast fibers. The method comprises the step of soaking the bast fiber stalks in a hot water bath for a short period of time for softening and loosening the outer bast from the inner core of the stalk. Stalks that are freshly-harvested may not require soaking in the hot water bath. The method further comprises the step of sequentially feeding each stalk into a plurality of scrim stations, each scrim station comprising a plurality of sets of scrim rolls for the separation of bast and core fibers, the scrim roll sets being configured to comprise a top scrim roll and a bottom scrim roll. The method further comprises the step of operating the last scrim roll set in the line of scrim stations at a speed moderately faster than the speed of the previous sets such that the previous scrim roll sets effectively hold the stalk in place while the last scrim roll set separates the bast from the core fiber. The last scrim roll set may either comprise grooves which are axially-aligned along the roll, or alternatively, a rough surface on the outside of the scrim roll, to aid in the removal of the bast from the core of the stalk.
An aspect within the present method includes the step of respectively scanning each stalk in order to acquire data in regard to the diameter of a large and a small end of the stalk. Next, the first and the second end of the stalks are cut at a predetermined angle of cut in order to enhance stalk scrim processing, the angle of cut being preferably variable in a range greater than 15° and less than 60°.
A further aspect within the present embodiment comprises the step of feeding the stalks through a flailing station prior to soaking the stalks in the hot water bath, wherein any limbs, branches or stubs are removed from the stalks. This flailing station may comprise two opposing rollers with flailing instruments attached thereto. If the bast plants are freshly-harvested, then flailing is necessary to remove unwanted branches and limbs, and leave only the bast stalks for processing. If the plants are not freshly-harvested, then the flailing step may be unnecessary because the limbs and branches will break off easily during the scrimming process.
A yet further aspect within the present embodiment comprises the step of feeding the stalks through a stalk incisor prior to sending the stalks through the scrim stations to produce longitudinal cuts or slices along the length of the stalks before the stalks are scrimmed. The stalk incisor may be similar in configuration to a “spike” roll, or may comprise rollers with blades aligned around the circumference of the rollers perpendicularly to the axis of the rollers. The longitudinal cuts help initiate and control the width of splits within a stalk, and improve the quality of subsequently produced scrim stalk material.
A still further aspect within the present invention comprises the step of cutting the stalks via a post-processing cutting station after the stalks are scrimmed, wherein the stalk material is cut to predetermined and desired lengths.
Another embodiment of the present invention comprises a computer program product that includes a computer readable medium that is usable by a control unit processor. The medium having stored thereon a sequence of instructions that when executed by a control unit processor causes the control unit processor to execute the step of scanning a stalk in order to acquire data in regard to the diameter of a large and a small end of the stalk. The method further determines the optimum spacing between a top scrim roll and a bottom scrim roll of a plurality of scrim roll sets based upon the acquired diameter of the large and small ends of the scanned stalk. The computer program product further comprises the step of dynamically adjusting the spacing between the top scrim roll and the bottom scrim roll of the scrim roll sets based upon the determined optimum spacing of each scrim roll set.
Therefore, 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. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
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The present invention relates generally to the timber products industry, and particularly to methods and apparatus for the separation of bast fibers. More particularly, the present invention relates to methods and apparatus for use in the separation of inner core from outer bast of bast plants using soaking, cutting, and scrimming methods and apparatuses.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Section 371 of International Application No. PCT/IB2008/000307, filed Feb. 12, 2008, which was published in the English language on Aug. 21, 2008 under International Publication No. WO 2008/099256 A1, and the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention is about alkali or alkaline-earth metal dispensers stable to environmental gases, in particular air, especially adapted for use in the fabrication of miniaturized devices.
[0003] A number of industrial applications require the presence of alkali or alkaline-earth metals in different physical forms, e.g., in the form of thin solid films deposited onto a surface of a device or in the form of vapors. Among these, one can remember photocathodes, in which the active element is a surface made of an alkali metal (or of an intermetallic compound containing an alkali metal); CRTs, in which a deposit of an alkaline-earth metal (typically barium) on the inner surface of the tube acts as a trap for gases, keeping the required degree of vacuum inside the same tube; atomic clocks, in which an electromagnetic radiation is passed through vapors of an alkali metal (rubidium or, more commonly, cesium); atomic interferometers, described in International Patent Application No. WO 2006/084113, and atomic gyroscopes, described in European patent application No. EP 1865283; and refrigeration units based on the tunnel effect, in which cooling is due to transport of electrons between a cathode and an anode, and a deposit of an alkali metal on at least the electron-emitting surface of the cathode helps reduce the work function of the cathode and consequently the energy required for operating the system. Detailed information about this mechanism, called “thermotunneling”, can be found in the article “Refrigeration by combined tunneling and thermionic emission in vacuum: use of nanometer scale design” of Y. Hishinuma et al., published in Applied Physics Letters, vol. 78, no. 17, pages 2572-2574 (2001), while an example of use in an actual device is given in U.S. Pat. No. 6,876,123 B2.
[0004] Alkali or alkaline-earth metals are not easy to handle or ship due to their high reactivity towards atmospheric gases and moisture. Dispensers of these metals, used for a long time, contain them in the form of stable compounds. Dispensers of alkali metals, in which these metals are present in form of their salts (e.g., chromates, vanadates, titanates and similar) are described, for instance, in U.S. Pat. Nos. 3,579,459 and 6,753,648 B2, and in European patent application No. EP 1598844 A1; dispensers of barium, containing the stable compound BaAl 4 , are described in a number of patents including, to cite but a few, U.S. Pat. Nos. 2,824,640 and 4,642,516; dispensers of calcium, containing the compound CaAl 2 , are described e.g., in U.S. Pat. No. 6,583,559 B1.
[0005] All of the dispensers disclosed in the above cited documents are however bulky, and not suitable for use in the production of, or for insertion in, miniaturized devices, such as for instance the thermotunneling refrigerating units described in the Hishinuma article cited above, or in miniaturized atomic clocks, such as those described in the paper “Microfabricated alkali atom vapor cells” of Li-Anne Liew et al. (Applied Physics Letters, vol. 84, no. 14, pages 2694-2696 (2004)).
[0006] For their proper working, it is necessary for the previously cited industrial applications that the inner cavity of the devices be kept under vacuum or anyway free from reactive gases. In the case of a thermotunneling refrigerating unit, the presence of gases between the cathode and the anode could hinder the traveling of electrons, and could cause the back-transfer of heat by convection. These units generally require a vacuum better than 10 −1 hectoPascal (hPa) and preferably in the range of 10 −4 hPa. In the case of atomic clocks, gases present in the cavity could react with the vapors of the alkali metal, thus causing the diminishing of the amount of free metal vapor and worsening of the working of the clock. Despite the fact that the manufacturing processes of these (and other) devices commonly comprise steps of evacuation of the cavities, phenomena like permeation from outside, leaks, and outgassing from the surfaces of said cavities reintroduce undesired gases in the same during the device life. In order to tackle this problem, it is known to add getter materials inside cavities, that is, materials capable of chemically reacting and thus strongly fixing gaseous species. Getter materials are generally metals like titanium, zirconium, vanadium, hafnium or niobium, or alloys of these (and mainly of titanium and/or zirconium) with one or more metals chosen among transition elements, Rare Earths and aluminum.
BRIEF SUMMARY OF THE INVENTION
[0007] The objects of the present invention are to provide alkali or alkaline-earth metal dispensers stable to environmental gases, in particular air, and especially adapted for use inside miniaturized devices, or in the processes for the manufacturing of the same devices, as well as to provide processes for the production of said dispensers.
[0008] These and other objects are achieved according to the present invention which, in a first aspect thereof, relates to a dispenser of an alkali or alkaline-earth metal, characterized by comprising a support carrying a deposit of a getter material and in that the alkali or alkaline-earth metal is present in the dispenser in the form of elemental metal protected from the environment by said deposit of getter material.
[0009] The dispensers of the invention may be realized according to two main modalities. In the first modality the alkali or alkaline-earth metal is present in the dispenser in the form of a deposit of said metal, completely covered by the deposit of getter material. In the second modality the alkali or alkaline-earth metal is dispersed inside at least part of the deposit of getter material.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are 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.
[0011] In the drawings:
[0012] FIG. 1 represents a sectional and cut-away view of a dispenser of the invention realized according to a first modality;
[0013] FIGS. 2 through 4 represent sectional and cut-away views of dispensers constituting alternative embodiments of the invention in its first modality;
[0014] FIG. 5 represents a sectional and cut-away view of a dispenser of the invention realized according to a second modality; and
[0015] FIG. 6 represents a sectional and cut-away view of a variation of the support of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0016] In the drawings, dimensions and dimensional ratios of the various elements represented are not correct, but rather altered for the sake of readability of the figures. In particular, the heights of the deposits of getter material and of the deposits of alkali or alkaline-earth metals have been strongly increased in order to make the representation of such elements comprehensible.
[0017] The support of the dispensers of the invention may be realized with a wide variety of materials, provided that they are compatible both with the process of production of the dispensers and with the processes of production of the devices in which the dispensers are used. The most suitable materials for realizing the support are metals, metal alloys, semiconductors, glasses or ceramic materials, and in particular kovar (an alloy based on iron, nickel, cobalt and minor percentages of other elements), silicon, germanium, silicon carbide, sapphire, quartz, glass, pyrex, indium phosphide and gallium arsenide. It is also possible, however, that applications arise in which the support may be realized with other materials, such as polymers (e.g., in the form of foils).
[0018] Dispensers according to the invention can be produced for the release of essentially any alkali or alkaline-earth metals. Beryllium is less preferred due to its high evaporation temperature and toxicity, and francium and radium due to their radioactivity, but it is not excluded that dispensers of these metals may be produced according to the invention. For use in common industrial applications, the most preferred metals are lithium, sodium, potassium, rubidium, cesium, magnesium, calcium, strontium and barium.
[0019] In the rest of the description, for the sake of brevity, alkali and alkaline-earth metals will also be simply referred to as evaporable metals. Furthermore, in parts of the following description reference will be made, as an example, to the use of cesium, but any teachings can be applied to the other evaporable metals as well.
[0020] The getter materials suitable for the realization of the invention may be constituted by a single metal, or they may have a multi-metal composition. In the case of a single metal, this may be hafnium, niobium, vanadium, and preferably either titanium or zirconium. In the case of multi-metal materials, generally are used alloys based on titanium and/or zirconium with at least another element chosen among the transition elements, Rare Earths and aluminum, such as the Zr—Al alloys described in U.S. Pat. No. 3,203,901 (particularly the alloy of weight percent composition Zr 84%-A16%), the Zr—Ni alloys of U.S. Pat. No. 4,071,335 (particularly the alloy of weight composition Zr 75.7%-Ni 24.3%), the Zr—Fe alloys of U.S. Pat. No. 4,306,887 (particularly the alloy of weight composition Zr 76.6%-Fe 23.4%), the Zr—V—Fe alloys of U.S. Pat. No. 4,312,669 (particularly the alloy of weight composition Zr 70%-V 24.6%-Fe 5.4%), the Zr—Ni-A-M alloys (where A stands for one or more Rare Earth elements and M stands for one or more elements chosen among cobalt, copper, iron, aluminum, tin, titanium and silicon) of U.S. Pat. No. 4,668,424, the alloys Zr—Co-A, in which A is an element chosen among yttrium, lanthanum, Rare Earths or mixtures thereof, of U.S. Pat. No. 5,961,750 (particularly the alloy of weight composition Zr 80.8%-Co 14.2%-A 5%) and, finally, the Zr—V—Ti alloys of U.S. Pat. No. 6,468,043 B1. As known in the field, getter materials require for their proper working a thermal treatment, referred to as activation, at temperatures comprised between about 300 and 600° C. (depending on the specific composition of the material). This treatment causes the diffusion of the atoms of oxygen, nitrogen, or carbon, sorbed by the getter surface soon after its production, towards the inner part of the grains of the material, thus exposing a fresh surface of metal atoms, active in the sorption of gases.
[0021] FIG. 1 represents a sectional view of a support of the invention realized according to its first modality, in its more general embodiment.
[0022] Dispenser 10 comprises a support 11 onto which is formed a deposit 12 of cesium completely covered by a deposit 13 of a getter material. The thickness of the cesium deposit is comprised between 1 and 100 nanometers (nm) and preferably between 10 and 50 nm, while the getter material deposit has a thickness comprised between 100 nm and 10 micrometer (μm) and preferably between 200 nm and 5 μm.
[0023] With this configuration, the deposit 13 of getter material, jointly with support 11 , protects cesium deposit 12 both mechanically and chemically. Mechanically, the getter deposit avoids, for instance, that the cesium deposit moves on support 11 following melting that could take place during the process of production of the final devices in which cesium is to be released. Chemically, the getter sorbs the traces of noxious gases possibly present during said process and avoids reaction of cesium with them.
[0024] The same heating treatment that fractures the deposit of getter material causes its activation as well, so that at the time of cesium evaporation the environment inside the cavity is essentially free of potentially noxious gas impurities. In the specific case of thermotunneling refrigerating units, however, even a non-complete getter activation at the time of cesium evaporation is acceptable, because the oxidation of the thin film of metal deposited onto the cathode further improves the work function value of the same, with a lowering from 2.14 to 1.2 eV passing from metallic cesium to its oxide.
[0025] The dimensions of the getter material deposit are not necessarily uniform around the cesium deposit, and in particular the thickness of getter material on the lateral sides of the cesium deposit may be greater than the thickness of the layer above the cesium deposit.
[0026] FIGS. 2 to 4 show preferred alternative embodiments of the dispenser generically illustrated in FIG. 1 .
[0027] FIG. 2 shows in section and cut-away view a dispenser of the invention, 20 , according to a first preferred embodiment. In this case the cesium deposit, 22 , does not directly contact support 11 , but rather between this support and the cesium deposit is interposed a barrier layer, 24 , whose function is to avoid cesium diffusion into the support material, which could cause a reduced evaporation yield; above deposit 22 is present a deposit 23 of getter material. The lateral dimensions on support 11 of deposit 23 and layer 24 are the same, and these completely surround the cesium deposit.
[0028] For the thickness of the deposits of cesium and getter material, the same values previously given hold, while the thickness of the barrier layer 24 may be comprised between about 100 nm and 10 μm. Suitable materials are tantalum, platinum, gold (or combinations of these), any of the previously mentioned getter materials, titanium nitride and silicon nitride.
[0029] FIG. 3 shows in section and cut-away view a dispenser of the invention, 30 , according to a second preferred embodiment. In this case barrier layer 34 and cesium deposit 32 have the same lateral dimensions, and are both surrounded by the getter material deposit 33 that is in contact with the support 11 . The barrier layer is thus in contact with the getter material only laterally, while the cesium deposit is confined above and laterally by the getter material, and below by the barrier layer. This second embodiment turns out to be even more preferred because its production process is more convenient than that of the dispenser of FIG. 2 , as explained in detail later.
[0030] FIG. 4 shows a variation of the dispenser of FIG. 3 . In this dispenser, 40 , both upper deposit 43 and barrier layer 44 , which together completely surround the cesium deposit 42 , are made of getter material (preferably but not necessarily of same composition). This embodiment has the advantage of increasing the amount of getter material and thus its capability to sorb impurities. The thickness of the barrier layer 44 is preferably higher than the thickness of deposit 43 covering the cesium deposit. This condition guarantees the efficiency of layer 44 as a barrier, because during heating of the system cesium should cross a higher getter material thickness to reach support 11 than for crossing deposit 43 ; this is also helped by the fact that deposit 43 fractures more easily than layer 44 because the latter is restrained in its lateral movements by adhesion to the support itself. Both deposit 43 and layer 44 may have a thickness comprised between 100 nm and 10 μm, while the cesium deposit has the same thickness values given above. Though FIG. 4 represents a variation of FIG. 3 , this measure (getter material used both for deposit 43 and layer 44 ) could be adopted also for the production of a deposit as described with reference to FIG. 2 (namely, with the barrier layer and the getter deposit having the same lateral dimensions).
[0031] FIG. 5 represents a section and cut-away view of a support of the invention, 50 , realized according to the second cited modality, in its more general embodiment.
[0032] In this case on support 11 is present a deposit 53 of getter material into which an evaporable metal is dispersed. The evaporable metal is trapped and shielded by the getter structure and is released during a suitable thermal treatment of the latter, similar to what happens with the supports realized according to the first modality. The deposits of getter material having dispersed inside an evaporable metal according to this embodiment may have a thickness comprised between 100 nm and 10 μm, with a weight percentage of the metal comprised between 1 and 20%, preferably between 3 and 10% of the total weight of the deposit.
[0033] In this modality as well, it is possible to adopt the use of a barrier layer that insulates the volume where the evaporable metal is present from contact with the support. A structure of this kind is shown in FIG. 6 : dispenser 60 is formed by support 11 on which is present a barrier layer 64 , and on this a deposit 63 of getter material in which is dispersed the evaporable metal. The thickness of layer 64 may be comprised between 100 nm and 10 μm. Barrier layer 64 may be made of the same getter material used for deposit 63 or of a different material, chosen among the materials previously cited for performing this function.
[0034] Clearly, in all embodiments so far described, the sum of thicknesses of the various layers and deposits cited must be compatible with the realization of the final device in which the dispenser must be present, or with the process for manufacturing the same. In thermotunneling refrigerating units, for instance, cathode and anode are very close to each other, spaced apart a distance on the order of a few tens of nanometers. In this case, if one of the electrodes (e.g., the cathode) is built on the same support 11 of the dispenser, the sum of the thickness values of the different deposits and layers making up the dispenser of the invention must be such that the two electrodes are not shorted, and preferably not higher than the thickness of the electrode on support 11 .
[0035] The dispensers of the invention may comprise an integrated heater (case not shown in the drawings). With this measure it is possible to have a better control of the process of getter activation and evaporation of the evaporable metal. Furthermore, in case the support of the dispenser forms a part of the walls of the cavity of the final device, the presence of the integrated heater also allows subsequent reactivations of the getter, in order to reinstate its sorbing capability during the life of said device. The heater may be a resistance (formed, e.g., via depositing by screen-printing one or more tracks of a paste of resistive material) placed on the side of support 11 opposed to the one where the deposits of getter material and evaporable metals are obtained. Alternatively, it is possible to have the heater on the same side of the support where said deposits are present, providing feedthroughs for its power supply and forming the deposits characteristic of the invention on the heater area. A solution of this kind, for the heating of getter layers in the cavities of micromechanical devices, is described in International Patent Application No. WO 2004/065289 in the name of the present applicant.
[0036] In a second aspect thereof, the invention consists in a process for producing the dispensers described above.
[0037] The dispensers of the invention are produced with techniques typical of the semiconductors industry, with subsequent depositions of the various materials, delimiting the area of the support onto which the depositions take place by masking.
[0038] As a source of evaporable metal it is possible to use a source based on controlled thermal evaporation, such as shown for instance in patent application WO 2006/057021 in the name of the applicant. The duration of the deposition process controls the thickness of the layer produced, while the regions onto which the deposition takes place are selected through a suitable masking of the support. As is well known, masking may be mechanical and realized with a self-standing mask, generally a thin metallic foil with openings having shape, dimensions, and placement on the mask corresponding to those of the desired deposits. Alternatively, it is possible to adopt masks produced in-situ, directly on the support, with polymeric materials that can be selectively removed, for instance following sensitization with UV radiation and subsequent removal of the sensitized (or non-sensitized) areas by chemical etching. Maskings of the second kind are more suitable when deposits with small lateral dimensions, generally below 100 μm, are to be obtained, while maskings of the first kind can be sufficient for higher dimensions.
[0039] After deposition of the evaporable metal, deposition of the getter material layer is carried out, typically by sputtering. The sputtering technique is widely known in the field of deposition of thin layers, and does not require a detailed description here. Its application to getter materials is described, for instance, in U.S. Pat. No. 6,468,043 and in International Patent Application Publication No. WO 2006/109343. For the obtainment of porous getter layers, optimized for obtaining good values of gas sorption speed, it is preferable to operate according to the special conditions taught in this latter document, namely, working with a relatively high pressure of gas (generally argon) in the chamber and a low power applied between target and support, and preferably keeping cool the support onto which deposition is performed and with a high distance between target and support. Vice versa, for the production of getter layers with barrier functionality (such as layer 44 previously described), it is preferable to operate with such conditions as to obtain dense deposits, which are the conditions typical of sputtering processes, that is, low gas pressure in chamber, high electrical power applied, non-cooled support and low distance target-support.
[0040] In order to realize the invention in its first modality it is necessary that the lateral dimensions of the deposit of evaporable metal be lower than those of the overlying getter material layer. As a consequence, it is necessary to use at least two different masks: a first mask with openings of lower dimensions for depositing the evaporable metal and a second mask with openings of greater dimensions for depositing the getter material.
[0041] In the case of the support of FIG. 2 , the second mask (wider openings) is employed at the beginning to effect the deposition of the barrier layer ( 24 ), then the first mask for the deposition of the evaporable metal ( 22 ), and finally the second mask is used again for the deposition of the getter material ( 23 ). The barrier layer, when this is not realized with getter material, can be deposited with techniques like evaporation, sputtering and “Chemical Vapor Deposition”, that provide for layers with high density and thus with good barrier properties.
[0042] From the production process standpoint, the support of FIG. 3 turns out to be preferable, as it allows for the use of the first mask (the one with openings with lower dimensions) for the production of the barrier layer ( 34 ) and subsequently of the deposit of evaporable metal ( 32 ), and then employment of the second mask for depositing the getter material ( 33 ). In this way an operation of mask substitution is saved, which would imply dead-times and criticalities annexed to the need of precise alignment of masks in subsequent depositions.
[0043] In the above described processes, the deposition chamber for forming the deposits of evaporable metal and of getter material may be the same or the support may be transferred between two connected chambers, one dedicated to sputtering processes and the other to evaporation processes.
[0044] In case a support as the one shown in FIG. 5 is produced, the upper layer of getter material having dispersed inside the evaporable metal may be produced using the sputtering technique alone, starting with a target made in its turn of getter material with dispersed therein the desired metal or by co-deposition, carrying out simultaneously the deposition of the getter material through sputtering and that of the evaporable metal through evaporation. This second operation mode is known and deposition systems suitable to carry it out exist (for instance, the IonCell systems produced by Plasmion Corp. of Hoboken, N.J., USA).
[0045] In the case of production of a dispenser as described with reference to FIG. 6 (dispenser 60 ), this is best accomplished in a single chamber and during an uninterrupted process, by first depositing layer 64 of pure getter material, and as soon as the desired thickness for layer 64 is reached, by starting co-deposition of the same getter material along with the desired evaporable metal.
[0046] Although the dispensers of the invention can be produced one-by-one, preferably they are produced in processes typical of the semiconductor industry, in which on a common support (e.g., a silicon wafer), operating with suitable maskings (as it is well known in the field) a plurality of dispensers are produced. They are then suitably singled out at the end of the process in order to produce the final dispensers. The wafer with a multiplicity of dispensers can also be joined to another wafer carrying a corresponding number of active elements of final devices (e.g., thermotunneling refrigerating units), and the assembly of the two wafers separated into single devices when these are completed (a technique known in the field as “dicing”).
[0047] 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.
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There are described dispensers ( 10; 20; 30; 40; 50; 60 ) of alkali or alkaline-earth metals, comprising deposits of getter materials ( 13; 23; 33; 43; 53; 63 ) and alkali or alkaline-earth metal sources ( 12, 22; 32; 42; 53; 63 ), in which the sources of alkali or alkaline-earth metal are protected from environmental gases by said deposits of getter materials.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a lubricator for moving well equipment through a flow conductor.
2. The Prior Art
For various reasons, plugs or other well tools are positioned within well flow conductors prior to assembly of an underwater wellhead. Upon or after completion of the underwater wellhead, the plugs are removed to premit subsequent fluid flow through the conductor.
Some underwater wellheads are assembled within a submerged and enclosed work chamber. The work chamber is formed on the guide base of the underwater wellhead and provides a limited space within which personnel and equipment may maneuver. A portion of the underwater well flow conductor extends into the work chamber. Well equipment is run several feet through the flow conductor to retrieve the well plug therefrom.
Several factors prevent the use of conventional methods for retrieving such a well plug. First, the limited space inside the work chamber will not accommodate conventional wireline or pumpdown lubricators. Second, wireline equipment cannot develop the large downward forces required to unlock the well plug from the flow conductor. The distance between the well plug and the end of the flow conductor is too short for wireline equipment to develop those forces. Third, at this stage of the completion of the underwater well, the underwater wellhead is not fully equipped with pumpdown flow lines and related equipment. Conventional pumpdown operations therefore cannot be used to retrieve the well plug.
Rod-type lubricators have been used to run retrieval equipment. One form of rod-type lubricator has an elongate cylinder, a piston movable in the cylinder, and a single element rod. One stroke of the piston is designed to move the rod and the attached retrieval equipment a distance sufficient to reach the well plug. The rod extrudes longitudinally beyond the cylinder prior to the piston stroke. The stroke of the piston and the length of the rod are both greater than the distance between the end of the flow conductor and the well plug. The plugs are generally approximately 4 feet from the end of the flow conductor. The lubricator and extruded rod therefore have a longitudinal dimension in excess of 8 feet. Such a rod-type lubricator requires too much longitudinal space for some of the underwater pressure vessels presently utilized. When the reach rod extrudes, its end can engage the wall of the work chamber. If the piston should fail, the rod could be pushed through the chamber wall. The integrity of the chamber would be destroyed and the lives of the personnel therein endangered. Another form of rod-type lubricator employs a segmented rod. Otherwise, it is similar to the first form. Again, a single stroke of the piston moves the rod and the retrival equipment a distance sufficient to reach the well plug. During controlled movement of the piston, the rod segments may be added or removed as desired. However, failure of the piston could result in the rod being extruded. Under such circumstances, the entire length of the rod would extrude out of the lubricator. Due to space limitations in the work chamber, if that occurred, the end of the rod would engage and rupture the wall of the work chamber.
OBJECTS OF THE INVENTION
An object of this invention is to provide a shorter rod-type lubricator then is presently available without shortening the distance through which well equipment may be moved by the lubricator.
Another object of this invention is to increase the distance through which a rod-type lubricator can move well equipment while shortening the longitudinal length of the lubricator.
Another object of this invention is to provide rod-type lubricator wherein the lubricator rod is prevented from extruding beyond the lubricator housing to thereby protect the integrity of a surrounding underwater work chamber in the event that the lubricator piston fails.
Another object of this invention is to provide a shorter rod-type lubricator then is presently available and have a section of the lubricator housing be removable so that the lubricator may be further shortened, if desired.
These and other objects and features of advantage of this invention will be apparent from the drawings, the detailed description, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like numerals indicate like parts and wherein an illustrative embodiment of this invention is shown:
FIG. 1 is a view partly in elevation and partly in section of an underwater well installation wherein the rod-type lubricator of this invention may be utilized;
FIGS. 2A and 2B are continuation quarter-sectional views of the lubricator and a portion of the well installation of FIG. 1;
FIG. 3 is a view corresponding to FIG. 2A showing another operative position of the lubricator;
FIG. 4 is a perspective view of a portion of the lubricator; and
FIG. 5 is a perspective view similar to that of FIG. 4 showing the lubricator with its rod support portion removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an underwater wellhead installation prior to the hook-up of the subsea tree and flow lines.
A surface casing 10 extends upwardly from the ocean floor (not shown). Near the upper extremity of the surface casing 10 is formed a guide base 12. A work chamber 14 is secured to the upper end of the surface casing 10 above the guide base 12. Sea water is evacuated from the work chamber 14. The chamber 14 is filled with air at atmospheric pressure. Personnel work within the chamber 14 to establish the connections for the underwater tree and the flow lines. Personnel may be lowered to the work chamber 14 within a service capsule 16 (only a portion of which is shown). A hatch 18 of the work chamber provides access between the service capsule 16 and the work chamber 14.
The upper end of the surface casing 10, within the work chamber 14, is provided with a casing head 20. The normal tubing hanger (not shown) is positioned within the casing head 20. From the tubing hanger, the well tubing strings (not shown) hang downwardly and extend through the surface casing 10 into the well. While the well was being drilled and tested, a blowout preventer stack would have been positioned on top of the casing head 20. After testing, the well was killed. Well tools, such as plugs, were positioned within the bores of the tubing strings. The blowout preventer stack was removed. To prepare the well for production, the underwater tree, generally indicated at 22, is attached to the casing head 20. However, the well plug(s) still are positioned within the bore(s) of the tubing string(s). The plug(s) must be removed prior to production. To remove a well plug from the bore of the tubing string, a lubricator 24 is connected to the tree 22. The lubricator 24 moves retrieval equipment through the tree 22. The lubricator 24 is operated to manipulate the retrieval equipment so that the plug is unlatched from the tubing string. Thereafter, the lubricator 24 withdraws the retrieval equipment and plug from the tree 22.
A bull nose 26 extends through the wall of the work chamber 14. One end of a flow line bundle 28 is pulled to the bull nose 26 and is received therein. Within the work chamber 14, personnel will connect a flow line loop between the end of the flow line bundle 28 and the tree 22. However, a plug (not shown) has been positioned within the end of the flow line bundle 28 to prevent trash or sea water from entering the flow lines. The plug is removed prior to connection of the flow line loop. To do so, a lubricator 24 may be attached to one end 30 of a valve block 32 formed on the bull nose 26.
Space limitations within the work chamber 14 and the variable distance between the end of the lubricator 24 and the location of the well tool or plug within the respective well flow conductor, impose seemingly contradictory criteria for a lubricator 24. The space limitations within the work chamber 14 limit the length of the lubricator 24. However, the lubricator 24 must move well equipment between its end and the location of the landed tool or well plug. That distance through which the well equipment is moved may be greater than the length of the lubricator 24. If the lubricator piston fails, well fluid pressure may tend to extrude the lubricator rod. Such uncontrolled extrusion of the rod should not danger the integrity of the work chamber 14. Additionally, the lubricator 24 preferably includes a removable section to permit the lubricator's length to be further reduced.
In FIGS. 2A and 2B, the lubricator 24 is connected to the top of the underwater tree 22 (only a portion of which is shown in FIG. 2B). The lubricator 24 will move retrieval equipment 34 through the tree 22. The retrieval equipment 34 will engage and retrieve the tool 36. The tool 36 is landed and latched within a well flow conductor 38 and positioned below the base of the tree 22. The retrieval equipment 34 and tool 36 may be structured in accordance with the disclosure of copending application Ser. No. 786,380 filed Apr. 11, 1977.
The lubricator 24 includes housing means 40, rod means 42, piston means 44, and coupling means 46. Rod means 42 is moved through the lubricator housing means 40, and through the well flow conductor 38, is response to movement of piston means 44. Coupling means 46 selectively renders rod means 42 moveable with piston means 44. Coupling means 46 is disengageable from rod means 42. Rod means 42 is held stationary with respect to housing means 40 when coupling means 46 is disengaged therefrom. Piston means 44 may then be stroked between its two extreme positions without moving rod means 42. Coupling means 46 is thereafter re-engaged with rod means 42 and again renders rod means 42 movable with piston means 44. Additionally, the length of rod means 42 is varied by the addition or subtraction of reach segments. The rod means 42 may therefore extend between the lubricator 24 and any desired depth in the well flow conductor 38. In such manner, the retrieval equipment 34 is moved the required distance.
Lubricator housing means 40 has bore means 48 extending longitudinally therethrough. When housing means 40 is attached to a well installation, such as to the tree 22, bore means 48 communicates with and is aligned with the flow path 50 through the well flow conductor 38. Housing means 40 includes means, such as the threads 52 illustrated, with which it is attached to the well installation or tree 22.
Rod means 42 moves longitudinally through bore means 48 and into the flow path 50 of the well flow conductor 38. To prevent well fluids from escaping from the flow path 50 through the lubricator 24, packing means 54 seals between housing means 40 and rod means 42. Inwardly facing recess means 56 is formed along a portion of bore means 48 and receives packing means 54. Adjusting nut means 58 defines one end of recess means 56 with its downwardly facing surface 58a. The longitudinal confinement of packing means 54 within recess means 56 is adjusted by moving adjusting nut means 58 longitudinally with respect to housing means 40.
If packing means 54 should fail, the lubricator 24 includes a back-up sealing system. The back-up sealing system, when rendered effective, will prevent well fluids from escaping through the lubricator 24 from the flow path 50. The back-up sealing system is rendered effective when rod means 42 is fully extruded. Below recess means 56, a downwardly facing internal annular shoulder 59 is formed on housing section 40a. The shoulder 59 defines a portion of bore means 48. Rod means 42 carries seal means 61, such as the O-ring illustrated. When rod means 42 is fully extruded, seal means 61 sealingly engages shoulder 59 and seals between rod means 42 and housing means 40.
Housing means 40 forms longitudinally extending chamber means 60. Piston means 44 is disposed within chamber means 60 and moves longitudinally therein to move rod means 42. The illustrated chamber means 60 is annular and is formed within housing means 40 concentrically around bore means 48. To form bore means 48 and chamber means 60, housing means 40 includes an inner sleeve or inner housing section 40a to which is connected, as at threads 40d, a cylindrical body or outer housing section 40b. The outer wall 40e of inner housing section 40a defines the inner cylindrical surface of chamber means 60. The inner wall 40e of section 40b defines the other cylindrical surface of chamber means 60.
Hydraulic fluid is admitted to and removed from chamber means 60 via port means extending through housing means 40 and opening into chamber means 60. Fluid is admitted to one portion of chamber means 60 on one side of piston means 44 and removed from another portion of chamber means 60 on the other side of piston means 44 to move piston means 44. Two port means are provided. First port means 62 opens into one portion 60a of chamber means 60 which portion will be on one side (e.g., above) of piston means 44 throughout the entire extent of longitudinal movement of piston means 44. Second port means 62 opens into another portion 60b of cylinder means 60 which portion will be on the other side (e.g., below) of piston means 44 throughout the entire extent of longitudinal movement of piston means 44.
Housing means 40 also includes third port means 66 extending therethrough and opening into bore means 48 between packing means 54 and connecting means 52. Gauge means, schematically indicated at 68, is preferably connected to port means 66. Guage means 68 provides an indication, at all times, of the pressure of fluids confined within bore means 48.
Housing means 40 also includes a support section 40c. During operation of the lubricator 24 a portion of rod means 42 extends along and within the support section 40c. The support section 40c enables that portion of rod means 42 to be supported and controlled by other components of the lubricator 24. However, the support section 40c may be disconnected from the remaining portion of the lubricator 24. Normally, the support section 40c of housing means 40 is interconnected with the other housing sections. L-slots 70 and lugs 72 interconnect the support section 40c and the other housing sections. That interconnecting means permits the segment section 40c to be readily removed from the remaining portion of the lubricator 24. The illustrated L-slot means 70 are formed in the support section 40c. They include a longitudinally extending portion 70a and a circumferentially extending portion 70b. Lug means 72 are formed on the exterior surface and in close proximity to one, upper, end of housing section 40b (see FIG. 5).
Piston means 44 is disposed within chamber means 60 and is longitudinally movable with respect to housing means 40. Pressurization of one portion 60a of chamber means 60 moves piston means 44 in one direction to a first extreme position (see FIG. 2AO. Pressurization of another portion 60b of chamber means 60 moves piston means in the other direction to a second extreme position (see FIG. 3). The illustrated piston means 44 is annular and is disposed concentrically within lubricator housing means 40 around inner housing section 40a.
Seal means 74 and 76 carried by piston means 44 and seal means 78 carried by housing means 40 seal between piston means 44 and housing means 40. Seal means 74 and 78 seal between piston means 44 and outer housing section 40b. Seal means 76 seals between piston means 44 and inner housing section 40a. The difference between the seal affective areas of seal means 74 and 78 is acted upon by the pressure of fluid within the one portion 60a of chamber means 60. That pressure tends to move piston means 44 in one direction towards its first extreme (FIG. 2A) position. The difference between the seal affected areas of seal means 74 and 76 is acted upon by the pressure of fluid within the other portion 60b of chamber means 60. That pressure tends to move piston means in a second direction towards its second extreme (FIG. 3) position.
A hydraulic control system for selectively admitting fluid into the one portion 60a of chamber means 60 while removing fluid from the other portion 60b of chamber means 60 and vice versa is illustrated schematically in FIGS. 2A and 3. Source means 80 provides pressurized hydraulic fluid. The pressurized hydraulic fluid communicates between source means 80 and four-way valve means 82 through conduit means 84. Two conduits 86 and 88 communicate between four-way valve means 82 and the first and second port means 62 and 64 of the lubricator 24, respectively. Another conduit 90 communicates between four-way valve means 82 and a tank or reservoir 92. Four-way valve means 82 is movable between first and second positions. In its first position (see FIG. 2A) pressurized hydraulic fluid communicates between source means 80 and first port means 62. In that manner, pressurized hydraulic fluid is admitted into the one portion 60a of chamber means 60 on one side of piston means 44. At the same time, hydraulic fluid is being displaced from the other portion 60b of chamber means 60 on the other side of piston means 44 and through four-way valve means 82 to reservoir 92. In its second position (see FIG. 3) four-way valve means 82 communicates pressurized hydraulic fluid between source means 80 and second port means 64. Additionally, communication is permitted between first port means 62 and the reservoir 92. Therefore, fluid is admitted into the chamber portion 60b and displaced from the chamber portion 60a.
Preferably, to prevent too rapid of a movement of rod means 42, the speed at which piston means 44 moves is controlled. As chamber means 60 has a rather large effective area, a substantial volume of hydraulic fluid is admitted into and simultaneously displaced from chamber means 60 during movement of piston means 44. One manner of controlling the speed of movement for piston means 44 is to control the flow rate of fluid being displaced from chamber means 60. That flow rate may be controlled by providing a sized orifice 90a in conduit 90 between four-way valve means 82 and reservoir 92.
Coupling means 46 selectively renders rod means 42 movable in response to movement of piston means 44. However, since piston means 44 is disposed in chamber means 60 and is inaccessible to coupling means 46, means 94 associated with piston means 44 extend out of chamber means 60. Such means 94 may comprise a cylinderical member 94 extending from piston means 44 out of cylinder means 60. Coupling means 46 coacts with the member 94 to render rod means 42 movable with piston means 44. The upper end portion 94a of member 94 coacts with and receivs coupling means 46. The end portion 94a includes slot means 96 sized to receive coupling means 46. When received with slot means 96, coupling means 46 can engage rod means 42 and render rod means 42 movable in response to movement of piston menas 44. However, when coupling means 46 is not received within slot means 96, piston means 44 may move without moving rod means 42. An aperture 94b, extending longitudinally through the upper end portion 94a, is sized so that rod means 42 may pass therethrough. Therefore, when coupling means 46 is not disposed in slot means 96, movement of piston means 44 does not result in corresponding movement of rod means 42. Instead, rod means 42 may be held stationary in a position extending through the aperture 94b. Movement of piston means 44 would then not tend to move rod means 42.
Rod means 42 is moved longitudinally through the lubricator 24 to move well equipment 34 through flow path 50 of the well flow conductor 38. One end of rod means 42 includes means for connecting well equipment 34 thereto. This connecting means 98 may be the threads shown.
Rod means 42 comprises a plurality of segments, two of which are shown at 42a and 42b. For the rod means 42 shown, one segment 42a is the well equipment handling segment. It includes the connecting means 98 for connecting the rod means 42 to the well equipment 34. The other segment 42b is a reach segment. During operation of the lubricator 24, additional reach segments 42b will be connected to and form a portion of rod means 42. In such manner, the distance through which rod means 42 moves well equipment 34 is increased as desired. Additional reach segments for rod means 42 could be formed similar or identical to the illustrated reach segment 42b; preferably addition segments are identical to segment 42b.
All of the rod segments may be readily interconnected and disconnected. The means for connecting one rod segment to another is the same for any two rod segments which will be interconnected. As illustrated, for the rod segments 42a and 42b, each segment may have identical female threaded connecting means 100a and 100b at one end thereof. The reach segments 42b would then all have a complementary, identical male threaded connecting means 102 which can threadedly engage any one of the female threaded connecting means 100. To interconnect the reach segment 42b with the equipment handling segment 42a, the male threads 102 of the reach segment 42b are threaded into the female threads 100a of the segment 42a. In a similar manner, an additional reach segment may be interconnected to segment 42b.
Rod means 42 includes a plurality of means engageable by coupling means 46. Each of the rod segments includes at least one such means. The engageable means 104 are spaced along the rod means 42. The distance between adjacent engageable means 104 is no greater than the distance between the first and second extreme positions of piston means 44. Thus, rod means 42 may be held stationary while coupling means 46 is disengaged from one engageable means 104 and piston means 44 is moved between its first and second extreme positions. Coupling means 46 may thereafter be engaged with another engageable means 104. As illustrated in the drawings, the engageable means 104 may be an annular recess 104 formed in each segment of rod means 42. For rod segment 42a, the annular recess is designated as 104a; for rod segment 42b, it is designated 104b.
The engageable means 104 are preferably spaced along rod means 42 so that a single stroke of piston means 44 will move rod means 42 a distance substantially equal to the length of one reach segment 42b. For example, when piston means 44 is in the FIG. 2A position, coupling means 46 may engage recess means 104a. Movement of piston means 44 to the FIG. 3 position, permits coupling means 46 to engage recess means 104b. Thereafter, when piston means 44 is returned to the FIG. 2A position, rod means 42 is moved a distance substantially equal to the length of rod segment 42b.
Coupling means 46 is selectively engagable with rod means 42 and renders rod means 42 movable in response to movement of piston means 44. As best seen in FIGS. 4 and 5, coupling means 46 may comprise a substantially U-shaped lug. The thickness and width of the lug permit it to be inserted into slot means 96. The legs 46a and 46b of coupling means 46 are spaced apart and are adapted to be received within recess means 104 to thereby engage rod means 42. When coupling means 46 is inserted into slot means 96, with its legs 46a and 46b received within recess means 104, rod means 42 and piston means 44 are coupled together. Neither can move without corresponding movement of the other.
It will be noted that coupling means 46 does not include a handle or an extension. Therefore when forces are applied to piston means 44 and rod means 42, it will be exceedingly difficult to inadvertently extract coupling means 46 from slot means 96 and recess means 104. Should coupling means 46 become inadvertently disengaged from recess means 104, well fluids could force rod means 42 to extrude from the well flow conductor 38. Depending upon the number of interconnected segments forming rod means 42, uncontrolled extrusion of the rod means 42 could have disastrous consequences. For example, rod means 42 could rupture a wall of the work chamber 14 or injure personnel therein.
To permit the manipulation of coupling means 46 and the interconnection of reach segments 42b to, and their disconnection from, rod means 42, housing section 40c includes longitudinally extending window means 106. Window means 106 extends for substantially the entire length of housing section 40c and is longer than the length of a single reach segment 42b. When piston means 44 is in its first position (see FIG. 2A) a reach segment 42b may be manipulated. Such manipulation may be to disconnect the segment 42b from rod means 42 and remove it from within the lubricator housing means 40 through window means 106. Conversely, a reach segment 42b may be inserted into housing means 40 through window means 106 and thereafter joined to rod means 42. In either extreme position of piston means 44, coupling means 46 may be manipulated to either extract it from slot means 96 or insert it into slot means 96. Window means 106 is sized to permit that manipulation. If desired, coupling means 46 could project out of slot means 96. Window means 106 would then be sized so that piston means 44 could move between its extreme positions without coupling means 46 engaging housing section 40c.
Selectively operative stop means prevent uncontrolled extrusion of rod means 42. To positively prevent rod extrusion, two selectively operable stop means are provided. Depending upon the sequential operating position of the lubricator 24, one of these stop means can be rendered operative to prevent uncontrolled extrusion of rod means 42.
The first stop means prevents rod means 42 from extruding out of the housing section 40c. This first stop means is carried by the housing section 40c and may comprise the inwardly and downwardly facing end surface 108 of stop nut means 110. Stop nut means 110 includes outer threads 112. The threads 112 permit stop nut means 110 to be easily threaded into and out of the correspondingly threaded bore 114 of the housing section 40c. The precise position of the stop surface 108 relative to the housing section 40c may therefore be adjusted by advancing stop nut means 110 with respect to the thread 114. When stop nut means 110 is screwed into the threaded bore 114 and housing section 40c is connected to the remaining portion of the lubricator 24, stop nut means 110 will prevent rod means 42 from extruding out of the housing section 40c regardless of whether or not coupling means 46 is engaging recess means 104.
However, stop nut means 110 may not always be effective to prevent extrusion of rod means 42. At certain times, the housing section 40c may be removed from the lubricator 24. At other times, stop nut means 110 may be removed from the housing section 40c. Therefore, a second selectively operable stop means is provided. It can be rendered effective either before or after the first selectively operable stop means is rendered ineffective.
The second selectively operable stop means (see FIGS. 4 and 5) is associated with the housing section 40b. It can be rendered operative even when the housing section 40c is removed. It may be selectively engaged by coupling means 46. Thereafter, the second stop means prevents longitudinal movement of coupling means 46, rod means 42 and piston means 44 until coupling means 46 is disengaged therefrom. The illustrated second stop means comprises finger means 116 formed on housing section 40b. The upper end of housing section 40b includes a cut-out portion 118 which is aligned with window means 106 when housing section 40c is connected to the remaining portion of the lubricator 24. The cut-out portion 118 permits complete movement of piston means 44 to the FIG. 2A position before coupling means 46 is engaged by housing section 40b. Coupling means 46 can pass by finger means 116 during longitudinal movement of piston means 44. However, when desired, the coupling means 46 may be moved laterally slightly, by rotating rod means 42, so that a portion thereof becomes engaged under the downwardly facing shoulder 116a of the projecting finger means 116. The shoulder 116a and the upwardly facing surface 118a of cut-out 118 then prevent longitudinal movement of coupling means 46, rod means 42 and piston means 44.
Even if piston means 44 fails and neither of the stop means are rendered operable, with coupling means 46 coupling the movement of rod means 42 and piston 44, the distance which rod means 42 can extrude is limited to a single stroke of piston means 44. That distance is approximately 18 inches.
Means for holding rod means 42 and for manipulating rod segments 42b are associable with the housing means 40. Whenever the lubricator 24 is positioned vertically on a well flow conductor 38, rod means 42 could drop through the flow passage means 50 under the influence of gravity. Holding means 120 prevents rod means 42 from dropping. Holding means 120 additionally manipulates reach rod segments 42b so that they may be added to or removed from rod means 42. The holding and manipulating means 120 includes a stem portion 120a sized to extend through a bore 122 formed in the stop nut means 110. At the end of the stem portion 120a are formed means 120b for engaging and holding rod means 42 or a rod segment. The means 120b may comprise the male threads 120b shown. The threads 120b are complementary to the female threads 100 of each rod segment. They are, therefore, identical to the threads 102 of the reach segments 42b. To manipulate the means 120, and a rod segment when it is attached thereto, the handling and manipulating means 120 includes a knob portion 120c. The knob portion 120c cannot pass through the bore 122 of stop nut means 110.
In operation, the lubricator 24 of this invention is utilized to move well equipment through a well flow conductor.
For example, a well tool 36, such as a well plug structured in accordance with the disclosure of the aforementioned application Ser. No. 786,380, would have previously been landed, locked and sealed in the well flow conductor 38. The lubricator 24 will move the retrieval equipment 34, also structured in accordance with the disclosure of application Ser. No. 786,380, through the flow conductor 38 to retrieve the plug 36.
The tool 36 would have been installed prior to removal of the underwater blowout preventer stack. The tool or plug 36 maintains the well under control until suitable valves or a tree can be installed. It also prevents sea water from entering the well after the underwater blowout preventer stack has been removed. During assembly of an underwater production wellhead, a tree 22 is lowered to the upstanding casing head 20 and attached thereto. A work chamber 14 is formed around the tree 22. Sea water is evacuated from the work chamber 14. Personnel are admitted thereto, to complete assembly of the underwater production wellhead, through hatch 18.
While the well tool 36 is in the flow conductor 38, the tree 22 is flanged to the tubing head (not shown). Thereafter, pressures are preferably equalized across the tool 36. The tool 36 can be retrieved from the well flow conductor 38 utilizing the retrieval equipment 34 and lubricator 24.
During the retrieval operation, the valves of the tree 22 will be opened so that the retrieval equipment 34 can move therethrough. Once the retrieval equipment 34 has engaged the well tool 36 and has unlocked it from the flow conductor 38, the tool 36 is no longer effective to confine well fluids. The lubricator 24 thereafter withdraws the retrieval equipment 34 and plug 36 through the flow conductor 38. After the plug 36 has been moved sufficiently, a valve of the tree 22 can be closed below it. Well fluids are bled from the lubricator 24. The lubricator 24 can then be removed from the wellhead.
As illustrated in FIG. 2B, the retrieval equipment 34 must pass through a tree valve 22a prior to reaching the well tool 36. The valve 22a may be the top valve of the tree 22. The lubricator 24 will be joined to the tree 22 above the valve 22a. Between the lubricator 24 and valve 22a will be connected a blowout preventer 124. The blowout preventer 124 will be closed to seal around rod means 42 in the event that well fluids attempt to escape from the well flow conductor 38 during operation of the lubricator 24. The blowout preventer 124 may be a Hydril type "GKS" wire-line stripper and blowout preventer illustrated on pages 3348 and 3349 on the "COMPOSITE CATALOG OF OILFIELD EQUIPMENT AND SERVICES" 1976-77 edition. The height of such a blowout preventer is relatively short. When size and space limitations are important, utilizing equipment that is relatively short is advantageous.
A connector 126 connects the blowout preventer 124 and valve 22a. The connector 126 may be an Otis Quick Union as illustrated on page 3984 of the "COMPOSITE CATALOG OF OILFIELD EQUIPMENT AND SERVICES" 1974-75 edition.
A connector 128 connects the lubricator 24 to the blowout preventer 124. The connector 128 may also be an Otis Quick Union.
Prior to connecting the lubricator 24 in communication with the well flow conductor 38, the retrieval equipment 34 is attached to rod means 42.
Assume that the equipment handling section 42a of rod means 42 is coupled for movement with piston means 44 by coupling means 46 (e.g., coupling means 46 is engaging recess means 104a). To render the equipment connecting means 98 of rod means 42 accessible, piston means is moved to the FIG. 2A position. To do so, four-way valve means 82 is moved to its first position. Hydraulic fluid from source means 80 pressurizes the chamber portion 60a. Piston means 44 is moved thereby. The retrieval equipment 34 may then be connected to the threaded connecting means 98 of rod section 42a.
The lubricator 24 may now be connected to the respective well installation such as by connecting it to the blowout preventer 124. The connector 128 is made up with the threads 52 of lubricator housing means 40. Bore means 48 through lubricator housing means 40 is aligned with the flow path 50 through the well flow conductor 38. The tree valves may be opened so that the retrieving equipment 34 and lubricator rod means 42 may pass therethrough.
The housing support section 40c is connected to housing section 40b. To do so, the longitudinally extending portion 70a of the L-slot means 70 are aligned with the lugs 72. The housing support section 40c is moved longitudinally towards the housing section 40b until the lugs 72 become aligned with the circumferentially extending portion 70b of the L-slot means 70. The housing section 40c is rotated. The lugs 72 become disposed within the circumferentially portions 70b of L-slot means 70. Housing support section 40c is thereby joined to the remaining portion of the lubricator housing means 40.
At this time, a reach segment 42b may be added to the equipment handling segment 42a. Additional segments 42b may be added to rod means 42 in either of two ways. The first method is utilized whenever space limitations inside the work chamber are such that the handling and manipulating means 120 is in close proximity to the interior wall of the work chamber 14. The second method may be utilized whenever there is approximately 24 inches between the interior wall of the work chamber 14 and the upper end of the lubricator 24. The first method is preferred as less space is required.
In accordance with the first method of adding rod segments 42b, the rod segments 42b are inserted into housing means 40 through window means 106. A rod segment 42b may be added to rod means 42 when piston means 44 is in its first extreme (FIG. 2A) position. Coupling means 46 will be received within slot means 96 and will be engaging a recess means 104. Coupling means 46 will thereby maintain that portion of rod means 42 which is already formed and disposed within housing means 40 longitudinally stationary. Generally, the handling and manipulating means 120 will be withdrawn from the bore 122 of stop nut means 110. Stop nut means 110 is unscrewed a distance approximately equal to the length of the thread 100b of the rod connecting means. A reach segment 42b is inserted through window means 106 into housing means 40. The male connecting means 102 of the added reach segment 42b is made up with the female connecting means 100a of the original rod means 42. After this connection has been made up, stop nut means 110 is screwed inwardly until its surface 108 engages the upstanding end of rod means 42. The threads 120c of holding and manipulating means are made up the threads 100b of rod means 42 to hold rod means longitudinally stationary. Thereafter, the lubricator 24 is operated to move rod means 42 and the attached well equipment 34 through the flow conductor 38.
In accordance with the second method of adding rod segments 42b to the rod means 42, the segment 42b to be added is inserted into the lubricator housing means 40 through bore 114. Prior to adding a segment in this manner, piston means 44 is moved to its first position. Coupling means 46 is inserted into slot means and engages recess means 104. Preferably, rod means 42 is rotated slightly so that coupling means 46 becomes lodged under the surface 116a of finger means 116. Longitudinal movement of rod means 42 is thereby prevented. Stop nut means 110 may now be safely unscrewed and removed from threaded bore 114. The stem portion 120a of holding means 120 is inserted through the bore 122 of stop nut means 110. The male threads 120c of the holding means 120 engage and make up with the female threads 100b of a reach segment 42b. The reach segment 42b is inserted through the bore 114. Stop nut means 110 is rotated so that its threads 112 engage the threads within the bore 114. At the same time, the holding and manipulating means 120 is rotated. The male threaded connecting means 102b of the reach segment 42b makes up with the female threaded connecting means 100a of the equipment handling segment 42a. The lubricator 24 is now in the position illustrated in FIG. 2A.
Once the lubricator 24 in in the FIG. 2A position, coupling means 46 may be safely withdrawn from recess means 104 and slot means 96. Rod means 42 will remain held in the position illustrated. The surface 108 of stop nut 110 prevents the rod means 42 from being extruded out of the lubricator due to the force of pressurized well fluids within the flow path 50. The holding and manipulating 120 prevents rod means 42 from dropping into the flow path under the influence of gravity.
The lubricator 24 is operated to move the well equipment 34 through the well flow conductor 38. During the operation, piston means 44 undergoes multiple strokes and the length of rod means 42 is increased by interconnecting additional segments 42b thereto. Piston means 44 is moved in one direction to vary the point along rod means 42 where coupling means 46 is engaged. Piston means 44 is moved in another direction to move rod means 42 and well equipment 34.
For example, once the lubricator is in the FIG. 2A configuration, piston means 44 cannot move rod means 42 and the equipment 34 downwardly. The lubricator 24 will first have to assume the configuration of FIG. 3.
The holding means 120 and stop nut means 110 will retain rod means 42 longitudinally stationary while the piston means 44 is moved to the FIG. 3 position. Prior to moving piston means 44, coupling means 46 is withdrawn from recess means 104 and slot means 96. Four-way valve is rotated from its first position to its second position. Pressurized hydraulic fluid from source means 80 is admitted to chamber portion 60b through second port means 64. At the same time, hydraulic fluid is displaced from the other chamber portion 60b to reservoir 92. Under the action of the pressurized hydraulic fluid, piston means 44 moves to the FIG. 3 position. Coupling means 46 is reinserted into slot means 96 until it engages recess means 104b. The lubricator 24 is now in the position illustrated in FIG. 3. To permit coupled movement of piston means 44 and rod means 42, the holding means 120 is disconnected from the reach segment 42b. Piston means 44 may then be moved from the FIG. 3 position to the FIG. 2A position. To move piston means 44, four-way valve means 82 is rotated back to its first position. Pressurized hydraulic fluid from source means 80 enters chamber portion 60a through port means 62. Simultaneously, fluid is displaced from chamber portion 60b through second port means 64 and routed to reservoir 92. Piston means 44 moves between its FIG. 3 position and its FIG. 2A position. Rod means 42 moves therewith.
If, during the movement of piston means 44 from the FIG. 3 position to the FIG. 2A position, the retrieval equipment 34 reaches the landed well tool 36, the retrieval equipment 34 is manipulated to unlatch the tool 36. If, however, the retrieval equipment 34 does not move a distance sufficient to reach the landed tool 36, an additional reach segment is added to rod means 42. The lubricator 24 is then operated so that piston means 42 moves the lengthened rod means 42. The well equipment 34 is thereby moved further into the well flow conductor 38. If necessary, still additional reach segments are added to rod means 42. The well equipment 34 is moved by the lengthened rod means 42 any desired distance through the well flow conductor.
Once piston means 44 reaches the FIG. 2A position, if an additional segment 42b is to be added to rod means 42, the rod means 42 is preferably maintained longitudinally stationary while an additional segment 42b is being added thereto. Coupling means 46 may be rotated slightly so that it becomes disposed under the projecting finger means 116. Coupling means 46 remains engaged with the recess means 104 of rod means 42. Coupling means 46 is also confined by the downwardly facing surface 116a of finger means 116 and the upwadly facing bottom surface 118a of cut-out 118. Rod means 42 cannot extrude from the lubricator 24 or drop downward therein. An additional rod segment 42b may be added to the rod means 42 as previously explained.
Once the well equipment 34 reaches the landed and locked well tool 36, the well equipment 34 is manipulated to retrieve the tool 36. The equipment is manipulated by manipulating the rod means 42 with piston means 44. The retrieval of the tool 36 by the equipment 34 is more fully explained in the aforementioned application Ser. No. 786,380. As explained in that application, the prong 34a of the retrieval equipment 34 engages and moves the equalizing valve means 36a of the tool 36 in a position opening the tool's equalizing flow passage means 36b. The collet 34b urges the prong 34a outwardly until the prong 34a engages the tool's fishing neck recess 36c. Pressures are equalized across the tool 36. An upward application of force to the retrieval equipment 34 will then unlatch the tool 36 from the well flow conductor 38. The tool 36 may thereafter be retrieved upwardly through the well flow conductor 38.
Upon opening of the tool's equalizing flow passage means 36b, high pressure well fluids from below the tool 36, which had been confined, are now admitted up to the bore 48 of the lubricator 24. Packing means 54 prevents these well fluids from escaping through the lubricator 24. Gauge means 68 is monitored to verify that the equalizing passage means 36b has in fact been opened and that pressures have in fact been equalized across the tool 36.
Once it is verified that the equalizing passage means 36b is open and that the pressures are equalized, upward forces are applied to rod means 42 to retrieve the well tool 36 from the well flow conductor 38. The lubricator 20 is operated substantially in reverse to the manner previously described to withdraw the tool 36 from the well flow conductor 38.
During upward retrieval of the well equipment 36, piston means 44 undergoes multiple strokes and rod means 42 is shortened. Segments 42b are removed from rod emans 42 substantially in reverse to the manner in which they were added to rod means 42.
Preferably, as soon as the tool 35 had been moved a distance sufficient to position the tool 36 above a valve 22a of the tree 22, the valve 22a is closed. Well fluids in the flow conductor are then confined by the valve 22a. Fluid within the bore 48 of the lubricator 24 is bled off. The lubricator 24 may now be disconnected from the well installation by disconnecting connector 128.
Thus, the reach of the lubricator 24 is not limited to the stroke of piston means 44. During operation of the lubricator 24, as many reach segments 42b as desired may be made up to form rod means 42. The reach of the lubricator 24 is increased with each reach rod segment 42b joined to rod means 42. During operation of the lubricator 24, rod means 42 is prevented from extruding from the lubricator 24 and the well flow conductor. Even if piston means 44 fails and rod means 42 does attempt to extrude from the lubricator 24,the extrusion will be stopped. If segments 42b are being inserted and removed through window means 106, stop nut means 110 will be operable. The extrusion of rod means 42 will be stopped by the engagement of the upstanding end of rod means 42 with the surface 108 of stop nut means 110. If segments 42b are being inserted and removed through bore 114, extrusion of rod means will stop whenever piston means 44 reaches its FIG. 3 position. Coupling means 46, by engaging recess means 104, will prevent further extrusion of rod means 42. At most, only one rod segment 42b will be extruded through the bore 114. Since, for such an extrusion to occur, the rod segments were being inserted through the bore, there will be enough space within the chamber 14 for one segment to extrude without endangering the integrity of the chamber 14.
Eventhough the lubricator 24 is relatively short when compared with previous lubricators, as can be seen in FIG. 1, the lubricator 24 may interfere with the closing of hatch 18. If it is desired to close the hatch 18, the lubricator 24 may be shortened. To shorten the lubricator 24, piston means 44 is moved to the FIG. 2A position. Coupling means 46 is moved laterally slightly, by rotating rod means 42, to lodge a portion thereof under projecting finger means 116. The rod segment 42b which extends into the housing support section 40c is disconnected from the rod means 42 and withdrawn from the section 40c. The housing support section 40c is rotated. The lug means 72 becomes aligned with the longitudinally extending portions 70a of L-slot means 70. The housing sectin 40c is lifted off of the remaining portion of the lubricator. The upper end of the shortened lubricator 24 is illustrated in perspective, in FIG. 5.
From the foregoing, it can be seen that the objects of this invention have been attained. The lubricator is capable of moving well equipment through a well flow conductor. The lubricator is a rod-type lubricator. Its rods positively move the well equipment through the flow conductor in response to movement of a lubricator piston. However, the amount of movement which may be imparted to the well equipment is not limited to the stroke of the piston. As many reach rod segments as desired may be added to the lubricator rod to increase the amount of movement imparted to the well equipment. The lubricator piston undergoes multiple strokes to permit the addition of additional reach rod segments. The piston is moved in one direction to move the rod and attached equipment into the flow conductor. The piston is moved in another direction to change the location where the rod is coupled to the piston. The rod is held longitudinally stationary while it is not rendered movable with the piston. The rod is thereby prevented from extruding due to the force of well fluids within the well flow conductor or dropping into the well flow conductor under the force of gravity. If desired, the lubricator may be partially disassembled. While partially disassembled, the lubricator rod is again prevented from extruding or falling. The partial disassembly further shortens the overall length of the lubricator.
The foregoing description and disclosure of the invention is illustrative and explanatory thereof. Various changes in the size, shape, and materials, as well as in the details of the illustrated construction, may be utilized within the scope of the appended claims without departing from the spirit of the invention.
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Disclosed is a rod-type lubricator for moving well equipment through a flow conductor. A piston controls movement of the lubricator rod. The rod includes an equipment handling segment and reach segments. As many reach segments as desired may be employed. The distance through which the well equipment may be moved is greater than the stroke of the piston. This abstract is neither intended to define the invention of the application which, of course, is measured by the claims, nor is it intended to limit the scope of the invention in any way.
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TECHNICAL FIELD
[0001] The disclosure generally relates to airbag inflators and specifically to control systems for airbag inflators that may be tailored for anticipated events.
BACKGROUND
[0002] An airbag is typically inflated with a pressurized source of gas. While airbags originally included single stage inflators, or inflators that would supply a constant effective flow area for a variable pressure, some recent airbag inflators have been adapted to supply more than one flow rate to inflate the airbag. These ‘dual stage’ airbag inflators typically are initiated by a control logic that determines what ‘type’ of crash event is being experienced and provides a selected flow rate to inflate the airbag. However, these dual stage inflators typically provide only adaptive vents, adaptive columns, dual-stage pyro inflators, or other systems that provide limited utility. Hybrid pyro inflators may also be used, but are sensitive to pressure waves within the system that affect the burn and subsequent development of gas flow and pressure.
[0003] With continual development in understanding crash dynamics and what parameters would be useful in altering inflation mass flow rates and to what degree, dual stage airbag inflators may no longer provide a desired flow rate for a specific initiating event that can be somewhat accurately detected and compensated for in an airbag inflation sequence. What is needed, therefore, is an apparatus and method for inflating an airbag that may be tailored to a specific defined initiation event. A favorable apparatus would be readily altered for use in different vehicle types, such as small cars, medium duty trucks, and light duty trucks.
SUMMARY
[0004] An illustrative embodiment includes a method of inflating an airbag with a fluid. The method includes sending a signal to open a first valve and opening the first valve. The method also includes directing a control pressure through the first valve and toward a second valve. The method further includes throttling the second valve in response to the control pressure. The throttling of the second valve produces a variable inflation mass flow rate of the fluid at a second valve outlet. Opening the first valve and closing the first valve are performed as a step function to achieve a desired predetermined variable inflation mass flow rate of the airbag
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Referring now to the drawings, preferred illustrative embodiments are shown in detail. Although the drawings represent some embodiments, the drawings are not necessarily to scale and certain features may be exaggerated, removed, or partially sectioned to better illustrate and explain the present invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the claims to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.
[0006] FIG. 1 is a schematic view of an airbag inflator system according to an embodiment.
[0007] FIG. 2 is a schematic view of a control valve according to an embodiment, illustrated in a first configuration.
[0008] FIG. 3 is a schematic view of a control valve according to an embodiment, illustrated in a second configuration.
[0009] FIG. 4 is a graphical representation of various mass flow rates for selected exemplary operational modes of the system of FIG. 1 .
DETAILED DESCRIPTION
[0010] FIG. 1 illustrates an embodiment of an airbag inflator system 20 . The system 20 includes a gas supply container 22 , a main valve 24 , a control valve 26 , an airbag 28 , a control module 30 , a flow meter 32 , a primary gas pressure sensor 34 , a secondary gas pressure sensor 36 , occupant sensors 38 , and crash sensors 40 . The main valve 24 is connected to the module 30 via a communication link 50 and is opened by the module 30 to connect the gas supply container 22 with the control valve 26 . The primary gas pressure sensor 34 senses the pressure inside the gas supply container 22 and is connected to the module 30 via a communication link 52 . The secondary gas pressure sensor 36 senses the pressure inside the control valve 26 and is connected to the module 30 via a communication link 54 . The flow meter 32 senses the mass flow of gas between the control valve 26 and the airbag 28 and is connected to the module 30 via a communication link 56 .
[0011] In the embodiment illustrated, the gas supply container 22 is a source of stored gas at about 12,000 psi ( kpa), although other suitable gas supplies may be used. The control valve 26 is opened with pyrotechnics, although other opening mechanisms may be used. The airbag 28 is a conventional airbag of standard or non-standard design.
[0012] As best seen in FIG. 2 , the control valve 26 includes a valve body 70 , a main inlet 72 , a main outlet 74 , and a vent 76 . In the embodiment illustrated, the body 70 houses a solenoid valve 80 , a ring valve 82 , and an actuation piston 84 . Specifically, the body 70 defines an inlet passageway 90 that opens into a shared passageway 92 that opens to both a ring valve inlet 94 and a solenoid valve inlet 96 . The solenoid valve inlet 96 opens to a solenoid valve chamber 100 which is in fluid communication with a piston cylinder 102 at a first cylinder end 104 and a solenoid valve vent 106 . The ring valve inlet 94 includes a ring valve seat mating surface 110 and a ring valve plate chamber 112 that opens to both a control valve outlet 114 and the piston cylinder 102 at a second cylinder end 116 .
[0013] The solenoid valve 80 is positioned within the solenoid valve chamber 100 . The solenoid valve is switchable between a first configuration, or an open configuration, where the solenoid valve inlet 96 is in fluid communication with the first cylinder end 104 of the piston cylinder 102 , and a second, or closed, configuration, where the solenoid valve inlet 96 is in fluid communication with the solenoid valve vent 106 . The control valve 26 includes a ring valve seat 120 , a ring valve plate 122 , a ring valve plunger 124 , and the piston 84 attached to the ring valve plunger 124 . The ring valve seat 120 is circumscribed by the ring valve seat mating surface 110 . The ring valve plate 122 , the ring valve plunger 124 , and the piston 84 are attached to move axially along an axis A-A as a single device. The ring valve seat 120 is defined in part by a seat inlet surface 130 and a seat mating surface 132 . The ring valve plate 122 is defined in part by a plate outlet surface 136 and a plate mating surface 138 . The ring valve seat 120 includes ring valve apertures 140 formed therein where each ring valve aperture 140 opens to both the seat inlet surface 130 and the seat mating surface 132 . The ring valve plate 122 includes ring valve plate apertures 142 formed therein where each ring valve plate aperture 142 opens to both the plate outlet surface 136 and the plate mating surface 138 . The ring valve seat 120 and the ring valve plate 122 matingly engage with the seat mating surface 132 in contact with the plate mating surface 138 so as to permit a flow of fluid therethrough. That is, both the ring valve seat 120 and the ring valve plate 122 align such that at least a portion of the ring valve apertures 140 align with at least a portion of the ring valve plate apertures 142 , in the embodiment illustrated.
[0014] The solenoid valve 80 includes a solenoid valve plunger 150 , a coil 152 , and a spring 154 . As best seen in FIG. 2 , when the solenoid valve 80 is in the first (open) configuration, the plunger 150 seals the solenoid valve vent 106 from the solenoid valve chamber 100 . As best seen in FIG. 3 , when the solenoid valve 80 is in the second (closed) configuration, the plunger 150 seals the solenoid valve inlet 96 from the solenoid valve chamber 100 .
[0015] As best seen in FIG. 2 , when the plate mating surface 138 of the ring valve plate 122 is mated with the seat mating surface 132 of the ring valve seat 120 , the partial alignment of the apertures 140 , 142 create an effective area EA 1 at the mating surfaces 132 , 138 for flow of a fluid (not numbered) therethrough. As best seen in FIG. 3 , when the plate mating surface 138 of the ring valve plate 122 is spaced from the seat mating surface 132 of the ring valve seat 120 , the fluid may flow through the apertures 140 , 142 while not restricted by the effective area EA 1 , to create an effective area EA 2 for flow of a fluid therethrough. The effective area EA 2 may generally be the lesser combined area of apertures 140 and the combined area of apertures 142 .
[0016] When the solenoid valve 80 is in the first configuration, ( FIG. 2 ) any fluid that flows into the solenoid valve 80 will be directed toward the first cylinder end 104 of the piston cylinder 102 . When enough fluid enters the first cylinder end 104 of the piston cylinder 102 at a sufficient pressure, the piston 84 is urged toward the ring valve seat 120 , thereby urging the ring valve plate 122 to matingly engage the ring valve seat 120 such that surface 132 contacts the surface 138 . Therefore, when the solenoid valve 80 is in the first configuration, the control valve 26 will limit the flow of the fluid by permitting flow through effective area EA 1 .
[0017] When the solenoid valve 80 is in the second configuration, no fluid will flow into the solenoid valve 80 and the first end 104 of the piston chamber 102 will be vented through the solenoid valve vent 106 to atmosphere. The flow of fluid through the apertures 140 will urge the ring valve plate 122 to move away from the ring valve seat 120 . Therefore, when the solenoid valve 80 is in the second configuration, the control valve 26 will limit the flow of the fluid by permitting flow through effective area EA 2 .
[0018] Referring back to FIG. 1 , the flow meter 32 detects the mass flow of the fluid between the control valve outlet 114 and the airbag 28 and sends a signal to the control module 30 via the link 56 . The primary gas pressure sensor 34 detects the gas pressure within the gas supply container 22 and sends a signal to the control module 30 via the link 52 . The secondary gas pressure sensor 36 detects the gas pressure within the first end 104 of the cylinder 102 and sends a signal to the control module 30 via the link 54 . In the embodiment illustrated, the occupant sensors 38 include occupant position, seat belt status (buckled, unbuckled, etc. . . . ) weight, and height, and the crash sensors 40 include vehicle weight, vehicle speed, estimated weight and speed of potential collision vehicle, etc. Collectively, these inputs to the occupant sensors 38 and the crash sensors 40 are referred to as inflation parameters.
[0019] The control module 30 includes a microprocessor 200 . A portion of the control logic of the microprocessor 200 is illustrated schematically at 208 . The control module 30 is connected to the occupant sensors 38 via a communication link 210 . The control module 30 is connected to the crash sensors 40 via a communication link 212 . The control module 30 is connected to the solenoid valve 80 via a communication link 214 .
[0020] FIG. 4 illustrates exemplary embodiments desired variable inflation mass flow rates for anticipated events. That is, differing crash events may be counter acted by deploying an airbag differently, depending upon various detected inflation parameters.
[0021] In a first event, labeled ‘small car, event 1 ’, the airbag 28 is deployed as the main valve 24 is opened and the control valve 26 is opened in the second state to permit a flow through the second effective area EA 2 . Accordingly, the mass flow rate illustrated for the first event is a high flow rate that diminishes with the reduction in pressure in the gas supply container 22 .
[0022] In a second event labeled ‘small car, event 4 ’, the airbag 28 is deployed as the main valve 24 is opened and the control valve 26 is opened in the second state for approximately 3 milliseconds (ms) to permit a flow through the second effective area EA 2 . The control valve 26 is then switched to the first state ( FIG. 2 ) for approximately 27 milliseconds (ms) to permit a flow through the first effective area EA 1 . Accordingly, the mass flow rate illustrated for the second event is a high flow rate for 3 ms, switching to a low flow rate for about 27 ms, and then returning back to a higher flow rate that diminishes with the reduction in pressure in the gas supply container 22 .
[0023] In a third event labeled ‘light truck, event 6 ’, the airbag 28 is deployed as the main valve 24 is opened and the control valve 26 is opened in the second state for approximately 3 milliseconds (ms) to permit a flow through the second effective area EA 2 . The control valve 26 is then switched to the first state ( FIG. 2 ) to permit a flow through the first effective area EA 1 which yields a low flow rate that diminishes with the reduction in pressure in the gas supply container 22 .
[0024] In a fourth event labeled ‘medium truck, event 3 ’, the airbag 28 is deployed as the main valve 24 is opened and the control valve 26 is opened in the second state for approximately 3 milliseconds (ms) to permit a flow through the second effective area EA 2 . The control valve 26 is then switched to the first state ( FIG. 2 ) for approximately 7 milliseconds (ms) to permit a flow through the first effective area EA 1 which yields a low flow rate. The control valve 26 is then switched to the second state from the first state and then oscillated between the first state and the second state 5 times with the oscillations occurring about every 2 ms. The control valve is maintained in the second state for about 10 ms and then switched back to the first state; Accordingly, the mass flow rate illustrated for the fourth event is a high flow rate for 3 ms, switching to a low flow rate for about 7 ms, and then oscillating between a higher flow rate and a lower flow rate, then maintaining a higher flow rate that diminishes with the reduction in pressure in the gas supply container 22 , then finishing with a low flow rate that diminishes with the reduction in pressure in the gas supply container 22 .
[0025] While FIG. 4 presents exemplary embodiments of desired airbag inflation curves, it is understood that an infinite number of examples may exist as newly developed crash simulations and detectors for potential crash and occupant parameters are available.
[0026] In operation of the system 20 , the control module 30 may interpret signals from the crash sensors 40 as a crash event. This interpretation may involve only one sensor (such as an accelerometer) or multiple crash sensors 40 . When a determination is made that a crash event is occurring, or is imminent, the control module 30 will evaluate information from the occupant sensors to determine input parameters such as occupant position, seat belt status (buckled, unbuckled, etc. . . . ) weight, height, to name a few, and determine what inflation curve to employ. Importantly, an inflation curve, such as the exemplary inflation curves of FIG. 4 , may be determined by a look-up table, may be standard curves selected for various ranges of parameters, or may be determined by an algorithm exclusively for each individual event.
[0027] Once a desired inflation curve is determined, the control module 30 will then deploy the system 20 so as to inflate the airbag 28 to simulate, or closely emulate the desired curve. Importantly, data from actual crash tests may be incorporated into the deployment logic to encourage the selection of an appropriate inflation curve. The control module 30 will open the main valve 24 and switch the solenoid valve 80 , if required, the effect the desired inflation curve (as best seen in FIG. 4 ).
[0028] The preceding description has been presented only to illustrate and describe exemplary embodiments of the methods and systems of the present invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. It will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. The invention may be practiced otherwise than is specifically explained and illustrated without departing from its spirit or scope. The scope of the invention is limited solely by the following claims.
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A method of inflating an airbag with a fluid includes sending a signal to open a first valve and opening the first valve. The method also includes directing a control pressure through the first valve and toward a second valve. The method further includes throttling the second valve in response to the control pressure. The throttling of the second valve produces a variable inflation mass flow rate of the fluid at a second valve outlet. Opening the first valve and closing the first valve are performed as a step function to achieve a desired predetermined variable inflation mass flow rate of the airbag.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. application Ser. No. 10/507,398 filed Aug. 24, 2005 which is a U.S. National Stage Completion of PCT/DE03/00744 filed on Mar. 6, 2003 which claims priority to German Application No. DE 102 10 486.7 filed on Mar. 11, 2002.
FIELD
The invention relates to a container, especially a bucket or similar, comprising an opening, which is orientated upwards and which can be closed by a cover, and a peripheral container edge, which is drawn outwards in a downward direction on the container wall, where the cover is detachably connected thereto and whereon at least one tongue-like element is connected in such a way that at least one part of the cover is raised due to a pivoting movement away from a starting position on the container wall.
BACKGROUND
Containers or vessels of this kind, which can be manufactured from elastic plastic materials by the injection moulding method, in particular, are widely used because of their inexpensive manufacture and their low weight. They are eminently suited to the stocking, storage and transport of pourable goods in liquid or also granulated form in handy packagings, without having to accept major restrictions as regards weight or shape as a result of the container itself. Moreover, the contents of the container need not be consumed in a single operation, as the container can be re-sealed with a cover, meaning that the contents can still be used after opening the container once or several times.
However, this initially highly positive feature entails the disadvantage that, as a result, the container must in some way be provided with an indication for the user or buyer to show whether or not an opening procedure has already taken place at some time; in other words, the intactness or original condition of the container should preferably be apparent even at only a fleeting glance.
In general, the removal of a cover from a container is facilitated by raising an area of the cover, for which purpose an aid of the nature of a tongue-like element is used, such as known from U.S. Pat. No. 3,753,512, for example.
A container of the kind mentioned in the opening paragraph is known, for example, from EP 0 565 967 B2, which describes a container to whose container edge a tongue-like element is connected that raises the cover as a result of a pivoting movement away from a starting position. In this context, at least one of the face edges of the ends of a fastening flange is supposed to be connected to the associated edge of the tongue-like element via thin-walled, plastic webs or a plastic film that are easy to tear off. A tamper-proof seal of this kind is disadvantageous because, being easy to tear off, these webs can also be detached unintentionally, thus indicating opening that has not in fact taken place. In addition, the intended indication of previous opening is also not necessarily unequivocal. If, for example, the cover is placed back onto the container after being raised, and the tongue-like element returned to its starting position, it may be that the webs still remaining on at least one end of the edges more likely suggest that the container has not yet been opened.
On a container disclosed in EP 1 052 183 A1, a tongue-like element connected to the container likewise serves to raise the cover. When in its starting position, sections of the tongue-like element are overlapped, without engaging, by one or more web-like elements, these elements being designed to break open or be deformed when the tongue-like element is moved away from its starting position in order to open the container. However, it can happen in this context that, after subsequent re-closing, when the tongue-like element is again in its starting position, the element or elements is or are likewise back in their original position, i.e. come to rest on the tongue-like element, meaning that indication of the previous opening of the container is not guaranteed. At the same time, the web-like elements overlapping the tongue-like element are also susceptible to being damaged or torn off, e.g. during transport, this again meaning that opening of the container would be indicated without actually having taken place.
SUMMARY
Therefore, the object of the invention is to create a container with a device for raising the cover located on the container, which is easy and inexpensive to manufacture and displays a device that is capable of unequivocally indicating previous opening of the container.
According to the invention, the object is solved in that the tongue-like element engages the container edge from behind with at least one part of the tongue-like element, the part of the tongue-like element can be guided outwards, in front of the container edge, by the pivoting movement, and the part of the tongue-like element cannot be guided back behind the container edge when the tongue-like element is pivoted back towards the starting position.
The part of the tongue-like element engaging the container edge from behind initially ensures that no parts of the tongue-like element project unfavourably from the container, and also that no parts designed to be deformed, torn off or broken open are exposed to the risk of being damaged prior to first-time use as intended. During the pivoting movement to be performed in order to raise the cover, the part of the tongue-like element engaging the container edge from behind is guided outwards, in front of the container edge. This provides a visible indication that makes it unequivocally clear whether or not the container has already been opened at some time, in that the part of the tongue-like element previously covered by an area of the container edge is suddenly visible to the user. In this context, the part of the tongue-like element is designed in such a way that pivoting the tongue-like element back, or replacing the cover after opening the container, does not lead to a situation where the part of the tongue-like element can be guided back behind the container edge. Rather, the part of the tongue-like element comes to rest on the container edge during this movement, mechanically opposing the return movement. In this context, a further indication of prior use is that the tongue-like element itself can no longer be completely returned to its starting position and stands a certain distance off from the wall of the container, this not affecting the fact that re-closing of the container by means of the cover is, of course, still possible. Finally, the design of the part of the tongue-like element to some extent also permits unintentional movement of the tongue-like element, without this impairing the information to be communicated, in which context the tongue-like element is at the same time protected against accidental damage.
In a preferred embodiment, the part of the tongue-like element is designed as an integral part of the tongue-like element. It is easy to manufacture as a result, there being no need to provide additional moulds or subsequent moulding-on operations. In turn, the tongue-like element is accommodated in an opening left in the peripheral container edge, its radial extension essentially corresponding to that of the remainder of the container edge. Although not subject to any restrictions in terms of shape, it is often of rectangular or trapezoidal design.
The part of the tongue-like element can preferably be deformed or broken open during the pivoting movement of the tongue-like element. In this way, the part of the tongue-like element can be guided outwards, past the comparatively rigid edge areas of the container, during the pivoting movement. When the tongue-like element is pivoted back, the part(s) of the tongue-like element then come to rest from the outside on the edge areas that previously covered them, meaning that they are then positioned between the container edge and the side of the tongue-like element facing this edge, as a result of which the pivoting movement of the tongue-like element towards the starting position is impeded and complete pivoting back is prevented, especially when replacing the cover. Both the part(s) of the tongue-like element lying on the container edge, and also the position of the tongue-like element itself, are thus visible as an indication of previous opening of the container.
In a preferred embodiment of the container according to the invention, the container edge displays, in the region of the tongue-like element, a downward-pointing edge projection that engages a recess in the tongue-like element. In this context, the essentially random contour of this downward-pointing edge projection adapts to the recess provided in the tongue-like element, clearance being provided between the edge projection and the tongue-like element. As a result, when performing the pivoting movement, which takes place via a hinge, the tongue-like element can be pivoted away from the edge projection, meaning that the edge projection disengages from the recess. In this context, the edge projection is preferably provided with a tongue that is engaged by the part of the tongue-like element from behind. This tongue is of curved, forward-projecting design. Consequently, the part of the tongue-like element located in the region of the recess is overlapped by the tongue located on the edge projection, meaning that the latter does not itself engage the recess in the tongue-like element. The pivoting movement of the tongue-like element leads to the part of the tongue-like element acting on the side of the tongue facing the container wall, this causing deformation of the part of the tongue-like element towards the container wall. The rest of the tongue-like element then pulls the part of the tongue-like element past the tongue, meaning that the part of the tongue-like element moves to the side of the tongue facing away from the container wall. The length and shape of the tongue now prevent the part of the tongue-like element from being moved back behind the tongue in the opposite direction.
To facilitate the raising of the cover brought about by the tongue-like element, provision can be made in a further preferred embodiment for a predetermined breaking line to be located in the area of the tongue-like element engaging the tongue from behind. When the part of the tongue-like element acts on the edge projection or the tongue, the material of the part of the tongue-like element partly breaks open, meaning that less force has to be applied to perform the pivoting movement. In this embodiment, a corresponding design of the edge projection or the tongue again ensures that it is not possible to guide the part of the tongue-like element back behind the edge area which it previously engaged from behind.
In an advantageous embodiment, webs partially overlapping the recess are located on the side of the tongue-like element facing the container wall as parts of the tongue-like element between the edge projection and the container wall. These webs are, for example, of beam-like design and connected to the tongue-like element at one or more points in the edge area of the recess. During the pivoting movement of the tongue-like element, they act on the side of the edge projection facing the container wall and are initially bent back towards the container wall, before subsequently being guided forwards, past the edge projection and through the clearance between the edge projection and the tongue-like element. When pivoting the tongue-like element back, the webs can then no longer be threaded back through and come to rest on the outside of the edge projection. As a result, the tongue-like element can again not return to its starting position.
To protect the tongue-like element against unintentional operation, it can also be advantageous to provide for the tongue-like element to be connected to the edge projection by breakable links. These bridge the clearance between the tongue-like element and the edge projection at certain points and prevent movement of the tongue-like element relative to the rest of the container. The links can then easily be detached during first-time operation of the tongue-like element in the process of raising the cover. In a further development, the tongue-like element can, for example, also be connected to the container edge by breakable links to provide additional protection against unintentional operation of the tongue-like element.
In a further advantageous embodiment of the container according to the invention, parts of the tongue-like element are provided on the lateral ends of the tongue-like element, which engage the respective lateral ends of the container edge facing the tongue-like element from behind. These parts of the tongue-like element can initially likewise be designed in the form of beam-like webs, which engage the container edge opposite the lateral ends of the tongue-like element from behind at individual points. In addition, however, an embodiment of the parts of the tongue-like element is also conceivable where, for example, the parts initially run perpendicular to the container wall in the manner of wings or louvres and are then angled, engaging the container edge from behind over part or all of the height of the tongue-like element. In this context, the mode of action of such parts of the tongue-like element in the form of louvres during the pivoting movements is in principle identical to that of the webs. This also makes it apparent that a host of possible varieties appears conceivable as regards the parts of the tongue-like element engaging the edge projection or the lateral edge of the container from behind.
Moreover, it is advantageous to provide ribs between the side of the tongue-like element facing the container wall and the container wall to impede a pivoting movement towards the container wall. This additionally ensures that any attempt to get the tongue-like element into its starting position by force when pivoting it back will be unsuccessful. Furthermore, the tongue-like element can be additionally stiffened and stabilised by these ribs.
For the purpose of providing additional safety during transport, it is advantageous in a further embodiment for the downward-facing edge side of the tongue-like element to stand back relative to the lower end of the container edge drawn downwards on the container wall. This caters to the fact that tilting movements and skewing can occur during transport, meaning that this measure attempts to prevent unintentional operation of the tongue-like element and the associated raising of the cover by impeding intervention on the tongue-like element.
It is furthermore advantageous for the tongue-like element on a container according to the invention to display at least one operating hole for performing the pivoting movement. This facilitates the intended use of the tongue-like element, since the person using it is given a hole for the hand performing the pivoting movement of the tongue-like element, or its fingers, and can perform the movement easily and reliably as a result.
Moreover, it is advantageous in a further development for the side of the tongue-like element facing away from the container wall to display a textured surface. This can prevent slipping of the area of the hand of a user that comes into contact with this surface when operating the tongue-like element, meaning that the surface provided with ribs, for example, benefits safe handling of the container.
In a further advantageous embodiment, at least one part of the tongue-like element located on the tongue-like element displays a mark that is at least partly covered by an area of the container edge when the tongue-like element is in its starting position. The mark can comprise both lettering and a coloured marking, where, for example, it would be conceivable to design the part of the tongue-like element in a different colour than the container in order to ensure greater attention of an observer to the part of the tongue-like element, which is then completely visible after opening. The mark is, however, not limited to this kind of marking. Rather, further, very different types of marking are also conceivable.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail below on the basis of several practical examples. The associated drawings show the following:
FIG. 1 A front view of the edge area of a first embodiment of the container according to the invention, with a tongue-like element,
FIGS. 2 , 3 A sectional view of the container in FIG. 1 along Line II-II, with the cover in place and the tongue-like element in its starting position and in its pivoted position,
FIG. 4 A perspective front view of a further embodiment of the container, with container edge, tongue-like element and edge projection, as well as webs engaging the lateral edge of the container as the parts of the tongue-like element,
FIG. 5 A view of the edge area of a further embodiment from below, with webs engaging the edge projection from behind and louvre-like parts of the tongue-like element that engage the lateral edge from behind,
FIGS. 6 , 7 Front views of two further embodiments of the tongue-like element, with operating holes, and
FIGS. 8 , 9 Front views of a further embodiment with the tongue-like element in its starting position and in its pivoted position.
DETAILED DESCRIPTION
FIG. 1 shows a front view of an area of peripheral container edge 2 of container 1 , made of a thermoplastic material, without cover 3 . Starting from the invisible container opening at the upper end of container edge 2 and flange 4 located there, container edge 2 extends downwards along container wall 5 . Between two lateral edges 6 of container edge 2 , an opening 7 is provided that is open towards the bottom and into which tongue-like element 8 , connected to the container edge, fits in its starting position, at a distance from the lateral edges. The plane cross-section of tongue-like element 8 , the side of which facing the observer is provided with ribs 9 , tapers in the downward direction, while the downward-facing edges of tongue-like element 8 , which can in principle be of any desired shape, and of lateral edges 6 end at the same level. In this context, ribs 9 can be provided both to prevent slipping and also for stiffening tongue-like element 8 .
In the middle of the upward-facing edge area of tongue-like element 8 is recess 10 , which is engaged by downward-facing edge projection 11 , which tapers slightly in this direction and protrudes from container edge 2 . Located on edge projection 11 , and leading down from it and away from the container at an angle, is tongue 12 , which overlaps the part of the tongue-like element 13 , which is opposite edge projection 11 and located on tongue-like element 8 . A pivoting movement of tongue-like element 8 towards the observer guides the part of the tongue-like element 13 past tongue 12 , meaning that the part of the tongue-like element 13 previously covered by tongue 12 is then visible, whereas its invisible rear side is then opposite tongue 12 and, owing to the shape and arrangement of tongue 12 , can not be guided back past it.
FIGS. 2 and 3 show a sectional view of edge area 1 of the container in FIG. 1 along Line II-II, with cover 3 in place. In FIG. 2 , tongue-like element 8 is initially in its starting position. It can likewise be seen that cover 3 is detachably connected to the edge area of the container via flange 4 and snap-fit device 14 . In this context, peripheral inner edge 15 of the cover sits on inner wall 16 of container 1 in sealing fashion in the area of flange 4 . Outer edge 17 of the cover is designed with inward-protruding projection 18 in such a way that it forms snap-fit device 14 together with protruding nose 19 of container edge 2 . The underside of outer edge 17 is supported on edge projection 11 of container edge 2 and on tongue-like element 8 . In addition, reinforcing ribs 21 are also integrally moulded on the inner side of tongue-like element 8 with the aim of impeding pivoting movement of tongue-like element 8 towards container wall 5 .
FIG. 3 shows tongue-like element 8 , connected to container edge 2 , after a pivoting movement to be performed in the direction of the arrow has taken place. During the pivoting movement, the part of the tongue-like element 13 located on tongue-like element 8 acts on tongue 12 , initially pressing it in an upward direction, together with edge projection 11 . In this process, snap-in device 14 disengages, projection 18 of outer edge 17 of cover 3 being moved past nose 19 of container edge 2 and coming to rest on its upward-facing side. At the same time, inner edge 15 of cover 3 slides upwards on the inner wall of the container, still forming a seal. Cover 3 can subsequently be easily released from container 1 . When the pivoting movement is continued, the part of the tongue-like element 13 is finally guided past tongue 12 , meaning that the sides of the part of the tongue-like element 13 and of tongue-like element 8 facing container wall 2 are opposite the tongue. The pivoting movement of tongue-like element 8 gives a free view of lateral edge 6 , which was previously hidden in FIG. 2 . It can also be seen from FIG. 3 that the shape and arrangement of edge projection 11 and tongue 12 prevent pivoting of tongue-like element 8 back into its starting position, this movement causing the rear side of the part of the tongue-like element 13 and of tongue-like element 8 to come to rest on the outer side of tongue 12 .
In principle, the further embodiment presented in a perspective front view in FIG. 4 shows an area of container edge 2 without cover 3 , similar to the illustration in FIG. 1 . Here, container edge 2 is provided, on both lateral ends of tongue-like element 8 and in the area of edge projection 11 , with axial interruptions 24 , which continue in the axial direction into opening 7 between lateral edges 6 and recess 10 of tongue-like element 8 . Interruptions 24 permit independent movement of tongue-like element 8 relative to edge projection 11 and lateral edges 6 .
Again, tongue-like element 8 , accommodated by opening 7 , can be seen in its starting position. In this case, however, the lateral ends of tongue-like element 8 run parallel to lateral edges 6 , which are arranged in a perpendicular direction, meaning that tongue-like element 8 does not taper in the downward direction. Again, edge projection 11 protrudes into recess 10 , located centrally in the upper edge area of tongue-like element 8 . Rectangular strip element 22 with semi-circular end pieces 23 is integrally moulded on the end of edge projection 11 facing tongue-like element 8 , the edges of strip element 22 and end pieces 23 lying opposite the edges of recess 10 at a distance. For stabilisation, stiffening web 25 is provided on the outer side facing away from container wall 5 , partly covering strip element 22 and end pieces 23 . On the side of tongue-like element 8 facing away from the observer, parts of the tongue-like element 13 are integrally moulded in the form of webs between tongue-like element 8 and container wall 5 , partly overlapping recess 10 and thus engaging strip element 22 and end pieces from behind. In the same way, at the two ends of the tongue-like element facing lateral edges 6 , lateral edges 6 are each engaged from behind by longitudinal webs provided on the tongue-like element there as parts of the tongue-like element 13 . During the pivoting movement taking place when opening, the parts of the tongue-like element 13 act on the sides of the rigid strip elements/end pieces, or of the rigid lateral edge, facing the container wall, are pivoted and simultaneously deformed, and guided past the rigid parts towards the front. Once they have passed the obstacles, the elasticity of the material causes them to essentially resume their previous, integrally moulded position on tongue-like element 8 . In this way, when the tongue-like element is pivoted back, they come to rest on the outer side of those parts of the edge of container 1 that they were previously guided past. To improve handling, the top side of tongue-like element 8 is again provided with ribs 9 in this embodiment.
FIG. 5 shows a perspective bottom view of the edge area of a further embodiment. Peripheral container edge 2 with lateral edges 6 can initially be seen in this figure. Opening 7 , which is located between lateral edges 6 , continues into interruptions 24 . Located between lateral edges 6 is tongue-like element 8 , the lower edge and ribs 9 of which can be seen. Wing or louvre-like parts of the tongue-like element 13 are integrally moulded on the two lateral ends of tongue-like element 8 . These engage lateral edges 6 from behind in that they initially protrude perpendicularly from tongue-like element 8 towards container wall 5 and then at an angle towards the lateral edges. In this context, the parts of the tongue-like element 13 extend in the perpendicular direction from the lower edge of tongue-like element 8 over the length of the edge of the tongue-like element opposite lateral edge 6 .
More towards the centre of tongue-like element 8 , reinforcing ribs 21 are provided on the rear side of the tongue-like element to promote stability, alongside the parts of the tongue-like element 13 . Even farther towards the centre of tongue-like element 8 , there then follow further parts of the tongue-like element 13 , which are designed to be guided past edge projection 11 (not shown). These parts of the tongue-like element 13 again display an area pointing perpendicularly towards container wall 5 and an angled area which, however, points away from lateral edges 6 in this case. Between the ends of these parts of the tongue-like element 13 are three domes 26 , located on container wall 5 and projecting perpendicularly from it. The rear side of container edge 2 extends between these domes 26 , which are provided for reinforcement and stiffening, while edge projection 11 (not shown) is located on their top side. Therefore, in this embodiment, the parts of the tongue-like element 13 are again guided past both the edge projection and the lateral edges during the pivoting movement. In this context, the design of the parts of the tongue-like element 13 , with a section perpendicular to container wall 5 and a section angled relative to it, is particularly favourable for resiliently opposing any attempt to move tongue-like element 8 back towards its starting position. During this movement, the parts of the tongue-like element 13 come to rest on the outer side of the edge areas that they previously engaged from behind, meaning that the tongue-like element stands out at an angle relative to the rest of container edge 2 .
FIGS. 6 and 7 show two further embodiments of tongue-like element 8 , where the functional principle of the tongue-like element essentially corresponds to that in FIG. 1 , although the end of tongue-like element 8 itself facing container edge is drawn farther into container edge 2 , meaning that a generally larger edge projection 11 is obtained. Tongue-like element 8 , which tapers in the upward direction up to container edge 2 in the case of FIG. 6 , displays several operating holes 27 at its lower edge, into which a user can insert his fingers to perform the pivoting movement. Furthermore, reinforcing ribs 21 , indicated by broken lines, are integrally moulded on the side of the tongue-like element facing the container wall. Also shown as broken lines on the side of edge projection 11 facing container wall 5 are domes 26 , which are integrally moulded there. In addition, edge projection 11 in FIG. 6 is connected to tongue-like element 8 by breakable links 28 in the form of connecting webs in order to protect tongue-like element 8 against unintentional operation.
In FIG. 7 , opening 7 with associated tongue-like element 8 is located within container edge 2 , meaning that no opening 7 that is open towards the bottom and bordered by lateral edges 6 is formed. The largest part of tongue-like element 8 in terms of area is taken up by the single operating hole 27 , into which several fingers of an operating hand can be inserted simultaneously to perform the pivoting movement of the tongue-like element.
Finally, FIGS. 8 and 9 show two different positions of tongue-like element 8 of a further embodiment, namely the starting position and the pivoted position of tongue-like element 8 . In this context, the arrangement of domes 26 , located between container wall 5 and tongue-like element 8 , corresponds to the illustration in FIG. 6 . The part of the tongue-like element 13 located centrally on tongue-like element 8 displays essentially vertical, free lateral ends opposite the edges of tongue-like element 8 , which are connected to the latter by breakable links 29 . In this context, the part of the tongue-like element 13 is covered by tongue 12 and is connected in pivoting fashion to tongue-like element 8 via area of thinner material 30 at its end facing operating holes 27 . Furthermore, located on the ends of tongue-like element 8 facing lateral edges 6 are parts of the tongue-like element 13 , which initially engage lateral edges 6 in FIG. 8 from behind. After reaching into operating holes 27 , pivoting of tongue-like element 8 out of the plane shown in the figure towards the observer results in links 29 breaking and in both part of the tongue-like element 13 located in the centre of tongue-like element 8 and also parts of the tongue-like element 13 engaging lateral edges 6 from behind being guided forwards. During the pivoting movement, the centrally located part of the tongue-like element initially comes into contact with tongue 12 from behind and, following breaking of links 29 , is pivoted towards container wall 5 , area of thinner material 30 serving as the pivoting axis in this context. Following the pivoting movement and corresponding raising of cover 3 (not shown), the situation illustrated in FIG. 9 results. It can be seen there that the part of the tongue-like element 13 that pivots about area of thinner material 30 has been guided past tongue 12 , residues of now broken links 29 remaining either on the part of the tongue-like element 13 itself, or on tongue-like element 8 , or on both, while the lateral parts of the tongue-like element were guided past the lateral edges. Complete pivoting back of tongue-like element 8 is prevented by the fact that the central part of the tongue-like element 13 comes to rest on tongue 12 and the lateral parts of the tongue-like element 13 comes to rest on lateral edge 6 , meaning that tongue-like element 8 stands off from its starting position at a certain angle.
LIST OF REFERENCE NUMBERS
1 Container
2 Container edge
3 Cover
4 Flange
5 Container wall
6 Lateral edge
7 Opening
8 Tongue-like element
9 Rib
10 Recess
11 Edge projection
12 Tongue
13 Part of the tongue-like element
14 Snap-fit device
15 Inner edge of the cover
16 Inner wall
17 Outer edge of the cover
18 Projection
19 Nose
21 Reinforcing rib
22 Strip element
23 Semi-circular end piece
24 Interruption
25 Stiffening web
26 Dome
27 Operating hole
28 Breakable links
29 Breakable links
30 Area of thinner material
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A container, especially a bucket or similar, comprising an opening, which is orientated upwards and which can be closed by a cover, and a peripheral container edge, which is drawn outwards in a downward direction on the container wall, where the cover is detachably connected thereto and whereon at least one pivotal tab is connected in such a way that at least one part of the cover is raised due to a pivoting movement away from a starting position on the container wall, and engages with the container edge from behind with part of the pivotal tab which can be guided outwards by the pivoting movement to a position in front of the container wall and the part of the pivotal tab is prevented from being guided behind the container edge when the pivotal tab pivots back in the direction of the initial position.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a dishwasher, and more particularly, to a dishwasher and a door hinge that allow easy coupling of a door cover and a door liner that form a door.
[0003] 2. Description of the Related Art
[0004] A dishwasher is a home appliance that sprays high-pressure wash liquid through spray nozzles to wash and remove food residue left on surfaces of dishes. Specifically, a dishwasher includes a tub forming a wash compartment, and a sump installed at the bottom of the tub for storing wash liquid. Installed inside the sump is a wash pump that pumps wash liquid to the spray nozzles. The wash liquid pumped to the spray nozzles is discharged under high pressure through spray holes at the ends of the nozzles. The high-pressure wash liquid spray collides with the surfaces of dishes, so that food residue and other impurities on the dishes fall to the floor of the tub.
[0005] A door, that opens and closes the front of the dishwasher tub, includes a door liner and a door cover installed in front of the door liner to enhance the outward appearance of the dishwasher. The door is coupled to a door hinge installed at the side of the tub to open and close the tub.
[0006] However, the fastening structure of the door according to the related art lacks a portion that guides the insertion of the door cover during the process of assembling the door cover to the front portion of the door liner. Therefore, the door cover and the door liner can be improperly aligned. That is, the upper portion of the door liner and that of the door cover do not align with each other, or the sides of the door liner and the door cover do not accurately align. Accordingly, the process of accurately aligning the door cover with the front of the door liner during assembly is time-consuming, and a lot of manpower is wasted by assembly workers fitting door covers to door liners by hand.
SUMMARY OF THE INVENTION
[0007] Accordingly, the present invention is directed to a dishwasher and a door hinge that substantially obviate one or more problems due to limitations and disadvantages of the related art.
[0008] An object of the present invention is to provide a dishwasher and a door hinge that allow easy assembly of a door cover and a door liner.
[0009] 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 objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0010] To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, there is provided dishwasher including: a tub frame; a door liner pivotably installed for opening and closing an inside of the tub frame; a door hinge coupled at a respective end of the tub frame and the door liner, the door hinge being a pivoting axis of the door liner; a door cover coupled to the door liner; and a door cover support plate for aligning a position of the door cover during an assembly of the door cover and the door liner.
[0011] In another aspect of the present invention, there is provided a door hinge of a dishwasher coupled to an end of a door including a door cover and a door liner and an end of a tub, the door hinge being an axis of rotation for the door when the tub is opened and closed, wherein the door hinge includes: a hinge body; a hinge arm extending a predetermined distance from an end of the hinge body; a front support plate bent from a side of the hinge body and contacting a front portion of the door liner; a side support plate bent from the front support plate and contacting a side of the door liner; and a door cover support plate formed on the hinge body for aligning a position of the door cover during an assembly of the door cover and the door liner.
[0012] In a further aspect of the present invention, there is provided a door hinge of a dishwasher coupled to an end of a door including a door cover and a door liner and an end of a tub, the door hinge being an axis of rotation for the door when the tub is opened and closed, wherein the door hinge includes: a hinge body; and a door cover support plate formed on the hinge body for aligning a position of the door cover during an assembly of the door cover and the door liner.
[0013] The dishwasher and the door hinge according to the present invention allow a much easier assembly of a door cover (forming the front of a door) and a door liner by smoothly inserting the door cover along and into the door liner.
[0014] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
[0016] FIG. 1 is a sectional side view of a dishwasher according to the present invention;
[0017] FIG. 2 is a perspective view of a door cover according to the present invention;
[0018] FIG. 3 is a perspective view of a door hinge according to the present invention; and
[0019] FIG. 4 is a perspective view showing the assembling of a door cover and a door hinge according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0021] FIG. 1 is a sectional side view of a dishwasher according to the present invention.
[0022] Referring to FIG. 1 , a dishwasher 100 according to the present invention includes a tub 110 , a tub frame 150 , a door hinge 200 , a spring 160 , a door liner 120 , an air brake 130 , and a water level sensor 140 .
[0023] The tub 110 forms a wash compartment within for holding wash liquid. The tub frame 150 is installed at the front periphery of the tub 110 to retain the shape of the tub 110 . The door hinge 200 is installed at the bottom of the tub frame 150 , with the door coupled at its upper end. The door hinge 200 pivots centrally around a hinge inserted into the side of the tub frame 150 . One end of the spring 160 is connected to one end of the door hinge 200 , and the other end of the spring 160 is coupled to an end of the door frame so that the spring expands. The door liner 120 is fastened to the other end portion of the door hinge 200 to open and close the front of the tub 110 . The door cover 170 (to be described below) is installed at the front of the door liner 120 . The air brake 130 is installed on the side of the tub 110 , and forms passages for wash liquid to flow through. The water level sensor 140 allows wash liquid that enters the air brake 130 to enter the tub 110 , and senses the water level inside the tub 110 .
[0024] In the above-structured dishwasher, in order to open the door, a user grasps the door and pulls in a forward direction, so that the door hinge 200 rotates in a clockwise direction (in FIG. 1 ). The spring 160 connected to the end of the hinge 200 contracts. In reverse, when the user closes the door, the door hinge 200 rotates in a counter-clockwise direction, so that the spring 160 expands. The elasticity of the spring 160 prompts the door to return to a closed position from an open position when a user lets go of it.
[0025] FIG. 2 is a perspective view of a door cover according to the present invention.
[0026] Referring to FIG. 2 , the door cover 170 according to the present invention is roughly square in shape and is installed at the front of the door liner 120 .
[0027] Both sides of the front portion 171 of the door cover 170 are bent, so that the ends of the door cover 170 are “u”-shaped. Specifically, both sides of the door cover 170 are bent at right angles to form a bent portion 172 . A further right angle bend inward at the end of the bent portion 172 forms a sliding portion 173 . The sliding portion 173 may be parallel with the front of the door cover 170 . A fastening hole 174 is formed in the sliding portion 173 for inserting a predetermined fastening member therethrough.
[0028] In order to couple the front portion of the door liner 120 to the door cover 170 , a door cover support panel ( 240 in FIG. 3 ) is inserted between the sliding portion 173 and the front portion 171 . The door cover support panel 240 is formed on the door hinge 200 .
[0029] The process of coupling the door cover 170 to the door liner 120 will now be described with reference to the diagrams.
[0030] FIG. 3 is a perspective view of a door hinge according to the present invention.
[0031] Referring to FIG. 3 , the door hinge 200 according to the present invention may be made of a metal material having a predetermined hardness.
[0032] The door hinge 200 includes a hinge body 210 , a hinge arm 220 , a front support plate 211 , a side support plate 230 , a spring hook 222 , and a door cover support plate 240 .
[0033] The hinge arm 220 extends a predetermined distance from the lower end of the hinge body 210 . A “u”-shaped spring hook 222 is formed at the end of the hinge arm 220 . The spring hook 222 couples to one end of the spring 160 .
[0034] The front support plate 211 bends at a right angle from an end of the hinge body 210 . The front portion of the door liner 120 is adhered to the front support plate 211 . At least one fastening hole 212 is formed on the front support plate 211 .
[0035] The side support plate 230 is bent once again from the front support plate 211 . The side support plate 230 is adhered to the side of the door liner 120 . A door liner fastening hole 231 is formed on the side support plate 230 . A predetermined fastening member is coupled to the door liner fastening hole 231 to couple the side support plate 230 to the door liner 120 .
[0036] The hinge arm 220 has a pivoting slot 221 formed thereon that can catch and pivot on a hinge 101 . The hinge 101 formed on the tub frame 150 catches on the pivoting slot 221 . Thus, the door hinge 200 and the door can pivot on the axis of the hinge 101 .
[0037] The door cover support plate 240 is bent at an end of the hinge body 210 , the end of the bent portion extends a predetermined distance upwards. Therefore, the end of the door cover support plate 240 protrudes a predetermined length from the hinge body 210 . The door cover support plate 240 is formed on an end of the hinge body 210 other than that on which the hinge arm 220 is formed. This door cover support plate 240 allows for a smooth assembly of the door cover 170 , which will be described below. A door cover fastening hole 241 is formed on the curved extension of the hinge body 210 that is the door cover support plate 240 .
[0038] In door hinge 200 is coupled so that it can pivot at both lower ends of the tub frame 150 .
[0039] In further detail, the door cover support plate 240 moves in a forward direction of the dishwasher 100 , and the side support plate 230 presses against the sides of the door liner 120 , as the door hinge 200 is installed on the tub frame 150 . Here, the pivoting slot 221 of the door hinge 200 catches on the hinge 101 of the tub frame 150 . Then, the door hinge 200 rotates on the axis of the hinge 101 with respect to the tub frame 150 .
[0040] In this state, one end of the spring 160 couples to the spring hook 222 . The end of the spring 160 catches on the spring hook 222 through the pulley 102 . Then, the door hinge 200 is pulled by the spring 160 , so that the door hinge 200 is pressed and retained against the tub frame 150 .
[0041] When the door liner 120 is pressed against the door hinge 200 , bolts or other fastening members are coupled to the door liner fastening hole 231 /the fastening hole 212 , and the opposite fastening holes of the door liner 120 . In this way, the door liner 120 and the door hinge 200 are fastened.
[0042] Here, the inner surface of the front portion of the door cover 170 presses against the front portion of the door cover support plate 240 and slides, so that the door hinge 200 easily inserts into the door cover 170 . This process is described further below.
[0043] FIG. 4 is a perspective view showing the assembling of a door cover and a door hinge according to the present invention.
[0044] Referring to FIG. 4 , the inside of the front portion 171 of the door cover 170 contacts the front portion of the door cover support plate 240 and slides, so that the door cover 170 is inserted. Furthermore, the outer surface of he hinge body 210 contacts the inner surface of the curved portion bent portion 172 and slides downward. Also, the lower portion of the door cover 170 slides up to the lower portion of the door hinge 200 , whereupon a bolt or other fastening member is passed through the fastening hole 174 formed in the sliding portion 173 of the door cover 170 and the door cover fastening hole 241 of the door cover support plate 240 . Then, the door cover 170 and the door hinge 200 are fastened.
[0045] The above assembly process, a user does not have to manipulate the door cover 170 to precisely align the fastening hole formed in the door cover 170 with the fastening hole formed in the door liner 120 . Accordingly, the assembling time required to couple the door cover 170 is substantially reduced.
[0046] The dishwasher, and the door hinge according to the present invention allows the door cover formed at the front of the door to be inserted by sliding along the door liner, to greatly simplify the assembling process.
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A dishwasher and a door hinge thereof are provided. The dishwasher and the door hinge include a door cover support plate that aligns a position of a door cover during assembly of the door cover and a door liner.
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FIELD
[0001] This disclosure relates to electrochemical cell encasements including covers and cases.
BACKGROUND
[0002] The following discussion discloses electrochemical cells and methods of making cells for use in an implantable medical device (IMD) that is very compact, such that IMD can be readily implanted in small spaces within the patient's anatomy. As such devices get smaller, new challenges in manufacturing of components, such as batteries present themselves. One of the challenges is making battery encasements, for example covers and cases, that can be reliably manufactured to remain sealed during use within a human body. It is known that the welding of certain metals can form areas at the weld that are more susceptible to hydrogen cracking or embrittlement than the base metals. The root of the weld is typically the weakest spot in a welded structure due to stress concentration effect.
SUMMARY
[0003] Applicants have discovered a design for an electrochemical cell encasement including a cover and a case in which the welded joints formed at the cover and case interface are created in lower stress areas of the encasement.
[0004] In one embodiment, the battery case is hollow except for one end and has a cylindrical shape and has a circular cross section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is section view of a battery assembly;
[0006] FIG. 2 is close-up section view of a battery cover;
[0007] FIG. 3 is a close-up section view of a battery case;
[0008] FIG. 4 is a close-up section view of a known battery cover;
[0009] FIG. 5 is a close-up section view of a known battery case;
[0010] FIG. 6 is a depiction of the von Mises stress distribution in the proximity of the weld due to internal pressurization of a known design for an electrochemical cell case and cover;
[0011] FIG. 7 is a depiction of the von Mises stress distribution in the proximity of the weld due to internal pressurization of a design for a battery case and cover of the disclosure;
[0012] FIG. 8 is a close-up perspective view of a battery cover of the disclosure; and
[0013] FIG. 9 is a close-up perspective view of a battery case of the disclosure.
DETAILED DESCRIPTION
[0014] “Anode” and “cathode” are used as these terms are commonly understood in reference to electrochemical cells, for example, batteries and capacitors.
[0015] The electrochemical cells described in this disclosure are useful in compact implantable medical devices (IMDs) that can be implanted within small spaces of an anatomy, such as the vasculature or an organ, for example a chamber of a heart. The same reference numbers are used in multiple figures when referring to the same element of the disclosure.
[0016] Battery assembly 10 for an implantable medical device is shown in FIG. 1 . In this embodiment, battery assembly 10 includes a generally cylindrical battery case 12 and corresponding battery cover 14 . Battery case 12 and battery cover 14 will be discussed in greater detail below. Within battery case 12 is the anode 16 , cathode 18 and separator 20 . Each of the anode 16 , cathode 18 and separator are generally coaxial with one another. Embedded within the cathode is current collector 22 which is connected to feedthrough pin 24 . The feedthrough pin 24 can be connected to for example, an electronics assembly for an implantable medical device. The battery assembly as depicted provides that in operation, the battery case and cover have a negative potential, also known as “case negative” polarity. The outer surfaces of the battery assembly are designed to be exposed to bodily fluids when implanted. The battery case has a generally tubular shape and is generally circular in cross section. Other shapes in cross section include ovate, elliptical, or any other suitable shape. Of course the battery shape of the battery cover is designed to attach to the battery case as described in this application.
[0017] Useful battery materials include a case and cover made of an electrically conductive material such as alpha-beta and beta titanium alloys such as Ti-6Al4V or Ti-15Mo, respectively, stainless steels, titanium, for example grade 1, or any other grade, an anode of for example, lithium metal, a cathode of for example, a hybrid mixture of carbon monofluoride (CF x ) and silver vanadium oxide (CSVO)and may further contain carbon black or polytetrafluoroethylene (PTFE), or both and the separator 20 can include porous polypropylene film, such as that provided by Celgard, LLC of Charlotte, N.C. (e.g., CELGARD 2500, CELGARD 4560, and the like). The battery assembly also includes a liquid electrolyte (not shown) for facilitating ionic transport and forming a conductive pathway between the anode 16 and the cathode 18 . The feedthrough pin and the current collector are made from an electrically conductive material such as titanium, platinum, niobium, molybdenum, alloys of titanium, stainless steel, or alloys of any of these. The feedthrough pin is normally a solid unitary component.
[0018] FIGS. 2 and 3 depict battery cover 14 and battery case 12 in close-up. Battery cover 14 includes a fillport 26 for adding electrolyte and an opening 28 for the feedthrough pin 24 . Battery case 12 has an open end 13 and a closed end 9 and a cylindrical or tubular portion 7 . After electrolyte is added through the fillport, the fillport is sealed. Width 30 of the battery case 12 cooperates with internal width 32 of battery cover 32 to form a robust fit. When battery cover 14 is fitted onto the open end 13 of the battery case 12 , battery cover 14 is welded to the open end 13 of the case 12 . The battery cover and the battery case are centered about an axis 15 .
[0019] FIGS. 8 and 9 depict the battery cover and case depicted in FIGS. 2 and 3 in perspective views.
[0020] In this embodiment, the battery cover 14 includes a divot or indentation 17 for identification of the exterior surface of the battery cover due to its relatively small size. For example, the outside diameter of the battery case and the battery cover can range from about 2 mm to about 7.5 mm and can be any diameter between about 2 mm and about 7.5 mm. The length of the battery assembly can range from about 8 mm to about 90 mm and can be any length between about 8 mm and about 90 mm.
[0021] When the battery cover 14 is mated to battery case 12 , inside surface 34 of flange 36 abuts outside surface 38 of lip 40 and bottom surface 42 of flange 36 abuts ledge 44 of the battery case 12 . Lip 40 fits or protrudes within the groove 43 in battery cover 14 . Groove 43 has a substantially rectangular section 45 adjacent to a substantially triangular section 47 and within the groove. Lip 40 fits within substantially rectangular section 45 and may or may not extend to contact or abut the top surface 58 of groove. The outside surface 35 of groove 43 corresponds to the inside surface of flange 34 . Substantially triangular section 47 has a shape substantially that of a right triangle, for example, a 30-60-90 right triangle.
[0022] In this embodiment, the width A of the lip 40 is a width that extends from the diameter of case inner surface 49 to a point between case outer surface diameter 51 . Case outer surface diameter 51 is greater than case inner surface diameter and case inner surface diameter is less than case outer surface diameter. Ledge 44 has a width F that extends substantially horizontally from the outside surface 38 of lip 40 to the case outer surface diameter 51 .
[0023] Battery cover 14 has a width B, top surface 52 , bottom surface 54 and outside surface 56 . Groove 43 has a depth C that substantially corresponds to the height D of the lip 40 of the case. The width A of the lip 40 substantially corresponds to the width E of the substantially rectangular section 45 of the groove. The overall width H of the groove 43 as measured at the bottom surface 58 of cover is the sum of width H of the substantially rectangular section 45 of groove and the width I of the base of the substantially triangular section 47 . The width G of flange 36 substantially corresponds to the width F of ledge 44 . The width G of flange 36 extends from the outside surface 56 of cover 14 to the inside surface of flange 34 , which is also the outside surface 35 of groove 43 .
[0024] In this embodiment, the lip, flange, ledge, bottom surface and groove are annular (see FIGS. 8 and 9 ). Of course, the shape of these elements, and others described in this application, are dependent upon the overall shape of the battery case and the battery cover.
[0025] The battery cover can be mated to the battery case by mating the lip 40 of the case within the groove 43 of the cover. When the cover and the case are mated together, the bottom surface of the flange abuts the surface of the ledge and forms a joint 60 , referring to FIG. 1 . The battery cover 14 may be welded to the battery case 12 at the joint by known means for example, laser welding, either continuous or pulse.
[0026] Applicants have discovered that the welding of the battery cap and battery case disclosed in this application provides a weld zone having lower stress than a known design, discussed in more detail below.
[0027] A known design for a substantially cylindrical battery case 100 and cover 102 is shown in FIGS. 4 and 5 . In the design shown in FIGS. 4 and 5 , cover portion width 104 is designed to cooperatively fit inside the internal case width 106 . When fitted together, cover joint surface 108 and case joint surface 110 would abut and then be welded together at the seam formed by the two abutted surfaces. In this design, Applicants determined that high material stress was located within the weld zone. This phenomenon is shown in FIG. 6 .
[0028] FIG. 6 shows a depiction of cover 100 mated to case 102 of the known design depicted in FIGS. 4 and 5 . Weld zone 112 is shown covering the resulting weld joint 114 and surrounding area within a radius. Through finite element analysis (FEA), the highest stress found in the known design was found in localized area 116 when the battery assembly is loaded with an internal pressure. This localized area 116 of stress lies within or overlaps in the weld zone 112 .
[0029] FIG. 7 shows a depiction of battery cover 14 mated to battery case 12 of the design of the disclosure. Weld zone 48 is shown covering the resulting weld joint 50 and surrounding area within a radius. Through the same finite element analysis as described above, the highest stress found in the design disclosed in FIGS. 2 and 3 was found in localized area 52 . As can be seen, localized area 52 is outside of the weld zone 48 and is located where the material is less susceptible to cracking. Another advantage of the disclosed design is that the maximum stress is reduced because of less stress concentration.
[0030] In one aspect the disclosure provides a method including forming a case for an electrochemical cell, the case including a case outer surface having a diameter or x or y dimension, a case inner surface having a diameter or x or y dimension less than the diameter or x or y dimension of the case outer surface, a closed end, and an open end, the open end of the case having a lip and a ledge, the lip having a height and a width, the width of the lip extending from the case inner surface to a point between the diameter or x or y dimension of the inner and outer case surfaces, the ledge having a surface extending from the lip to the case outer surface, and forming a cover for attaching to the open end of the case, the cover including a cover outer diameter or x or y dimension, a groove extending inwardly from a bottom surface of the cover, a flange having a bottom surface and the flange having a width extending from the outer surface of the cover to the outer surface of the groove, the groove having a substantially rectangular section and may have a substantially triangular section, the rectangular section having an opening for receiving the lip of the case and the bottom surface of the flange formed to abut the surface of the ledge.
[0031] In another aspect, the disclosure provides an apparatus including a case for an electrochemical cell, the case including a case outer surface having a diameter or an x or y dimension, a case inner surface having a diameter or x or y dimension less than the diameter of the case outer surface, a closed end, and an open end, the open end of the case having a lip and a ledge, the lip having a height and a width, the width of the lip extending from the case inner surface to a point between the diameter of the inner and outer case surfaces, the ledge having a surface extending from the lip to the case outer surface and a cover for attaching to the open end of the case, the cover including a cover outer diameter or x or y dimension, a groove extending inwardly from a bottom surface of the cover, a flange having a bottom surface and the flange having a width extending from the outer surface of the cover to the outer surface of the groove, the groove having a substantially rectangular section, the rectangular section having an opening for receiving the lip of the case and the bottom surface of the flange formed to abut the surface of the ledge.
[0032] It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. Of note, the system components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Moreover, while certain embodiments or figures described herein may illustrate features not expressly indicated on other figures or embodiments, it is understood that the features and components of the system and devices disclosed herein are not necessarily exclusive of each other and may be included in a variety of different combinations or configurations without departing from the scope and spirit of the invention. A variety of modifications and variations are possible in light of the above teachings without departing from the scope and spirit of the invention, which is limited only by the following claims.
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An encasement for an electrochemical cell and method of making such encasement is discloses. The design of the encasement results in an encasement having an area of high stress located away from the weld zone area of the encasement, where the cover and the case are welded together.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to a capacitor of a semiconductor device and a method for manufacturing such capacitors that improves the reliability of processing yield and device operation by forming a plate electrode with p-type polysilicon layer and thereby preventing a write operation failure resulting from concentration of holes in the plate electrode terminal during a data write operation.
[0003] 2. Description of the Prior Art
[0004] Recently, it has become more difficult to form a capacitor with sufficient capacitance due to reductions in cell size resulting from increasingly high integration levels in semiconductor devices.
[0005] Particularly in Dynamic Random Access Memory ‘DRAM’ devices consisting of a MOS transistor and a capacitor, it is important to fabricate a capacitor, which typically occupies the majority of the space in each memory cell, that has a large capacitance but uses as little space as possible.
[0006] Currently, capacitors having a polysilicon conductor typically use an oxide film, a nitride film or stacked layers thereof, such as an oxide-nitride-oxide ‘ONO’ structure, as a dielectric layer.
[0007] In order to increase capacitance, determined by the equation:
(ε 0 ×ε r ×A)/T
[0008] (where ε 0 is the permittivity of free space, ε r is the dielectric constant of the dielectric film, A is the surface area of the capacitor, and T is the thickness of the dielectric film), the general practice has been to use dielectric materials with a high dielectric constant, reduce the thickness of dielectric film; and/or increase the effective surface area of the capacitor.
[0009] However, each of these methods has problems. First, it is difficult to implement a device using a dielectric with a high dielectric constant such as Ta 2 O 5 , TiO 2 , or SrTiO 3 to production devices since the reliability and the characteristics of the thin film, such as a junction breakdown voltage of Ta 2 O 5 , TiO 2 , or SrTiO 3 are not reliably known. The method of reducing the thickness of a dielectric film has a problem of deteriorating the reliability of a capacitor since the dielectric film is more easily destroyed during the device operation.
[0010] In order to increase a surface area of the capacitor, capacitors have been formed as multilayer structures of polysilicon layers that are penetrated and connected to act as fin structures or by forming a storage electrode in the shape of an open cylinder in the upper part of contact. However, if the height of a capacitor is increased, subsequent processing becomes difficult due to the stepped topography and obtaining high capacitance becomes difficult due to the decreased surface area of the device available to form such structures in highly integrated DRAMs.
[0011] A design in which the number of cells is more than twice that of the conventional cells per bit line has been used to increase the capacitance of cell capacitor in order to improve cell efficiency. However, since the available surface area for a capacitor is decreased, conventional fin or cylinder type capacitors typically attempt to increase the effective surface area by increasing the height of a capacitor, decreasing the gap between storage electrodes, or using hemispherical grain ‘HSG’ silicon.
SUMMARY OF THE INVENTION
[0012] The present invention overcomes the above-mentioned problems of the prior art and provides a capacitor for semiconductor devices and method of manufacturing such capacitors that improves the operational characteristics of the resulting devices, by making holes the main carriers and concentrating them at the ends of the plate electrodes, thereby preventing decreased capacitance when 0V is applied to a storage electrode and +V cc /2 to a plate electrode during a “0” data write.
[0013] The present invention is also characterized in forming the p-type polysilicon layer by one of a variety of doping methods including doping an initially undoped polysilicon layer by ion-implanting B or BF 2 ; by making B 2 H 6 , BF 3 or BCl 3 react with O 2 to form a B-doped oxide on the polysilicon layer and then diffusing B from the oxide into a polysilicon layer; by coating and diffusing liquid source BBr 3 or (CH 2 O) 3 B; or by making B 2 H 6 , BF 3 or BCl 3 react with SiH 4 or Si 2 H 6 in a CVD chamber to produce B-doped polysilicon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The objects and aspects of the present invention will become apparent from the following description of embodiments with reference to the accompanying drawings in which:
[0015] [0015]FIG. 1 a is a cross-sectional view illustrating a conventional method of forming an electrode of a capacitor.
[0016] FIG 1 b is a cross-sectional view illustrating another conventional method of forming an electrode of a capacitor.
[0017] [0017]FIGS. 2 a and 2 b are cross-sectional views illustrating depletion and accumulation states in the conventional capacitor.
[0018] [0018]FIG. 3 is a cross-sectional view illustrating a “1” data write operation of a conventional capacitor.
[0019] [0019]FIG. 4 is a cross-sectional view illustrating a “0” data write operation of a conventional capacitor.
[0020] [0020]FIG. 5 is a graph illustrating capacitance according to a bias voltage of the conventional capacitor.
[0021] [0021]FIG. 6 is a cross-sectional view illustrating a capacitor in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Generally, a storage electrode and a plate electrode are formed of an n-typed polysilicon layer doped with phosphorus ‘P’.
[0023] [0023]FIG. 1 a is cross-sectional view illustrating a conventional capacitor electrode and FIG. 1 b is a cross-sectional view illustrating another conventional capacitor electrode. FIG. 2 a and FIG. 2 b are cross-sectional views illustrating depletion and accumulation phenomena of the conventional capacitor.
[0024] [0024]FIG. 1 a is a conventional method of forming an electrode of a capacitor. A undoped polysilicon layer 10 is formed and then a P 2 O 5 film 12 is formed on the polysilicon layer 10 by exposing the polysilicon layer 10 to a gaseous doping source in a diffusion chamber. P of the P 2 O 5 film is diffused into the polysilicon layer, forming an n-typed polysilicon layers, and then the P 2 O 5 12 is removed.
[0025] Here, a gas mixture of POCl 3 and O 2 is used as the doping source.
[0026] [0026]FIG. 1 b illustrates another conventional method of forming an electrode of a capacitor. By performing Chemical Vapor Deposition process using a gas mixture of either SiH 4 and PH 3 or Si 2 H 6 and PH 3 or a combination thereof, a P-doped polysilicon layer 14 is formed.
[0027] As shown in FIG. 2 a , an electrode of a capacitor 20 formed by the conventional method comprises a storage electrode 22 which is an n-type polysilicon layer, the main carrier of which is an electron, a plate electrode 24 separated by a dielectric film 26 . When a positive (+) voltage is applied to the storage electrode 22 , a depletion of the main carrier occurs and a depletion region 28 is formed. Also, as shown in FIG. 2 b , when a positive voltage is applied to the plate electrode 24 , an electron accumulation occurs and an accumulation region 30 is formed.
[0028] These characteristics of an operation of a capacitor are as follows: FIG. 3 is a cross-sectional view illustrating a “1” data write operation of the conventional capacitor, FIG. 4 is a cross-sectional view illustrating a “0” data write operation, and FIG. 5 is a capacitance graph in accordance with a bias voltage of the conventional capacitor.
[0029] First, when storing a data “1” in a capacitor 20 , 0V is applied to a storage electrode 22 and—V ss /2 to a plate electrode 24 , and, as shown in FIG. 3, more depletion occurs closer to the interface of the storage electrode 22 and the dielectric 26 . When storing a data “0” in the capacitor 20 , 0V is applied to the storage electrode 22 and +V cc /2 to the plate electrode 24 . As a result, as shown in FIG. 4, a depletion region 28 is formed close to the interface of the plate electrode 24 with the dielectric 26 .
[0030] As described above, when the impurity concentration is not fully saturated, the depletion phenomenon is intensified as the voltages applied to electrodes increase in electrodes of capacitor formed by the conventional method. As shown in FIG. 5, when the amount of the impurity dose is small, the desired capacitance of approximately 25 fF cannot be obtained and write operation failures occur. There is a limit in increasing the amount of doping in order to prevent the depletions mentioned above.
[0031] Because the lower storage electrode is formed with a higher aspect ratio during manufacturing process of plate electrodes, phosphorus, with its relatively lower turnover rate compared to Si, cannot move fully into the inside of the electrode, thereby decreasing doping concentration of electrodes actually formed.
[0032] The problem described above cannot be overcome since the aspect ratio increases are necessary to maintain capacitance as devices become smaller and the distance between storage electrodes decreases.
[0033] Hereafter, a capacitor of a semiconductor device and manufacturing method for the same will be explained in detail referring to the attached drawings.
[0034] [0034]FIG. 6 is a cross-sectional view of a capacitor formed in accordance with the present invention. A capacitor comprises a storage electrode 42 formed of an n-type polysilicon layer, a plate electrode 44 formed of a p-type polysilicon layer separated by a dielectric film 46 .
[0035] Since the main carriers of plate electrode 44 are holes as a result of forming plate electrode 44 of the capacitor 40 from a p-type polysilicon layer, holes are concentrated on the ends of the plate electrode and a capacitance does not decrease when 0V is applied to a storage electrode and +V cc /2 to a plate electrode during the write operation of data “0” write to the capacitor. As a result, the reliability of “0” data write operation is improved.
[0036] The p-type polysilicon layer is formed by doping B on a undoped polysilicon layer through ex-situ or in-situ methods.
[0037] As an example of ex-situ method, there is provided a first method of ion-implanting B or BF 2 after forming an undoped polysilicon layer.
[0038] There is provided a second method of forming an oxide film doped with B on the surface of the polysilicon layer by reacting B 2 H 6 , BF 3 or BCl 3 with O 2 , and then diffusing B from oxide film into the polysilicon layer.
[0039] There is provided a third method for coating a liquid source such as BBr 3 or (CH 2 O) 3 B on the surface of a undoped polysilicon layer and then diffusing B into the polysilicon layer.
[0040] Also, there is provided an in-situ method of forming a p-type polysilicon layer doped with B by reacting B 2 H 6 , BF 3 or BCl 3 with SiH 4 or Si 2 H 6 in a CVD device.
[0041] As is apparent from the above description, in accordance with the present invention, a capacitor of a semiconductor device and manufacturing method for the same is provided by forming a plate electrode from a B-doped polysilicon layer, applying 0V to a storage electrode and +V cc /2 to a plate electrode when “0” data is written, thereby preventing holes, which are the main carriers in the plate electrode, from being concentrated on the ends of plate electrode. Accordingly, it is possible to prevent the degradation of capacitance, and improve processing yield, and improve the reliability of device operation.
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The present invention generally relates to a capacitor of a semiconductor device and a method of manufacturing such capacitors that improve the processing yield and the reliability of device operation by forming the plate electrode from a p-type polysilicon, thereby improving device resistance to write operation failures resulting from concentration of holes in the plate electrode terminal during a data write operation.
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This application is a division of application Ser. No. 965,901, filed Dec. 14, 1978, now U.S. Pat. No. 4,272,245 issued June 9, 1981.
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for measuring a chemical characteristic of a liquid. More particularly, it relates to a method and apparatus for measuring the pH value of a blood sample.
The pH value of blood is a frequently measured physiological parameter which provides an indication of proper acid-base balance and blood-gas exchange through the lungs. In the field of obstetrics, such a test is often made if there are indications of fetal distress during labor which may be caused by the fetus not receiving sufficient oxygen from the mother through the placenta. In such cases, a blood sample is taken by making a small incision on the fetal scalp and placing a capillary tube in the proximity of the incision whereby the blood is drawn up into the interior portions of the tube through capillary action. The standard clinical device for measuring blood pH is the blood-gas analyzer such as the pH Blood Gas System and Supply manufactured by Corning Medical Corporation. Such analyzers require the transfer of the blood sample from the capillary tube to a receptacle in the instrument. As is known in the art, if any ambient air mixes with the blood sample, the pH value will change. Hence, there is a good possibility of contaminating the blood sample during the transfer from the original collecting device to the instrument. Moreover, since such analyzers are complex and costly devices, they are typically located only in the hospital lab where they need to be operated by a skilled technician. As a result, there is often considerable delay between the time of taking the blood sample until the results from the lab are received. Of course, such delays are undesirable in emergency situations.
U.S. Pat. Nos. 3,911,901 to Niedrach et al, 3,049,118 to Arthur et al, and 3,399,667 to Nishimoto et al disclose representative devices for measuring the pH value of blood samples. However, they have all been relatively complex and costly to manufacture. Moreover, their use has been limited to trained personnel. Furthermore, none of them have permitted direct pH measurement from the same device which collected the blood sample. Another drawback in many of the prior art devices is that they required large quantities of the liquid to be tested. Unfortunately, it is often difficult to readily obtain sizable samples.
OBJECTS AND SUMMARY OF THE INVENTION
Therefore, it is the primary object of this invention to provide a method and apparatus for measuring the chemical characteristics of a liquid, such as the pH value of a blood sample, in which the measurement is taken from the liquid in the same device in which it was collected.
It is another object of this invention to permit such measurements to be taken from a relatively small sample quantity.
It is a further object of this invention to provide a method and apparatus for inexpensively accomplishing the above objective without necessitating the use of trained personnel.
According to the broadest aspect of this invention, the chemical characteristic measurement is taken by first calibrating the test apparatus by measuring the electrical potential established when an indicating and reference electrode are immersed in a solution. It is a feature of this invention that the solution provides a two-fold purpose: first, to calibrate the electrodes and secondly, to provide an electrolytic bridge between the liquid sample and the reference electrode. After calibration, the liquid sample is brought into contact with the indicating electrode. According to another aspect of this invention, the device is designed so that the sample is introduced in such a manner so as to remove the solution which would otherwise be contacting the indicating electrode. The solution does, however, remain in the device and provides an electrolytic bridge from the liquid sample to the reference electrode. Accordingly, the potential thus established, when compared to the previously taken calibration factor, provides an accurate indication of the chemical characteristic of the liquid sample. This technique can be utilized by relatively inexperienced personnel, does not require large quantities of the liquid sample, and may be embodied in inexpensive apparatus which may be disposable.
In one embodiment of this invention, the sample is collected in a capillary tube. The open end of the capillary tube containing the sample is placed over one end of the indicating electrode immersed in the electrolyte solution along with the spaced reference electrode. A disposable cassette is provided for housing the two electrodes. The indicating electrode is disposed in a guide channel for positioning the end of the capillary tube over the indicating electrode. Preferably, means are provided for introducing the electrolyte solution into the cassette to cover both electrodes whereby a first calibrating potential is established therebetween. When the capillary tube is placed over the indicating electrode, the liquid sample displaces the solution so that a subsequently taken measurement is derived from the half-cell potential between the sample and indicating electrode due to the chemical characteristic of the sample. The solution is buffered near the expected pH value of the liquid and further provides a stable electrochemical environment for the reference electrode.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention will become more apparent upon reading the following specification and by reference to the drawings in which:
FIG. 1 is a top plan view of one embodiment of the apparatus for this invention;
FIG. 2 is a cross-sectional view along the lines 2--2 of FIG. 1;
FIG. 3 is a view of the apparatus shown in FIG. 2 illustrating one manner of introducing the electrolyte into the apparatus;
FIG. 4 is a view similar to FIG. 3 which illustrates the capillary tube being placed over the indicating electrode;
FIG. 5 is an enlarged partial cross-sectional view of FIG. 4 illustrating the capillary tube-indicating electrode engagement;
FIG. 6 is a cross-sectional view illustrating another embodiment of the apparatus of this invention; and
FIG. 7 is an exploded cross-sectional view of still another embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, there is shown a box-like cassette 10 which is preferably made of plastic. Cassette 10, in this embodiment, includes two longitudinally extended channels 12 and 14, which terminate at one end in openings 16 and 18, respectively, at top cover 20. Bottom portions of channels 12 and 14 are connected by a transverse bridging chamber 22.
An indicating electrode 24 is centrally disposed along the major longitudinal axis of channel 12 and projects from the bottom portion of chamber 22 upwardly into the confines of channel 12. Indicating electrode 24, according to one aspect of this invention, is a stainless steel rod which is made by first coating the outer surface thereof with an insulating resin 25 such as EPOXYLITE's No. 6001-M Electrode Insulator solution which may be applied and cured according to manufacturer's specifications. The tip of the rod is then polished by known methods such as with a grinding wheel to remove resin therefrom. The upper portion of the rod is then placed into an electrolytic solution containing antimony and a potential is established between the rod and the electrolyte. Since only the exposed tip is conductive, a layer (see FIG. 5) of antimony is electroplated only onto the tip 26 of the rod serving as indicator electrode 24.
In this embodiment, lower portions of the rod are press fit into a conductive connector 28 to provide electrical connection to external circuitry. In order to provide better electrical contact between electrode 24 and connector 28, the insulating resin 25 is removed from lower portions of electrode 24 at the mating interface with connector 28. Alternatively, the electrodes may be mounted in their respective connectors prior to the above described electroplating procedure Accordingly, the tip 26 of indicating electrode 24 is disposed within confines of guide channel 12 and provides the only chemically reactive portion of electrode 24. As will become more apparent later herein, the diameter of guide channel 12 is slightly larger than the outside diameter of the well-known capillary tubes used to take blood samples. The diameter of electrode 24 is slightly smaller than the inside diameter of the capillary tube. For a capillary tube having an outside diameter of 1.5 mm and an inside diameter of 1.1 mm, the diameter of guide tube 12 may be about 1.6 mm whereas the diameter of electrode 24 may be about 0.25 mm. It should be noted that these dimensions are given merely for illustrative purposes and that no limitation is intended thereby.
A reference electrode 30 similarly has a tip portion 32 disposed in channel 14 and lower portions thereof coupled to a connector 34. Reference electrode 30 can be made of a variety of metal-metal salt materials which develop a stable half-cell potential when immersed in an electrolyte. Preferably, reference electrode 30 is a silver wire having a silver-chloride coating. Such electrodes are well known in the art. In the embodiment shown in FIGS. 1-5, reference electrode 30 is a rigid structure having a pointed tip 32.
A capsule 36 having a breakable membrane is disposed in channel 14 above tip 32 of reference electrode 30. In accordance with this preferred embodiment, capsule 36 contains a sufficient amount of electrolyte 38 to cover electrodes 24 and 30 when the membrane is broken as shown in FIG. 3. As shown in FIG. 3, capsule 36 may be broken by pushing a rod 42 against a slidable stopper 40 which, in turn, urges capsule 36 against electrode tip 32 to break the capsule membrane and introduce the electrolyte 38 into interior portions of the cassette 10. Other means for immersing electrodes 24 and 30 in the electrolyte 38 can be readily envisioned. For example, FIG. 6 shows an alternative embodiment for cassette 10 in which common reference numerals are utilized to identify common elements. In this alternative embodiment, a flexible pouch 42 contains electrolyte 38. A one-way valve flap 44 interfaces channel 14 with pouch 42 in such a way that upon squeezing pouch 42, the electrolyte 38 flows into channel 12, 14 and chamber 22 to cover electrodes 24 and 30. It should be noted that in this embodiment, reference electrode 30 need not be rigid since it is not needed to puncture capsule 36 shown in the previous embodiment.
FIG. 7 illustrates still another embodiment where socket 80 coupled to suitable electronic measurement equipment 82 includes a rod 84 which presses upwardly on piston 86 when cassette 10 is inserted thereon with pins 88 and 90 engaging connectors 34 and 28, respectively. The solution 38 is contained in a chamber 92 above piston 86 such that upon placement of cassette 10 on socket 80, piston 86 causes the solution 38 to break membrane 94 and cover electrodes 24 and 30. In this embodiment, guide channel 12 includes a relief 96 which conforms to the connector portion of a syringe (not shown) which may be used as an alternate source of supplying the liquid sample. The embodiment of FIG. 7 also includes an overflow chamber 98 coupled to chamber 22 and includes an air vent 100 to equalize the pressures within cassette 10.
According to still another aspect of this invention, the electrolyte 38 is buffered at a pH value near the middle of the physiological range. Furthermore, electrolyte 38 includes substantially the same reactant ion concentration that is about the same as that of the liquid to be tested. In this embodiment, where the reference electrode 30 is a silver/silver-chloride mixture, the reactant ions are chloride ions. The reactant ions are those ions which develop the half-cell potential with the reference electrode. As will be more fully understood herein, diffusion of the reactant ions in the sample under test is prevented from reaching the reference electrode which may, in turn, disturb the accuracy of the measurement. Where the liquid under test is blood, electrolyte 38 is preferably an aqueous solution of tris (hydroxymethyl) aminomethane (CH 2 OH) 3 CNH 2 , hydrochloric acid and sodium chloride. The tris is available from a variety of chemical manufacturers and is known in the art. The electrolyte 38 may be prepared by providing a 0.1 Normal tris solution by dissolving 121.14 mg of the tris in 1,000 ml of distilled water. A 0.01 Normal solution of hydrochloric acid is prepared by diluting 10 ml of 1.0 Normal hydrochloric acid with 1,000 ml of distilled water. In repairing the electrolyte, the tris and hydrochloric acid solution may be mixed together in varying quantities according to the following table to provide a buffer solution pH value between 7 and 9.
TABLE I______________________________________pH/25° C. Tris, 0.1 N HCl .01 N______________________________________7.00 50.0 ml 46.6 ml7.10 50.0 45.77.20 50.0 44.77.30 50.0 43.77.40 50.0 42.07.50 50.0 40.37.60 50.0 38.57.70 50.0 36.67.80 50.0 34.57.90 50.0 32.08.00 50.0 29.28.10 50.0 26.28.20 50.0 22.98.30 50.0 19.98.40 50.0 17.28.50 50.0 14.78.60 50.0 12.18.70 50.0 10.38.80 50.0 8.58.90 50.0 7.09.0 50.0 5.7______________________________________
Consequently a buffer solution having an approximate 10/1 to 1/1 ratio of tris to hydrochloric acid has been found to provide pH value of between 7 and 9. Preferably, the buffer solution should have a pH value between 7.2 and 7.5, more specifically about 7.3, which correlates to the normally encountered pH values of blood.
Sodium chloride is then added to the buffer solution in order to supply a chloride ion concentration substantially the same as that found in human blood, that being approximately 103 milliequivalents meq. It has been found that about 252 mg of sodium chloride per 100 ml of the buffer solution should provide the desired 103 meq chloride ion concentration for a 7.30 pH solution. It is understood, however, that these numbers are only by way of a specified example and should not be construed as limiting. For example, the quantity of sodium chloride depends upon the quantity of HCl used to determine the pH of the solution.
It should be noted that variations of the above example will become apparent to one skilled in the art depending for example, upon the electrode materials utilized and the liquid to be tested. According to the teachings of this invention, to the extent the liquid to be measured contains an ion that may react with the reference electrode, and thus produce an erroneous reading of the property to be measured, electrolyte 38 should have a concentration of that reactive ion substantially the same as that contained by the liquid to prevent migration of the liquid's reactive ions to the reference electrode such that the reference measurement is unaffected by the reactive ion. Specifically, with relationship to the preferred embodiment, the chloride ion concentration should be substantially the same as that of blood. The pH value of the electrolyte should closely approximate that of the liquid under test. Preferably, the pH value of the electrolyte 38 should be approximately between 7 and 9, and more specifically, between 7.2 and 7.5, when the liquid under test is blood. However, it is important that the pH value of electrolyte 38, whatever it is, be stable since it is used as a constant in the test liquid measurement as will now be described.
According to the method of this invention, electrolyte 38 is introduced into cassette 10 to cover both indicating electrode 24 and reference electrode 30. This can be accomplished, for example, as shown in FIG. 3 by pressing capsule against electrode 30 to burst the capsule 36 containing electrolyte 38. Alternatively, as shown in FIG. 6 pouch 42 can be squeezed to force electrolyte 38 into interior portions of the cassette 10 containing electrodes 24 and 30. As shown in the embodiment of FIG. 7, the electrolyte 38 is introduced when cassette 10 is placed on socket 80. It should be noted that while it is a feature of this invention that electrolyte 38 is self-contained with cassette 10, the electrolyte can be introduced by other external means.
A calibration potential is thus established between electrodes 24 and 30. As is known in the art, the potential difference between these electrodes is due to the two half-cell EMF's established between the indicating electrode 24 and electrolyte 38, and the reference electrode 30 and the electrolyte 38. This potential can be measured by straight forward electronic techniques by coupling connectors 28 and 34 to the external measuring circuitry 82. Preferably, the circuitry first measures the output potential and makes two calibrating checks. First, it makes sure that the potential is within predetermined high-low limits. Secondly, it checks the rate of drift of the potential measurement and insures that it is below a certain drift factor. Then, it solves the following equation for C:
V=K[pH]+C
Where:
V is the measured potential;
pH is the known pH value of electrolyte 38;
K is a constant associated with the electrode sensitivity; and
C is a calibration constant.
The calculated value of C is then stored, for example, in a known random access memory (RAM), for later retrieval purposes. It should be noted that this invention only requires a single-point calibration of the electrodes since electrolyte 38 is buffered at the middle of the most critical region in which the device operates and the expected range of chemical values from the test liquid is relatively narrow. However, a two-point calibration can be made, if desired, depending on the test liquid to account for different electrode sensitivites. However, where the apparatus of the present invention is utilized to measure the pH of blood, only the single-point technique is required which measures the offset potential difference between the electrodes utilized.
In the embodiments of FIGS. 1-6, capillary tube 50 which has previously collected blood sample 52 in its bore 54, is then placed in guide channel 12 via opening 16. Capillary tube 50 may include a wax-like stopper 56 on its upper portion to close one end of tube 50 in order to maintain blood 52 in bore 54 as is known in the art. Tube 50 is then slid along guide tube 12 until tip 26 of indicating electrode 24 protrudes into tube bore 54 to engage the blood 52 therein as can be seen in FIGS. 4 and 5. As can be seen most clearly in FIG. 5, the relative dimensions of guide tube 12 and electrode 24 with respect to tube 50 automatically centers tube 50 in channel 12 to provide unobstructed engagement with tip 26 of electrode 24. When tube 50 slides over electrode 24, the electrolyte 38 is displaced so that only blood 52 contacts the chemically active tip 26 of electrode 24. Consequently, a new half-cell potential is established between electrode 24 and blood 52. However, the same half-cell potential remains at the interface between reference electrode 30 and electrolyte 38. In the embodiment of FIG. 7, the connector of the syringe is seated on relief 96 and the blood in the syringe is forced into channel 12, thereby displacing the electrolyte 38 from indicating electrode tip 26.
It can now be understood that by providing the same chloride concentration in electrolyte 38 as that of blood 52, the migration of the chloride ions in blood 52 to reference electrode 30 is prevented which might disturb the original half-cell potential which was used to provide the calibration potential. Accordingly, the same electrolyte 38 can be used as both a calibrating solution and as a bridge between blood 52 and reference electrode 30 during the pH measurement. This measurement is accomplished by again sensing the electrical potential between electrodes 24 and 30. Since the calibration constant C was calculated in the prior calibration measurement, the pH value of the blood 52 can be calculated by solving for pH in the equation set forth above. The electronics in measuring apparatus 82 can be conventionally set up to retrieve the value of C previously stored in the memory and insert it into the equation, with the apparatus solving for the value of pH using well known techniques. The cassette 10 may remain on socket 82 during both the calibration step and pH measurement step. The operator may merely push a button (not shown) which causes the calculation of C, subsequently introduce the blood into cassette 10, and thereafter press another button (not shown) to take the pH measurement of the sample. The sensed pH value can then be displayed by suitable devices in the measuring equipment 82.
It is now readily apparent that the present invention provideds a relatively inexpensive means by which chemical characteristics of a liquid can be measured. The cassette 10, including electrodes 24 and 30, can be inexpensively manufactured so that it may be disposable. Moreover, the tests can be accomplished by relatively inexperienced personnel. Even more importantly, since the measurement is taken from the same device in which the sample is collected, the possibility of contamination is greatly decreased. Equally important is that the present invention provides a device which is capable of providing these measurements from extremely small sample sizes. It should be understood that obvious modifications to the unique concepts described herein may become apparent to one skilled in the art. Therefore, while this invention has been described in connection with particular examples thereof, no limitation is intended thereby except that as defined in the following claims.
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A method and apparatus for measuring a chemical characteristic of a liquid such as its hydrogen ion activity or pH value. A disposable cassette having a reference and indicating electrode therein utilizes the same solution to first calibrate the device and then as an electrolytic bridge from the liquid sample to the reference electrode. The solution has the properties of a buffered pH and also provides a stable electrochemical environment around the reference electrode. In one embodiment, a volume of a liquid sample is placed into a capillary tube and the open end of the tube is then placed over the indicating electrode immersed in the solution. The electrical potential between the indicating electrode and the spaced reference electrode in the electrolyte solution provides a measurement of the pH value of the liquid when compared to the calibration potential previously measured without the liquid sample contacting the indicating electrode.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to aliphatic dinitriles, and more particularly to aromatic-aliphatic dinitriles containing no hydrogen atoms alpha to the cyano groups.
2. Description of the Prior Art
Neopentyl diamine is known and polyamides have been made from this diamine.
SUMMARY OF THE INVENTION
There have now been discovered aromatic-aliphatic dinitriles of the formula ##STR2## where Ar is an arylene selected from the group consisting of 1,2-phenylenes, 1,3-phenylenes, 1,4-phenylenes, 2,2'-biphenylenes, 3,3'-biphenylenes, 4,4'-biphenylenes, 4,4'-phenyleneoxyphenylenes, 4,4'-phenylenemethylenephenylenes and 2,6-naphthylenes, said arylene being unsubstituted or substituted with halo, lower alkyl or phenyl. These dinitriles are useful for the preparation of the corresponding diamines which are intermediates for the preparation of thermally stable, rigid polyamides.
The term "halo" is intended to include chloro, bromo, fluoro and iodo. The term "lower alkyl" is intended to include alkyls of 1 to 6 carbon atoms. The substituted phenylene may have 1 to 4 of the specified substituents, the substituted biphenylene and phenyleneoxyphenylene may have 1 to 8 of these substituents, the substituted phenylenemethylenephenylene may have 1 to 10 of these substituents, and the substituted naphthylene may have 1 to 6 of these substituents. The term "rigid" is used in conjunction with polymers to denote the presence of a sufficient quantity of aromatic rings in the backbone of the polymer to provide stiffness.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The dinitriles of this invention are prepared by reacting the lithium salt of isobutyronitrile, generated in situ, with an α,α'-dihaloaromatic compound of the formula
X--CH.sub.2 --Ar--CH.sub.2 --X
in which Ar is arylene as defined above, and X is Br or Cl at a temperature low enough to prevent the undesired decomposition of the lithium salt, e.g., in the range of -50° to -100° C., in a medium which at the appropriate temperature is a satisfactory solvent for both the lithium salt and the α,α'-dihaloaromatic compound, and under an inert dry atmosphere, e.g., nitrogen, helium, argon and the like, according to the following equation: ##STR3## The solvent must also be nonreactive with the lithium salt, and its progenitors, e.g., it must be nonprotic. Ethers, especially cyclic ethers, e.g., tetrahydrofuran, are preferred solvents.
The lithium salt is generated in the reaction medium at the appropriate temperature by first reacting a hindered secondary amine, such as diisopropylamine, with a lower alkyllithium, such as n-butyllithium, to bring about the formation of the lithium salt of the hindered secondary amine, followed by addition of anhydrous isobutyronitrile. After allowing an appropriate time for the reaction to take place at the prescribed temperature, e.g., at least several hours, the reaction mixture is allowed to warm to room temperature, and the product is isolated and purified by conventional methods.
The arylene groups embraced in the definition of Ar above are readily obtained by selection of the α,α'-dihaloaromatic compound. For example, suitable compounds include:
α,α'-dibromo-m-xylene
α,α'-dibromo-p-xylene
α,α'-dibromo-o-xylene
α,α'-dichloro-m-xylene
α,α'-dibromo-2-chloro-p-xylene
α,α'-dibromo-2-methyl-p-xylene
α,α,-2-tribromo-p-xylene
3,6-bis(chloromethyl)durene
2,2'-bis(bromomethyl)biphenyl
2,2'-bis(chloromethyl)biphenyl
4,4'-bis(bromomethyl)-3,3'-difluorobiphenyl
3,3'-dichloro-4,4'-bis(bromomethyl)biphenyl
3-chloro-4,4'-bis(bromomethyl)biphenyl
2,6-bis(bromomethyl)naphthalene
2,6-bis(chloromethyl)naphthalene
1,5-dichloro-2,6-bis(bromomethyl)naphthalene
1-chloro-2,6-bis(bromomethyl)naphthalene
3,3'-bis(bromomethyl)biphenyl
4,4'-bis(bromomethyl)biphenyl
4,4'-bis(chloromethyl)biphenyl
4,4'-bis(bromomethyl)diphenyl oxide
4,4'-bis(chloromethyl)diphenyl oxide
4,4'-bis(bromomethyl)diphenylmethane
4,4'-bis(chloromethyl)diphenylmethane
and the like.
The diamines corresponding to the dinitriles of this invention are prepared by heating the dinitrile with a dialkylaluminum hydride, preferably diisobutylaluminum hydride, for several hours in an inert anhydrous nonprotic solvent, e.g., a hydrocarbon and preferably an aromatic hydrocarbon, at a temperature sufficiently elevated above room temperature so that the reaction occurs at a convenient rate, e.g., 120° C., under a dry inert atmosphere, e.g., nitrogen, argon, helium and the like. After the reaction period is over, the intermediate aluminum salts are hydrolyzed by the gradual addition of a solution of water in a lower aliphatic alcohol, e.g., methanol. The following equations presumably represent the steps involved. ##STR4## The by-product hydrated aluminum oxide is removed by filtration and the desired diamine is isolated and purified by conventional means.
The polyamides are prepared by reacting the diamines with either acid chlorides of dibasic acids in the presence of an acid acceptor, or with diphenyl esters of dibasic acids. With the acid chlorides of aliphatic dibasic acids, e.g., sebacyl chloride, ##STR5## a convenient method for preparing the polyamides comprises a solution polymerization in which a solution of the acid chloride in an inert nonprotic solvent, e.g., chloroform, carbon tetrachloride, and the like, is added quickly to a stirred solution of the diamine and a tertiary amine, e.g., triethylamine, as the acid acceptor, in the same solvent. These condensation polymerizations are usually carried out at ambient temperature, but higher or lower temperatures are also satisfactory. The isolation of the product usually involves the addition of a nonsolvent for the polymer, followed by thorough washing of the polymer in water. These procedures are discussed by P. W. Morgan in "Condensation Polymers by Interfacial and Solution Methods" Wiley, 1965.
A convenient method for the preparation of polyamides from the acid chlorides of aromatic dibasic acids, e.g., terephthaloyl chloride, involves an interfacial polymerization technique in which the diamine is dispersed in a rapidly stirred mixture of water, an inert water-immiscible solvent, e.g., chloroform, carbon tetrachloride and the like, a dispersing agent, e.g., sodium lauryl sulfate, and a water soluble acid acceptor, e.g., sodium carbonate. The acid chloride, dissolved in the same inert, water-immiscible solvent, is then added rapidly. Such procedures and the methods for isolating and purifying the products are also described by P. W. Morgan in the reference noted above.
Suitable acid chlorides of dibasic acids for reacting with the diamines to prepare the polyamides include:
adipyl dichloride
sebacyl dichloride
malonyl dichloride
isophthaloyl dichloride
terephthaloyl dichloride
chloroterephthaloyl dichloride
methylterephthaloyl dichloride
ethylterephthaloyl dichloride
5-tert-butylisophthaloyl dichloride
tetrafluoroterephthaloyl dichloride
tetrachloroterephthaloyl dichloride
tetrabromoterephthaloyl dichloride
tetraiodoterephthaloyl dichloride
tetramethylterephthaloyl dichloride
2,5-diphenylterephthaloyl dichloride
4,4'-biphenyldicarbonyl dichloride
2,2',3,3',5,5',6,6'-octafluoro-4,4'-biphenyldicarbonyl dichloride
2,2'-dibromo-4,4'-biphenyldicarbonyl dichloride
2,2',6,6'-tetrachloro-4,4'-biphenyldicarbonyl dichloride
2,2'-diiodo-4,4'-biphenyldicarbonyl dichloride
2,2'-dimethyl-4,4'-biphenyldicarbonyl dichloride
4,4'-oxydibenzoyl dichloride
3,3'-dimethyl-4,4'-oxydibenzoyl dichloride
2,6-naphthalenedicarbonyl dichloride
1,3,4,5,7,8-hexachloro-2,6-naphthalenedicarbonyl dichloride
1,4-cyclohexanedicarbonyl dichloride
1-methyl-2,3-cyclobutanedicarbonyl dichloride
bis(4-chlorocarbonylphenyl)methane
bis(4-chlorocarbonylphenyl)dichloromethane
2,2'-bis(4-chlorocarbonylphenyl)propane
and the like.
To prepare polyamides by reactions of the diamines with diphenyl esters, it is only necessary to intimately mix the diamine and the diphenyl ester in a suitable vessel and then apply heat so that an exchange reaction occurs with the expulsion of phenol: ##STR6## At temperatures of about 200° C. and higher the reaction occurs at a convenient rate, and is completed in a few hours. The temperature can be raised in the later portion of the reaction period to facilitate the driving off of by-product phenol. The removal of phenol is also facilitated by evacuation of the reaction vessel, e.g., with an oil pump. When the reaction is completed, the polymer is isolated and purified by conventional methods. Exchange reactions for the preparation of polyamides from diamines and the aryl esters of dibasic acids are described in "Encyclopedia of Polymer Science and Technology", Vol. 10, pg. 487, Wiley, 1969. The diphenyl esters corresponding to the diacid chlorides listed above may be used in this exchange reaction with the diamines to prepare the polyamides.
Because the dinitriles of this invention are free of hydrogen atoms alpha to the cyano groups, the polyamides, prepared from the corresponding diamines are much superior in thermal stability to the corresponding polyamides having hydrogen atoms beta to nitrogen. This is particularly advantageous in melt processing these polyamides, for example, in melt spinning of fibers. The most thermally stable of these polyamides, and therefore a preferred group, are the polyamides derived from aromatic diacids.
EXAMPLES OF THE INVENTION
The following examples illustrate the novel dinitriles of this invention and their utility for preparing useful polyamides. In these examples parts are by weight unless otherwise indicated, and all temperatures are expressed in degrees Centigrade. All equipment was dried in an oven at 135° before assembly and flushed with dry nitrogen after assembly. Weighing and handling of all the diamines was carried out in a nitrogen dry box. The alcohol used in these examples was 95% ethanol denatured with benzene.
EXAMPLE 1
1,4-Bis(2-methyl-2-cyanopropyl)benzene ##STR7##
In a 2-liter flask, equipped with a magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, a dropping funnel, and a syringe adapter, was placed 900 ml of anhydrous tetrahydrofuran (THF) and 42 ml (30.32 g, 0.30 M) of diisopropylamine (via syringe). The stirred mixture was cooled in a dry ice-acetone bath, and then 138.6 ml of 2.17 N (0.30 M) n-butyllithium in hexane was added via syringe. After the mixture had stirred for 1 hr, a solution of 20.52 g (0.297 M) of freshly distilled isobutyronitrile in 60 ml of anhydrous THF was added in 20 minutes. Following an additional 1 hr and 7 min. of stirring at dry ice temperature, a solution of 39.57 g (0.150 M) of α,α'-dibromo-p-xylene in 450 ml of anhydrous THF was added in 1 hr 23 min. The mixture was stirred at dry ice temperature for 2 hr 15 min. and then overnight as the cooling bath warmed to room temperature. Stirring was continued for 4 days at room temperature. The suspended white solid was removed by filtration, rinsed on the filter with THF and dried: wt = 13.74 g, mp = 193°-195°. The filtrate was distilled on the water pump to remove the solvent, and the residue, a mixture of brown oil and solid, was stirred with 100 ml of methanol which dissolved the brown oil. Filtration of the mixture, rinsing of the solid on the filter with methanol, and drying of the solid under nitrogen gave an additional 15.7 g of crude 1,4-bis(2-methyl-2-cyanopropyl)benzene melting at 192°-194.5° (total yield = 82%). Dissolving of this material in refluxing acetone (28.5 ml/g), filtration of the hot solution through a coarse sintered glass funnel to remove some insoluble material, and cooling of the filtrate at 8°-10° gave the product as colorless needles melting at 194°-195°.
Anal. Calcd. for C 16 H 20 N 2 : C, 79.95; H, 8.39; N, 11.66. Found: C, 79.79; 79.96 H, 8.21; 8.37 N, 11.83 11.67.
EXAMPLE 2
1,3-Bis(2-methyl-2-cyanopropyl)benzene ##STR8##
In a dry 2-liter flask, equipped with a large magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, an addition funnel, and a syringe adapter, was placed 900 ml of anhydrous THF and 42 ml (30.32 g, 0.300 M) of diisopropylamine (via syringe). The mixture was cooled in a dry ice-acetone bath and, with stirring, 125.3 ml of 2.4 molar (0.300 M) n-butyllithium in hexane was added via syringe. After the mixture had stirred for 1 hr 35 min, 20.52 g (0.297 M) of freshly distilled isobutyronitrile in 60 ml of THF was added in 30 minutes. Following another 70 minutes of stirring, 39.57 g (0.150 M) of α,α'-dibromo-m-xylene was added all at once. The mixture was stirred for 2 hrs at -76°, and then overnight as the cooling bath warmed to room temperature. After an additional day of stirring at room temperature, the mixture was distilled on the water pump to yield a semisolid residue. Dissolving this material in 700 ml of chloroform, followed by three extractions of the resulting solution with 200 ml of water (with HCl acidification during the first extraction), drying over anhydrous magnesium sulfate, and removal of the solvent on the water pump, gave 35.5 g (98%) of a slowly crystallizing, brown solid. This material was further dried on an oil pump: mp = 58°-63°. All of this material was stirred with 2 liters of refluxing cyclohexane, but an appreciable quantity of an oily material was insoluble. Decanting of the solution from this oil, followed by cooling, yielded 18.0 g of 1,3-bis(2-methyl-2-cyanopropyl)benzene as almost colorless prisms melting at 69°-70°. Refluxing of the filtrate with Darco, followed by filtration, evaporation to about 500 ml, seeding, and cooling, yielded an additional 9.16 g of product melting at 68°-70°.
Anal. Calc'd for C 16 H 20 N 2 : C, 79.95; H, 8.39; N, 11.66 Found: C, 79.88; 79.69 H, 8.04; 8.31 N, 11.74 11.56.
EXAMPLE 3
1,4-Bis(2-methyl-2-cyanopropyl)tetramethylbenzene ##STR9##
In a 1-liter flask, equipped with a magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, an addition funnel, and a syringe adapter, was put 500 ml of anhydrous THF and 14 ml (10.10 g, 0.10 M) of diisopropylamine (via syringe). The flask was cooled in a dry ice-acetone bath and, with stirring, 41.8 ml of 2.4 molar (0.100 M) n-butyllithium in hexane was added via a syringe. The mixture was stirred for 1 hr, and then a solution of 6.48 g (0.094 M) of freshly distilled isobutyronitrile in 20 ml of anhydrous THF was added in 20 minutes. After an additional 65 minutes of stirring, 11.55 g (0.050 M) of 3,6-bis(chloromethyl)durene was added all at once. The mixture was stirred for 5 hrs at -76°, and then overnight as the cooling bath warmed to room temperature. Filtration of the solid, rinsing on the filter with THF, and drying under nitrogen, yielded 8.50 g of crude 1,4-bis(2-methyl-2-cyanopropyl)tetramethylbenzene melting at 187°-190°. Evaporation of the filtrate to dryness yielded additional solid which was dissolved in 325 ml of chloroform. Extraction of this solution three times with 100 ml of water (with HCl-acidification during the first extraction), drying of the chloroform solution over anhydrous magnesium sulfate, and removal of the solvent in vacuo, yielded an additional 5.30 g of crude product (93% total yield) melting at 162°-180°. Recrystallization of this material from acetone yielded the product as colorless needles melting at 192.5°-193°.
Anal. Calc'd for C 20 H 28 N 2 : C, 81.03; H, 9.52; N, 9.45. Found: C, 81.31; 81.14 H, 9.35; 9.57 N, 9.46 9.41.
The infrared spectrum of this material contains bands at 3.31μ (=CH), 3.35 and 3.40μ (saturated CH), 4.48μ (--C.tbd.N), 6.69μ (aromatic C═C) and 7.18 and 7.30μ (gem-dimethyl).
EXAMPLE 4
3,3'-Bis(2-methyl-2-cyanopropyl)biphenyl ##STR10##
In a 500-ml flask, equipped with a magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, a dropping funnel and a syringe adapter, was put 150 ml of anhydrous THF and 7.0 ml (5.05 g, 0.050 M) of diisopropylamine (via syringe). The flask was cooled in a dry ice bath, and with stirring, 23.1 ml of 2.17 molar (0.050 M) n-butyllithium in hexane was added via syringe. The mixture was stirred for 55 minutes, and then a solution of 3.42 g (0.049 M) of freshly distilled isobutyronitrile in 10 ml of anhydrous THF was added dropwise in 7 minutes. After an additional 20 minutes of stirring, a solution of 8.50 g (0.0250 M) of 3,3'-bis(bromomethyl)biphenyl in 75 ml of anhydrous THF was added during 38 minutes. The mixture was allowed to warm to room temperature as it stirred overnight. During the addition, the mixture developed an intense blue color. This color was still apparent on the day after the mixture had warmed to room temperature, but after two additional days of stirring at room temperature, the mixture was light brown and clear. The solvent was removed on the water pump and the resulting residue was dissolved in 200 ml of chloroform. Washing of this solution three times with 100 ml of water (with HCl acidification during the first washing), drying the solution over anhydrous magnesium sulfate, removal of the solvent on the water pump, and drying the resulting residue in vacuo, gave 7.50 g (95%) of crude 3,3'-bis(2-methyl-2-cyanopropyl)biphenyl melting at 96°-103°. Dissolving this material in hot cyclohexane, refluxing the resulting solution with Darco, filtering through Celite, evaporating the filtrate to 125 ml, and cooling it at 8°-10°, gave 5.36 g of the product as colorless prisms melting at 106.5°-108.5°.
Anal. Calc'd for C 22 H 24 N 2 : C, 83.50; H, 7.64; N, 8.86 Found: C, 83.74; 83.57 H, 7.60; 7.53 N, 8.63 8.60.
The infrared spectrum (KBr) contains bands at 3.25μ (═CH), 3.32, 3.37 and 3.44μ (saturated CH), 4.45μ (--C.tbd.N), 6.19 and 6.28 μ (aromatic C═C) and 12.7 and 14.04μ (meta disubstituted benzene).
EXAMPLE 5
2,6-Bis(2-methyl-2-cyanopropyl)naphthalene ##STR11##
In a 1-liter flask, equipped as described in Example 4, was put 400 ml of anhydrous THF and 14.00 ml (10.10 g, 0.10 M) of diisopropylamine. The flask was cooled in a dry ice bath and, with stirring, 48.3 ml of 2.29 molar (0.111 M) n-butyllithium in hexane was added via a syringe. The mixture was stirred for 75 minutes and then 6.84 g of freshly distilled isobutyronitrile in 20 ml of anhydrous THF was added during 12 minutes. After an additional 23 minutes of stirring, 15.2 g of 2,6-bis(bromomethyl)naphthalene was added all at once. The mixture was stirred at -76° for 21/2 hrs and then overnight as the bath warmed to room temperature. After an additional 31/2 days of stirring at room temperature, the mixture was filtered and the resulting solid was rinsed on the funnel with THF and dried under nitrogen: wt = 3.13 g, mp = 181.8°-184°. Evaporation of the filtrate to dryness on the water pump yielded additional solid which was dissolved in 700 ml of chloroform. Extraction of the chloroform solution three times with 300 ml of water (with HCl acidification during the first extraction), and removal of the solvent in vacuo yielded additional crude product, which after drying in a vacuum oven at room temperature, weighed 10.00 g and melted at 178°-180°. Recrystallization of this material from acetone yielded 2,6-bis(2-methyl-2 -cyanopropyl)naphthalene melting at 183.5°-184.5°.
Anal. Calc'd for C 20 H 22 N 2 : C, 82.71; H, 7.64; N, 9.65 Found: C, 83.21; 82.93 H, 7.84; 7.73 N, 9.70 9.62.
The infrared spectrum of this material contains a C.tbd.N stretch band at 4.45μ.
EXAMPLE 6
Preparation of 4,4'-Bis(2-methyl-2-cyanopropyl)biphenyl ##STR12##
In a 500-ml flask, equipped as described in Example 4, was placed 250 ml of anhydrous THF and 7.00 ml of diisopropylamine (via syringe). The flask was cooled in a dry ice bath and, with stirring, 21.0 ml of 2.4 molar n-butyllithium in hexane was added via a syringe. The mixture was stirred for 1 hour and then 3.42 g of freshly distilled isobutyronitrile in 20 ml of THF was added in 20 minutes. After an additional hour of stirring, 8.50 g of 4,4'-bis(bromomethyl)biphenyl was added all at once. Stirring at -76° was continued for several hours and overnight as the cooling bath warmed to room temperature. After an additional day of stirring, the solvent was distilled on the water pump. The resulting semisolid residue was dissolved in 500 ml of chloroform and the chloroform solution was extracted 4 times with water (with HCl acidification during the first extraction). Drying the solution over anhydrous magnesium sulfate, filtering, and removal of the solvent in vacuo gave 6.8 g of crude 4,4'-bis(2-methyl-2-cyanopropyl)biphenyl melting at 174°-182°. After several recrystallizations from acetone, the product melted at 189.3°-190.8°.
Anal. Calc'd for C 22 H 24 N 2 : C, 83.50; H, 7.64; N, 8.86 Found: C, 82.81; 83.43 82.94 H, 7.94; 7.86 7.90 N, 8.69 8.79 8.80.
EXAMPLE 7
3,3'-Dichloro-4,4'-bis(2-methyl-2-cyanopropyl)biphenyl ##STR13##
In a 500-ml flask, equipped as described in Example 4, was placed 150 ml of anhydrous THF and 7.0 ml of diisopropylamine (via syringe). The flask was cooled at -76° and, with stirring, 21.0 ml of 2.4 molar n-butyllithium in hexane was added via syringe. The mixture was stirred for 1 hr 25 min and the 3.42 g of freshly distilled isobutyronitrile in 10 ml of THF was added in 20 minutes. After an additional 25 minutes of stirring, a solution of 10.22 g of 3,3'-dichloro-4,4'-bis(bromomethyl)biphenyl in 100 ml of THF was added with stirring during 1 hr 20 min. The mixture was stirred at -76° for 1 hr 45 min and then overnight as the cooling bath warmed to room temperature. After an additional 2 days of stirring at room temperature, the solvent was removed in vacuo. The resulting residue was dissolved in 200 ml of chloroform and the chloroform solution was extracted 3 times with 100 ml of water (with HCl acidification during the first extraction). Drying the solution over anhydrous magnesium sulfate, filtering, and removal of the solvent in vacuo, gave 7.5 g of crude 3,3'-dichloro-4,4'-bis(2-methyl-2-cyanopropyl)biphenyl melting at 148°-156°. A recrystallization from acetone, with a filtration of the hot solution to remove some insoluble material, gave product melting at 162°-164°.
Anal. Calc'd for C 22 H 22 Cl 2 N 2 : C, 68.57; H, 5.76; Cl, 18.40; N, 7.27. Found: C, 68.36; 68.80 68.28 H, 5.93; 6.09 5.69 Cl, 18.14; 18.34 N, 7.48 7.19.
EXAMPLE 8
1-Bis(2-methyl-2-cyanopropyl)benzene ##STR14##
In a dry 1-liter flask, equipped with a large magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, an addition funnel, and a syringe adapter, was placed 570 ml of anhydrous THF, and 26.5 ml of diisopropylamine (via syringe). The mixture was cooled in a dry ice bath, and with stirring, 73.1 ml of 2.6 molar n-butyllithium in hexane was added via syringe. After the mixture had stirred for 1 hr, a solution of 13.1 g of freshly distilled isobutyronitrile in 40 ml of THF was added in 25 min. Following another 35 min of stirring, 25.0 g of α,α'-dibromo-o-xylene was added all at once. The mixture was stirred for 1 hr at -76°, and then overnight as the dry ice bath warmed to room temperature. After an additional 2 days of stirring at room temperature, the mixture was distilled on the water pump to remove the solvent. Dissolving of the resulting residue in 400 ml of chloroform, followed by 3 extractions of the chloroform solution with 200 ml of water (with HCl acidification during the first extraction), drying over anhydrous magnesium sulfate, and removal of the solvent on the water pump, gave 21.50 g (94%) of crude 1,2-bis(2-methyl-2-cyanopropyl)benzene melting at 76°-80°. Refluxing of this material with Darco in 425 ml of cyclohexane, followed by filtration, evaporation of the filtrate to 250 ml, seeding and then cooling to 8°-10°, gave 18.30 g of the product melting at 81.5-82°.
Anal. Calc'd for C 16 H 20 N 2 : C, 79.95; H, 8.39; N, 11.66. Found: C, 78.98; 79.32 H, 8.46; 8.34 N, 11.69 11.54.
EXAMPLE 9
This example shows the preparation of a polyamide from 1,4-bis(2-methyl-2-cyanopropyl)benzene.
(a) Preparation of 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene ##STR15##
In a 2-liter flask, equipped with a magnetic stirrer, a reflux condenser capped with a nigrogen bubbler, and an additional funnel, was placed 7.50 g (0.0312 M) of 1,4-bis(2-methyl-2-cyanopropyl)benzene and 300 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 107 ml of a 24.1% solution (0.150 M) of diisobutylaluminum hydride in toluene was added from the addition funnel in 28 min. The mixture was then refluxed for 16 hrs. After the mixture had been cooled in an ice-water bath, a solution of 6 ml of water in 30 ml of methanol was added dropwise with stirring. This was followed by the dropwise addition of a solution of 30 ml of water in 60 ml of methanol. The mixture was stirred vigorously for 1 hr while being cooled in the ice-water bath, and then for an additional hour at room temperature. The mixture was filtered under nitrogen, the solid was washed thoroughly on the filter with toluene, and the combined filtrate and rinsings were distilled on the water pump. The resulting residue crystallized on cooling to room temperature. Further drying on the oil pump gave 5.28 g (68%) of crude 1,4-bis(2,2-dimethyl-3-aminopropyl)benzene melting at 53°-56° to a cloudy melt. Distillation of this material through a small Vigreux still gave the product as a colorless liquid boiling at 131°-132°/0.60 mm. The solidified material melted to a clear melt at 53.5-54.75°.
Anal. Calc'd for C 16 H 28 N 2 : C, 77.36; H, 11.36; N, 11.28 C, 77.68; 77.07 77.15 H, 11.44; 11.30 11.27 N, 11.04 11.14.
The infrared spectrum contains bands at 2.93, 3.00 and 6.15μ (--NH 2 ), 3.28μ (shoulder) (═CH), 3.38 and 3.48μ (saturated CH), 6.59 and 6.77μ (aromatic C═C), 7.21 and 7.33 μ (gemdimethyl), and 11.86μ (p-disubstituted aromatic).
(b) Preparation of a Polyamide from 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene and Sebacyl Chloride ##STR16##
In a 3-liter flask, equipped with a paddle stirrer, a reflux condenser, and a nitrogen bubbler, was placed 25.00 g of 1,5-bis(2,2-dimethyl-3-aminopropyl)benzene, 31.0 ml of triethylamine, and 350 ml of chloroform which had been passed through basic alumina under nitrogen directly into the reaction flask. With vigorous stirring at room temperature, 24.07 g of freshly distilled sebacyl chloride in 100 ml of purified chloroform was added all at once. The mixture was stirred for 45 minutes and then 1500 ml of hexane was added to precipitate the polymer. After 15 minutes of stirring, the mixture was allowed to stand overnight. With stirring, a solution of 150 ml of concentrated hydrochloric acid in 600 ml of water was added. The coagulated polymer was filtered, rinsed on the filter with water, and then washed in a blender once with 600 ml of water, once with 600 ml of acetone and three times with 600 ml of water. The isolated polymer was dried overnight in a vacuum oven at 70°. There was thus obtained 32.6 g (78%) of product: inherent viscosity (0.05% in m-cresol at 25°) = 1.32.
A clear, tough, colorless film was pressed at 180° and 500 lbs pressure from a portion of this polymer. Another portion of the polymer was melt spun through a spinnerette (0.020 inch × 0.04 inch) at 248° to 270° to give filament which, after cold drawing, had strengths of about 1.5 grams/denier.
The product of another experiment, on 1/10 the scale of that just described, was further characterized by elemental analysis and infrared spectroscopy.
Anal. Calc'd for (C 26 H 42 N 2 O 2 ) n : C, 75.31; H, 10.21; N, 6.76 Found: C, 75.20; 75.66 H, 10.90; 10.89 N, 6.94 6.95.
The infrared spectrum contained bands at 3.03μ(--NH), 3.42 and 3.48μ (saturated CH), 6.08 and 6.45μ (amide I and II bands), 6.60μ (aromatic C═C), and 7.30 and 7.32μ (gemdimethyl).
EXAMPLE 10
This example illustrates the preparation of a polyamide from 1,3-bis(2-methyl-2-cyanopropyl)benzene.
(a) Preparation of 1,3-Bis(2,2-dimethyl-3-aminopropyl)benzene ##STR17##
In a 1-liter flask, equipped with a paddle stirrer, a reflux condenser, capped with a nitrogen bubbler, and an addition funnel, was placed 7.50 g of 1,3-bis(2-methyl-2-cyanopropyl)benzene and 250 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 107 ml of a 25% solution of diisobutylaluminum hydride in toluene was added in 1 hr. The mixture was refluxed for 17 hrs 15 min. The mixture was then worked up as described in Example 9(a). Upon distillation of the isolated product through a small Vigreux still, there was obtained 3.51 g of 1,3-bis(2,2-dimethyl-3-aminopropyl)benzene as a colorless liquid distilling at 105°-110°/0.05 mm.
Anal. Calc'd for C 16 H 28 N 2 : C, 77.36; H, 11.36; N, 11.28. Found: C, 77.59; 77.29 H, 11.31; 11.23 N, 11.36; 11.50.
(b) Preparation of a Polyamide from 1,3-Bis(2,2-dimethyl-3-aminopropyl)benzene and Sebacyl Chloride ##STR18##
In a 300-ml flask, equipped with a paddle stirrer, a reflux condenser and a nitrogen bubbler, was put 4.00 g of 1,3-bis(2,2-dimethyl-3-aminopropyl)benzene, 5.00 ml of triethylamine, and 50 ml of chloroform which had been passed through basic alumina under nitrogen. With vigorous stirring, a solution of 3.85 g of sebacyl chloride (freshly distilled) in 25 ml of purified chloroform was added all at once. The mixture was stirred for 10 minutes and poured into 500 ml of hexane with stirring. Stirring was continued for a few minutes, the mixture was filtered, and the isolated solid was rinsed on the filter with hexane. The dried solid was washed in a blender once with 200 ml of water and once with 100 ml of acetone. The resulting sticky polymer was dried in a vacuum oven at room temperature and then washed in the blender three times with 200 ml of water. After being dried in a vacuum oven at 70°, the polymer weighed 3.20 g: inherent viscosity (0.05% in m-cresol at 25°) = 0.36.
EXAMPLE 11
This example illustrates the preparation of a polyamide from 1,4-bis(2-methyl-2-cyanopropyl)tetramethylbenzene.
(a) Preparation of 1,4-Bis(2,2-dimethyl-3-aminopropyl)tetramethylbenzene ##STR19##
In a 1-liter flask, equipped as described in Example 9(a), was put 6.17 g of 1,4-bis(2-methyl-2-cyanopropyl)tetramethylbenzene and 200 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 71.3 ml of a 24.1% solution of diisobutylaluminum hydride in toluene was added in 25 min. The mixture was refluxed for 22 hrs and allowed to stand at room temperature for 3 days. After the mixture had been cooled in an ice-water bath, a solution of 4 ml of water in 20 ml of methanol was added dropwise with stirring. This was followed by the dropwise addition of a solution of 20 ml of water in 40 ml of methanol. The mixture was then stirred at room temperature for several hours and allowed to stand at room temperature for 3 days. The mixture was filtered under nitrogen, the solid was washed thoroughly with toluene on the filter, and the combined filtrate and rinsings were distilled on the water pump. A solid residue resulted which, after further drying in a vacuum oven at room temperature, weighed 5.21 g and melted at 97°-99°. Sublimation of this material at 125°-145°/0.50 mm gave 1,4-bis(2,2-dimethyl-3-aminopropyl)tetramethylbenzene as a colorless crystalline solid melting at 97.5°-98.5°.
Anal. Calc'd for C 20 H 36 N 2 : C, 78.88; H, 11.92; N, 9.20. Found: C, 78.62; 78.55 H, 12.05; 12.08 N, 9.89; 10.09.
The infrared spectrum contains bands at 2.96; 3.03, and 6.20μ (--NH 2 ), 3.38 and 3.43μ (saturated CH), 6.73μ (aromatic C═C), and 7.23 and 7.36μ (gem-dimethyl).
(b) Preparation of a Polyamide from 1,4-Bis(2,2-dimethyl-3-aminopropyl)tetramethylbenzene and Sebacyl Chloride ##STR20##
In a 1-liter flask, equipped with a paddle stirrer, a reflux condenser, and a nitrogen bubbler, was placed 10.00 g of 1,4-bis(2,2-dimethyl-3-aminopropyl)tetramethylbenzene, 10.1 ml of triethylamine, and 125 ml of chloroform which had been passed through basic alumina under nitrogen. The reaction flask was cooled in a room-temperature water bath, and with vigorous stirring a solution of 7.85 g of freshly distilled sebacyl chloride in 50 ml of purified chloroform was added all at once. After the mixture had been stirred vigorously for another 30 minutes, 500 ml of hexane was added, and stirring was continued for 30 minutes. Then with stirring, 200 ml of water was added. Stirring was continued for a short time and the mixture was allowed to stand at room temperature overnight. The polymer was isolated by filtration, rinsed on the filter with water, and then washed in a blender once with 200 ml of water, once with 200 ml of acetone, and three times with 200 ml of water. The isolated polymer was dried overnight in a vacuum oven at 70°. There was thus obtained 9.50 g (61%) of product: inherent viscosity (0.05% in m-cresol at 25°) = 0.38. A clear, colorless, brittle film was pressed at 180° and 500 lbs pressure.
EXAMPLE 12
This example illustrates the preparation of a polyamide from 3,3'-bis(2-methyl-2-cyanopropyl)biphenyl.
(a) Preparation of 3,3'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl ##STR21##
In a 2-liter flask, equipped as described in Example 9(a), was put 10.90 g of 3,3'-bis(2-methyl-2-cyanopropyl)biphenyl and 500 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 118 ml of a 25% solution of diisobutylaluminum hydride in toluene was added in 25 minutes. The mixture was refluxed for 18 hrs, and then allowed to stand at room temperature for 1 day. After the mixture had been cooled in an ice-water bath, a solution of 7 ml of water in 35 ml of methanol was added dropwise with stirring. This was followed by the dropwise addition of a solution of 33 ml of water in 66 ml of methanol. The ice-water bath was removed, and the mixture was stirred for 1 hour. The mixture was filtered under nitrogen, the solid was washed thoroughly with toluene on the filter, and the combined filtrate and rinsings were distilled on the water pump. The cloudy viscous residue weighed 10.8 g after it was evacuated for several hours with the oil pump at room temperature. Distillation of this material through a small Vigreux still gave 5.94 g of 3,3'-bis(2,2-dimethyl-3-aminopropyl)biphenyl as a clear, colorless, viscous liquid boiling at 159°-168°/0.2-0.5 mm.
Anal. Calc'd for C 22 H 32 N 2 : C, 81.42; H, 9.94; N, 8.63 Found: C, 81.31; 81.40 H, 10.19; 10.57 N, 8.29 8.47.
(b) Preparation of a Polyamide from 3,3'-Bis(2,2-dimethyl3-aminopropyl)biphenyl and Diphenyl Bibenzoate ##STR22##
In a 50-ml round bottomed flask, flushed out with nitrogen, was placed 5.05 g of 3,3'-bis(2,2-dimethyl-3-aminopropyl)biphenyl and 6.14 g of diphenyl bibenzoate. The flask was then fitted with a 15 cm extension tube which had an adaptor for connecting to a nitrogen bubbler and for the insertion of a nitrogen capillary into the reaction vessel. The flask was then heated for 20 minutes in an oil bath at about 220° with the nitrogen capillary positioned above the reaction mixture. The capillary was then lowered so that nitrogen bubbled up through the reaction mixture and the heating at 220° continued for about 4 hours. The bath was then heated more strongly so that its temperature rose to 270° in the next hour. Heating at 270° was continued for 1 hr 30 min. During the final hour of the heating period, the flask was evacuated with an oil pump. The flask was then removed from the oil bath and allowed to cool to room temperature. The flask was broken and the polymer was isolated: weight = 8.2 (˜ 100%) of clear, amber-colored, tough solid: inherent viscosity (0.05% in m-cresol at 25°) = 0.29.
Long tough fibers could be drawn from this polymer heated on a metal block at 300°-310°. A clear, colorless, tough film was pressed at 220° and 500 lbs pressure.
EXAMPLE 13
This example illustrates the preparation of a polyamide from 2,6-bis(2-methyl-2-cyanopropyl)naphthalene.
(a) Preparation of 2,6-Bis(2,2-dimethyl-3-aminopropyl)naphthalene ##STR23##
In a 1-liter flask, equipped as described in Example 10(a), was put 9.06 g of 2,6-bis(2-methyl-2-cyanopropyl)naphthalene and 300 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 107 ml of a 25% solution of diisobutylaluminum hydride in toluene was added in 55 minutes. The mixture was then refluxed for 20 hrs. After the mixture had been cooled in an ice-water bath, a solution of 6 ml of water in 30 ml of methanol was added with stirring during 55 minutes. This was followed by the addition of a solution of 30 ml of water in 60 ml of methanol during 1 hr 35 min. The mixture was stirred for 1 hr while being cooled in the ice-water bath and then at room temperature overnight. The mixture was filtered under nitrogen, the solid was washed thoroughly with toluene on the filter, and the combined filtrate and rinsings were distilled on the water pump. The resulting solid residue, after being dried in vacuo for about 2 hrs, weighed 8.0 g and melted at 97°-98.25°. Sublimation of this material at 145°-165°/0.6 mm gave 2,6-bis(2,2-dimethyl-3-aminopropyl)naphthalene as a colorless, crystalline solid melting at 96.75°-98.50°.
Anal. Calc'd for C 20 H 30 N 2 : C, 80.48; H, 10.13; N, 9.39. Found: C, 82.09; 81.74 H, 10.45; 10.48 N, 9.85 9.77.
The infrared spectrum contains bands at 2.98 and 3.06 μ (--NH 2 ), 3.29 μ (unsaturated CH), 3.38, 3.43 and 3.50 μ (saturated CH), 6.23, 6.65 and 6.80 μ (--NH 2 and/or aromatic C═C), and 7.22 and 7.33 μ (gem-dimethyl).
(b) Preparation of a Polyamide from 2,6-Bis(2,2-dimethyl-3-aminopropyl)naphthalene and Diphenyl Terephthalate ##STR24##
In a polymer tube (23 cm × 2.5 cm), fitted with a side arm and well flushed with nitrogen was put 5.00 g of 2,6-bis(2,2-dimethyl-3-aminopropyl)naphthalene and 5.33 g of diphenyl terephthalate. A nitrogen capillary was positioned in the tube so that the end of the capillary was above the reaction mixture. The tube was lowered into the vapor of a 220° vapor bath and heated at that temperature for 4 hrs 30 min. After 1 hr 15 min at 220°, the capillary was lowered so that the nitrogen bubbled up through the reaction mixture. The tube was then heated at 280° for 2 hrs 30 min. During the last 30 min of this heating, the tube was evacuated at about 2.5 mm. After the tube had cooled to room temperature, it was broken and the polymer was isolated: 5.61 g (78%), inherent viscosity (0.05% in mcresol at 25°) = 0.20.
EXAMPLE 14
This example illustrates the preparation of a polyamide from 4,4'-bis(2-methyl-2-cyanopropyl)biphenyl.
(a) Preparation of 4,4'-Bis(2,2-dimethyl-3-aminopropyl)-biphenyl ##STR25##
In a 1-liter flask, equipped as described in Example 10(a), was put 6.54 g of 4,4'-bis(2-methyl-2-cyanopropyl)biphenyl and 400 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 71 ml of a 25% solution of diisobutylaluminum hydride in toluene was added in 30 minutes. The mixture was then refluxed for 17 hrs 40 min. After the mixture had been cooled in an ice-water bath, a solution of 5 ml of water in 22 ml of methanol was added dropwise with stirring in 1 hr. This was followed by the dropwise addition of a solution of 20 ml of water in 40 ml of methanol in 1 hr. The mixture was stirred for 1 hr while being cooled in the ice bath and for 1 hr at room temperature. It then stood at room temperature for one day. The mixture was filtered under nitrogen, the solid was washed thoroughly with toluene on the filter, and the combined filtrate and rinsings were distilled on the water pump. The resulting solid, after drying in vacuo, weighed 5.5 g and melted at 97°-99°. Sublimation at 185°-200°/0.10 mm gave 4,4'-bis(2,2-dimethyl-3-aminopropyl)biphenyl as a colorless crystalline solid.
Anal. Calc'd for C 22 H 32 N 2 : C, 81.42; H, 9.94; N, 8.63. Found: C, 81.31; 81.29 H, 10.11; 10.36 N, 8.87 8.68.
(b) Preparation of a Polyamide from 4,4'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl and Diphenyl Bibenzoate ##STR26##
In a large test tube (30 cm × 3.5 cm), well flushed with nitrogen and fitted with a 2-hole rubber stopper containing a straight glass tube and a right angle glass tube, was put 4.0 g of 4,4'-bis(2,2-dimethyl-3-aminopropyl)-biphenyl and 4.86 g of diphenyl bibenzoate. A nitrogen capillary was fitted into the straight tube and positioned so that its end was above the reaction mixture. The right angle tube was connected to a nitrogen bubbler. The test tube was lowered into the vapor of a 220° vapor bath and heated at that temperature for 3 hrs 45 min. The tube was then heated in a 280° vapor bath for 1 hr 25 min. During the last 40 minutes the tube was evacuated with an oil pump. After the tube had cooled to room temperature, the polymer was isolated: 6.5 g (99%). Successive washings of the polymer in a blender with 100 ml of water, 100 ml of acetone, and then 3 times with 100 ml of water and then drying in a vacuum oven at 70° gave 6.16 g of product: inherent viscosity (0.05% in sulfuric acid at 25°) = 0.40.
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Aromatic-aliphatic dinitriles of the formula ##STR1## in which Ar is an arylene or substituted arylene are useful in the preparation of the corresponding amines which are intermediates for the preparation of thermally stable, rigid, polyamides.
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The present invention relates to a process, a product, and a procedure for the manufacture of structural elements by curing molding compositions which are based on thermosetting phenolic resins. The structural elements may be used as building materials, building stones, floor tiles, roofing tiles, sewer pipes and as other molded articles in the construction industry.
BACKGROUND OF THE INVENTION
The presently most widespread technology for the manufacture of structural elements such as roofing tiles, floor tiles, etc., is based on the well established kiln technology, or on the processing of cement. In both cases the quality of the product depends on the starting materials, and on high quality labor and high energy cost manufacturing methods. In addition, high costs for molds are involved. Frequently, individual items are subject to breakage, resulting in a high reject rate. Furthermore, shortages in the supply of raw material occur.
It is therefore an object of this invention to make available a highly fireproof material, with high compressive strength, and bending strength characteristics, at favorable cost, and based on simple raw materials, such as sand, to which a plastic resin is added and to do so while avoiding or substantially reducing the disadvantages listed above. In addition, relatively simple processing techniques, and independence from cement as a raw material, are further objectives of the invention.
SUMMARY OF THE INVENTION
The present invention provides a process for manufacturing structural elements including the steps of mixing minerals as well as low melting metallic substances to form a molding composition based on thermosetting phenolic resins, and then curing the molding composition to form structural elements.
The present invention also provides a product produced in accordance with the novel process.
According to the invention, the above-mentioned objectives are achieved through the use of a molding composition which consists of a combination in minerals, and also comprises low melting metallic substances.
DETAILED DESCRIPTION
The novel manufacturing procedures, hereinafter described in detail, do not require special raw material grades, nor is a special pretreatment of the inorganic materials a necessity. The manufacturing procedure excludes the use of cement and sodium or potassium silicate solutions (waterglass).
The primary binders used are commercially available organic thermosetting resins, such as, for instance, phenolic resins. Their highest strength characteristics are achieved by curing under controlled temperature conditions of from 40-450° C. To achieve the highest level of mechanical properties of the items produced, up to refractory characteristics at 1300° C., the invention calls for the use of a secondary binder, in the form of low melting metals, which are ground together with a predetermined quantity of inorganic materials, such as, for instance, clay or quartz containing clay. Such a powdery blend is added to the prepared crude molding composition, and mixed in the dry state until a homogenous material is in hand. Once compressed and cured, the resulting article exhibits the exact predetermined strength characteristics, and all the other technical and physical characteristics of the products heretofore used in the building industry.
The high strength characteristics can be achieved due to the fact that the microscopic particles of the low melting metal compounds begin to sinter already at low temperatures and react in sequence. This causes the formation of a monolithic space-lattice structure consisting of these compounds and the oxides. This chemical process, and the curing of the resin, occur completely independent of each other and without influencing each other.
The principal inorganic component is a sand of unspecified chemical composition with a moisture content at the pit of from 5-8%. The procedure according to this invention also applies to other products or structural elements, such as floor tiles of all types, building materials and building stones, and also other structured elements which share a common technological character. Despite the differing final use-areas of the products manufactured from this molding composition, they are all characterized by the following economical advantages:
(a) for the manufacture of these articles, all the common types of sands can be used;
(b) overall production and energy costs are reduced;
(c) capital investment costs are reduced;
(d) substantially lower labor costs; and
(e) increased productivity of the work cycle.
The invention is described in greater detail in the following examples:
EXAMPLE I
In a mechanical mixer the following components are mixed together:
88 parts by weight of moist undried sand which is characterized by an average grain size of from 1.5-0.08 millimeters;
6 parts by weight of a phenolic resole resin with a viscosity of 3300 centipoise, and a combustion residue of 80%,
6 parts by weight of the blend of low melting metals, e.g. Pb--Sn--Al.
This mixture, constituting a homogenous blend, with a residual moisture content of 8%, is then suitable for compression molding at pressures of from 20°-150 Kg/cm 2 . The resulting molded articles are then cured according to known procedures in a drying oven, or in heated molds. The temperature required for the curing step depends on the type of phenol resol resin used, and may be from 20°-450° C.
The prepared molding composition, as per the technical description, is ready for shaping and compression. The sintering of the finished parts occurs in stages. During the first stage the resin is cured at temperatures from 20°-450° C., and results in structurally strengthening the molded article. The essential mechanical characteristics achieved during this step, i.e., a bending strength of 210 Kp/cm 2 , are already higher than those of conventional building materials. The subsequent sintering is achieved by means of the low melting metal compounds. Therefore, the resulting metal compounds products are dimensionally stable and highly refractory, up to a temperature of 1300° C.
EXAMPLE II
The following components are blended together:
92% by weight of undried sand with a grain size of from 2-0.08 millimeters;
4% by weight of a phenol resole resin with a viscosity of 3500 centipoise at 20° C.;
2% by weight of bonding clay; and
2% by weight of powdered Wood's metal.
Processing is essentially identical to Example I. The molding composition is prepared stepwise. The individual components are added to the continuous blending process. The resin component is heated to about 28°-30° C., and then the bonding clay is added in powdered form. Finally the low melting metals or metal compounds are added and the total composite is well mixed, for example, for a period of 10 minutes. Curing and molding are then carried out in the manner described before.
EXAMPLE III
The following materials are blended in respective amounts:
88% by weight of sand, as described in examples I and II;
3% by weight of a phenol resole resin with a viscosity of 9-11 centipoise at 20° C.;
3% by weight of a phenol resole resin with a viscosity of 3300-3700 centipoise at 20° C.;
1% by weight of toluene sulfonic acid in 65% solution;
2% by weight of bonding clay;
2% by weight of Silumin metal powder; and
1% by weight of powdered tin.
Preparation, blending, processing, molding and curing was done as described in the previous examples.
It is to be understood that the examples only describe certain practical approaches to the invention. The invention is not limited to the practical examples listed.
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A product and a process for manufacturing the product, such as structural elements, wherein there is mixed together minerals as well as low melting metallic substances, to form a molding composition based on thermosetting phenolic resins. The mixed molding composition is then cured to form the product or structural elements.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to intraocular lenses, and more particularly, to an intraocular refractive correction lens that corrects eyesight and contains an ultraviolet radiation (“UVR”) absorber that can reduce or eliminate cataract formation, and to a method of implanting an intraocular lens (“IOL”) to correct eyesight and reduce or eliminate cataract formation.
[0003] 2. Description of the Related Art
[0004] The number one cause of blindness in the world is cataracts. A cataract is any change in the structure of the natural crystalline lens in the eye that leads to a loss of transparency. Although factors such as nutrition and genetics play a role in cataract formation, UVR exposure is primarily responsible. Ultraviolet light exposure has been proven to promote cataract formation. The clouding of the lens is irreversible, and once the cataracts begin to impair daily activities, the only treatment is surgical removal of the lens.
[0005] The formation of cataracts probably involves a number of physiological factors. However, a high correlation between cataract incidence and solar radiation, as well as the known cataract producing effects of oxygen, suggests that free radical exposure results in a cascade of toxic reactions leading to cataract formation.
[0006] Epidemiological and clinical evidence shows a link between UVR overexposure and cortical cataracts. The mechanism may be lens epithelial cell death rather than a disruption of equatorial cells, as had been thought. Early and complete protection from environmental UVR may help forestall the formation of cortical cataracts.
[0007] It is well accepted that the exposure to free radicals causes many of the changes in lens proteins throughout life. Proteins within the lens are damaged, probably by repeated exposure to ultraviolet light and oxygen. These modifications might lead to the formation of protein “clumps” that scatter light and contribute to the development of cataracts. The lens takes the brunt of this exposure since one of its prime functions is to serve as an optical filter to minimize the amount of UV light the retina receives. However, this filtering process also subjects the lens to constant exposure to free radicals and potential free radical damage.
[0008] The fraction of sunlight of most concern is the long wave, or near ultraviolet range, which is characterized by wavelength of 300-400 nanometers (nm). This band of ultraviolet radiation is known to cause damage to the eye by inducing chemical changes in the lens and retina. Though short wavelength light with wavelengths below 300 nm typically does not reach the earth's surface because of the atmospheric ozone layers, most of the long wave ultraviolet radiation in the 300-400 nm range is capable of penetrating to the surface of the earth.
[0009] Various parts of the eye absorb portions of the incident light that strikes the eyes so that only the unabsorbed or transmitted portions reach the retina. The cornea generally absorbs wavelengths up to about 340 nm. The natural crystalline lens absorbs most of the ultraviolet wavelengths between 300 and 400 nm. Other parts of the eye absorb portions of the visible spectrum. It is thought by the inventors that the natural lens can be protected, and cataracts delayed or prevented, if an artificial lens absorbs the UV radiation that would otherwise be absorbed by the natural lens.
[0010] For those persons who have had their natural lens removed, for example as a result of cataracts, injury or disease, a condition known as aphakia, UV light is no longer absorbed, but is instead transmitted to the retina. Lenses used to replace the natural lens such as IOLs usually contain compounds that function as UV absorbers, preventing the transmission of wavelengths of between 300-400 nm to the retina.
[0011] For sunglasses intended to provide ultraviolet protection, it is important that the lenses block a wide range of UV radiation, including UV radiation with wavelengths below 380 nm. In fact, recent concern on the effects of UV radiation to the eye has indicated a desire that sunglasses effectively block radiation with wavelengths lower than 400 nm.
[0012] Researchers involved in the study of lens implants in the phakic eye are focused on vision correction. The prior art discloses IOLs for placement in either the posterior or anterior chamber of the eye or for iris-fixated placement. However, most of these IOLs are made of polymethylmethacrylate (“PMMA”), a hard material. A hard material requires a larger incision for implantation, which causes more trauma to the eye. Almost all of the lenses in the prior art are merely for treatment of nearsightedness (myopia), and very rarely for farsightedness (hyperopia) or astigmatism.
[0013] There is no known lens in the art that can correct presbyopia or astigmatism. Moreover, there is no known lens that can treat myopia, hyperopia, compound myopic astigmatism, compound hyperopic astigmatism, or astigmatism in combination with presbyopia.
[0014] There is no known lens in the art that can prevent or delay the onset of cataract formation, or prevent or delay the onset of presbyopia.
[0015] Thus, it would be desirable to have an IOL that can treat the disorders of myopia, hyperopia, astigmatism and presbyopia, alone or in combination. Ideally, such a lens would be deformable, so that it could be implanted in a patient's eye with a smaller incision than that required by a hard lens. In addition, the lens should contain UV-absorbing materials, which can serve the multiple purposes of preventing cataract formation, delaying the onset of presbyopia, and preventing the degradation of the IOL.
SUMMARY OF THE INVENTION
[0016] The method of the present invention can correct presbyopia and astigmatism, alone or in combination, by placing an IOL in the phakic eye of the patient. In addition to these conditions, the method of the present invention can correct the combination of astigmatism and myopia or astigmatism and hyperopia.
[0017] A lens in accordance with the present invention is made of a deformable material, such as silicone, hydrogel, collagen/acrylic blends, acrylic, or collagen/hema blends (collamer). Use of such materials causes less trauma to the eye during surgery because the lens must be inserted into the eye through an incision, and a such a lens can be deformed to fit into an incision smaller than the lens.
[0018] Moreover, by placing a UV-absorbing compound in the lens, the formation of cataracts and the onset of presbyopia can be delayed or prevented. These UV absorbing compounds may also extend the life of the IOL.
[0019] In one embodiment of the method of the present invention, an IOL that can improve vision, as well as absorb harmful UV radiation is placed in the posterior chamber of a phakic eye. This promotes the overall health of the eye by delaying cataract formation, presbyopia, and degradation of the IOL.
[0020] Additionally, a lens in accordance with the present invention can correct hyperopia, presbyopia and astigmatism through the use of an anterior chamber placed or iris-fixated IOL.
[0021] A lens in accordance with the present invention can correct hyperopia with a biconvex or convex-plano optic. Astigmatism is corrected with a toric element in the lens optic.
DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a section view of an eye;
[0023] [0023]FIG. 2 is a plan view of an intraocular lens for placement in the posterior chamber of the eye in accordance with the present invention;
[0024] [0024]FIG. 3 is a section view of the intraocular lens of FIG. 2 placed in the posterior chamber of the eye;
[0025] [0025]FIG. 4 is a perspective view of another intraocular lens for placement in the posterior chamber of the eye in accordance with the present invention;
[0026] [0026]FIG. 5 is a section view of the intraocular lens of FIG. 4 placed in the posterior chamber of the eye;
[0027] [0027]FIG. 6 is a plan view of an intraocular lens for placement in the anterior chamber of the eye in accordance with the present invention;
[0028] [0028]FIG. 7 is a section view of the intraocular lens of FIG. 6 placed in the anterior chamber of the eye;
[0029] [0029]FIG. 8 is a plan view of an intraocular lens for iris fixated placement in the eye in accordance with the present invention;
[0030] [0030]FIG. 9 is a section view of the intraocular lens of FIG. 8 fixated on the iris;
[0031] [0031]FIG. 10 is a plan view of an intraocular lens optic for the treatment of presbyopia in accordance with the present invention; and
[0032] [0032]FIG. 11 is a plan view of an intraocular lens optic according to the invention showing the toric element for astigmatism correction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] [0033]FIG. 1 illustrates the major components of the anterior segment of an eye 20 . The major ocular components of an eye include a retina (not shown) and a cornea 14 . Cornea 14 connects to a sclera 16 at a limbus 18 . The anterior segment of eye 20 is divided into two principle chambers by an iris 22 and a pupil 24 . Cornea 14 and iris 22 define an anterior chamber 26 . Iris 22 , a natural crystalline lens 32 and zonules 34 define a posterior chamber 28 .
[0034] Natural crystalline lens 32 is located behind pupil 24 as defined by iris 22 . Natural crystalline lens 32 is attached to a ciliary body 35 at its periphery by zonules 34 . Eye 20 is deformable and zonules 34 allow lens 32 to deform to achieve a required focus to ensure that an image falls directly on the retina. Spectacles or contact lenses are required to compensate for errors in the focus of lens 32 during accommodation or axial length of the eye. Also present in the anterior segment of eye 20 is a ciliary sulcus 36 .
[0035] As can be seen in FIGS. 2, 4, 6 and 8 , lenses 40 , 40 ′ 40 ″, and 40 ″′, respectively, in accordance with the present invention can come in several different shapes. Lens 40 of the present invention comprises two main elements: an optic element 42 and a haptic element 44 . Optic element 42 consists of the portion of lens 40 which is in the field of vision of the wearer and thus provides vision correction. Optic element 42 also can include a UV radiation absorbing compound.
[0036] Haptic element 44 surrounds optic element 42 and does not participate in vision correction. Rather, haptic element 44 positions lens 40 . Haptic element 44 can either be a single element, for example a circular element, or multiple elements, for example legs extending from lens 40 . For lenses with one haptic, the maximum diagonal haptic dimension refers to the maximum measurable distance between two points on the haptic. For haptics with multiple elements, the maximum diagonal haptic dimension is the straight diagonal distance from the distal end of one haptic to the distal end of an opposite haptic. Haptic element 44 also can include a UV-absorbing compound, which would delay the onset and progression of degradation of the supporting elements of an IOL.
[0037] The present invention also advantageously uses UV-absorbing materials for corrective lenses 40 in the phakic eye. It is known that UV light can increase the chance of cataract formation. The present invention reduces the likelihood of cataract formation, a common problem for people who are exposed to UV radiation found in sunlight, by using UV absorbing materials in lens 40 . It is known that the presence of an IOL in a phakic eye can increase the chance of cataract formation. The present invention also reduces the likelihood of IOL-induced cataract formation by reducing the additive effects of UV radiation and the presence of an IOL within a phakic eye.
[0038] Turning now to FIGS. 2 and 4, alternate embodiments of the invention are shown in which lens 40 or 40 ′ is designed for placement in posterior chamber 28 of the anterior segment of an eye 20 . Lens 40 or 40 ′ can be constructed of a material that is deformable. Such materials include silicone, hydrogel, collagen/acrylic blends, acrylic, and collagen/hema blends (collamer). Use of such material allows lens 40 or 40 ′ to be inserted through a smaller incision, which causes less trauma to the eye. Optic element 42 or 42 ′ of lens 40 or 40 ′ respectively can be constructed to be either a negative refracting lens or a positive refracting lens. Additionally, optic element 42 or 42 ′ can include a toric element (not shown) for astigmatism correction.
[0039] Lens 40 or 40 ′ for placement in posterior chamber 28 of anterior segment of an eye 20 can be held in place by either of two methods. As shown in FIG. 3, a first method calls for the diagonal haptic dimension of lens 40 to be greater than the diameter of ciliary sulcus 36 , allowing haptic element 44 to contact ciliary sulcus 36 . This contact is required for adequate vaulting of lens 40 in order to maintain a gap 46 between lens 40 and the anterior surface of crystalline lens 32 . In this method, the maximum diagonal haptic dimension of haptic element 44 of lens 40 is determined by the size of the wearer's eye, and can be any size from under 10 to over 15 mm, but is preferably from 10.5 to about 14.0 mm.
[0040] A second method for securing lens 40 ′ for placement in posterior chamber 28 of anterior segment of an eye 20 is shown in FIG. 5. This method requires the diagonal haptic dimension of lens 40 ′ to be less than the diameter of ciliary sulcus 36 , thus haptic element 44 ′ cannot contact ciliary sulcus 36 . The interaction between optic element 42 ′ and pupil results in centration of lens 40 ′. The radius of curvature of lens 40 ′ creates a Bernoulli effect, which helps float lens 40 ′ anteriorly, away from the natural crystalline lens 32 . In this method, haptic element 44 ′ can flare out in width in order to maximize the ability of lens 40 ′ to float freely in the eye, without interfering with the eye's natural crystalline lens 32 . In this method, the maximum diagonal haptic dimension of haptic element 44 ′ of lens 40 ′ is again determined by the needs of the wearer, and can range from under 10 to over 12 mm, but is preferably in the range from about 10.0 to about 11.8 mm.
[0041] In addition to the above disclosed properties, lens 40 or 40 ′ can also contain a UV absorbing compound. See U.S. Pat. Nos. 5,133,745 and 4,528,311, incorporated herein by reference, for examples of effective UV absorbing compounds and methods for incorporating them into plastics. A compound that absorbs light in the 300-400 nm range is believed to be the most beneficial for reducing or preventing the formation of cataracts, delaying or preventing the onset of presbyopia, and preventing or delaying the degradation of the IOL.
[0042] Referring now to FIGS. 6 and 7, a third embodiment of the invention is shown in which lens 40 ″ is designed for placement in anterior chamber 26 of anterior segment of an eye 20 . Lens 40 ″ can be constructed of a material that is deformable, as previously described. Optic element 42 ″ of lens 40 ″ can be constructed to be either a negative refracting lens or a positive refracting lens. Additionally, optic element 42 ″ can include a toric element (not shown) for astigmatism correction.
[0043] Optic element 42 ″ of lens 40 ″ for placement in anterior chamber 26 of anterior segment of an eye 20 has a diameter determined by the needs of the wearer, and can range from about 5 to about 8 mm, but is preferably from 5.5 to 7.0 mm. Lens 40 ″ can have two haptic elements 44 ″, preferably made of flexible PMMA or acrylic. Each haptic element 44 ″ has two footplates 50 , thereby providing a 4-point fixation in the anterior chamber angle. Haptic elements 44 ″ suspend lens 40 ″ in anterior chamber 26 of anterior segment of an eye 20 at a vault angle above 0 and up to several degrees, but preferably at a vault angle of about 2 to 5 degrees.
[0044] Implantation of lens 40 ″ in anterior chamber 26 of anterior segment of an eye 20 can be aided by the use of a flexible lens glide (not shown). The maximum diagonal haptic dimension of lens 40 ″ can vary from 10 mm to over 15 mm to permit proper fitting, but a range from 11.5 mm to 15.0 mm in 0.5 mm steps is sufficient to address most eyes. The length of lens 40 ″ is to be determined by adding 1.0 mm to the horizontal corneal diameter (white-to-white) measurement, in mm. No positioning holes are needed in optic element 42 ″ or haptic element 44 ″.
[0045] Lens 40 ″ also can contain a UV-absorbing compound as previously described.
[0046] Referring now to FIGS. 8 and 9, a fourth embodiment of the invention is shown in which lens 40 ″′ is designed for fixation to iris 22 . Lens 40 ′″ can be constructed of a material that is deformable as previously described.
[0047] Optic element 42 ″′ of lens 40 ″′ can be constructed to be either a negative refracting lens or a positive refracting lens. Additionally, the optic element 42 ″′ can include a toric element (not shown) for astigmatism correction.
[0048] Optic element 42 ″′ can have a diameter determined by the needs of the wearer, and can range from about 5 mm to about 8 mm, but is preferably from 5.5 to 7.0 mm. The maximum diagonal haptic dimension for lens 40 ″′ for fixation to iris 22 is also determined by the needs of the wearer, and may range about 7 mm to about 10 mm, but preferably is from 7.5 to 9.0 mm. The vault height for lens 40 ′″ is in a range around 1 mm, preferably from 0.90 mm to 1.05 mm. Lens 40 ″′ is fixed to iris 22 by enclavation of midperipheral iris stroma in gap 52 at the distal end of each haptic element 44 ′″.
[0049] [0049]FIG. 10 illustrates an optic element 42 ″″ of a lens for treatment of presbyopia. Optic element 42 ″″ for the treatment of presbyopia can be used in conjunction with any of the lens embodiments previously described and placed in any chamber of the eye as previously described. Optic element 42 ″″ can be attached to a haptic element (not shown) as previously described in other embodiments of the invention. Optic element 42 ″″ is noticeably distinguished from an optic element for treatment of other disorders in that there are two different focus zones 43 and 45 of optic element 42 ″″. Inner focus zone 43 is for distance focusing, and is typically around 2 mm in diameter. Outer focus zone 45 is designed for near focusing, and comprises the remainder of optic element 42 ″″. Additionally, zone 45 of the optic element 42 ″″ can be designed to include one or more intermediate and/or distance focus zones (not shown) within the near focusing area.
[0050] Finally, referring to FIG. 11, an optic element 42 v is shown for the correction of astigmatism. Optic element 42 v can be used in conjunction with any of the previously described lenses and placed in any chamber of the eye as previously described. Optic element 42 v can be attached to a haptic element (not shown) as previously described in other embodiments of the invention. Toric element 48 of optic element 42 v is a cylindrical lens with its steepest radius of curvature in its shortest dimension 49 . Toric element 48 is on the anterior surface of optic element 42 v . Optic element 42 v can be oriented in the eye such that the flattest radius of curvature of toric element 48 aligned with the axis of the plus cylinder of the patient's refraction.
[0051] Thus, there has been described an IOL that can treat presbyopia, alone or in combination with myopia, hyperopia, and astigmatism. The disclosed IOL can also correct astigmatism, alone, or in combination with myopia or hyperopia.
[0052] A method for preventing or delaying cataract formation by using an IOL that has UV absorbing properties has also been disclosed, as has a method for delaying or preventing the onset of presbyopia by using an IOL with UV absorbing materials. Finally, a method for preventing or delaying the degradation of the IOL has been disclosed by using UV absorbing compounds in the IOL.
[0053] Whereas the present invention has been described with respect to specific embodiments thereof, it will be understood that various changes and modifications will be suggested to one of ordinary skill in the art and it is intended that the invention encompass such changes and modifications as fall within the scope of the appended claims.
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An intraocular lens (IOL) corrects vision disorders and prevents the formation of cataracts. The IOL can be inserted in the anterior or posterior chamber of the eye, or can be iris-fixated. The IOL can correct for myopia, hyperopia, presbyopia and/or astigmatism. Additionally, the IOL contains an ultraviolet radiation (UVR) blocker, that absorbs UVR in the 300-400 nm range. The absorption of the UVR allows the IOL to reduce or eliminate cataract formation.
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Parts of this invention were conceived during performance of a contract between The Eastman Dental Center and the National Institute of Dental Research Contract No. N01-DE-72571.
This application is a continuation-in-part of application Ser. No. 325,815, filed on Mar. 20, 1989, now U.S. Pat. No. 5,049,077.
FIELD OF THE INVENTION
This invention relates generally to systems for retaining and dispensing caries preventative media (fluoride) intraorally for sustained-controlled release to the teeth by the saliva over a long period of time (weeks or months) and to holders for use within the mouth which retain and protect an intra-oral fluoride-releasing device (IFRD). The combination of an IFRD and its holder comprises an intra-oral flouride-releasing system (IFRS). This invention is generally useful in intra-oral medication holders for long term timed release tablets of medication in the mouth without significant irritation of oral tissue.
BACKGROUND OF THE INVENTION
Dental research has had remarkable success in dental caries prevention. Specifically, it has been found that roughly fifty percent of children ages six through seventeen living in the United States are caries free. This remarkable progress during the last twenty years is due, in part, to better oral hygiene, use of fluoridated water, and fluoridated products, i.e., dentifrices.
Nevertheless, there are patients who remain susceptible to dental caries. For instance, twenty percent of all children account for roughly sixty Percent of all carious lesions. Also, certain subjects with diminished salivary functions are especially prone to caries, because they produce limited amounts of saliva. Other risk factors, such as poor oral hygiene, physical or mental handicaps, and certain systemic diseases or disorders may also predispose individuals to dental caries.
Recent studies have demonstrated that elevated concentrations of fluoride in the mouth for extended periods will help reduce caries. A source of such fluoride is contained in controlled-release fluoride tablets which have been called intra-oral fluoride releasing devices (IFRD's). These IFRD's release fluoride into the oral cavity for extended periods up to six months to enhance prevention of dental caries.
Previous attempts to retain IFRD's in the mouth have failed for a variety of reasons. For instance, IFRD's produced by Southern Research Institute were designed to be bonded directly to the teeth. These IFRD's were found susceptible to debonding from masticatory forces or were subject to excessive wear caused by abrasives contained in toothpastes. What is desirable, therefore, is a system whereby IFRD tablets can be safely secured and retained in the mouth until their fluoride supply is exhausted.
In addition, it is desirable to have a system (an intra-oral fluoride release system or IFRS) whereby the tablets can be replaced periodically following depletion of their fluoride content. It is further desirable for these systems to be broadly useful for children undergoing active orthodontic treatment. In general these children have an increased risk to caries development because they are not able to adequately brush their teeth. It is also desirable to provide an IFRS which does not cause severe irritation to mouth tissues What is meant by severe irritation is ulceration or acute inflammation which interferes with oral function and nutrition, such as pain, induration or necrosis or purulent exudate from tissue in the vicinity of the IFRS.
SUMMARY OF THE INVENTION
Accordingly, it is the principal object of this invention to provide an IFRS whereby the foregoing problems and needs are resolved and more particularly to provide intra-oral IFRD holders which can be safely placed and securely retained in the mouth for an indefinite period.
Briefly described, a system according to the invention comprises a holder which has a retaining member, such as a plate or band with a back surface adapted to be disposed on a surface of a tooth. This back surface is connected to a pair of opposed retaining sides within which the tablet can be placed, either directly on the plate, or in a carrier releasably connected to the plate. At the ends of the opposed retaining sides are a pair of retaining posts. These posts can be wrapped with ligatures, which extend over the tablet so that the tablet is exposed in the mouth but remains in place within the holder. An openable cover may be mounted on and extend across the retaining side. Fluoride is delivered to the oral cavity by the IFRD tablets at therapeutic levels continuing for up to six months. The IFRD can be replaced by removing and replacing the ligatures or opening the cover, removing and reinserting the carrier with a fresh tablet, or replacing the system (the IFRD and the holder) in its entirety.
These and other objects and embodiments of the invention will be better understood with the attached figures and detailed description of the drawings, in which:
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment in accordance with the invention shown attached to a tooth;
FIG. 2 is an exploded perspective view of the embodiment of the invention shown in FIG. 1 fluoride tablet;
FIG. 3 is a top view of the retaining member of the holder of the embodiment of the invention shown in FIG. 1;
FIG. 4 is a side view of the retaining member shown in FIG. 3;
FIG. 5 is a front view of the retaining member shown in FIG. 3.
FIG. 6 is a perspective view of another embodiment of the retaining member;
FIG. 7, 7B and 7C are perspective views of variations of a second embodiment in accordance with the present invention;
FIG. 7A is a cross-sectional view across lines 7--7 of the embodiment shown in FIG. 7;
FIG. 8 is a perspective view of a third embodiment in accordance with the present invention; and
FIG. 9A, 9B, 9C are respectively a perspective and two side views of a fourth embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
As seen from FIGS. 1, 2, 3, 4 and 5, there is provided in accordance with a first embodiment of the present invention, an IFRS having a holder 10 for tablets which will be emplaced in the mouth. These tablets are generally controlled release fluoride tablets and are oval or kidney bean shaped such as tablet 100 as seen in FIG. 2. The holder 10 is generally comprised of a band 20 which wraps around the tooth and a retaining member R. This retaining member R will generally be formed of a plate 30 having back surface which is attached, as by spot welding, to the band 20. The member R has retaining sides 40, as best seen in FIGS. 2 and 3. The tablet 100 generally fits snugly within the retaining sides 40 and against the anterior surface of the holder 10. The posterior surface of the plate may be cusp shaped to conform to the outer surface of the tooth.
In order to secure the attachment of the tablet 100 to the holder 10, the plate 30 has a pair of retaining posts 50. These posts 50 have knob-like projections 55, usually with indentations around which miniature elastic bands, known as ligature bands 200, can be attached. When the tablet 100 is inserted into the holder 10, the ligature bands 200 are placed around the knobs 55 so that they snugly hold the tablet 100 within the holder 10, as seen best in FIG. 1. The band 20 then is generally applied around the tooth. Instead of ligature bands, stainless steel ligature wires may be used, and the term ligatures or ligature bands should be taken as encompassing both endless bands and wires.
The method of application will proceed as follows: The tooth generally will have separators placed into the interdental spaces to gain dental ligament space so as to insert the band 20. The band 20 is then inserted around the tooth and made to fit snugly. The tablet 100 is placed onto the plate 30 of the holder 10. The ligature bands 200 are placed around the retaining post knobs 55 and allow the tablet to be releasably retained and protected in the mouth. As can be appreciated, if the intra-oral fluoride tablet 100 is broken in the mouth or releases its fluoride content, the ligature bands 200 can be removed, and a new tablet 100 can be inserted into the holder 10. In this way, the holder 10 can achieve any necessary permanence in the mouth dependent upon the desired dental procedure.
Another holder 10 having a retaining member 130 on a band 120 can be seen in FIG. 6. While the retaining member 30 disclosed in FIGS. 1-5 is generally oval to accommodate an oval shaped tablet, the member 130 in FIG. 6 is generally rectangular. This will hold in place a generally rectangular tablet. As can be seen, the band 120 has attached to it the back surface of the base plate of the retaining member 130. This holder 130 has two retaining sides 140 and two retaining posts 150. The pair of retaining posts is disposed between the two retaining sides 140. On each retaining post 150 there are knobs 155, around which can fit ligature bands 200, as in FIGS. 1-5. Thus, a rectangular shaped tablet is placed against the base plate of the member 130 and between its retaining sides 140. Then, the ligature bands 200 are wrapped around retaining post knobs 155. Again, the device properly remains around the tooth and hygienic treatment is possible.
As seen in FIG. 7 and FIG. 7A, there is provided a holder 210 having a band 220 which has attached to it a retaining member 230 having a plate 231 with sides 231a, 231b. The back surface of plate 231 is attached to the band 220. The plate 231 has connected to it a pair of retaining sides 231a, 231b. Each of the retaining sides 231a, 231b has a notch 242, containing a step 242a. The retaining member 230 slidably receives a drawer 250 having flanges 267 which are received within the notches 242. The step 242a in notch 242 mates with step 267a in flange 267 to keep the drawer 250 in place. This drawer 250 is generally rectangular in shape and will contain a front grill 260 and a pair of side grills 265. A detent ridge 252 on the plate 231 releasably snaps the drawer in place with step 251 in flange 267 of drawer 250 in the position shown, to prevent forward dislodgment with an extension piston.
The front and side grills 260, 265 contain sufficiently large openings so that an IFRD tablet comes into contact with the saliva in the mouth. Because the notches 242 allow the drawer 250 to slide in and out, the tablet 100 can be emplaced within the drawer 250 and then slid into the notches. The drawer 250 can be removed and a new tablet 100 can be inserted, allowing an indefinite period of reuse.
Alternately, drawer 250 can be secured by ligature bands 200 as seen in FIG. 7B. In this aspect of the present embodiment, retaining sides 240 contain retaining posts 255 much like the retaining posts 50, 150 of the earlier embodiments. After emplacement of the drawer 250 into the retaining sides 240 with a tablet 100 in place, the drawer 250 is held by ligature bands 200.
Of course, as seen in FIG. 7C, the device of the present invention can be configured so that the retaining sides and drawer form a single grill shaped retaining unit 270. This retaining unit 270 has an open side into which the tablet 100 is placed. Ligature bands 200 are then wrapped over the retaining unit opening, and securely around posts 255. Operation of the holder will be identical to the previous embodiments.
Another third embodiment of the invention can be seen in FIG. 8. This embodiment provides a holder 310 which can be used along with orthodontic dental brackets (seen as brackets 331) which are attached to a band 333. As can be seen from FIG. 8, there is an oval or rectangular shaped retaining member 330 with a cage or retaining wall 340 which generally conforms to the shape of one of the intra-oral fluoride tablets (IFRD). This retaining wall 340 has a back plate to which a post 360 is attached. An end 361 of this post extends through one side of the cage 340. The other end 365 of the post 360 is "Z" shaped, to allow an optional range of intra-oral placement. The "Z" shaped end 365 can be inserted into one of the dental brackets 331 which provides an archwire slot. Alternately, cage 340 can be attached to the tooth directly by means of adhesive. Or, the back of the base plate of the member 330 of the holder can be attached using a band as in the system as shown in FIGS. 1-7.
This holder 310 has a cover of resilient material 350 containing a grill 345. This cover has fingers 348 which curl around a rod 347, attached to the lower side of a cage 340, forming a hinge. On the cover 350 there is also a rib detent 349. This detent may catch on a projection 351 on the upper side of the cage which snugly causes the cover to attach to the cage and cover the front thereof. Thus, the cover can be opened and the tablet can be inserted within the retaining cage 340. This holder 310 can be removed and used more than one time (i.e., for other patients or moved to other brackets elsewhere in the mouth). This causes this embodiment to be versatile and may be preferred for those patients needing or having other orthodontic appliances.
Finally, a fourth embodiment of the present invention can be seen in FIGS. 9A-9C. There is disclosed a holder 410 having a pair of side retaining walls or bands 420 which are wrapped around the tooth. Onto the band 420 is welded a back surface 430 having hinged claws 440. These claws 440 are pivoted about posts 450 to allow emplacement of the tablet 100 on the back surface 430. When in place the claws are approximated and kept closed by the wrapping of ligature bands around the claws 440. In this manner, the holder 410 adequately retains and exposes a tablet for use. Alternately, claws 440 can be connected with a longitudinal bar. If so, a spring clip as demonstrated in FIG. 8 can be used to retain the IFRD tablet in holder 410.
It should be noted that all the holder embodiments are preferably made of a high strength aluminum or other metal (e.g., stainless steel) or, in the alternative, a non-degradeable bio-compatible hardened plastic. The material withstands masticatory forces in the mouth, yet still allows large open areas of contact with the saliva to allow release of fluoride to the oral cavity.
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A system for long term releasing of medication in the mouth, and especially an intra-oral fluoride releasing system (IFRS) for releasing fluoride over a long term for inhibiting the formation of caries in the teeth. The system uses a holder for retaining and protecting intra-oral fluoride tablets or other intra-oral medicament in the form of fluoride releasing devices (IFRD). The holder has a plate with retaining sides and retaining posts or a carrier. The tablet will fit within the holder. The tablet may be located in the carrier, or ligature bands can be tied around the tablet in order to releasably hold the IFRD within the holder. The system causes a level of fluoride to be maintained over a long term within the mouth which has been found chemically effective for caries control and without causing severe irritation to oral tissues.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a Continuation application of U.S. Ser. No. 11/505,848 filed on Aug. 18, 2006, which is a Continuation application of U.S. Ser. No. 10/728,935 filed on Dec. 8, 2003, now issued U.S. Pat. No. 7,097,282, which is a Continuation application of U.S. Ser. No. 10/102,700 filed on Mar. 22, 2002, now issued U.S. Pat. No. 6,692,113, all of which are herein incorporated by reference.
CO-PENDING APPLICATIONS
[0002] Various methods, systems and apparatus relating to the present invention are disclosed in the following co-pending applications filed by the applicant or assignee of the present invention:
[0000] U.S. Pat. Nos. 6,428,133, 6,526,658, 6,795,215, 7,154,638.
[0003] The disclosures of these co-pending applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0004] The following invention relates to a printhead module assembly for a printer.
[0005] More particularly, though not exclusively, the invention relates to a printhead module assembly for an A4 pagewidth drop on demand printer capable of printing up to 1600 dpi photographic quality at up to 160 pages per minute.
[0006] The overall design of a printer in which the printhead module assembly can be utilized revolves around the use of replaceable printhead modules in an array approximately 8½ inches (21 cm) long. An advantage of such a system is the ability to easily remove and replace any defective modules in a printhead array. This would eliminate having to scrap an entire printhead if only one chip is defective.
[0007] A printhead module in such a printer can be comprised of a “Memjet” chip, being a chip having mounted thereon a vast number of thermo-actuators in micro-mechanics and micro-electromechanical systems (MEMS). Such actuators might be those as disclosed in U.S. Pat. No. 6,044,646 to the present applicant, however, might be other MEMS print chips.
[0008] In a typical embodiment, eleven “Memjet” tiles can butt together in a metal channel to form a complete 8½ inch printhead assembly.
[0009] The printhead, being the environment within which the printhead module assemblies of the present invention are to be situated, might typically have six ink chambers and be capable of printing four color process (CMYK) as well as infra-red ink and fixative. An air pump would supply filtered air through a seventh chamber to the printhead, which could be used to keep foreign particles away from its ink nozzles.
[0010] Each printhead module receives ink via an elastomeric extrusion that transfers the ink. Typically, the printhead assembly is suitable for printing A4 paper without the need for scanning movement of the printhead across the paper width.
[0011] The printheads themselves are modular, so printhead arrays can be configured to form printheads of arbitrary width.
[0012] Additionally, a second printhead assembly can be mounted on the opposite side of a paper feed path to enable double-sided high speed printing.
OBJECTS OF THE INVENTION
[0013] It is an object of the present invention to provide an improved printhead module assembly.
[0014] It is another object of the invention to provide a printhead assembly having improved modules therein.
SUMMARY OF THE INVENTION
[0015] According to a first aspect of the invention, there is provided a printhead assembly which comprises
[0016] an elongate support structure; and
[0017] at least one printhead module positioned in the support structure, along a length of the support structure, the, or each printhead module comprising
an ink feed member that defines a number of ink channels in fluid communication with an ink supply, the ink feed member having a plurality of outlet openings from which ink can be fed; an ink delivery assembly that is positioned on the ink feed member, the ink delivery assembly defining a mounting formation to permit a printhead chip to be mounted on the ink delivery system, a plurality of ink inlets that are in fluid communication with the outlet openings of the ink feed member, a plurality of exit holes and tortuous ink flow paths from each ink inlet to a number of respective exit holes; and an elongate printhead chip that is mounted on the mounting formation, the printhead chip incorporating a plurality of nozzle arrangements that extend along a length of the chip, the printhead chip being positioned so that the ink can be fed from the exit holes to the printhead chip.
[0021] The support structure may be in the form of an elongate channel member and the assembly may include a plurality of printhead modules positioned in a channel defined by the channel member.
[0022] The elongate channel member may be of a nickel iron alloy that is annealed to enhance dimensional stability.
[0023] Each ink feed member may be in the form of an extrusion of an elastomeric material, the channels extending longitudinally in the extrusion and the outlet openings being holes defined in a surface of the extrusion to be in fluid communication with respective ink channels.
[0024] Each ink delivery assembly may include a pair of micro-moldings that are positioned so that a lower micro-molding is interposed between an upper micro-molding and the ink feed member. The lower micro-molding may define a plurality of ink chambers in fluid communication with respective outlet openings of the ink feed member, via the ink inlets. The upper micro-molding may define the exit holes in fluid communication with the ink chambers.
[0025] The micro-moldings may both be of a liquid crystal polymer.
[0026] The ink delivery assembly may include a film member that is interposed between the upper and lower micro-moldings. The film member may define a plurality of openings to permit the passage of ink. The film member may have an adhesive layer on both sides of the film member so that the film member serves to provide adhesion between the micro-moldings.
[0027] The ink feed member may define an air channel and the ink delivery assembly may define an air path in fluid communication with the air channel that terminates at an exhaust hole defined by the upper micro-molding so that air driven through the ink delivery assembly from the air channel serves to repel a print medium from the printhead module during a printing operation.
[0028] According to a second aspect of the invention, there is provided a printhead module for a printhead assembly incorporating a plurality of said modules positioned substantially across a pagewidth in a drop on demand ink jet printer, comprising:
[0029] an upper micro-molding locating a print chip having a plurality of ink jet nozzles, the upper micro-molding having ink channels delivering ink to said print chip,
[0030] a lower micro-molding having inlets through which ink is received from a source of ink, and
[0031] a mid-package film adhered between said upper and lower micro-moldings and having holes through which ink passes from the lower micro-molding to the upper micro-molding.
[0032] Preferably the mid-package film is made of an inert polymer.
[0033] Preferably the holes of the mid-package film are laser ablated.
[0034] Preferably the mid-package film has an adhesive layer on opposed faces thereof, providing adhesion between the upper micro-molding, the mid-package film and the lower micro-molding.
[0035] Preferably the upper micro-molding has an alignment pin passing through an aperture in the mid-package film and received within a recess in the lower micro-molding, the pin serving to align the upper micro-molding, the mid-package film and the lower micro-molding when they are bonded together.
[0036] Preferably the inlets of the lower micro-molding are formed on an underside thereof.
[0037] Preferably six said inlets are provided for individual inks.
[0038] Preferably the lower micro-molding also includes an air inlet.
[0039] Preferably the air inlet includes a slot extending across the lower micro-molding.
[0040] Preferably the upper micro-molding includes exit holes corresponding to inlets on a backing layer of the print chip.
[0041] Preferably the backing layer is made of silicon.
[0042] Preferably the printhead module further comprises an elastomeric pad on an edge of the lower micro-molding.
[0043] Preferably the upper and lower micro-moldings are made of Liquid Crystal Polymer (LCP).
[0044] Preferably an upper surface of the upper micro-molding has a series of alternating air inlets and outlets cooperative with a capping device to redirect a flow of air through the upper micro-molding.
[0045] Preferably each printhead module has an elastomeric pad on an edge of its lower micro-molding, the elastomeric pads bearing against an inner surface of the channel to positively locate the printhead modules within the channel.
[0046] As used herein, the term “ink” is intended to mean any fluid which flows through the printhead to be delivered to print media. The fluid may be one of many different colored inks, infra-red ink, a fixative or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings wherein:
[0048] FIG. 1 is a schematic overall view of a printhead;
[0049] FIG. 2 is a schematic exploded view of the printhead of FIG. 1 ;
[0050] FIG. 3 is a schematic exploded view of an ink jet module;
[0051] FIG. 3 a is a schematic exploded inverted illustration of the ink jet module of FIG. 3 ;
[0052] FIG. 4 is a schematic illustration of an assembled ink jet module;
[0053] FIG. 5 is a schematic inverted illustration of the module of FIG. 4 ;
[0054] FIG. 6 is a schematic close-up illustration of the module of FIG. 4 ;
[0055] FIG. 7 is a schematic illustration of a chip sub-assembly;
[0056] FIG. 8 a is a schematic side elevational view of the printhead of FIG. 1 ;
[0057] FIG. 8 b is a schematic plan view of the printhead of FIG. 8 a;
[0058] FIG. 8 c is a schematic side view (other side) of the printhead of FIG. 8 a;
[0059] FIG. 8 d is a schematic inverted plan view of the printhead of FIG. 8 b;
[0060] FIG. 9 is a schematic cross-sectional end elevational view of the printhead of FIG. 1 ;
[0061] FIG. 10 is a schematic illustration of the printhead of FIG. 1 in an uncapped configuration;
[0062] FIG. 11 is a schematic illustration of the printhead of FIG. 10 in a capped configuration;
[0063] FIG. 12 a is a schematic illustration of a capping device;
[0064] FIG. 12 b is a schematic illustration of the capping device of FIG. 12 a , viewed from a different angle;
[0065] FIG. 13 is a schematic illustration showing the loading of an ink jet module into a printhead;
[0066] FIG. 14 is a schematic end elevational view of the printhead illustrating the printhead module loading method;
[0067] FIG. 15 is a schematic cut-away illustration of the printhead assembly of FIG. 1 ;
[0068] FIG. 16 is a schematic close-up illustration of a portion of the printhead of FIG. 15 showing greater detail in the area of the “Memjet” chip;
[0069] FIG. 17 is a schematic illustration of the end portion of a metal channel and a printhead location molding;
[0070] FIG. 18 a is a schematic illustration of an end portion of an elastomeric ink delivery extrusion and a molded end cap; and
[0071] FIG. 18 b is a schematic illustration of the end cap of FIG. 18 a in an out-folded configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0072] In FIG. 1 of the accompanying drawings there is schematically depicted an overall view of a printhead assembly. FIG. 2 shows the core components of the assembly in an exploded configuration. The printhead assembly 10 of the preferred embodiment comprises eleven printhead modules 11 situated along a metal “Invar” channel 16 . At the heart of each printhead module 11 is a “Memjet” chip 23 ( FIG. 3 ). The particular chip chosen in the preferred embodiment being a six-color configuration.
[0073] The “Memjet” printhead modules 11 are comprised of the “Memjet” chip 23 , a fine pitch flex PCB 26 and two micro-moldings 28 and 34 sandwiching a mid-package film 35 . Each module 11 forms a sealed unit with independent ink chambers 63 ( FIG. 9 ) which feed the chip 23 . The modules 11 plug directly onto a flexible elastomeric extrusion 15 which carries air, ink and fixitive (see channels 49 - 55 in FIG. 15 ). The upper surface of the extrusion 15 has repeated patterns of holes 21 which align with ink inlets 32 ( FIG. 3 a ) on the underside of each module 11 . The extrusion 15 is bonded onto a flex PCB (flexible printed circuit board).
[0074] The fine pitch flex PCB 26 wraps down the side of each printhead module 11 and makes contact with the flex PCB 17 ( FIG. 9 ). The flex PCB 17 carries two busbars 19 (positive) and 20 (negative) for powering each module 11 , as well as all data connections. The flex PCB 17 is bonded onto the continuous metal “Invar” channel 16 . The metal channel 16 serves to hold the modules 11 in place and is designed to have a similar coefficient of thermal expansion to that of silicon used in the modules.
[0075] A capping device 12 is used to cover the “Memjet” chips 23 when not in use. The capping device is typically made of spring steel with an onsert molded elastomeric pad 47 ( FIG. 12 a ). The pad 47 serves to duct air into the “Memjet” chip 23 when uncapped and cut off air and cover a nozzle guard 24 ( FIG. 9 ) when capped. The capping device 12 is actuated by a camshaft 13 that typically rotates throughout 180°.
[0076] The overall thickness of the “Memjet” chip is typically 0.6 mm which includes a 150 micron inlet backing layer 27 and a nozzle guard 24 of 150 micron thickness. These elements are assembled at the wafer scale.
[0077] The nozzle guard 24 allows filtered air into an 80 micron cavity 64 ( FIG. 16 ) above the “Memjet” ink nozzles 62 . The pressurized air flows through microdroplet holes 45 in the nozzle guard 24 (with the ink during a printing operation) and serves to protect the delicate “Memjet” nozzles 62 by repelling foreign particles.
[0078] A silicon chip backing layer 27 ducts ink from the printhead module packaging directly into the rows of “Memjet” nozzles 62 . The “Memjet” chip 23 is wire bonded 25 from bond pads on the chip at 116 positions to the fine pitch flex PCB 26 . The wire bonds are on a 120 micron pitch and are cut as they are bonded onto the fine pitch flex PCB pads ( FIG. 3 ). The fine pitch flex PCB 26 carries data and power from the flex PCB 17 via a series of gold contact pads 69 along the edge of the flex PCB.
[0079] The wire bonding operation between chip and fine pitch flex PCB 26 may be done remotely, before transporting, placing and adhering the chip assembly into the printhead module assembly. Alternatively, the “Memjet” chips 23 can be adhered into the upper micro-molding 28 first and then the fine pitch flex PCB 26 can be adhered into place. The wire bonding operation could then take place in situ, with no danger of distorting the moldings 28 and 34 . The upper micro-molding 28 can be made of a Liquid Crystal Polymer (LCP) blend. Since the crystal structure of the upper micro-molding 28 is minute, the heat distortion temperature (180° C.-260° C.), the continuous usage temperature (200° C.-240° C.) and soldering heat durability (260° C. for 10 seconds to 310° C. for 10 seconds) are high, regardless of the relatively low melting point.
[0080] Each printhead module 11 includes an upper micro-molding 28 and a lower micro-molding 34 separated by a mid-package film layer 35 shown in FIG. 3 .
[0081] The mid-package film layer 35 can be an inert polymer such as polyimide, which has good chemical resistance and dimensional stability. The mid-package film layer 35 can have laser ablated holes 65 and can comprise a double-sided adhesive (ie. an adhesive layer on both faces) providing adhesion between the upper micro-molding, the mid-package film layer and the lower micro-molding.
[0082] The upper micro-molding 28 has a pair of alignment pins 29 passing through corresponding apertures in the mid-package film layer 35 to be received within corresponding recesses 66 in the lower micro-molding 34 . This serves to align the components when they are bonded together. Once bonded together, the upper and lower micro-moldings form a tortuous ink and air path in the complete “Memjet” printhead module 11 . In addition, an upper surface of the upper micro-molding 28 has a pair of opposed recesses 39 which serve as robot pick-up points for picking and placing the micro-molding.
[0083] There are annular ink inlets 32 in the underside of the lower micro-molding 34 . In a preferred embodiment, there are six such inlets 32 for various inks (black, yellow, magenta, cyan, fixitive and infrared). There is also provided an air inlet slot 67 . The air inlet slot 67 extends across the lower micro-molding 34 to a secondary inlet which expels air through an exhaust hole 33 , through an aligned hole 68 in fine pitch flex PCB 26 . This serves to repel the print media from the printhead during printing. The ink inlets 32 continue in the undersurface of the upper micro-molding 28 as does a path from the air inlet slot 67 . The ink inlets lead to 200 micron exit holes also indicated at 32 in FIG. 3 . These holes correspond to the inlets on the silicon backing layer 27 of the “Memjet” chip 23 .
[0084] There is a pair of elastomeric pads 36 on an edge of the lower micro-molding 34 . These serve to take up tolerance and positively located the printhead modules 11 into the metal channel 16 when the modules are micro-placed during assembly.
[0085] A preferred material for the “Memjet” micro-moldings is a LCP. This has suitable flow characteristics for the fine detail in the moldings and has a relatively low coefficient of thermal expansion.
[0086] Robot picker details are included in the upper micro-molding 28 to enable accurate placement of the printhead modules 11 during assembly.
[0087] The upper surface of the upper micro-molding 28 as shown in FIG. 3 has a series of alternating air inlets and outlets 31 and 30 . These act in conjunction with the capping device 12 and are either sealed off or grouped into air inlet/outlet chambers, depending upon the position of the capping device 12 . They connect air diverted from the inlet slot 67 to the chip 23 depending upon whether the unit is capped or uncapped.
[0088] A capper cam detail 40 including a ramp for the capping device is shown at two locations in the upper surface of the upper micro-molding 28 . This facilitates a desirable movement of the capping device 12 to cap or uncap the chip and the air chambers. That is, as the capping device is caused to move laterally across the print chip during a capping or uncapping operation, the ramp of the capper cam detail 40 serves to elastically distort and capping device as it is moved by operation of the camshaft 13 so as to prevent scraping of the device against the nozzle guard 24 .
[0089] The “Memjet” chip assembly 23 is picked and bonded into the upper micro-molding 28 on the printhead module 11 . The fine pitch flex PCB 26 is bonded and wrapped around the side of the assembled printhead module 11 as shown in FIG. 4 . After this initial bonding operation, the chip 23 has more sealant or adhesive 46 applied to its long edges. This serves to “pot” the bond wires 25 ( FIG. 6 ), seal the “Memjet” chip 23 to the molding 28 and form a sealed gallery into which filtered air can flow and exhaust through the nozzle guard 24 .
[0090] The flex PCB 17 carries all data and power connections from the main PCB (not shown) to each “Memjet” printhead module 11 . The flex PCB 17 has a series of gold plated, domed contacts 69 ( FIG. 2 ) which interface with contact pads 41 , 42 and 43 that are located, together with section 44 , on the fine pitch flex PCB 26 of each “Memjet” printhead module 11 .
[0091] Two copper busbar strips 19 and 20 , typically of 200 micron thickness, are jigged and soldered into place on the flex PCB 17 . The busbars 19 and 20 connect to a flex termination which also carries data
[0092] The flex PCB 17 is approximately 340 mm in length and is formed from a 14 mm wide strip. It is bonded into the metal channel 16 during assembly and exits from one end of the printhead assembly only.
[0093] The metal U-channel 16 into which the main components are place is of a special alloy called “Invar 36”. It is a 36% nickel iron alloy possessing a coefficient of thermal expansion of 1/10 th that of carbon steel at temperatures up to 400° F. The Invar is annealed for optimal dimensional stability.
[0094] Additionally, the Invar is nickel plated to a 0.056% thickness of the wall section. This helps to further match it to the coefficient of thermal expansion of silicon which is 2×10 −6 per ° C.
[0095] The Invar channel 16 functions to capture the “Memjet” printhead modules 11 in a precise alignment relative to each other and to impart enough force on the modules 11 so as to form a seal between the ink inlets 32 on each printhead module and the outlet holes 21 that are laser ablated into the elastomeric ink delivery extrusion 15 .
[0096] The similar coefficient of thermal expansion of the Invar channel to the silicon chips allows similar relative movement during temperature changes. The elastomeric pads 36 on one side of each printhead module 11 serve to “lubricate” them within the channel 16 to take up any further lateral coefficient of thermal expansion tolerances without losing alignment. The Invar channel is a cold rolled, annealed and nickel plated strip. Apart from two bends that are required in its formation, the channel has two square cut-outs 80 at each end. These mate with snap fittings 81 on the printhead location moldings 14 ( FIG. 17 ).
[0097] The elastomeric ink delivery extrusion 15 is a non-hydrophobic, precision component. Its function is to transport ink and air to the “Memjet” printhead modules 11 . The extrusion is bonded onto the top of the flex PCB 17 during assembly and it has two types of molded end caps. One of these end caps is shown at 70 in FIG. 18 a.
[0098] A series of patterned holes 21 are present on the upper surface of the extrusion 15 . These are laser ablated into the upper surface. To this end, a mask is made and placed on the surface of the extrusion, which then has focused laser light applied to it. The holes 21 are evaporated from the upper surface, but the laser does not cut into the lower surface of extrusion 15 due to the focal length of the laser light.
[0099] Eleven repeated patterns of the laser ablated holes 21 form the ink and air outlets 21 of the extrusion 15 . These interface with the annular ring inlets 32 on the underside of the “Memjet” printhead module lower micro-molding 34 . A different pattern of larger holes (not shown but concealed beneath the upper plate 71 of end cap 70 in FIG. 18 a ) is ablated into one end of the extrusion 15 . These mate with apertures 75 having annular ribs formed in the same way as those on the underside of each lower micro-molding 34 described earlier. Ink and air delivery hoses 78 are connected to respective connectors 76 that extend from the upper plate 71 . Due to the inherent flexibility of the extrusion 15 , it can contort into many ink connection mounting configurations without restricting ink and air flow. The molded end cap 70 has a spine 73 from which the upper and lower plates are integrally hinged. The spine 73 includes a row of plugs 74 that are received within the ends of the respective flow passages of the extrusion 15 .
[0100] The other end of the extrusion 15 is capped with simple plugs which block the channels in a similar way as the plugs 74 on spine 17 .
[0101] The end cap 70 clamps onto the ink extrusion 15 by way of snap engagement tabs 77 . Once assembled with the delivery hoses 78 , ink and air can be received from ink reservoirs and an air pump, possibly with filtration means. The end cap 70 can be connected to either end of the extrusion, ie. at either end of the printhead.
[0102] The plugs 74 are pushed into the channels of the extrusion 15 and the plates 71 and 72 are folded over. The snap engagement tabs 77 clamp the molding and prevent it from slipping off the extrusion. As the plates are snapped together, they form a sealed collar arrangement around the end of the extrusion. Instead of providing individual hoses 78 pushed onto the connectors 76 , the molding 70 might interface directly with an ink cartridge. A sealing pin arrangement can also be applied to this molding 70 . For example, a perforated, hollow metal pin with an elastomeric collar can be fitted to the top of the inlet connectors 76 . This would allow the inlets to automatically seal with an ink cartridge when the cartridge is inserted. The air inlet and hose might be smaller than the other inlets in order to avoid accidental charging of the airways with ink.
[0103] The capping device 12 for the “Memjet” printhead would typically be formed of stainless spring steel. An elastomeric seal or onsert molding 47 is attached to the capping device as shown in FIGS. 12 a and 12 b . The metal part from which the capping device is made is punched as a blank and then inserted into an injection molding tool ready for the elastomeric onsert to be shot onto its underside. Small holes 79 ( FIG. 12 b ) are present on the upper surface of the metal capping device 12 and can be formed as burst holes. They serve to key the onsert molding 47 to the metal. After the molding 47 is applied, the blank is inserted into a press tool, where additional bending operations and forming of integral springs 48 takes place.
[0104] The elastomeric onsert molding 47 has a series of rectangular recesses or air chambers 56 . These create chambers when uncapped. The chambers 56 are positioned over the air inlet and exhaust holes 31 and 30 of the upper micro-molding 28 in the “Memjet” printhead module 11 . These allow the air to flow from one inlet to the next outlet. When the capping device 12 is moved forward to the “home” capped position as depicted in FIG. 11 , these airways 32 are sealed off with a blank section of the onsert molding 47 cutting off airflow to the “Memjet” chip 23 . This prevents the filtered air from drying out and therefore blocking the delicate “Memjet” nozzles.
[0105] Another function of the onsert molding 47 is to cover and clamp against the nozzle guard 24 on the “Memjet” chip 23 . This protects against drying out, but primarily keeps foreign particles such as paper dust from entering the chip and damaging the nozzles. The chip is only exposed during a printing operation, when filtered air is also exiting along with the ink drops through the nozzle guard 24 . This positive air pressure repels foreign particles during the printing process and the capping device protects the chip in times of inactivity.
[0106] The integral springs 48 bias the capping device 12 away from the side of the metal channel 16 . The capping device 12 applies a compressive force to the top of the printhead module 11 and the underside of the metal channel 16 . The lateral capping motion of the capping device 12 is governed by an eccentric camshaft 13 mounted against the side of the capping device. It pushes the device 12 against the metal channel 16 . During this movement, the bosses 57 beneath the upper surface of the capping device 12 ride over the respective ramps 40 formed in the upper micro-molding 28 . This action flexes the capping device and raises its top surface to raise the onsert molding 47 as it is moved laterally into position onto the top of the nozzle guard 24 .
[0107] The camshaft 13 , which is reversible, is held in position by two printhead location moldings 14 . The camshaft 11 can have a flat surface built in one end or be otherwise provided with a spline or keyway to accept gear 22 or another type of motion controller.
[0108] The “Memjet” chip and printhead module are assembled as follows:
1. The “Memjet” chip 23 is dry tested in flight by a pick and place robot, which also dices the wafer and transports individual chips to a fine pitch flex PCB bonding area. 2. When accepted, the “Memjet” chip 23 is placed 530 microns apart from the fine pitch flex PCB 26 and has wire bonds 25 applied between the bond pads on the chip and the conductive pads on the fine pitch flex PCB. This constitutes the “Memjet” chip assembly. 3. An alternative to step 2 is to apply adhesive to the internal walls of the chip cavity in the upper micro-molding 28 of the printhead module and bond the chip into place first. The fine pitch flex PCB 26 can then be applied to the upper surface of the micro-molding and wrapped over the side. Wire bonds 25 are then applied between the bond pads on the chip and the fine pitch flex PCB. 4. The “Memjet” chip assembly is vacuum transported to a bonding area where the printhead modules are stored. 5. Adhesive is applied to the lower internal walls of the chip cavity and to the area where the fine pitch flex PCB is going to be located in the upper micro-molding of the printhead module. 6. The chip assembly (and fine pitch flex PCB) are bonded into place. The fine pitch flex PCB is carefully wrapped around the side of the upper micro-molding so as not to strain the wire bonds. This may be considered as a two step gluing operation if it is deemed that the fine pitch flex PCB might stress the wire bonds. A line of adhesive running parallel to the chip can be applied at the same time as the internal chip cavity walls are coated. This allows the chip assembly and fine pitch flex PCB to be seated into the chip cavity and the fine pitch flex PCB allowed to bond to the micro-molding without additional stress. After curing, a secondary gluing operation could apply adhesive to the short side wall of the upper micro-molding in the fine pitch flex PCB area. This allows the fine pitch flex PCB to be wrapped around the micro-molding and secured, while still being firmly bonded in place along on the top edge under the wire bonds. 7. In the final bonding operation, the upper part of the nozzle guard is adhered to the upper micro-molding, forming a sealed air chamber. Adhesive is also applied to the opposite long edge of the “Memjet” chip, where the bond wires become ‘potted’ during the process. 8. The modules are ‘wet’ tested with pure water to ensure reliable performance and then dried out. 9. The modules are transported to a clean storage area, prior to inclusion into a printhead assembly, or packaged as individual units. This completes the assembly of the “Memjet” printhead module assembly. 10. The metal Invar channel 16 is picked and placed in a jig. 11. The flex PCB 17 is picked and primed with adhesive on the busbar side, positioned and bonded into place on the floor and one side of the metal channel. 12. The flexible ink extrusion 15 is picked and has adhesive applied to the underside. It is then positioned and bonded into place on top of the flex PCB 17 . One of the printhead location end caps is also fitted to the extrusion exit end. This constitutes the channel assembly.
[0121] The laser ablation process is as follows:
13. The channel assembly is transported to an eximir laser ablation area. 14. The assembly is put into a jig, the extrusion positioned, masked and laser ablated. This forms the ink holes in the upper surface. 15. The ink extrusion 15 has the ink and air connector molding 70 applied. Pressurized air or pure water is flushed through the extrusion to clear any debris. 16. The end cap molding 70 is applied to the extrusion 15 . It is then dried with hot air. 17. The channel assembly is transported to the printhead module area for immediate module assembly. Alternatively, a thin film can be applied over the ablated holes and the channel assembly can be stored until required.
[0127] The printhead module to channel is assembled as follows:
18. The channel assembly is picked, placed and clamped into place in a transverse stage in the printhead assembly area. 19. As shown in FIG. 14 , a robot tool 58 grips the sides of the metal channel and pivots at pivot point against the underside face to effectively flex the channel apart by 200 to 300 microns. The forces applied are shown generally as force vectors F in FIG. 14 . This allows the first “Memjet” printhead module to be robot picked and placed (relative to the first contact pads on the flex PCB 17 and ink extrusion holes) into the channel assembly. This is further facilitated by a recess 59 formed in the body of each module 11 . 20. The tool 58 is relaxed, the printhead module captured by the resilience of the Invar channel and the transverse stage moves the assembly forward by 19.81 mm. 21. The tool 58 grips the sides of the channel again and flexes it apart ready for the next printhead module. 22. A second printhead module 11 is picked and placed into the channel 50 microns from the previous module. 23. An adjustment actuator arm locates the end of the second printhead module. The arm is guided by the optical alignment of fiducials on each strip. As the adjustment arm pushes the printhead module over, the gap between the fiducials is closed until they reach an exact pitch of 19.812 mm. 24. The tool 58 is relaxed and the adjustment arm is removed, securing the second printhead module in place. 25. This process is repeated until the channel assembly has been fully loaded with printhead modules. The unit is removed from the transverse stage and transported to the capping assembly area. Alternatively, a thin film can be applied over the nozzle guards of the printhead modules to act as a cap and the unit can be stored as required.
[0136] The capping device is assembled as follows:
26. The printhead assembly is transported to a capping area. The capping device 12 is picked, flexed apart slightly and pushed over the first module 11 and the metal channel 16 in the printhead assembly. It automatically seats itself into the assembly by virtue of the bosses 57 in the steel locating in the recesses 83 in the upper micro-molding in which a respective ramp 40 is located. 27. Subsequent capping devices are applied to all the printhead modules. 28. When completed, the camshaft 13 is seated into the printhead location molding 14 of the assembly. It has the second printhead location molding seated onto the free end and this molding is snapped over the end of the metal channel, holding the camshaft and capping devices captive. 29. A molded gear 22 or other motion control device can be added to either end of the camshaft 13 at this point. 30. The capping assembly is mechanically tested.
[0142] Print charging is as follows:
31. The printhead assembly 10 is moved to the testing area. Inks are applied through the “Memjet” modular printhead under pressure. Air is expelled through the “Memjet” nozzles during priming. When charged, the printhead can be electrically connected and tested. 32. Electrical connections are made and tested as follows: 33. Power and data connections are made to the PCB. Final testing can commence, and when passed, the “Memjet” modular printhead is capped and has a plastic sealing film applied over the underside that protects the printhead until product installation.
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An ink delivery system is provided for delivering ink to a plurality of printhead modules. The ink delivery system includes a channel structure defining a channel and a first pair of locating formations on either side of the channel. A printhead module location molding defines both a bight configured to receive the channel structure and a second pair of locating formations which form a complementary fastening arrangement with the first locating formations. An ink delivery extrusion is configured to be located within the channel and defines a plurality of internal ink channels. The extrusion further defines a plurality of groups of holes for engaging with respective printhead modules. The holes of each group extend from respective ink channels. An endcap is configured to cap the ink channels at an end of the ink delivery extrusion.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
Description of Attached Appendix
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] This invention relates generally to the field of snowboarding and more specifically to Angularly Adjustable Mechanism for Snowboard Bindings. Snowboard binding systems generally use a toothed disk bolted directly to the snowboard whereas the disk mates with a toothed recess in the boot binding. Altering the angular orientation is a time-consuming trial and error process necessitating disassembly and reassembly to eventually arrive -at a satisfactory alignment. However, a snowboarder may not use the same boot orientation for all snow surfaces. Half-pipes, slaloms, and downhill runs all might lend themselves to differing stances primarily the angular orientation of the bindings to the longitudinal axis of the snowboard.
[0005] In addition to the desirability of changing the angular orientation of the bindings to accommodate riding the snowboard over varying terrain, the bottom of the slope provides another opportunity for changing binding orientation. Typically after a downhill run, the snowboard rider will unbuckle one boot to propel himself or herself forward much like a skateboarder with the other boot still bound to the board. Unlike normal riding where the longitudinal axis of the snowboard is aligned side-to-side with feet and hips, during level-ground locomotion, the snowboard is aligned front-to-rear, with the boot still bound at a nearly perpendicular angle to what is anatomically comfortable. In addition to being very uncomfortable, it can lead to or exacerbate strains and other maladies in the leg. Using an Angularly Adjustable Mechanism for Snowboard Bindings, the rider in this situation can orient the boot still bound with the longitudinal axis of the snowboard and travel more easily and with greater comfort and safety, especially when mounting and dismounting the chair lift.
[0006] Prior devices have been invented for snowboard binding adjustment as described in the following patents:
U.S Pat. No. Patentee Issue Date 5,941,552 Beran Aug. 24, 1999 5,947,488 Gorza Sep. 7, 1999 5,028,068 Donovan Jul. 2, 1991 5,897,128 McKenzie Apr. 27, 1999 6,206,402 Tanaka Mar. 27, 2001 5,782,476 Fardie Jul. 21, 1998 5,667,237 Lauer Sep. 16, 1997 5,586,779 Dawes Dec. 24, 1996 6,318,749 Eglitis Nov. 20, 2001 6,022,040 Buzbee Feb. 8, 2000
[0007] The prior patents: U.S. Pat. No. 5,941,552 Adjustable Snowboard Binding Apparatus and Method, U.S. Pat. No. 5,947,488 Angular Adjustment Device, Particularly for a Snowboard Binding, U.S. Pat. No. 5,028,068 Quick-Action Adjustable Snow Boot Binding Mounting, U.S. Pat. No. 5,897,128 Pivotally Adjustable Binding For Snowboards, U.S. Pat. No. 6,206,402 Snowboard Binding Adjustment Mechanism, U.S. Pat. No. 5,782,476 Snowboard Binding Mechanism, U.S. Pat. No. 5,667,237 Rotary Locking Feature For Snowboard Binding, U.S. Pat. No. 5,586,779 Adjustable Snowboard Boot Binding Apparatus, and U.S. Pat. No. 6,318,749 Angularly Adjustable Snowboard Binding Mount all require a lever to lock and unlock angular adjustment device.
[0008] U.S. Pat. No. 6,022,040 Freely Rotating Step-In Snowboard Binding provides no means of locking the binding's swiveling device. A rider employing a snowboard equipped with this device would have far less control over the snowboard than a rigidly secured binding.
[0009] Unlike prior inventions, the Angular Adjustment Mechanism for Snowboard Bindings positioned between the snowboard and boot binding allows angular adjustment between the snowboard rider's boot bindings and the snowboard without the need for any tools or levers. The user can make adjustments at any time by weighting the board with either foot and lifting and rotating the opposite foot. A lifting action releases the mechanism allowing for the adjustment of angular orientation. Removal of the lifting force engages the locking mechanism preventing further angular movement.
BRIEF SUMMARY OF THE INVENTION
[0010] The primary object of the invention is the convenience of adjusting the angular orientation of the snowboard bindings easily at any time, even while in motion. Another object of the invention is no external levers or tools to perform the adjustment of binding orientation. Another object of the invention is no unintended angular motion. Another object of the invention is a device that is unaffected by board torsion. A further object of the invention is to use existing bolt holes on snowboards and boot bindings to allow a retrofit of conventional boards and bindings currently on the market.
[0011] In accordance with a preferred embodiment of the invention, there is disclosed an Angular Adjustment Mechanism for Snowboard Bindings comprising: upper plate, upper gear coupling, wave washer, upper retainer, lower retainer, and lower gear coupling.
[0012] Other objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
[0014] FIG. 1 a is an exploded view showing the position of the invention relative to the snowboard and boot binding.
[0015] FIG. 1 b is a perspective view of the portions of the invention which mate with the snowboard and boot binding.
[0016] FIG. 2 a is an exploded view of the invention.
[0017] FIG. 2 b is a side view of the assembled invention.
[0018] FIG. 3 a is a cross sectional side view of the invention in its engaged configuration.
[0019] FIG. 3 b is a cross sectional side view of the invention in its disengaged configuration.
[0020] FIG. 4 a and FIG. 4 b are perspective views of the invention illustrating its use.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
[0022] In accordance with the present invention, FIG. 1 a shows the position of Angular Adjustment Mechanism for Snowboard Bindings 10 in an exploded position relative to both boot binding 20 and section of snowboard 40 . Those portions of the invention which mate rigidly to either the snowboard 40 or the boot binding 20 are shown in FIG. 1 b . Referencing both FIGS. 1 a and 1 b , upper plate 11 and upper gear coupling 12 are shown with a bolt hole pattern matching that of boot binding 20 and, when incorporated, would mate rigidly to same. Lower retainer 16 and lower gear coupling 15 are shown with a bolt hole pattern matching that of snowboard 40 and, when incorporated, would mate rigidly to same. The components shown in use in Angular Adjustment Mechanism for Snowboard Bindings 10 in all figures are shown substantially thicker than necessary for purposes of clarity of illustration and can therefore be reduced in size for manufacturing.
[0023] FIG. 2 a shows an exploded view of the Angular Adjustment Mechanism for Snowboard Bindings 10 . Upper plate 11 and upper gear coupling 12 both mount rigidly to boot binding using bolts or similar fasteners (not shown). Lower retainer 16 and lower gear coupling 15 , both mount rigidly to snowboard using bolts or similar fasteners (not shown). The upper retainer 13 features a lip at its top with bolt holes for affixing to upper plate 11 using bolts or similar fasteners (not shown). Inside the upper retainer 13 , at its bottom is a lip extending inwards. The lower retainer 16 features a lip at its top extending outwards. When assembled, the lower lip of upper retainer 13 is below the upper lip of lower retainer 16 which prevents a detachment of upper retainer 13 and lower retainer 16 and provides an annular cavity between these two features. Within this cavity is positioned wave washer 14 . Wave washer 14 provides a tension force that drives the combination of upper gear coupling 12 and lower gear coupling 15 together which locks the mechanism from rotating when external forces are absent.
[0024] Wave washer 14 is an undulating ring of spring steel that provides a resistive opposition to compression forces. Washers of differing stiffness or a plurality of washers could be made available to fit the user's preferences. Alternative components might include belleville washers, compression springs, or elastomers.
[0025] Upper plate 11 and upper gear coupling 12 are shown as separate items but can be constructed as one piece. Furthermore, lower retainer 16 and and lower gear coupling 15 are shown as separate items but can be constructed as one piece.
[0026] Upper gear coupling 12 and lower gear coupling 15 are plates with one side comprised of radially-extending raised teeth. When upper gear coupling 12 and lower gear coupling 15 are engaged (teeth of one extended into the recesses of the other), radial forces from the rider can be transmitted to the snowboard. Upper gear coupling 12 and lower gear coupling 15 are shown with a coarse tooth spacing for clarity of illustration, but more closely-spaced teeth would provide for a wider selection of boot angular orientation.
[0027] FIG. 2 b shows a side view of the mechanism fully assembled. As shown, there is upper retainer 13 fastened to upper plate 11 . Also visible is lower retainer 16 .
[0028] To illustrate the principles of operation, there is shown in FIGS. 3 a and 3 b cross-sectional side views of the assembled mechanism. Upper plate 11 and upper gear coupling 12 are both mounted rigidly to the boot binding. Lower retainer 16 and lower gear coupling 15 are both mounted rigidly to snowboard. Upper retainer 13 would be positioned as shown surrounding lower retainer 16 . The lower lip of upper retainer 13 is a slip fit over the vertical side walls of lower retainer 16 such that relative vertical motion is allowed, but snow and grime will not pass the touching surfaces to get inside. Wave washer 14 is positioned within the cavity formed by the lower inside lip of upper retainer 13 and the upper outside lip of lower retainer 16 .
[0029] While there are no external forces on the mechanism shown in FIG. 3 a , the wave washer 14 exerts pressure upward against lower retainer 16 and simultaneously downward against upper retainer 13 . This forces the upper part of the assembly (upper plate 11 , upper gear coupling 12 , and upper retainer 13 ) down against the lower part of the assembly (lower gear coupling 15 and lower retainer 16 ), thereby forcing together into a mating relationship upper gear coupling 12 and lower gear coupling 15 , which prevents any angular rotation of the top portion with respect to the lower portion.
[0030] FIG. 3 b illustrates the mechanism when it is disengaged. When the upper portion of the assembly (upper plate 11 , upper gear coupling 12 , and upper retainer 13 ) which is attached rigidly to the boot binding is forced upward while simultaneously the lower portion of the assembly (lower gear coupling 15 and lower retainer 16 ) which is attached to the snowboard is forced downward, the resistance'to compression of the wave washer 14 is overcome. The wave washer 14 then becomes substantially flattened as the upper and lower portions of the assembly are forced apart. When the separation of the upper and lower portions of the assembly become sufficiently great, the upper gear coupling 12 and lower gear coupling 15 become disengaged and the upper portion of the assembly is free to swivel in an angular direction with respect to the lower portion.
[0031] In accordance with the present invention, FIGS. 4 a and 4 b illustrate a typical application. In these figures, the present invention Angular Adjustment Mechanism for Snowboard Bindings is mounted between the underside of boot binding 20 and the upper surface of snowboard 40 and is therefore concealed from view. In a static circumstance (no external forces applied), the Angular Adjustment Mechanism for Snowboard Bindings is locked and no angular motion is possible. To initiate intended angular repositioning, in FIG. 4 a , the snowboard rider puts his or her weight on one boot 30 (indicated in the figure by the “down” arrow). Simultaneously, the rider lifts up on the other boot (indicated in the figure by the “up” arrow) which disengages the locking feature of the Angular Adjustment Mechanism for Snowboard Bindings which permits the angular rotation of the boot 30 in any orientation desirable ( FIG. 4 b ). Relieving the opposing forces on the Angular Adjustment Mechanism for Snowboard Bindings re-engages the locking mechanism prohibiting further angular motion. The preceding steps may be repeated in the opposite order to adjust the other boot's angular orientation.
[0032] While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
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The Angular Adjustment Mechanism for Snowboard Bindings positioned between the snowboard and boot bindings allows angular adjustment between the snowboard rider's boot bindings and the snowboard without the need for any tools or levers. The user can make adjustments at any time by weighting the board with either foot and lifting and rotating the opposite foot. A lifting action releases the mechanism allowing for the adjustment of angular orientation. Removal of the lifting force engages the locking mechanism preventing further angular movement.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a communication system using an active line and a standby line for improving reliability of communication.
[0002] In order to transmit large amounts of information, for example, a communication system by means of optical communication is utilized. An example of a large amount of information includes image information, and that of a live telecast, the above communication system is utilized. It is important in a live telecast to avoid an incident causing interruption of image. For this purpose, the communication cable of the communication system is multiplexed. For example, the active line and the standby line are used for communication (Jpn. unexamined patent publication No. 8-293854).
[0003] FIG. 1 is a diagram exemplifying the conventional communication system by means of the active line and the standby line used for optical communication. The communication system comprises the master apparatus 101 , and the slave apparatus 102 . The master apparatus 101 comprises the first transmitter/receiver unit 103 , and the first optical switching unit 104 , and the slave apparatus 102 comprises the second transmitter/receiver unit 105 , and the second optical switching unit 106 .
[0004] The first optical switching unit 104 comprises the terminals 109 , 110 , and 111 . The terminal 109 is connected to the first transmitter/receiver unit 103 , the terminal 110 is connected to the active line 107 , and the terminal 111 is connected to the standby line 108 . The first optical switching unit 104 is able to connect the terminal 109 to the terminal 110 or 111 . Similar to the above configuration, the second optical switching unit 106 comprises the terminal 102 , 113 , and 114 . The terminal 112 is connected to the second transmitter/receiver unit 105 , the terminal 113 is connected to the active line 107 , and the terminal 114 is connected to the standby line 108 . The second optical switching unit 106 is able to connect the terminal 102 to the terminal 113 or 114 .
[0005] As shown in FIG. 1 , the terminal 109 is connected to the terminal 110 in the first optical switching unit 104 , and the terminal 112 is connected to the terminal 113 in the second optical switching unit 106 , so that it becomes possible to the communication by means of the active line 107 is carried out. If interruption occurs in the active line 107 , the terminal 109 and the terminal 111 are connected in the first optical switching unit 104 , and the terminal 112 and the terminal 114 are connected in the second optical switching unit 106 , so that communication by means of the standby line 108 is carried out.
[0006] Further, FIG. 2 is a diagram exemplifying a configuration of the optical switching unit used for the first optical switching unit 104 and the second optical switching unit 106 . The optical switching unit comprises the input/output terminal 201 , 202 , 203 , and the mirror 204 . When the mirror 204 is inserted, optical transmission/reception between the input/output terminal 202 and 203 becomes possible. Accordingly, for example, as a result of the communication between the input/output terminal 202 and the terminal 110 , between the input/output terminal 201 and the terminal 111 , and between the input/output terminal 203 and the terminal 109 , the first optical switching unit 104 can be configured. Similarly, the above can be applied to the second optical switching unit 106 .
[0007] Note that, although selection of two-to-one optical input/output is possible in FIG. 2 , selection of two-to-two optical input/output is also possible.
[0008] FIG. 3 is a diagram exemplifying a configuration of the optical switching unit, which is able to select two-to-two optical input/output. The optical switching unit shown in FIG. 3 comprises the input/output terminal 201 , 202 , 203 and 205 . When the mirror 204 is inserted, optical transmission/reception between the input/output terminal 201 and 205 , and between the input/output terminal 202 and 203 become possible. Meanwhile, when the mirror 204 is not inserted, optical transmission/reception between the input/output terminal 201 and 203 , and between the input/output terminal 202 and 205 become possible.
[0009] The cited document: Jpn. unexamined patent publication No. 8-293854
[0010] According to the configuration the master apparatus and the slave apparatus comprise the optical switching unit, it is necessary to perform switching in the first optical switching unit of the master apparatus and in the second optical switching unit of the slave apparatus at the same time. However, it is difficult to perform the switching at the same time. For example, for some reason, if the master apparatus detects the occurrence of temporary interruption such as instantaneous interruption of the active line, and the slave apparatus does not detect it, and the switching only in the first optical switching unit of the master apparatus is carried out, and communication between the master apparatus and the slave apparatus becomes impossible. Further, in cases where the switching are respectively performed in the master apparatus and the slave apparatus, if the timings of the switching are not same, the communication is impossible.
BRIEF SUMMARY OF THE INVENTION
[0011] It is an objective of the present invention to carry out smooth switching between an active line and a standby line in a communication system using the active line and the standby line.
[0012] In order to achieve the above objective, according to the present invention, a communication system, wherein one of the master apparatus or the slave apparatus comprises an optical switching unit, the other comprises an optical coupler unit, and if bad communication status of the active line is detected in the apparatus comprising the optical switching unit, the standby line is used by causing the optical switching unit to perform switching to the standby line, is provided.
[0013] The optical switching unit exists only in the master apparatus or the slave apparatus, so that it enables smooth switching between the active line and the standby line. Accordingly, the above deficiency is overcome.
[0014] The apparatus comprising the optical switching unit monitors the optical signal transmitted from said slave apparatus via said standby line, and if level of said optical signal is lower than a predetermined level or is undetectable, the connection to said optical switching unit may be maintained.
[0015] According to the above configuration, even if the apparatus, which does not comprise the optical switching unit, becomes unable to transmit the signal for some reason such as a maintenance problem, the active line remains in use, so that it becomes possible to avoid interruption of signals due to unnecessary switching in the optical switching unit.
[0016] In addition, in cases where the standby line is used, the apparatus comprising the optical switching unit may be able to acquire an approval signal for returning to the active line.
[0017] According to the above configuration, in the case of recovery of the active line from interruption, it becomes possible to return to the active line at the appropriate moment.
[0018] As described above, according to the present invention, it becomes possible to carry out smooth switching between an active line and a standby line in a communication system using the active line and the standby line.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Accompanying the specification are figures which assist in illustrating the embodiments of the invention, in which:
[0020] FIG. 1 is a diagram exemplifying the conventional communication system;
[0021] FIG. 2 is a diagram exemplifying a configuration of the optical switching unit;
[0022] FIG. 3 is a diagram exemplifying a configuration of the optical switching unit;
[0023] FIG. 4 is a functional block diagram of the bidirectional optical communication system of the first embodiment of the present invention;
[0024] FIG. 5 is a diagram exemplifying a configuration of the first receiver/transmitter 403 ;
[0025] FIG. 6 is a diagram exemplifying a configuration of the second receiver/transmitter 407 ;
[0026] FIG. 7 is a schematic diagram of the configuration of the optical coupler unit;
[0027] FIG. 8 is a diagram exemplifying a configuration of the optical coupler unit;
[0028] FIG. 9 is a diagram illustrating driving of the optical switching unit 404 by the optical switch driving unit 405 ;
[0029] FIG. 10 is a flow chart explaining processing flow in the master apparatus;
[0030] FIG. 11 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the second embodiment of the present invention;
[0031] FIG. 12 is a diagram illustrating connection between the first receiver/transmitter and the level monitoring unit;
[0032] FIG. 13 is a flow chart explaining processing flow in the master apparatus;
[0033] FIG. 14 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the second embodiment of the present invention;
[0034] FIG. 15 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the third embodiment of the present invention;
[0035] FIG. 16 is a flow chart explaining processing flow in the master apparatus;
[0036] FIG. 17 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the fourth embodiment of the present invention;
[0037] FIG. 18 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the fifth embodiment of the present invention;
[0038] FIG. 19 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the sixth embodiment of the present invention;
[0039] FIG. 20 is a graph in which the horizontal axis 2001 indicates wavelength, and the vertical axis 2002 indicates optical signal level.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Embodiments of the present invention will be described hereinbelow with reference to the drawings. The present invention is not to be limited to the above embodiments and able to be embodied in various forms without departing from the scope thereof.
[0041] As the first embodiment of the present invention, a communication system, wherein one of the master apparatus or the slave apparatus comprises a switching unit, which is able to select an active line or a standby line, another comprises a coupler unit, which couples said active line and standby line, and if bad communication status of the active line is detected in the apparatus comprising the switching unit, the standby line is used by causing the switching unit to perform switching to the standby line, will be described. In addition, hereinbelow, the bidirectional optical communication system as an example of the above communication system, which carries out bidirectional optical communication by means of cables or fibers passed by optical signals, will be described.
[0042] FIG. 4 is a functional block diagram of the bidirectional optical communication system of the first embodiment of the present invention. The bidirectional optical communication system comprises the master apparatus 401 and the slave apparatus 402 .
[0043] The master apparatus 401 comprises the first transmitter/receiver unit 403 , and the optical switching unit 404 , and the optical switch driving unit 405 . The slave apparatus 402 comprises the optical coupler unit 406 , and the second transmitter/receiver unit 407 .
[0044] The master apparatus 401 and the slave apparatus 402 are able to carry out bidirectional communication by means of the active line 408 and the standby line 409 . Note that the active line 408 and the standby line 409 consist of optical cable or optical fiber.
[0045] The ‘first transmitter/receiver unit’ 403 receives an optical signal. Therefore, it comprises transmission means for optical signal and reception means for optical signal.
[0046] FIG. 5 is a diagram exemplifying a configuration of the first receiver/transmitter 403 . The first transmitter/receiver unit 403 comprises the transmission means 501 , 502 , 503 etc., which transmit optical signals, and further comprises at least one reception means 504 , which receives the optical signal. The communication path for transmitting the optical signal used by the transmission means 501 , 502 , 503 , and the reception means 504 are finally assembled, and extracted to the outside of the first receiver/transmitter 403 . Note that, for example, it is preferable that wavelengths of the optical signals transmitted by the respective transmission means are different, so that the signals transmitted by the transmission means 501 , 502 , and 503 are distinguishable by the receiver. Therefore, it is preferable that signals of multiple wavelengths are multiplexed and transmitted/received.
[0047] For example, a dielectric multilayer filter (TFF) transmits only an optical signal of any one wavelength, and reflects signals of all other wavelengths. Further, when an optical signal of any one wavelength is irradiated to the one side of the dielectric multilayer filter, and optical signals of multiplexed wavelengths are irradiated to the other side of it, all optical signals of multiplexed wavelengths are reflected, and the optical signal of any one wavelength irradiated to the one side is added. By means of this property, the transmission means 501 , 502 , and 503 etc. and the reception means 504 are linked together through TFF, so that it becomes possible to carry out multiplexing and transmission/reception of lights of multiple wavelengths.
[0048] The ‘optical switching unit’ 404 is configured by a switch such as optical switches shown in FIG. 2 or 3 , which is able to select the active line 408 or the standby line 409 to be connected to the first transmitter/receiver unit 403 . Note that, distinction between the active line 408 and the standby line 409 may be relative. Therefore, a line currently connected to the first transmitter/receiver unit 403 may be named as an active line, and the other may be named as a standby line. Alternatively, distinction between the active line 408 and the standby line 409 may be absolute. Therefore, the line mainly used may be named as an active line.
[0049] The ‘optical switch driving unit’ 405 is for driving the optical switching unit 404 . In cases where the optical switching unit 404 is configured by the optical switch shown in FIG. 2 or 3 , it controls insertion/removal of the mirror 204 . For example, by controlling an actuator, insertion/removal of the mirror 204 is carried out.
[0050] The ‘optical coupler unit’ 406 couples the active line 408 and the standby line 409 . Therefore, it couples optical signals to be transmitted to the slave apparatus 402 via the active line 408 and the standby line 409 , and separates the optical signal transmitted from the second transmitter/receiver unit 407 , which will be described hereinbelow, and outputs them via the active line 408 and to the standby line 409 .
[0051] FIG. 7 is a schematic diagram of the configuration of the optical coupler unit. In the optical coupler unit 406 , the terminal 701 , 702 , and 703 exist, the terminal 701 is connected to the second transmitter/receiver unit 407 , the terminal 702 is connected to the active line 408 , and the terminal 703 is connected to the standby line 409 . The optical signals transmitted to the slave apparatus 402 via the active line 408 and the standby line 409 are coupled and transmitted to the terminal 701 , and outputted to the second transmitter/receiver unit 407 . Meanwhile, the optical signal transmitted to the terminal 701 by the second transmitter/receiver unit 407 is separated and transmitted to the terminal 702 and the terminal 703 , and outputted to the active line 408 and the standby line 409 .
[0052] FIG. 8 is a diagram exemplifying a configuration of the optical coupler unit 406 . In FIG. 8 , the optical coupler is configured by two optical fibers 801 and 802 , which have been fusion bonded at the portion 803 . By means of this configuration, the optical signal inputted to the edge point 804 is separately outputted to the edge point 805 and 806 . Meanwhile, the optical signals inputted to the edge point 805 and 806 are coupled and are outputted to the edge point 804 . Accordingly, by relating the edge point 804 to the terminal 701 , and by relating the edge point 805 and 806 to the terminal 702 and 703 , respectively, the optical coupler 406 can be configured.
[0053] The ‘second transmitter/receiver unit’ 407 receives an optical signal. Further, as described above, it is connected to the optical coupler unit 406 . The second transmitter/receiver unit 407 comprises transmission means for optical signal and reception means for optical signal.
[0054] FIG. 6 is a diagram exemplifying a configuration of the second receiver/transmitter 407 . The second transmitter/receiver unit 407 comprises the reception means 601 , 602 , 603 etc., which receive optical signals, and further comprises at least one transmission means 604 , which transmits the optical signal. The communication path for transmitting the optical signal used by the reception means 601 , 602 , 603 , and the transmission means 604 are finally assembled, and extracted to the outside of the second receiver/transmitter 407 . Note that, for example, it is preferable that wavelengths of the optical signals received by the respective reception means are different, so that the signals received by the reception means 601 , 602 , and 603 are transmitted from different transmission means. For example, as described above, multiplexing the wavelengths is carried out by means of TFF. Therefore, it is preferable that the reception means 601 receives the light of the wavelength transmitted by the transmission means 501 , the reception means 602 receives the light of the wavelength transmitted by the transmission means 502 , and the reception means 603 receives the light of the wavelength transmitted by the transmission means 503 .
[0055] In the first embodiment, the optical switching unit 404 is driven by the optical switch driving unit 405 in the master apparatus 401 as described hereinbelow. Normally, the active line 408 and the first transmitter/receiver unit 403 are connected. If bad communication status of the active line 408 is detected through the optical signal received by the first transmitter/receiver 403 , the standby line 409 and the first transmitter/receiver unit 403 are connected. The terms ‘bad communication status’ means, for example, the level of the optical signal transmitted from the slave apparatus decreases, so that communication becomes impossible or almost impossible. Further, a state, in which the interruption in communication occurs, for example, an error concerning parity increases, or a state, in which occurrence of the interruption is expected, is caused. This bad communication status is, for example, detected by the reception means of the first transmitter/receiver unit 403 . Alternatively, a monitoring unit for communication status of the active line other than the reception unit of the first transmitter/receiver unit 403 may be provided.
[0056] FIG. 9 is a diagram illustrating driving of the optical switching unit 404 by the optical switch driving unit 405 . FIG. 9 ( a ) shows a normal state, in which the active line 408 and the first transmitter/receiver unit 403 are connected. For example, in cases where the optical switching unit 404 is configured by means of the optical switch shown in FIG. 3 , the terminal 901 , 902 , 903 , and 904 are related to the input/output terminal 201 , 203 , 202 , and 205 , respectively, and the mirror 204 is removed. FIG. 9 ( b ) shows a connection state in cases where bad communication status of the active line 408 is detected. The terminal 901 and 904 are connected, and the standby line 409 and the first transmitter/receiver unit 403 are connected. This state corresponds to the state shown in FIG. 3 , in which the mirror 204 is inserted into the optical switch.
[0057] FIG. 10 is a flow chart explaining processing flow in the master apparatus. In step S 1001 , the active line and the first transmitter/receiver unit are connected (the connection step in a normal state). This is a normal connection. After that, in step S 11002 , detection of bad communication status of the active line is awaited. If bad communication status of the active line is detected, in step S 1003 , the standby line and the first transmitter/receiver unit are connected (the connection step in abnormal state).
[0058] Note that, after the standby line and the first transmitter/receiver unit are connected, the names of the standby line and the active line may be exchanged. Therefore, this is the case where distinction between the active line and the standby line is relative, so that the communication path, to which the code 408 is attached, may be named as active line. In such case, after the processing of step S 1003 , names of the standby line and the active line are exchanged and step S 1002 is carried out.
[0059] According to the first embodiment, the optical switching unit exists only in the master apparatus, so that it enables smooth switching between the active line and the standby line.
[0060] As the second embodiment of the present invention, the bidirectional optical communication system, wherein the master apparatus monitors the optical signal transmitted from said slave apparatus via said standby line, and maintains the connection to the optical switching unit if said level monitoring unit detects that level of the optical signal is lower than a predetermined level, or is undetectable.
[0061] FIG. 11 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the second embodiment of the present invention. The master apparatus 1101 comprises the first transmitter/receiver unit 403 , and the optical switching unit 404 , the optical switch driving unit 405 , and the level monitoring unit 1102 , and the optical switch driving unit 405 comprises the maintaining means upon detecting insufficient level 1103 . The configuration of the slave apparatus is the same as that of the first embodiment. Therefore, the bidirectional optical communication system of the second embodiment is the bidirectional optical communication system according to the first embodiment, wherein the master apparatus comprises the level monitoring unit, and the optical switch driving unit comprises the maintaining means upon detecting insufficient level.
[0062] The ‘level monitoring unit’ 1102 monitors the optical signal transmitted from the slave apparatus 402 via the standby line 409 . For example, the monitoring is carried out by measuring intensity of the optical signal or frequency of occurrence of errors in information in the optical communication. Therefore, the level monitoring unit 1102 is connected to the standby line.
[0063] FIG. 12 is a diagram illustrating a connection between the first receiver/transmitter and the level monitoring unit. FIG. 12 ( a ) corresponds to the normal state. The optical switching unit 404 connects the active line 408 and the first transmitter/receiver unit 403 , and the standby line 409 and the level monitoring unit 1102 . FIG. 12 ( b ) corresponds to the state in which bad communication status of the active line is detected through the optical signal received by the first transmitter/receiver. The optical switching unit 404 connects the standby line 409 and the first transmitter/receiver unit 403 , and may connect the active line 408 and the level monitoring unit 1102 . For example, in cases where names of the active line and the standby line are exchanged due to the bad communication status of the active line, the communication line, to which the code 408 is attached, is connected to the level monitoring unit 1102 .
[0064] The ‘maintaining means upon detecting insufficient level’ 1103 maintains the connection to the optical switching unit 404 if the level monitoring unit 1102 detects that level of said optical signal is lower than a predetermined level. Here, the term ‘said optical signal’ corresponds to the optical signal transmitted from the stave apparatus 402 via the standby line 409 . Further, the terms ‘maintains the connection to the optical switching unit 404 ’ means that the connection between the active line 408 and the first transmitter/receiver unit 403 is maintained.
[0065] In the present invention, since the optical signal transmitted from the first transmitter/receiver unit is divided by the optical coupler unit of the slave apparatus, basically, the same optical signal is transmitted from the slave apparatus 402 via the active line 408 and the standby line 409 . If an interruption such as disconnection of the standby line 409 occurs, connection between the standby line 409 and the first transmitter/receiver unit 403 is worthless, so that connection between the active line 408 and the first transmitter/receiver unit 403 is maintained. Further, in cases where a portion or all of the transmission means of the second transmitter/receiver unit 407 stop due to a maintenance of the second transmitter/receiver unit 407 etc., level of the optical signal received by the first transmitter/receiver unit 403 decreases or the optical signal received by the first transmitter/receiver unit 403 disappears even if any interruption occurs in the active line 408 , so that there is a possibility that bad communication status of the active line is detected. However, there is no actual interruption in the active line 408 , and switching between the active line and the standby line is unnecessary, so that connection between the active line 408 and the first transmitter/receiver unit 403 is maintained.
[0066] FIG. 13 is a flow chart explaining processing flow in the master apparatus. In step S 1301 , the active line 408 and the first transmitter/receiver unit 403 are connected (the connection step in normal state). In step S 1302 , detection of bad communication status of the active line is awaited. If bad communication status of the active line is detected, in step S 1303 , it is determined whether the level monitoring unit 1102 has detected an optical signal, in other terms, whether the level of the optical signal transmitted via the standby line 409 is lower than a predetermined level. If the optical signal has been detected, step S 1304 is carried out. If not, processing returns to step S 1302 . In step S 1304 , the standby line 409 and the first transmitter/receiver unit 403 are connected (the connection step in abnormal state).
[0067] According to the second embodiment, it becomes possible to prevent unnecessary switching between the active line and the standby line in cases where the standby line is unavailable or it appears that interruption occurs in the active line. Specifically, in case where it appears that interruption occurs in the active line even if there is no actual interruption, it becomes possible to prevent instantaneous interruption of communication, which occurs upon switching from the active line to the standby line.
[0068] As the third embodiment of the present invention, the bidirectional optical communication system, wherein the master apparatus is able to acquire an approval signal for returning to a state of using the active line, will be described.
[0069] FIG. 14 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the third embodiment of the present invention. The master apparatus 1401 comprises the first transmitter/receiver unit 403 , and the optical switching unit 404 , the optical switch driving unit 405 , and the monitoring unit for communication status of active line 1402 , and the optical switch driving unit 405 may comprise the acquisition means for approval signal 1403 . In addition, as shown in FIG. 15 , the master apparatus may comprise the level monitoring unit, and the optical switch driving unit may comprise the maintaining means upon detecting insufficient level. The configuration of the slave apparatus is the same as that of the first or second embodiment. Therefore, the bidirectional optical communication system of the third embodiment is the bidirectional optical communication system according to the first or second embodiment, wherein the master apparatus comprises the monitoring unit for communication status of active line, and the optical switch driving unit comprises the acquisition means for approval signal.
[0070] The ‘monitoring unit for communication status of active line’ 1402 is able to monitor a communication status of the active line 408 . The monitoring unit for communication status of active line 1402 is able to monitor the communication status of the active line 408 even when the standby line 409 and the first transmitter/receiver unit 403 are connected. Therefore, as shown in FIG. 14 or 15 , the monitoring unit for communication status of active line 1402 acquires the optical signal of the active line 408 from the optical switching unit 404 . Alternatively, the optical signal transmitted from the slave apparatus via the active line 408 may be divided by an optical coupler etc., and may be acquired.
[0071] The ‘acquisition means for approval signal’ 1403 acquires an approval signal if the optical switching unit 404 of the master apparatus 1401 connects the standby line 409 to the first transmitter/receiver 403 , and the monitoring unit for communication status of active line 1402 detects good communication status of the active line 408 . Here, the term ‘approval signal’ corresponds to a signal for causing the optical switching unit 404 to connect the active line 408 and the first transmitter/receiver 403 . For example, this signal is inputted from the input apparatus connected to the master apparatus 1401 , and is acquired by the acquisition means for approval signal 1403 . Alternatively, the signal, which indicates that the monitoring unit for communication status of active line 1402 detects good communication status of the active line 408 after bad communication status, may be an approval signal, and may be acquired by the acquisition means for approval signal 1403 .
[0072] FIG. 16 is a flow chart explaining processing flow in the master apparatus. In step S 1601 , the active line 408 and the first transmitter/receiver unit 403 are connected (the connection step in normal state). In step S 1602 , detection of bad communication status of the active line is awaited. If bad communication status of the active line is detected, in step S 1603 , the standby line 409 and the first transmitter/receiver unit 403 are connected. After that, in step S 1604 , detection of good communication status of the active line 408 by the monitoring unit for communication status of active line 1402 is awaited. If the good communication status of the active line 408 is detected, in step S 1605 , acquisition of the approval signal by the acquisition means for approval signal 1403 is awaited. When the approval signal is acquired, in step S 1605 , the active line 408 and the first transmitter/receiver unit 403 are connected.
[0073] Note that, in cases where the master apparatus may comprise the level monitoring unit, and the optical switch driving unit may comprise the maintaining means upon detecting insufficient level as in the second embodiment, a step, which is for determining whether the level monitoring unit has detected the optical signal, is added between step S 1602 and S 1603 . If the optical signal has not been detected, processing returns to step S 1602 , and if the optical signal has been detected, step S 1603 is carried out.
[0074] According to the third embodiment, it becomes possible to return to a state of using the active line at appropriate timing in cases where interruption once occurs in the active line and is later recovered.
[0075] As the fourth embodiment of the present invention, the bidirectional optical communication system, wherein the ‘predetermined level’ described in the second embodiment is stored, will be described.
[0076] FIG. 17 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the fourth embodiment of the present invention. The master apparatus 1701 comprises the first transmitter/receiver unit 403 , and the optical switching unit 404 , and the optical switch driving unit 405 , and the optical switch driving unit 405 may comprise the maintaining means upon detecting insufficient level 1103 , and the level monitoring unit 1102 comprises the storing means for predetermined level 1702 . The configuration of the slave apparatus is the same as that of the second embodiment. Therefore, the bidirectional optical communication system of the fourth embodiment is the bidirectional optical communication system according to the second embodiment, wherein the level monitoring unit of the master apparatus comprises the storing means for predetermined level.
[0077] The ‘storing means for predetermined level’ 1702 stores said predetermined level. For example, in cases where a portion including the level monitoring unit 1102 is implemented by means of microcomputer etc., the storing means for predetermined level is configured by means of a flash memory, and the predetermined level is stored in the flash memory. Note that, the storing means for predetermined level may be configured by means of an ordinary semiconductor memory, instead of the memory such as a flash memory, which performs permanent storage. Accordingly, in the fourth embodiment, the level monitoring unit 1102 reads a predetermined level from the storing means for predetermined level 1702 according to necessity, and compares the read level and the level of the optical signal transmitted from the slave apparatus via the standby line. The terms ‘according to necessity’ refers to such as the case where the level monitoring unit 1102 becomes operatable after turning on or reset of the master apparatus is carried out, the case where passage of a certain period of time or of a predetermined time is detected, or the case where a predetermined level stored by the storing means for predetermined level is changed.
[0078] According to the fourth embodiment, it becomes possible to remove botheration in setting a predetermined level of the level monitoring unit 1102 with respect to each turning on etc. of the master apparatus, and to change the predetermined level as described hereinbelow.
[0079] As the fifth embodiment of the present invention, the bidirectional optical communication system, wherein the ‘predetermined level’ described in the second embodiment is changeable, will be described.
[0080] FIG. 18 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the fifth embodiment of the present invention. The master apparatus 1801 comprises the first transmitter/receiver unit 403 , and the optical switching unit 404 , and the optical switch driving unit 405 , and the optical switch driving unit 405 may comprise the maintaining means upon detecting insufficient level 1103 , and the level monitoring unit 1102 comprises the storing means for predetermined level 1702 , the acquisition means for predetermined level 1802 , and the changing means for predetermined level 1803 . The configuration of the slave apparatus is the same as that of the fourth embodiment. Therefore, the bidirectional optical communication system of the fifth embodiment is the bidirectional optical communication system according to the fourth embodiment, wherein the level monitoring unit of the master apparatus comprises the acquisition means for predetermined level and the changing means for predetermined level
[0081] The ‘acquisition means for predetermined level’ 1802 acquires the predetermined level to be stored by the storing means for predetermined level. This acquisition may be carried out, for example, by acquiring a value inputted to the input apparatus connected to the master apparatus 1801 . For example, the input apparatus may be a personal computer, which comprises a keyboard, a mouse, and a display, and to which an operator of the master apparatus can input the value.
[0082] In addition, the acquisition means for predetermined level 1802 may appropriately generate the level. For example, in cases where the operation of an amplifier of the signal in the standby line changes according to passage of time, a different level according to the passage of time may be generated.
[0083] The ‘changing means for predetermined level’ 1803 changes the predetermined level stored by the storing means for predetermined level 1702 to the level acquired by the acquisition means for predetermined level 1802 .
[0084] Accordingly, in the fifth embodiment, when a level is acquired by the acquisition means for predetermined level 1802 , the changing means for predetermined level 1803 changes the predetermined level stored by the storing means for predetermined level 1702 to the level acquired by the acquisition means for predetermined level 1802 . After that, the level monitoring unit 1102 reads a predetermined level stored by the storing means for predetermined level according to necessity, and compares the read level and the level of the optical signal transmitted from the slave apparatus via the standby line.
[0085] According to the fifth embodiment, it becomes possible to change the level of the optical signal, at which the maintaining means upon detecting insufficient level 1103 operates. For example, in cases where the number of transmission means of the second transmitter/receiver unit, or in cases where setting of an amplifier for the standby line is changed, it becomes possible to set an appropriate level.
[0086] As the sixth embodiment of the present invention, the bidirectional optical communication system, which detects number of transmission means of the second transmitter/receiver unit, and changes the ‘predetermined level’, will be described.
[0087] FIG. 19 is a functional block diagram of the master apparatus of the bidirectional optical communication system of the sixth embodiment of the present invention. The master apparatus 1901 comprises the first transmitter/receiver unit 403 , and the optical switching unit 404 , and the optical switch driving unit 405 , and the optical switch driving unit 405 may comprise the maintaining means upon detecting insufficient level 1103 , and the level monitoring unit 1102 comprises the storing means for predetermined level 1702 , the acquisition means for predetermined level 1802 , the changing means for predetermined level 1803 , and the detection means for number of transmission means 1902 . The configuration of the slave apparatus is the same as that of the fifth embodiment. Therefore, the bidirectional optical communication system of the sixth embodiment is the bidirectional optical communication system according to the fifth embodiment, wherein the level monitoring unit of the master apparatus comprises the detection means for number of transmission means 1902 .
[0088] The ‘the detection means for number of transmission means’ 1902 detects number of transmission means, which transmits the optical signal, of the second transmitter/receiver unit 407 . For example, at least one transmission means of the second transmitter/receiver unit 407 transmits information indicating a configuration of the second transmitter/receiver unit 407 , which includes the number of the transmission means etc., and based on the transmitted information, the detection means for number of transmission means 1902 detects the number of the transmission means. Alternatively, in cases where transmission is carried out by means of different wavelengths with respect to each transmission means, by measuring intensity of the optical signal for the wavelength, and by detecting number of maximal points of the intensity, it becomes possible to detect the number of transmission means.
[0089] FIG. 20 is a graph in which the horizontal axis 2001 indicates wavelength, and the vertical axis 2002 indicates optical signal level. In this case, three maximal points exist, so that the number of transmission means is three.
[0090] In the sixth embodiment, the acquisition means for predetermined level 1802 acquires the level based on the number detected by the detection means for number of transmission means 1902 . For example, the value acquired by multiplying a preliminary determined value for one transmission means by the number of transmission means is generated as a level.
[0091] According to the sixth embodiment, level according to the number of transmission means of the second transmitter/receiver unit is a predetermined level, so that it becomes possible to appropriately determine whether interruption occurs in the standby line.
[0092] The bidirectional optical communication system of the present invention is effective in carrying out smooth switching between an active line and a standby line in the case of interruption, and is beneficial in industrial use.
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A bidirectional optical communication system employing a living line and a standby line. One of a master unit and a slave unit has a photoswitch for switching between the living line and the standby line and the other has a photocoupler for collecting the living line and the standby line. When deterioration in communication state of the living line is detected on the side having the photoswitch, the photoswitch on that side is switched to use the standby line.
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RELATED APPLICATIONS
[0001] This is a continuation of Ser. No. 14/066,174; filed Oct. 29, 2013 for “Medical Gas Manifold.”
BACKGROUND
[0002] The present invention relates to the safe and proper handling of gases in the medical (e.g., hospital) environment.
[0003] A number of gases are used in the hospital environment, both for patient care and for other various purposes.
[0004] Oxygen is typically supplied for patients who require supplemental oxygen as part of their care. Nitrous oxide (N 2 O) has anesthetic properties and is typically supplied to operating rooms (surgical suites) for preoperative and operative procedures. Nitrogen is typically used to power mechanical items such as surgical equipment. Carbon dioxide is typically used to handle (e.g., inflate or suspend) tissue during surgery and also in some types of laser surgery. “Medical air” is typically used for patient inhalation via ventilators or for breathing treatment. “Instrument air” is another term for compressed air, typically used to drive mechanical tools. Additionally, mixtures of these gases and other gases, as well as vacuum capabilities, are typically part of the hospital environment.
[0005] In typical medical or hospital applications, oxygen is best delivered for end use at pressures of around 55 pounds per square inch (psi), nitrous oxide at about 50 psi, nitrogen at about 175 psi, carbon dioxide at about 50 psi, medical air at about 55 psi, and instrument air at about 175 psi.
[0006] The amounts of such gases used in a hospital tend to be rather large. Thus, in accordance with the ideal gas law (or its more sophisticated versions), the volume required to store gases at room temperature and typical delivery pressures also would be very large. Because of that, and as is the case in other gas-delivery circumstances, hospital gases are typically stored in groups (“banks”) of either high-pressure cylinders (e.g., at pressures up to about 2500 psi) or cryogenic tanks (oxygen and nitrogen) and then delivered at the lower end use pressures using appropriate regulators and associated hardware.
[0007] Because of the hospital environment, such regulators and related delivery hardware must meet stringent requirements that are not typical elsewhere; i.e., the hospital context is unique in a number of circumstances. Relevant best practices are well understood and have become codified in various regulations. These include (but are not limited to) the NFPA regulations in United States (e.g. 38 CFR 51.200), the CSA regulations in Canada, and the ISO regulations in Europe.
[0008] The combinations of different gas sources, different pressures at both the source and delivery positions, and the various regulations applicable to the hospital or medical environment, all create complications that must be addressed in the gas delivery system.
[0009] As used herein, the term “regulator” refers to a mechanical device that controllably reduces the pressure of an incoming gas and delivers it for use at a specified lower pressure (or pressure range). Accordingly, in the hospital environment regulators must transfer gas from high-pressure cylinders (up to 2500 psi) to the intended pressures just described, or from cryogenic cylinders. Although cryogenic cylinders store gas as a liquid, they still contain internal gas pressures of about 300 psi.
[0010] One of the requirements for the gas delivery system—particularly in hospitals—is redundancy; i.e., the gas supply cannot be interrupted under any normal circumstances (e.g., repair or resupply) or even in many abnormal circumstances. Because of that, hospitals typically have at least a primary source of gases (the “primary side”) and a complementary back up set of gases referred to as the “secondary side.” In turn, the hospital gas delivery system must likewise include primary side regulators and other delivery equipment and separate secondary side regulators and delivery equipment. In best practices, the flow of each and every gas will continue without interruption if one side is shut off. The most typical circumstance is to transfer from the primary side to the secondary side so that the primary side tanks can be replaced with full ones when empty. Additionally, other circumstances (both typical and unforeseen) can also create interruptions and the gas regular system must be able to handle such events without allowing interruptions in the gas flow.
[0011] Conventionally, the required equipment and redundancy is built from existing (“off-the-shelf”) components. Although such readily available parts can superficially lower initial costs, such conventional equipment (e.g., regulators, valves, fittings) can suffer from certain disadvantages.
[0012] As one disadvantage, certain polymer rubbers (elastomers) have properties that make them incompatible with certain hospital gases. Generally, some elastomers are compatible with oxygen, but not nitrous oxide or carbon dioxide (and vice versa). As an example, some halogenated elastomers give off toxic fumes when ignited.
[0013] In particular, the (potentially) large pressure changes within regulators (e.g., from 2500 psi in a bank to 250 psi in a manifold) can produce adiabatic compression that significantly elevates the gas temperature. When the gas is oxygen in the presence of hydrocarbon-based elastomers (e.g., sealing O-rings and related parts), combustion can- and does-result. In particular, hydrocarbon rubbers such as polyurethane, styrene butadiene, polyisoprene and ethylene-propylene-diene ignite easily, and have high fuel value and heat release.
[0014] Halogenated elastomers such as Viton® can favorably withstand higher temperatures than such other elastomers. For example, Viton® has a rated combustion temperature of about 400° F., while nitrile butyl rubbers are on the order of 212° F. Nevertheless, when halogenated elastomers burn, they tend to detrimentally release halogen gases and gas compounds.
[0015] Some such halogenated elastomers tend to absorb carbon dioxide and nitrous oxide and then disperse such absorbed gases rapidly under a relatively large pressure release, such as those experienced in high-pressure-to-low pressure regulators. In turn, such release tends to physically harm (i.e., blister or blow out) the elastomer piece and thus destroy its function, and in turn the function of the entire regulator. Some non-halogenated polymers avoid the absorption problems, but (as noted previously) suffer from a tendency to ignite in the presence of oxygen undergoing adiabatic compression.
[0016] As a result, in conventional regulators and structures incorporating regulators, some or all of the typical polymer fittings (e.g., o-rings, diaphragms, etc.) must be selected based upon the gas being used even though the equipment being fitted is otherwise identical in most or all respects. In a sense, this bases the polymer choice on potential disadvantages rather than on potential advantages. Such fittings can reduce efficiency and thus increase overall cost, for both manufacture and use (maintenance). In some cases, different regulators with different elastomers are used for the different gases, but at higher cost and lower efficiency.
[0017] As a separate and distinct problem, the regulators used in hospitals, along with their associated valves, gauges and fittings need to stay structurally intact under pressure, and a user (e.g., maintenance worker) should not be able to remove items from the regulator structure while the pieces are pressurized. This is a safety issue.
[0018] As a third distinct issue, the piston assemblies used in conventional regulators can permit larger than desired drops in pressure during flow. The elastomer diaphragms used in conventional regulators tend to have more “droop.” More specifically, pressure regulation is a function of inlet pressure. As the inlet pressure source is reduced, regulator delivery pressure may either rise or fall depending upon the regulator design. In both cases this is known as regulator “droop.” The side loading design of many regulator piston assemblies tends to increase both the friction and the droop of the assembly. Additionally, balancing the piston assembly on the line regulator also tends to increase friction and droop.
[0019] As another independent problem, regulators must be serviced from time to time and are typically mounted on a wall. The nature of much conventional regulator construction, however, makes it very difficult to operate or repair a regulator while it is in position on the wall (“vertical”). Typically the regulator and a number of associated parts must be removed from the wall or it's housing, serviced, and then returned. This series of steps decreases efficiency, takes extra time, and thus increases the cost of use.
[0020] Finally, in many conventional hospital gas delivery systems the user must review the manifold directly in order to understand the status (pressure and flow) of the various gases. Therefore, unless a person is constantly viewing or frequently inspecting the relevant gauges (or other output), real-time information will be delayed or in some cases missed altogether.
SUMMARY
[0021] In one aspect, the invention is a gas pressure regulator that includes a reciprocating piston assembly that engages and disengages from a seat to open the higher pressure and lower pressure sides of the regulator to one another. The regulator includes an elastomer seal between the seat and the piston assembly that has an ignition rating sufficient to avoid combustion in the presence of oxygen at pressure differentials that are a factor of between 5 and 10 between the higher pressure and lower pressure sides of the regulator.
[0022] In a second aspect, the invention is a gas pressure manifold that is particularly suitable for medical industry applications. In this aspect, the invention includes at least one pair of bank regulator bodies for supporting regulators that moderate the flow of high-pressure gas from a gas source while providing redundancy for continuous gas flow through at least one regulator at all times, at least one pair of line regulator bodies for holding line regulators in gas communication with the bank regulators, and with the bank regulator bodies and the line regulator bodies being joined by at least one brace bar for preventing the brace bar from being removed when the forgings are under pressure.
[0023] In another aspect, the invention is a gas pressure regulator that includes a regulator body, a piston assembly in the regulator body, a spring chamber, a spring in the spring chamber, and a cup shaped piston diagram in the spring chamber and surrounding the portions of the spring adjacent the piston valve for eliminating or minimizing the flexing of various materials under pressure in the regulator.
[0024] In another aspect, the invention is a medical gas alarm system for use in a healthcare facility having medical gas systems which severally deliver a plurality of medical gases to a plurality of locations in the healthcare facility and having a network of computer devices. In this aspect, the invention includes a gas pressure manifold included in the network of computer devices in which the gas pressure manifold includes bank regulators, line regulators, and pressure sensors associated with each regulator, and network connectors between the sensors and the remainder of the network for remote monitoring of cylinder pressure levels, alarm status, event logs, and similar items from any computer on the network.
[0025] The foregoing and other objects and advantages of the invention and the manner in which the same are accomplished will become clearer based on the followed detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a perspective view of the manifold external housing.
[0027] FIG. 2 is a perspective view of the manifold with the housing removed.
[0028] FIG. 3 is a front elevational view of the manifold and the control box.
[0029] FIG. 4 is a front elevational view of a second embodiment of the manifold and control box.
[0030] FIG. 5 is a front elevational view of the forging portion of the manifold.
[0031] FIG. 6 is a side elevational view of the forging of FIG. 5 .
[0032] FIG. 7 is an exploded perspective view of one of the line regulators in the context of the manifold.
[0033] FIG. 8 is a perspective exploded view of one of the bank regulators in the context of the manifold.
[0034] FIG. 9 is a cross-sectional view of a bank regulator.
[0035] FIG. 10 is a cross-sectional view of a line regulator.
[0036] FIG. 11 is a schematic diagram of a network that includes the manifold.
[0037] FIG. 12 is a perspective view of a single forging according to the invention.
[0038] FIG. 13 is a rear perspective view of a manifold according to the invention.
[0039] FIG. 14 is an exploded perspective view of the inlet and inlet filter according to the invention.
DETAILED DESCRIPTION
[0040] The terms “hospital” and “medical” are used in a descriptive rather than limiting context in this specification, and the invention's advantages apply in the general context regardless of whether or not the particular environment is a hospital per se.
[0041] FIG. 1 is a perspective view of the medical gas manifold of the invention inside of a housing broadly designated at 20 . In typical embodiments, the housing is formed of an appropriate sheet-metal, the nature of which should be consistent with the local environment and medical applications, but that otherwise can be selected by those of ordinary skill in the art without undue experimentation.
[0042] The manifold includes an inlet fitting 21 and an outlet fitting 22 . A reserve header inlet 23 is positioned adjacent the inlet 21 , and a relief valve fitting 24 is adjacent the outlet fitting 22 . In exemplary embodiments, the inlet portion of the bank regulator ( 43 , 70 ; FIG. 2 ) also includes a gas-inlet filter ( FIG. 14 ) which is formed of a shaped portion of sintered bronze, a material that has improved heat retention, acts as a flame arrestor, has better particle retention, and slows gas velocity better than some other materials.
[0043] A control box broadly designated at 25 is positioned adjacent the housing 29 and can be mounted on the same back panel 26 as the main portions of the manifold.
[0044] To assist in use, the manifold includes a left bank pressure gauge 27 , a right bank pressure gauge 30 and a delivery pressure gauge 31 . These are mounted in (or flush with) a face plate 32 which includes a plurality of light emitting diode (LED) indicators.
[0045] Each respective bank has an empty signal LED 33 , a ready signal LED 34 and an in use signal LED 35 . A changeover LED 36 indicates when the manifold is switching between banks. The forging 41 helps to (among other advantages) eliminate the leaks to which conventional separate items are more susceptible.
[0046] FIG. 2 is a perspective view of the manifold broadly designated at 40 with the housing 29 removed. The manifold is formed from one or more forgings which are broadly designated at 41 . The forging in an isolated context is perhaps best illustrated in FIGS. 5 , 6 and 12 .
[0047] The manifold 40 includes at least one pair of bank regulator bodies 124 (e.g., FIGS. 6 and 7 ) for supporting bank regulators 43 , 70 that moderate the flow of high-pressure gas from a gas source while providing redundancy for continuous gas flow through at least one of the bank regulators at all times. At least one pair of line regulator bodies 103 hold line regulators 52 , 71 in gas communication with the bank regulators 43 , 70 .
[0048] The bank regulator bodies and the line regulator bodies are joined by at least one brace bar 28 so that the relationship prevents the brace bar from being removed when the forgings are under pressure.
[0049] Some features of the manifold, it's structure, and its operations can be identified by following the flow of gas in the illustrated embodiments. Thus, gas from a bank (of tanks or cryogenic cylinders) enters the manifold through the inlet fitting 21 and the inlet pipe 42 , from which it reaches the right (or “primary”) side bank regulator 43 . More detailed views of the bank regulator 43 are set forth in FIGS. 8 and 9 . Those skilled in the art understand, of course, that “primary” and “secondary” refer to the mode of use rather than to any absolute right or left orientation.
[0050] A pressure switch 44 is connected to the right bank regulator 43 along with a bleed valve 45 and a bank pressure gauge 46 . A solenoid valve 47 and (optionally) a dome pressure regulator (not illustrated in this embodiment) help control the operation of the bank regulator 43 through the various piping connections which, for purposes of clarity, are not all individually labeled. Their structure and function are nevertheless both typical and well understood by the skilled person.
[0051] The vertical portion of the forging 41 that extends outwardly from the bank regulator 43 includes a check valve (not shown in FIG. 2 ) as well as the reserve header port 51 .
[0052] As generally well understood by the skilled person and as explained in the Background, the purpose of the bank regulator 43 is to reduce the high pressure of the gas received from the bank tanks or cryogenic cylinders to an intermediate pressure which is more suitable for the more detailed control provided by the line regulators.
[0053] Accordingly, FIG. 2 likewise illustrates a right (primary) line regulator 52 which is likewise fixed in a portion of the forging 41 . The right line regulator 52 delivers gas at the desired pressure through the outlet 22 which is illustrated in the context of a zero clearance fitting 53 . A similar zero clearance fitting 54 is on the relief valve outlet 24 .
[0054] FIG. 2 also illustrates an intermediate relief valve 55 , a line relief valve 56 , a vent valve 57 , and a service valve 64 . The intermediate relief valve 55 is connected to the overall relief valve 24 through a tube 61 and the line relief valve 56 is likewise connected to this destination by the tube 62 . In FIG. 2 the tubes 61 and 62 , along with the smaller tubes which are unnumbered for clarity purposes, are formed of rigid copper tubing. This is in accordance with ISO standards. Depending upon the regulatory overlay in the country or jurisdiction of use, some or all of the tubing can be formed of an appropriate flexible polymer material provided it is otherwise consistent with the physical, chemical, safety, and other relevant requirements.
[0055] FIG. 2 also illustrates a service bleed valve 63 and a knobbed service valve 64 .
[0056] FIG. 2 also illustrates a plurality of pipe fittings, connectors, elbows, and the like each of which is generally well understood both in terms of their general structure and function and their structure and function in the context of the manifold of the invention.
[0057] FIG. 3 illustrates all of the items in FIG. 2 , as well as several that are clearer in the front elevational view.
[0058] Some of these items include the respective locking collars 65 on the inlet pipes 42 (and the corresponding secondary inlet pipe 29 ) and respective isolation (ball) valves 66 located in the forging 41 between each respective bank regulator 43 and line regulator 52 . It will be generally understood, of course, that where identical items are shown in parallel with one another, they are the same item and serve the same purpose, with the only difference being that one set serves a gas bank or cylinders entering the manifold from the left and the other serves the gas bank or cylinders entering the manifold from the right. For example, an inlet fitting 37 corresponds to the secondary inlet in the same manner as the inlet fitting 21 corresponds to the primary inlet.
[0059] FIG. 3 also illustrates that a plurality of electrical wires and cables help control various items. Many of these pass through the cable covers 67 illustrated on the left-hand side of FIG. 3 from which they enter the control box 25 . The nature of the electrical controls is generally otherwise conventional and well understood by those of skill in this art. As set forth with respect to FIG. 11 , these controls also help connect the manifold to a hospital computer network (or its equivalent).
[0060] In some embodiments the manifold can include a dome pressure regulator which can be connected to the solenoid valve and the bank regulators. Although positioning is a matter of design choice, in the illustrated embodiments, when a dome pressure regulator is included, it can be positioned in the lower portions of the housing 20 .
[0061] Each of the regulators is associated with a respective check valve. The check valves are maintained in the portion of the forging extending vertically above each respective bank or line regulator. For the sake of completeness, the left (secondary) bank regulator is labeled at 70 and the left (secondary) line regulator at 71 .
[0062] FIG. 4 is a front elevational of view of a second embodiment of the invention broadly designated at 38 which meets the Canadian (i.e., CSA) design and regulatory criteria. Much of the regulator is generally the same as described with respect to FIG. 3 , but under CSA standards, a check valve cannot be positioned between the line regulator and the outlet.
[0063] Accordingly, in this embodiment the line regulators 71 and 52 are connected to isolation valves 72 and 73 respectively. Pressure relief valves 74 and 75 are also connected to the regulators 71 and 52 . The isolation valves 72 and 73 are connected to a sub-manifold 76 which provides the functional connection to the vent valve 57 and the service valve 64 , as well as a common outlet 77 . This embodiment also includes line regulator pressure gauges 80 and 81 respectively.
[0064] The remaining items in FIG. 4 are the same structurally and functionally as in FIG. 3 and carry the same reference numerals.
[0065] FIGS. 5 and 6 illustrate the forging 41 somewhat more clearly in partial isolation from a number of the items in FIGS. 1-4 . A number of the items are, of course, the same as in FIGS. 1-4 and thus carry the same reference numerals. In particular, FIGS. 5-8 show two forgings 41 stacked on top of one another and connected by the brace bar 28 and with the intermediate isolation valves 73 .
[0066] In the manifold of the invention the bank regulator bodies 124 are part of a common forging 41 and the line regulators are part of a common forging 41 , and the brace bar 28 is fixed to each of the common forgings. In the illustrated embodiment, the brace bar 28 is shown having several rectangular plate portions, but it will be understood that this configuration is exemplary of the possibilities rather than limiting.
[0067] In turn, the common forgings 41 comprise respective metal bridging webs 48 between the bank regulator bodies and the line regulator bodies, and the brace bar 28 is fixed to each of the respective metal bridging webs.
[0068] In exemplary embodiments, the regulator bodies and the brace bar 28 are formed of metal.
[0069] In the CSA version illustrated in FIG. 4 , the bank regulator bodies are formed in a common forging, but the line regulator bodies are separate. Thus, the brace 28 bar is fixed to the common bank regulator forging and then individually to the line regulator bodies 103 .
[0070] Some of the items that are more clearly illustrated include, however, the handles 83 on the isolation valves 73 . FIGS. 5 and 6 also more clearly illustrate the respective inlet for the gas 84 , the pressure gauge 85 and the switch 86 .
[0071] FIG. 7 is an exploded view of the left line regulator 71 and FIG. 10 is a corresponding cross-sectional view. FIG. 7 illustrates the regulator spring 90 which is received in the spring chamber 91 and bears against a cup-shaped piston diaphragm 95 . The piston diaphragm 95 surrounds portions of the spring 90 adjacent the piston assembly 101 and its seat 97 and helps minimize or eliminate the oblique flexing that the spring 90 would otherwise undergo (or exert) under pressure. The spring pressure (and thus the regulator's set pressure) can be adjusted using the adjustment screw 92 and it's locknut 93 . Respective spring buttons 94 are positioned at the top and bottom of the spring 90 . In exemplary embodiments the bank regulator spring 114 is formed of stainless steel, because it has a higher threshold temperature for promoted combustion than some other typical spring metals.
[0072] As noted previously, upper and lower spring buttons 94 are positioned at opposite ends of the spring 90 , and each of the spring buttons includes a gimbal-type indentation (e.g., FIGS. 9 and 10 ). The adjustment screw 92 includes a well-rounded nose 132 ( FIG. 10 ) that engages the gimbal on the upper spring button, and a rounded projecting floor portion 97 on the cylindrical piston diaphragm 95 engages the lower spring gimbal. These parts cooperate to mitigate the effect of varying spring squareness and help direct the regulator forces linearly rather than obliquely. In turn, these items keep the regulator parts aligned during operation, which increases the regulator's accuracy and precision, and reduces its droop. The cup shape of the piston diaphragm 95 also captures the spring and spring buttons in a manner that allows the regulator parts to be removed from the regulator bodies while the regulator bodies remain fixed with the remainder of the manifold. From a practical standpoint, this means that the regulator parts can be removed and serviced (or replaced) while the remainder of the manifold remains in its in-use location and position (which is often a vertical orientation). In contrast, the multiple parts of a conventional regulator tend to separate quickly (and disadvantageously) unless the entire regulator—and in some cases the entire manifold—is removed from its in-use position and then serviced elsewhere.
[0073] The piston diaphragm of the invention is illustrated at 95 , and in exemplary embodiments is formed of brass. As FIG. 7 illustrates, the spring 90 and its buttons 94 are positioned between the piston diaphragm 95 and the spring chamber 91 . A pusher post button 96 is beneath and bears against the piston diagram 95 on one side and the seat ring 97 with an O-ring (too small to be clear in this illustration) on the other side. The piston diaphragm 95 carries an O-ring 100 around its circumference generally about halfway between the top and the bottom of the diaphragm 95 . A piston assembly 101 is beneath and bears against the seat ring 97 and is surrounded by the seat spring 102 , which closes the seat. The spring chamber 91 threads into the regulator body 103 and a body O-ring 104 helps create and preserve a seal against leakage in the overall regulator structure.
[0074] As illustrated in both FIG. 7 and FIG. 10 , the piston assembly 101 is free to reciprocate in its piston chamber 99 without the conventional sealing O-ring that typically surrounds such a piston in a regulator (e.g., the O-ring 118 in the bank regulator). Avoiding the O-ring helps the piston move more smoothly, which in turn reduces the droop.
[0075] In exemplary embodiments, and as set forth with respect to FIG. 10 , an HNBR elastomer is incorporated in the piston assembly 101 to provide a higher temperature rating.
[0076] FIG. 7 also illustrates that in a manner analogous to the openings in the bank regulators (e.g., FIG. 6 ), the regulator body 103 includes a bleed valve opening 105 , a pressure gauge port 106 , and (if desired) a pressure switch port 107 .
[0077] The remaining items in FIG. 7 are the same as shown in and described with respect to FIGS. 1-6 and will not be repeated here.
[0078] FIG. 8 is an exploded view similar to FIG. 7 , but illustrating the left bank regulator 70 in the exploded view. FIG. 8 illustrates an adjustment screw 110 that carries an O-ring 111 and a locknut 112 . The spring chamber is illustrated at 113 and the spring at 114 . The spring rests between the piston diaphragm 115 (which again includes an O-ring 117 ) and a spring button 116 .
[0079] A seat ring 120 is beneath piston diagram 115 with a pusher post button 121 in between. The seat ring 120 carries an O-ring (not shown in FIG. 8 ). The seat ring can be formed of monel alloys (i.e., specialized nickel-copper alloys), brass, or stainless steel. The piston assembly is illustrated at 122 and rests in a seat spring 123 . The seat spring 123 is preferably formed of austenitic nickel-chromium based “superalloy” (e.g., Inconel 750) or of a copper beryllium alloy. In turn, these parts rest in the regulator body 124 with pressure being maintained in place by the O-ring 125 . The remaining elements in FIG. 8 are either the same as those described and illustrated in the exploded portion, or in the preceding drawings.
[0080] FIG. 9 is a cross-sectional view of the bank regulator 70 of FIG. 8 and FIG. 10 is a cross-sectional view of the line regulator of FIG. 7 .
[0081] Most of the elements illustrated in FIGS. 9 and 10 have already been described, but FIGS. 9 and 10 include some additional details. FIGS. 9 and 10 illustrate the regulators in their open positions.
[0082] FIG. 9 illustrates more details of the piston assembly 122 in a line regulator. In the illustrated embodiment, the piston assembly includes a piston base 87 , a piston stem 88 and the O-ring 130 between the base 87 and the stem 88 . An O-ring 127 is on the seat ring 120 , and the O-ring 130 is between the piston assembly and the seat 120 . An O-ring 118 is positioned at the bottom of the piston assembly 122 .
[0083] In particular, the seat O-ring 130 functions as the seal between the high pressure (e.g., 2500 psi) and lower pressure (e.g., 250 psi) portions of the regulator. Because of that, in the invention the O-ring 130 is formed of an elastomer that can withstand adiabatic compression of a factor of at least 5, and preferably 10 (pressure to pressure) without igniting in oxygen. Certain rigid engineering polymers meet this requirement, but are not sufficiently flexible for the regulator's purpose. Various combinations of polysilphenylene-siloxane and polyphosphagene have high temperature combustion rations, but a highly favorable choice appears to the hydrogenated nitrile butyl rubber (“HNBR”).
[0084] HNBR has good viscoelastic properties, a service temperature range of between about −40° C. to +150° C. (−40 to 300 F), resistance to fluids of various chemical compositions and excellent resistance to strongly alkaline and aggressive fluids. HNBR is a derivative of nitrile rubber, which is hydrogenated in solution using precious metal catalysts. Different grades can be made by precise control of the proportion of unconverted double bonds in the material. HNBR is resistant to thermo-oxidative aging, with typical service life ratings that correspond to a long-term exposure of 1000 hours at 150° C. (about 300 F).
[0085] FIG. 10 shows some additional details about the line regulator. These include the rounded nose 132 on the adjustment screw 92 . FIG. 10 also shows the O-ring 133 on the seat ring 97 as well as the O-ring 134 in the piston assembly 101 .
[0086] FIG. 12 is a perspective view of a single forging 41 and illustrated the regulator bodies 124 and the metal bridging web 48 .
[0087] FIG. 13 is a perspective view of the manifold 40 that illustrates the manner in which the brace bar 28 connects two forgings 41 together.
[0088] FIG. 14 is an exploded perspective view of the inlet pipe 42 illustrating the sintered bronze filter 58 . The filter 58 has a body that includes a longitudinally-projecting portion that has a frustum shape in the illustrated embodiment. In exemplary embodiments, the filter 58 is formed of sintered bronze with a 40 micron size. The volume and shape of the filter 58 helps slow gas velocity, improve heat rejection, and retain particles more efficiently than simpler shapes. FIG. 14 also illustrates a retaining ring 59 for the filter 58 and an O-ring 68 for the inlet pipe 42 .
[0089] FIG. 11 illustrates the use of the manifold in connection with network capability for a medical air system. This is consistent with the TOTALALERT™ system from Atlas Copco/BeaconMedaes (Rock Hill, S.C.). This aspect off the invention is also consistent with the systems described in U.S. Pat. Nos. 7,768,414; 7,145,467; and 6,987,448, the contents of which are incorporated entirely herein by reference.
[0090] An exemplary embodiment is a medical gas alarm system for use in a healthcare facility having a medical gas system which delivers a plurality of medical gases to a plurality of locations in the healthcare facility and having a network of computer devices. In this context, the invention includes a gas pressure manifold that communicates with the network of computer devices. As already described, the gas pressure manifold includes bank regulators, line regulators, and pressure sensors associated with each regulator. Network connectors between the sensors and the remainder of the network permit remote monitoring of cylinder pressure levels, alarm status, event logs, and similar items, using any computer on the network. The system likewise typically includes a network hub (or equivalent), an Internet connection (with firewall), and an email server.
[0091] In most cases, the medical gas system includes vacuum pumps and medical air pumps that are also in communication with the network. In exemplary embodiments, any and all alarm devices in the system communicate with the network.
[0092] FIG. 11 illustrates that the manifold (illustrated in its housing 20 ) can be networked to an appropriate Ethernet hub 136 . The hub 136 (or its equivalent) is in turn connected to a computer 137 with web browsing capability or to any equivalent device such as a tablet or smart phone. An alarm 140 is connected to the network as are other portions of the medical air system. These are symbolically illustrated at 141 , 142 , and 143 in the drawings, and can represent various aspects of the medical air system, such as the medical air supply 141 , a crawl-type vacuum 142 , or a lubricated rotary vane vacuum 143 .
[0093] An email server 144 is connected to the network and can communicate internally through the hub 36 or with the Internet 145 , with a firewall 146 typically being included for security purposes. The email server can generate messages that, using the Internet, can be directed to one or more cellular phones 147 or their equivalent; i.e. the term “cellular phone” is used in a broad sense to incorporate devices that can receive text messages, email, or other communications, including but not limited to smart phones and tablet computers. Additionally, such messages can be received by more conventional computers (“PC”s or “laptops”) that have either Wi-Fi or cellular capability or both depending upon context.
[0094] The TOTALALERT™ network monitors medical air, medical vacuum, medical master alarm, medical area alarms, and now the medical manifold of the invention. No additional software is required and the equipment on the network reside as IP points on the user's intranet. One key feature of the TOTALALERT™ network is that a single web page displays all of the equipment on the network. Although other systems may add embedded software to a product, none appear to include a centralized web page from which all of the individual components can be monitored.
[0095] In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms have been employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.
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A gas pressure regulator is disclosed that includes a reciprocating piston that engages and disengages from a seat to open the higher pressure and lower pressure sides of the regulator to one another. The regulator includes an elastomer seal between the seat and the piston that has an ignition rating sufficient to avoid combustion in the presence of oxygen at pressure differentials that are a factor of between 5 and 10 between the higher pressure and lower pressure sides of the regulator.
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CROSS REFERENCE
The present invention cross references the U.S. Patent Application of the same inventor January Kister, titled “Freely Deflecting Knee Probe With Controlled Scrub Motion” filed May 21, 2004, application Ser. No. 10/850,921, which is hereby incorporated by reference.
FIELD OF INVENTION
The present invention relates to cantilever probes. In particular, the present invention relates to a cantilever probe with angle fixture and a probe apparatus therewith.
BACKGROUND OF INVENTION
Continuing miniaturization of cantilever probes imposes new challenges for their positioning and fixing within a probe apparatus. Cantilever probes are commonly fixed with their peripheral ends having their cantilever portion with the contacting tip free suspended to provide the required flexibility. To provide sufficient positioning accuracy, the fixture portion of the cantilever probe is commonly extensively dimensioned, which in turn consumes extensive real estate forcing multilayer cantilever probe assemblies with varying cantilever geometries. Such varying cantilever geometries result in different deflection behavior and limited average positioning accuracy of all cantilever probes of a probe apparatus. In addition, cantilever probes of the prior art are commonly fixed in a surrounding fashion along a linear fixture element, which requires additional surrounding referencing and/or positioning structures, which in turn consume additional space between the cantilever probes.
Prior art cantilever probes are commonly fabricated with lengthy peripheral structures for a sufficient fanning out between the ever decreasing test contact pitches and circuit board contacts of the probe apparatus. Peripheral fan-out structures may be a multitude of the cantilever portion, which reduces the positioning accuracy of the ever decreasing cantilevers and contacting tips.
For the reasons stated above, there exists a need for a cantilever probe and probe assembly that provides maximum contacting tip accuracy together with homogeneous deflection behavior within a minimum footprint. In addition, cantilever probes may be simple and highly consistent in geometry for inexpensive mass production. Other affiliated structures of the probe apparatus may be inexpensively fabricated to accommodate for highly individualized probe apparatus configurations. The present invention addresses these needs.
SUMMARY
A cantilever probe has an elbow for bonding to a dual plane fixture plate having two substantially non parallel fixture surfaces in an angle corresponding to the elbow. The dual plane angled fixture between elbow and fixture plate provides for a highly stiff and precise hold of the bonded cantilever probe with minimal real estate consumption. The cantilever probe may feature at least two positioning pins one of which may be placed at the contacting tip and the other one may extend from at least one of two contacting faces of the elbow. The elbow positioning pin may fit into a corresponding elbow pin hole on one of the fixture surfaces. The tip positioning pin may fit into a corresponding tip pin hole of a sacrificial assembly plate temporarily combined with the fixture plate for a precise positioning of the cantilever probes during curing, setting or hardening of a bonding agent between the fixture plate an the elbow. After assembly of a number of cantilever probes, the sacrificial plate may be removed and the tip pins eventually sanded to a common plane.
Separate fan-out beams may be aligned with beam positioning pins on and attached to the fixture plate. The fan-out beams are aligned and conductively connected with their probe connect ends to respective probe elbows once the cantilever probes are fixed. The fan-out beams in turn may be conductively connected with their respective peripheral connect ends to well known large pitch apparatus terminals of a circuit board. Cantilever probes and fan-out beams may have geometries suitable for inexpensive mass fabrication by well known masked electro deposition fabrication techniques. A probe apparatus may be easily customized by providing varying drill patterns of the positioning holes for fan-out beams and cantilever probes to match pitch requirements of the tested circuit chips.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A is a front view of an exemplary cantilever probe of the preferred embodiment parallel a symmetry plane of the cantilever probe.
FIG. 1B is a perspective view of the cantilever probe of FIG. 1A .
FIG. 2 is the perspective view of a first portion of a fixture plate including two fixture surfaces and elbow alignment holes.
FIG. 3 is the perspective view of the fixture plate of FIG. 2 together with a sacrificial spacing structure and sacrificial assembly plate.
FIG. 4 is the perspective view of the plates of FIG. 3 with a number of assembled cantilever probes of FIGS. 1A , 1 B.
FIG. 5 is the perspective view of assembled probes and fixture plate of FIG. 4 with removed sacrificial spacing structure and sacrificial assembly plate.
FIG. 6 is the perspective view of a second portion of a fixture plate including the first portion of FIG. 2 and alignment holes for fan-out beams.
FIG. 7 is the perspective view of an exemplary fan-out beam.
FIG. 8 is the perspective view of the assembled cantilever probes and fixture plate of FIG. 5 , the fixture plate of FIG. 6 and a number of assembled fan-out beams of FIG. 7 conductively connected with respective cantilever probes.
DETAILED DESCRIPTION
Referring to FIGS. 1A , 1 B, a cantilever probe 1 for test contacting a well known test contact of a tested electronic circuitry along a contacting axis CA may have a tip positioning pin 14 configured for the test contacting. The tip positioning pin 14 may also be configured for an aligning insertion in a respective one of tip pin holes 43 A– 43 N (see FIG. 3 ) also along the contacting axis CA. The cantilever probe 1 may further feature a cantilever 13 for resiliently holding the tip positioning pin 14 with respect to the contacting axis CA with a predetermined deflection behavior including a well known scrub motion along the symmetry plane SP.
A base arm 11 may rigidly extend from said cantilever probe 13 such that operational deflection of the cantilever 13 leaves a base arm assembly face 111 substantially free of deformation. An offset arm 12 extends substantially rigid from the base arm 11 in a substantially non parallel elbow angle AE defining together with the base arm 11 a fixture elbow 10 for rigidly fixing the cantilever probe 1 preferably via base arm assembly face 111 and offset arm assembly face 122 . An elbow positioning pin 15 extends from one of the base arm 11 and the offset arm 12 along an elbow pin axis PA, which is substantially parallel to the contacting axis CA. The elbow positioning pin 15 is configured for an aligning insertion in a respective one of elbow pin holes 23 A– 23 N (see FIGS. 2 , 6 ) together with aligning insertion of the tip positioning pin 14 . The base arm assembly face 111 has a length 111 L and the offset arm assembly face 121 has length 121 L. The contacting axis CA is in a probe pin distance AP to the elbow pin axis PA.
The cantilever 13 may preferably have a bend 131 terminating at the base arm 11 , which in turn may preferably extend substantially parallel to the contacting axis CA. In that case, the elbow positioning pin 14 may extend from the offset arm 12 .
The cantilever 13 , the base arm 11 and the offset arm 12 may have a continuously protruding profile perpendicular with respect to the symmetry plane SP and the contacting axis CA. In such case, the cantilever probe 1 may be fabricated by a masked electro deposition process in which a central layer including the position pins 14 , 15 is interposed between profile layers. As a result, the positioning tips 14 , 15 may have at least rectangular but preferably square cross section. The cantilever probe 1 may consequently be also substantially symmetric with respect to the symmetry plane SP that coincides with the contacting axis CA and the elbow pin axis PA.
Deflection behavior of the cantilever 13 may be tuned by adjusting the cantilever length 13 L, cantilever height 13 H, profile width 1 W as well as shape and material composition of the cantilever 13 as may be well appreciated by anyone skilled in the art. Furthermore, instead of the cantilever 13 another suspension structure may be employed such as a suspension knee disclosed in the cross referenced U.S. Application, titled “Freely Deflecting Knee Probe With Controlled Scrub Motion”. Thereby, the tip positioning pin may be combined with the suspension knee at the contacting face.
Referring to FIG. 2 , a probe fixture plate 2 for fixedly holding a number of cantilever probes 1 may have a first fixture surface 22 featuring a number of primary positioning holes 23 A– 23 N for the aligned insertion of a number of elbow positioning pins 15 . The probe fixture plate 2 may additionally feature a second fixture surface 21 in a substantially non parallel fixture surface angle SA to said first fixture surface 22 . The fixture surface angle SA corresponds to the elbow angle AE. The second fixture surface 22 preferably extends in substantially constant offset 23 O to an array direction of the positioning holes 23 A– 23 N arrayed with positioning hole pitch 23 P.
In case the primary elbow positioning holes 23 A– 23 N are linearly arrayed, the second fixture surface 21 may be planar. The fixture surface angle SA may be perpendicular. Referring to FIG. 3 , a temporary plate assembly 100 may include a sacrificial assembly plate 4 separable attached to an attachment face 24 of the probe fixture plate 2 . The sacrificial assembly plate 4 has a third surface 42 with secondary tip positioning holes 43 A– 43 N in a probe positioning hole offset AL that corresponds to the probe pin distance AP. A secondary hole pitch 43 P may be preferably equal or less than the primary hole pitch 23 P. The attachment face 24 may be opposite the first fixture surface 22 .
The third surface 42 may be in a surface offset 40 H to the first fixture surface 22 in direction of the primary holes 23 A– 23 N and secondary holes 43 A– 43 N. In the case where the surface offset 40 H is substantially larger than a fixture plate height 20 H, a sacrificial spacing structure 3 may be interposed between the probe fixture plate 2 and the sacrificial assembly plate 2 . Sacrificial assembly plate 4 and sacrificial spacing structure 3 may be separable by use of a selectively dissolvable solder or other bonding agent as may be well appreciated by anyone skilled in the art.
Referring to FIG. 4 , a probe bonding assembly 101 may include the temporary plate assembly 100 and a number of cantilever probes 1 A– 1 N aligned inserted with their elbow positioning pins 15 in a respective one of the elbow positioning holes 23 A– 23 N and their tip positioning pins 14 concurrently aligned inserted in a respective one of the tip positioning holes 43 A– 43 N. As a result, the base arm assembly face 111 may be brought into a combining proximity with the second fixture surface 21 and the offset arm assembly face 121 may be brought into a combining proximity with the first fixture surface 22 . For that purpose, the elbow pin axis PA may be in an assembly face offset PO to the adjacent assembly face that is equal or slightly larger the constant offset 23 O between the center of the elbow positioning holes 23 A– 23 N and the second fixture surface 21 . In case of the cantilever probe 1 the assembly face offset PO is between offset arm assembly face 121 and the elbow positioning pin 15 .
A robotic probe assembling may be accomplished in combination with a vacuum fixture holding a cantilever probe 1 and moving it towards assembly position in direction along the contacting axis CA and elbow pin axis PA. In cases where the scale of the positioning pins 14 , 15 is close to the positioning accuracy of the robotic assembly system, a sequential aligned insertion may be accomplished by varying the elbow pin height 15 H from the tip pin height 14 H. Once a first aligned insertion is accomplished, the second aligned insertion may be attempted without risk of again misaligning the other of the positioning pins 14 , 15 .
Referring to FIG. 5 , a fixed probe assembly 102 features a number of cantilever probes 1 A– 1 N fixed with their respective fixture elbows 10 A– 10 N to the fixture plate 2 preferably by applying a combining or bonding agent in the combining proximity between the assembly faces 111 , 121 and their respective fixture surfaces 21 , 22 . A combining or bonding agent may be for example an epoxy or a solder. In case a solder is used, an electrically conductive connection may be simultaneously established between the fixture elbows 10 A– 10 N and eventual conductive traces on one or both of the fixture surfaces 21 , 22 . Sacrificial assembly plate 4 and eventual sacrificial spacing structure 3 are removed. The tip positioning pins 14 A– 14 N are configured to operate additionally for test contacting along their respective contacting axis CAA-CAN with an eventual scrub motion. For that purpose, the tip positioning pins 14 A– 14 N may be adjusted to a common tip clearance 1 H by a sanding operation.
The contacting axes CAA-CAN are in a contacting pitch 1 P that corresponds to the secondary hole pitch 43 P. In case of linear arrayed elbow positioning holes 23 A– 23 N and planar second fixture surface 21 , the cantilever probes 1 may be parallel assembled with constant gap 1 G and constant profile width 1 W.
The elbow positioning holes 23 A– 23 N may also be arrayed with curvature and the second fixture surface 21 may be concentric as well as the secondary positioning holes 43 A– 43 N being concentrically arrayed with proportionally reduced secondary hole pitch 43 P. In that case, the cantilever probes 1 may be arrayed with minimal contacting pitch 1 . Furthermore, the probes 1 may have a proportionally decreasing profile width 1 resulting again in a constant probe spacing 1 G. Another advantage may be a favorably balanced stress distribution as a result of the profile width 1 increasing proportionally with the distance from the contacting axes CAA-CAN, which corresponds to the bending stress increasing in the cantilever 13 away from the contacting axes CAA-CAN as may be well appreciated by anyone skilled in the art.
The angled fixture is particularly advantageous in minimizing an overall real estate of the fixed probe assembly in perpendicular extension to the contacting axes CAA-CAN. This results on one hand from utilizing the second fixture surface 21 preferably parallel to the contacting axes CAA-CAN, which consumes only a minimal real estate independently of the fixture plate height 20 H. The minimized overall real estate results on the other hand from an increased stiffness and thermal stability of the angled fixture due to the three dimensional configuration of the bonding interface between fixture surfaces 22 , 21 and the assembly faces 121 , 111 together with a reduced combining proximity and minimal use of combining agent. Further more, the bonding interface is free of lateral structures in between adjacent cantilever probes 1 , resulting in a maximum profile width 1 , which in turn assists in designing suspension structures highly resistant against inadvertent deviating torsion bending.
Referring to FIG. 6 , the first fixture surface 22 may further feature alignment holes 25 A– 25 N and orienting holes 26 A– 26 N. Each of the alignment holes 25 A– 25 N defines with a respective one of the orienting holes 26 A– 26 N one of the positioning axes 27 A– 27 N. The positioning axes 27 A– 27 N may be oriented in a fan-out angle AF with respect to an adjacent one of the positioning axes 27 A– 27 N. Consequently, an alignment hole distance DA between adjacent ones of the alignment holes 25 A– 25 N is substantially smaller than an orienting hole distance DO between adjacent ones of the orienting holes 26 A– 26 N. The alignment hole distance DA is about the same as the positioning hole pitch 23 P. The distance of the positioning axes 27 A– 27 N corresponds to a beam pin distance 57 (see FIG. 7 ).
Particular advantageous is a fabrication step of concurrently drilling all holes 23 A– 23 N, 43 A– 43 N, 25 A– 25 N and 26 A– 26 N without need of intermediate repositioning of the temporary plate assembly 100 , which provides for highest hole position accuracies with minimal machining effort. In that way highly individualized probe assemblies may be fabricated in combination with standardized cantilever probes 1 and fan-out beams 5 (see FIG. 7 ).
Referring to FIG. 7 , a fan-out beam 5 may be fabricated from electrically conductive material with a beam length 51 L. The fan-out beam 5 may have a probe connect end 52 and a peripheral connect end 53 on a connect surface 51 . Opposite the connect surface 51 may be a beam attachment face 56 featuring an elbow alignment pin in the proximity of the probe connect end 52 . A fan-out orienting pin 55 may be with its orienting pin axis 55 C in a beam pin distance 57 to alignment pin axis 54 C. The fan-out beam 5 may be fabricated similarly like the cantilever probe 1 with a masked electro deposition process in a multi layer fashion.
Referring to FIG. 8 , a probe and fan-out beam assembly 103 features a fixed probe assembly 102 with the fixture plate 2 of FIG. 6 with respect to which a number of fan-out beams 5 A– 5 C are positioned via their elbow alignment pins 54 in respective ones of the alignment pin holes 25 A– 25 N and oriented with their orienting pins 55 in respective ones of the orienting pin holes 26 A– 26 N such that their probe connect ends 52 A– 52 N are in close proximity to respective ones of elbow fixtures 10 A– 10 N. The fan-out beams 5 may be bonded or combined with its attachment face 56 with the first fixture surface 22 . Conductive bridges 6 A– 6 N electrically conductive connect fixture elbows 10 A– 10 N with respective ones of the probe connect ends 52 A– 52 N such that a solid conductive path is established between the tip positioning pins 14 A– 14 N and respective ones of the peripheral connect ends 53 A– 53 N. The conductive bridges 6 A– 6 N may be fabricated by well known wire bonding and/or wedge bonding techniques.
The fan-out beams 5 may be alternately lengthened for a zigzag connect end pattern for increased spacing between adjacent ones of the peripheral connect ends 53 A– 53 N, which may be conductively connected to well known assembly contacts of a probe apparatus.
Fixed probe assembly 102 and/or probe and fan-out beam assembly 103 may be part of a probe apparatus for testing electronic circuitry. Fan-out beams 5 and probes 1 may be economically fabricated in large number in a common configuration and combined with individually fabricated fixture plates 2 .
Accordingly, the scope of the invention described in the specification above is set forth in the following claims and their legal equivalent:
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A cantilever probe has an elbow for bonding to a dual plane fixture plate for a highly stiff and precise angled fixture of the bonded cantilever probe with minimal real estate consumption. The cantilever probe may feature a tip positioning pin and an elbow positioning pin fitting into corresponding holes of the fixture plate and a sacrificial assembly plate. Separate fan-out beams may be attached to the fixture plate and conductively connected to respective elbows once the cantilever probes are fixed. The fan-out beams in turn may be conductively connected with their respective peripheral ends to large pitch apparatus terminals of a circuit board. A probe apparatus may be easily customized by providing varying drill patterns of the positioning holes for fan-out beams and cantilever probes to match pitch requirements of the tested circuit chips.
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CONTRACTUAL ORIGIN OF THE INVENTION
The United States Government has rights in this invention pursuant to Contract No. W-31-109-ENG-38 between the U.S. Department of Energy and the University of Chicago, representing Argonne National Laboratory.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for producing hydrogen peroxide, and more specifically, this invention relates to a method for producing hydrogen peroxide via the utilization of advanced membrane technology
2. Background of the Invention
Environmental considerations and regulations continue to prompt industries to use compounds which are less detrimental to the ecosystem. One example is the dramatic increase in the use of hydrogen peroxide for pulp and paper industry applications. Instead of relying on chlorine and chlorine dioxide bleaching processes, many paper producers now utilize chemithermo-mechanical pulping where hydrogen peroxide facilitates pulp brightness. The use of hydrogen peroxide in this industry has increased-to approximately 300,000 metric tons, which is 50 percent of current North American production capacity. Such usage will continue to increase significantly.
The use of hydrogen peroxide is expanding quickly in other markets as well, such as in water and waste treatment, mining, chemical processing, textiles and industrial cleaning. Current world wide production annually is 1.4 million metric tons, with a 7 percent annual growth rate.
Hydrogen peroxide production is controlled by a few chemical companies that produce it in large scale plants as a 70 percent concentrate. However, the highly oxidative characteristics of that level of concentration requires nearly immediate dilution to 50 percent concentration for safe transport. Ultimately, hydrogen peroxide is used in concentrations of approximately 5-10 percent. Typical H 2 O 2 production processes are based on anthraquinone reduction-oxidation chemistry. The typical process steps are (1) hydrogenation of anthraquinone working solution in a fixed bed reactor; (2) separation of the catalyst fines; (3) oxidation of the hydrogenated anthraquinone working solution by air in a multi-stage packed bed tower while simultaneously producing H 2 O 2 in the organic stream; (4) extraction of the H 2 O 2 from the anthraquinone working solution by water in a multistage counter-current extraction column process; (5) recovery and polish purification of the anthraquinone working solution, the accompanying solvents, and their recycle to the hydrogenator; and (6) recovery, polish purification and-stabilization of the H 2 O 2 product.
The typical process outlined above, disclosed in U.S. Pat. Nos. 2,158,525 and 2,215,883 to Pfliderer and Riedel, respectively is suitable for large scale production of H 2 O 2 . However, the process is unsuitable for small scale production (500-1,000 metric tons per year) and medium scale production (5,000 metric tons per year). This is because the packed tower used for oxidation, and the column for H 2 O 2 extraction are very large and do not easily scale up or down for modularity and operational flexibility. For example, for a nominal 5,000 metric ton per year mini-plant, the oxidation-tower will have three beds 4.5 feet in diameter and 15 feet tall, stacked in series. The height of the equipment for this single oxidation process is more than 60 feet.
Conventional processes to extract H 2 O 2 from reaction liquor also has several drawbacks. Such processes utilize counter-current, multi-stage, liquid-liquid extraction of the anthraquinone working solution (AQS) with water. However, these procedures result in a very low (1:20, i.e., one part water extract to 20 parts of AQS) phase ratio between water extract and the AQS. H 2 O 2 concentration in the aqueous fraction has to be high in these processes so that subsequent H 2 O 2 isolation steps can proceed more economically. As such, typical extractors are multi-stage, very large in volume and difficult to scale down. These systems can be highly unstable and thus require a high degree of operational control. Finally, a certain amount of the polar solvents also enters the final aqueous phase in these processes. This results in contamination of the H 2 O 2 phase and ultimately, loss of the solvent. Typical extraction equipment has 23 countercurrent stages and is approximately 100 feet tall.
Efforts have been made to minimize ancillary reducing reactions (leading primarily to nuclear hydrogenation of the aromatic nuclei of the working solution) to prevent loss of solvent and anthraquinone feedstock (U.S. Pat. No. 3,009,782 to Porter). However, final fractions of H 2 O 2 still contain high levels of organic contaminants that require further isolation and polishing.
Finally, and not surprisingly, the costs associated with the typical highly capital- and energy-intensive, large scale hydrogen peroxide processes are passed on to low-volume end users. These end users would benefit from methods for producing hydrogen peroxide more economically.
A need exists in the art for a process to produce hydrogen peroxide without the concomitant capital costs and handling problems associated with current production schemes. The process would allow effective H 2 O 2 production in small plant environments and therefore would have a small size or footprint compared to the footprint of the "host" industrial site. Finally, the H 2 O 2 process would be as modular as possible with the ability for quick start-up, shut-down and turnaround, while also accommodating variability in production rates.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for producing hydrogen peroxide that overcomes many of the disadvantages and shortcomings of the prior art.
It is another object of the present invention to provide a process for economically producing hydrogen peroxide. A feature of the invention is the utilization of membrane technologies to isolate hydrogen peroxide from the process reaction liquid. An advantage of the invention is the rendering of hydrogen peroxide that is virtually free of organics. Another advantage of the invention is the ability to retain expensive organic solvents in reaction liquors for reuse.
Yet another object of the present invention is to provide a modularized process for producing hydrogen peroxide. A feature of the process is supplanting multi-stage packed bed oxidation towers found in typical peroxide production systems with membrane systems. An advantage of the invention is the minimization of the footprint and costs associated with the production of hydrogen peroxide.
Briefly, a method for producing hydrogen peroxide is provided comprising supplying an anthraquinone-containing solution; subjecting the solution to hydrogen to hydrogenate the anthraquinone; mixing air with the solution containing hydrogenated anthraquinone to oxidize the solution; contacting the oxidized solution with a hydrophilic membrane to produce a permeate; and recovering hydrogen peroxide from the permeate.
BRIEF DESCRIPTION OF THE DRAWING
These and other objects and advantages of the present invention will become readily apparent upon consideration of the following detailed description and attached drawing, wherein
FIG. 1 is a schematic diagram of a method for producing hydrogen peroxide, in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides an improved process for production of H 2 O 2 via mini-plants by the use of advanced membrane technologies of perfusion, perstraction and pervaporation.
The invented process revolves around the well known successive hydrogenation and oxidation of alkytanthraquinones depicted below in Equations 1 and 2. ##STR1## where R connotes an alkyl group, such as ethyl, and the hydrogenation catalyst is any suitable catalyst that fosters the reduction of the quinone group to the hydroquinone group.
An exemplary embodiment of the invented process is designated as numeral 10, in FIG. 1. Briefly, starter anthraquinone material 12 is first selected. While a myriad of alkyl anthraquinones are suitable for H 2 O 2 production, the inventors choose to illustrate their process using 2-ethyl anthraquinone and-tetrahydro 2-ethyl anthraquinone as the starter anthraquinone material 12. However, the choice of starter materials here should not be construed as limiting the invented process to these species. Rather, a myriad of working materials are suitable, including, but not limited to, 2-ethylanthraquinone, 2-isopropylanthraquinone, 2-sec-butylanthraquinone, 2-t-butylanthraquinone, 2-sec-amylanthraquinone, 1,3-dimethylanthraquinone, 2,3-dimethyl-anthraquinone, 1,4 dimethylanthraquinone, 2,7-dimethylanthraquinone, amylanthraquinone, tetrahydroamylanthraquinone and combinations thereof.
This starter material 12 is solubilized via a ternary solvent system into an initial stream 13 to yield a homogenous liquid phase 14. This phase 1-4 is subjected to a hydrogenation step 15. The hydrogenation step converts 2-ethyl anthraquinone to 2-ethyl anthrahydroquinone and tetrahydro 2-ethyl anthraquinone to tetrahydro 2-ethyl anthrahydroquinone to comprise a hydrogenated solution 16. The hydrogenated solution 16 is then subjected to a particulate removal step 18 so as to remove any catalyst fines. The now filtered hydrogenated solution is oxidized via a membrane perfusion reactor 20, which consists of a porous membrane system to produce finely divided air bubbles to saturate the solution with oxygen. As can be noted in Equation 2, supra, this oxidation step regenerates the starter anthraquinone materials and the desired product, hydrogen peroxide.
The oxidized solution 21, now containing hydrogen peroxide, is contacted with a pervaporation membrane 23 associated with a pervaporation and/or perstraction process 22 so as to produce a permeate 25 containing polar, volatile compounds, namely water and hydrogen peroxide. This permeate 25 can be subjected to further polishing 26 such as distillation so as to boil off water and other lower fractions, thereby leaving the hydrogen peroxide. Materials retained by the pervaporation membrane 23, such as solvents and anthraquinones are recirculated via a recirculation means 24 back to the make-up stream step 13, noted supra, for reuse.
Solvent System Detail
In the pure state, 2-ethyl anthraquinone (EAQ) and tetrahydro 2-ethyl anthraquinone (THEAQ) are solids and must be pretreated by being dissolved in an appropriate solvent system. The EAQ and THEAQ are soluble in one type of solvent and their hydrogenation products 2-ethyl anthrahydroquinone (EAHQ) and tetrahydro 2-ethyl anthrahydroquinone (THEAHQ), respectively, are soluble in another type of solvent. The mix of the EAQ and THEAQ, and their hydrogenation products, all dissolved in their appropriate solvents, is called the anthraquinone working solution (AQS).
The initial stream 13 results from the use of a ternary solvent mix solvent A, B and C. Solvent A is chosen to dissolve EAQ and THEAQ, which are readily soluble in alkylated aromatic solvents. Solvent B is chosen to solubilize the hydrogenated intermediates EAHQ and THEAHQ, which are polar compounds. Solvent C provides more compatibility between the two solvent systems, and also improves the rate and selectivity of the hydrogenation step.
Solvent A is a mixture of alkylated aromatics. A suitable mixture, commercially available from Shell Oil Co., is CYCLO-SOL 63™. This trade name compound is typically bench-marked as having 80 percent C-10 and C-11 alkyl benzenes, 3.2 percent C-8, C-9 and C-12 alkyl benzenes, 13.3 percent cyclo alkyl benzenes, and 3.5 percent naphthalene. Other suitable alkylated aromatics are commercially available from Exxon Corp., as Aromatic 150™ and Aromatic 100™.
Solvent B is a polar solvent, such as Tri(w-ethyl hexyl) phosphate (TOF). Another suitable polar solvent for solubilizing the hydrogenated anthraquinone materials is diisobutylcarbinol.
Solvent C candidates include tetra alkyl ureas such as N,N-Diethyl-N,N-Di-n-Butyl-urea (DEDBU).
A typical composition of the working solution (AQS) is disclosed in Table 1, below:
TABLE 1______________________________________Composition of an Exemplary Anthraquinone Working SolutionComponent Weight Percent.sup.1______________________________________2-ethyl anthraquinone (EAQ) 4.5tetrahydro 2-ethyl anthraquinone (THEAQ) 13.5Polar Solvent.sup.2 10.0Tetra alkyl urea.sup.3 0-10Inerts + miscellaneous.sup.4 4.0Alkylated aromatic solvent.sup.5 remainder______________________________________ .sup.1 Values to add to 100. .sup.2 A suitable polar solvent is tri (wethyl hexyl) phosphate. .sup.3 A suitable urea compound is N,NDiethyl-N,N-Di-n-Butyl urea. .sup.4 Inerts generally are epoxides of anthraquinones. .sup.5 Such as Cyclosol-63.
The above exemplary composition should not be construed as limiting the anthraquinone working solution to certain weight percent values. Rather, a myriad of weight percents for the AQS working solution produce good results. For example, suitable ranges for 2-ethyl anthraquinone is approximately 3.5 to 6 weight percent. Suitable ranges for the tetrahydro 2-ethyl anthraquinone is approximately 10 and 15 weight percent. A suitable range for the polar solvent is approximately 8 to 12 weight percent.
Hydrogenation Detail
The hydrogenation step 15 is carried out in a fixed bed reactor at pressures ranging from approximately 3 to 10 atmospheres, and at temperatures ranging from between approximately 35° C. and 70° C., with preferred temperatures ranging from between approximately 40° C. and 50° C. The catalyst in the hydrogenation reactor is comprised of any of the suitable catalysts known to foster the reduction of the quinone group to the hydroquinone group, as for instance Raney nickel, or one of the noble metals such as ruthenium, rubidium, platinum, rhodium or palladium. Palladium, as one of the more common catalysts employed, is used herein at 0.3-0.35 weight percent dispersed on alumina, wherein the alumina used is delta or theta alumina and therefore substantially free of alpha, gamma, or alpha alumina monohydrate.
The hydrogen feed 17 is substantially free of catalyst poisoning chemicals, such as sulfur compounds, carbon monoxide, and chlorine compounds. Also, to maintain a positive output at bleed-offs and through the hydrogenation reactor, between approximately 1 and 10 percent of the hydrogen feed 17 is an inert carrier gas such as nitrogen, argon, neon, helium and noble fluids, generally.
Fresh hydrogen is mixed with recycled hydrogen and fed with the AQS in a down-flow mode to the packed bed hydrogenation reactor 15 where the catalyst particles are dispersed in vertical cylindrical tubes arranged to provide a high degree of contacting efficiency. Generally, from 20 to 200 liters per minute per square foot of catalyst bed cross area is a suitable range. After hydrogenation occurs in the tubular reactors, the converted gas is re-compressed and recycled via a gas recirculation loop 19 while the AQS is passed through in-line filters in the particulate removal step 18 to remove any hydrogenation catalyst fines. In as much as the hydrogenation step is somewhat exothermic, the hydrogenated AQS may need to be cooled prior to feeding the solution to the next phase of the process, which is the oxidation step, discussed below. Solution temperatures adjusted to between approximately 20° C. and 70° C. are suitable for the next step of the process.
Oxidation Detail
As noted above, conventional oxidation processes employ packed bed or bubble column reactors which require large reactor volumes and heights. However, the invented method utilizes more compact membrane-based perfusion contactors.
Membranes with very high porosity that can enable the dispersion of very fine gas bubbles into a liquid stream are used to mix an oxygen containing fluid, such as air, oxygen gas, or some other oxygen-containing gas, into the hydrogenated AQS and oxidize it. One such membrane, comprised mainly of polypropylene, is manufactured by Hoechst Celanese Inc. and sold under the trade name Cellgard™. Oxidation via the Cellgard™ membrane occurs in the oxidation step 20 when liquid contacts a first side of the membrane and the oxygen-containing fluid (e.g. gas such as air or oxygen) contacts a second side of the membrane. The gas which may be compressed, first flows through microtubules contained on the second side of the membrane. The microtubule structure allows the gas to pass through the fine pores of the first side of the membrane to mix with the liquid. Generally, the average residence time of the liquid in the perfusion membrane can range from between approximately 0.5 minutes to 5 minutes. Oxygen-containing gas pressures applied to the second side of the membrane can range from between approximately 1-4 atmospheres (15-60 psi).
The use of these types of membranes results in very high contact efficiency between liquid and gas. Furthermore, unlike typical oxidation modules, small volume structures provide suitable oxidation rates, with oxidation reactor volumes reduced by approximately 90 percent. This type of oxidation module 20 provides tremendous operational flexibility for easy start up and shut down while also accommodating variations in production rates.
Other suitable membranes can, be made from finely sintered metals, ceramic and polymeric materials, such as polysulfonic and polyvinylidenefluoride.
H 2 O 2 Separation Detail
The nominal concentration of H 2 O 2 in the oxidized AQS solution 21 is 10-20 grams per liter. As noted above, it is the separation of this low concentration of H 2 O 2 from the reaction liquor, and concomitantly obtaining the same H 2 O 2 concentration in the permeate, that proves to be problematic with conventional production processes.
The invented extraction process 22 utilizes pervaporation membranes 23 to greatly simplify the extraction process, particularly for small or mini-plant operations. In this pervaporation process step, hydrophilic membranes enable the permeation of aqueous and volatile hydrophilic constituents of the mixture while retaining the non-hydrophilic and non-volatile constituents for recycle.
Generally, the pervaporation membranes 23 employed consist of a nonporous polyvinyl alcohol active layer on a porous supporting layer. For example, membranes manufactured by GFT, Inc. in Neunkirchen-Heinitz, Germany, having the GFT PerVap 1001 or 1005 trade names consist of a non-porous polyvinyl alcohol active layer on a porous supporting layer made of polyester and polyacrylonitrile which are resistant to organics. Another membrane which has alkali resistance is marketed as GFT PerVap 2001. Here, the porous supporting layer is poly-acrylonitrile, only. Another Manufacturer of such membranes is Texaco, Inc. of White Plains, N.Y., and a typical hydrophilic membrane is TexSep 1B. Membranes made of Nafion (Dupont) which is hydrophilic-derivatized Teflon also can be used.
The oxidized AQS, which contains low concentration of hydrophilic compounds and volatile H 2 O 2 , is fed to the pervaporation unit where H 2 O 2 and H 2 O selectively permeates through the membrane. The organics, including the polar but nonvolatile solvent tri (w-ethyl hexyl) phosphate, are retained and recirculated via a recirculation loop 24. A number of advantages are realized as a result of the utilization of the pervaporation unit. First, the selectivity of the membrane is very high (>>100) and hence the resulting H 2 O 2 permeate 25 is essentially organic free. Furthermore, solvent losses are negligible. These low solvent concentrations in the permeate also results in the elimination of the formation of undesirable emulsions in permeate streams, which is typical in conventional processes.
H 2 O 2 flux rates through the pervaporation membrane of 0.1 to 1.0 kilograms per minute per square meter are obtained in the invented process. Desired flux rates, and desired concentrations of H 2 O 2 (i.e. 10-50 percent H 2 O 2 in water) can be maintained by the addition of water to the AQS stream during pervaporation. One preferable final target H 2 O 2 concentration is approximately 40 percent H 2 O 2 in water.
Water also can be added to the permeate side of the membrane. Given that water has an affinity to pull H 2 O 2 out of solution, this modified process essentially becomes a pervaporation/perstraction stage whereby the added water enhances the H 2 O 2 extraction from the AQS. The amount of water added to the AQS stream is determined by the desired final concentration of H 2 O 2 . Alternatively, only a first amount of water can be added to the AQS process stream, with a second amount of water to be added to the permeate, to achieve desired H 2 O 2 dilutions.
While the invention has been described with reference to details of the illustrated embodiment, these details are not intended to limit the scope of the invention as defined in the appended claims.
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An integrated membrane-based process method for producing hydrogen peroxide is provided comprising oxidizing hydrogenated anthraquinones with air bubbles which were created with a porous membrane, and then contacting the oxidized solution with a hydrophilic membrane to produce an organics free, H 2 O 2 laden permeate.
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This invention was made with government support under U01 CA52956 awarded by the National Cancer Institute. The government has certain rights in the invention.
FIELD OF THE INVENTION
This invention relates to compositions and methods of selectively inhibiting tumors and, more particularly, to treating a malignant melanoma using plant-derived compounds.
BACKGROUND OF THE INVENTION
Over the past four decades the incidence of melanoma has been increasing at a higher rate than any other type of cancer. It is now theorized that one in 90 American Caucasians will develop malignant melanoma in their lifetime. While an increasing proportion of melanomas are diagnosed sufficiently early to respond to surgical treatment and achieve a greater than 90% ten-year survival rate, it is estimated that nearly 7,000 individuals suffering from metastatic melanoma will die in the United States this year.
For patients with metastatic melanoma not amenable to surgical extirpation, treatment options are limited. 5-(3,3-dimethyl-1-triazenyl)-1-H-imidazole-4-carboxamide (dacarbazine, DTIC) is the most efficacious single chemotherapeutic agent for melanoma having an overall response rate of 24%. But the duration of response to DTIC is generally quite poor. Combination therapy with other synthetic and recombinant agents, including N,N'-bis(2-chloroethyl)-N-nitrosurea (carmustine, BCNU), cisplatin, tamoxifen, interferon-alpha (INF-α) and interleukin-2 (IL-2), has a higher response rate (e.g., 30-50%) in some trials, but a durable complete response rate is uncommon and toxicity is increased. Sequential chemotherapy has promise, but, clearly, current treatment options for individuals suffering from metastatic melanoma are unsatisfactory.
Various drugs derived from natural products, such as adriamycin (doxorubicin) derivatives, bleomycin, etoposide and vincristine, and their derivatives, have been tested for efficacy against melanoma either as single agents or in combination therapy. However, similar to the synthetic and recombinant compounds, these compounds exhibit low response rates, transient complete responses and high toxicities.
Nonetheless, as demonstrated by known and presently-used cancer chemotherapeutic agents, plant-derived natural products are a proven source of effective drugs. Two such useful natural product drugs are paclitaxel (taxol) and camptothecin. Paclitaxel originally derived from the bark of the Pacific yew tree Taxus brevifolia Nutt. (Taxaceae), currently is used for the treatment of refractory or residual ovarian cancer. More recently, clinical trials have been performed to investigate the possible role of paclitaxel in the treatment of metastatic melanoma. As a single agent, taxol displays activity comparable to cisplatin and IL-2. Taxol functions by a unique mode of action, and promotes the polymerization of tubulin. Thus, the antitumor response mediated by taxol is due to its antimitotic activity. The second drug of prominence, camptothecin, was isolated from the stem bark of a Chinese tree, Camptotheca acuminata Decaisne (Nyssaceae). Camptothecin also functions by a novel mechanism of action, i.e., the inhibition of topoisomerase I. Phase II trials of a water-soluble camptothecin pro-drug analog, Irinotican (CPT-11), have been completed in Japan against a variety of tumors with response rates ranging from 0% (lymphoma) to 50% (small cell lung). Topotecan, another water-soluble camptothecin analog, currently is undergoing Phase II clinical trials in the United States.
Previous antitumor data from various animal models utilizing betulinic acid have been extremely variable and apparently inconsistent. For example, betulinic acid was reported to demonstrate dose-dependent activity against the Walker 256 murine carcinosarcoma tumor system at dose levels of 300 and 500 mg/kg (milligrams per kilogram) body weight. In contrast, a subsequent report indicated the compound was inactive in the Walker 256 (400 mg/kg) and in the L1210 murine lymphocytic leukemia (200 mg/kg) models. Tests conducted at the National Cancer Institute confirmed these negative data.
Similarly, antitumor activity of betulinic acid in the P-388 murine lymphocyte test system has been suggested. However, activity was not supported by tests conducted by the National Cancer Institute. More recently, betulinic acid was shown to block phorbol ester-induced inflammation and epidermal ornithine decarboxylase accumulation in the mouse ear model. Consistent with these observations, the carcinogenic response in the two-stage mouse skin model was inhibited. Thus, some weak indications of antitumor activity by betulinic acid have been reported, but, until the present invention, no previous reports or data suggested that betulinic acid was useful for the selective control or treatment of human melanoma.
SUMMARY OF THE INVENTION
The present invention is directed to a method and composition for inhibiting tumor growth. The active compound, betulinic acid, is isolated by a method comprising the steps of preparing an extract from the stem bark of Ziziphus mauritiana to mediate a selective cytotoxic profile against human melanoma in a subject panel of human cancer cell lines, conducting a bioassay-directed fractionation based on the profile of biological activity using cultured human melanoma cells (MEL-2) as the monitor, and obtaining betulinic acid therefrom as the active compound.
An important aspect of the present invention therefore is to provide a method and composition for inhibiting tumor growth and, particularly, for inhibiting the growth of melanoma using a natural product-derived compound.
Another aspect of the present invention is to provide a treatment method using betulinic acid to prevent the growth or spread of cancerous cells, wherein the betulinic acid is applied in a topical preparation.
Another aspect of the present invention is to overcome the problem of high mammalian toxicity associated with synthetic anticancer agents by using a natural product-derived compound, e.g., betulinic acid.
Still another aspect of the present invention is to overcome the problem of insufficient availability associated with synthetic anticancer agents by utilizing the readily available, naturally-available betulinic acid.
These and other aspects of the present invention will become apparent from the description of the invention disclosed below, which descriptions are intended to limit neither the spirit or scope of the invention but are only offered as illustrations of the preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plot of mean tumor volume [in cubic centimeters (cm 3 )] vs. time for nonestablished MEL-2 tumors in control mice and mice treated with increasing dosages of betulinic acid;
FIG. 2 is a plot of mean tumor volume (in cm 3 ) vs. time for established MEL-2 tumors in control mice and mice treated with DTIC or betulinic acid;
FIG. 3(A) is a plot of the 50 Kbp (kilobase pairs) band as % total DNA v. time for treatment of MEL-2 cells with 2 μg/ml (micrograms per milliliter) betulinic acid;
FIG. 3(B) is a plot of the 50 Kbp band as total DNA versus concentration of betulinic acid (μg/ml); and
FIGS. 4 and 5 are plots of mean tumor volume (cm 3 ) vs. time for established and nonestablished MEL-1 tumors in control mice and mice treated with increasing doses of betulinic acid.
DETAILED DESCRIPTION OF THE INVENTION
As shown in Table 1, in vitro growth of MEL-2 cells was inhibited by betulinic acid, i.e., an ED 50 value of about 2 μg/ml. However, none of the other cancer cell lines tested was affected by betulinic acid (i.e., ED 50 values of greater than 20 μg/ml). Such clearly defined cell-type specificity demonstrated by betulinic acid is both new and unexpected.
For example, as illustrated in Table 1, other known antitumor agents, such as paclitaxel, camptothecin, ellipticine, homoharringtonine, mithramycin A, podopyllotoxin, vinblastine and vincristine, demonstrated relatively intense, nonselective cytotoxic activity with no discernible cell-type selectivity. Moreover, the cytotoxic response mediated by betulinic acid is not exclusively limited to the MEL-2 melanoma cell line. Dose-response studies performed with additional human melanoma cell lines, designated MEL-1, MEL-3 and MEL-4, demonstrated ED 50 values of 1.1, 3.3 and 4.8 μg/ml, respectively.
In the following Table 1, the extracted betulinic acid and the other pure compounds were tested for cycotoxity against the following cultured human cell lines: A431 (squamous cells), BC-1(breast), COL-2 (colon), HT-1080 (sarcoma), KB, LNCaP (prostate), LU-1 (lung), MEL-2 (melanoma), U373 (glioma) and ZR-75-1 (breast).
TABLE 1__________________________________________________________________________Cytotoxic Activity Profile of the Crude Ethyl Acetate Extract ObtainedfromZiziphus mauritiana, Betulinic acid, Other Antineoplastic AgentsED.sub.50 (μg/ml)Compound A431 BC-1 COL-2 HT-1080 KB LNCaP LU-1 MEL-2 U373 ZR 75-1__________________________________________________________________________Ziziphus mauritiana >20 >20 >20 9.5 >20 >20 5.2 3.7 >20 15.8crude extractBetulinic acid >20 >20 >20 >20 >20 >20 >20 2.0 >20 >20Taxol 0.00 0.02 0.02 0.00 0.02 0.02 0.00 0.06 0.008 0.02Camptothecin 0.00 0.07 0.005 0.01 0.00 0.006 0.00 0.02 0.000 0.001Ellipticine 0.5 0.2 0.3 1.8 0.04 0.8 0.02 0.9 1.6 0.9Homoharringtonine 0.02 0.03 0.1 0.01 0.00 0.03 0.03 0.04 0.2 0.06Mithramycin A 0.09 0.3 0.06 1.5 0.09 0.05 0.2 1.2 0.04 0.2Podophyllotoxin 0.03 0.03 0.005 0.00 0.08 0.04 0.00 0.003 0.004 0.4Vinblastine 0.05 0.06 0.01 0.02 0.04 0.1 0.02 0.01 1.1 0.3Vincristine 0.01 0.01 0.02 0.02 0.00 0.1 0.05 0.02 0.06 0.4__________________________________________________________________________
Betulinic acid has the structural formula: ##STR1## Betulinic acid is fairly widespread in the plant kingdom, and, as a compound frequently encountered, some previous biological activities have been reported.
Betulinic acid was obtained by extracting a sample of air-dried, milled stem bark (450 g) of Z. mauritiana with 80% aqueous methanol. The aqueous methanol extract then was partitioned successively with hexane and ethyl acetate to provide hexane, ethyl acetate and aqueous extracts. Among these extracts, the ethyl acetate (13.5 g) extract showed cytotoxic activity against a cultured melanoma cell line (MEL-2) with an ED 50 of 3.7 μg/ml. The ethyl acetate extract was chromatographed on a silica gel column using hexane-ethyl acetate (4:1 to 1:4) as eluent to give 10 fractions. Fractions 3 and 4 were combined and subjected to further fractionation to afford an active fraction (fraction 16) showing a major single spot by thin-layer chromatography [R f 0.67: CHCl 3 :MeOH (chloroform:methanol) (10:1)], which yielded 72 mg of colorless needles after repeated crystallization from methanol (overall yield from dried plant material: 0.016% w/w).
As confirmed by the data summarized in Table 1, betulinic acid has been reported as noncytotoxic with respect to cultured KB cells. Cytotoxicity of the crude extracts and purified compounds was determined in a number of cultured human cancer cell lines. Table 1 sets forth the various types of cancer cells evaluated. The cells were cultured in appropriate media and under standard conditions. To maintain logarithmic growth, the media were changed 24 hours prior to cytotoxic assays. On the day of the assay, the cells were harvested by trypsinization, counted, diluted in media, and added to 96-well plates containing test compounds dissolved in DMSO; the final DMSO concentration was 0.05%.
The plates were incubated for three days. Following the incubation period, the cells were fixed and stained with sulforhodamine B (SRB) dye. The bound dye was liberated with Tris base, and the OD 515 was measured on an ELISA reader. The growth of the betulinic acid-treated cells was determined by the OD 515 values, and the growth was compared to the OD 515 values of DMSO-treated control cells. Dose response studies were performed to generate ED 50 values.
The isolated active compound, betulinic acid (ED 50 of 2.0 μg/ml for MEL-2), has a molecular formula of C 30 H 48 O 3 , as determined by high-resolution mass spectral analysis, a melting point range of 292°-293° C. (decomposition). The literature melting point range for betulinic acid is 290°-293° C. A mixed melting point range with a known sample of betulinic acid was not depressed. The optical rotation of the compound was measured as +7.3° (c=1.2; pyridine) (lit. +7.5°). The identity of the isolated compound as betulinic acid was confirmed by comparing the above physical properties, as well as 1 H-nmr, 13 C-nmr and mass spectral data of the isolated compound, with physical data and spectra of a known sample of betulinic acid as reported in the literature.
To test the in vivo ability of betulinic acid to serve as an antineoplastic agent against malignant melanoma, a series of studies was performed with athymic (nude) mice injected subcutaneously with human melanoma cells (MEL-2). The initial study investigated the activity of betulinic acid against unestablished tumors. Treatment with betulinic acid began on day 1, i.e., 24 hours, following tumor cell injection. At doses of 50, 250, and 500 mg/kg (milligram per kilogram) body weight, betulinic acid demonstrated effective inhibition of tumor growth with p values of 0,001 for each dose versus a control (FIG. 1).
In particular, the data plotted in FIG. 1 was derived from experiments wherein four week old athymic mice were injected subcutaneously in the right flank with 3.0×10 8 UISO MEL-2 cells. UISO MEL-2 is a cell line derived from metastatic melanoma from human pleural fluid. Drug treatment was initiated on the day following tumor cell injection and continued every fourth day for a total of six doses. Four control animals received 0.5 ml intraperitoneal (IP) of PVP control solution, while treated animals (4 per group) received 50, 250 or 500 mg/kg/dose IP betulinic acid/PVP in deionized H 2 O. Betulinic acid was coprecipitated with PVP to increase solubility and bioavailability. The mice were weighed, and the tumors measured with a micrometer every other day throughout the study. All animals were sacrificed and autopsied on day 33, when the mean tumor volume in the control animals was approximately one cm 3 .
There was greater inhibition of tumor growth at the highest dose of betulinic acid versus the lowest dose (p=0.04). Toxicity was not associated with the betulinic acid treatment because toxicity is indicated by loss of body weight or other forms of acute toxicity. No weight loss was observed.
Next, in vivo testing of betulinic acid was performed on established melanomas. In this study, treatment was withheld until day 13, by which time a palpable tumor mass was present in all mice. As illustrated in FIG. 2, under these conditions betulinic acid successfully abrogated tumor growth (p=0.0001). Furthermore, tumor growth did not parallel that of the control (untreated) group even 14 days after the termination of treatment.
In particular, with respect to FIG. 2, four-week-old athymic mice were injected with 5×108 MEL-2 cells subcutaneously in the right flank. Four treatment groups of five mice each were studied. In one group, the mice received 250 mg/kg/dose of IP betulinic acid/PVP every third day for six total doses initiated the day following tumor cell injection. The control group received 0.5 ml IP saline. A DTIC treatment group received 4 mg/kg/dose IP DTIC every third day from day 13 to day 28 of the study. The betulinic acid treatment group received 250 mg/kg/dose IP betulinic acid/PVP every third day from day 13 to day 27. The control and DTIC-treated mice were sacrificed and autopsied on day 36 due to their large tumor burden. The remaining mice were sacrificed and autopsied on day 41.
As illustrated in FIG. 2, the efficacy of betulinic acid also was compared to DTIC, which is clinically available for the treatment of metastatic melanoma. The dose of DTIC, which is limited by toxicity, was selected to be equivalent to that administered to human patients. Tumor growth in the betulinic acid-treated group was significantly less than that observed in the DTIC-treated animals (p =0.0001). Compared to controls, DTIC produced a significant, but less pronounced, reduction in tumor growth, with a p value of 0.01. A fourth group in this study was treated with a schedule similar to that in the initial study. Under these conditions, betulinic acid, as demonstrated before, significantly inhibited tumor development (p =0.0001) and caused a prolonged reduction in tumor growth of up to three weeks following treatment termination.
FIGS. 4 and 5 illustrate that betulinic acid also showed activity against MEL-1 cells. In particular, with respect to FIGS. 4 and 5, four week old athymic mice were injected subcutaneously in the right flank with 5.0×10 8 UISO MEL-1 cells. Drug treatment was initiated on the day following tumor cell injection and continued every fourth day for a total of six doses. Four control animals received 0.5 ml intraperitoneal (IP) saline, while treated animals (4 per group) received 5, 50 or 250 mg/kg/dose IP betulinic acid/PVP in dd H 2 O. The mice were weighed, and tumors were measured with a micrometer every third day throughout the study. Treated animals were sacrificed and autopsied on day 41, when the mean tumor volume in the control mice was approximately 0.5 cm 3 . The control mice then received six doses of 50 mg/kg every fourth day beginning day 41 and were sacrificed and autopsied on day 71.
The results illustrated in FIGS. 4 and 5 with respect to MEL-1 cells were similar to the results illustrated in FIGS. 1 and 2. Betulinic acid therefore is active both against MEL-1 and MEL-2 cells.
The mechanism by which antitumor agents mediated their activity is of great theoretical and clinical importance. Therefore, the mode of action by which betulinic acid mediates the melanoma-specific effect was investigated. Visual inspection of melanoma cells treated with betulinic acid revealed numerous surface blebs. This observation, as opposed to cellular membrane collapse, suggested the induction of apoptosis. One of the most common molecular and cellular anatomical markers of apoptosis is the formation of "DNA ladders", which correspond to the products of random endonucleolytic digestion of inter-nucleosomal DNA. Although recent studies have shown that a lack of DNA laddering does not necessarily indicate a failure to undergo apoptosis, double-strand DNA scission that yields a fragment of about 50 kilobase pairs (Kbp) has been shown to consistently correlate with induction of apoptosis by various treatments in a variety of cell lines. Thus, generation of the 50 Kbp fragment is a reliable and general indicator of apoptosis. Generation of the fragment occurs upstream of the process leading to DNA ladders and represents a key early step in the commitment to apoptosis.
Therefore, an important feature of the present invention is a method of analyzing and quantifying the formation of the 50 Kbp fragment as a biomarker for induction of apoptosis in human cancer cell lines. This method comprises treatment of cells in culture, followed by analysis of the total cellular DNA content using agarose field-inversion gel electrophoresis. Under these conditions, the 50 Kbp fragment is resolved as a diffuse band. The fraction of the total cellular DNA represented by the 50 Kbp fragment is determined by densitometry on the contour of this band.
To investigate the ability of betulinic acid to induce apoptosis, the above-described method was adapted for use with the MEL-2 cell line. As shown in FIG. 3A, time-dependent formation of a 50 Kbp DNA fragment was induced by betulinic acid with MEL-2 cells. Induction was at a maximum after a 56 hour treatment period. After this time period, a decline in the relative amount of the 50 Kbp fragment was observed, probably due to internal degradation. Also observed in the agarose gel were DNA fragments of about 146 and about 194 Kbp, which are theorized to be precursors in the process leading to the formation of the 50 Kbp fragment. Additionally, the induction of apoptosis (50 Kbp fragment) mediated by betulinic acid was dose-dependent (FIG. 3B), and the ED 50 value (about 1.5 μg/ml) observed in the apoptotic response closely approximated the ED 50 value previously determined for the cytotoxic response (Table 1).
With further respect to FIG. 3A, cultured MEL-2 cells (10 6 cells inoculated per 25 cm 2 flask) were treated with 2 g/ml betulinic acid (200 μg/ml DMSO, diluted 1:100 in media) for 24, 32, 48, 56 and 72 hours. After the treatment, the cells were harvested, collected by centrifugation, then snap frozen in liquid nitrogen for subsequent analysis. Samples were analyzed on a 1% agarose gel in a Hoefer HE100 SuperSub apparatus cooled to 10° C. by a circulating water bath. The electrode buffer was 0.5× TBE buffer containing 0.25 μg/ml ethidium bromide and was circulated during electrophoresis. Each gel included 20 μL Sigma Pulse Marker 0.1-200 Kbp DNA size markers. Prior to sample loading, 50 μL 2% SDS was added to each sample well. Each sample tube was rapidly thawed, then the pelleted cells were immediately transferred in a volume about 50 μL to the well containing SDS. Each well then was overlaid with molten LMP agarose, which was allowed to gel prior to placing the gel tray in the SuperSub apparatus.
Electrophoresis was performed at 172 volts for a total of 18 hours using two sequential field inversion programs with pulse ramping. The DNA/ethidium bromide fluorescence was excited on a UV transilluminator and photographed using Polaroid type 55 P/N film. The negative was analyzed using a PDI scanning densitometer and Quantity One software. The intensity of the 50 Kbp fragment was determined by measuring the contour optical density (OD×mm 2 ) as a percent of the total optical density in the sample lane, including the sample well. The decrease in the 50 Kbp band definition caused by internal degradation, and does not represent a reversal of the process.
With further respect to FIG. 3B, cultured MEL-2 cells were treated for 56 hours with the following concentrations of betulinic acid: 0, 0.1, 1.0, 2.0, 4.0 and 8.0 μg/ml. The cells were harvested and apoptosis measured as described for FIG. 3A. The experiment was repeated and a similar dose-response curve was observed (data not shown).
These data suggest a causal relationship, and it is theorized that betulinic acid-mediated apoptosis is responsible for the antitumor effect observed with athymic mice. Time-course experiments with human lymphocytes treated in the same manner with betulinic acid at concentrations of 2 and 20 μg/ml did not demonstrate formation of the 50 Kbp fragment (data not shown) indicating the specificity and possible safety of the test compound.
Taking into account a unique in vitro cytotoxicity profile, a significant in vivo activity, and mode of action, betulinic acid is an exceptionally attractive compound for treating human melanoma. Betulinic acid also is relatively innocuous toxicitywise, as evidenced by repeatedly administering 500 mg/kg doses of betulinic acid without causing acute signs of toxicity or a decrease in body weight. Betulinic acid was previously found to be inactive in a Hippocratic screen at 200 and 400 mg/kg doses.
Betulinic acid also does not suffer from the drawback of scarcity. Betulinic acid is a common triterpene available from many species throughout the plant kingdom. More importantly, a betulinic acid analog, betulin, is the major constituent of white-barked birch species (up to 22% yield), and betulin is easily oxidized to betulinic acid.
In addition to betulinic acid, betulinic acid derivatives can be used in a topically-applied composition to selectively treat and inhibit a melanoma. Betulinic acid derivatives include, but are not limited to esters of betulinic acid, such as betulinic acid esterified with an alcohol having one to sixteen carbon atoms, or amides of betulinic acid, such as betulinic acid reacted with ammonia or a primary or secondary amine having alkyl groups containing one to ten carbon atoms.
Another betulinic acid derivative is a salt of betulinic acid. Exemplary, but nonlimiting, betulinic acid salts include an alkali metal salt, like a sodium or potassium salt; an alkaline earth metal salt, like a calcium or magnesium salt; an ammonium or alkylammonium salt, wherein the alkylammonium cation has one to three alkyl groups and each alkyl group independently has one to four carbon atoms; or transition metal salt.
Other betulinic acid derivatives also can be used in the composition and method of the present invention. One other derivative is the aldehyde corresponding to betulinic acid or betulin. Another derivative is acetylated betulinic acid, wherein an acetyl group is positioned at the hydroxyl group of betulinic acid.
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A composition and method of inhibiting tumor growth and treating malignant melanoma without toxic side effects are disclosed. Betulinic acid or a betulinic acid derivative is the active compound of the composition, which is topically applied to the situs of tumor. Betulinic acid is obtained by the steps of preparing an extract from the stem bark of Ziziphus mauritiana to mediate selective cytotoxic profile against human melanoma in the subject panel of human cancer cell lines, conducting a bioassay-directed fractionation based on the profile of biological activity using cultured human melanoma cells as the monitor, and obtaining betulinic acid.
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This is a divisional of co-pending application Ser. No. 561,882 filed on December 15, 1983, now U.S. Pat. No. 4,689,896.
DISCLOSURE
This invention relates generally to clothes dryers and laundry systems and, more particularly, to improvements therein which render clothes drying and laundry operations more energy efficient.
BACKGROUND
Domestic clothes dryers typically employ a cylindrical basket or drum mounted in a housing for rotation about its horizontal axis. At its front end, the drum is open to a port in the cabinet of the dryer which may be opened and closed by a hinged door. The drum is rotated, usually by an electric motor and belt drive, to tumble wet clothing that has been placed therein, and such tumbling action may be facilitated by one or more baffles circumferentially arranged about and fixed to the inside cylindrical wall of the drum. As the wet clothes are tumbled, heated air is passed through the drum to promote evaporation.
In some dryers, the entire periphery of the drum is perforated to allow heated air to directly enter the drum from an enclosed outer casing. In other dryers, a perforated inlet area may be at the front or rear end of the drum, and such drum revolves in a full or partial casing that has an inlet opening and an outlet opening either at opposite sides thereof or at the same side in spaced relation.
Domestic clothes dryers typically draw air from the room in which they are located and exhaust the moisture-laden air exiting the drum through a vent duct to the outside of the home. If the dryer is located in an air-conditioned or heated environment, a significant quantity of the preconditioned air would be lost during operation of the dryer and would require replacement by unconditioned air drawn from the outside. Another common practice has been to exhaust the moisture-laden air back into the room, particularly during the winter months, for heat reclamation and humidifying purposes, and many convenience devices have been provided for this purpose. This however may be undesirable for a number of reasons, one being the possibility of damage to or premature failure of various dryer components such as the electric motor and controls therefor due to the resultant high humidity in the dryer's immediate environment. In addition, the resultant recycling of moisture-laden air will lengthen the drying time in view of its lessened ability to extract moisture from wet clothing being dried.
In gas clothes dryers, the utilized burner is often of the single port type which directs the burner flame into a tube where the hot combustion products mix with dilution air. The thusly heated air is then drawn through and exhausted from the drum by a blower which may be driven by the same motor driving the drum. The temperature of the exhausted air is monitored by a thermostat which cycles a gas control valve between on and off positions indirectly to maintain the clothing temperature within a preselected safe range.
Most if not all dryers, whether gas or electric, employ a filter or lint trap to remove entrained lint from the air exiting the drum. From time to time, the filter must be removed and cleaned of trapped lint to ensure proper air flow and operation of the dryer. For obvious reasons, a clogged filter will adversely affect the dryer's performance and efficiency. Heretofore, it has been the responsibility of the operator to check the filter which may require removal of the filter for visual inspection. If the operator forgets, the dryer might then be operated at less than peak efficiency or possibly with damaging results.
SUMMARY OF THE INVENTION
The present invention provides a number of improvements in clothes dryers which serve to improve dryer performance and efficiency. According to one feature of the invention, an improved clothes dryer includes a diffuser located inside the dryer drum for receiving heater air flow and directing the same towards and into intimate contact with wet clothing in the drum at a plurality of locations spaced along the axial length of the drum. The diffuser may be in the form of an arcuate plenum disposed in the upper interior part of the drum which has an inlet at one end for receiving the heated air and a plurality of downwardly directed outlets spaced along its axial length. In another form, the diffuser may include at least one and preferably a plurality of axially elongate hollow baffles circumferentially arranged about the inside wall of the drum, each baffle having a heated air inlet at one end and a plurality of inwardly directed outlets spaced along its axial length. The baffles may be fixed to the drum for common rotation or selectively rotated about the axis of a stationary or oppositely rotating drum to effect the desired tumbling action of the wet clothing.
According to another feature of the invention, a regulator is employed to proportionally modulate the heat input rate of the air heater, whether gas or electric, in response to sensed temperature conditions inside the drum or drying chamber. Accordingly, the regulator is operative to maintain a desired preselected temperature in the drying chamber on a steady state basis. Alternatively or additionally, a multi-speed or variable speed blower is utilized to control drying temperature and provide improved overall drying efficiency.
The present invention also provides a clogged filter detector which generates an output signal indicating a clogged filter condition that may be used to disable drying operation until the filter is cleaned or simply to indicate visually or audibly that the filter requires cleaning. The detector is responsive to the rate of forced air flow through the dryer and operates to indicate a clogged filter or other air flow obstruction when the flow rate drops below a predetermined minimum acceptable level.
Further in accordance with the invention, there is provided a laundry system wherein hot dry air in the attic of a building is ducted to the air intake of the dryer to improve drying efficiency. Furthermore, warm mositure-laden air being exhausted from the dryer is passed through a heat exchanger in a water storage tank coupled between the water supply line and a hot water heater in the building, whereby otherwise wasted heat is reclaimed and used to preheat the water passing into the hot water heater. The cooler water in the storage tank also serves to condense the moisture in the air being exhausted from the dryer thereby to dehumidify the air before venting of the same into the building's interior space rather than to the outside. Heated drain water from a washing machine also may be directed by a thermostatically controlled valve through another heat exchanger in the water storage tank whenever the drain water temperature exceeds the temperature of the water in the tank.
To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various ways in which the principles of the invention may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
In the annexed drawings:
FIG. 1 is a sectional view through one form of a dryer according to the present invention, such section being taken substantially along the central vertical plane of the dryer;
FIG. 2 is a fragmentary vertical section through the dryer of FIG. 1 taken substantially along the line 2--2 thereof;
FIG. 3 is a vertical section through the dryer of FIG. 1 taken substantially along the line 3--3 thereof;
FIG. 4 is a vertical section through another form of dryer according to the invention, such being taken substantially along the central vertical plane of the dryer with only pertinent portions of the dryer being illustrated;
FIG. 5 is a vertical section through the dryer of FIG. 4 taken substantially along the line 5--5 thereof;
FIG. 6 is a diagrammatic illustration of a dryer temperature control system according to the invention;
FIG. 7 is a diagrammatic illustration of another dryer temperature control system according to the invention;
FIG. 8 is a diagrammatic illustration of a laundry system according to the present invention;
FIG. 9 is a vertical section through still another form of dryer according to the invention, such being taken substantially along the central vertical plane of the dryer with only pertinent portions of the dryer being illustrated;
FIG. 10 is a vertical section through the dryer of FIG. 9 taken substantially along the line 10--10 thereof; and
FIG. 11 is a fragmentary perspective view of a dryer illustrating another feature of the invention.
DETAILED DESCRIPTION
Referring now in detail to the drawings and initially to FIGS. 1-3, one form of clothes dryer according to the invention is designated generally by reference numeral 10. In considerable part, the clothes dryer 10 may be of conventional construction, such including a cylindrical drum 12 and an outer casing or cabinet 14 of rectilinear shape. The cabinet 14 includes a front panel 16, side panels 18, top panel 20, rear panel 22 and bottom panel or base 24. The panels may be secured to and supported by suitable framing and the top panel 20 may have mounted thereon a control housing 26.
The cabinet 14 is divided into front and rear compartments 30 and 32 by a vertical panel 34. The front compartment 30 accommodates the drum 12 which has a cylindrical side wall 36 and front and rear end walls 38 and 40. Projecting rearwardly from the drum's rear end wall 40 coaxial with the drum's horizontal axis 42 is a tubular drum shaft 44. The drum shaft 44 is journaled for rotation in a bearing 46 which is mounted in the divider panel 34 at a central opening therein, and such divider panel may be provided with stiffening ribs or the like as needed to support the weight of the drum. At its front end, the drum is further supported for rotation about its horizontal axis by a pair of roller assemblies 48 mounted on the cabinet base 24. The roller assemblies include respective rollers 50 which engage the drum's side wall 36 at opposite ends of a horizontal chord through the drum and at an elevation lower than that of the drum's axis 42. The roller assemblies in essence form a cradle in which the drum rotates.
The drum shaft 44 extends rearwardly beyond the divider panel 34 and has mounted thereon a large belt pulley 54. The pulley 54 is transversely aligned with a smaller belt pulley 56 mounted on the shaft of an electric motor 58 which may be mounted on the cabinet base 24 in offset relation to the drum as seen in FIG. 3. Trained about the pulleys 54 and 56 is a drive belt 60 which drivingly connects the drum shaft 44 to the motor 58. Accordingly, operation of the motor will rotatably drive the drum while the relatively sized pulleys 54 and 56 provide for desired speed reduction and torque amplification.
The drum shaft 44 also has mounted thereon a smaller pulley 64 which is transversely aligned with a still smaller pulley 66 mounted on the fan shaft of a blower 68. Trained about the pulleys 64 and 66 is another belt 70. Accordingly, the blower will be rotatably driven along with the drum upon operation of the motor at a speed dictated by the relative sizes of the pulleys in the drive train.
The inlet to the blower 68 is connected by a duct 74 to an air supply and heater assembly designated generally by reference numeral 76. The assembly 76 may include a gas burner 78 and an elongate mixing tube 80 of conventional type. The gas burner is located at the inlet of the mixing tube through which dilution air is drawn upon operation of the blower 68 for mixing with the hot combustion products generated by the burner. Through passages in the cabinet 14, the dilution air may be supplied from the immediate dryer environment. However, in a preferred laundry system discussed below, hot dry air may be ducted from an attic into the mixing tube inlet area which, in such system, would be closed to the immediate dryer environment. Although a gas heated dryer is illustrated, the air supply and heater assembly 76 alternatively may include an electric heating element and associated heating chamber and ducts in the case of an electrically heated dryer.
If a gas burner is employed as shown, there may be provided a gas pilot 81 which is located near the gas burner 78 and an electric igniter 82 for the gas pilot. To reduce electrical energy consumption, the igniter may operate only at the beginning of a drying cycle to light the pilot which stays lit during the drying cycle and serves to ignite the burner which may be cycled on and off during the drying cycle as dictated by a thermostatic control.
Following the path of heated air flow through the dryer 10, the blower 68 is connected to a duct 84 which has an axial portion 86 extending through the tubular drum shaft 44 for connection to a diffuser supply duct 88 located within the drum 12. The duct 88 extends radially upwardly from the drum's axis in close relationship to the drum's rear end wall 40, there however being sufficient clearance to allow rotation of the drum relative to such duct. At its upper end, such duct 88 is connected to and supports an elongate diffuser 90 which extends axially substantially the full axial length of the drum.
The diffuser 90, which is generally arcuate or banana shape in transverse cross section as seen in FIG. 2, has a convexly curved, radially inner or bottom wall 94 facing downwardly and a convexly curved, radially outer or upper wall 96 which is joined at its longitudinal edges to respective longitudinal edges of the bottom wall of form a plenum chamber 98. The diffuser also has end walls 100 and 102 closing opposite ends of the chamber 98 and an opening 104 in the bottom wall 94 which effects communication between the duct 88 and chamber 98. The bottom wall of the diffuser also has a plurality of small openings or diffuser outlets 106 spaced along its axial length and across its transverse width. Such outlets serve to direct air flow from the chamber 98 downwardly against clothing being tumbled in the drum uniformly over the axial length of the drum.
As seen in FIGS. 1 and 2, the top wall 96 of the diffuser is radially inwardly spaced from the cylindrical side wall 36 of the drum 12 to allow for passage, during rotation of the drum relative to the diffuser, of one or more baffles 110 affixed to and extending axially along the drum's side wall. Such baffles 110 are provided to enhance the tumbling action of clothing in the drum when rotated.
With further reference to FIGS. 1 and 2, the drum 12 can be seen to have a central circular opening 114 in its front end wall 38 which is coextensive with an opening or port 116 provided in the front panel 16 of the cabinet 14. The cabinet port 116 may be opened and closed by a door 118 which is hinged to the front cabinet panel for opening and closing movement. The door 118, which normally will be closed during dryer operation, may be opened to allow clothing to be placed in or removed from the drum through the opening 114 and port 116.
When closed, the door 118 forms a planar continuation of the front cabinet panel 16 which is spaced from the front end wall 38 of the drum 12. Mounted on the back side of the door 118 is a semicircular cradle or holder 124 for a circular lint filter or trap 126. The lint trap 126 includes an inwardly concave screen or filter element 128 which serves to remove and trap any lint that may be entrained in the air flow exiting the drum through the drum opening 114. When the door is closed, the annular peripheral edge of the lint trap 126 will be located closely adjacent the periphery of the drum opening 114 so that substantially all air flow exiting the drum will pass through the screen 128 before passage into an outer chamber 130 which substantially envelops the drum within the front cabinet compartment 30.
The chamber 130 is interiorly defined by the drum 12 and outwardly by corresponding portions of the cabinet panels 16, 18, 20 and 34 which preferably have insulation 131 affixed to their interior sides to prevent against heat loss. In addition, the chamber 130 is substantially isolated from the lower part 132 of the front cabinet compartment 30, which may house the motor 58 and heater assembly 76, by elongate closure plates 134. The closure plates 134 have their outer longitudinal edges fixed to respective cabinet panels and their inner longitudinal edges positioned close to adjacent corresponding walls of the drum. The closure members, however, are sufficiently spaced from the drum to allow for drum rotation and wiper elements or the like may be affixed to such closure members to span the resultant gap to prevent passage of air from the chamber 130 to the lower part 132 of the front compartment 30.
At the upper rear of the outer chamber 130, the divider panel 34 is provided with an opening 140 through which air flow is exhausted from such chamber. Connected to the divider panel 34 at such opening is a vent duct 142 which extends rearwardly and through an opening 144 in the rear panel 22. The vent duct 142 at its rear or exit end may be coupled to an exhaust duct which may lead, for example, to the outside.
Within the vent duct 142, there is provided a clogged filter detector including a flapper 148 which may be made of lightweight metal or plastic. The flapper is pivotally mounted at its upper end to the top of the vent duct by a pivot 150 for free swinging movement between its illustrated solid line and phantom line positions. Accordingly, by its own weight, the flapper is biased to its solid line or vertical position. When in such vertical position, the flapper will substantially close the air flow path through the vent duct, such flapper having a diameter or transverse dimension closely corresponding to the inside diameter or transverse dimension of the duct. It also is noted that such flapper accordingly will substantially or almost completely stop the escape of preconditioned room air through the vent duct to the outside when the dryer blower is idle, such providing additional energy savings.
The clogged filter detector also includes a switch 154 which is mounted to the top of the vent duct to the rear of the flapper pivot 150. The switch has a plunger or lever 156 disposed to be actuated by the flapper 148 when such flapper is in its phantom line position.
In addition to the aforedescribed components, suitable control circuitry and components are provided to effect controlled operation of the drum. Such components may include, for example, a timer 157 which sequences the dryer through a drying cycle or selected one of a number of different drying cycles. A start switch 158 and drying temperature selector switch 159 also may be provided along with other conventional dryer circuit components such as a door open interrupt switch.
To use the dryer, wet clothing may be placed in the drum 12 which interiorly defines the drying chamber of the dryer. With the door 118 closed, a drying cycle may be commenced as by setting the timer 157 and pressing the start switch 158. During the drying cycle, the motor 58 will be energized to rotate the drum and drive the blower 68 which generates air flow through the dryer, the air being supplied from and heated by the air supply and heater assembly 76.
Air flow forced by the blower 68 is directed by the ducts 84 and 88 to the chamber 98 in the diffuser 90. From there, the heated air flow is directed downwardly by the diffuser outlets 106 against the clothing being tumbled in the dryer to promote rapid drying, i.e., rapid evaporation of moisture from the clothing. Moisture laden air passing out of the drum through the drum opening 114 will pass through the lint trap 126 and into the outer chamber 130 for exhausting through the vent duct 142. As the air passes through the lint trap, lint entrained therein will be captured.
If the lint trap is relatively clean or unclogged, air flow through the dryer upon start-up will be sufficient to urge the flapper 148 to its phantom line position seen in FIG. 1 whereupon the switch 154 will be actuated. Thereafter, the flapper will be held in such switch actuating position as long as air flow is not degraded to an unacceptable level by a substantial accumulation of lint in the lint trap. However, when there is a substantial accumulation of lint or other obstruction in the air flow path through the dryer, air flow will become substantially impeded with the result that air flow through the vent duct 142 will be insufficient to maintain the flapper 148 in its switch actuating position. Consequently, the flapper will drop away from the switch which in turn will generate a signal indicating a clogged filter or other obstruction to flow.
The switch 154 may be of the normally closed type and connected in circuit with an indicator light 160 provided on the control housing 26 as seen in FIG. 2. As long as the switch is actuated by the flapper 148, the switch will be held open and the light will remain off. However, upon deactuation or closure of the switch, the light will be illuminated to provide a visual indication that the lint trap has become clogged and requires cleaning. Alternatively or additionally, the switch may be connected in circuit with a buzzer 162 (FIG. 2) or the like which generates an audible alarm upon deactuation of the switch 154. In another arrangement, the switch may be connected in the main power circuit of the dryer so as to stop dryer operation upon deactuation. As will be appreciated, a timer may be associated with the switch so as to allow time for the flapper 148 to assume its switch actuating position upon dryer start-up to avoid false signals and/or to allow dryer start-up. Of course, alternative arrangements may be provided, it being the purpose of the clogged filter detector either to provide a visual indication of the lint trap's condition or to effect appropriate control or shut-down of the dryer when the filter is clogged and requires cleaning. It also is noted that the detector will be responsive to other adverse conditions which substantially impede or adversely affect air flow through the dryer such as clogging in any of the associated air flow ducts or upon failure of the blower 68.
FIGS. 4 and 5
Another form of diffuser according to the invention is designated generally by reference numeral 170 in FIGS. 4 and 5, wherein primed reference numerals designate elements corresponding generally to those identified above by the same unprimed reference numerals. Like the diffuser 90, the diffuser 170 is located inside the dryer drum 12' which may be rotatably mounted in the front compartment of the cabinet 14' in a manner similar to that which is shown in FIGS. 1-3. As seen in FIG. 4, the drum 12' has a drum shaft 44' journaled for rotation in a bearing 46' which is mounted in the divider panel 34' of the cabinet 14'.
The diffuser 170 includes at least one and preferably a plurality of axially elongate hollow baffles 172 which are connected to and supported by respective radially extending ducts 174. At their radially inner ends, the ducts 174 are joined together and to an axially extending duct 176 which extends through the tubular drum shaft 44'. The duct 176 extends axially beyond the drum shaft and into a diffuser supply duct 84' which is connected at its other end to a blower in a manner similar to that shown in FIGS. 1-3. If desired, any suitable means may be provided to seal any space between the union of the duct 176 and supply duct 84' while allowing for rotation of the duct 176 relative to the duct 84'.
On that portion of the duct 176 extending between the supply duct 84' and drum shaft 44', there is mounted a pulley 180 which is transversely aligned with a smaller pulley 182 mounted on the shaft of the electric motor 58'. The pulley 182 is in addition to the pulley 56' which is drivingly connected by the belt 60' to the drum shaft pulley 54'. Trained about the pulleys 180 and 182 is a belt 184 which is twisted to form a figure eight whereby the duct 176 will be rotated in a direction opposite to that of the drum shaft 44' upon operation of the motor. If desired, a spacer pulley assembly 186 may be provided to prevent rubbing of the belt 184 at its overlap.
Referring now more particularly to the diffuser 170, the ducts 174 are positioned close to the drum's rear end wall 40', there however being sufficient clearance to allow relative rotation between such ducts and the drum 12'. At their radially outer ends, the ducts 174 are connected to the baffles 172 which extend axially substantially the full axial length of the drum. As shown, each baffle has a generally triangular cross-sectional shape, such being formed by a radially outer wall 190 and two relatively inclined side walls 192 which are joined at a vertex 194. The walls together form an axially elongate plenum chamber 196 which is closed at its front end by an end wall 198. The radially outer wall 190 is outwardly convexly curved to match the curve of the drum's cylindrical side wall 36' and further is closely positioned to such side wall to prevent clothing from being caught between the baffle and the drum upon their relative rotation. If desired, suitable sealing strips may be mounted to the baffles so as to contact the inner surface of the drum to ensure that clothing is not caught between the rotating baffles and the inner surface of the drum.
The side or generally radially inwardly projecting walls 192 of each baffle 172 are provided with a plurality of small openings or diffuser outlets 202 spaced along their axial lengths and across their transverse widths. Such outlets serve to direct air flow from the diffuser chamber 196 towards and against clothing being tumbled in the drum by rotation of the baffles relative to the drum. This arrangement greatly promotes rapid drying of clothing in the drum.
The diffuser 170 may be utilized in other arrangements than as illustrated. For example, the diffuser baffles 172 may be collectively rotated in a stationary drum. Accordingly, the diffuser baffles by themselves will effect the desired tumbling action of the clothing. On the other hand, the diffuser baffles may be stationary while the drum is rotated. Advantageous results also may be obtained by fixing the diffuser baffles to the drum for common rotation therewith. Accordingly, a separate drive for the diffuser may be eliminated.
FIG. 6
Referring now to FIG. 6, a gas dryer temperature control system according to the invention is diagramatically illustrated and designated by reference numeral 200. The system 200 includes a temperature sensor 202 which monitors the temperature in the drying chamber of the dryer. In the FIG. 1 embodiment, such temperature sensor 202 could be mounted within the drum 12 on the duct 88 and connected to the control panel 26 by a line 203 passing through the duct 86. The temperature sensor 202 is connected to a thermostatically modulated gas control valve 204 connected in the gas supply line 206 leading to the dryer's burner 208. In operation, the gas control valve regulates the quantity of fuel supplied to the burner for combustion in reverse proportion to sensed temperature, thereby correspondingly modulating the heat input rate of the dryer's air heater.
As will be appreciated, the system 200 serves to maintain a desired steady state temperature inside the drum to obtain an improvement in drying efficiency while preventing excess heating of clothing, particularly during the latter part of the drying cycle. A relatively high heat input rate can be tolerated when the clothing in the dryer contains substantial moisture as at the start of the drying cycle. Such high heat input rate is desirable to maximize the drying rate during the initial portion of the cycle. However, as the clothing dries, it will become less tolerant to high temperatures. With the present system, the gas control valve 204, in response to the resultant increase in temperature sensed by the temperature sensor 202, will proportionately decrease the gas flow rate to burner 208 thereby to maintain the desired steady state temperature. Such arrangement provides numerous advantages over conventional systems wherein intermittent heat is supplied by a cycling burner, one being the prevention of "harsh" or overheated drying.
Although shown and described for use in a gas dryer, the system 200 may be modified for use in an electric dryer. In this case, the gas control valve 204 would be replaced, for example, by a current regulator which controls the current being supplied to the dryer's heating element in reverse proportion to sensed temperature. In either case, the valve or regulator 204 operates to maintain a desired temperature in the drying chamber on a steady state basis. The temperature sensor 202 also may be coupled into a safety limit temperature control circuit which disables dryer operation upon an excessive temperature being reached by reason of a system failure.
FIG. 7
FIG. 7, another temperature control system according to the invention is designated generally by reference numeral 210. In such system, there is provided a multi-speed or variable speed blower 212 and a control 214 therefor. The control 214 is connected to the dryer's air heater 216 which operates or cycles between on and off conditions in conventional manner to maintain the air temperature within a desired range. When the air heater is on, the control 214 operates the blower 212 at a high speed while at other times, the control operates the blower at a low speed.
FIG. 8
In FIG. 8, a laundry system according to the invention is diagramatically illustrated and designated generally by reference numeral 220. The laundry system 220 may be employed in commercial and residential buildings and particularly in buildings having an attic wherein hot dry air accumulates. As shown, the laundry system generally comprises a clothes dryer 222, clothes washer 224, hot water heater 226 and water storage tank 228, which all are desirably located in close proximity to one another within the building. Except as otherwise indicated, the dryer, washer and heater maybe of any type.
The water storage tank 228 has an inlet 232 connected to the building's water supply line 234 and an outlet 236 connected by line 238 to the inlet 240 of the hot water heater 226. At its outlet 242, the hot water heater is connected by a line 244 to the hot water inlet 246 of the washer 224. The washer also has a cold water inlet 248 connected by line 250 to the water supply line 234, and a drain 252 connected by line 254 to the inlet of a solenoid operated, three-way valve 256.
The valve 256 has two outlets respectively connected to lines 260 and 262. The line 260 leads to the drain or sewer line 264 of the building whereas the line 262 is connected to the inlet of a heat exchanger 266 located within the water storage tank 228. The heat exchanger may be of conventional fluid/fluid type and has its outlet connected by line 268 to the sewer line 264. The valve accordingly will operate to direct drain water from the washer either directly to the sewer line 264 or indirectly via the heat exchanger 266.
Operation of the valve 256 is effected automatically by a thermostatic control 270 including temperature sensors 271 and 272 which sense water temperature in the line 254 and in the storage tank 228, respectively. When the temperature of water in line 254 exceeds the temperature of water in the storage tank, the control 270 operates the valve 256 to direct washer drain water through the heat exchanger 266. Otherwise, the valve 256 connects line 254 to line 260 thereby to bypass the heat exchanger. Accordingly, otherwise wasted heat from the washer's drain water is reclaimed and used to preheat the water being supplied from the water storage tank to the hot water heater 226, thus reducing the amount of energy otherwise required by the hot water heater to raise the temperature of relatively cold water in water supply line 234 to desired temperature in the hot water heater.
Referring now to the dryer 222, such has an air supply inlet 273 connected by a duct 274 to the building's attic. As previously indicated, the dryer's air supply inlet may be closed to the dryer's immediate environment so that only air supplied by the duct 274 is drawn through the dryer for drying purposes. If desired, the duct may be provided with a flapper valve 275 or the like to provide for selective connection of the dryer to the attic or to another air source. When attic air conditions are not satisfactory, the flapper valve 275 may be switched so that the dryer intakes air from outside the building or from the immediate dryer environment.
By supplying air to the dryer from the attic or outside the building, a number of advantages are obtained, e.g., no development of negative pressure in the conditioned environment of the building which consequently causes drafts and no additional energy consumption required to condition replacement air to desired ambient temperature. Moreover, the use of hot dry attic air or other solar heated air reduces the amount of energy consumed by the dryer to raise the temperature of supply air to desired temperature for use in the dryer.
Further in accordance with the invention, the dryer's exhaust vent 276 is connected by a duct 278 to a gas/liquid heat exchanger 280 located within the water storage tank 228. The heat exchanger 280 serves to effect transfer of heat from the dryer's hot exhaust to the water held in the water storage tank prior to the air being discharged via an exhaust duct 282 to the outside or the dryer's immediate environment. Connected to the lower end of the air passage through the heat exchanger 280 is a drain line 284 which directs any condensate to the building's sewer line. As will be appreciated, the passage of the dryer's hot moist exhaust through the heat exchanger will serve to dehumidify the air prior to its passage, for example, into the dryer's immediate environment.
Also provided is another gas-liquid heat exchanger 290 located within the water storage tank 228 which has its inlet connected by a duct 292 to the attic and its outlet connected by a duct 294 to the exhaust vent 282. In line with the duct 294 is a blower 296 which is operated by a thermostatic control 298 including temperature sensors 300 and 302 respectively located in the attic and in the storage tank 228. When the attic air temperature exceeds the temperature of the water in the storage tank, the control 298 operates the blower to draw attic air through the heat exchanger 290 for transfer of heat from such air to the water in the storage tank. The gas-liquid heat exchanger 290 may consist of a serpentine air duct lying on the bottom of the water storage tank which is equipped with a drain for any condensate.
FIGS. 9 and 10
In FIGS. 9 and 10, pertinent portions of another dryer embodiment according to the invention are indicated generally at 300. The dryer 300 includes a cylindrical drum 302 which is housed in the front compartment 304 of a cabinet 306. The front panel 308 of the cabinet 306 has a central opening 310 which is opened and closed by a door 312 suitably hinged to the front panel 308 for opening and closing movement. When the door 312 is in its closed position, the compartment 304 is substantially or entirely sealed to the outside except as noted below.
The drum 302 has a front end wall 316 provided with an opening 318 coextensive with the opening 310 in the front panel 308 of the cabinet 306. The front end wall 316 is peripherally joined to a cylindrical side wall 320 which is perforated over its entire peripheral extent. The drum 302 is further formed by a rear end wall 322. Unlike conventional drums, the cylindrical side wall 320 is mounted for rotation on its axis on the circular rear end wall 322 by means of a peripheral bearing assembly 324. Consequently, the cylindrical side wall and front end wall can rotate relative to the rear end wall which is fixedly secured to a vertical support panel 326 of the cabinet 306.
As illustrated, rotation of the drum 302 is effected by a friction drive belt 330 which is trained around the side wall 320 and a drive pulley 332 mounted on the shaft of an electric motor 334. It further is noted that any suitable means may be provided to rotatably support the front end of the drum to reduce moment forces on the bearing assembly 324.
Below the drum 302 there is provided a jacket 336 which is generally arcuate in transverse cross section as seen in FIG. 10. The jacket 336 has a concave top wall 338 facing upwardly and located closely adjacent the outer diameter of the drum side wall 320. The jacket further has bottom and end walls defining with the top wall 338 a plenum chamber 340 which is connected at an opening 342 to a duct 344 which in turn is connected to a source of heated air diagramatically indicated at 346.
As shown, the top wall 338 is perforated by means of openings 350 over its entire arcuate extent. Consequently, air flow exiting through the openings 350 is directed upwardly towards the side wall 320 of the drum for passage into the interior of the drum through the openings or perforations 352 in the drum side wall 320.
The dryer 300 further is provided with an exhaust opening 356 in the stationary rear wall 322 of the drum 302. In communication with the opening 356 is an exhaust vent 358 which may be connected to a blower diagramatically illustrated at 360. The blower in turn can be connected by a suitable exhaust duct to the outside, heat exchanger, etc.
In operation, the motor 334 is operated to rotate the drum to effect tumbling action of clothes positioned therein. In addition, the blower 360 is operated to exhaust moisture laden air from the interior of the drum via the opening 356 and vent duct 358. As negative pressure is developed inside the drum 302, the jacket 336 will supply heated air from the source 346 thereof for drying the clothing contained and being tumbled inside the drum 302. As will be appreciated, the diffuser directs the heated air into the lower portion of the drum where the clothing normally resides while moisture laden air is exhausted from the upper portion of the drum through the vent duct 358. If desired, the blower alternatively may be located upstream of the jacket 336, such blower operating to force heated air into the jacket for passage into the drum and ultimate exhausting via the vent duct 358.
FIG. 11
Referring now to FIG. 11, another feature of the invention is illustrated. As shown, a removable arcuate screen 370 may be provided to prevent depositation of lint on moving parts located in the lower portion of the dryer such as an electric motor and associated pulleys, gears, etc. The screen is insertable through an opening 372 in the front panel 374 of the dryer cabinet 376 for positioning slightly below the outer surface of the dryer drum 378. When thusly positioned, the screen closes off and covers the lower portion of the clothes dryer housing the motor and other moving parts. The screen 370 also may serve to protect against lint being drawn into an air heater assembly having its inlet located in the lower portion of the clothes dryer.
Although the invention has been shown and described with respect to preferred embodiments, it is obvious that equivalent alterations or modifications will occur to others skilled in the art upon the reading and understanding of the specification. It further is noted that many of the features of the invention, although shown in separate embodiments or illustrations, may be employed in combination with other features together to provide for improved efficiency and performance. The present invention includes all such equivalent alterations and modifications, and is limited only by the scope of the following claims.
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An improved clothes dryer characterized by a diffuser located inside the dryer drum for receiving heated air flow and directing the same towards and into intimate contact with wet clothing in the drum at a plurality of locations spaced along the axial length of the drum. Also provided is a dryer temperature control system operative to control the temperature in the dryer drum by maintaining a desired preselected temperature on a steady basis and/or by varying the rate of air flow through the dryer drum; a clogged filter detector operative to generate an output signal indicating a clogged filter in response to the rate of forced air flow through the dryer dropping below a predetermined minimum acceptable level, and a laundry system wherein hot dry attic air is supplied to the dryer while the hot dryer exhaust and drain water from a washer is used to preheat water in a storage tank prior to such water being supplied to a hot water heater.
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BACKGROUND
1. Field of the Disclosure
The present disclosure relates to the field of transportation aerodynamics. More specifically, disclosed is an apparatus to improve the aerodynamic and fuel efficiency of an over-the-road cargo vehicle.
2. Brief Discussion of Related Art
The predominant mode of transportation for commercial goods throughout the United States, the developed world and elsewhere is cargo truck, among these including a tractor-trailer truck. For this mode of transportation, fuel represents the largest single cost component. Therefore, any measureable improvement in fuel efficiency of such vehicles is worthwhile.
In particular, in the developed world, where tractor-trailer trucks travel long distances of well-developed highways at a generally high speed, aerodynamic drag represents a major source of inefficiency. One source of such aerodynamic inefficiency is the geometry of the truck, which is essentially an elongated rectangular prism. In particular, the airflow properties over the trailing edge of the trailer create a large trailing negative pressure vortex, which greatly contributes to drag.
One recent technology to improve aerodynamic efficiency is colloquially called a “boat tail”. A boat tail is an attachment to the rear end of the trailer which acts as a fairing to gradually reduce the cross-sectional area of the trailer, and thus reduce the size and intensity of the trailing vortex and its associated drag. One investigation by the Platform for Aerodynamic Road Transport (PART), a research affiliate of the Delft University of Technology, Netherlands, suggests a boat tail can contribute a 4.5% improvement in fuel efficiency.
However, a boat tail as it is currently practiced has a practical size limit that still necessitates an abrupt geometry change at its trailing edge. Furthermore, a trailer is accessed via doors at its rear. Any sort of boat tail impedes access to such doors. For many such tractor/trailer trucks the container itself is transferable in order to be used by intermodal transportation (i.e., train, or cargo ship). In those circumstances, the aerodynamics are either substantially different (e.g. rail), or not even a concern (i.e., container ship). In such cases, the inviolable requirement is that the container keep its standardized size and shape, to enable its intermodal transfer. Permanent alterations to the shape of the trailer to improve efficiency are therefore impossible, to say nothing of the cost-effectiveness in construction of a box trailer. Even an aerodynamically effective successful boat tail should therefore be temporary, removable or interchangeable for most practical effect.
Furthermore, in loading or unloading, a road-use trailer is most commonly backed up to an elevated loading dock. Attempts to deal with this problem include making the boat tail inflatable, or foldable. Still, a boat tail remains an operational obstacle to loading and unloading.
Therefore, the present state of the art is lacking. Other solutions in place of or in addition to a boat tail may yield even better aerodynamic results and/or greater operational advantages.
SUMMARY
In order to overcome these and other weaknesses, drawbacks, and deficiencies in the known art, provided according to the present disclosure is an aerodynamic drag reduction device for use on an over-the-road cargo vehicle, the vehicle having a prismatically shaped cargo area, including a rear face of the cargo area substantially perpendicular to the direction of travel. The device includes a plurality of resilient prongs arranged along a rear edge of the vehicle body, each of the prongs extending from a respective fixed end secured to the vehicle body rearward in a flow-wise direction beyond the rear edge of the vehicle body to a respective free end. Each prong is separated from an adjacent prong in the plurality. Each prong is further flexible to permit deflection of the free end above and below a first plane defined by the surface of the vehicle to which the plurality of prongs is secured. Such deflection is caused by the properties of the airflow over the vehicle at a predetermined speed. Each prong is further resistant to deflecting in a direction parallel to the first plane.
Alternately or additionally, a shaft of each prong has a perpendicular cross section with an area moment of inertia that is lowest around a neutral axis of the cross section that is substantially parallel to the first plane.
Optionally, each prong may include a composite construction of two or more material sections, each material having a different modulus of elasticity. Each prong may optionally include a vulcanized rubber material in some embodiments. In certain embodiments, each prong has a substantially uniform cross-section. In others, each prong has a tapered cross-section, in height or width, or both. For certain embodiments of the present disclosure, each prong has radiused corners at its respective connection to the space separating it from an adjacent prong.
Further described according to the present disclosure, optionally the plurality of prongs are secured to the vehicle with the capability to be repositioned from a deployed position having the free ends extended beyond a rear edge of the vehicle body, to a retracted position having the free end nearer to or forward of the rear edge of the vehicle body. In some cases, the device is slideable in a flow-wise direction to reposition the prongs.
In other embodiments, the device is secured to a rotating frame member which is operative to be rotated between the deployed position and a retracted position. For certain rotatable deployed embodiments, the device is itself rotatable on the rotating frame member to maintain an orientation of the prongs in a rearward extending direction. Optionally, the rotating frame member may be securable in one of the deployed or the retracted positions.
BRIEF DESCRIPTION OF THE FIGURES
These and other embodiments of the present disclosure will become apparent from the following detailed description read in connection with the accompanying drawings, wherein
FIG. 1 illustrates a generally conventional tractor-trailer cargo truck, having added thereto a drag-reducing airflow baffle according to the present disclosure;
FIG. 2 illustrates a detailed view of the upper rear portion of the cargo truck indicated by circle 2 in FIG. 1 ;
FIG. 3 illustrates a drag-reducing airflow baffle according to a first embodiment of the present disclosure;
FIG. 4 illustrates a cross-section view of one baffle prong taken along line 4 - 4 of FIG. 3 ;
FIG. 5 illustrates a drag-reducing airflow baffle according to a second embodiment of the present disclosure;
FIG. 6 illustrates a cross-section view of one baffle prong taken along line 6 - 6 of FIG. 5 ;
FIG. 7 illustrates on embodiment of a baffle-retracting scheme according to the present disclosure;
FIG. 8A illustrates a second embodiment of a baffle-retracting scheme according to the present disclosure, having the baffle retracted;
FIG. 8B illustrates the second embodiment of a baffle-retracting scheme according to the present disclosure, having the baffle in an intermediate position; and
FIG. 8C illustrates the second embodiment of a baffle-retracting scheme according to the present disclosure, having the baffle deployed.
DETAILED DESCRIPTION
Referring now to FIG. 1 , illustrated is a tractor-trailer truck, generally 100 , the features of which are largely conventional. While a tractor-trailer 100 is described, the present disclosure will be seen as applicable to any cargo vehicle with a prismatic shape of the cargo section, for example and without limitation, a box truck, a car-pulled trailer, or the like. The tractor cab 110 includes a cabin for the operators and an engine (not shown) to power itself and pull one or more attached trailers 120 . Airflow streamlines 130 , 140 depict the flow of air over the truck 100 at generally highway speeds, e.g., 60 miles per hour (MPH) or roughly 95 kilometers per hour (kM/h).
Attached to the rear of the trailer 120 is an airflow baffle 150 . Airflow baffle 150 is visible vertically in FIG. 1 , being attached to a near side on the trailer 120 . Not visible in FIG. 1 , is a further baffle 150 that can be mounted vertically at the rear of trailer 120 along an opposite side facing away from the viewer. Another baffle 150 may be mounted horizontally across a top of the trailer 120 , again extending rearward analogous to the baffle 150 shown in FIG. 1 .
The prismatic geometry of a standard trailer 120 , in particular the abrupt change of shape at its trailing end, creates a large low pressure vortex immediately behind the trailer 120 when there is airflow over the trailer 120 , for example at highway speed. This low pressure vortex is a large contributor to aerodynamic drag. In order to minimize the drag associated with this trailing vortex it is advantageous to control or influence the flow of air into the space immediately behind the trailer.
With reference to FIG. 2 , the upper rear end of the trailer 120 is depicted without any baffle 150 attached thereto to illustrate the typical airflow behavior. Experimental observation and computational fluid dynamics flow simulation indicates that, at the abrupt right-angle trailing edge of the trailer 120 the flow induced is characterized by a dynamic sinusoidal or wavelike pattern, generally indicated by streamlines 202 . This flow pattern is dynamic in the sense that the wave pattern shifts with a sinusoidal or wavelike characteristic as flow over the trailer 120 separates from the trailer 120 and mixes with fluid behind the trailer 120 . This sinusoidal or wavelike flow pattern is accompanied by mixing vortices 204 . In order to delay the separation of airflow from the trailer, and thus reduce drag formed by the separation, it would be beneficial if the surface of the trailer could be made to move with the sinusoidal or wavelike flow pattern. In this manner, the mixing of airflow over the trailer 120 into the trailing vortex would be controlled, and distributed over a greater volume as the separation is extended behind the trailer 120 . The intensity of the pressure differential behind the trailer 120 is therefore reduced, and with it the accompanying drag.
Referring Now to FIG. 3 , the flow baffle 150 provides prongs 152 that are positioned to extend in the flow-wise direction, generally aligned with a longitudinal axis of the trailer 120 , which can be seen as extending in parallel to the x-axis direction as depicted in FIG. 1 . Prongs 152 are separated from one another by spaces 154 , which spaces allow respective free ends 156 of individual prongs 152 to move independently of one another. Opposite the free end 156 of each prong 152 is a fixed end 158 . The free end 156 of each prong 152 is connected to a respective fixed end 158 by a shaft 162 . Fixed ends 158 may be secured to one another and the baffle 150 in general by a common spine 160 . The space between prongs 152 at the spine 160 may be provided with individual or blended fillets 164 , in order to avoid stress concentration. Alternately or additionally, the fixed ends 158 may be secured to the trailer 120 itself.
In a very particular embodiment, the prongs 152 are approximately 2 inches in width, between about 0.5 to 1 inches in thickness, and up to about 14 inches in length. Spacing 154 between the prongs 152 can be about 1 inch. However, these dimensions are offered as an example only, and should not be taken to limit the scope of the disclosure. These and other relevant dimensions are left to the particular application as determined by those skilled in the art taken in light of Applicant's present disclosure.
The baffle 150 is secured to the trailer 120 to permit the shaft 162 of each prong 152 to extend, in whole or in part, rearward beyond a trailing edge of the trailer 120 . Moreover, the prongs 152 are resiliently constructed to permit their flexure above or below a plane defined by a side surface of the trailer 120 to which they are secured. The degree of resiliency and flexure will be subject to adjustment according to the individual circumstances. Among the factors to be considered are the dimensions of the trailer 120 , the design operating speed at which drag is to be minimized, resultant Reynolds number for the particular flow, etc. As a first order approximation, prongs 152 constructed of vulcanized rubber display what is considered to be an adequate degree of resiliency for the present application.
Composite makeup may be employed as well, for example the prongs having a core of a harder material, ductile metals, resilient plastics or the like, with additional flexibility afforded by a covering of more flexible material over this core. Optionally, some or all of the baffle 150 in gross may have the same composite construction as the prongs 152 . The cross-sectional view of the prong 152 indicates a composite construction, including a core 168 having an alternate material, in particular a differing modulus of elasticity, as the material comprising the remainder of the prong 152 . The cross-sectional shape of the core 168 need not necessarily conform to that of the prong 152 as a whole. Moreover, the length of the core 168 may optionally be less than that of the prong 152 . The core 168 may have a uniform cross-section, or it may taper or otherwise change in cross-sectional area without regard to the shape of the prong 152 .
The precise cross-sectional dimension of the prongs 152 will also affect the flexibility of the prongs 152 . Generally speaking, it is considered desirable that the prongs have flexibility to deflect above or below the designated mounting plane, but only limited flexibility laterally within the mounting plane. To this end, the cross-sectional geometry should exhibit a greater area moment of inertia (alternately called second moment of area) around any axis extending out of the mounting plane as compared with the area moment of inertia around any axis lying in or parallel to the mounting plane. As a result, the prongs will resist flexing around any axis having a higher area moment of inertia, which can be by design an axis lying parallel to the mounting plane.
As an example only, and with reference to FIG. 4 , a cross-section view of the prong 152 taken along section line 4 - 4 in FIG. 3 , illustrates that the prong 152 , and particularly its shaft 162 , have a lowest area moment of inertia around the horizontal axis 165 passing through the center of the shaft 162 . In certain embodiments, the corners 166 of the shaft 162 may be rounded to avoid stress concentrations and improve durability in service.
Referring now to FIG. 5 , illustrated is an alternate embodiment of a baffle, generally 250 . A full description of the features common with the foregoing embodiment of FIGS. 3-4 will be apparent to those skilled in the art, and the following description will highlight the differences therewith. Baffle 250 has prongs 252 separated from one another by spaces 254 . The shaft 262 of each prong 252 is tapered in its width at it extends rearwardly in a flow-wise direction, with a tape r angle 270 defined by θ. FIG. 6 is a cross-section view of the prong 252 taken along section line 6 - 6 in FIG. 5 . Here again, the prong 252 , and particularly its shaft 262 , have a lowest moment of inertia around the horizontal axis 264 passing through the center of the shaft 262 . Accordingly, they will tend to flex above or below the mounting plane, and resist lateral deflection within or parallel to the mounting plane. Alternately or additionally, the prong cross-section may be tapered in height to influence the propensity of the prong to defect vertically (as viewed in FIG. 4 or 6 only; the prepared axis of deflection will generally be laterally for baffles installed on a side surface of the trailer) rather than horizontally.
The cross-sectional view of the prong 252 indicates a composite construction, including a core 268 having an alternate material, in particular a differing modulus of elasticity, as the material comprising the remainder of the prong 252 . Notably, the cross-sectional shape of the core 268 need not necessarily conform to that of the prong 252 as a whole. Moreover, the length of the core 268 may optionally be less than that of the prong 252 . The core 268 may have a uniform cross-section, or it may taper or otherwise change in cross-sectional area without regard to the shape of the prong 252 .
A trailer 120 fitted with one or more baffles 150 , 250 , obtains its benefit of drag reduction in transit at highway speeds. However, such a trailer 120 should preferably be compatible with the existing trucking infrastructure in other phases of operation, namely loading and unloading. Loading and unloading of the trailer 120 is most commonly accomplished by one or more doors at the rear face 122 of the trailer 120 . Moreover, for this purpose, a raised loading dock (not shown) is commonly provided level with the bottom 125 of the trailer 120 . The height of such a dock is generally standardized. In order for the trailer 120 to be backed into position adjacent to such a loading dock for loading and unloading, it is desirable that the baffles 150 or 250 be retractable such that they do not extend beyond the rear face 122 of the trailer 120 .
Referring now to FIG. 7 , illustrated is a mounting arrangement where the baffle 150 is mounted to the trailer 120 in a manner that permits the baffle 150 to be shifted along a longitudinal axis of the trailer 120 . In particular, a plurality of pegs 180 is provided on the trailer 120 , which fit respectively into one or more of in spaces 154 between adjacent prongs 152 . Accordingly, the baffle 150 can slide longitudinally along the trailer 120 from a position with free ends 156 extended beyond the rear face 122 of the trailer 120 , as shown in FIG. 7 , to a retracted position having the free ends 156 longitudinally forward of the trailer rear face 122 (not shown). Moreover, the baffle 150 may be adapted to be secured in one of several intermediate positions as well. With the baffle 150 retracted, it does not impact nor interfere with the trailer 120 backing into to a loading dock, nor access to the trailer 120 from the same. The baffle 150 may be secured in the extended, retracted, or any intermediate position by any number of conventional means known in the art.
FIGS. 8A-8C illustrate an alternate mounting embodiment for baffles 150 . In this embodiment, one or more baffles 150 are mounted to a pivoting frame 310 . The pivoting frame is mounted to the trailer by a plurality of mounts 312 . A handle 314 is attached to the frame 310 to allow a user to pivot the frame 310 between retracted and deployed positions. One or more handle latches 316 , 318 are provided to hold the handle 314 , and thereby the frame 310 , in either the retracted or extended positions, respectively.
Baffles 150 are carried by the frame 310 on arms 320 , such that a rotation of the frame 310 from its retracted position illustrated in FIG. 8A , to an intermediate position illustrated in FIG. 8B , places the baffles 150 with the fixed ends 158 in proximity to the rear face 122 of the trailer 120 . From this intermediate position of FIG. 8B , in this particular embodiment, the baffles 150 may be mounted to the arms 320 in a pivotal manner, such that the baffles 150 are rotated into an operating position illustrated in FIG. 8C , having the free ends 156 of the prongs 152 extending rearward beyond the rear face 122 of the trailer 120 . Thus, with the frame 310 holding the baffles 150 in their retracted position of FIG. 8A , the baffles 150 may nonetheless be stowed with the free ends 156 of the prongs 152 generally aligned with a direction of airflow. In other embodiments, the operator of the trailer 120 might find it convenient to operate the trailer 120 with the baffles 150 in a position having the prongs 152 forward-facing.
The foregoing examples of baffle retraction in FIGS. 7 , 8 are depicted on a side surface of the trailer 120 . They will be understood to be equally applicable to the opposing side surface and/or a top surface of the trailer 120 as well. Furthermore, the baffle 150 as described herein will be seen as equally applicable to other vehicles, or portions thereon, including for example and without limitation the arrangement of a baffle 150 or 250 as described herein to the tractor cab 110 .
It will be appreciated that variants of the above-disclosed embodiments and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
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An aerodynamic drag reduction device for use on an over-the-road cargo vehicle. The vehicle has a prismatically shaped cargo area, which includes a rear face of the cargo area substantially perpendicular to the direction of travel. The device comprises a plurality of resilient prongs arranged along a rear edge of the vehicle body, extending from a respective fixed end secured to the vehicle body rearward in a flow-wise direction beyond the rear edge of the vehicle body to a respective free end. Each prong is separated from an adjacent prong in the plurality, and each is flexible to permit deflection, under the influence of airflow over the vehicle at a predetermined speed, above and below a first plane defined by the surface of the vehicle to which the plurality of prongs is secured. Each prong is further resistant to deflecting in a direction parallel to the first plane.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application Ser. No. 60/623,960 filed Nov. 1, 2004 and incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] A. Field of the Invention
[0003] This invention relates to an ergodynamic desktop, allowing users to avoid problems consistent with remaining in the same positions for long periods of time.
[0004] B. Description of the Prior Art
[0005] Along with the advancement of modern technology, people spend more and more time in front of desks, especially when computers are used. Programmers, secretaries, and many other workers spend long hours each day sitting with a fixed posture in front of a computer, staring at a fixed monitor screen, and typing on a fixed keyboard. This kind of a working habit is known to have notoriously harmful effects on health, causing complaints, serious physical damage, stress, depression, and other illnesses. It is especially tiring for the eyes, resulting in vision reduction. Many companies pay to have their employees treated with massage therapy as means of relaxation from the stressful working conditions.
[0006] Various types of desks have been designed in order to optimize the ergonomics of the working environments. However, the great disadvantage of all such designs is that they are limited to static configurations, i.e. the desk is adjusted to an “ideal” position and then fixed, hoping that this position would be the best for the users. It has been realized that, in fact, no “ideal” position is really ideal, as long as the same position is kept long enough. Clinical studies have shown that even if the “best” configurations recommended by the health professionals are chosen, undesired negative effects can result when the users have been kept at these configurations for an extended period of time, as only a limited group of muscles are used and the regions of worn out are not well distributed but rather focused on few localized hot spots. In other words, no configuration is absolutely the best, as long as the configuration remains static.
[0007] Therefore, workers get tired in any position if they have to keep the same position for extended periods of time. In addition, with the increased use of computers, requiring their users to have extended working hours with intensive concentration and attention, there are increasingly large numbers of medical problems reported.
[0008] Some attempts have been made to design furniture with adjustable configurations to best fit the user's specific need for “optimized” ergonomics: for example, office chairs with several levers for posture adjustments, or computer desks with adjustable height, angle, etc. have been made available on the market. However, these types of furniture still have the problems associated with the furniture that is not adjustable because the adjustable designs are still only adjustable to a limited number of preset positions, with few degrees of freedom, and once these pieces of furniture are adjusted, they still restrict the users to the same static positions.
[0009] What is, therefore, needed is a dynamic desktop that will allow its users to gradually and continuously change positions over time so that they are not locked in any one position, which causes fatigue, muscle cramps, eye strain, and other related problems such as back and neck pain and carpal tunnel syndrome.
SUMMARY OF THE INVENTION
[0010] This invention meets the current need for a superior dynamic desktop. A novel ergodynamic desktop is provided by introducing the new concept of slowly varying configurations to dynamic desktops, allowing people to perform physical and mental exercises effortlessly while working at the desktops, and thus reducing the risk of developing related illnesses.
[0011] As a highly dynamic system, the human body is in constant physiological motion, e.g. cardiac, respiratory, and gastrointestinal motions, and is best kept healthy with frequent movement and exercise. It is, therefore, very desirable to introduce slowly varying configurations into the designs of furniture. The present invention is designed to have slowly and constantly varying configurations, which are subsequently followed by the user, gradually in a way very much like practicing the oriental exercises of Tai-Chi or Yoga. This type of adiabatic follow up can be considered a form of physical and mental massage, which provides the user with pleasant feelings, as well as greatly reduces tension and stress. For example, different muscle groups will be used and the pressure will be well distributed over broad regions. The long-term effects will be the reduced risks of illness leading to an improvement of physical condition and efficiency of the workers.
[0012] Accordingly, it is an object of the invention to provide a dynamically moving desktop to increase the efficiency and productivity of workers, especially workers using computers.
[0013] Another object of the invention is to provide a dynamically moving desktop to reduce the strain on workers, especially workers using computers, thus reducing the number of illnesses these workers experience that are related to the use of static desktops.
[0014] Still other objects and intentions will become obvious and/or apparent from the following description, drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The features, aspects and advantages of the new ergodynamic desktop will become further understood with reference to the following description, appended claims and accompanying drawings wherein:
[0016] FIG. 1 is a perspective view of an embodiment of the ergodynamic desktop having one assembly providing linear sinusoidal movement;
[0017] FIG. 2 is a perspective view of an embodiment of the ergodynamic desktop having a first assembly providing linear sinusoidal movement (see FIG. 1 ) and having a second assembly providing parallel movement along a circular path;
[0018] FIG. 3 is a plan view showing the component parts located on the lower supporting element of the assembly of FIG. 1 ;
[0019] FIG. 4 is a plan cross-sectional view of the upper tray element of the assembly of FIG. 1 ;
[0020] FIG. 5 is a plan cross-sectional view of the assembly of FIG. 1 ;
[0021] FIG. 6 is a partially cut-away plan view of the second assembly of FIG. 2 , with the top board partially removed;
[0022] FIG. 7 is a side elevational view in cross-section along line 7 - 7 of the second assembly of FIG. 6 ;
[0023] FIG. 8 is an enlarged side elevational view in cross-section, showing cutout A of FIG. 6 ; and
[0024] FIG. 9 is an enlarged side elevational view in cross-section, showing cutout B of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] The present invention is directed to a novel ergodynamic desktop, used to prevent health problems related to remaining in the same position behind desks for long periods of time and therefore used to improve the efficiency and well-being of workers.
[0026] Several specific preferred embodiments of such an ergodynamic desktop, in the form of dynamic computer desktops, are described herein to address the health issues mentioned above. Applying the concept of slowly varying configurations, additive attachments to standard desks are proposed as a simple and inexpensive but effective solution to the problem. These examples are only used to illustrate rather than limit the applications of the invention. The specific design is accomplished with a number of practical considerations, such as cost, ease of use, robustness, and simplicity. Numerous variations, combinations, extensions, and improvements of these designs are possible, based upon the general principles disclosed, which are impossible to list here exhaustively.
[0027] One preferred embodiment of the ergodynamic desktop is shown in FIG. 1 . With reference to FIG. 1 , the preferred embodiment is an assembly 10 , which can be placed on top of a standard computer desk (or any table, as shown on the octagonal table surface in FIG. 1 ), allowing for a slow motion of anything placed on the assembly 10 , thus forming a dynamically moving desktop. The assembly 10 has two trays. The lower tray 20 is in touch with the computer desk or table, without motion. The lower tray 20 may simply be placed on top of the desk, or it may be secured to the top of the desk for additional stability and to prevent accidental dislocation of the assembly 10 . The upper tray 30 is in constant but very slow motion. Anything placed on the upper tray 30 of the assembly 10 , e.g. computer monitor, keyboard, and mouse, will move along with the upper tray 30 . A typical moving pattern can be a left to right or right to left motion (shown by the directional arrows on the surface of the table in FIG. 1 ) in a sinusoidal linear form, similar to a pendulum. A typical time period for a complete motion cycle is four (4) minutes. It should be noted that the assembly 10 is a dynamic desktop that does not have to be used with a computer. It can be used simply as a general purpose dynamic desktop, whenever slow motion needs to be introduced. For example, it can be used as a dynamic reading table to reduce the stress on the eyes of the readers.
[0028] Another preferred embodiment is shown in FIG. 2 . The embodiment further comprises an assembly 40 , which can be used independently of or in combination with the assembly 10 . Similarly to the assembly 10 , the assembly 40 has two trays. The lower tray 50 of the assembly 40 is placed on top of or is secured to the upper tray 30 of assembly 10 . The upper tray 60 of the assembly 40 is in a slow circular parallel motion, either clockwise or counterclockwise, as shown by the semi-circular directional arrow in FIG. 2 . Exactly speaking, the motion is a parallel motion but along a circular path. A typical time period for a complete motion cycle is approximately three (3) minutes. The assembly 40 can be used independently or in combination with the assembly 10 . When the assembly 40 is used in combination with the assembly 10 , rather complex motion patterns can be generated as a summation of a liner sinusoidal motion of the assembly 10 and a circular constant motion of the assembly 40 . With reference to FIG. 2 , the system can be used with a typical desktop computer as follows: the mouse and keyboard placed on the assembly 10 undergo a linear sinusoidal motion in the left to right or right to left direction, while the monitor placed on the assembly 40 moves in a more complex pattern as a summation of a circular motion on top of the assembly 40 , in addition to the linear sinusoidal motion of assembly 10 .
[0029] As said previously, the assembly 10 can be separated into two component parts, a lower tray 20 that has a baseboard 70 (the bottom surface of the lower tray 20 , see FIG. 3 ), which is placed on top of an ordinary desk, and an upper tray 30 that is moving slowly in the left to right or right to left direction.
[0030] FIG. 3 shows more details of the lower tray 20 of the assembly 10 . The electric motor 80 is mounted on an extended area, located at the top of the drawing. A large spur gear 90 is mounted at the upper-centre of the baseboard 70 . The large spur gear 90 is also linked with a small gear 100 attached to the motor 80 . A pin 110 is positioned near the rim on the large spur gear 90 , which forces the upper tray 30 of the assembly 10 to move back and forth. A door slide 120 is mounted at the lower-centre of the base board 70 and guides the moving upper tray 30 to move only in the left to right or right to left direction.
[0031] FIG. 4 shows more details of the upper tray 30 of the assembly 10 . There is a top surface (not shown) mounted on a large frame 130 , with small rollers (wheels) 140 distributed all around the frame 130 . The top surface may be made out of transparent materials, such as Lexan glass, showing the internal mechanisms at work. Two parallel bars 150 are also mounted on the frame 130 , as well as on the moving plate of the door slide 120 , preferably by using mounting screws 160 .
[0032] FIG. 5 illustrates an assembled assembly 10 in a working condition, after the upper tray 30 and the lower tray 20 are put together (the top surface of the upper tray 30 is not shown, but it may be made from a transparent material). The large spur gear 90 fixed on the lower tray 20 of the assembly 10 , between the upper tray 30 and the baseboard 70 of the lower tray 20 , is driven by the small gear 100 directly fixed on a slow moving electric motor. When the gear 90 rotates, the parallel bars 150 will be pushed by the pin 110 back and forth in the right-and-left directions along the door slide 120 , together with the upper tray 30 of the assembly 10 . Small rollers 140 are distributed along the frame 130 of the upper tray 30 , taking the weight of loading and reducing the friction as much as possible.
[0033] FIG. 6 illustrates the assembly 40 with the upper tray 60 partially removed. It can be seen that there are four corner elements 170 , as well as one central element 180 . Each of the corner elements has a small wheel 190 , supporting the weight loaded on the upper tray 60 as shown in FIG. 7 , while allowing it to freely undergo a circular parallel motion. Five solid dots indicate five pins 230 connecting the upper tray 60 to the four corner elements 170 as well as the central element 180 . The central element 180 has a circular shape. It contains an internal gear 200 driven by a small gear 210 attached to a slow moving electric motor 220 mounted underneath the baseboard, shown in FIG. 7 . When the central element 180 rotates, it enables the upper tray 60 to perform a circularly parallel motion defined together with all four corner elements 170 connected to the upper tray 60 .
[0034] FIG. 7 shows the side view schematics of the assembly 40 . The relationship between the internal gear system and the electric motor 220 is also shown. FIG. 7 further shows the vertical positions of all components in the system, including the upper tray 60 and the lower tray 50 .
[0035] FIG. 8 , an enlarged cutout A of FIG. 7 , shows details of any one of the four identical corner elements 170 from a side view. A small wheel 190 , capable of supporting a significant amount of weigh loaded on the upper tray 60 , is mounted to a horizontal metal bar 240 that is free to rotate about the axis defined by the vertical pin on the right. The vertical pin is fixed to the baseboard 245 as part of a Chicago screw 250 at a location of one of four feet near the corners. A rubber foot 260 helps the baseboard 245 of the assembly 40 remain in the same position, without slipping. Note that the assembly 40 may also be secured to the upper tray 30 of the assembly 10 for superior stability and to prevent it from slipping, but in that case the assembly 40 cannot be as freely repositioned anywhere on the upper tray 30 as in the preferred configuration.
[0036] FIG. 9 , an enlarged cutout B of FIG. 7 , shows the details of the central element 180 . The large internal gear 200 is linked to a small gear 210 that is attached to a slow moving electric motor 220 mounted under the baseboard 245 . A horizontal metal bar 270 is mounted on the internal gear 200 along a radial direction. The vertical pin is fixed to the baseboard 245 as part of a Chicago screw 280 . As the internal gear 200 rotates, the horizontal metal bar 270 will push the top board 275 of the upper tray 60 into a circular parallel motion.
[0037] The slow moving motors 80 and 220 can be either DC or AC type, or they could be stepping motors. The stepping motor is particularly suited for a computer desktop because the motor can be controlled by software run on the computer. The user can then easily choose the style of the motion and even develop user-defined programs to control the movements in a desired fashion. Motion parameters such as direction, amplitude, and speed can all be easily altered at the user's discretion.
[0038] The ergodynamic desktop described above is only one of many inventive possibilities. The descriptions on the preferred embodiments are only intended to serve as illustrations rather than limitations of the invention. Variations, modifications, and extensions are unlimited based on the general principles of the invention.
[0039] For example, the present invention may further incorporate dynamic motion into the design of the computer monitor itself. The latest model monitor using a liquid crystal display (LCD) screen is particularly suited for such designs, since the significantly reduced weight and size would allow various types of motion, including nodding, tilting, left-and-right turning.
[0040] Indeed, to achieve the same goals as the ergodynamic desktop of the invention, it is not necessary to create special hardware at all. Software approach sometimes can do even better. For example, the display on a computer screen can be easily made a lot healthier by introducing the concept of slow varying configurations. Today, most computer software applications use framed display areas called “windows.” These windows usually occupy only part of the entire screen, leaving some room for possible movement. It is conceivable to have a display option of any software as turning “on” or “off” a drifting function of the windows. At most times, the drifting function is “on”, but it can be easily turned off when performing careful tasks such as detailed drawing, etc.
[0041] Besides the location of windows, many other parameters or configurations of a computer display can be easily made slowly varying, given the tremendous flexibility and possibilities in computer programming. Candidates of these parameters include font size, color, brightness, contrast, or even focus. A slightly defocused but dynamically drifting display might be healthier than a very sharp but static one. In fact, many types of display software that constantly vary these parameters have already been developed for years. They serve some other purposes however, and are typically called “screen savers,” but similar techniques can protect the people's eyes as well.
[0042] Another very important application of the concept of slowly varying configurations is environment control. People usually try to find the most comfortable parameter settings (such as temperature), keeping the environment at these parameter levels. As briefly discussed before, this philosophy may not necessarily be healthy. Human bodies are very different from machines. They are naturally capable of adjusting themselves to follow the environment. More importantly, they need constant variations, stimuli, massages, and exercise to keep alive. Therefore, slowly varying a large family of parameters may be beneficial to a human body. A partial list of these parameters is given below: temperature, humidity, air pressure, airflow, oxygen level, dust concentration, gravity, magnetic fields, and even noise levels. (It has been reported that absolute silence can drive people crazy.) One thing is almost certain, the healthiest settings must be dynamic.
[0043] The scope of the invention will now be indicated in the claims.
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A novel concept of ergodynamic desktops with slowly varying configurations for ergonomic purposes is provided. Very slow motions are incorporated into the design of desktops, usually used by computer users. The introduced motion is at such a slow pace that it is hardly noticeable, similar to the adiabatic motions of hour or minute hands on a clock. Users of the desktops are therefore induced to adjust their body posture accordingly in a gradual and healthy manner, while still continuing to perform their normal activities without interruption. These desktop designs allow a natural and effortless combination of normal life and exercise. When used in a working environment, they will be useful to improve the health and to enhance the efficiency of workers.
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FIELD OF THE INVENTION
[0001] The present invention relates to a device and an associated method, in which a function is provided which processes input variables and generates functional output signals. These output variables are prepared, stored and held in readiness for readout operations. Given the presence of specific surrounding-field data, an instantaneous data record is safeguarded in a nonvolatile memory device until it has been read out via an interface. This control device and the associated method make it possible to test control possibilities planned in future in vehicles, without having to fear unexpected and unwanted function reactions which have an effect on the vehicle dynamics. The function provided in the control device may advantageously be an algorithm which is able to recognize the probability of a collision of one's own vehicle with a target object, and optionally is able to initiate a full braking or a steering intervention or a combination of both. In this context, the full braking represents a deceleration of the vehicle which lies in the range of the maximum possible deceleration for the vehicle in question.
BACKGROUND INFORMATION
[0002] European Published Patent No. 0 976 627 discusses a braking control for a vehicle. If a radar system of a vehicle having braking control detects an object in front of the vehicle, then an estimating device judges the probability that the vehicle will collide with the object. If the estimation judgment reveals that a collision probability exists, then an automatic braking unit brings about an automatic braking to avoid an imminent collision. If, during the automatic braking, a driver-activated braking input is detected, then the urgency of the driver braking is estimated and the automatic braking control generates a braking force which corresponds to the driver input. A gentle transition from the automatic braking to the driver-controlled braking thereby results.
[0003] German Published Patent No. 38 30 790 discusses a method and a device for the automatic avoidance of collisions for automatically controllable vehicles. With the aid of this method and device, in danger situations caused by obstacles, the intention is to carry out a collision-avoiding acceleration, braking and/or evasive maneuver using an automatic collision avoidance system. This is accomplished by a hierarchically constructed method and by an associated device, data of the vehicle and its setpoint path being acquired by sensors, and setpoint signals of the vehicle path ascertained therefrom being fed to a second hierarchical step of a collision-avoidance device together with the data of an obstacle path acquired, for example, by sensors, and above that, in a third hierarchical step, the final controlling elements of the vehicle control are triggered along the lines of a collision avoidance.
SUMMARY OF THE INVENTION
[0004] The present invention is based on a device for making signals available in a motor vehicle, as a function of input signals, particularly regarding distance and relative velocity with respect to an object in the direction of travel. Provision is made in a device according to an exemplary embodiment of the present invention for a function which prepares, stores and holds non-convertible manipulated variables in readiness for readout operations for the specific vehicle. The non-convertible manipulated variables are output signals of the function which could be output to final controlling elements, but which are obtained and stored for evaluation purposes.
[0005] The function, which is provided in the device, may advantageously relate to control possibilities intended in future. They may advantageously be vehicle functions which represent future functionalities in motor vehicles.
[0006] It may also be advantageous that the non-convertible manipulated variables, which are made available by the function, represent the triggering and implementation of an automatic braking and an automatic steering intervention, respectively, a deceleration which lies in the range of the maximum possible deceleration for the vehicle in question being provided in particular as braking, and as steering intervention, a steering movement of the wheels of the motor vehicle being provided such that evasion of an obstacle is made possible in time. A safety system of this type assumes an active braking device which may be triggered electronically and independently of a brake pedal actuation, and assumes an electronically controlled steering which may be triggered independently of a steering wheel motion.
[0007] Moreover, it may be advantageous that the function provided, as part of the control device, may be supplied with at least one of the following variables as input variable:
distance to the vehicle in front, relative velocity of the vehicle in front with respect to one's own vehicle, sway of the vehicle in front relative to one's own vehicle, velocity of one's own vehicle, acceleration of one's own vehicle, yaw rate, lateral acceleration of one's own vehicle, steering wheel angle, relative lateral velocity of the vehicle in front with respect to one's own vehicle, width of the detected target object, height of the detected target object, and road coefficient of friction.
[0020] According to an exemplary embodiment of the present invention, it may not be necessary that all the variables listed be supplied to the function; only one or several of the variables specified, or additional variables not named may also be fed to the function.
[0021] The input variables of the intended function may advantageously be made available by at least one of the following devices:
radar sensor, lidar sensor, video sensor, stereo video sensor, yaw rate sensor, steering angle sensor, or wheel speed sensor.
[0029] Furthermore, provision is made within the scope of an exemplary embodiment of the present invention that one or more of these sensors is connected to a control unit, and the function of the exemplary embodiment receives input variables from this control unit. For example, the wheel speed may be supplied to the function from an ABS control unit or from a control unit of an electronic stability program.
[0030] Furthermore, it may be advantageous that an activation signal may be given to the control device from outside, whereby the non-convertible manipulated variables of the provided function are able to be output to final controlling elements, and thus become convertible manipulated variables. This activation, executable at any time, may also be deactivated again at any time, in that the control device receives a deactivation signal from outside which influences the provided function in such a manner that the convertible manipulated variables become non-convertible manipulated variables.
[0031] Another advantage may be that the variables made available by the function, and the data which belong to the variables and are decisive for forming them, as well as further data which indicate the moment and the situation of the triggering signal, are stored in a nonvolatile memory and are held in readiness there for readout operations.
[0032] It may be advantageous that the control device in which the function is provided is a device for adaptive cruise control.
[0033] The adaptive cruise control may advantageously includes a stop-&-go control by which the speed-controlled vehicle is braked until it comes to a standstill, and after standstill, may be started up again autonomously or after driver acknowledgment, as may occur in queues at traffic signals or during traffic jams.
[0034] It may be advantageous that the stored variables, as well as the associated data, may only be overwritten after the readout.
[0035] It may also be advantageous that a design protects the nonvolatile memory device from destruction caused by an accident, so that even after a collision and associated destruction of the device in which the function of an exemplary embodiment of the present invention is provided, readout of the stored data is possible.
[0036] Moreover, it may be advantageous that the triggering signal for a braking or a steering intervention is output when the inequality
−(d/vr)≦sqrt(2·deltayFlucht/|ay|)·alphai (1)
is satisfied, where d represents the distance to the vehicle in front; vr represents the relative velocity of the vehicle in front with respect to one's own vehicle, which, given approach of the two vehicles, is negative; deltayFlucht represents half the width of one's own vehicle minus the minimal distance of the known target object to the extended center vehicle axis of one's own vehicle plus half the object expansion of the known target object perpendicular to the extended center vehicle axis of one's own vehicle; ay represents the average, maximally possible lateral acceleration of the vehicle during an evasive maneuver; and alphai represents a safety factor of less than 1.
[0038] Furthermore, it may be advantageous that the non-convertible variables made available are stored either as a data record of all input variables upon occurrence of the triggering signal, or in a class system which records the occurrence frequency of the triggering signal as a function of various safety factors alphai, or only when
−(vr/d)·sqrt(2·deltayFlucht/|ay|)·alphai (2)
reaches a value which is greater than the smallest value of a fixed number of previously achieved peak values.
[0040] It may also be advantageous that a false release of the triggering signal may be determined by evaluating input data, and given the presence of a determined false release, a further data record is stored. A false release in this sense is a triggering signal which turns out to be unwarranted based on the ambient situation and the further travel course.
[0041] In addition, it may be advantageous that the data stored in the nonvolatile memory are stored in an encrypted fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIG. 1 shows a block diagram of an exemplary embodiment of the control device.
[0043] FIG. 2 shows a diagram for assessing the probability of collision.
[0044] FIG. 3 shows a flowchart of an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0045] FIG. 1 shows a control device ( 1 ) which, inter alia, contains a microprocessor ( 2 ) in which, among other things, provided function ( 13 ) is implemented. Moreover, control device ( 1 ) contains an input circuit ( 3 ) via which control device ( 1 ) receives input variables ( 9 , 11 ) from at least one measured-value acquisition device ( 8 , 10 ). Control device ( 1 ) also contains an output circuit ( 14 ) via which output variables ( 17 , 18 ) may be routed to one or more final controlling elements ( 15 , 16 ). Control device ( 1 ) includes an interface ( 6 ), via which control device ( 1 ) is able to communicate with an external diagnostic unit or analyzing unit. To this end, it may be necessary to connect to interface ( 6 ) of control device ( 1 ) a communication medium, which may advantageously be an interface cable ( 12 ), which in turn is connected to an external diagnostic or analyzing device. It is also possible that the interface, via which the control device communicates with a diagnostic or analyzing unit, not be designed as shown in FIG. 1 , but rather that the same CAN bus via which the control device receives and outputs the input and output signals, respectively, be used for diagnostic and analyzing operations. Moreover, control device ( 1 ) contains a nonvolatile memory ( 4 ) in which data records ( 5 ) may be stored if necessary and held in readiness for readout operations. The control device components: input circuit ( 3 ), output circuit ( 14 ), communication interface ( 6 ), microprocessor ( 2 ) and nonvolatile memory ( 4 ) are interconnected by an internal communication system ( 7 ) via which data and information may be exchanged in any direction.
[0046] FIG. 2 shows a sketch with which provided function ( 13 ) is able to decide whether the vehicle driver can still avoid an imminent collision in time. Inertial system ( 21 ) of the vehicle is made of a longitudinal direction ( 31 ) and a transverse direction ( 30 ). This vehicle ( 21 ) is moving in the direction of longitudinal direction ( 31 ) with relative velocity vr ( 35 ) with respect to a recognized target object ZO ( 22 ). A device ( 8 , 10 ) for making input variables ( 9 , 11 ) available—in the present example it is an angular-resolution radar sensor—has detected a target object ZO ( 22 ) in distance dstrich ( 25 ) and at angle phi ( 26 ). This target object may be a vehicle traveling in front, or else a stationary object on the roadway. In this example, the indicated radar sensor is mounted in longitudinal vehicle axis ( 23 ), and thus is mounted at vehicle center ( 32 ). This vehicle-center position ( 32 ) has a lateral offset y=0. In this example, left front vehicle corner ( 33 ) may advantageously have a lateral offset of y>0. As a result, right front vehicle corner ( 34 ) has a lateral offset of y<0. The distance in longitudinal direction d ( 27 ) and lateral offset ym ( 28 ) may now be calculated from measured relative polar coordinates dstrich ( 25 ) and phi ( 26 ). The width of target object ZO, thus the expansion of the target object perpendicular to the longitudinal vehicle axis, may either be predefined by a fixed parameter for the case when the object width cannot be resolved sufficiently finely, or else, given a sufficiently fine resolution by the sensor, may be taken into account by a recognized width calculated from the measured values. In the present exemplary embodiment, this lateral expansion is represented by variable deltayobj ( 29 ) which amounts to half the object width. For the further calculation for the detected target object ( 22 ), the range between values ym-deltayobj and ym+deltaobj is assumed for the lateral expansion. In the present exemplary embodiment, broken line ( 24 ) represents the avoidance trajectory of the left, front vehicle corner. This avoidance trajectory describes a possible movement of vehicle corner ( 33 ) with respect to the vehicle in front, which results during an evasive maneuver to avoid a collision relative to target object ZO ( 22 ). Also for the instance that vehicle ( 21 ) would like to overtake object ( 22 ) in front, and to that end falls out of the lane to the left, an avoidance trajectory results as represented by dot-dash line ( 36 ), which, however, has a different shape.
[0047] The minimal distance at which an evasion is still possible from the standpoint of vehicle dynamics may be compared to the minimal distance at which a collision-avoiding full braking is still possible. It may then be determined that only at small relative velocities is the minimal distance at which an evasion is possible is less than the minimal distance at which a collision-avoiding full braking is still possible. Consequently, only in the case of a small relative velocity with respect to the vehicle in front may a collision be avoided by a braking which could no longer have been avoided by evasion. However, at greater relative velocities, the severity of the collision may be reduced by an active full braking due to the reduction of impact energy (collision mitigation).
[0048] In the following, a formulation is described which provides a braking intervention close to the maximum deceleration possible for the vehicle, when an evasion of the vehicle in front is no longer possible. To that end, the variable TTC (time-to-collision) is introduced which describes the period of time until the calculated collision. This remaining time is calculated at
TTC=d /(− vr ) (3).
[0049] If, using lateral acceleration ay, it is possible within this time to foresee an avoidance trajectory ( 24 ) which runs before target object ZO ( 22 ), then a steering intervention may still be carried out to avoid collision. Lateral acceleration ay is the average, maximum possible lateral acceleration the vehicle is able to achieve with a steering maneuver. If it is no longer possible within this time to carry out an evasive maneuver with lateral acceleration ay according to the type of avoidance trajectory ( 24 ), then the triggering of a panic or full braking is induced.
[0050] From the time-acceleration rule, the equation
t=sqrt (2 ·|y|/|ay |) (4)
is known, where ay is the lateral acceleration and y represents the lateral path which may need to be covered to avoid the collision. This lateral path, which may need to be covered before the collision, is designated in the following as deltayFlucht. In the present exemplary embodiment, this lateral path deltayFlucht according to FIG. 2 is calculated from half the vehicle width yl minus the lateral offset of the target object ym ( 28 ) plus the lateral object imprecision deltayobj. Thus, yielded from equation 4 is
t=sqrt (2·( yl−|ym|+deltayobj )/| ay |) (5).
[0052] Since this lateral path may need to be covered before expiration of the time remaining until the collision, equation 3 and equation 5 may be combined to form the following inequality:
−(d/vr)≦sqrt(2·(yl−|ym|+deltayobj)/|ay|) (6)
[0053] This inequality is also established as triggering threshold. As long as this inequality is not satisfied, the driver still has sufficient time to carry out an evasive maneuver, or else he intends merely a passing maneuver. If this inequality, which represents the triggering threshold, is satisfied, then there is a threat of a collision with the traveling or stationary object in front, and a panic or full braking is automatically initiated. The inequality, which describes the triggering threshold, may additionally be expanded by a safety factor, resulting in
−(d/vr)≦sqrt(2·(yl−|ym|+deltayobj)/|ay|)·alphai (7)
[0054] By the selection of alphai <1, a reserve may advantageously be planned for in the decision of the inequality. The decision as to whether only a steering intervention or only a braking intervention or a combination of steering and braking intervention should be carried out may advantageously be decided by the same conditional equation, by using different safety factors alphai for each triggering. To this end, it may be necessary that the respective type of intervention was activated beforehand.
[0055] If one of the plurality of possible triggering thresholds is exceeded, then a first memory concept provides that the data relevant at this moment for the interpretation of the ambient situation are stored in nonvolatile memory ( 4 ) as data record ( 5 ). This memory concept has the advantage that after a collision has occurred, the manner in which the accident happened may be reconstructed. According to a further memory concept, provision is made in function ( 13 ) for a plurality of triggering thresholds which may advantageously be differentiated by different safety factors alphai. In this case, the triggering frequency is stored in nonvolatile memory ( 4 ) as a function of the various triggering thresholds, and thus of the various safety factors alphai. This memory concept may have the advantage that only very little memory capacity may be necessary. Furthermore, this concept may make it possible to ascertain a suitable safety factor alphai empirically. If sufficient memory space is available, then in a similar manner as in the first memory concept, in each case a data record having data relevant for the interpretation of the ambient situation may be stored in nonvolatile memory ( 4 ) for each or a maximum number of triggerings.
[0056] The triggerings which correspond to an insensitive threshold, e.g. given smaller alphai, may advantageously receive priority in the memory allocation. Thus, in the event that the memory space is no longer sufficient for further triggering data records, a previously stored data record is erased if this triggering was initiated with a more sensitive threshold.
[0057] A third memory concept provides that the two expressions to the left and to the right of the inequality sign of triggering inequality (equation 7) are ascertained individually, and a stipulated number of previously achieved peak values is stored. If the instantaneously ascertained value is above the smallest previously stored peak value, then the instantaneous value is newly included, and the previously smallest stored peak value is erased. When working with this memory concept, it may be advantageous that one is able to get along with a very small memory capacity.
[0058] Data record ( 5 ) may be read out from nonvolatile memory ( 4 ) in various ways. Thus, data record ( 5 ) may be transmitted via internal communication system ( 7 ) and interface ( 6 ) to an external unit during the standard inspection. It is also possible, after an accident has taken place, to read out data record ( 5 ) from nonvolatile memory ( 4 ) in the same manner via internal communication system ( 7 ) and interface ( 6 ). Moreover, data record ( 5 ) may be read out from control device ( 1 ) on a spontaneous basis. After data record ( 5 ) has been read out from memory ( 4 ), it is both possible to erase the previously accumulated data, or else to allow the previously accumulated data to remain in the memory and to complete it in the further course of travel.
[0059] One possibly advantageous exemplary embodiment provides that function ( 13 ) is activated by an activation signal, which is given from the outside via interface ( 6 ) to control device ( 1 ) by authorized personnel during a visit at a service station, and thus the non-convertible manipulated variables are additionally given to output circuit ( 14 ), and consequently become convertible manipulated variables. If it turns out that test function ( 13 ) is suitable for practical application, then in this manner the functionality of control device ( 1 ) may be subsequently expanded in an inexpensive and uncomplicated manner. In the same manner, it is possible to deactivate activated test function ( 13 ) by way of an externally triggered deactivation signal by authorized personnel, for example, during a stop at a service station, which means the convertible manipulated variables again become non-convertible manipulated variables. This may become necessary for the case when, contrary to expectations, the function turns out to be unreliable, since, for example, it does not react appropriately to special surrounding-field situations.
[0060] Moreover, it is possible to provide a false-alarm detection. If triggering threshold according to equation 7 is exceeded, then a triggering signal is initiated which corresponds to a panic or full braking. If, for example, in the further course, the time until collision (TTC) increases again, or an evasion again becomes possible, then it may be that the triggering condition is subsequently no longer satisfied. In this case, provided function ( 13 ) is able to recognize automatically that the triggering of a panic or full braking is not appropriate, and this triggering signal corresponds to a false alarm. Upon detection of such a false alarm, data may advantageously also be stored, so that the cause of the false alarm may be analyzed. These data may be the same variables as in the case of a triggering; however, it is also possible that further signals are stored which are used for self-diagnostics, in particular self-diagnostic signals of the connected ambient sensors, as well.
[0061] FIG. 3 shows a flowchart of a possible specific embodiment. After start ( 40 ) of the algorithm has been carried out, in whose scope a self-test and an initialization are provided, a first read-in of input variables ( 42 ) is implemented. In following step ( 43 ), these input variables are inserted into a condition; in the present example, it is an inequality. If the condition shown is not satisfied, then the instantaneous risk of collision is very small and no automatic intervention in braking or steering may be necessary. This condition may be different depending on the type of vehicle function intended in future. Thus, conditions are also possible which are made of a plurality of individual conditions. If the condition indicated in FIG. 3 is not satisfied, then the algorithm branches to “no”, and new input variables are read in in a new run-through of block ( 42 ). This indicates too small an instantaneous probability of collision, so that no braking and/or steering intervention is to be carried out. Should the condition in block ( 43 ) be satisfied, then a high risk of collision may be expected. By a branching from (43) to “yes”, prior to triggering of a braking or steering intervention, it is queried in block ( 44 ) whether an output to final controlling elements was activated. If this query in block ( 44 ) reveals that no output to final controlling elements should be implemented, then the instantaneous values of the signals relevant for the reconstruction of the ambient situation are stored in block ( 45 ), and are held in readiness for future readout operations in the memory device. If the query in block ( 44 ) reveals that an output of manipulated variables to final controlling elements was activated, then in block ( 46 ), a braking and/or steering intervention is triggered and carried out as a function of the recognized instantaneous driving situation. It is also within the scope of an exemplary embodiment of the present invention that an instantaneous data record is stored in response to the triggering of a braking or steering intervention.
[0062] After the instantaneous data have been stored in block ( 45 ) or after a braking or steering intervention has been carried out in block ( 46 ), the sequence of the algorithm is forwarded to point ( 41 ), and from there, continued with a read in operation once again in block ( 42 ).
[0063] A further specific embodiment provides that the data which are stored in the nonvolatile memory of the control device are additionally stored in a nonvolatile memory of a further control unit which is connected to the first control device through a data communication medium. A loss of data because of destruction of the first control device due to an accident may thereby be avoided. The further control unit may be a control unit for controlling any vehicle function such as ABS, electronic stability program, engine management, on-board computer or the like.
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A device and an associated method are provided, in which a function processes input variables and generates functional output signals. These output signals are stored and held in readiness for readout operations. Given the presence of specific conditions, an instantaneous data record is safeguarded in a nonvolatile memory device until it has been read out via an interface. The control device and the associated method make it possible to test control possibilities planned in future, without having to fear unexpected and unwanted function reactions which have an effect on the vehicle dynamics.
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BACKGROUND OF THE INVENTION
The present invention relates to novel crosslinked and substituted biocompatible polysaccharides, characterized by improved rheological properties and optionally exhibiting advantageous properties introduced by the substituents, such as, for example, a moisturizing or lipophilizing action, in comparison with a conventional crosslinked polysaccharide, and which can be used as biomaterials, in particular in the field of filler surgery, tissue repair or as articular material or fluids.
Numerous substituted and crosslinked polysaccharides are known from the prior art but none of the processes of the prior art has made it possible to obtain polysaccharides exhibiting the synergistically improved rheological properties according to the present invention.
EP 0 265 116 on behalf of FIDIA, describes crosslinked compounds substituted via ester functional groups on the —COOH functional groups of the polysaccharide. Specifically, the hyaluronic acid chains are crosslinked via ester bridges formed by intra- or intermolecular reaction between aliphatic polyalcohols and the carboxylic acid functional groups of the polysaccharide. Substitution also takes place via the ester functional groups of the polysaccharide by the grafting of small molecules carrying hydroxyl functional groups, such as ethanol or benzyl alcohol, for example.
In EP 0 341 745, also on behalf of FIDIA, the polymer is “self-crosslinked” in the sense that the ester functional groups are formed between the carboxyl functional groups of the polysaccharide and the hydroxyl functional groups of one and the same chain or of another chain, without crosslinking agent. The patent also discloses crosslinked and substituted polymers. The substituents are in this instance also alcohol chains, such as ethanol or benzyl alcohol, and are grafted to the polysaccharide via the carboxyl functional groups of the latter.
Patent application WO 99/43728, on behalf of FIDIA, reports hyaluronic acids sulfated in the N-position or O-position. These polysaccharides, which can, as in the abovementioned patent applications, be self-crosslinked or crosslinked via ester bridges (EP 0 256 116 and EP 0 341 745), are subsequently grafted with polyurethanes. A complex matrix of different cocrosslinked polymers is thus obtained. However, these products are also crosslinked via ester functional groups and furthermore require the use of at least three steps of synthesis in the case of a matrix of O- or N-sulfated polysaccharide and of polyurethane. Thus, they do not present a satisfactory solution.
Patent EP 0 749 982, on behalf of HERCULES, teaches the preparation of polymers substituted by hindered phenol compounds, with antioxidizing properties, which can optionally be crosslinked. The crosslinking is carried out by conventional means of the prior art using polyfunctional epoxides or corresponding halohydrins (U.S. Pat. No. 4,716,224, U.S. Pat. No. 4,863,907, EP 0 507 604 A2, U.S. Pat. No. 4,716,154, U.S. Pat. No. 4,772,419, U.S. Pat. No. 4,957,744), polyhydric alcohols (U.S. Pat. No. 4,582,865, U.S. Pat. No. 4,605,691), divinyl sulfone (U.S. Pat. No. 5,128,326, U.S. Pat. No. 4,582,865) and aldehydes (U.S. Pat. No. 4,713,448). According to the preferred embodiment, the polymer is crosslinked by reaction with carboxylic acids or polyacid anhydrides, in order to again result in the formation of esters. The compounds described in the prior art thus have a high density of ester functional groups in the majority of cases.
Cocrosslinked polymers are also known from the prior art, for example those described in patent application WO 2005/012364, on behalf of ANTEIS, which exhibit an improved persistence by the formation of a matrix by cocrosslinking of one or more polymers. These cocrosslinked polysaccharides can in addition be substituted by polymers having a low average molecular weight or small nonpolymeric molecules. These polymers are generally hyaluronic acid cocrosslinked with cellulose, to which compound will subsequently be grafted, via the crosslinking agent, with small polymers, such as heparin or hyaluronic acid, carrying benzyl esters (Mw<50 000 kDa). In some cases, antioxidants, such as vitamin C, are also grafted via the crosslinking agent.
U.S. Pat. No. 4,605,691, on behalf of Balazs (Biomatrix), also teaches a cocrosslinking process (a process of formation of cocrosslinked polymers). This time it concerns the cocrosslinking of hyaluronic acid with collagen, cellulose, heparin or carminic acid.
The common feature of the processes described in the prior art is that the substitutions or graftings which result in the functionalization take place via the crosslinking agent. In comparison with a crosslinking alone, this is reflected in a competition between reaction for crosslinking and functionalization via the crosslinking agent.
A person skilled in the art should thus always take care to properly adjust the amount of crosslinking agent introduced in order for the functionalization not to limit the crosslinking, which would result in a modification to the final properties of the gel according to the respective kinetics of the reactions.
Specifically, if the crosslinking takes place before the introduction of the functional agent, care will have to be taken, on the one hand, that the functional agent is introduced homogeneously into the crosslinked polymer network and, on the other hand, that there remains sufficient crosslinking agent to functionalize the polymer. If all is consumed, it is then necessary to add a further amount of crosslinking agent; the risk then arises of possible overcrosslinking. In some cases, a person skilled in the art will even have to substitute before crosslinking in order to limit the “competition” effects.
A person skilled in the art will thus still be confronted with a choice: to substitute before or after having crosslinked the polymer and to adjust the reaction conditions, taking into account the polymer/crosslinking agent and functionalization agent/crosslinking agent reaction rates. This choice thus becomes a crucial and problematic step of the process.
Water-soluble celluloses, such as sulfoalkylcelluloses substituted by sulfoalkyls and ethers, are also known. The desired aim is to obtain high functionalization in order to obtain water-soluble sulfoalkylcelluloses; see, for example, U.S. Pat. No. 4,990,609 on behalf of WOLFF WALSRODE. For this type of functionalization, sultones are often used for their high reactivity, which makes possible a high degree of functionalization and improves the solubility of the final product due to the strong presence of sulfonate functional groups. However, if it is desired to crosslink in a second step, the high degrees of substitution can interfere with the satisfactory crosslinking of the polymer. Furthermore, the functionalization conditions are often too drastic for the polysaccharide not to be damaged to the point of irredeemably diminishing its rheological properties; see, for example, the compounds described in U.S. Pat. No. 3,046,272.
This is because it is known that polysaccharides, for example hyaluronic acid, exhibit relatively poor resistance to alkaline conditions and it is known that, during the crosslinking or deacetylation of hyaluronic acid in sodium hydroxide solution, decomposition occurs (Simkovic et al., Carbohydrate Polymers, 41, 2000, 9-14); in point of fact, the reactions described in the prior art are often lengthy and/or under pH conditions which result in decomposition.
Under the highly concentrated alkaline conditions and at the high temperatures to which polysaccharides are subjected in processes, such as those described in U.S. Pat. No. 4,321,367 or in U.S. Pat. No. 4,175,183, it has been demonstrated (see the comparative examples below) that decomposition of the polysaccharide takes place.
Thus, in the processes described in the prior art, although relatively easy to carry out, the processes for producing a crosslinked and substituted polymer are very often lengthy and require several steps because of the successive addition of the various ingredients in order to avoid competition between the various polymers and grafts which will be attached to the polysaccharide via the crosslinking agent. Furthermore, due to the reaction times and the reaction conditions, the resulting polymer can have damaged rheological properties.
The present invention makes it possible to solve all of the disadvantages of the processes of the prior art and makes it possible in addition to obtain polysaccharides having rheological properties which are synergistically improved.
It relates to a process for the preparation of crosslinked and substituted polysaccharides. Principally, the crosslinking and substitution reactions in this process are carried out simultaneously, under the same experimental conditions and on the same reaction sites, the hydroxyl functional groups of the polysaccharide, this being the case without there being competition between the different entities involved, the substitutions not being carried out via the crosslinking agent. The degrees of substitution and crosslinking obtained are thus comparable to those obtained by reactions carried out sequentially and the rheological properties of the polysaccharides are improved.
The present invention also relates to a crosslinked and substituted polysaccharide obtained by the process according to the invention, the rheology of which, in particular the viscoelasticity of which, is increased in comparison not only with the simply substituted polysaccharide but also in comparison with the solely crosslinked polysaccharide and in comparison with the substituted and then crosslinked polysaccharide.
In addition, the substituents can introduce advantageous properties, for example biological properties, into the polysaccharide according to the invention, the rheological properties of which are improved. The synergistic effect is all the more surprising as it is retained during the sterilization of the substituted and crosslinked polysaccharide.
The present invention thus makes it possible to combine the advantages relating to the substitution and those relating to the crosslinking without modifying the individual characteristics of each of these modifications taken separately and in particular without damaging the rheological properties since they are synergistically improved.
The invention relates to a process for the simultaneous substitution and crosslinking of a polysaccharide via its hydroxyl functional groups, in an aqueous phase, comprising the following steps:
a polysaccharide is placed in an aqueous medium, it is brought into the presence of at least one precursor of a substituent, it is brought into the presence of a crosslinking agent, the substituted and crosslinked polysaccharide is obtained and isolated, wherein, said process is carried out in the presence of a basic or acidic catalyst, the concentration of which is between 3.16×10 −7 and 0.32 mol/L, and at a temperature of less than 60° C.
The term “via its hydroxyl functional groups” is understood to mean the fact that the substitutions and the crosslinkings are carried out on the —OH groups carried by the polysaccharides.
The process can also be characterized by a reactive catalyst ratio or RCR.
This reactive catalyst ratio (RCR) is defined as being:
R
C
R
=
(
Number
of
moles
reactive
functional
groups
of
the
catalyst
introduced
into
the
reaction
medium
)
(
Number
of
moles
disacharide
unit
introduced
into
the
reaction
medium
)
In one embodiment, the reactive catalyst ratio in the process according to the invention is between 0.02:1 and 3:1.
In one embodiment, the reactive catalyst ratio in the process according to the invention is between 0.2:1 and 3:1.
In one embodiment, the reactive catalyst ratio in the process according to the invention is between 0.3:1 and 3:1.
In one embodiment, the reactive catalyst ratio in the process according to the invention is between 0.5:1 and 2:1.
In one embodiment, the reactive catalyst ratio in the process according to the invention is between 0.7:1 and 1.5:1.
In one embodiment, the reactive catalyst ratio in the process according to the invention is 1.75:1.
In one embodiment, the reactive catalyst ratio in the process according to the invention is 1:1.
In one embodiment, the reactive catalyst ratio in the process according to the invention is 0.8:1.
In one embodiment, the reactive catalyst ratio in the process according to the invention is 0.06:1.
In one embodiment, the catalyst in the process according to the invention is a base.
In this embodiment, the reactive functional group of the catalyst is the HO − ion.
In the aqueous phase, the situation is that pH=14+log([HO − ]) and [HO − ]=10 −(14-pH) .
In one embodiment, the concentration of catalyst HO − in the process according to the invention is between 10 −6 mol/L and 0.32 mol/L, such that 10 −6 mol/L≦[HO − ]≦0.32 mol/L.
In one embodiment, the concentration of catalyst HO − in the process according to the invention is between 3.16×10 −4 mol/L and 3.16×10 −2 mol/L, such that 3.16×10 −4 mol/L≦[HO − ]≦3.16×10 −2 mol/L.
In one embodiment, the catalyst in the process according to the invention is an inorganic base.
In one embodiment, the inorganic base in the process according to the invention is chosen from the group consisting of soda (sodium hydroxide) or potash (potassium hydroxide).
In one embodiment, the concentration by weight of the inorganic base in the process according to the invention is between 1.2×10 −5 % and 1.3%.
In one embodiment, the concentration by weight of the inorganic base in the process according to the invention is between 0.25% and 1.1%.
In one embodiment, the concentration by weight of the inorganic base in the process according to the invention is 1%.
In one embodiment, the concentration by weight of the inorganic base in the process according to the invention is 0.5%.
In one embodiment, the catalyst in the process according to the invention is an organic base.
In one embodiment, the organic base in the process according to the invention is pyridine.
In one embodiment, the pH of the aqueous reaction medium in the process according to the invention is basic.
In one embodiment, the pH of the aqueous reaction medium in the process according to the invention is within a range from 8 to 13.5.
In one embodiment, the pH of the aqueous reaction medium in the process according to the invention is within a range from 10.5 to 12.5.
In one embodiment, the catalyst in the process according to the invention is an acid.
In this embodiment, the reactive functional group of the catalyst is the H 3 O + ion.
In one embodiment, the concentration of catalyst H 3 O + in the process according to the invention is between 3.16×10 −7 mol/L and 0.01 mol/L, such that 3.16×10 −7 mol/L≦[H 3 O − ]≦0.01 mol/L.
In one embodiment, the concentration of catalyst H 3 O + in the process according to the invention is between 10 −6 mol/L and 3.16×10 −5 mol/L, such that 10 −6 mol/L≦[H 3 O + ]≦3.16×10 −5 mol/L.
In the aqueous phase, the situation is that pH=−log([H 3 O + ]) and [H 3 O + ]=10 −pH .
In one embodiment, the acid in the process according to the invention is an inorganic acid.
In one embodiment, the inorganic acid in the process according to the invention is hydrochloric acid.
In one embodiment, the concentration by weight of the inorganic acid in the process according to the invention is between 1.14×10 −5 % and 1.15%.
In one embodiment, the concentration by weight of the inorganic acid in the process according to the invention is between 0.05% and 1%.
In one embodiment, the concentration by weight of the inorganic acid in the process according to the invention is between 0.05% and 0.36%.
In one embodiment, the catalyst in the process according to the invention is an organic acid.
In one embodiment, the organic acid is chosen from the group consisting of glutamic acid and acetic acid.
In one embodiment, the concentration by weight of the organic acid in the process according to the invention is between 0.25% and 2%.
In one embodiment, the concentration by weight of the organic acid in the process according to the invention is between 0.25% and 1.1%.
In one embodiment, the concentration by weight of the organic acid in the process according to the invention is 1%.
In one embodiment, the pH of the aqueous reaction medium in the process according to the invention is acidic.
In one embodiment, the pH of the aqueous reaction medium in the process according to the invention is within a range from 2 to 6.5.
In one embodiment, the pH of the aqueous reaction medium in the process according to the invention is within a range from 4.5 to 6.
The basic or acidic catalyst is soluble in an aqueous medium.
In one embodiment, the polysaccharide in the process according to the invention is chosen from the group consisting of hyaluronic acid or one of its salts, chitosan, cellulose and their derivatives.
In one embodiment, the polysaccharide is hyaluronic acid.
In one embodiment, the polysaccharide is sodium hyaluronate.
In one embodiment, the polysaccharide is chitosan.
In one embodiment, the chitosan is partially deacetylated.
In one embodiment, a chitosan with a degree of deacetylation of approximately 80% is used.
In one embodiment, the polysaccharide is cellulose or one of its derivatives.
In one embodiment, the polysaccharide is carboxymethylcellulose.
The term Mw or “molecular weight” is used to describe the weight-average molecular weight of the polysaccharide, measured in daltons.
In one embodiment, the molecular weight of the polysaccharide is within a range from 0.01 MDa to 4.0 MDa.
In one embodiment, the molecular weight of the polysaccharide is within a range from 0.1 MDa to 3.6 MDa.
In one embodiment, the molecular weight of the polysaccharide is within a range from 0.10 MDa to 0.15 MDa.
In one embodiment, the molecular weight of the polysaccharide is within a range from 0.9 MDa to 2 MDa.
In one embodiment, the molecular weight of the polysaccharide is within a range from 2.5 to 3.6 MDa.
In one embodiment, the molecular weight Mw of the polysaccharide is 2.7 MDa.
In one embodiment, the molecular weight Mw of the polysaccharide is 1.5 MDa.
In one embodiment, the molecular weight Mw of the polysaccharide is 1.0 MDa.
In one embodiment, the molecular weight Mw of the polysaccharide is 120 000 Da.
In one embodiment, the crosslinking agent in the process according to the invention is bi- or polyfunctional.
In one embodiment, the bi- or polyfunctional crosslinking agent in the process according to the invention has at least one epoxide functional group.
In one embodiment, the bi- or polyfunctional crosslinking agent in the process according to the invention is chosen from the group consisting of ethylene glycol diglycidyl ether, butanediol diglycidyl ether, polyglycerol polyglycidyl ether, polyethylene glycol diglycidyl ether, polypropylene glycol diglycidyl ether, a bisepoxy or a polyepoxy, such as 1,2,3,4-diepoxybutane or 1,2,7,8-diepoxyoctane.
In one embodiment, the bi- or polyfunctional crosslinking agent in the process according to the invention is epichlorohydrin.
In one embodiment, the bi- or polyfunctional crosslinking agent in the process according to the invention has at least one vinyl functional group.
In one embodiment, the bi- or polyfunctional crosslinking agent in the process according to the invention is a dialkyl sulfone wherein the identical or different and linear or branched alkyl groups are chains having from 1 to 4 carbon atoms.
In one embodiment, the bi- or polyfunctional crosslinking agent in the process according to the invention is divinyl sulfone.
In one embodiment, the crosslinking agent in the process according to the invention is a mono-, bi- or polyaldehyde.
In one embodiment, the crosslinking agent in the process according to the invention is formaldehyde.
In one embodiment, the crosslinking agent in the process according to the invention is glutaraldehyde.
In one embodiment, the molar ratio of the crosslinking agent to the polysaccharide employed in the process according to the invention is within a range from 0.001 to 0.5.
In one embodiment, the molar ratio of the crosslinking agent to the polysaccharide employed in the process according to the invention is within a range from 0.01 to 0.3.
In one embodiment, the molar ratio of the crosslinking agent to the polysaccharide employed in the process according to the invention is within a range from 0.05 to 0.2.
In one embodiment, the molar ratio of the crosslinking agent to the polysaccharide employed in the process according to the invention is equal to 0.07.
In one embodiment, the molar ratio of the crosslinking agent to the polysaccharide employed in the process according to the invention is equal to 0.08.
In one embodiment, the molar ratio of the crosslinking agent to the polysaccharide employed in the process according to the invention is equal to 0.10.
In one embodiment, the molar ratio of the crosslinking agent to the polysaccharide employed in the process according to the invention is equal to 0.14.
In one embodiment, the molar ratio of the crosslinking agent to the polysaccharide employed in the process according to the invention is equal to 0.21.
In one embodiment, the precursor of the substituent in the process according to the invention is chosen from the group of the molecules comprising just one reactive functional group chosen from the group consisting of vinyl, epoxide, allyl, ketone, aldehyde, thiocyanate, halide, isocyanate, halosilicon, nitrile and sultone functional groups.
The term “reactive functional group” is understood to mean a functional group capable of forming a bond with a hydroxyl functional group of the polysaccharide.
In one embodiment, the bond is formed by creation of an ether bond.
In one embodiment, the bond is formed by creation of a hemiacetal bond.
In one embodiment, the bond is formed by the creation of a urethane bond.
Under the conditions of the process according to the invention, the formation of an ester functional group is thus excluded.
In one embodiment, the precursor of the substituent in the process according to the invention is chosen from the group consisting of molecules additionally comprising at least one advantageous functional group or group, inert with regard to the substitution and crosslinking reactions, chosen from the group consisting of sulfonate, linear or branched alkyl, substituted or unsubstituted aromatic, sulfate, thiol, monosaccharide, phosphate, phosphonate, carbonate and ester groups or functional groups.
The term “inert” is understood to mean a functional group which does not react under the conditions of implementation of the process and which is stable under the conditions of storage of the product obtained according to the process of the invention. A functional group which, under the conditions of implementation of the process, would be capable of not reacting with any of the functional groups of the polysaccharide or with any of the functional groups of the crosslinking agent or with any of the reactive functional groups of the precursor of the substituent is thus inert under the conditions of implementation of the process.
In one embodiment, the precursor of the substituent in the process according to the invention is chosen from the group consisting of the molecules of general formula F—R-(G) x , wherein:
F is a reactive functional group chosen from the group consisting of substituted or unsubstituted vinyl, substituted or unsubstituted epoxide, substituted or unsubstituted allyl, ketone, aldehyde, thiocyanate, halide, isocyanate, halosilicon, nitrile and sultone functional groups; R is a bond or an alkyl chain having from 1 to 12 carbon atoms, linear or branched, substituted or unsubstituted aromatic, saturated or unsaturated, optionally comprising one or more heteroatoms; G is either a hydrogen or an advantageous functional group or group, which are inert, chosen from the group consisting of the sulfonate, linear or branched alkyl, substituted or unsubstituted aromatic, sulfate, thiol, monosaccharide, phosphate, phosphonate, carbonate and ester groups or functional groups; x is a natural integer such that 1≦x≦3.
In one embodiment, F in the process according to the invention is a vinyl functional group and the precursor of the substituent is chosen from the group consisting of compounds of formula:
R and G being as defined above,
R 1 , R 2 and R 3 , which are identical or different, being either a hydrogen atom or an alkyl chain having from 1 to 3 carbon atoms.
In one embodiment, F in the process according to the invention is an epoxide functional group and the precursor of the substituent is chosen from the group consisting of compounds of formula:
R and G being as defined above,
R 1 , R 2 and R 3 being as defined above.
In one embodiment, F in the process according to the invention is an allyl functional group and the precursor of the substituent is chosen from the group consisting of compounds of formula:
R and G being as defined above,
R 1 , R 2 and R 3 being as defined above,
R 4 and R 5 , which are identical or different, being either a hydrogen atom or an alkyl chain having from 1 to 3 carbon atoms.
In one embodiment, G in the process according to the invention is a sulfate functional group.
In one embodiment, G in the process according to the invention is a hydrogen atom.
In one embodiment, G in the process according to the invention is a sulfonate functional group.
In one embodiment, the precursor of the substituent in the process according to the invention is chosen from the group consisting of allyl-sulfates, epoxy-sulfates, vinyl-sulfonates and epoxy-alkanes.
In one embodiment, the substituent in the process according to the invention is chosen from the group consisting of vinylsulfonic acid and its salts, epoxybutane and sodium allyl sulfate.
In one embodiment, the polyfunctional crosslinking agent in the process according to the invention is 1,4-butanediol diglycidyl ether (BDDE) and the precursor of the substituent is sodium vinylsulfonate.
In one embodiment, the polyfunctional crosslinking agent in the process according to the invention is 1,4-butanediol diglycidyl ether (BDDE) and the precursor of the substituent is sodium allyl sulfate.
In one embodiment, the polyfunctional crosslinking agent in the process according to the invention is 1,4-butanediol diglycidyl ether (BDDE) and the precursor of the substituent is epoxybutane.
In one embodiment, the polyfunctional crosslinking agent in the process according to the invention is divinyl sulfone and the precursor of the substituent is sodium vinylsulfonate.
In one embodiment, the molar ratio of the precursor of the substituent to the polysaccharide employed in the process according to the invention is within a range from 0.001 to 4.00.
In one embodiment, the molar ratio of the precursor of the substituent to the polysaccharide employed in the process according to the invention is within a range from 0.20 to 2.20.
In one embodiment, the molar ratio of the precursor of the substituent to the polysaccharide employed in the process according to the invention is equal to 0.24.
In one embodiment, the molar ratio of the precursor of the substituent to the polysaccharide employed in the process according to the invention is equal to 0.30.
In one embodiment, the molar ratio of the precursor of the substituent to the polysaccharide employed in the process according to the invention is equal to 0.35.
In one embodiment, the molar ratio of the precursor of the substituent to the polysaccharide employed in the process according to the invention is equal to 0.90.
In one embodiment, the molar ratio of the precursor of the substituent to the polysaccharide employed in the process according to the invention is equal to 1.00.
In one embodiment, the molar ratio of the precursor of the substituent to the polysaccharide employed in the process according to the invention is equal to 1.60.
In one embodiment, the molar ratio of the precursor of the substituent to the polysaccharide employed in the process according to the invention is equal to 2.00.
Principally, the crosslinking and substitution reactions in the process according to the invention are carried out simultaneously, under the same experimental conditions and on the same reaction sites of the polysaccharide, this being the case without there being competition between the various entities involved. The degrees of substitution and crosslinking are the same as those of the reactions carried out in isolation.
The process thus makes it possible to be able to control the crosslinking independently of the substitution in order to facilitate the preparation of the gels and to be able to easily adapt the product according to the use thereof.
The present invention, because the substitution and the crosslinking are simultaneous, makes it possible to limit the time during which the polysaccharide is present in an alkaline medium which decomposes it if residence is prolonged. Specifically, it is well known that, in the case of a simple substitution in an alkaline medium, for example, hyaluronic acid is rapidly decomposed and loses all its gelling and viscoelastic properties. A surprising effect of the invention is that the fact that the crosslinking and substitution reactions are simultaneous protects the polysaccharide during the reaction and makes it possible to obtain a synergistic effect with regard to the rheological properties, in particular the elasticity of the polysaccharide, which is greatly increased.
The advantages related to the fact that the crosslinking/substitution reactions are simultaneous are not limited to advantages visible on the final product, such as a better elasticity, a good homogeneity of the gel, homogeneous distribution of the substituents or the limitation of the decomposition of the polysaccharide during the crosslinking/substitution, but also comprise the reaction time and in particular the number of reaction steps. The process of the invention makes possible simultaneous introduction of all the reactants. Just one single reaction step offers not only a considerable saving in time but also limits losses of time and of solvents. As all the reactions involved, namely crosslinking and substitution reactions, take place under the same conditions, the catalyst introduced will be active for both reactions without it being necessary to increase its amount in comparison with a simple crosslinking. The absence of competition between crosslinking and substitution prevents it from being necessary to add an excess of reactant in order to compensate for the decomposition thereof or the excessively rapid consumption thereof.
The process of the invention does not use catalysts other than simple acids or bases, does not use organic solvents and does not use activating agents, and the atomic balance of the reaction is good, given the absence of formation of byproducts.
The latter point is the other advantage of the invention: the process of the invention does not produce byproducts which have to be removed during the purification. It is simply a matter of rinsing the product in order to remove the excess crosslinking agent and catalyst. In view of the applications of the polysaccharides obtained, in particular as biomaterials, this absence of byproducts is a real competitive advantage.
The process which makes it possible to obtain the compounds of the present invention differs from the prior art in that the simple implementation thereof makes it possible, surprisingly, to substitute and crosslink a polysaccharide simultaneously without the substitution being in competition with the crosslinking. Better control is thus exercised over the degree of crosslinking or the degree of substitution.
The process which makes it possible to obtain the products of the present invention offers complete freedom with regard to the parametering of each of the reactions occurring simultaneously and independently in the reaction medium. It is thus possible to modify the degree of crosslinking without influencing the substitution and, conversely, it is possible to modify the degree of substitution without influencing the crosslinking.
The implementation of the crosslinking process of the invention makes it possible to obtain a product of high homogeneity which can be easily injected. Surprisingly, the process according to the invention makes it possible to enhance the rheological properties of the crosslinked polysaccharides without having to employ more crosslinking agent. In addition, it makes it possible to introduce other properties, such as hydration or lipophilicity.
The process of the invention is such that it is possible to envisage carrying out up to three reactions simultaneously. The term “three simultaneous reactions” is understood to mean a crosslinking simultaneously with a double substitution.
In one embodiment, the polysaccharide obtained by the process according to the invention is substituted on its hydroxyl functional groups.
The degree of substituent introduced (DSI) is defined as being:
D
S
I
=
(
Number
of
moles
of
reactive
fonctional
groups
of
the
substituent
introduced
into
the
reaction
medium
)
(
Number
of
moles
of
disaccharide
unit
introduced
into
the
reaction
medium
)
In one embodiment, the degree of substituent introduced in the process according to the invention is within a range from 0.001 to 4.00 (0.001≦DSI≦4.00).
In one embodiment, the degree of substituent introduced in the process according to the invention is within a range from 0.20 to 2.20 (0.20≦DSI≦2.20).
In one embodiment, the degree of substituent introduced in the process according to the invention is equal to 0.24.
In one embodiment, the degree of substituent introduced in the process according to the invention is equal to 0.30.
In one embodiment, the degree of substituent introduced in the process according to the invention is equal to 0.35.
In one embodiment, the degree of substituent introduced in the process according to the invention is equal to 0.90.
In one embodiment, the degree of substituent introduced in the process according to the invention is equal to 1.00.
In one embodiment, the degree of substituent introduced in the process according to the invention is equal to 1.60.
In one embodiment, the degree of substituent introduced in the process according to the invention is equal to 2.00.
In one embodiment, the polysaccharide obtained in the process according to the invention is crosslinked by the reaction of the crosslinking agent with its hydroxyl functional groups.
The degree of crosslinking agent introduced (DCI) is defined as being:
D
C
I
=
(
Number
of
moles
crosslinking
agent
introduced
into
t
he
reaction
medium
)
(
Number
of
moles
disacharide
unit
introduced
into
the
reaction
medium
)
In one embodiment, the degree of crosslinking agent introduced in the process according to the invention is within a range from 0.001 to 0.5.
In one embodiment, the degree of crosslinking agent introduced in the process according to the invention is within a range from 0.01 to 0.3.
In one embodiment, the degree of crosslinking agent introduced in the process according to the invention is 0.07.
In one embodiment, the degree of crosslinking agent introduced in the process according to the invention is 0.08.
In one embodiment, the degree of crosslinking agent introduced in the process according to the invention is 0.10.
In one embodiment, the degree of crosslinking agent introduced in the process according to the invention is 0.14.
In one embodiment, the degree of crosslinking agent introduced in the process according to the invention is 0.21.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is within a range from 4% to 20%, as percentage by weight.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is within a range from 6% to 16%, as percentage by weight.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is within a range from 8% to 14%, as percentage by weight.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is 5.7%, as percentage by weight.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is 6.3%, as percentage by weight.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is 10.3%, as percentage by weight.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is 11.1%, as percentage by weight.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is 12.2%, as percentage by weight.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is 13.5%, as percentage by weight.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is 14.3%, as percentage by weight.
In one embodiment, the ratio of the weight of polysaccharide employed to the weight of water employed in the process according to the invention is 15.8%, as percentage by weight.
In one embodiment, the process according to the invention is carried out at room temperature.
The term “room temperature” is understood to mean a temperature between 18° C. and 25° C.
In one embodiment, the process according to the invention is carried out at a temperature of greater than 25° C.
In one embodiment, the process according to the invention is carried out at a temperature of less than 60° C.
In one embodiment, the process according to the invention is carried out at a temperature of between 39° C. and 60° C.
In one embodiment, the process according to the invention is carried out at a temperature of 40° C.
In one embodiment, the process according to the invention is carried out at a temperature of 50° C.
In one embodiment, the process according to the invention is carried out for a period of time within a range from 15 minutes to 48 hours.
In one embodiment, the process according to the invention is carried out for a period of time of 1 to 2 hours.
In one embodiment, the process according to the invention is carried out for a period of time of 2 to 3 hours.
In one embodiment, the process according to the invention is carried out for a period of time of 3 to 4 hours.
In one embodiment, the process according to the invention is carried out for a period of time of 4 to 5 hours.
In one embodiment, the process according to the invention additionally comprises a step of washing the polysaccharide obtained.
In one embodiment, the process according to the invention additionally comprises a step of washing the polysaccharide obtained with a buffer solution having a pH of approximately 7.
In one embodiment, the process according to the invention additionally comprises a step of washing the polysaccharide obtained with purified water.
In one embodiment, the crosslinking of the polysaccharide in the product obtained according to the process of the invention is carried out by dialiyldialkyl sulfone bridges of formula PS—O—(CH2)n-S(O2)-(CH2)n-O—PS, where “PS” represents the polysaccharide residue and n represents an integer such that 1≦n≦4.
In one embodiment, the crosslinking of the polysaccharide in the product obtained according to the process of the invention is carried out by diethyl sulfone bridges of formula PS—O—CH 2 —CH 2 —S(O 2 )—CH 2 —CH 2 —O—PS.
In one embodiment, the crosslinking of the polysaccharide in the product obtained according to the process of the invention is carried out by bridges of formula PS—O—CH 2 —CH(OH)—CH 2 —X—CH 2 —CH(OH)—CH 2 —O—PS, the X group being either an alkyl chain having from 2 to 6 carbon atoms or a polyether chain.
In one embodiment, the crosslinking of the polysaccharide in the product obtained according to the process of the invention is carried out by ether bridges of formula PS—O—CH 2 —O—PS.
In one embodiment, the crosslinking of the polysaccharide in the product obtained according to the process of the invention is carried out by hemiacetal bridges of formula PS—O—CH(OH)—(CH 2 ) m —CH(OH)—O—PS, where m is an integer such that 0≦m≦4.
In one embodiment, the polysaccharide in the product obtained according to the process of the invention carries, on at least one of its hydroxyl functional groups, at least one substituent resulting from vinylsulfonic acid, 2-ethoxyethylsulfonic acid.
In one embodiment, the polysaccharide in the product obtained according to the process of the invention carries, on at least one of its hydroxyl functional groups, at least one substituent resulting from epoxybutane, 1-ethoxybutan-2-ol.
In one embodiment, the polysaccharide in the product obtained according to the process of the invention carries, on at least one of its hydroxyl functional groups, at least one substituent resulting from sodium allyl sulfate, sodium 3-propoxy sulfate.
The invention relates to the use of a hydrogel obtained according to the process of the invention in the formulation of a viscosupplementation composition.
The process according to the invention also relates to the compositions comprising a polysaccharide obtained by the process according to the invention.
In one embodiment, the polysaccharide obtained by the process according to the invention is in the gel or hydrogel form.
On conclusion of the crosslinking and substitution, it may be advantageous to neutralize the gel obtained according to standard processes known in the field, for example by addition of acid, when the process is carried out in a basic medium, and by addition of a base, when the process is carried out in an acidic medium.
The mixture obtained on conclusion of the process of the invention can optionally be subjected to an additional hydration step, in order to obtain a gel in the form of an injectable hydrogel suitable for the applications envisaged.
This hydration is generally carried out, in an aqueous medium, by simple mixing of the crosslinked and substituted gel with an aqueous solution, advantageously a buffered physiological aqueous solution, so as to obtain a final concentration which can vary within very wide proportions, according to the nature of the polysaccharides used, according to their respective degrees of crosslinking and also according to the use envisaged. The buffered solution which can be used can, for example, be an iso-osmolar physiological solution exhibiting a pH of between approximately 6.8 and approximately 7.5.
This final concentration of total polysaccharides is generally between approximately 5 and approximately 100 mg/g, preferably between approximately 5 and approximately 50 mg/g, for example approximately 20 mg/g, of hydrogel.
The invention relates to the use of a polysaccharide obtained according to the process of the invention in the formulation of a viscosupplementation composition.
The invention relates to the use of a polysaccharide obtained according to the process of the invention in the formulation of a composition for filling in wrinkles.
The applications targeted are more particularly the applications commonly observed in the context of injectable polysaccharide viscoelastic products used or which can potentially be used in the following pathologies or treatments:
cosmetic injections: for filling in wrinkles, skin defects or defects Of volume (cheekbones, chins, lips); treatment of osteoarthritis, injection into the joint to replace or supplement deficient synovial fluid; periurethral injection in the treatment of urinary incontinence by sphincter insufficiency; postsurgical injection for preventing peritoneal adhesions in particular; injection subsequent to surgery for far-sightedness by scleral incisions using a laser; injection into the vitreous cavity.
More particularly, in cosmetic surgery, according to its viscoelastic properties and properties of persistence, the hydrogel obtained according to the process of the invention can be used:
for filling in fine, moderate or deep wrinkles and can be injected with thin needles (27-gauge, for example); as volumizing product with injection via needles with a larger diameter, for example from 22- to 26-gauge, and with a greater length (30 to 40 mm, for example); in this case, its cohesive nature will make it possible to guarantee that it is maintained at the site of the injection.
The polysaccharide obtained according to the process of the invention also has an important application in joint surgery and in dental surgery for filling in periodontal pockets, for example.
These implementational examples are in no way limiting, the polysaccharide obtained according to the process of the present invention being more widely provided for:
filling in volumes; generating spaces within certain tissues, thus promoting their optimum functioning; replacing deficient physiological fluids.
The polysaccharide obtained according to the process of the invention also has an application in the preparation of bone substitutes.
The polysaccharide obtained according to the process of the invention can also have an entirely advantageous application as matrix for releasing one (or more) active principle(s) dispersed beforehand within it. The term “active principle” is understood to mean any product which is active pharmacologically: medicinal active principle, antioxidant active principle (sorbitol, mannitol, and the like), antiseptic active principle, anti-inflammatory active principle, local anesthetic active principle (lidocaine, and the like), and the like.
In practice, the polysaccharide obtained according to the process of the invention, preferably after purification and hydration to give the hydrogel, can be packaged, for example in syringes, and sterilized according to any means known per se (for example by autoclaving) in order to be sold and/or used directly.
According to another aspect, the present invention relates to a kit comprising a polysaccharide obtained according to the process of the invention packaged in a sterile syringe.
The characteristics of the polysaccharides obtained according to the process of the invention are demonstrated in the examples below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : NMR spectrum of the gel G1A.
FIG. 2 : NMR spectrum of the gel REF1A. Comparison to FIG. 1 confirms the chemical substitution (via a covalent bond) of the VSA on the hydroxyl functional group of the NaHA.
FIG. 3 : Elasticity G′ in Pa as a function of the degree of substitution (DS). The results represented in FIG. 3 show that the elasticity G′ of the gels increases with the degree of substituent introduced: the chemical modification is indeed responsible for the optimization in the viscoelastic properties of the gels.
DETAILED DESCRIPTION
Examples
The degrees of substituent introduced (DSI), degree of crosslinking agent introduced (DCI) and reactive catalyst ratio in the examples which follow are defined by:
Degree of Crosslinking Agent Introduced:
DCI=Number of moles of crosslinking agent introduced into the reaction medium/number of moles of disaccharide unit introduced into the reaction medium
Degree of Substituent Introduced:
DSI=Number of moles of reactive functional groups of the substituent introduced into the reaction medium/number of moles of disaccharide unit introduced into the reaction medium
Reactive Catalyst Ratio
RCR=Number of moles of reactive functional groups of the catalyst introduced into the reaction medium/number of moles of disaccharide unit introduced into the reaction medium
Example 1
Demonstration of the Synergistic Effect with Regard to the Rheological Properties of the Substitution Carried Out Simultaneously with the Crosslinking
The following steps are described below:
Substitution of VSA (sodium salt of vinylsulfonic acid) on noncrosslinked NaHA (sodium hyaluronate) Characterization of the substitution Crosslinking of NaHA by BDDE (1,4-butanediol diglycidyl ether) Substitution of VSA (sodium salt of vinylsulfonic acid) on NaHA simultaneously with crosslinking by BDDE (1,4-butanediol diglycidyl ether) Substitution of VSA (sodium salt of vinylsulfonic acid) on NaHA followed by crosslinking by BDDE (1,4-butanediol diglycidyl ether) Demonstration of the synergistic effect on the rheological properties introduced by the substitution carried out simultaneously with the crosslinking
Gel G1A Synthesis: Substitution of VSA (Sodium Salt of Vinylsulfonic Acid) on Noncrosslinked NaHA, at a Temperature of 50° C. and in an Alkaline Medium (RCR=0.8:1)
Step a): Hydration of sodium hyaluronate fibers in the form of a noncrosslinked gel
Sodium hyaluronate fibers of injectable grade (0.9 g, i.e. 2.24 mmol; molecular weight: approximately 2.7 MDa) are weighed out in a container. A 1% aqueous solution of sodium hydroxide (0.25 mol/L, i.e. 1.85 mmol of HO − introduced into the medium) in water (7.4 g) is added (RCR=0.8:1) and the combined mixture is homogenized for approximately 1 hour using a spatula at room temperature and 900 mmHg.
Step b): Substitution
VSA (102 mg, i.e. 0.78 mmol) is added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized with a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for 2 h 10. The degree of substituent introduced DSI is equal to approximately 0.35.
Step c): Neutralization, Purification
The substituted final gel is subsequently neutralized by addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 20 mg/g of HA (hyaluronic acid). This gel is subsequently homogenized before being packaged in syringes which are sterilized by autoclaving. A substituted and sterilized NaHA hydrogel G1A is thus obtained.
Gel REF1A Synthesis
The gel REF1A is synthesized according to the procedure for gel G1A described above, the VSA being replaced with water for parenteral injection (WPI).
Characterization of the Chemical Modifications to the Gels G1A and REF1A by Liquid 1 H NMR
The NMR spectrum of the gel G1A is represented in FIG. 1 .
The NMR spectrum of the gel REF1A is represented in FIG. 2 .
Comparison of the spectra of FIGS. 1 and 2 makes it possible to confirm the chemical substitution (via a covalent bond) of the VSA on the hydroxyl functional group of the NaHA.
Gel G1B Synthesis: Crosslinking of NaHA by BDDE (1,4-Butanediol Diglycidyl Ether), at a Temperature of 50° C. and in an Alkaline Medium (RCR=0.8:1)
Step a): Identical to step a) of the synthesis of the gel G1A
Step b): Crosslinking
BDDE (65 mg, i.e. 0.32 mmol) is added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for 2 h 10. The degree of crosslinking agent introduced DCI is equal to approximately 0.14.
Step c): Neutralization, Purification
The crosslinked final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 20 mg/g of HA. This gel is subsequently homogenized before being filled into syringes which are sterilized by autoclaving. A crosslinked and sterilized NaHA hydrogel G1B is thus obtained.
Gel G1C Synthesis: Substitution of VSA (Sodium Salt of Vinylsulfonic Acid) on NaHA Simultaneously with Crosslinking by BDDE (1,4-Butanediol Diglycidyl Ether), at a Temperature of 50° C. and in an Alkaline Medium (RCR=0.8:1)
Step a): Identical to Step a) of the Synthesis of the Gel G1A
Step b): Crosslinking and Substitution
BDDE (65 mg, i.e. 0.32 mmol) and VSA (102 mg, i.e. 0.78 mmol) are added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for 2 h 10. The degree of crosslinking agent introduced DCI is equal to approximately 0.14 and the degree of substituent introduced DSI is equal to approximately 0.35.
Step c): Neutralization, Purification
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 20 mg/g of HA. This gel is subsequently homogenized before being packaged in syringes which are sterilized by autoclaving. A crosslinked, substituted and sterilized NaHA hydrogel G1C is thus obtained.
Gel G1D synthesis: Substitution of VSA (sodium salt of vinylsulfonic acid) on NaHA followed by crosslinking by BDDE (1,4-butanediol diglycidyl ether), at a temperature of 40° C. and in an alkaline medium (RCR=0.8:1)
Step a): Identical to step a) of the synthesis of the gel G1A
Step b): Substitution
VSA (102 mg, i.e. 0.78 mmol) is added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 40° C. for 1 h 00. The degree of substituent introduced DSI is equal to approximately 0.35. The time and the temperature were reduced in comparison with the G1A test in order to retain a gel thick enough for the following crosslinking step.
Step c): Crosslinking
BDDE (65 mg, i.e. 0.32 mmol) is added to the noncrosslinked substituted sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for 2 h 10. The degree of crosslinking agent introduced DCI is equal to approximately 0.14.
Step d): Neutralization, Purification
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 20 mg/g of HA. This gel is subsequently homogenized before being packaged in syringes which are sterilized by autoclaving. A substituted, then crosslinked and sterilized NaHA hydrogel G1D is thus obtained.
Demonstration of the Synergistic Effect on the Rheological Properties Introduced by the Substitution Simultaneously with the Crosslinking
The viscosity n of the sterile gels is characterized on a TA Instruments AR 2000 Ex rheometer, under controlled stress conditions at 25° C. The viscosity value is recorded at a stress of 0.02 s −1 .
The elastic component G′ and the viscous component G″ of the sterile gels are characterized on a TA Instruments AR 2000 Ex rheometer, in oscillation at 25° C., the values of the elastic and viscous components being recorded at a frequency of 1 Hz.
The rheological results are presented in table I below:
TABLE I
G1A
G1B
G1C
G1D
Viscosity: η (Pa · s) at 0.02 s −1
7
1822
1959
1502
Elastic component: G′ (Pa) at 1 Hz
0.5
107
131
78
Viscous component: G″ (Pa) at 1 Hz
3
27
29
22
The substitution on a gel simultaneously with the crosslinking (G1C test) introduces superior viscoelastic properties in comparison with the gels:
simply substituted (gel G1A), simply crosslinked (gel G1B), first substituted and then crosslinked (gel G1D).
Surprisingly, the substitution carried out simultaneously with a crosslinking synergistically improves the rheological properties of the gels obtained.
Example 2
VSA (Sodium Salt of Vinylsulfonic Acid) Substitution on NaHA Simultaneously with Crosslinking by BDDE (1,4-Butanediol Diglycidyl Ether), at a Temperature of 50° C. and in an Alkaline Medium (RCR=0.8:1)
This example makes it possible to demonstrate, by the measurement of the rheological properties:
the substitution of the vinyl functional group on the NaHA during crosslinking and the difference in structure introduced by the substitution, the better resistance to radical decomposition of the substituted and crosslinked gel.
Gel G2 synthesis
Step a): Hydration of Sodium Hyaluronate Fibers in the Form of a Noncrosslinked Gel
Sodium hyaluronate fibers of injectable grade (0.9 g, i.e. 2.24 mmol; molecular weight: approximately 2.7 MDa) are weighed out in a container. A 1% aqueous solution of sodium hydroxide (0.25 mol/L, i.e. 1.85 mmol of HO − introduced into the medium) in water (7.4 g) is added (RCR=0.8:1) and the combined mixture is homogenized for approximately 1 hour using a spatula at room temperature and 900 mmHg.
Step b): Crosslinking and Substitution
BDDE (65 mg, i.e. 0.32 mmol) and VSA (70 mg, i.e. 0.54 mmol) are added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for 2 h 10. The degree of crosslinking agent introduced DCI is equal to approximately 0.14 and the degree of substituent introduced DSI is equal to approximately 0.24.
Step c): Neutralization, Purification
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 20 mg/g of HA. This gel is subsequently homogenized before being packaged in syringes which are sterilized by autoclaving. A crosslinked, substituted and sterilized NaHA hydrogel G2 is thus obtained.
Gel REF2 synthesis
The gel REF2 is synthesized according to the procedure for the gel G2 described above, the VSA being replaced with water for parenteral injection (WPI).
Characterization of the Extrusion Force or “Injectability” and of the Elasticity of the Gels G2 and REF2
The extrusion force is characterized on a Mecmesin tensile/compression testing machine under a rate of compression of 50 mm/min with 27G ½″ needles; the results are given in the table below.
The elasticity of the sterile gels is characterized on a TA Instruments AR 2000 Ex rheometer, in oscillation at 25° C., the value of the elasticity being recorded at a frequency of 1 Hz; the results are presented in table II below.
TABLE II
G2
REF2
Extrusion force (N), 27G ½″ needle, Rate 50 mm/min
35
38
Elasticity: G′ (Pa) at 1 Hz
116
105
The substitution makes it possible to obtain finished products of greater rheology (+10%) for levels of injectability which are slightly lower (−8%). These rheological data confirm the chemical modification to the NaHA and thus the substitution of the vinyl functional group on the NaHA during crosslinking.
Test on Radical Decomposition of the Gels G2 and REF2
The gels were also characterized by a test on radical decomposition in vitro at 37° C. This test makes it possible to simulate the subsequent persistence in vivo (intradermal, intra-articular, and the like) of the injected gels.
It was developed on the basis of the test described in the publication “ Antioxidant activities of sulfated polysaccharides from brown and red seaweeds ”, Rocha de Souza, J. Appl. Phycol. (2007), 19, 153-160.
The gels are decomposed by the free radicals generated by the Fenton reaction between hydrogen peroxide and ferrous ions. The decomposition is monitored by rheology at 37° C., the complex viscosity being measured. The curves of the trend in the decomposition results for these 2 gels subsequently make it possible to evaluate the half-lives of these different gels (period of time necessary to have n*=n* 0 /2, in minutes, with n* 0 =complex viscosity at t 0 of the gel characterized). The half-lives obtained are given in table III below.
TABLE III
G2
REF2
Half-life (minutes)
8.0
5.1
Thus, for an injectability which is slightly lower and which makes it possible to retain good control of the surgical action, the half-lives of the modified gels obtained according to the invention are longer, guaranteeing a greater time of persistence in vivo, this being the case even with the low degree of substitution tested.
Example 3
VSA (Sodium Salt of Vinylsulfonic Acid) Substitution on NaHA Simultaneously with Crosslinking by BDDE (1,4-Butanediol Diglycidyl Ether), at a Temperature of 50° C. and in an Alkaline Medium (RCR=0.8:1)
This example makes it possible to demonstrate by rheology the increase in elasticity introduced into the gel as a function of the degree of substitution.
Gel G3A and gel G3B Synthesis
The synthesis of the gels is identical to that of the gels G1C and G2, with the amounts of VSA adjusted to the tested degrees of substituent introduced; see table IV below.
TABLE IV
DSI
G3A
1.00
G3B
2.00
Characterization of the Elasticity of the Gels G3A and G3B
The elasticity of the gels is characterized on a TA Instruments AR 2000 Ex rheometer described in example 2; the results are given in table V below.
TABLE V
G2
G1C
G3A
G3B
REF2
Degree of substituent introduced, DSI
0.24
0.35
1.00
2.00
—
Elasticity: G′ (Pa) at 1 Hz
116
131
199
213
105
The results represented graphically in FIG. 3 show that the elasticity G′ of the gels increases with the degree of substituent introduced: the chemical modification is indeed responsible for the optimization in the viscoelastic properties of the gels.
Example 4
EB (Epoxybutane) Substitution on NaHA Simultaneously with Crosslinking by BDDE (1,4-Butanediol Diglycidyl Ether), at a Temperature of 50° C. and in an Alkaline Medium (RCR=0.8:1)
This example makes it possible to demonstrate by rheology the substitution of an epoxy functional group on NaHA simultaneously with crosslinking.
Gel G4 Synthesis
Step a): Identical with Step a) of the Synthesis of the Gel G1A
Step b): Crosslinking and Substitution
BDDE (65 mg, i.e. 0.32 mmol) and EB (147 mg, i.e. 2.02 mmol) are added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for 2 h 10. The degree of crosslinking agent introduced DCI is equal to approximately 0.14 and the degree of substituent introduced DSI is equal to approximately 0.90.
Step c): Neutralization, Purification
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 20 mg/g of HA. This gel is subsequently homogenized before being packaged in syringes. A crosslinked, substituted and sterilized NaHA hydrogel G4 is thus obtained.
Gel REF4 Synthesis
The gel REF4 is synthesized according to the procedure for the gel G4 described above, the EB being replaced with water for parenteral injection (WPI).
Characterization of the Elasticity of the Gels G4 and REF4
The elasticity of the gels is characterized on the TA Instruments AR 2000 Ex rheometer described in example 2; the results are given in table VI below.
TABLE VI
G4
REF4
Elasticity: G′ (Pa) at 1 Hz
180
150
The substitution of a molecule comprising an epoxy reactive group on the NaHA is confirmed by the rheological results: the chemical modification makes it possible to obtain finished products having a higher elasticity.
These rheological data confirm the substitution of the epoxide functional group on the NaHA during crosslinking.
Example 5
VSA (Sodium Salt of Vinylsulfonic Acid) Substitution on NaHA Simultaneously with Crosslinking by BDDE (1,4-Butanediol Diglycidyl Ether), at a Temperature of 50° C. and in an Alkaline Medium (RCR=0.7:1)
This example makes it possible to demonstrate by rheology the substitution on NaHA of low molecular weight.
Gel G5 Synthesis
Step a): Hydration of Sodium Hyaluronate Fibers in the Form of a Noncrosslinked Gel
Sodium hyaluronate fibers of injectable grade (0.9 g, i.e. 2.24 mmol; molecular weight: approximately 1.5 MDa) are weighed out in a container. A 1% aqueous solution of sodium hydroxide (0.25 mol/L, i.e. 1.57 mmol of HO − introduced into the medium) in water (6.3 g) is added (RCR=0.7:1) and the combined mixture is homogenized for approximately 1 hour using a spatula at room temperature and 900 mmHg.
Step b): Crosslinking and Substitution
BDDE (30 mg, i.e. 0.15 mmol) and VSA (87 mg, i.e. 0.67 mmol) are added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for 2 h 10. The degree of crosslinking agent introduced DCI is equal to approximately 0.07 and the degree of substituent introduced DSI is equal to approximately 0.30.
STEP C): NEUTRALIZATION, PURIFICATION
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 20 mg/g of HA. This gel is subsequently homogenized before being packaged in syringes. A crosslinked and substituted NaHA hydrogel G5 is thus obtained.
Gel REF5 Synthesis
The gel REF5 is synthesized according to the procedure for the gel G5 described above, the VSA being replaced with water for parenteral injection (WPI).
Characterization of the elasticity of the gels G5 and REF5
The elasticity of the gels is characterized on a TA Instruments AR 2000 Ex rheometer described in example 2; the results are given in table VII below.
TABLE VII
G5
REF5
Elasticity: G′ (Pa) at 1 Hz
519
433
The substitution makes it possible to obtain finished products having a higher elasticity. These rheological data, like those of example 2 (NaHA of high molecular weight), confirm that the substitution can be carried out on NaHA having different molecular weights.
Example 6
VSA (sodium salt of vinylsulfonic acid) substitution on CMC (carboxymethylcellulose) simultaneously with crosslinking by BDDE (1,4-butanediol diglycidyl ether), at a temperature of 50° C. and in an alkaline medium (RCR=1:1)
This example makes it possible to demonstrate by rheology the substitution on a polysaccharide other than NaHA.
Gel G6 Synthesis
Step a): Hydration of CMC in the Form of a Noncrosslinked Gel
0.93 g, i.e. 2.20 mmol of sodium CMC (supplied by Sigma, molecular weight: approximately 1.0 MDa) is weighed out in a container. A 1% aqueous solution of sodium hydroxide (0.25 mol/L, i.e. 2.25 mmol of HO − introduced into the reaction medium) in water (9.0 g) is added (RCR=1:1) and the combined mixture is homogenized for approximately 90 minutes using a spatula at room temperature and 900 mmHg.
Step b): Crosslinking and Substitution
BDDE (37 mg, i.e. 0.18 mmol) and VSA (87 mg, i.e. 0.67 mmol) are added to the noncrosslinked CMC gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for 3 h 35. The degree of crosslinking agent introduced DCI is equal to approximately 0.08 and the degree of substituent introduced DSI is equal to approximately 0.30.
Step c): Neutralization, Purification
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 30 mg/g of CMC. This gel is subsequently homogenized before being packaged in syringes. A crosslinked and substituted CMC hydrogel G6 is thus obtained.
Gel REF6 Synthesis
The gel REF6 is synthesized according to the procedure for the gel G6 described above, the VSA being replaced with water for parenteral injection (WPI).
Characterization of the elasticity of the gels G6 and REF6
The elasticity of the gels is characterized on a TA Instruments AR 2000 Ex rheometer described in example 2; the results are given in table VIII below.
TABLE VIII
G6
REF6
Elasticity: G′ (Pa) at 1 Hz
524
483
The substitution makes it possible to obtain finished products having a higher elasticity. These rheological data, like those of example 2 (NaHA), confirm that the substitution can be carried out on different polysaccharide backbones, in particular cellulose derivatives.
Example 7
EB (epoxybutane) substitution on CH (chitosan) simultaneously with crosslinking by BDDE (1,4-butanediol diglycidyl ether), at a temperature of 50° C. and in a weak acidic medium (RCR=0.06:1) and strong acidic medium (RCR=1:1)
This example makes it possible to demonstrate by rheology the substitution in an acidic medium simultaneously with the crosslinking.
Gel G1A Synthesis (in a Weak Acidic Medium)
Step a): Hydration of CH in the Form of a Noncrosslinked Gel
0.99 g, i.e. 2.93 mmol, of CH with a degree of deacetylation of the order of 80% (supplied by Kitozyme, molecular weight: approximately 120 000 Da) is weighed out in a container. A 1% aqueous solution of glutamic acid (0.07 mol/L) in water (9.0 g) is added. As glutamic acid is a weak acid, it is partially dissociated in water. The pH of the aqueous solution can be calculated via the following formula (determined as a result of approximations): pH=(½ pKa)−(½ log [Glutamic Acid]), i.e. pH=(½×2.19)×(½×log(0.07))=1.67. The concentration of hydronium H 3 O + ion can be calculated by the following formula: [H 3 O + ]=10 −pH , i.e. [H 3 O + ]=0.02 mol/L, i.e. 0.19 mmol of hydronium ions introduced into the reaction medium (RCR=0.06:1). The combined mixture is homogenized for approximately 90 minutes using a spatula at room temperature and 900 mmHg. The pH of the reaction medium is 5.3.
Step b): Crosslinking and Substitution
BDDE (60 mg, i.e. 0.30 mmol) and EB (337 mg, i.e. 4.68 mmol) are added to the noncrosslinked CH gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for. The degree of crosslinking agent introduced DCI is equal to approximately 0.10 and the degree of substituent introduced DSI is equal to approximately 1.60.
STEP C): NEUTRALIZATION, PURIFICATION
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N sodium hydroxide solution and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 22 mg/g of CH. This gel is subsequently homogenized before being packaged in syringes which are sterilized by autoclaving. A crosslinked, substituted and sterilized CH hydrogel G7a is thus obtained.
Gel G7b Synthesis (in a Strong Acidic Medium)
Step a): Hydration of CH in the Form of a Noncrosslinked Gel
0.99 g, i.e. 2.93 mmol, of CH with a degree of deacetylation of the order of 80% (supplied by Kitozyme, molecular weight: approximately 120 000 Da) is weighed out in a container. A 1.15% aqueous solution of hydrochloric acid (0.32 mol/L, i.e. 2.88 mol of H 3 O + ions introduced into the reaction medium=>RCR=1:1) in water (9.0 g) is added. The combined mixture is homogenized for approximately 90 minutes using a spatula at room temperature and 900 mmHg. The pH of the reaction medium is 3.
Step b): Crosslinking and Substitution
BDDE (60 mg, i.e. 0.30 mmol) and EB (337 mg, i.e. 4.68 mmol) are added to the noncrosslinked CH gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for. The degree of crosslinking agent introduced DCI is equal to approximately 0.10 and the degree of substituent introduced DSI is equal to approximately 1.60.
Step c): Neutralization, Purification
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N sodium hydroxide solution and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 22 mg/g of CH. This gel is subsequently homogenized before being packaged in syringes which are sterilized by autoclaving. A crosslinked, substituted and sterilized CH hydrogel G7b is thus obtained.
Gel REF7 Synthesis
The gel REF7 is synthesized according to the procedure for the gel G7 described above, the EB being replaced with water for parenteral injection (WPI).
Characterization of the viscosity of the gels G7a and REF7
The 2 gels G7a and REF7 are more viscous than elastic in consistency and are thus characterized in viscosity.
The viscosity of the sterile gels is characterized on a TA Instruments AR 2000 Ex rheometer described in example 1; the results are given in table IX below.
TABLE IX
G7a
REF7
Viscosity (Pa · s)
67.1
35.4
The substitution makes it possible to obtain finished products of greater rheology. These rheological data, like those of example 2 (NaHA under basic conditions) and 6 (CMC under basic conditions), confirm that the substitution can be carried out on different polysaccharide backbones and under both acidic and basic conditions.
Example 8
VSA (Sodium Salt of Vinylsulfonic Acid) Substitution on NaHA Simultaneously with Crosslinking by DVS (Divinyl Sulfone), at a Temperature of 40° C. and in an Alkaline Medium (RCR=1.75:1)
This example makes it possible to demonstrate by rheology the substitution on an NaHA bridged with different crosslinking agents.
Gel G8 Synthesis
Step a): Hydration of Sodium Hyaluronate Fibers in the Form of a Noncrosslinked Gel
Sodium hyaluronate fibers of injectable grade (0.9 g, i.e. 2.24 mmol; molecular weight: approximately 2.7 MDa) are weighed out in a container. A 1% aqueous solution of sodium hydroxide (0.25 mol/L, i.e. 3.92 mmol of HO − introduced into the medium) in water (15.7 g) is added (RCR=1.75:1) and the combined mixture is homogenized for approximately 1 hour using a spatula at room temperature and 900 mmHg.
Step b): Crosslinking and Substitution
DVS (57 mg, i.e. 0.48 mmol) and VSA (87 mg, i.e. 0.67 mmol) are added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 40° C. for 1 h 00. The degree of crosslinking agent introduced DCI is equal to approximately 0.21 and the degree of substituent introduced DSI is equal to approximately 0.30.
Step c): Neutralization, Purification
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 20 mg/g of HA. This gel is subsequently homogenized before being packaged in syringes. A crosslinked and substituted NaHA hydrogel G8 is thus obtained.
Gel REF8 Synthesis
The gel REF8 is synthesized according to the procedure for the gel G8 described above, the VSA being replaced with water for parenteral injection (WPI).
Characterization of the Elasticity of the Gels G8 and REF8
The elasticity of the gels is characterized on a TA Instruments AR 2000 Ex rheometer described in example 2; the results are given in table X below.
TABLE X
G8
REF8
Elasticity: G′ (Pa) at 1 Hz
110
103
The substitution makes it possible to obtain finished products having a higher elasticity. These rheological data, like those of example 2 (crosslinking with BDDE), confirm that the substitution can be carried out at the same time as a bridging of the polysaccharide, whatever the nature of the crosslinking agent.
Example 9
SAS (Sodium Allyl Sulfate) Substitution on NaHA Simultaneously with Crosslinking by BDDE (1,4-Butanediol Diglycidyl Ether), at a Temperature of 50° C. and in an Alkaline Medium (RCR=0.8:1)
This example makes it possible to demonstrate, by rheology:
the substitution of the allyl functional group on the NaHA during crosslinking and the difference in structure introduced by the substitution, the better resistance to radical decomposition of the gel substituted with a sulfate pendant group.
Gel G9 Synthesis
Step a): Identical to Step a) of the Synthesis of the Gel G1A
Step b): Crosslinking and Substitution
BDDE (65 mg, i.e. 0.32 mmol) and SAS (111 mg, i.e. 0.68 mmol) are added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 50° C. for 2 h 10. The degree of crosslinking agent introduced DCI is equal to approximately 0.14 and the degree of substituent introduced DSI is equal to approximately 0.30.
Step c): Neutralization, Purification
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 20 mg/g of HA. This gel is subsequently homogenized before being packaged in syringes which are sterilized by autoclaving. A crosslinked, substituted and sterilized NaHA hydrogel G9 is thus obtained.
Gel REF9 Synthesis
The gel REF9 is synthesized according to the procedure of the gel G9 described above, the SAS being replaced with water for parenteral injection (WPI).
Characterization of the Elasticity of the Gels G9 and REF9
The elasticity of the sterile gels is characterized on a TA Instruments AR 2000 Ex rheometer described in example 2; the results are given in table XI below.
TABLE XI
G9
REF9
Elasticity: G′ (Pa) at 1 Hz
123
105
The substitution makes it possible to obtain finished products of greater rheology (+17%). These rheological data confirm the substitution of the allyl functional group on the NaHA simultaneously with the crosslinking.
Test on Radical Decomposition of the Gels G9 and REF9
The gels were also characterized by a test on in vitro radical decomposition at the temperature, described in example 2. The half-lives obtained are given in table XII below.
TABLE XII
G9
REF9
Half-life (minutes)
12.6
6.6
Thus, the half-lives of the gels substituted with a sulfate pendant group obtained according to the invention are longer, guaranteeing a greater time of persistence in vivo.
Counterexamples
Counterexample 1
This counterexample is similar to example 1 carried out under drastic temperature and pH conditions of the prior art.
a) Gel G1Ca Synthesis: Substitution of VSA (Sodium Salt of Vinylsulfonic Acid) on NaHA Simultaneously with Crosslinking by BDDE (1,4-Butanediol Diglycidyl Ether), at a Temperature of 80° C. And in a Concentrated Alkaline Medium (RCR of 4.1:1)
Step a): Hydration of Sodium Hyaluronate Fibers in the Form of a Noncrosslinked Gel
Sodium hyaluronate fibers of injectable grade (0.9 g, i.e. 2.24 mmol; molecular weight: approximately 2.7 MDa) are weighed out in a container. A 5% aqueous solution of sodium hydroxide (1.25 mol/L, i.e. 9.25 mmol of HO − introduced into the medium) in water (7.4 g) is added (RCR of 4.1:1) and the combined mixture is homogenized for approximately 1 hour using a spatula at room temperature and 900 mmHg.
Step b): Crosslinking and Substitution
BDDE (65 mg, i.e. 0.32 mmol) and VSA (102 mg, i.e. 0.78 mmol) are added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 80° C. for 2 h 10 in order to obtain a degree of crosslinking agent introduced DCI of approximately 0.14 and a degree of substituent introduced DSI of approximately 0.35.
After 20 minutes at 80° C., the reaction medium has completely decomposed (liquid, brown, “caramelized” appearance).
A high temperature (80° C.) and the use of a concentrated sodium hydroxide solution decompose the polysaccharide network and thus disrupt the substitution and the crosslinking of the polymer chains.
b) Gel G1Cb synthesis: Substitution of VSA (sodium salt of vinylsulfonic acid) on NaHA simultaneously with crosslinking by BDDE (1,4-butanediol diglycidyl ether), at a temperature of 80° C. and in a concentrated alkaline medium (RCR of 8.2:1)
Step a): Hydration of Sodium Hyaluronate Fibers in the Form of a Noncrosslinked Gel
Sodium hyaluronate fibers of injectable grade (0.9 g, i.e. 2.24 mmol; molecular weight: approximately 2.7 MDa) are weighed out in a container. A 10% aqueous solution of sodium hydroxide (2.5 mol/L, i.e. 18.5 mmol of HO − introduced into the medium) in water (7.4 g) is added (RCR of 8.2:1) and the combined mixture is homogenized for approximately 1 hour using a spatula at room temperature and 900 mmHg.
Step b): Crosslinking and Substitution
BDDE (65 mg, i.e. 0.32 mmol) and VSA (102 mg, i.e. 0.78 mmol) are added to the noncrosslinked sodium hyaluronate (NaHA) gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 80° C. for 2 h 10 in order to obtain a degree of crosslinking agent introduced DCI of approximately 0.14 and a degree of substituent introduced DSI of approximately 0.35.
After 15 minutes at 80° C., the reaction medium has completely decomposed (liquid, brown, “caramelized” appearance).
A high temperature (80° C.) and the use of a concentrated sodium hydroxide solution decompose the polysaccharide network and thus disrupt the substitution and the crosslinking of the polymer chains.
Counterexample 2
This counterexample is similar to example 6 carried out under drastic temperature and pH conditions of the prior art.
a) VSA (sodium salt of vinylsulfonic acid) substitution on CMC (carboxymethylcellulose) simultaneously with crosslinking by BDDE (1,4-butanediol diglycidyl ether), at a temperature of 80° C. and in a concentrated alkaline medium (RCR of 5.1:1)
Gel G6a Synthesis
Step a): Hydration of CMC in the Form of a Noncrosslinked Gel
0.93 g, i.e. 2.20 mmol of sodium CMC (supplied by Sigma, molecular weight: approximately 1.0 MDa) is weighed out in a container. A 5% aqueous solution of sodium hydroxide (1.25 mol/L, i.e. 11.25 mmol of HO − introduced into the medium) in water (9.0 g) is added (RCR of 5.1:1) and the combined mixture is homogenized for approximately 90 minutes using a spatula at room temperature and 900 mmHg.
Step b): Crosslinking and Substitution
BDDE (37 mg, i.e. 0.18 mmol) and VSA (87 mg, i.e. 0.67 mmol) are added to the noncrosslinked CMC gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 80° C. for 3 h 35 in order to obtain a degree of crosslinking agent introduced DCI of approximately 0.08 and a degree of substituent introduced DSI of approximately 0.30.
Step c): Neutralization, Purification
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 30 mg/g of CMC. This gel is subsequently homogenized before being packaged in syringes. A crosslinked and substituted CMC hydrogel G6a is thus obtained.
The gel has an excessively liquid, excessively dispersive and not sufficiently elastic appearance.
b) VSA (sodium salt of vinylsulfonic acid) substitution on CMC (carboxymethylcellulose) simultaneously with crosslinking by BDDE (1,4-butanediol diglycidyl ether), at a temperature of 80° C. and in a concentrated alkaline medium (RCR of 10.2:1)
Gel G6b Synthesis
Step a): Hydration of CMC in the Form of a Noncrosslinked Gel
0.93 g, i.e. 2.20 mmol of sodium CMC (supplied by Sigma, molecular weight: approximately 1.0 MDa) is weighed out in a container. A 10% aqueous solution of sodium hydroxide (2.5 mol/L, i.e. 22.5 mmol of HO − introduced into the medium) in water (9.0 g) is added (RCR of 10.2:1) and the combined mixture is homogenized for approximately 90 minutes using a spatula at room temperature and 900 mmHg.
Step b): Crosslinking and Substitution
BDDE (37 mg, i.e. 0.18 mmol) and VSA (87 mg, i.e. 0.67 mmol) are added to the noncrosslinked CMC gel obtained in the preceding step, the combined mixture being homogenized using a spatula for approximately 30 minutes at a temperature of 12-14° C. The combined mixture is subsequently placed on a water bath at 80° C. for 3 h 35 in order to obtain a degree of crosslinking agent introduced DCI of approximately 0.08 and a degree of substituent introduced DSI of approximately 0.30.
Step c): Neutralization, Purification
The crosslinked and substituted final gel is subsequently neutralized by the addition of 1N HCl and placed in a phosphate buffer bath in order to stabilize the pH and to make possible the hydration or swelling thereof in order to obtain a gel comprising 30 mg/g of CMC. This gel is subsequently homogenized before being packaged in syringes. A crosslinked and substituted CMC hydrogel G6b is thus obtained.
The gel has an excessively liquid, excessively dispersive and not sufficiently elastic appearance.
c) Characterization of the Elasticity of the Gels G6a and G6b
The elasticity of the gels is characterized on a TA Instruments AR 2000 Ex rheometer described in example 2; the results are given in the table below.
G6a
G6b
G6
REF6
Elasticity: G′ (Pa) at 1 Hz
17
12
524
483
The rheological data confirm the aspects observed: the gels do not have the expected consistency and they do not exhibit the viscoelastic properties required for the applications targeted.
A high temperature (80° C.) and the use of a concentrated sodium hydroxide solution decompose the polysaccharide network and thus disrupt the grafting and the crosslinking of the polymer chains.
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A process for the simultaneous substitution and crosslinking of a polysaccharide via its hydroxyl functional groups, in an aqueous phase, which includes the following steps:
a polysaccharide is placed in an aqueous medium, it is brought into the presence of at least one precursor of a substituent, it is brought into the presence of a crosslinking agent, the substituted and crosslinked polysaccharide is obtained and isolated,
wherein process is carried out in the presence of a basic or acidic catalyst, the concentration of which is between 3.16×10 −7 and 0.32 mol/L, and at a temperature of less than 60° C. In one embodiment, the polysaccharide is in the form of a gel or hydrogel which is used in particular as augmentation biomaterial.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of U.S. application Ser. No. 10/404,452, filed Apr. 2, 2003, now U.S. Pat. No. 7,012,769, which is a continuation application of U.S. application Ser. No. 10/277,830, filed Oct. 23, 2002, now U.S. Pat. No. 6,590,726 which is a continuation of U.S. Ser. No. 09/809,047, filed Mar. 16, 2001, now U.S. Pat. No. 6,498,691, which is a continuation application of U.S. application Ser. No. 09/654,962, filed Sep. 5, 2000, now U.S. Pat. No. 6,324,025, which is a continuation of U.S. Ser. No. 09/567,005, filed May 9, 2000, now U.S. Pat. No. 6,278,564, which is a continuation application of U.S. Ser. No. 09/326,595, filed Jun. 7, 1999, now U.S. Pat. No. 6,069,757, which is a continuation of U.S. application Ser. No. 09/188,303, filed Nov. 10, 1998, now U.S. Pat. No. 6,002,536, which is a continuation of U.S. application Ser. No. 08/917,176, filed Aug. 25, 1997, now U.S. Pat. No. 5,862,004, which is a continuation of U.S. application Ser. No. 08/620,879, filed Mar. 22, 1996, now U.S. Pat. No. 5,699,203, and copending with U.S. application Ser. No. 08/620,880, filed Mar. 22, 1996, now U.S. Pat. No. 5,673,154, which are continuations of U.S. application Ser. No. 08/457,597, filed Jun. 1, 1995, now U.S. Pat. No. 5,530,598, which is a continuation of U.S. application Ser. No. 08/457,486, filed Jun. 1, 1995, now U.S. Pat. No. 5,517,368, which is a continuation of U.S. application Ser. No. 08/238,528, filed May 5, 1994, now U.S. Pat. No. 5,671,095, which is a divisional of U.S. application Ser. No. 07/727,059, filed Jul. 8, 1991, now U.S. Pat. No. 5,337,199, the subject matter of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
The present invention relates to a system for transmitting a digital video signal and recording the received video signal. More particularly, the present invention relates to great extension of the range of use of a digital signal recording/reproducing system by greatly shortening a recording time through transmission of a video signal in a compressed form, and further relates to great extension of the range of use of a digital signal recording/reproducing system by making the number of signals to be recorded and a recording/reproducing time variable.
As a digital magnetic recording/reproducing system (hereinafter referred to as VTR) is conventionally known, for example, a D2 format VTR. In such a conventional digital VTR, the elongation or shortening of a reproducing time is possible by using variable-speed reproduction. However, the prior art reference does not at all disclose high-speed recording in which a recording time is shortened to 1/m, multiple recording in which a plurality of signals are recorded, and the compression/expansion of a recording/reproducing time.
The above-mentioned conventional digital VTR has a feature that a high quality is attained and there is no deterioration caused by dubbing. However, the shortening of a dubbing time is not taken into consideration. Therefore, for example, in the case where a two-hour program is to be recorded, two hours are required. Thus, there is a drawback that inconveniences are encountered in use. Also, the multiplexing of recording signals is not taken into consideration. Therefore, for example, when two kinds of programs are to be simultaneously recorded or reproduced, two VTR's are required. This also causes inconveniences in use.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a digital VTR in which high-speed recording onto a tape can be made with the same format as that used in standard-speed recording, to provide a transmission signal processing system for transmitting at a high speed a video signal to be recorded by such a digital VTR, and to extend the range of use of the digital VTR by shortening a recording time. For example, the digital VTR can be used in such a manner that a two-hour program is recorded in about ten minutes and is reproduced at a standard speed.
The above object is achieved as follows. A video signal and an audio signal are subjected to time-base compression to 1/m, bit compression to 1/n, addition of a parity signal and modulation, and are thereafter transmitted or outputted. The transmitted signal is received, is subjected to demodulation, error correction, addition of a parity signal and modulation, and is thereafter recorded, onto a magnetic tape which travels at a travel speed m times as high as that upon normal reproduction, by use of a magnetic head on a cylinder which rotates at a frequency m times as high as that upon normal reproduction. The signal on the magnetic tape traveling at a travel speed upon normal reproduction is reproduced by a magnetic head on the cylinder which rotates at a frequency upon normal reproduction. The reproduced signal is subjected to demodulation, error correction, bit expansion of video and audio signals and D/A conversion, and is thereafter outputted. Address signals corresponding to a plurality of VTR's may be transmitted prior to a signal to be recorded. Further, control signals indicative of the start of recording and the stop of recording may be transmitted. The transmitted signals are received and error-corrected, and controls of the standby for recording, the start of recording and the stop of recording are made on the basis of the control signals.
With the above construction, since the video signal and the audio signal are time-base compressed to 1/m and bit-compressed to 1/n, a transmission time is shortened to 1/m and a signal band turns to m/n. The time-base compressed and bit-compressed signal is transmitted after addition of a parity signal for error correction and modulation to a code adapted for a transmission path. The transmitted signal is received and demodulated. The detection of an error produced in a transmitting system and the correction for the error can be made using the added parity signal. The error-corrected signal is added with a parity signal for correction for an error produced in a magnetic recording/reproducing system and is modulated to a code adapted for the magnetic recording/reproducing system. Upon recording, since the rotation frequency of the cylinder and the travel speed of the magnetic tape are increased by m times, the recording onto the magnetic tape can be made at an m-tuple speed. Upon reproduction, by setting the rotation frequency of the cylinder and the travel speed of the magnetic tape to normal ones, the reproduction at a normal speed can be made. The reproduced signal is code-demodulated. The detection of an error produced in the magnetic recording/reproducing system and the correction for the error can be made on the basis of the parity signal. By bit-expanding the video signal and the audio signal compressed by the transmission signal processing system, the original video and audio signal can be restored. The bit-expanded signal is converted into an analog signal by a D/A converter. Simultaneous and selective control of the start/stop of recording for a multiplicity of VTR's can be made in such a manner that the address signals corresponding to the VTR's are transmitted prior to a signal to be recorded, the correction for an error of the received signal is made, required VTR's are brought into recording standby conditions by the corrected address signals, and the controls of the start of recording and the stop of recording are made by the transmitted control signals.
Another object of the present invention is to provide a digital signal recording/reproducing system in which multiple recording onto a tape can be made with the same format as that used in standard recording and simultaneous multiple reproduction is possible, and to extend the range of use of a digital VTR by compressing/expanding a recording/reproducing time in accordance with the transmission rate of a multiplexed input/output signal and the number of signals in the multiplexed input/output signal.
This object is achieved as follows. There are provided means for selecting one or plural desired signals from a time-base compressed and time-division multiplexed digital input signal, and helical scan recording means for making time-division multiplex recording of the selected signals with a time-base compressed speed after selection being retained. There is further provided means for reproducing the recorded signals with the rotation speed of a cylinder, a tape speed and so on being set to values proportional to the transmission rate of a reproduction signal and the number of signals to be simultaneously reproduced and with the signal being time-base expanded or being retained as time-base compressed.
With the above construction, N kinds of desired signals selected from the multiplexed input digital signal and time-base compressed to 1/K are subjected to time-division multiplex recording with a time-base compressed speed after selection being retained. Upon reproduction, for example, if both the cylinder rotation speed and the tape speed are set to N/K times, a recording track and a reproducing track coincide with each other and the use of a reproducing time K/N times as long as a recording time enables the reproduction of each of the N kinds of signals at a standard speed. Also, if both the cylinder rotation speed and the tape speed are set to (M×N)/K times, a recording track and a reproducing track coincide with each other and the use of a reproducing time as K/(M×N) times as long as the recording time enables the reproduction of each of the N kinds of signals at an M-tuple speed. In the case where L kinds of signals are selected from among the N kinds of reproduced signals and a processing speed at a reproduction signal processing circuit is set to L×M times as long as a standard reproduction processing speed, each of the L kinds of signals among the N kinds of multiple-recorded signals is outputted at a speed M times as high as a standard speed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a digital transmission signal processing system and a recording/reproducing system according to an embodiment of the present invention;
FIG. 2 is a block diagram of a recording/reproducing system according to another embodiment of the present invention;
FIG. 3 is a diagram for explaining the conventional parity adding method;
FIG. 4 is a block diagram of a recording/reproducing system according to still another embodiment of the present invention;
FIG. 5 is a block diagram of a digital transmission signal processing system and a recording/reproducing system according to a further embodiment of the present invention;
FIG. 6 shows the format of control signals used in one of applications of the present invention;
FIG. 7 is a block diagram of a still further embodiment of the present invention;
FIG. 8 shows one example of the specification of signals to be recorded;
FIG. 9 is a block diagram of a furthermore embodiment of the present invention;
FIGS. 10 , 11 and 12 are block diagrams of different examples of applications of the present invention;
FIG. 13 is a block diagram for explaining one example of the operation of the embodiment shown in FIG. 7 ;
FIG. 14 is a timing chart showing the waveforms of signals involved in the example shown in FIG. 13 ;
FIG. 15 is a block diagram for explaining another example of the operation of the embodiment shown in FIG. 7 ;
FIG. 16 is a timing chart showing the waveforms of signals involved in the example shown in FIG. 15 ;
FIG. 17 is a table showing some applications of the examples shown in FIGS. 13 and 15 ;
FIG. 18 is a block diagram of a still furthermore embodiment of the present invention; and
FIGS. 19 and 20 are signal diagrams for explaining different operations of the embodiment shown in FIG. 18 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will now be explained by use of FIG. 1 . In the figure, reference numerals 1 and 40 denote magnetic tapes, numerals 2 , 3 , 41 and 42 magnetic heads, numerals 4 and 43 cylinders, numerals 5 and 44 capstans, numerals 10 and 50 servo control circuits, numerals 20 , 31 and 60 demodulation circuits, numerals 21 , 32 and 61 error correction circuits, numerals 22 and 23 compression circuits, numerals 24 and 33 parity addition circuits, numerals 25 and 34 modulation circuits, numerals 26 a transmission circuit, numeral 27 a transmission path, numeral 30 a reception circuit, numerals 62 and 63 expansion circuits, numerals 64 and 65 D/A conversion circuits, numeral 70 a video signal output terminal, and numeral 71 an audio signal output terminal.
Firstly, the operation of a transmission signal processing system will be explained. Digital video and audio signals recorded on the magnetic tape 1 are reproduced by the magnetic heads 2 and 3 mounted on the cylinder 4 and are inputted to the demodulation circuit 20 . The magnetic tape 1 travels by virtue of the capstan 5 . The travel speed of the magnetic tape 1 and the rotation frequency of the cylinder 4 are, for example, ten times as high as the tape travel speed and the cylinder rotation speed upon normal reproduction. Accordingly, the signal inputted to the demodulation circuit 20 is a signal time-compressed to one tenth. For example, a 120-minute signal recorded on the magnetic tape 1 can be reproduced in 12 minutes.
Generally, in the case where a digital signal is to be recorded on a magnetic recording medium, the signal is recorded after having been modulated into scrambled NRZ code, M 2 code or the like. The demodulation circuit 20 performs a demodulation processing, that is, a signal processing for restoring the thus modulated signal into original digital data. The signal demodulated by the demodulation circuit 20 is inputted to the error correction circuit 21 in which erroneous data produced in a magnetic recording/reproducing process is detected and the correction for the erroneous data is made. Further, the signal is separated into a video signal and an audio signal which are in turn inputted to the compression circuits 22 and 23 , respectively. The video signal is bit-compressed through, for example, discrete cosine conversion. The audio signal is bit-compressed through, for example, non-linear quantization or differential PCM. As a result, the transmission rate of the video signal and the audio signal in total is reduced to, for example, one twentieth.
Output signals of the compression circuits 22 and 23 are inputted to the parity addition circuit 24 for performing a signal processing which includes adding a parity signal for error correction and outputting the video signal and the audio signal serially in accordance with a transmission format. A serial output signal of the parity addition circuit 24 is inputted to the modulation circuit 25 . In the modulation circuit 25 , the serial signal is modulated in accordance with the characteristic and the frequency band of the transmission path 27 . For example, in the case where the signal is transmitted in an electric wave form, quadruple phase shift keying (QPSK) is made. The modulated signal is inputted to the transmission circuit 26 from which it is outputted to the transmission path 27 .
As apparent from the foregoing explanation of the operation of the transmission signal processing system, it is possible to transmit a signal at a speed which is ten times as high as a normal speed.
The above embodiment has been shown in conjunction with the case where a signal from the VTR is reproduced. However, a signal source is not limited to the VTR and may include a magnetic disk device, an optical disk device or the like.
Next, explanation will be made of the operation of the VTR for receiving and recording the transmitted signal. The signal transmitted from the transmission signal processing system is received by the reception circuit 30 . The received signal is inputted to the demodulation circuit 31 . The demodulation circuit 31 is provided corresponding to the modulation and demodulates the signal to the original signal. The demodulated signal is inputted to the error correction circuit 32 in which the detection of and the correction for an error produced in the transmission path 27 are made on the basis of the parity signal added by the parity addition circuit 24 . At this time, in the case where the S/N ratio of the transmission system is not sufficient so that complete correction for the error is impossible, correction is made through, for example, signal replacement, by use of the signal correlation.
An output signal of the error correction circuit 32 is inputted to the parity addition circuit 33 . In the parity addition circuit 33 , a parity signal for detecting an error produced in a recording/reproducing process and making correction for the error is added. The parity-added signal is inputted to the modulation circuit 34 . In the modulation circuit 34 , the signal is modulated to scrambled NRZ code, M 2 code or the like as mentioned above. The modulated signal is recorded on the magnetic tape 40 by the magnetic heads 41 and 42 mounted on the cylinder 43 .
Since the signal supplied to the magnetic heads 41 and 42 is a signal which is time-base compressed to one tenth as compared with a signal upon normal operation, the servo control circuit 50 controls the cylinder 43 and the capstan 44 so that the rotation frequency of the cylinder 43 and the travel speed of the magnetic tape 40 become ten times as high as those upon normal recording. Also, in order to record a predetermined signal at a predetermined position on the magnetic, tape 40 , synchronization information is detected from the received signal to control the phase of rotation of the cylinder 41 on the basis of the detected synchronization information.
Next, the operation of the VTR for reproducing the thus recorded signal will be explained. Upon reproduction, the travel speed of the magnetic tape 40 and the rotation frequency of the cylinder 43 are set to those upon normal reproduction. The reproduced signal is inputted to the demodulation circuit 60 . The demodulation circuit 60 is provided corresponding to the modulation circuit 34 and demodulates the modulated signal. The demodulated signal is inputted to the error correction circuit 61 in which the detection of an error produced in the magnetic recording/reproducing system and the correction for the error are made on the basis of the parity signal added by the parity addition circuit 33 . In the case where there is an error which cannot be corrected, the error is properly corrected by use of the signal correlation. Also, the signal is outputted after having been separated into a video signal and an audio signal.
The video signal is inputted to the expansion circuit 62 . The expansion circuit 62 is provided corresponding to the compression circuit 22 and restores the compressed video signal into the original video signal. An output signal of the expansion circuit 62 is inputted to the D/A conversion circuit 64 and is converted thereby into an analog video signal which is in turn outputted from the terminal 70 .
The audio signal is inputted to the expansion circuit 63 . The expansion circuit 63 is provided corresponding to the compression circuit 23 and restores the compressed audio signal into the original audio signal. An output signal of the expansion circuit 63 is inputted to the D/A conversion circuit 65 and is converted thereby into an analog audio signal which is in turn outputted from the terminal 71 .
In the foregoing, the embodiment of the present invention has been shown and the operation thereof has been explained. According to the present invention, a video signal and an audio signal over a long time can be transmitted and recorded in a short time, thereby making it possible to extend the range of use of the digital VTR.
Another embodiment of the present invention is shown in FIG. 2 . FIG. 2 is partially similar to FIG. 1 . The same parts in FIG. 2 as those in FIG. 1 are denoted by the same reference numerals as those used in FIG. 1 and detailed explanation thereof will be omitted. The embodiment shown in FIG. 2 concerns a VTR in which a signal transmitted/received at a high speed can be recorded while being monitored.
In FIG. 2 , reference numeral 80 denotes a change-over switch, numeral 81 an error correction circuit, and numeral 82 a memory circuit. An error corrected video signal outputted from the error correction circuit 81 is inputted through the memory circuit 82 to a terminal R side of the change over switch 80 which is selected upon recording. The memory circuit 82 has a memory capacity for at least one field. The video signal received at a high speed is stored into a memory of the memory circuit 82 with the number of frames being reduced. The stored signal is read from the memory at a normal speed and is inputted to an expansion circuit 62 .
Upon reproduction, a video signal output of an error correction circuit 61 is inputted to a terminal P side of the change-over switch 80 which is selected upon reproduction. Accordingly, the operation of the embodiment of FIG. 2 upon reproduction is similar to that of the embodiment shown in FIG. 1 .
In the embodiment shown in FIG. 2 , upon recording, the video signal outputted from the error correction circuit 81 is inputted to the expansion circuit 62 through the memory circuit 82 . Alternatively, an output signal of a modulation circuit 34 may be inputted to a demodulation circuit 60 through a memory circuit. Also, in the case where the operating speed of the demodulation circuit 60 or the error correction circuit 61 leaves a margin, a memory circuit may be properly placed at a post stage. Or, in the case where the storage capacity of the error correction circuit 61 or the expansion circuit 62 leaves a margin, the circuit may be used as a memory circuit or any additional memory circuit may be omitted.
As has been explained in the above, the embodiment shown in FIG. 2 makes it possible to record a received video signal while monitoring it in the form of a picture having a reduced number of frames.
In the embodiment shown in FIG. 1 , the parity signal is added in order to make the detection of and the correction for an error which may be produced in the transmission system or the magnetic recording/reproducing system. One example of a parity adding method is shown in FIG. 3 in conjunction with the case of a D2 format VTR. In the D2 format VTR, a signal for one field is divided into a plurality of segments for signal processing. FIG. 3 shows one segment. In FIG. 3 , reference numeral 90 represents a group of video data, numeral 91 a group of outer code parities, and numeral 92 a group of inner code parities. Firstly, outer code parities are added for data of the matrix-like arranged video data group 90 which lie in a vertical direction in FIG. 3 . Thereafter, inner code parities are added for data of the video data group 90 and the outer code parity group 91 lying in a horizontal direction in FIG. 3 , thereby producing a signal to be recorded. Though detailed explanation of the generation of parities will be omitted herein, the parities are generated in accordance with a generating function G(x).
In the embodiment shown in FIG. 1 , if the same parity generation manner is employed by the parity addition circuits 24 and 33 , the error correction circuits 32 and 61 may hold the most part thereof in common. Namely, since the error correction circuits 32 and 61 are circuits which are respectively used upon recording and upon reproduction, it is possible to reduce the circuit scale or size by using the most part of the circuits 32 and 61 in common.
Further, in the case where the same parity generation manner is employed by the parity addition circuits 24 and 33 in the embodiment shown in FIG. 1 , it is possible to further reduce the circuit scale or-size of the recording/reproducing system. The construction in that case is shown in FIG. 4 as still another embodiment of the present invention. FIG. 4 is partially common to FIG. 1 or 2 . The parts in FIG. 4 common to those in FIG. 1 or 2 are denoted by the same reference numerals as those used in FIG. 1 or 2 and detailed explanation thereof will be omitted.
The embodiment shown in FIG. 4 is based on a concept that an error produced in a transmission system and an error produced in a magnetic recording/reproducing system are simultaneously detected and corrected by an error correction circuit 61 . Accordingly, a signal received by a reception circuit 30 is demodulated by a demodulation circuit 31 and is inputted to a modulation circuit 34 without being subjected to error correction and parity addition. The subsequent processing is the same as that in the embodiment shown in FIG. 1 or 2 . Namely, a reproduced signal is inputted to the error correction circuit 61 after demodulation by a demodulation circuit 60 . As mentioned above, an error produced in the transmission system and an error produced in the magnetic recording/reproducing system are simultaneously detected and corrected by the error correction circuit 61 in the reproducing system.
In the embodiment shown in FIG. 4 , the error correction circuit 32 and the parity addition circuit 33 can be removed as compared with the embodiment shown in FIG. 1 or 2 , thereby making it possible to reduce the circuit scale.
Though having not been mentioned in the foregoing embodiments, in a helical scan VTR as shown, since a signal becomes discontinuous when a track jump is made upon reproduction, the recording is made with an amble signal being added to the heading portion of a signal. Since the addition of an amble signal is employed in the D2 format VTR, detailed explanation thereof will be omitted. Also, in order to define a starting position of a signal, a synchronizing signal is properly added. Since the addition of a synchronizing signal is known in, for example, the D2 format VTR, detailed explanation thereof will be omitted.
In the embodiment shown in FIG. 1 , the addition of an amble signal may be made by the parity addition circuit 24 . Alternatively, it may be made on the recording/reproducing system side in order to enhance the efficiency of use of the transmission path 27 . In this case, the addition of an amble signal can be made by the parity addition circuit 33 . As for the embodiment shown in FIG. 4 , in the case where the addition of an amble signal is to be made on the recording/reproducing system side, the amble signal can be added by the modulation circuit 34 . In the case where the addition of an amble signal is made on the recording/reproducing system side, it is possible to enhance the efficiency of use of the transmission path 27 . On the other hand, in the case where the addition of an amble signal is made on the transmission signal processing system side, the lowering of the cost of a VTR can be attained as a great effect when a signal is sent to a multiplicity of VTR's simultaneously.
FIG. 5 shows a further embodiment of the present invention in which the further reduction of the circuit scale of a VTR on the receiving side and hence the further lowering of the cost can be attained in the case where a signal is sent to a multiplicity of VTR's simultaneously.
FIG. 5 is partially common to FIG. 1 , 2 or 4 . The parts in FIG. 5 common to those in FIG. 1 , 2 or 4 are denoted by the same reference numerals as those used in FIG. 1 , 2 or 4 and detailed explanation thereof will be omitted. In FIG. 5 , reference numeral 100 denotes a modulation circuit. The embodiment shown in FIG. 5 is based on a concept that a signal processing required upon a recording mode of a VTR is performed on the transmitting side. Namely, modulation adapted for magnetic recording/reproduction, for example, a signal processing corresponding to the modulation circuit 34 shown in FIG. 4 is performed on the transmission signal processing system side. After parities have been added by a parity addition circuit 24 of the transmission signal processing system, the modulation adapted for the magnetic recording/reproduction is performed by the modulation circuit 100 . Therefore, modulation adapted for transmission is performed by a modulation circuit 25 . As a modulation system employed by the modulation circuit 100 is suitable a system which does not cause the extension of a frequency band by modulation, for example, scrambled NRZ. A signal modulated by the modulation circuit 25 is transmitted to a transmission path 27 through a transmission circuit 26 in a manner to that in the embodiment shown in FIG. 1 .
The signal received by a reception circuit 30 through the transmission path 27 is inputted to a demodulation circuit 31 in which the signal is subjected to demodulation corresponding to the modulation circuit 25 . Since the signal demodulated by the demodulation circuit 31 is one which has already been subjected by the modulation circuit 10 to the modulation adapted for the magnetic recording/reproduction, the signal is recorded on a magnetic tape 40 by magnetic heads 41 and 42 as it is. As a result, the same recording as that in the embodiment shown in FIG. 4 is made. An operation upon reproduction is similar to that in the embodiment shown in FIG. 4 .
As apparent from the above, the present embodiment makes it possible to remarkably reduce the circuit scale of the VTR.
According to one of applications of the present invention, it is possible to transmit a signal from a transmission signal processing system to a multiplicity of VTR's through a transmission path simultaneously and at a high speed, as has already been mentioned. In this case, it is difficult to control a multiplicity of ‘VTR's simultaneously. Further, it is required to make a control which causes specified ones of the VTR's to perform recording operations and specified others of the VTR's not to perform recording operations. A technique for realizing such a control will be shown just below.
For the above purpose, control signals are transmitted prior to transmission of a signal to be recorded. One example of the control signals is shown in FIG. 6 . In the figure, reference numeral 110 denotes a synchronizing signal, numeral 111 an ID signal indicative of a control to be made, numeral 112 an address signal indicative of a VTR to be controlled, numeral 113 a control signal for bringing a VTR designated by the address signal 112 into a recording mode, numeral 114 a control signal for stopping the recording, numerals 115 and 116 blank signals, and numeral 120 a recording signal to be actually recorded.
The ID signal 111 indicating the transmission of the address signals 112 indicative of VTR's in which a signal is to be recorded, is transmitted at a predetermined position relative to the synchronizing signal 110 to bring each VTR into a standby condition. After all the address signals have been transmitted, the ID signal 113 is transmitted to start the recording of the signal 120 in the designated VTR's. After the signal 120 has been transmitted, the ID signal 114 to control the stop of recording is transmitted. Each of the blank signals 115 and 116 is a signal for conforming a signal transmission format to the other transmission signal and is therefore an insignificant signal portion.
In the embodiments shown in FIGS. 1 and 5 , those control signals are produced by a control signal generation circuit 130 and are transmitted with parities which are added by the parity addition circuit 24 for making correction for an error produced during transmission.
In the VTR shown in FIG. 1 , the control signals are detected by a control circuit 131 after the reception by the reception circuit 30 , the demodulation by the demodulation circuit 31 and the correction by the error correction circuit 32 for an error produced during transmission to make a control for the recording and the stop of recording in the recording/reproducing system.
In the case of the VTR's shown in FIGS. 4 and 5 , an output signal of the demodulation circuit 31 is inputted to the error correction circuit 61 for a need of making correction for an error produced during transmission and error-corrected control signals are inputted to a control circuit 131 . In a change-over circuit 132 , the terminal R side for selecting an output signal of the demodulation circuit 31 is selected upon recording and the terminal P side for selecting an output signal of the demodulation circuit 60 is selected upon reproduction.
As apparent from the foregoing, the present embodiment makes it possible to control a multiplicity of VTR's selectively and simultaneously.
Also, the use of the change-over circuit 132 and a memory circuit makes it possible to record a signal while monitoring it in the form of a picture having a reduced number of frames, as explained in conjunction with the embodiment shown in FIG. 2 .
Next, a still further embodiment of the present invention will be explained by use of FIG. 7 . In the figure, reference numeral 301 denotes an input terminal for standard analog video signal, numeral 302 an input terminal for standard digital video signal, numeral 303 an input terminal for high-speed digital video signal, numeral 305 a recording system mode change-over switch, numeral 306 a recording system change-over signal generation circuit, numeral 310 an A/D converter, numeral 320 a change-over circuit, numeral 330 a data compression circuit, numeral 340 a change-over circuit, numeral 350 a recording system signal processing circuit for performing a signal processing which includes addition of error correction code and modulation for recording, numeral 370 a cylinder, numeral 371 a magnetic tape, numerals 372 and 372 ′ magnetic heads, numeral 380 a reproducing system signal processing circuit for performing a signal processing which includes demodulation for reproduction, error detection and error correction. Numeral 390 a change-over circuit, numeral 400 a data expansion circuit, numeral 420 a D/A converter, numeral 431 an output terminal for standard analog video signal, numeral 432 an output terminal for standard digital video signal, numeral 433 an output terminal for high-speed digital video signal, numeral 435 a reproducing system mode change-over switch, and numeral 436 a reproducing system change-over signal generation circuit.
The present embodiment is an example of a digital magnetic recording/reproducing system which has recording modes of standard-speed recording and high-speed recording and reproduction modes of standard-speed reproduction and high-speed reproduction. FIG. 8 shows one example of the specification of input video signals.
Firstly, explanation will be made of standard-speed recording. A digital signal into which an analog video signal inputted from the input terminal 301 is converted by the A/D converter 310 or an equivalent digital signal which is inputted from the input terminal 302 , is switched or selected by the change-over circuit 320 , is subjected to a predetermined data compression processing by the data compression circuit 330 and is thereafter inputted to a terminal 340 a of the changeover circuit 340 . In the change-over circuit 340 , a change-over to connect the terminal 340 a and a terminal 340 c is made by a change-over signal from the recording system change-over signal generation circuit 306 . Thereby, the data-compressed signal is inputted to the recording system signal processing circuit 350 . In the recording system signal processing circuit 350 , a signal processing such as channel division, addition of error correction code and modulation for recording is performed at a predetermined processing clock adapted for the data-compressed signal. Thereafter, the signal is supplied to the magnetic heads 372 and 372 ′ mounted on the cylinder 370 so that it is recorded onto the magnetic tape 371 . The cylinder 370 and the magnetic tape 371 are controlled by a servo control circuit 360 . The servo control circuit 360 controls a cylinder motor and a capstan motor so as to provide a cylinder rotation speed and a tape speed for standard speed and so as to be synchronized with the input video signal.
Next, explanation will be made of high-speed recording. A high-speed digital video signal inputted from the input terminal 303 is sent to a terminal 340 b of the change-over circuit 340 . Since the high-speed digital video signal is a signal which has already been subjected to a data compression processing, it is not necessary to pass the signal through the data compression circuit 330 . A change-over to connect the terminal 340 b and the terminal 340 c is made by a change-over signal from the recording system change-over signal generation circuit 306 so that the high-speed digital video signal is inputted to the recording system signal processing circuit 350 . In the recording system signal processing circuit 350 , a signal processing similar to that in the case of the standard-speed recording is performed at a predetermined processing clock adapted for the high-speed digital video signal. Thereafter, the signal is supplied to the magnetic heads 372 and 372 ′ mounted on the cylinder 370 so that it is recorded onto the magnetic tape 371 . The cylinder 370 and the magnetic tape 371 are controlled by the servo control circuit 360 . The servo control circuit 360 control the cylinder motor and the capstan motor so as to provide a predetermined cylinder rotation speed and a predetermined tape speed and so as to be synchronized with the input video signal.
In the present invention, the recording onto the tape can be made with the quite same format in both the standard-speed recording and the high-speed recording, thereby making it possible to greatly shorten a recording time in the high-speed recording mode.
Next, explanation will be made of a signal processing upon reproduction. In the present embodiment, the recording pattern on the magnetic tape is the same whichever of the standard-speed recording and the high-speed recording is selected as a recording mode. Therefore, either standard-speed reproduction or high-speed reproduction can be selected irrespective of the recording mode.
Firstly, the standard-speed reproduction will be explained. The servo control circuit 360 controls the cylinder motor and the capstan motor so that a cylinder rotation speed and a tape speed for standard speed are provided. A signal reproduced by the magnetic heads 372 and 372 ′ is inputted to the reproducing system signal processing circuit 380 . In the reproducing system signal processing circuit 380 , a signal processing such as demodulation for reproduction, channel synthesis, error detection and error correction is performed at a predetermined processing clock adapted for the standard-speed reproduction. Thereafter, the signal is supplied to a terminal 390 a of the change-over circuit 390 . In the change-over circuit 390 , a changeover to connect the terminal 390 a and a terminal 390 c is made upon standard-speed reproduction by a change-over signal from the reproducing system change-over signal generation circuit 436 . Thereby, the reproduced signal is supplied to the data expansion circuit 400 . In the data expansion circuit 400 , a signal processing reverse to the data compression processing upon recording is performed so that the signal is restored to the original signal. Thereby, the original transmission rate is restored. The data-expanded reproduction signal is sent to the D/A converter 420 on one hand to be outputted as an analog video signal from the output terminal 431 after D/A conversion and is sent to the output terminal 432 on the other hand to be outputted as a digital video signal therefrom.
Next, explanation will be made of the high-speed reproduction. The servo control circuit 360 controls the cylinder motor and the capstan motor so that a predetermined cylinder rotation speed and a predetermined tape speed adapted for the high-speed reproduction are provided. A signal reproduced by the magnetic heads 372 and 372 ′ is inputted to the reproducing system signal processing circuit 380 . In the reproducing system signal processing circuit 380 , a signal processing such as demodulation for reproduction, channel synthesis, error detection and error correction is performed at a predetermined processing clocks adapted for the high-speed reproduction. Thereafter, the high-speed reproduction signal is supplied to the terminal 390 a of the change-over circuit 390 . In the change-over circuit 390 , a change-over to connect the terminal 390 a and a terminal 390 b is made upon high-speed reproduction. Thereby, the high-speed digital video signal is outputted from the output terminal 433 .
A furthermore embodiment of the present invention will be explained by use of FIG. 9 . The construction of the present embodiment is similar to that of the embodiment shown in FIG. 7 but is different therefrom in that the change-over circuit 340 is placed at a different position, the change-over circuit 390 used in FIG. 7 is eliminated and a change-over circuit 345 is newly added.
An input/output signal upon standard-speed recording/reproduction in the present embodiment is the same as that in the embodiment shown in FIG. 7 . As for high-speed recording and high-speed reproduction, however, the present embodiment is different from the embodiment of FIG. 7 in that the transmission of a high-speed digital video signal is made in the form of a recording format. Accordingly, upon high-speed recording, the high-speed digital video signal is not passed through a recording system signal processing circuit 350 but is recorded onto a tape through the change-over circuit 340 as it is. Upon high-speed reproduction, a reproduced signal is subjected to a signal processing for reproduction such as error detection and error correction by a reproducing system signal processing circuit 380 and is thereafter inputted to a terminal 345 b of the change-over circuit 345 . The signal supplied through the change-over circuit 345 to the recording system side signal processing circuit 350 is subjected to a signal processing for recording such as addition of error correction code and modulation for recording by the signal processing circuit 350 to form a recording format and is thereafter outputted as a high-speed digital video signal from an output terminal 433 .
The embodiments shown in FIGS. 7 and 9 have feature that high-speed recording and high-speed reproduction are possible. The best use of this feature can be made for dubbing or data communication with the result of effective shortening of a dubbing time, a data communication time or a data circuit line occupation time. Also, though those embodiments have been mentioned in conjunction with an example in which all of standard-speed recording, high-speed recording, standard-speed reproduction and high-speed reproduction modes are involved, it is not necessarily required to implement all of those modes. There may be considered an example in which only a necessary mode is provided in compliance with the purpose of use. FIG. 10 shows an embodiment in which a high-speed recording function is provided as a recording mode and at least a high-speed reproduction function is provided as a reproduction mode. Also, there may be considered an embodiment as a system for the exclusive use for reproduction in which at least a high-speed reproduction function is provided, as shown in FIG. 11 . Further, FIG. 12 shows an embodiment in which a high-speed recording function is provided as a recording mode and a standard-speed reproduction function is provided as a reproduction mode.
FIG. 13 is a block diagram of one example of the magnetic recording/reproducing system of the embodiment of FIG. 7 for explaining processings subsequent to the compression processing. In FIG. 13 , reference numeral 201 denotes a synchronization detection circuit, numeral 204 a recording modulation circuit, numeral 205 a cylinder servo control circuit, numeral 206 a capstan servo (or tape speed) control circuit, numeral 207 a reproduction reference signal generation circuit, numeral 210 a demodulation circuit, numeral 211 a cylinder, numeral 212 a pair of recording heads, numeral 213 a pair of reproducing heads, numeral 214 a capstan which controls the tape speed, numeral 215 a magnetic tape, numeral 216 a delivery reel, and numeral 217 a take-up reel. FIG. 14 is a timing chart of input and output signals in the example shown in FIG. 13 and schematically illustrate a compressed picture signal 251 which is an input signal, a synchronizing signal 252 of the picture signal, a standard-speed reproduction signal 255 which is an output signal, and a reproduction synchronizing signal 256 .
In the shown example, n-tuple speed recording is realized by making a tape speed and a cylinder rotation speed upon recording n times as high as those upon standard-speed reproduction. As shown in FIG. 14 , the compressed video signal as an input signal of the circuit shown in FIG. 13 and the synchronizing signal include information 251 for n pictures and n synchronizing pulses 252 synchronous therewith in a time when one picture is reproduced at a standard speed. The picture information is converted into a predetermined recording format by the recording modulation circuit 204 and is recorded onto the magnetic tape 215 by the recording heads 212 . At this time, a synchronizing signal for the cylinder servo control circuit 205 and the capstan-servo control circuit 206 is increased by n times in compliance with the n-tuple speed video signal, as shown by 252 in FIG. 14 , so that the rotation speed of the cylinder 211 and the feed speed of the magnetic tape 215 are increased by n times. Thereby, the recording onto the tape can be made with the quite same recording format as that in the case of the standard-speed recording. Upon reproduction, a synchronizing signal for the cylinder servo control circuit 205 and the capstan servo control circuit 206 is supplied from the reproduction reference signal generation circuit 207 to restore the cylinder rotation speed and the tape feed speed to those upon standard-speed reproduction, and a signal read by the reproducing heads 213 is demodulated by the demodulation circuit 210 and is outputted therefrom. In the circuit shown in FIG. 13 , if the input video signal and the synchronizing signal are ones of standard speed, standard-speed recording is possible. Also, n-tuple speed reproduction is possible if the frequency of an output signal from the reproduction reference signal generation circuit is increased by n times.
FIG. 15 is a block diagram of another example of the magnetic recording/reproducing system of the embodiment of FIG. 7 for explaining processings subsequent to the compression processing. FIG. 16 is a timing chart of input and output signals in the example shown in FIG. 15 . In FIG. 15 , the same reference numerals as those used in FIG. 13 denote the same or equivalent components as or to those shown in FIG. 13 . In FIG. 15 , reference numeral 202 denotes a ÷m circuit, numeral 203 recording system memories, numeral 208 a ÷m circuit, and numeral 209 reproducing system memories. In FIG. 16 , the same reference numerals as those used in FIG. 14 denote the same or equivalent signals as or to those shown in FIG. 14 . In FIG. 16 , reference numeral 253 denotes outputs of the recording system memories 203 and numeral 254 denotes an output of the ÷m circuit 208 or a synchronizing signal divided by m .
The embodiment shown in FIG. 15 is an example in which m pairs of recording heads are used to simultaneously record magnetic signals for m pictures on m tracks, thereby realizing high-speed recording while suppressing an increase in the cylinder rotation speed. Upon reproduction, m pairs of reproducing heads are used. Though FIG. 15 shows the case where two pairs of recording heads 212 are used to simultaneously record information for two pictures on two tracks, three or more pairs of heads can be used in a similar manner.
FIG. 17 is a table showing some examples of the tape speed and the cylinder rotation speed (rpm) in the embodiments shown in FIGS. 13 and 15 . In the table, high-speed recording or reproduction at a speed ten times as high as the standard speed is shown by way of example. Design for implementing another high-speed recording or reproduction is similarly possible. In the table shown in FIG. 17 , examples {circle around (1)}, {circle around (2)} and {circle around (3)} correspond to the embodiment shown in FIG. 13 and examples {circle around (4)} and {circle around (5)} correspond to the embodiment shown in FIG. 15 .
A still furthermore embodiment of a digital signal recording/reproducing system of the present invention will be explained by use of a block diagram shown in FIG. 18 .
In FIG. 18 , reference numeral 501 denotes a signal input terminal to which a plurality of video signals are inputted in a time-division multiplex form, numeral 502 a recording selection signal-input terminal to which a recording selection signal for selecting one or plural signals to be recorded from the multiplexed input signal is inputted, numeral 503 a recording signal selection circuit for selecting the signals to be recorded from the multiplexed input signal in accordance with the recording selection signal from the input terminal 502 , numeral 504 a recording signal processing circuit for subjecting the selected signals to a digital processing for recording onto a recording medium, numerals 505 and 505 ′ magnetic heads, numeral 506 a rotating drum, numeral 507 a magnetic tape or the recording medium, numeral 508 a servo circuit for controlling the rotation of the drum 506 and the travel of the tape 507 , numeral 511 a reproduction selection signal input terminal to which a reproduction selection signal for selecting one or plural signals to be outputted as a reproduction signal from among the multiple-recorded and reproduced signals is inputted, numeral 509 a reproduction signal selection circuit for selecting the signals to be outputted as a reproduction signal from among the multiple-recorded and reproduced signals in accordance with the reproduction selection signal from the input terminal 511 , numeral 510 a reproduction signal processing circuit for subjecting the selected signals to a digital processing, and numeral 512 a reproduction signal output terminal.
The time-division multiplexed input video signal from the signal input terminal 501 is supplied to the recording signal selection circuit 503 . The recording signal selection circuit 503 is also supplied with the recording selection signal from the recording selection signal input terminal 502 to make the selection of signals to be recorded. For example, in the case where six kinds of video signals A, B, C, D, E and F are inputted in a time-division multiplex form as shown in (a) of FIG. 19 and four signals A, B, C and D thereof are to be selected and recorded, an output of the recording signal selection circuit 503 is as shown in (b) of FIG. 19 . Such an output signal of the recording signal selection circuit 503 is inputted to the recording signal processing circuit 504 which in turn performs a signal processing for recording such as addition of error correction code. Also, the recording signal selection circuit 503 produces a speed control signal on the basis of the number of signals in the time-division multiplexed input video signal, the transmission rate of the input signal and the number of signals to be recorded which are selected by the recording selection signal. The speed control signal is supplied to the recording signal processing circuit 504 and the servo circuit 508 . For example, in the case where the input video signal is time-division multiplexed to sextuplet with each of six signals in the multiplexed input signal being transmitted at a rate time-base compressed to ⅙ and four signals among the six signals in the multiplexed input signal are to be selectively recorded, a signal indicative of a quadruple speed is produced as the speed control signal. Also, in the case where the input video signal is time-division multiplexed to sextuplet with each of six signals in the multiplexed input signal being transmitted at a rate time-base compressed to 1/12 and four signals among the six signals in the multiplexed input signal are to be selectively recorded, a signal indicative of a octuple speed is produced as the speed control signal. Namely, in the case where an input signal is multiplexed to N-plet, the compression rate of each of the N signals in the multiplexed input signal is 1/K and the number of signals to be selectively recorded is L, a speed control signal indicative of an (L×K)/N-tuple speed is produced. The operating speed of the recording signal processing circuit 504 which processes a signal from the recording signal selection circuit 503 , is changed in accordance with the speed control signal. For example, in the case of a speed control signal indicative of a quadruple speed, the recording signal processing circuit 504 performs a signal processing at a speed four times as high as a normal speed and supplies the processed signal to the magnetic heads 505 and 505 ′. Here, for example, in the case where the input video signal is time-division multiplexed to sextuplet with each of the six signals in the multiplexed input signal being transmitted at a rate time-base compressed to ⅙ and a speed control signal indicative of a quadruple speed is used to selectively record four signals from among the six signals, the speed of an input signal inputted to the recording signal processing circuit 504 is four times as high as that of one video signal having a normal speed and the recording signal processing circuit 504 processes this quadruple-speed input signal at a quadruple speed and supplies the processed signal to the magnetic heads, thereby making it possible to record all of the four selected signals. Also, if the recording signal selection circuit 503 is constructed so that signals to be selectively recorded are sequentially changed for every one track on the tape, compatibility can be held in regard to the number of signals to be selectively recorded and a processing speed by causing the recording signal processing circuit 504 to perform a completed processing for every one track. In the following, explanation will be made in conjunction with the case where each video signal is recorded in such a form completed for every track. However, it should be noted in advance that the present invention is applicable to another recording system, for example, a system in which signals are recorded in a form changed for every pixel, line or field. On the other hand, the servo circuit 508 supplied with the speed control signal indicative of the quadruple speed controls the rotation speed of the rotating drum 506 so that it becomes four times as high as a normal speed and the travel speed of the magnetic tape 507 so that it becomes four times as high as a normal speed. Thereby, four signals A, B, C and D are alternately recorded on successive tracks of the magnetic tape 507 , as shown in FIG. 20 . According to the control mentioned above, the pattern of recording tracks on the tape becomes the same irrespective of the number of signals in the multiplexed input signal, the transmission rate of each signal and the number of signals to be selectively recorded. In order to make a control upon reproduction easy, it is preferable that the number of selectively recorded signals and the identification codes or signal numbers thereof (for example, A, B, C and D or 0, 1, 2 and 3) are recorded as an ID signal for every track.
In the above example, the recording of the time-division multiplexed signal has been mentioned. However, it is needless to say that the present invention is also applicable to the case where the number of multipet signal components in an input video signal is 1 or the input video signal is not multiplexed. In such a case, since the recording signal processing circuit 504 and the servo circuit 508 operate at speeds proportional to the transmission rate of the input video signal, an effect is manifested, for example, in high-speed dubbing. As apparent from the foregoing explanation of the operation, it is of course that a multiplexed signal can be recorded at a high speed.
Upon reproduction, a signal reproduced from the magnetic tape 507 by the magnetic heads 505 and 505 ′ mounted on the rotating drum 506 is inputted to the reproduction signal selection circuit 509 . The reproduction signal selection circuit 509 produces a speed control signal, for example, by detecting the number of multiple-recorded signals from the ID signal included in the reproduced signal and sends the speed control signal to the servo circuit 508 . The speed control signal is a signal indicative of a speed four times as high as the normal reproduction speed in the case where the number of multiple-recorded signals is 4 and a signal indicative of a sextuple speed in the case where it is 6. In the case of the quadruple speed, the servo control circuit 508 supplied with the speed control signal indicative of the quadruple speed controls the rotation speed of the rotating drum 506 so that it becomes four times as high as a normal speed and the travel speed of the magnetic tape 7 so that it becomes four times as high as a normal speed. Thereby, there can be traced all of signals recorded so that the recording track pattern on the tape becomes the same irrespective of the number of signals to be selectively recorded. In a system which has not a signal indicative of the number of selectively recorded signals, there may be employed a method in which the speed control signal is manually set. In a system in which the number of signals to be recorded on the tape is fixed, the speed control signal has a fixed value. The reproduction signal selection circuit 509 receives a reproduction selection signal inputted from the reproduction selection signal input terminal 511 to select a desired signal(s) from among the signals reproduced by the magnetic heads 505 and 505 ′ and to output the selected signal as a reproduction signal to the reproduction signal processing circuit 510 . The reproduction signal selection circuit 509 also outputs a selection number signal indicative of the number of selected signals to the reproduction signal processing circuit 510 .
The reproduction signal processing circuit 510 performs a signal processing such as code error correction processing and picture signal processing for the reproduction signal at a processing speed corresponding, to the selection number signal and outputs the processed reproduction signal from the output terminal 512 . For example, in the case where the number indicated by the selection number signal is 2, the signal processing speed is two times as high as a normal speed and various processings are performed for each selected signal. For example, in the case where signals A and C are selected, the signals A and C are outputted alternately for each field. In the case where the number indicated by the selection number signal is 1, for example, when the reproduction selection signal from the reproduction selection signal input terminal 511 selects only the signal C, the reproduction signal processing circuit 510 performs the signal processing at the normal speed to output the signal as reproduced at a normal speed. As apparent from the above, the present embodiment makes it possible to simultaneously record any number of signals selected from among a plurality of signals in a multiplexed video signal and to simultaneously reproduce any number of signals from among the recorded signals.
In the case where a plurality of signals are simultaneously reproduced, a construction for outputting the reproduced signals from separate output terminals simultaneously and in parallel may be employed, particularly, in the case of an analog output, as a method other than the construction in which the plurality of reproduced signals are outputted in a time-division multiplex form, as mentioned above. Though in the above-mentioned example the reproduction signal is outputted at a reproduction speed for a usual video signal, the transmission rate of the reproduction signal may be made higher than the reproduction speed for the usual video signal in order to transmit the reproduction signal to another system in an analog or digital signal form at a high rate or to perform high-speed dubbing which is one of effects of the present embodiment. This can be realized in such a manner that the fundamental operating speed of there producing system is set to be higher than a normal reproduction speed and the operating speeds of the servo circuit 508 , the reproduction signal selection circuit 509 and the reproduction signal processing circuit 510 are changed in accordance with the number of multiple-recorded signals and/or the number of signals to be outputted as a reproduction signal with the above fundamental speed being the standard. If the transmission rate of a reproduction signal is made variable so that a rate adapted for a transmission path to which the reproduction signal is to be connected or the performance or function of a recorder by which the reproduction signal is to be recorded, can be selected.
As mentioned above, according to the present embodiment, it is possible to simultaneously record any number of signals selected from among a plurality of signals in a multiplexed video signal and to reproduce any number of signals from among the recorded signals at any speed. Also, in the case where a plurality of signals are selected and reproduced and the plurality of reproduced signals are simultaneously outputted in a time-division multiplex form or from separate output terminals in parallel, it is possible to arbitrarily set the transmission rate of an output signal.
The present embodiment has been explained in conjunction With the case where the present invention is applied to a helical-scan digital-recording VTR. It is of course that a similar effect can be obtained in the case where the present invention is applied to a fixed head VTR. The fixed head system is convenient for the structuring of a system since it has a higher degree of freedom for the setting of the units of division of a signal subjected to time-division multiple recording as compared with the helical scan system. Also, it is of course that the present invention is applicable to a recording/reproducing equipment other than the VTR or is applicable to a digital signal processing and analog recording system.
The present invention can be applied to not only the case where an input signal is time-division multiplexed, as mentioned above, but also the case where a plurality of signals are inputted simultaneously and in parallel. In the latter case, the recording signal selection circuit 503 is constructed to receive the input signals in parallel.
As has been mentioned in the foregoing, according to the present invention, it is possible to realize a digital VTR in which high-speed recording onto a tape can be made with the same format as that used in standard-speed reproduction. Further, there can be realized a transmission signal processing for transmitting at a high rate a video signal to be recorded by such a digital VTR. Also, in the case where a signal transmitted from the transmission signal processing system is to be recorded by a multiplicity of VTR's, it is possible to designate those ones of the multiplicity of VrR's by which recording is to be made and to make a control of the start/stop of recording.
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A transmitting apparatus and method for transmitting a digital signal in which a time-base compressor compresses the digital signal, a bit compressor compresses the time-base compressed signal from the time-base so that a transmission rate of the time-base compressed signal from the time-base compressor is higher than a transmission rate of the bit-compressed signal from the bit-compressor, and a transmitter transmits the bit compressed signal.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the present invention relate generally to processes for producing heavy oil. Various embodiments of the present invention are particularly useful in producing heavy oil emulsions that can be used in boilers in steam assisted gravity drainage (SAGD) processes for recovering heavy oil.
2. Description of the Related Art
Heavy oil is naturally formed oil with very high viscosity but often contains impurities such as sulfur. While conventional light oil has viscosities ranging from about 0.5 centipoise (cP) to about 100 cP, heavy oil has a viscosity that ranges from 100 cP to over 1,000,000 cP. Heavy oil reserves are estimated to equal about fifteen percent of the total remaining oil resources in the world. In the United States alone, heavy oil resources are estimated at about 30.5 billion barrels and heavy oil production accounts for a substantial portion of domestic oil production. For example, in California alone, heavy oil production accounts for over sixty percent of the states total oil production. With reserves of conventional light oil becoming more difficult to find, improved methods of heavy oil extractions have become more important. Unfortunately, heavy oil is typically expensive to extract and recovery is much slower and less complete than for lighter oil reserves. Therefore, there is a compelling need to develop a more efficient and effective means for extracting heavy oil.
Heavy oil that is too deep to be mined from the surface may be heated with hot fluids or steam to reduce the viscosity sufficiently for recovery by production wells. One thermal method, known as steam assisted gravity drainage (SAGD), provides for steam injection and oil production to be carried out through separate wells. The optimal configuration is an injector well which is substantially parallel to and situated above a producer well, which lies horizontally near the bottom of the formation. Thermal communication between the two wells is established by preheating the area between and around the injector well and producer well. Generally, such preheating is by steam circulation until the reservoir temperature between the injector and producer wellbore is at a temperature sufficient to drop the viscosity of the heavy oil so that it has sufficient mobility to flow to and be extracted through the producer well. Typically, preheating involves introducing steam through both the injector well and producer well. Steam circulation through the injector well and producer well will occur over a period of time. At some point before the circulation period ends, the temperature midway between the injector and producer will reach about 80 to 100° C. and the heavy oil will become movable (3000 cP or less). Once this occurs, the steam circulation rate for the producer well will be gradually reduced while the steam rate for the injector well will be maintained or increased. This imposes a pressure gradient from high, for the area around the injector well, to low, for the area around the producer well. With the oil viscosity low enough to move and the imposed pressure differential between the injection and production wellbores, steam (usually condensed to hot water) starts to flow from the injector into the producer. As the steam rate is continued to be adjusted downward in the producer well and upward in the injector well, the system arrives at steam assisted gravity drainage operation with no steam injection through the producer well and all the steam injection through the injector well. Once hydraulic communication is established between the pair of injector and producer wells, steam injection in the upper well and liquid production from the lower well can proceed. Due to gravity effects, the steam vapor tends to rise and develop a steam chamber at the top of the region being heated. The process is operated so that the liquid/vapor interface is maintained between the injector and producer wells to form a steam trap which prevents live steam from being produced through the producer well.
Once the formation has been preheated, SAGD operation can commence. In operation of the SAGD process, steam will come into contact with the heavy oil in the formation and, thus, heat the heavy oil and increase its mobility by lessening its viscosity. Heated heavy oil will tend to flow downward by gravity and collect around the producer well. Heated heavy oil is produced through the producer well as it collects. Steam contacting the heavy oil will lose heat and tend to condense into water. The water will also tend to flow downward toward the producer well and is produced with the heavy oil. Such produced water may be treated to reduce impurities and reheated in the boiler for subsequent injection.
Steam-based heavy oil recovery processes, such as SAGD processes described above, are most likely to burn natural gas as the fuel of choice to produce high-pressure steam for bitumen recovery. Steam requirements for such processes are on the order of two to five times as much steam as recovered oil. Thus, the cost of producing steam is one of the greatest operating expenses of recovery; the overall cost is greatly affected by the price of fuel used in producing steam. Thus, the use of natural gas as a fuel for producing steam reduces operating cost when the price of natural gas is low but these costs will increase proportionally as the price of natural gas increases. As a result, interest in alternative fuels is particularly kindled when the price of natural gas increases.
SUMMARY
In one embodiment of the present invention, there is provided a process for producing heavy oil from a subterranean region comprising withdrawing a heavy oil and water mixture from the subterranean region; separating at least a portion of the water from the heavy oil and water mixture to provide a first stream that contains the majority of the heavy oil from the heavy oil and water mixture and a second stream containing the portion of the water separated from the heavy oil and water mixture; emulsifying at least a portion of the first stream with a caustic and a surfactant and sufficient water, if any, from the second stream to produce an emulsified stream at the desired water content; introducing the emulsified stream as a fuel for a boiler to heat water and produce steam; and injecting the thus produced steam into the subterranean region.
In another embodiment of the present invention, there is provided a process for producing heavy oil from a subterranean region comprising: withdrawing a heavy oil and water mixture from the subterranean region; heating the heavy oil and water mixture; separating at least a portion of the water from the heavy oil and water mixture to provide a first stream that contains a majority of the heavy oil from the heavy oil and water mixture and a second stream containing the portion of the water separated from the heavy oil and water mixture; introducing a water stream into a boiler; splitting the first stream into a third stream and a fourth stream; adding a caustic to the fourth stream and sufficient water, if any, from the second stream to produce an emulsion at the desired water content, and emulsifying the thus resulting mixture to produce an emulsified stream; introducing the emulsified stream as a fuel for the boiler to thus heat the water stream and to produce steam; and injecting the thus produced steam into the subterranean region.
In still another embodiment of the present invention, there is provided the above processes where the water separated from the heavy oil and water mixture is heated in the boiler to produce steam and the steam is injected into the subterranean region to enhance heavy oil production.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 is a schematic illustration of a process in accordance with the current invention;
FIG. 2 is a phase diagram illustrating the results for a caustic used as an emulsifying agent for heavy oil in water containing salt;
FIG. 3 is a phase diagram illustrating the results for a surfactant used as an emulsifying agent for heavy oil in water containing salt;
FIG. 4 is a phase diagram illustrating the results for a surfactant and a caustic used as emulsifying agents for heavy oil in water containing salt;
FIG. 5 illustrates the stability of emulsified heavy oil in water where a caustic is the emulsifying agent both alone and with a surfactant.
NOTATION AND NOMENCLATURE
As used herein, the terms “a,” “an,” “the,” and “said” means one or more.
As used herein, the term “and/or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.
As used herein, the terms “comprising,” “comprises,” and “comprise” are open-ended transition terms used to transition from a subject recited before the term to one or elements recited after the term, where the element or elements listed after the transition term are not necessarily the only elements that make up of the subject.
As used herein, the terms “containing,” “contains,” and “contain” have the same open-ended meaning as “comprising,” “comprises,” and “comprise,” provided below.
As used herein, the terms “having,” “has,” and “have” have the same open-ended meaning as “comprising,” “comprises,” and “comprise,” provided above
As used herein, the terms “including,” “includes,” and “include” have the same open-ended meaning as “comprising,” “comprises,” and “comprise,” provided above.
As used herein, the term “heavy oil” means hydrocarbons having a viscosity from 100 cP to over 1,000,000 cP and generally includes bitumens, asphalts and tars.
As used herein, the term “oil-in-water emulsion” refers to a mixture that has a water continuous phase that contains droplets of oil.
As used herein, the term salt means primarily NaCl, but includes chlorides, carbonates, bicarbonates, bromides, sulfites, sulfates, and other anion species occurring in SAGD recycle water, along with any number of elemental cations, especially Na.
As used herein, the term “steam” refers to H 2 O in a gaseous state.
As used herein, the term “water” refers to H 2 O in a liquid state.
As used herein, the term “water-in-oil emulsion” refers to a mixture that has an oil continuous phase that contains droplets of water.
DETAILED DESCRIPTION
The following detailed description of various embodiments of the invention references the accompanying drawings which illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
Turning now to FIG. 1 , an embodiment of a process in accordance with the current invention is illustrated. A heavy oil and water mixture are extracted from a hydrocarbon reservoir contained in a subterranean region (illustrated as Box 8 ). Preferably, the heavy oil and water mixture has a viscosity below 50 cp and more preferably to below 15 cp. Generally, this will bring the heavy oil temperature into the range of about 110° C. to 180° C. depending on its viscosity, hydrocarbon components and added diluent. If necessary, the heavy oil and water mixture may be heated to reduce its viscosity.
The heavy oil and water mixture having a suitable viscosity, as described above, is transferred to separation vessel 16 through conduit 14 . Within separation vessel 16 , the heavy oil and water are allowed to separate in separation vessel 16 . Separation vessel 16 can be any suitable separation system for separating oil and water, such as a free water knock-out vessel for removal of free water followed by a treater vessel system comprising adding demulsifier chemicals, static or powered mixing and a treater vessel for a separation of water and oil. Separation vessel 16 will generally be about 130° C. at a pressure at least sufficient to keep the water phase liquid but may be 110° C. to 180° C. at a pressure at least sufficient to keep the water phase liquid. The water separated from the heavy oil is taken off through conduit 18 and the remaining heavy oil mixture is taken off through conduit 20 . The heavy oil and water mixture entering separation vessel 16 will generally have a water content of greater than 40% by volume and more typically will be about 60% to 85% water by volume, not including any added diluent. The heavy oil mixture exiting separation vessel 16 through conduit 20 will generally have a water content of 40% or less by volume and preferably the water content will be from 20% to 40% by volume in order to achieve a suitable oil-in-water emulsion. If the water content is too low, then water may be added as described below.
The water exiting separation vessel 16 will contain impurities, most notably NaCl but others such as other salts, solids, silica and sand-related compounds and hydrocarbons. The water will generally be introduced by conduit 18 into a water treatment vessel 22 . Optionally, a slipstream 12 could be removed from conduit 18 and supply water to the heavy oil in conduit 32 or emulsification unit 38 if more water is needed for emulsifying the bitumen. While it is desirable to treat the water to remove impurities, especially the more corrosive ones it is an advantage of this invention that need to remove the salt will we reduced or even eliminated. While the current invention will operate with water having lower salt content, it is also operable with the water having salt content greater than 4000 ppm. This advantage is two fold. The need to treat water supplied through conduit 12 is reduced or eliminated because the emulsions produced according to the current process are resistant to deterious effects of salt. Additionally, the necessity of treatment for water entering boiler 28 is reduced because of its reintroduction downhole.
Water coming from water treatment vessel 22 is introduced to boiler 28 through conduit 24 . Within boiler 28 , the water is heated to produce steam. The steam is then reintroduced to the hydrocarbon reservoir through conduit 30 for use in a SAGD type process. In addition to the water coming from water treatment vessel 22 , make up water can be introduced into conduit 24 and, hence, boiler 28 through conduit 26 . Optionally, instead of recycling water from water treatment vessel 22 to the boiler 28 , all the water for the boiler can be supplied through conduit 26 . However, this eliminates the benefit of recycling the water recovered from the reservoir.
The heavy oil mixture in conduit 20 is further processed and transferred to a pipeline or another transportation media. A portion of the heavy oil mixture is separate off from conduit 20 into conduit 32 . Surfactants 34 and caustic 36 are introduced into the heavy oil mixture along with additional water from conduit 12 , if necessary, to achieve the desired emulsion water content, and the combined stream is introduced into emulsification unit 38 . Suitable emulsification units are known in the industry such as static mixers, pressure drop devices, powered mixers in pipes or vessels, and combinations of these techniques. Within the emulsification unit 38 , the combined stream is treated to emulsify the heavy oil in the water. It is important that the conditions be sufficient to create an emulsion that is substantially an oil-in-water emulsion rather than a water-in-oil emulsion or a mixture of oil-in-water emulsions and water-in-oil emulsions. As illustrated in the examples below, sufficient surfactant and caustic should be added to ensure an oil-in-water emulsion is created.
It is an advantage of the current invention that the use of caustic increases the ability to form suitable emulsions in the presence of salt; thus, limiting the need to treat the heavy oil mixture or water to remove salt. Additionally, it has been found that the presence of group IIA ions, such as calcium and magnesium are undesirable and tend to make the emulsification more strongly favor the production of water-in-oil emulsions. Accordingly, the concentration of group IIA metal ions in the heavy oil stream going to emulsification unit 38 should be less than 250 ppm and more preferable less than 30 ppm.
The heavy oil emulsion removed from emulsification unit 38 should have an average droplet size of less than 20 microns. It has been discovered that suitable droplet size can be achieved for emulsions using caustic only or caustic and surfactant.
The heavy oil emulsion is removed from emulsification unit 38 through conduit 40 and introduce into boiler 28 . Within boiler 28 the heavy oil emulsion is burned as fuel to generate heat to heat water introduced into the boiler through conduit 24 .
Suitable caustics for use in making the heavy oil emulsion include, but are not limited to, NaOH, KOH, and NH 4 OH.
Suitable surfactants for us in making the heavy oil emulsions may be chosen from non-ionic, anionic, cationic, amphoteric surfactant and mixtures of one or more thereof. It is presently preferred to use non-ionic surfactants. In particular, it is preferred to use one or more non-ionic surfactants chosen from the following:
Polyethylene glycol sorbitan monolaurate; Polyoxyethylenesorbitan monopalmitate; Polyethylene glycol sorbitan monostearate; polyoxyethylenesorbitan monooleate; Polyoxyethylenesorbitan trioleate; Octylphenoxypolyethoxyethanol; tert-Octylphenoxy Polyethyl Alcohol; Polyoxyethylene(30) octylphenyl ether; tert-Octylphenoxy Polyethyl Alcohol; Polyethylene glycol tert-octylphenylether; Polyethylene glycol tert-octylphenyl ether; Polyoxyethylene(23) lauryl ether; Polyethylene glycol hexadecyl ether; Polyethylene glycol oxtadecyl ether; Polyoxyetehylene(20) oleyl ether; jklPolyoxyethylene(100) stearyl ether; Polyoxyethylene (12) isooctylphenyl ether; Polyoxyethylene(40) nonylphenylether; and Polyoxyethylene(150) dinonylphenyl ether.
EXAMPLES
All of the emulsions in these examples were made in a Waring Blender Model 30-60. The blender was mounted in a stand along with a controller both made by Chandler Engineering. The rig in total was designated as a Chandler Model 3060-110V Mixer. The blender set-up uses open-top SS mixing cups with about 200-250 ml volume and a ‘chop’ style propeller in the bottom.
Samples of bitumen were weighed into the mixing cups and placed in a temperature-controlled hot water bath, normally at 80° C. The surfactants and salt amounts were added to the pre-weighed water and mixed before addition on top of the bitumen in the mixing cup. A watch glass was placed over the mixing cup to minimize the evaporative water loss. The mixing cups were allowed to stand in the heating bath for 30 minutes before placing them in the Chandler Mixing Stand and spinning them, usually at 6000 rpm for 20 seconds. The emulsions were allowed to cool down for about 2 hours before making qualitative observations. Occasionally, microscope pictures were taken to verify the emulsion and the droplet size. Sometimes a particle size measurement was taken on a Malvert Instrument after the samples were diluted 100:1 with water.
1. Making Oil-in-Water Emulsions
The following conditions were met for making the oil-in-water emulsion.
Temperature:
Sufficient for oil viscosity <1000 cp (80° C.
was used for most of these bitumen runs)
Mixer Speed:
3000 rpm minimum 6000 rpm normally using a 2.5″
‘chop’ blade in 200 ml Waring Open-Top Mixing Cup
Mixing Time:
5 seconds minimum, normally 20 seconds
Water Content:
30 wt-% preferred for emulsion viscosity and stability,
20% minimum
Surfactant:
Caustic:
50-100% of the TAN titration value
for up to 4,000 ppm NaCl water
Non-ionic
2000-3000 ppm for up to at least
surfactant:
10,000 ppm NaCl water
Various combinations of caustic and
non-ionic surfactant depending on
saltwater.
2. Properties of the Oil-in-Water Emulsions
Almost all of the emulsions made by the above technique had an average droplet size, or Dp50, of 6-10 microns with a Dp10 of 3-5 microns and a Dp90 of 15-35 microns.
The viscosity of the oil-in-water emulsions is highly dependent on the water content of the emulsion, but with 30 wt-% water, an emulsion with a temperature in the range of 30° C. to 70° C. flows freely into a burner tip. A water content of 25% could be used if the emulsion temperature was about 40° C. to 80° C. Velocity ranges were dependent on obtaining temperatures high enough to sufficiently lower the viscosity without being so high that the emulsion would break down.
The emulsions were stable for at least 3 weeks without breaking into two phases though some gentle stirring was necessary to re-mix a think layer of water on top of the emulsion. The average particle size over the 3 week period increased only by 1 micron (see FIG. 5 ) which indicated good stability for the short times necessary for on-site combustion in accordance with the current invention.
Example 1
A bitumen sample having a Total Acid Number (TAN) of 2.6 (2.6 mg of KOH were required to neutralize the acid species in 1.0 g of the bitumen) was utilized.
Emulsions were made utilizing various concentrations of salt in the water. The ability of the various caustics to make emulsions in the presence of salt was tested. The caustics tested were NaOH, KOH, and NH 4 OH.
A phase diagram illustrating the results for NaOH is shown in FIG. 2 . As illustrated in the diagram NaOH can make emulsions up to approximately 4000 ppm salt in water.
KOH was similarly tested and the results indicated that KOH could make oil-in-water emulsions up to 5500 ppm salt in water.
NH 4 OH was similarly tested and the results illustrated that NH 4 OH made oil-in-water emulsions with pure water but did not make them with 4000 ppm salt water.
Example 2
Various commercial surfactants were tested utilizing various concentrations of salt in the water. Emulsions were made with and without caustics. The results indicated that the presence of the caustic did not lower the amount of surfactant necessary to make an oil-in-water emulsion but that the caustic made the emulsion more stable and less likely to separate into two phases over time.
Exemplary results can be seen in FIGS. 3 , 4 and 5 which show the results for the surfactant polyethylene glycol sorbitan monolaurate (PGSM). FIG. 3 is a phase diagram for emulsions made using PGSM and no caustic versus various concentrations of salt. FIG. 4 is a similar phase diagram for emulsions made using PGSM and caustic. FIG. 5 illustrates the stability of emulsions made with PGSM and caustic and with caustic alone. The emulsions in FIG. 5 were prepared from 0.06 g NaOH in 100 g total solution (70 g heavy oil and 30 g water) and contained 3000 ppm PGSM. The amount of caustic added equated to 46% of the heavy oil's TAN value.
The preferred forms of the invention described above are to be used as illustration only, and should not be used in a limiting sense to interpret the scope of the present invention. Modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention.
The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as it pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.
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A process for emulsifying and burning a portion of heavy oil extracted from an underground reservoir, wherein the emulsified heavy oil is burned to generate steam and a caustic is used to aid in emulsifying the heavy oil.
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TECHNICAL FIELD OF THE INVENTION
This invention relates to a connecting structure of concrete blocks and a connecting method therefor such as precast concrete (hereinafter called as "PC") member, and the like.
DESCRIPTION OF THE RELATED ART
In recent years, some concrete blocks such as PC member and the like have been frequently used in order to provide a labour saving in work as well as a rationalization in dwellings or buildings, other constructions and civil engineering and the like. And further various connecting structures and connecting methods therefor have been developed in respect to the connection of these concrete blocks.
As disclosed in the gazette of Japanese Utility Model Laid-Open No. Sho 62-159598 (hereinafter called as "(a)") and the gazette of Japanese Utility Model Publication No. Hei 2-23663 (hereinafter called as "(b)"), the connection of the PC members in the prior art has been performed in the step of (1) connecting the PC members from each other with bolts, or (2) welding the fittings fixed to the connecting surfaces of the PC members from each other, or (3) welding the connecting iron bars projected from the connecting surfaces of the PC members to each other, thereafter filling with mortar or adhesive agent and the like between their connected parts.
In addition, as indicated in the gazette of Japanese Utility Model Publication No. Hei 2-7995 (hereinafter called as "(c)"), the connecting structure in which the concrete blocks such as PC member and the like are connecting to each other with adhesive agent by applying the connector is disclosed as "the connecting structure of concrete blocks comprising a main body of concrete structure and a sub-body of concrete structure connected to the main body characterized in that some pin insertion holes of frustum of circular cone having an inner diameter slightly larger than an outer diameter of the insertion pin are formed at the predetermined locations at the connecting surface of the main body, through-pass holes of inverse frustum of circular cone having the same diameter as that of the pin insertion hole and extending coaxially are formed the locations at the connecting surface of the sub-body corresponding to the pin insertion holes, some pins are inserted from the through-pass holes over the main body and the sub-body and at the same time coupling material is filled around the pins." As indicated in the gazette of Japanese Utility Model Laid-Open No. Sho 62-151306 (hereinafter called as "(d)"), the connecting structure is disclosed as "the connecting structure of the PC members characterized in that a pair of PC members having connection grooves opened are arranged at each of the connecting surfaces, connector fittings provided with hollow parts having a plurality of feeding holes for mortar or adhesive agent are fitted into each of the grooves, either mortar or adhesive agent is poured into said hollow parts of the connector fittings and then either said mortar or adhesive agent is filled in the hollow parts and the clearances between the connecting grooves and the connector fittings as well as in the clearances between the connecting surfaces of each of the members".
However, the constitution disclosed in each of the aforesaid gazettes of Nos.(a) and (b) could be constructed such that the concrete structures can be easily connected to each other by inserting or fitting the bolts into the projected portions in the connected surfaces oppositely faced from each other in the concrete structures or by inserting the connector bolts into the coupler fittings, although they had some problems that it was necessary to arrange some concave portions for use in embedding the concrete structures and the coupling fittings or bolts, resulting in that their manufacturing steps became complicated. In addition, they had some problems that the concrete structures were loosened by vibration caused under the fastening arrangement with bolts and nuts. In addition, the prior art had a problem that when the connector fittings or bolts were buried with mortar or the like, the work required much time and so a lack of workability occurred. Further, the prior art had another problem that the connector fittings or bolts were rusted with rain water to expand by themselves to cause concrete or mortar to be damaged.
In addition, the configuration described in the gazette (c) above had a problem that after pins were inserted into pin insertion holes, binding material was filled in the holes, so that the pins hindered a filling operation to cause the binding material to be hardly filled. Additionally, the prior art had a still further problem that the binding material such as resin mortar or the like had a high viscosity, so that a filling operation took much time and a lack of workability occurred. In addition, since only the fine pins could be used, the pins were inserted into the pin insertion holes in slanted state and so the prior art had a problem that filling of the filling material was hardly accomplished and some non-uniformity were easily generated.
The configuration described in the gazette (d) had a problem that some grooves having a desired shape for fitting a groove forming mold should be cut and formed at the connecting surfaces of the PC members from external part in compliance with a size of the mold, resulting in that the work was troublesome and a lack of workability occurred. Further, the prior art had a problem that the mortar leakage preventing mold frame should be arranged during the connecting work, and after connecting work, the mold frame should be removed, then coating material had to be filled in the location where the mold frame was removed and the large number of steps was required, a skill in the work was required, a large number of working persons and time were required and a shortening of working period was lack. Further, the prior art had a problem that an air accumulation part was easily formed inside the hole due to a high viscosity of mortar and a mechanical strength was remarkably reduced.
DISCLOSURE OF THE INVENTION
This invention solves the aforesaid problems in the prior art and its object is to provide the connecting structure of concrete blocks and the connecting method therefor in which their strong connections can be carried out with an easy connecting structure, no removal of the connector occurs, their workability is remarkably improved, productivity of a building and the like is improved and at the same time an anti-disaster characteristic is superior.
In order to accomplish the object, the present invention has the following constitutions, respectively.
The connecting structure of concrete blocks as defined in claim 1 is comprising concrete blocks with a pair of opposing connecting holes bored at abutting surfaces between said concrete blocks; a connector consisting of a rod-like member with a hollow part, inserted and fixed said pair of opposing connecting holes; an adhesive agent poured from one end of said hollow part, flowed out of an opening at the end of said hollow part, and thus filled between the surface of said connector and circumferential walls of said connecting holes.
The connecting structure of concrete blocks as defined in claim 2 is comprising concrete blocks with a pair of connecting holes bored at abutting surfaces between said concrete blocks; a connector consisting of a rod-like member with a hollow part at a longitudinal central part and a branch pipe engaged with one end of said hollow part, inserted and fixed said pair of opposing connecting holes; an adhesive agent poured from one end of the hollow part of branch pipe, flowed out of an opening at the end of said hollow part of rod-like member, and thus filled between the surface of said connector and the circumferential walls of said connecting holes.
The connecting structure of concrete blocks as defined in claim 3 is comprising concrete blocks with a pair of connecting holes bored at abutting surfaces between said concrete blocks and a branch pipe installing groove on the surface of said abutting surfaces; a connector consisting of a rod-like member with hollow part at a longitudinal central part and a branch pipe engaging part having a hollow part at said rod-like member and communicated from an outer circumferential part of said rod-like member with said hollow part of said rod-like member, and a branch pipe fixed or removably engaged with said branch pipe engaging part, inserted and fixed said rod-like member in said pair of opposing connecting holes and said branch pipe in said groove; an adhesive agent poured into one end of said branch pipe, flowed out of an opening at the end of said hollow part of said rod-like member, and thus filled between the surface of said connector and the circumferential walls of said connecting holes.
The connecting structure of concrete blocks as defined in claim 4 is comprising concrete blocks with a pair of connecting holes bored at abutting surfaces between said concrete blocks; a connector consisting of a solid rod-like member with an adhesive agent feeding pipe formed in a longitudinal direction of its outer circumferential surface and an adhesive agent feeding pipe having an adhesive agent feeding-in part at one end and an adhesive agent flowing-out part at the other end, inserted and fixed said solid rod-like member in said pair of opposing connecting holes; an adhesive agent poured from said adhesive agent flowing-in part of said adhesive agent feeding pipe, flowed out of said adhesive agent flowing out part of said hollow part of said adhesive agent feeding pipe, and thus filled between the surface of said connector such as said solid rod-like member and the circumferential walls of said connecting holes.
The connecting structure of the concrete blocks as defined in claim 5 is comprising concrete blocks with a pair of connecting holes bored at abutting surfaces between said concrete blocks and a branch pipe installing groove on the surface of said abutting surfaces; a connector consisting a solid rod-like member with an adhesive agent feeding pipe formed in a longitudinal direction of its outer circumferential surface and an adhesive agent feeding pipe having the adhesive agent flowing-out parts at the both ends and a branch pipe linked with the middle of hollow part of said adhesive agent feeding pipe at its substantial central part, inserted and fixed said solid rod-like member in said pair of opposing connecting holes and said branch pipe in branch pipe installing groove; an adhesive agent poured from an adhesive agent flowing-in part of said branch pipe, flowed out of said flowing-out parts of said adhesive agent feeding pipe, and thus filled between the surface of said connector and the circumferential walls of said connecting holes.
The connecting method of concrete blocks as defined in claim 6 is comprising the steps of inserting and fixing a connector into and to connection holes of concrete blocks formed with a pair of connection holes having a diameter substantially the same as that of or slightly larger than a cross section of the connector at each of the abutting surfaces and abutting each of the concrete blocks; and pouring adhesive agent from one end of the hollow part of said connector inserted into and fixed to the connection holes at said step, flowing it out of the other end opening and filling the adhesive agent between the surface of said connector and the circumferential walls of said connection holes.
The connecting method of concrete blocks as defined in claim 7 is comprising the steps of inserting and fixing a rod-like member of the connector and a branch pipe into said connection holes and branch pipe installing grooves of a plurality of concrete blocks formed with the connection holes and branch pipe installing grooves having substantially the same diameter as or slightly larger than that of a cross section of the rod-like member of the connector or that of the branch pipe at each of the abutting surfaces and abutting each of the concrete blocks from each other; and pouring adhesive agent from an opening of the branch pipe of said connector inserted into and fixed to the connection holes and the branch pipe installing grooves at the aforesaid step, flowing it out from openings at both ends of said hollow part of said rod-like member of said connector and filling adhesive agent between the surface of said connector and a circumferential wall of said connection hole.
In this case, the concrete blocks are defined as PC members of secondary product of concrete such as PC panels used in a dwelling or a construction of building; PC floor beams; PC wall concretes used in concrete blocks, gate columns, fences, stone materials or railway tunnels or sealing work at an underground road or the like; U-shaped grooves; gutters; PC culverts; PC retaining walls; water passages and water tanks and the like. As adhesive agents, it is possible to apply mortar, various kinds of cements and resin concretes in addition to epoxy resin system, polyurethane resin system, vinyl acetate system, silicone adhesive agent. In the case that mortar or cement is applied, it is possible to prevent corrosion of the connector caused by dew formation or salt damage by applying a connector made of stainless steel, a connector having a surface made of synthetic resin or having a multi-layer structure or applying a connector made of ceramics.
In addition, it is possible to prevent adhesive agent from being leaked at the connecting surfaces by applying a sealing material such as a double-adhesive surface tape or a seal member and the like to the connecting surfaces of the concrete blocks to be connected to each other. Further, since it is possible to form an adhesive agent accumulation part enclosed by a seal material or an adhesive agent coating part to which adhesive agent is applied during connecting operation at the connecting surfaces, it is possible to apply different kinds of adhesive agents in advance.
Connection holes or cutting parts are merely formed at each of the abutting surfaces of the concrete blocks, connectors are inserted, fixed and embedded in the concrete blocks and then adhesive agent or mortar and the like are merely poured into them, so that the execution steps can be quite simplified and the number of steps of work can be reduced. Irrespective of a simple connecting structure, it is possible to perform a rigid connection of the concrete blocks, so that it is also possible to increase remarkably an effect of anti-disaster. Since a visual inspection hole is arranged, it is possible to pour adhesive agent down to a bottom part of the hole and the adhesive agent is charged through helical irregularities at the surface of the connector, resulting in that it is also possible to discharge air out of the connection holes and to prevent some charging patterns from being generated. In addition, it is also possible to prevent adhesive agent from being leaked out of the connecting surfaces through the seal material at the connecting surfaces and to get a quite strong adhering yield strength by applying different kinds of adhesive agents. It is possible to eliminate removal of the connectors, improve remarkably workability and further improve productivity of a building structure and the like.
As described above, the present invention is constructed such that the connectors are inserted into and fixed inside the concrete blocks and further coated with adhesive agent, so that it is possible to prevent salt damage or dew formation and further to make a remarkable improvement of durability at the connecting structure without producing any corrosion at all. In addition, since the connectors may not be visually seen from outside, it is possible to make a connected coupler structure and to increase an additive value of the structure. It is possible to prevent the structure from being fallen through a rigid connection of it and make a remarkable improvement of safety characteristic.
In addition, the concrete blocks such as PC plates made at a factory and the like in advance can be easily connected at a working site so as to construct a long and large concrete structure.
Since such effects as described above can be attained by a small number of connectors during execution of work, it is possible to realize both the connecting structure of the concrete blocks and their connecting method which can remarkably improve workability, labour-saving and rationalization during execution of work.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a substantial part showing a connecting structure of concrete blocks in the first preferred embodiment of the present invention.
FIG. 2 is an exploded perspective view of a connector in the first preferred embodiment of the present invention.
FIG. 3 is a sectional view of a substantial part showing a connecting method of concrete blocks in the first preferred embodiment of the present invention.
FIG. 4 is a sectional view of a substantial part of connection holes for schematically showing a flow of adhesive agent in a connecting method of the concrete blocks in the first preferred embodiment of the present invention.
FIG. 5 is a sectional view of a substantial part showing an example of another application of a connecting structure of concrete blocks in the first preferred embodiment of the present invention.
FIG. 6 is a sectional view of a substantial part of connection holes for schematically showing a flow of adhesive agent in a connecting method of the concrete blocks in the second preferred embodiment of the present invention.
FIG. 7(a) is a side elevational view of a conector in the second preferred embodiment of the present invention.
FIGS. 7(b) is a perspective view of a substantial part of a flowing-out end part of adhesive agent of a connector in the second preferred embodiment of the present invention.
FIGS. 8(a) to 8(e) are front views of a substantial part of a flowing-out end parts of an adhesive agent of various shapes of rod-like members of connectors in the second preferred embodiment of the present invention.
FIG. 9 is a sectional view of a substantial part showing a connecting structure of concrete blocks in the third preferred embodiment of the present invention.
FIG. 10 is a perspective view partly with broken line of a connector in the third preferred embodiment of the present invention.
FIG. 11 is a sectional view of a substantial part showing a connecting method of concrete blocks in the third preferred embodiment of the present invention.
FIG. 12 is a sectional view of a substantial part showing an example of another application of a connecting structure of concrete blocks in the third preferred embodiment of the present invention.
FIG. 13 is a sectional view of a substantial part showing a connecting structure of concrete blocks in the third preferred embodiment of the present invention.
FIG. 14 is a sectional view of a substantial part of connection holes for schematically showing a flow of adhesive agent in a connecting method of the concrete blocks in the fourth preferred embodiment of the present invention.
FIG. 15 is a sectional view of a substantial part showing a connecting structure of concrete blocks in the fifth preferred embodiment of the present invention.
FIG. 16 is a sectional view of a substantial part of connection holes for schematically showing a flow of adhesive agent in a connecting method of the concrete blocks in the fifth preferred embodiment of the present invention.
FIG. 17 is a sectional view of a substantial part showing a connecting structure of concrete blocks in the sixth preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, one preferred embodiment of the present invention will be described as follows.
(Preferred embodiment 1)
FIG. 1 is a sectional part of a substantial part for showing a connecting structure of concrete blocks in the first preferred embodiment of the present invention. 1a, 1a' denote a pair of connected PC members; 2 denotes a metallic connector having projections at extremity ends of a hollow rod-like member embedded in the connecting surfaces of the PC members 1a, 1a'; 3 denotes a hollow part for use in pouring adhesive agent with its both ends being formed in a central longitudinal direction of the connector 2; 4 denotes two projections formed at symmetrical positions of extremity ends of adhesive agent flowing-out part of the connector 2; 5 denotes connection holes for use in inserting and fixing a rod-like member of the connector 2 formed to be communicated with the connecting surfaces of the PC members 1a, 1a'; 6 denotes adhesive agent poured from one end of the hollow part 3 of the connector 2, flowed out of the other end of the hollow part 3 and filled between the surface of the connector 2 and the circumferential walls of the connection holes 5; and 7 denotes a plug embedded into the opening of the connection hole 5 made of concrete, mortal, rubber or the like.
In FIG. 2, 2 denotes connector; 3 denotes adhesive agent flowing-in hollow part; 4 denotes projections; 21 denotes a metallic hollow rod-like member; 22 denotes branch pipe engaging end part of rod-like member 21; 23 denotes convex or concave portions formed spirally at the outer surface; 24 denotes engaging part to rod-like member formed spirally at the hollow part 3 of branch pipe engaging end part 22 of rod-like member 21; 25 denotes branch pipe made of synthetic resin engaging spirally to engaging part to rod-like member 24 of rod-like member 21; 25' denotes an engaging groove inserted into and fixed to a drill and the like, when an engaging a branch pipe 25 formed at the end part of the branch pipe 25 with the rod-like member side engaging part 24 of branch pipe engaging end part 22 is released; 26 denotes a branch pipe hollow part communicated with the hollow part 3 of the rod-like member 21; 27 denotes engaging part engaged with rod-like member side engaging part 24 formed spirally at the end part of branch pipe 25.
A connecting method for the connecting structure of concrete blocks constructed as described above will be described as follows.
FIG. 3 is a perspective view of a substantial part for showing a connecting method for concrete blocks in the first preferred embodiment of the present invention. FIG. 4 is a sectional view of a substantial part of connection holes for schematically showing a flow of adhesive agent in the connecting method for concrete blocks in the first preferred embodiment of the present invention. 8 denotes an opening of connection holes 5.
At first, connection holes 5 having a diameter slightly larger than that of each of rod-like members 21 of the connector 2 and having a length slightly deeper than that of each of the rod-like members 21 are punched with a drill and the like at the abutting surfaces of a pair of PC members 1a, 1a' to be connected to each other. Then, adhesive agent 6 is applied to the abutting surfaces of a pair of PC members 1a, 1a' to be connected to each other as required, thereafter the connector 2 is inserted into and fixed to the connection holes 5 and each of the abutting surfaces are struck against to each other with the PC members 1a, 1a' being set in a horizontal orientation.
Then, they are held by holders such as wires, turnbuckles, pipe supports and the like as required in such a manner that the connected parts may not be separated from each other, thereafter adhesive agent of epoxy resin is poured at the opening of the branch pipe, and since the adhesive agent can be visually confirmed from the branch pipe and the opening 8 of the connection hole 5, resulting in that the adhesive agent is poured until the adhesive agent is overflown.
As shown in FIG. 4, the adhesive agent 6 is poured from the branch pipe hollow part 26 of the branch pipe 25 and further as shown by an arrow, the adhesive agent passes through the hollow part 3 of the connector 2 and fills a clearance between the surface of the connector 2 and the circumferential walls of the connection holes 5. In this case, a channeling or a short pass of the adhesive agent 6 is prevented under an effect of buffering at the projections or irregularities formed at the surface of the connector 2 and the adhesive agent 6 is filled in the clearance with a scarce leakage of it.
In addition, a subsequent feeding of the adhesive agent 6 enables the adhesive agent 6 to be visually confirmed for its ascending while filling the clearance between the outer surface of the branch pipe 9 and the circumferential walls of the connection holes 6, resulting in that some filling patterns can be prevented. Then, after removing the branch pipe 9, the opening 8 of the connection hole 5 is processed with sealing treatment by the plug 7 of concrete or rubber or mortar and the like as required. Upon curing the adhesive agent 6, the holder such as the pipe support and the like are removed as required.
As described above, according to the preferred embodiment, the connecting work for the PC members is a quite simple work in which the connection holes 5 are merely formed at the connecting surfaces, wherein the connecting method is also a quite simple work in which the connector 2 is inserted into and fixed to the connection holes 5 and the adhesive agent 6 is merely poured into the connection holes and a connecting structure having a superior mechanical strength can be obtained.
In addition, since it can be visually confirmed whether or not the adhesive agent 6 is sufficiently filled in the holes, it is possible to get a strong connecting structure having no adhering patterns. In addition, since the surface of the connector is covered with the adhesive agent 6, no corrosion and the like occur due to salt damage or deformation.
In the preferred embodiment, the adhesive agent is of epoxy resin adhesive agent, although the adhesive agent may be of mortar and the like as shown in FIG. 5. is a sectional view of a substantial part for showing another example of application of the connecting structure of concrete blocks in the first preferred embodiment of the present invention. This preferred embodiment is similar to the first preferred embodiment except that U-shaped water discharging blocks are applied as the PC members 1b', 1b' to be connected from each other, mortar is poured as adhesive agent and a plug is eliminated, so that its description will be eliminated.
(Preferred embodiment 2)
FIG. 6 is a sectional view of a substantial part of connection holes for schematically showing a flow of the adhesive agent in a connecting method of concrete blocks in the second preferred embodiment of the present invention.
FIG. 7(a) is a side elevational view of the connector in the second preferred embodiment, FIG. 7(b) is a perspective view for showing a substantial part of the flowing-out end of the adhesive agent and FIG. 8 is a front elevational view for showing a substantial part of the flowing-out end of the adhesive agent in various rod-like members of the connector in the second preferred embodiment.
2a denotes a metallic connector to which the branch pipe is removably engaged in the second preferred embodiment; 21a denotes a metallic hollow round rod-like member; 28 denotes an adhesive agent guiding groove formed in a concave shape at the surface of the adhesive agent flowing-out end formed to be an expanded shape; and 29 denotes an adhesive agent flowing-out end of the rod-like member 2 formed to be in an expanded shape.
In FIG. 8, (a) denotes a state in which a sectional shape of the rod-like member 21a is formed to be a substantial circular shape so as to facilitate an insertion of the rod-like member into a connection hole having a rough cut surface.
In FIG. 8, (b) denotes a state in which a sectional shape of the rod-like member 21a is of a substantial ellipse, wherein its object consists in dispersion of external force of the PC members connected at a right angle or crossed in slant as well as its reinforcement and prevention of rotation of the PC member. In particular, a bending stress applied from a direction of long diameter side is enforced. (c) to(e) denote a member of substantial rectangular shape or substantial hexagonal shape, a substantial triangular shape which is suitable for preventing a rotation between the PC members and connecting them to each other. In the examples of application (b) to (e), the rod-like members are not rotated, so that the projection part 4 toward the adhesive agent flowing-out end part may not be formed.
A content of this preferred embodiment differing from that of the first preferred embodiment consists in the fact that a connector 2a formed with an adhesive agent guiding groove 28 at an extremity end opening of an adhesive agent flowing-out side of the rod-like member is applied as a connector.
The connecting structure and the connecting method in the second preferred embodiment are similar to those of the first preferred embodiment and their description will be eliminated.
As described above, according to the preferred embodiment, since the adhesive agent flowing-out part of the connector is formed with the adhesive agent guiding groove 28, even if the adhesive agent such as mortar having a relative high viscosity is applied, the adhesive agent can be filled easily and without any air voids. In addition, in the case that a branch pipe 25a does not constitute any hindrance against embedding of the connector after pouring the adhesive agent, it is possible to improve workability by embedding the branch pipe 25a together with the connector.
(Preferred embodiment 3)
FIG. 9 is a sectional view of a substantial part for showing a connecting structure of concrete blocks in the third preferred embodiment of the present invention. FIG. 10 is a sectional view of a substantial part of connection holes for schematically showing a flow of adhesive agent in a connecting method of concrete blocks in the fourth preferred embodiment or the present invention. 1c, 1c' denote a pair of PC members to be connected from each other; 2b denotes a metallic connector having a branch pipe 25b fixed for use in pouring adhesive agent at a substantial central part in a longitudinal direction of a hollow rod-like member 21b embedded in the connecting surfaces of the PC members 1c, 1c'; 3b denotes a hollow part for use in pouring the adhesive agent opened at both ends formed in a central longitudinal direction of the connector 2b; 5a denotes connection holes for use in inserting and fixing the rod-like member 21b of the connector 2b punched to be communicated with the abutting surfaces of the PC members 1c, 1c'; 6 denotes adhesive agent poured from the opening of the branch pipe 25b of the connector 2b, flowed out of openings at both ends of the hollow part 3b of the connector 2b and filled between the surface of the connector 2b and the circumferential walls of the connection holes 5a; 12 denotes a branch pipe installing groove cut and formed at one abutting surface of the connection hole 5'; and 7a denotes a plug embedded at the opening of the branch pipe installing groove 12. 12 denotes a branch pipe installing groove cut and formed from the opening of the engaging hole 5a of the PC member 1c along the abutting surface; 23 denotes convex or concave portions formed at the surface of the rod-like member; 24 denotes an engaging part of the rod-like member to be engaged with the engaging part 27 of the branch pipe 25b bored from the circumferential surface of the central part of the rod-like member 21b to the hollow part 3b; 25' denotes an engaging groove of the branch pipe 25b; and 26 denotes a branch pipe hollow part.
A connecting method of the connecting structure of concrete blocks constructed as described above will be described as follows.
FIG. 11 is a perspective view of a substantial part for showing a connecting method of concrete blocks in the third preferred embodiment of the present invention. FIG. 12 is a sectional view of a substantial part of each of the connection holes for schematically showing a flow of adhesive agent in the connecting method for concrete blocks in the third preferred embodiment of the present invention. 13 denotes an opening of a branch pipe installing groove 12.
At first, connection holes 5a are bored with a drill and the like at the abutting surfaces of each of the PC members 1c, 1c' having a diameter slightly larger than that of the connector 2b and having such a depth as one to cause the central part of the connector 2b to reach the connecting surfaces of each of the PC members 1c, 1c'. Then, the branch pipe installing groove 12 for use in installing the branch pipe 9b is formed at the abutting surface of one communicating connecting hole 5a. Then, the connector 2b having the branch pipe 25 fixed thereto is inserted into and fixed to the connecting hole 5a communicated with the abutting surfaces and each of the abutting surfaces is struck against to each other while the PC members 1c, 1c' are being placed in a horizontal orientation. Then, they are held by holders such as wires, or turn-buckles, pipe supports and the like as required in such a manner that their connected parts may not be separated from each other, thereafter an adhesive agent pouring gun (not shown) is installed at the opening of the branch pipe 9b, the epoxy resin adhesive agent 6 is filled in the connection hole 5' through the hollow part 3b of the connector 2b until the adhesive agent 6 is visually confirmed at the opening 13 of the branch pipe installing groove 12 while the adhesive agent is filling the connection hole 5' from both end openings of the connector 2b.
As shown in FIG. 12, the adhesive agent 6 poured into the hollow part 26 of the branch pipe, passes through the hollow part 3b of the connector 2b and fills from the bottom part of connection hole 5a venting air to outside in a clearance between the outer surface of the connector 2b and the circumferential walls of the connection hole 5a. In this case, the surface of the connector 2b is formed with projections 23 for use in preventing channeling or short pass of the adhesive agent under an effect of buffer in the same manner as that of the preferred embodiment 1, so that the adhesive agent 6 is filled in the clearance with a scarce leakage. In addition, upon continuation of feeding of adhesive agent, it can be visually confirmed that the adhesive agent 6 returns back while it is filling the clearance between the branch pipe 9b and the circumferential walls of the branch pipe installing groove 12.
Then, the opening 13 of the branch pipe installing groove 12 is provided with a sealing processing by a plug and the like. After curing of the adhesive agent 6, the holders such as the pipe supports and the like are removed if the holders are used.
As described above, according to the preferred embodiment, it is possible to get the connecting structure having a superior mechanical strength by a quite simple work in which the connected surfaces of the PC members to be connected to each other are punched with some communicated connection holes and the abutted surface of connection hole is formed with the branch pipe installing groove and the connecting method is also a quite simple work for pouring the adhesive agent into the connector.
In addition, since it can be visually confirmed whether or not the adhesive agent is sufficiently filled in the same manner as that of the preferred embodiment 1, it is possible to get the rigid connecting structure having no adhering pattern.
In the preferred embodiment, although the connecting holes or the branch pipe installing grooves are punched from the connecting surfaces of the PC members, they may be formed in advance when the PC members are manufactured.
(Preferred embodiment 4)
FIG. 13 is a sectional view of a substantial part of a connecting structure of concrete blocks in the fourth preferred embodiment of the present invention. 1d, 1d' denote a pair of PC members to be connected to each other; 2c denotes a metallic connector having a projection 4c at an extremity end where a pipe-like adhesive agent feeding pipe 14 is installed in a longitudinal direction of an outer circumferential surface of a solid rod-like member embedded at the joint connected surfaces of the PC members 1d, 1d'; 5b denotes connection holes formed to be communicated with the abutting surfaces of a pair of PC members 1d, 1d' connected from each other; 6 denotes adhesive agent poured from the adhesive agent flowing-in part of the adhesive agent feeding pipe 14, flowed out from the adhesive agent flowing-out part to the bottom part of connection hole 5b and filled between the outer surface of the connector 2c and the circumferential wall of the connection hole 5b venting air to outside; and 7b denotes a plug embedded at the opening of the connection hole 5b.
A connecting method for the concrete blocks constructed as described above will be described as follows.
FIG. 14 is a sectional view of a substantial part of a connection hole for schematically showing a flow of adhesive agent in the connecting method for the concrete blocks in the fourth preferred embodiment of the present invention. 6a denotes an adhesive agent pouring gun.
Connection holes 5b having a diameter slightly larger than that of the connector 2c are bored with a drill and communicated with the abutting surfaces of the PC members 1d, 1d' with such a depth as one to cause the central part of the connector 2c to reach the joint connected surfaces. Then, the PC members 1d, 1d' are abutted to each other in such a manner that the connection holes 5b are communicated from each other and the members are temporarily fixed by a supporting connector. The connector 2c is inserted into the connection holes 5b and the projection 4c is pierced into the bottom part of the connection hole 5b. Then, the adhesive agent pouring gun 6a is installed at the opening of a pipe-like adhesive agent feeding pipe 14 and the adhesive agent is filled in the connection holes 5b through the hollow part of the pipe-like adhesive agent feeding pipe 14 until the adhesive agent 6 is visually confirmed at the opening of the connection hole 5b. The adhesive agent 6 is poured at the opening of the pipe-like adhesive agent feeding pipe 14 and as indicated by an arrow as shown in FIG. 14, the adhesive agent fills the clearance between the connector 2c and the circumferential walls of the connection holes 5b. In this case, either the channeling or the short pass of the adhesive agent 6 is prevented under an effect of buffer at the irregularities of surface of the connector 2c and so the adhesive agent 6 is filled in the clearance with a scarce leakage of it.
In addition, continuing of pouring of the adhesive agent 6 enables the adhesive agent 6 to be visually confirmed to return while filling the clearance between the outer surface of the pipe-like adhesive agent feeding pipe 14 and the connection holes 5b, resulting in that it is possible to prevent the charging patterns from being generated.
Upon visual confirmation of the adhesive agent 6 at the openings of the connection holes 5b, the engaged state between the adhesive agent pouring gun 6a and the adhesive agent feeding pipe 14 is released. During this period, since the connector 2c is fixed to the bottom part of the connection hole 5b with the projection 4 at its extremity end, it is not rotated or removed. Then, a plug 7b is embedded in flush with the opening of the connection hole 5b.
As described above, according to the preferred embodiment, the joint work at the PC members is a quite simple work and a quite easy work of forming the communication holes with a drill or the like, resulting in that it is possible to get the connecting structure having a superior mechanical strength.
In addition, since it is possible to make a visual check whether or not a sufficient filling of the adhesive agent occurs, it is possible to get the rigid connecting structure having no air voids in the adhesive agent. In addition, since the metallic solid connector is embedded at the connected parts, its yield force can be maintained against external forces such as earthquake or typhoon due to mechanical strength of the connector. In addition, since the connector is covered at its surface with adhesive agent, it may not be rusted by salt damage or immersed water or the like, resulting in that its safety characteristic can be remarkably improved.
(Preferred embodiment 5)
FIG. 15 is a sectional view of a substantial part for showing a connecting structure of concrete blocks in the fifth preferred embodiment of the present invention.
1e, 1e' denote a pair of PC members connected to each other; 2d denotes a metallic connector in which the adhesive agent flowing-in part is provided at a central part in a longitudinal direction of the outer circumferential surface of the solid rod-like member embedded at the connected surfaces of the PC members 1e, 1e' and further both ends are provided with an adhesive agent flowing-out part; 5b denotes a connection hole formed to be communicated at the connected surfaces of the PC members 1e, 1e', for use in inserting and fixing the rod-like member of the connector 2d; 6 denotes an adhesive agent poured from the adhesive agent pouring part at the central part in a longitudinal direction of the adhesive agent feeding pipe 15, flowed out of the adhesive agent flowing-out parts at both ends and filled between the surface of the rod-like member of the connector 2d and the circumferential walls of the connection holes 5b; and 16 denotes an adhesive agent flowing-in part installing groove cut and formed at the abutted surfaces from the opening of end of the connection holes 5b.
A connecting method for the connecting structure of concrete blocks constructed as described above will be described as follows.
FIG. 16 is a sectional view of a substantial part of connection holes for schematically showing a flow of adhesive agent in the connecting method of concrete blocks in the fifth preferred embodiment of the present invention.
25c denotes a branch pipe-like adhesive agent flowing-in part engaged at the central part of the adhesive agent feeding-in pipe 15.
At first, connection holes 5b having a substantial same diameters that of the connector 2d and having such a depth as one to cause a central part of the connector 2d to reach the connected surfaces of the PC members 1e, 1e' are formed to be communicated with the abutted surfaces of the PC members 1e, 1e' connected to each other, and an adhesive agent flowing-in part installing groove 16 is formed in advance at the abutting surface of one connection hole 5b to be communicated. Then, the connector 2d having the adhesive agent feeding-in pipe 15 provided with the adhesive agent flowing-in part 17 is inserted into the connection holes 5b communicated with the abutted surfaces, the PC members 1e, 1e' are abutted to each other and temporarily fixed by supporters and the like according to requirements.
Then, an adhesive agent pouring gun 6a is installed at the branch pipe 17 of the adhesive agent feeding pipe 15, and the adhesive agent 6 is filled in the connection hole 5b until the adhesive agent 6 is visually confirmed at the opening of the adhesive agent flowing-in part installing groove 16 while filling the surface of the connector 2c an d the connection holes 5b through openings at both ends of the adhesive agent feeding-in pipe 15.
As shown in FIG. 12, the adhesive agent 6 is poured at the opening of the adhesive agent flowing-in part 17 of the adhesive agent feeding-in pipe 15, flowed out of both opened ends of the pipe-like adhesive agent feeding-in pipe 15 and fills a clearance between the surface of the connector 2d and a circumferential wall of the connection hole 5'. In this case, since the surface of the connector 2d is formed with some projections for preventing channeling or short pass of the adhesive agent under an effect of buffer, the adhesive agent 6 is filled in the clearance with a scarce leakage of it. Further, continuation of pouring of the adhesive agent 6 enables the adhesive agent 6 to be visually confirmed to return back while filling the clearance between the adhesive agent flowing-in part 17 and the circumferential walls of the adhesive agent flowing-in part installing groove 16, resulting in that it is possible to prevent charging patterns.
Upon visual confirmation of the adhesive agent 6 at the opening of the adhesive agent flowing-in part installing groove 16, the engaged state between the adhesive agent flowing-in part and the adhesive agent feeding pipe 15 is released and then a plug is embedded in the opening of the adhesive agent flowing-in part installing groove 16.
As described above, according to the preferred embodiment, it is possible to get the connecting structure having a superior mechanical strength in which the connection holes are punched and formed to be communicated with the connected surfaces of the PC members connected to each other, the abutted surface of one connection hole is formed with the adhesive agent flowing-in part installing groove in a quite simple work and its connecting method is also carried out in a quite simple work for pouring the adhesive agent into the connector.
In addition, since it is possible to make a visual confirmation whether or not the adhesive agent is sufficiently filled in the structure in the same method as that of other preferred embodiments, it is possible to get the rigid connecting structure having no adhesive agent pattern. In addition, since the metallic solid connector is embedded at the connected parts, the mechanical strength of the connector enables its force of yield to be maintained against external forces such as earthquake or typhoon or the like. In addition, since the connector is covered at its surface with adhesive agent, the connector may not be rusted with salt damage or immersed water, resulting in that it is possible to improve its safety characteristic.
In the preferred embodiment, the connection holes or the adhesive agent flowing-in part installing grooves are bored at the connection surfaces of the PC members, although they may be formed in advance when the PC members are manufactured.
(Preferred embodiment 6)
FIG. 17 is a sectional view of a substantial part for showing the connecting structure of concrete blocks in the sixth preferred embodiment of the present invention.
Points differing from the first preferred embodiment of the present invention consist in the facts that the connected surfaces of the PC members 1f, 1f' connected to each other are bored in advance with through-pass holes 5c for use in embedding the connector, one end of the through-pass hole 5c is covered during connection to form the connection holes and the seal members 18 such as a double-surface adhesive tape or a seal and the like for preventing leakage of the adhesive agent are adhered to the connected surfaces.
A connecting method for the connecting structure of concrete blocks of the preferred embodiment constructed as described above will be described as follows.
At first, the opening opposite to the connected surface of the through-pass hole of the PC member if bored in advance is covered by a plug 7' made of concrete with such a space as one to enable a substantial half part of the connector 2e to be inserted into the hole being left and then the connection hole 5c is formed. Then, some seal members 18 are adhered to the connected surfaces of the PC member 1b" so as to prevent leakage of the adhesive agent and then the PC members 1f, 1f' are abutted from each other to be connected. Then, the connector 2e is inserted into and fixed at the opening of the connection hole 5c of the PC member if and the connection is carried out in the same method as that of the first preferred embodiment.
As described above, according to the preferred embodiment, since the seal members for preventing leakage of adhesive agent are adhered around the connection holes at the connected surfaces of the PC members connected to each other, it is possible to prevent adhesive agent from being leaked at the connected surfaces of the PC members during pouring of the adhesive agent and further it is possible to fill the connection holes without any air voids as well as to increase a connecting force.
______________________________________1a, 1a', 1b, 1b', 1c, 1c', PC member1d, 1d', 1e, 1e', 1f, 1f'2, 2a, 2b, 2c, 2d, 2e connector3, 3a, 3b hollow part4, 4c protrusion5, 5a, 5b, 5c connection hole6, 6' adhesive agent6a adhesive agent pouring gun7, 7a, 7b plug8 opening part12 branch pipe insertion and fixing groove13 opening part of branch pipe insertion and fixing groove14, 15 adhesive agent guiding pipe16 branch pipe insertion and fixing groove17 adhesive agent flowing-in part18 seal material21 rod-like member22 branch pipe engaging end part23 convex or concave portions24 rod-like member side engaging part25, 25b, 25c branch pipe25' engaging groove26 branch pipe hollow part27 engaging end part28 adhesive agent guiding groove29 adhesive agent flowing-out end part______________________________________
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The present invention provides a connecting structure of concrete blocks and a method for connecting the concrete blocks in which a special structure for use in connecting the concrete blocks is not required, a rigid connection can be carried out with a simple connecting structure, a removal of the connector is eliminated, a workability is remarkably improved, a productivity of buildings is improved and at the same time it has a superior anti-disaster effect. The connecting structure is comprised of either a hollow rod-like connection member, a plurality of concrete blocks, a pair of connecting holes bored at abutting surfaces between concrete blocks, and adhesive agent poured at one end of the connector flowed out the opposite end and thus filled between the exterior surface of said connector and circumferential walls of said connecting holes.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is the US National Stage of International Application No. PCT/EP2004/004175, filed Apr. 20, 2004 and claims the benefit thereof. The International Application claims the benefits of European Patent applications No. 03011741.0 EP filed May 23, 2003, all of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a bearing for axially mounting a rotor of a gas turbine, having a rotationally fixed bearing body which has a hydraulic piston arrangement for axially displacing the rotor from a first operating position into a second operating position, and having a hydraulic system fluidically connected to the hydraulic piston arrangement. The invention also relates to a gas turbine having such a bearing.
BACKGROUND OF THE INVENTION
[0003] Bearings of the aforesaid type are known per se from the prior art. The bearing body of annular design preferably surrounding the rotor of a gas turbine serves for the arrangement of a plurality of hydraulic pistons. The latter are mounted against stop surfaces formed on the rotor, so that the rotor is supported in the axial direction.
[0004] Such a bearing for displacing the rotor of a gas turbine has been disclosed by US 2002/0009361. Once the gas turbine and its rotor have completely warmed up and thus the temperature-induced material expansions have stopped, the rotor is displaced by means of the bearing from a first operating position into a second operating position against the direction of flow of the hot working medium. As a result, in the turbine unit, the radial gaps formed between the moving blade tips and guide rings opposite the latter are minimized, so that a higher power output of the gas turbine is achieved and the losses via the moving blade tips are minimized.
[0005] The failure of hydraulic medium when the rotor is already arranged in the second operating position causes the rotor to be pushed back into the first operating position by the axial thrust of the working medium, a factor which may lead to severe damage to the axial bearing, the rotor and the gas turbine.
[0006] The position of the rotor can be set by the position of the hydraulic pistons, which, depending on the set piston stroke, leads to an adjustment of the rotor of the gas turbine in the axial direction. The hydraulic piston arrangement therefore enables the rotor of the gas turbine to be oriented in relation to the bearing in accordance with the requirements and also enables it to be displaced from a first working position into a second working position. In a disadvantageous manner, however, the axial speed of the rotor occurring during the displacement of the rotor produces high dynamic forces, which may cause overloading of the bearing body, of the bearing housing and of the gas turbine. As a result of the axial displacement of the rotor, a total failure of the bearing may therefore occur. In this case, the moving of the rotor in the direction of flow is especially problematic, since very high thrusts act on the rotor in this displacement direction.
[0007] In addition, DE 23 57 881 A1 and U.S. Pat. No. 4,915,510 have each disclosed an axial bearing which compensates for an unintentional axial displacement, caused by changing axial thrusts, of the rotor. Furthermore, DE 39 26 556 A1 shows a self-balancing axial bearing for asymmetrical axial movements of the rotor.
SUMMARY OF THE INVENTION
[0008] Based thereon, an object of the invention, while avoiding the aforesaid disadvantages, is to provide a bearing which absorbs the bearing forces occurring as a result of high dynamic thrusts of the rotor and ensures reliable mounting of the rotor. It is also an object of the invention to specific a gas turbine in this respect.
[0009] To achieve the first-mentioned object, the invention proposes a bearing of the type described above which is characterized in that, to limit the displacement speed of the rotor, at least one restrictor for the hydraulic medium is provided between hydraulic piston arrangement and hydraulic system.
[0010] Owing to the fact that a restrictor is interposed according to the invention, the hydraulic medium displaced by the individual pistons is first of all directed through the restrictor, a factor which advantageously leads to a reduction in the kinetic energy and to a comparatively slow displacement of the rotor. The loads acting on the bearing body can thus be reduced, whereby the risk of overloading is minimized. Even at a maximum force acting on the rotor, kinetic energy can be sufficiently dissipated by the restrictor arranged between hydraulic piston arrangement and hydraulic system, so that overloading of the bearing as a result of dynamic forces of the rotor is prevented. Reliable mounting of the rotor of the gas turbine is thus ensured even during any possible occurrence of high dynamic thrusts.
[0011] The restrictor is advantageously arranged in the bearing body. Even in the unusual event of a line fracture in the hydraulic system, the hydraulic medium can only flow off quickly to a limited extent, which results in a low and thus non-damaging displacement speed of the rotor. The bearing, rotor and gas turbine are thus protected against defects which would be caused by an excessive displacement speed of the rotor. In this case, the restrictors are formed by flow constrictions.
[0012] In an advantageous development, the bearing can additionally have at least one flow-control valve, designed as a restrictor, between hydraulic piston arrangement and hydraulic system. This protection likewise increases the safety of the entire system and in addition makes it possible for the flow velocity of the hydraulic medium and thus the displacement speed of the rotor to be set.
[0013] Furthermore, in an advantageous development, the bearing can have at least one flow-control valve, designed as a restrictor, between hydraulic piston arrangement and hydraulic system. This protection likewise increases the safety of the entire system and in addition makes it possible for the flow velocity of the hydraulic medium and thus the displacement speed of the rotor to be set.
[0014] According to a further feature of the invention, provision is made for the hydraulic piston arrangement to have a plurality of pistons arranged in corresponding respective piston chambers. The arrangement of a plurality of hydraulic pistons advantageously achieves a more uniform introduction of force, which permits rectilinear and positionally accurate moving of the rotor of the gas turbine.
[0015] Furthermore, provision may be made with the invention for the piston chambers to be bores of cylindrical design. Of course, other geometrical configurations are also conceivable, but it has been found that in particular piston chambers of cylindrical design permit an optimized force distribution.
[0016] According to a special advantage of the invention, the piston chambers are fluidically connected to one another. This advantageously achieves a pressure balance between the individual piston chambers, thereby achieving, firstly, a uniform load distribution, but also, secondly, a uniformly rectilinear displacement of the rotor of the gas turbine. The individual piston chambers may in this case be fluidically connected to a common pressure space via appropriately designed bores or else may be fluidically connected to one another directly via appropriately designed bores. It is crucial that a pressure balance can be effected between the individual piston chambers.
[0017] According to a further feature of the invention, the hydraulic piston arrangement is of annular design and surrounds the rotor, of circular design in cross section, of the gas turbine. For optimized transmission of force from the hydraulic pistons to the rotor, the pistons are arranged equidistantly from one another with respect to the hydraulic piston arrangement of annular design, so that a uniform force distribution can be achieved. Depending on the configuration and size of the hydraulic piston arrangement of annular design, the common pressure space connecting the piston chambers to one another may likewise be of annular design and may surround the hydraulic piston arrangement.
[0018] According to a further feature of the invention, two hydraulic piston arrangements formed separately from one another are provided and are arranged opposite one another on the bearing body. In this configuration of the bearing according to the invention, the bearing body has a total of two hydraulic piston arrangements, which, depending on the configuration, have in each case a plurality of pistons. The pistons of the first hydraulic piston arrangement interact with a first stop surface and the pistons of the second hydraulic piston arrangement interact with a second stop surface. During a displacement of the rotor of the gas turbine, the pistons of the one hydraulic piston arrangement are extended as a result of this arrangement described above, whereas the pistons of the other hydraulic piston arrangement are retracted. During a displacement of the rotor in the opposite direction, a piston displacement of the hydraulic piston arrangement is likewise effected in the opposite direction. With respect to the thrust direction of the rotor, the one hydraulic piston arrangement is designated as main track bearing and the other hydraulic piston arrangement is designated as secondary track bearing.
[0019] According to a further feature of the invention, the two hydraulic piston arrangements, that is to say the main track bearing and the secondary track bearing, are fluidically connected to one another. The hydraulic medium displaced from one of the two hydraulic piston arrangements as a result of a displacement of the rotor can thus be used for the pressure buildup inside the other hydraulic piston arrangement.
[0020] If the rotor of the gas turbine is displaced against the thrust direction, a controlled shutdown of the gas turbine can no longer be ensured in the event of a failure of the hydraulic medium supply, for example due to a line fracture or the like. This is due to the fact that the hydraulic piston arrangement of the secondary track side of the bearing body, that is to say the secondary track mounting, can no longer be supplied with hydraulic medium. In order to be able to permit a specific shutdown of the gas turbine even in the event of a failure of the hydraulic medium supply, it is proposed according to a further feature of the invention that the two hydraulic piston arrangements be fluidically connected to one another with a 4/2-way directional control valve interposed. The arrangement of such a directional control valve advantageously makes it possible for hydraulic medium to be delivered from the cylinder chambers of the main track side of the bearing body into the cylinder chambers of the secondary track bearing even in the event of a failure of the hydraulic medium supply. For this purpose, the 4/2-way directional control valve is merely to be switched into a de-energized position. As a result of the thrust of the rotor of the gas turbine on the pistons of the main track bearing, the hydraulic medium is then delivered from the piston chambers of the hydraulic piston arrangement of the main track side into the piston chambers of the secondary track bearing. A controlled shutdown of the gas turbine can thus be ensured even in the event of a failure of the hydraulic medium supply.
[0021] In an especially advantageous manner, a gas turbine has a bearing having the aforesaid features.
BRIEF DESCRIPTION OF THE DRAWING
[0022] Further advantages and features of the invention follow from the description with reference to FIG. 1 , which shows in a partly sectioned side view a bearing designed according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The bearing 1 according to the invention is shown in FIG. 1 in a partly sectioned side view. This bearing 1 serves to axially mount and displace a rotor 8 of a gas turbine and comprises a bearing body 2 which serves to accommodate a first hydraulic piston arrangement 3 and a second hydraulic piston arrangement 4 . With respect to the thrust direction 7 of the rotor 8 , the hydraulic piston arrangement 3 is in this case arranged on the main track side 5 and the hydraulic piston arrangement 4 is arranged on the secondary track side 6 of the rotor 8 .
[0024] Both the hydraulic piston arrangement 3 and the hydraulic piston arrangement 4 are formed by a plurality of pistons 23 guided in respective piston chambers 22 . Via displaceably arranged intermediate elements, the pistons 23 of the hydraulic piston arrangement 3 act on the stop surface 24 formed on the rotor 8 , and the pistons 23 of the hydraulic piston arrangement 4 act on the stop surface 25 likewise formed on the rotor 8 , so that an axially displaceable mounting of the rotor 8 overall is formed. Via the arrangement of the hydraulic piston arrangements 3 and 4 in the bearing body 2 , the rotor 8 , for example of a gas turbine, can be positioned in a displaceable manner in the axial direction. For this purpose, the piston chambers 22 can be selectively filled with hydraulic medium, for example hydraulic oil, the hydraulic piston arrangement 3 and the hydraulic piston arrangement 4 being connected to a common hydraulic system 9 via the lines 10 and 11 .
[0025] Components of the hydraulic system 9 are a tank 12 , an accumulator 13 , a hydraulic pump 14 , check valves 15 , 16 and 17 , a 2/2-way directional control valve 18 , a 4/2-way directional control valve 19 and adjustable flow-control valves 20 and 21 . Restrictors 26 and 27 are provided between the hydraulic piston arrangements 3 and 4 and the hydraulic system 9 . The restrictors 26 , 27 are formed by flow constrictions, arranged directly in the bearing body 2 , for the hydraulic medium without a line for hydraulic medium being interposed. In addition, the flow-control valves 20 , 21 serve as further restrictors between the hydraulic piston arrangement 3 or 4 , respectively, and the hydraulic system 9 .
[0026] The movement of the rotor 8 is achieved by its axial displacement relative to the bearing body 2 by hydraulic medium being pumped either into the hydraulic piston arrangement 3 or into the hydraulic piston arrangement 4 . In the event of hydraulic medium being forced into the hydraulic piston arrangement 3 , the pistons 23 extend in accordance with the filled quantity of hydraulic medium and act on the stop surface 24 of the rotor 8 via the elements arranged in between. This results in a displacement of the rotor 8 against the thrust direction 7 , that is to say from a first operating position into a second operating position for reducing the radial gaps known in the prior art, thus to the left with respect to the image plane. Due to this longitudinal displacement of the rotor 8 , the stop surface 25 acts on the hydraulic piston arrangement 4 , and consequently hydraulic fluid is displaced from the corresponding piston chambers 22 and is fed via the line 11 to the hydraulic system 9 .
[0027] According to the invention, in order to avoid a situation in which the axial speed of the rotor 8 occurring during the displacement of the rotor 8 produces excessive dynamic forces, which could cause overloading of the bearing body 2 , the flow-control valves 20 , 21 and restrictors 26 , 27 embedded in the bearing body 2 are interposed between hydraulic piston arrangement 3 , on the one hand, and hydraulic piston arrangement 4 , on the other hand, and the hydraulic system 9 . Even at a maximum force during operation, said flow-control valves 20 , 21 and restrictors 26 , 27 can sufficiently dissipate kinetic energy to the rotor, so that overloading of the bearing 1 as a result of the dynamic forces of the rotor 8 is prevented.
[0028] During the loading which occurs during the faultless operation of the gas turbine with an intended displacement of the rotor 8 , the adjustable flow-control valves 20 , 21 limit the flow velocity of the hydraulic medium to a predetermined value. The displacement of the rotor 8 both in the thrust direction of the hot gases and against the thrust direction is thus effected at the predetermined comparatively slow speed.
[0029] In the event of a fault in the hydraulic system 9 , in the event of a failure of the flow-control valves 20 , 21 or even in the event of a line fracture of the line 10 , 11 , connected to the bearing body 2 , of the hydraulic system 9 , the restrictors 26 , 27 provided in the bearing body 2 limit the flow velocity of the hydraulic medium. The unforeseen displacement, taking place in the thrust direction 7 , of the rotor 8 from the second operating position back into the first operating position is then effected at a speed which protects the bearing body 2 from damage and which may be greater than the speed which is desired during faultless operation and which is set by means of the flow-control valves.
[0030] The flow constrictions in the bearing body, which are formed by the restrictors 26 , 27 , are calculated for an assumed maximum load which is higher than the operating load.
[0031] The restrictors 26 , 27 limit the displacement speed of the rotor only in the event of a fault, whereas the flow-control valves 20 , 21 limit the admissible displacement speed of the rotor during an intended displacement of the latter.
[0032] Furthermore, provision is made according to the invention for the hydraulic piston arrangement 3 and the hydraulic piston arrangement 4 to be fluidically connected to one another via the hydraulic system 9 with the 4/2-way directional control valve 19 arranged in between.
[0033] In addition, in bearing units previously known from the prior art, it is not possible in the event of the failure of the hydraulic medium supply in the case of a rotor displaced against the thrust direction to ensure a controlled shutdown of the gas turbine, since the hydraulic piston arrangement 4 on the secondary track side 6 of the bearing 1 cannot be supplied with hydraulic medium. This is remedied here by the 4/2-way directional control valve arranged according to the invention in between main track side 5 and secondary track side 6 . This is because this 4/2-way directional control valve can be switched into a de-energized position in the event of the failure of the hydraulic medium supply. To be precise, as a result of the thrust of the rotor 8 on the pistons 23 of the hydraulic piston arrangement 3 , hydraulic medium is delivered from the piston chambers 22 of the main track side 5 via the hydraulic system 9 into the piston chambers 22 of the secondary track side 6 . The pressure on the side of the secondary track therefore builds up, so that, in the event of a pressure drop, the rotor comes to a stop where it would likewise be if the bearing were not hydraulically adjustable. As a result, an emergency-running displacement of the rotor 8 can be achieved even if the hydraulic medium supply is interrupted, and consequently a controlled shutdown of the gas turbine remains possible.
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The invention relates to a bearing for axially mounting a rotor of a gas turbine. Said bearing comprises a bearing body that is disposed stationary relative to the position of the rotor, a hydraulic piston arrangement which is accommodated by the bearing body, and a hydraulic system that is fluidically connected to the hydraulic piston- arrangement. In order to create a bearing which also absorbs bearing forces that occur due to high dynamic thrusts of the rotor while ensuring secure mounting of the rotor, a diaphragm is mounted between the hydraulic piston arrangement and the hydraulic system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of Ser. No. 09/880,412 filed Jun. 12, 2001, pending, and incorporated by reference herein for all purpose.
TECHNICAL FIELD
The present invention relates to rain and run-off collection and diversion system and, in particular, to systems and methods for such systems that exhibit reduced debris accumulation.
BACKGROUND OF THE INVENTION
Diversion of rain from buildings is a well-known and beneficial practice. For centuries, architects and builders have understood the benefits of diverting rain to forestall erosion, maintain structural stability, and preserve vegetation. In recent decades, a multitude of systems have been developed to divert rain from structures and homes. Typically, such systems have been placed beneath or adjacent to the roofline to allow collection and diversion of rain accumulated from across the surface area of the structure roof. Such systems are sometimes called “gutter” systems.
Frequently, rain diversion systems employ gutters that are open channels to collect run-off from the roof. Diversion or gutter systems devised with open-channeled rain gutters tend to accumulate debris including sticks, leaves and other matter that is swept toward the gutter by the gravity-induced flow of water down the pitch of the roof. Such debris can cause malfunction of the system as well as significant problems with leakage and corrosion. Roof and structural rotting as well as erosion can be precipitated by the consequent accumulation of water without appropriate attendant diversion.
Consequently, a variety of gutter systems of varying complexity have been developed to inhibit debris accumulation in gutter systems. Simple systems have merely placed screens across open-faced gutter channels. These techniques commonly have their own debris accumulation problems. Other systems employ a deflector described by various terms such as “hood” or “shield” that deflect debris while the gutter accumulates water for diversion to determined locations. For example, in U.S. Pat. No. 4,757,649 to Vahldieck, a system is described that purportedly preferentially collects water and deflects debris over a continuous double-curved shield through which a spike passes to affix the shield to a back support wall of the gutter. The use of shields and other deflectors is well known, and a variety of prior systems modify the shape of the deflector to purportedly take better advantage of the surface tension qualities of diverted run off. For example, in U.S. Pat. No. 4,404,775 to Demartini, a system of longitudinal ridges is imposed on a deflector and is said to improve adhesion of the water to the deflector to improve transference to the gutter.
Others have developed systems to support debris deflectors or affix the deflector to the gutter. For example, in U.S. Pat. No. 4,497,146 to Demartini, a rain deflector support is described that purports to support the underside of a rain gutter deflector while positioning the deflector in relation to the gutter.
As diversions systems have become more complicated, so have the associated issues of cost, specialized material stock, and installation efficiency become more unwieldy. For example, most systems that employ a deflector affix the deflector with screws or clips that reduce flexibility of the system or add an extra part (in addition to the hanger) to the assembly. If the deflector cannot be easily unfastened from the gutter, repair and maintenance are complicated.
For a variety of reasons, diversion systems that deflect debris have not been adopted as widely as demand would suggest. There are a variety of reasons for this result. One reason for the minimal market penetration is the use of non-standard widths of metal stock or “coil” for the gutter trough above which the deflector is positioned. Non-standard coil sizes add significantly to the cost and availability of such systems.
There are two principal sizes of coil used to form the gutter channels known in the art as “troughs.” For the widely found five inch-wide (5″) gutter troughs, standard coil material of 11 and ⅞ inches (11⅞″) is employed (except in the Northeastern U.S. where 5″ gutter troughs are formed from 11 and ¾ inch (11¾″) stock). For the less widely found, but still common, six inch (6″) trough, fifteen inch (15″) coil is used.
In almost all deflection systems, when installed, a deflector must be inclined by a degree sufficient to impart velocity to the run-off great enough to impel debris from the deflector. This requires that the back of the trough, proximal to which the deflector is attached, be high enough to provide sufficient incline for the deflector. Debris deflection systems for 5″ trough gutters employ non-standard coil for the gutter as a result of taking material from the front of the trough to raise the back wall of the gutter. With known designs, if standard width coil of 11⅞ inches were used to form the trough, the shift of material around the standard trough form factor (as employed in the art to create the “OG” 5 inch gutter) from the front trough channel containment wall to the back wall of the trough to provide sufficient deflector inclination leaves insufficient material for the front. This process takes, however, material from the front border area of the trough to create the stiffening front channel edge that provides installation stability and standard hanger affixation capability.
The shape of the front of the gutter trough contributes to structural stability and, in some systems, provides an interface for hanger or deflector attachment. In particular, the shape of the border area of the gutter trough can significantly affect gutter stability during installation, an important consideration in any gutter system. Typically, lengths of gutter trough are formed in runs approximately 40 feet long. Without sufficient resistance to deformation, the gutter trough may fold or crease, particularly when being moved during installation, thus limiting run lengths and increasing installation difficulty. Consequently, 5″ gutter troughs with debris deflectors have typically used coil wider than 11⅞″ or 11¾″ for gutter formation to provide material sufficient to provide a stabilizing front gutter channel configuration with a raised back gutter trough wall to accommodate appropriate inclination of the deflector. Consequently, because of the higher cost of non-standard material, in particular, deflector-fitted 5″ trough gutter systems have cost significantly more than open-faced 5″ trough gutter systems crafted from standard sized coil material.
Previous system design, whether with 5″ or 6″ gutter troughs, has also contributed to unwieldy installation techniques, further increasing the expense of diversion systems that employ deflection hoods or shields. Some deflection systems form the trough and deflector from one piece of material. More commonly, the trough and deflector are separately formed and joined in place at the structure roof edge. Typically, two forming machines are employed during installation of a two-piece deflection system. One machine is dedicated to gutter trough formation, while the other is configured to form the deflector. The machines are typically placed side-by-side. The installation team typically first forms trough lengths sufficient to gutter the structure. The troughs are then affixed in place on the structure. After the troughs are fastened to the building, corresponding deflectors are formed and affixed to the in-place troughs. This process requires multiple trips to and from the forming machines as well as at least two trips up a ladder to install separately, the two large pieces of the system. The described process requires dexterity which, even if applied, cannot ameliorate the difficulty of moving long lengths of deflector that lack structural rigidity unless affixed to, and combined with, the gutter trough.
The inflexible nature of the affixation between hood and trough in prior systems results in several shortcomings. Replacement of deflector sections is made difficult by the inflexible nature of the affixation between deflector and trough. Nail or screw attachment of the deflector is at least semi-permanent, and when the deflector is attached by such means, the system is less easily repaired, serviced, or replaced. Other systems have more sophisticated deflector-attachment techniques, but those systems lack installation flexibility. For example, in U.S. Pat. No. 5,845,435 to Knudson, there is there purportedly described a system having a hood which snaps into particularly configured hangers affixed along the length of the gutter trough. In this system however, the deflector is opened wider to embrace coupling portions of a fastening support device. This is difficult to do with one hand. Installation flexibility is also minimal because, as described in Knudson, the hanger and trough are affixed to the structure before the deflector is attached to the gutter trough. As in other prior systems, this prevents creation of a structurally sound member before the deflector and gutter trough assembly is moved from the machine site to the eventual installation location, an advantage for installation having considerable value in reducing labor cost and inconvenience.
Consequently, what is needed therefore, is a rain collection and diversion system that employs standard-sized coil, has structural soundness and strength, and can be partially assembled close to the machine-site while being easily installed.
SUMMARY OF THE INVENTION
A shelf extends inwardly to the gutter trough from the front containment wall of a gutter trough to cooperate with a lip of a cavity structure of a hanger to provide structural stability and optional deflector attachment facility in a rain collection and diversion system. The hanger cavity structure has a containment lip, a portion of which extends over a portion of the inwardly extending shelf of the front containment wall to allow functional water bearing capacity of the trough and a lengthened back trough wall to accommodate hanger placement and deflector inclination. The hanger can include deflector-mating cavities that open toward each other to allow compression attachment of the deflector.
In a preferred embodiment, the deflector may be attached to a formed trough in which hangers are positioned to allow movement of the trough-deflector combination as a unit from the machine-site to the installation location on the structure. Associated installation methods are provided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a cross-sectional view of a prior art trough of a configuration that is common in the field.
FIG. 2 depicts a cross-sectional view of a trough configured in accordance with a preferred embodiment of the present invention.
FIG. 3 depicts a cross-sectional view of a trough, hanger and deflector assembly in accordance with a preferred embodiment of the present invention.
FIG. 4 depicts a cross-sectional view of a half-round trough, hanger and deflector assembly in accordance with a preferred embodiment of the present invention.
FIG. 5 depicts a cross-section of an enlarged area of the trough, hanger, and deflector depicted in FIG. 3 .
FIG. 6 depicts another embodiment of trough, hanger, and deflector devised in accordance with a preferred embodiment of the present invention.
FIG. 7 is an enlarged depiction showing a containment wall border area of a trough configured in accordance with a preferred embodiment of the present invention.
FIG. 8 is an enlarged depiction of a receptive cavity structure of a hanger configured in accordance with a preferred embodiment.
FIG. 9 depicts the border area of a trough and a receptive cavity structure of a hanger configured in accordance with a preferred embodiment of the present invention.
FIG. 10 depicts the border area of a trough and a receptive cavity structure of a hanger configured in accordance with an alternative embodiment of the present invention.
FIG. 11 depicts the border area of a trough and a receptive cavity structure of a hanger configured in accordance with an alternative embodiment of the present invention.
FIG. 12 depicts the border area of a trough and a receptive cavity structure of a hanger configured in accordance with another alternative embodiment of the present invention.
FIG. 13 is an end-on depiction of a forming machine disposed above a second forming machine as employed in a preferred embodiment of the present invention.
FIG. 14 is a plan view of two offset forming machines as employed in a preferred embodiment of the present invention.
FIG. 15 depicts two-armed run-out stands as employed in a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 depicts a cross-sectional view of a prior art trough 5 of standard configuration that is common in the field. As shown in FIG. 1, the depicted trough 5 has a folded edge or shelf along its front containment wall.
FIG. 2 depicts a cross-sectional view of a trough 10 configured in accordance with a preferred embodiment of the present invention. Trough 10 has a front containment wall 12 that has an inwardly projecting shelf 14 that is part of containment wall border area 16 of front containment wall 12 . Trough 10 has a back wall 18 . As shown, containment wall 12 need not be a planar wall but may take a variety of shapes and configurations to provide a containment function for collected liquid. Between front containment wall 12 and back wall 18 , a channel is formed for water collection and diversion bottomed with floor 20 . In an embodiment having a rounded or “half-round” trough, it will be recognized that there is no distinct floor 20 and front containment wall 12 and back wall 18 will not have traditional “wall” planar areas but blend into an arcuate floor area.
In a 5-inch embodiment of trough 10 in which there is approximately 5 inches between back wall 18 and the farthest reach of containment wall border area 16 , standard material coil of 11⅞ inches may be employed. As those of skill in the art will recognize, standard material coil may exhibit some variation in width depending upon manufacturer or local custom. Consequently, in a preferred embodiment employing standard material, standard material between 11⅝ inches and 12 inches in width may be employed to create trough 10 with a 5 inch opening. Certainly other sizes of troughs can be created to advantage by employment of the present invention. For example, the well-known 6-inch trough can be created in conformity with an alternative embodiment of the present invention by use of 15 inch material coil. Containment wall border area 16 may be formed by bending, folding, forming or other of the well-known means for configuring trough 10 . A preferred method for creating containment wall border area 16 is with a roller-based machine at the same time that the configuration of trough 10 is created from coil stock. When a 5 inch trough in accordance with a preferred embodiment of the present invention is created with a roller-based machine, the standard material coil stock is positioned so as to move the furthest reach of the formed back wall between ¾ and 1 inch from the place the furthest reach of the back wall would occupy in formation of a standard OG gutter trough so as to bring greater height to the back wall for deflector inclination during trough formation. As well as using forms in accordance with the present invention, the material is shifted around the form relative to the material placement employed in forming the OG gutter.
FIG. 3 depicts as assembly 15 , a cross-sectional view of trough 10 in use with hanger 30 and deflector 40 in accordance with a preferred embodiment of the present invention. The system described can be used either with or without deflector 40 .
As shown in FIG. 3, hanger 30 includes optional deflector attachment cavities 32 and 34 . In the depicted embodiment, hanger 30 is stamped from metal, but any number of materials and formation techniques may be used to create a hanger 30 having the features described here. For example, hanger 30 may be made of metal or plastic such as Teflon, or higher strength polys. If made of metal, hanger 30 can be forged, stamped, extruded, die cut or cast or other technique familiar to the trade. Hanger 30 includes receptive cavity structure 31 that will be later described in more detail while front containment wall 12 exhibits containment wall border area 16 that will be described in more detail. FIG. 4 depicts a cross-sectional view of a half-round trough assembled with a hanger and deflector in accordance with a preferred embodiment of the present invention.
With reference to FIGS. 3 and 5 (which figure illustrates an enlarged portion of FIG. 3 about the area of flex fold 42 ), deflector 40 is selectably attached to hanger 30 by insertion of flex fold 42 into cavity 34 and insertion of attachment fold 46 into cavity 32 . In a preferred compression embodiment, curve 44 provides a ready method to accomplish this selective attachment. Those of skill in the art will recognize that flex fold 42 and attachment fold 46 are first and second long axis perimeters of deflector 40 and need not be “folds” but may be any edge or fold or border of the deflector which may be inserted into the appropriate cavity of the hanger. This selectable attachment feature of deflector 40 as shown in this depiction of a preferred embodiment of the present invention allows assemblage of deflector 40 to hanger 30 before the assembly 15 is installed on a structure.
As shown in conjunction with FIG. 3 and FIG. 5, hanger 30 has optional penetrative prongs 36 shown penetrating back wall 18 of trough 10 . As shown more closely in FIG. 5, prongs 36 preferably have a concavity 38 that cooperates with dimple 39 on back wall 18 to preliminarily position hanger 30 for prong insertion through back wall 18 with an appropriate compression tool such as a specialized pliers or other readily available and adapted instrument. Back abutment 41 of hanger 30 is placed against back wall 18 with concavity 38 placed against dimple 39 and the compression tool pushes prongs through the back wall 18 . There need not be a specially configured structure for an abutment for hanger 30 , the back of the structure of hanger 30 disposed against back wall 18 being the abutment. The prongs are folded by the compression tool against the back of back wall 18 to affix hanger 30 . This operation can be performed before attachment of the trough to the structure and may be performed at the machine site or elsewhere to affix back wall 18 in relation to front containment wall 12 while creating a mechanically sound structure ready for attachment of deflector 40 . Hanger 30 need not have prongs 36 but their use is advantageous.
As described with continuing reference to FIGS. 3 and 5, flex fold 42 of deflector 40 cooperates with cavity 34 to allow a resistance hinge-like action of deflector 40 . In particular, deflector 40 may be lifted from hanger 30 by compression of curve 44 of deflector 40 to remove attachment fold 46 of deflector 40 from cavity 32 . The forward part of deflector 40 is then lifted from its position as flex fold 42 and cavity 32 allow a spring-like rotational opening of a gap between deflector 40 and hanger 30 through which fastener 50 may manipulated to install assembly 15 on the structure as fastener 50 is screwed or pounded or otherwise inserted into place. In embodiments with penetrative fasteners, fastener 50 may be a nail or screw or spike or other such projecting fastener, many of which are common in the field. Other techniques for hanging assembly 15 are known in the art. Hanger 30 includes, in a preferred embodiment, indent 48 to mate with ridge 52 of deflector 40 while stop 54 of hanger 30 inhibits deflector 30 from unpredicted separation from hanger 30 , particularly during installation or servicing. In a preferred embodiment, fastener 50 slides into a guide slot 56 created in hanger 30 to avoid addition of height or special platforms to hanger 30 . The compression fitting of deflector 40 into cavities 32 and 34 allows ready placement of deflector 40 on the trough 10 and hanger 30 combination at the machine-site to allow a single installation trip from machine site to installation site with the combined structure of deflector and trough.
FIG. 6 depicts another embodiment of assembly 15 devised in accordance with the present invention and which employs an extruded hanger 30 . FIG. 6 depicts fastener 50 as it would be engaged into a structure. Those of skill in the art will recognize that the disclosed configuration allows the front of deflector 40 to be lifted from hanger 30 to insert fastener 50 into the structure.
FIG. 7 is an enlarged depiction showing containment wall border area 16 of trough 10 of FIG. 3 . As shown in FIG. 7, containment wall border area 16 includes containment edge or shelf 52 that extends inwardly to the trough. Either part or all of containment shelf 52 may extend inwardly to the trough and that inward extension may be at an angle or horizontal orientation. In a preferred embodiment, containment wall border area 16 includes rise 53 . Containment shelf 52 may be folded, or a single material thickness and may extend horizontally (as shown in the preferred embodiment view of FIG. 7) or at an angle from the horizontal as shown in FIG. 10, or have a vertical extension as shown, for example, in FIG. 11 . Part or all of shelf 52 can, but need not, be canted at an angle to match the configuration of containment lip 54 of receptive cavity structure 31 of hanger 30 . Consequently, those of skill in the art will recognize that containment lip 54 may take a variety of configurations to cooperate with the variety of configurations of containment shelf 52 within the scope of the invention to extend a portion of containment lip 54 over a portion of containment shelf 52 and thereby, according to the vernacular of the present disclosure, “mate” containment lip 54 with containment shelf 52 . The part of containment shelf 52 that extends inwardly to the trough need not be the portion of shelf 52 over which a portion of containment lip 54 extends to mate with containment shelf 52 . When a portion of containment lip 54 extends over a portion of containment shelf 52 , the elements are mated.
FIG. 8 is an enlarged depiction of receptive cavity structure 31 of hanger 30 in a preferred embodiment. Receptive cavity structure 31 as shown in FIG. 8, includes fulcrum ridge 56 over which, rise 53 of front containment wall border area 16 tents.
FIG. 9 depicts a preferred disposition of containment lip 54 mated with containment shelf 52 to provide functional water bearing capacity for trough 10 while still allowing sufficient standard material coil to provide a back wall 18 of sufficient height to provide necessary inclination for deflector 40 . In this preferred depiction, containment lip 54 is mated with containment shelf 52 .
FIGS. 10, 11 , and 12 depict alternative arrangements for the mating between containment lip 54 and containment shelf 52 and they are included only as example embodiments and not as limitations for the scope of the present invention. FIG. 10 depicts an alternative embodiment of the invention showing containment shelf 52 as angled upward and containment lip 54 as angled downward as shelf 52 and lip 54 are mated. In other alternative and exemplar but not to be construed as limiting embodiments, containment lip 54 may be horizontal while containment shelf 52 is angled or containment lip 54 may be angled while containment shelf 52 exhibits a horizontal character or each may be independently angled or horizontal.
FIG. 11 shows another alternative embodiment of the present invention in which containment lip 54 extends over a vertical extension portion of containment shelf 52 . This is another example of the mating of containment lip 54 and containment shelf 52 .
FIG. 12 shows yet another alternative embodiment of the present invention in which containment lip 54 has an extension that deflects downward over a portion of containment shelf 52 . Containment lip 54 and containment shelf 52 are mated in the depiction of FIG. 12 .
The present invention provides numerous advantages during installation of the system. A preferred method for installation includes formation of deflector 40 with a machine placed above a forming machine dedicated to formation of trough 10 . FIG. 13 depicts forming machine 72 disposed above forming machine 70 in the bed 74 of a truck. The machines need not be placed on the truck bed that is merely shown as an exemplar setting. Preferably, a track is employed that allows forward and backward movement of upper machine 72 relative to the bottom machine 70 for maintenance of the lower machine 70 as will be recognized by those of skill in the art. Machine 70 is configured to form lengths of trough 10 configured in accordance with the present invention, while machine 72 is configured to form lengths of deflector 40 configured in accordance with the present invention.
In a preferred method in accordance with the present invention, material cradles 74 and 76 of the respective machines 70 and 72 are loaded with coil. Trough machine 70 consumes coil material 75 of 11⅞ inches in width in an application configured to produce troughs 5 inches in width. Other widths of coil may also be used. Cradle 76 of deflector machine 72 is loaded with coil material 77 of between 7⅝ inches and 8 inches to produce deflectors. Other widths may be used for larger or smaller configurations. Emergent from machine 70 are lengths 78 of trough 10 . Emergent from machine 72 are lengths 80 of deflector 40 .
As shown in FIG. 15, two-armed run-out stands 82 and 84 having upper arms 86 and lower arms 88 provide work placement for lengths of deflector 40 and trough 10 . End caps 90 a are placed in appropriate locations. In a preferred embodiment, end caps are two-piece, with piece 90 a fitted to troughs 10 and piece 90 b fitted to deflector 40 .
A preferred method for installation of the present system proceeds as follows. As length 78 of trough 10 is run from machine 70 , end caps 90 a are installed where appropriate, outlet sites are punched and outlets installed for joinder with downspouts, miters are cut and cavity structure 31 of hanger 30 is brought into place to mate containment lip 54 of hanger 30 with containment shelf 52 of trough 10 . Hangers 30 are punched through the backwall 18 of trough 10 and prongs 36 are crimped. These steps can be performed either at the machine or with the assistance of the run-out stands. Hanger fitted trough 10 is rested on run-out stands.
Corresponding length 80 of deflector 40 is run from machine 72 and is installed with end caps 90 b and miters are cut appropriate. Length 80 of deflector 40 is placed on length 78 of trough 10 as deflector attachment cavities 34 and 32 are used to retain deflector 40 . In alternative methods, cavity 34 is used to retain deflector 40 for conveyance to the installation location on the structure but, where some distance is involved, use of both cavities 32 and 34 keeps deflector 40 more securely retained. In either case, the entire assembly may then be transported to a location on a lower level such as ground, for example, corresponding to the eventual installation location on the structure. The process is repeated until all assemblies of trough, hangers and deflector have been processed.
Two installers are then employed on ladders or other riser to position each length of assembled trough, hangers, and deflector into place against the structure where the assembly is fastened into place in at least two locations. This is simplified by the feature of the present invention that allows compression fitting of the deflector into the appropriate cavities of hanger 30 . The process of two-installer positioning continues around the structure. One installer takes up a position on the roof of the structure or ladder and completes the affixation of the fasteners 50 . This can be readily performed by one person due to the compression fitting of deflector 40 that allows opening the assembly to reach fastener 50 . Once fasteners for a length of the assembly have been affixed, deflector 40 is compressed to fit flex fold 42 and attachment fold 46 of deflector 40 to cavities 34 and 32 respectively of deflector 40 . As the roof or ladder positioned installer proceeds with this procedure of fastener affixation, the second installer forms downspouts and attaches them to the structure.
Although the present invention has been described in detail, it will be apparent to those skilled in the art that the invention may be embodied in a variety of specific forms and that various changes, substitutions and alterations can be made without departing from the spirit and scope of the invention. The described embodiments are only illustrative and not restrictive and the scope of the invention is, therefore, indicated by the following claims.
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A shelf extends inwardly to the gutter trough from the front containment wall of a gutter trough to cooperate with a lip of a cavity structure of a hanger to provide structural stability and optional deflector attachment facility in a rain collection and diversion system. The hanger cavity structure has a containment lip a portion of which extends over a portion of the inwardly extending shelf of the front containment wall to allow functional water bearing capacity of the trough and a lengthened back trough wall to accommodate hanger placement and deflector inclination. The hanger can include deflector-mating cavities that open toward each other to allow compression attachment of the deflector. In a preferred embodiment, the deflector may be attached to a formed trough in which hangers are positioned to allow movement of the trough-deflector combination as a unit from the machine-site to the installation location on the structure. Associated installation methods are provided.
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RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 11/678,905 filed Feb. 26, 2007, now U.S. Pat. No. 7,343,985.
BACKGROUND
1. Field of the Invention
The field of the invention pertains to drilling fluid additives that may be used to remediate bit balling that otherwise occurs in clay and shale (hereafter referred to collectively as ‘clay’) zones as a well is drilled.
2. Description of the Related Art
Water-based drilling mud systems are usually employed during the drilling of a well, such as an oil or gas well. The well bore may penetrate a clay zone, and this circumstance exposes naturally occurring clay minerals. Water in the mud is able to hydrate the clay minerals, which then typically swell to cause a number of known problems.
The clay problems may be addressed by using chemical treating agents. This is done using salts and/or polymers in the drilling mud. Salts, such as KCl or CaCl, reduce the clay swelling and dispersion. Such polymers as partially hydrolyzed polyacrylamide are sometimes added to the drilling mud used to encapsulate the clay, thus keeping the clay from hydrating and swelling. Alternatively, oil-based mud may be used to prevent the swelling phenomenon, but since oil mud also contains water, it is necessary that the salinity of the water be sufficiently high to prevent water from entering the clay by osmosis.
Bit balling is one problem that is frequently encountered when drilling through clay. The problem is caused by the tendency of hydrated clay minerals to stick or adhere to the bit and bottom-hole assembly of a drill string. Although this problem may also occur in oil based mud, it is relatively rare as compared to water-based mud. From an operations standpoint, bit balling is evidenced by increased pump pressures as the flow pathway through the well bore annulus becomes blocked, reduced rates of penetration, blocked shaker screens, a required over-pull tension that occurs due to a restricted annulus when tripping pipe, and possible stuck pipe.
Once bit balling is diagnosed, conventional methods of remediation are to increase the weight on the bit, add chemicals and perhaps pull the drill pipe out of the hole to clean the bit and bottom hole assembly. For a water-based mud, a detergent may be added to the drilling mud to reduce the ability of the hydrated clay to stick to the bit and bottom hole assembly. Glycol may also be added at about 3% to 4% of system volume. This often fails to cure the problem.
Preventative measures against bit balling include the review of prior drilling reports to ascertain and adopt procedures that have previously worked in the geographic area to overcome bit balling. A KCl/polymer or CaCl/polymer mud may be used to inhibit the swelling of clays. The selection of a bit may also affect bit balling, where it is known that polycrystalline diamond compact bits are more prone to balling than are tri-cone bits, and it is further the case that the arrangement of teeth structures on tri-cone bits may affect bit balling. This is shown for example, in U.S. Pat. No. 4,984,643 issued to Isbell et al.
Another way to address the problem of bit balling is to optimize the mud system hydraulics. This may be done for either large or small bore bits. In addition to sizing the nozzles for optimum delivery of hydraulic horsepower, it is also possible to direct the nozzle discharge to optimize bottom-hole cleaning in a ‘mud pick’ configuration. This is reported, for example, in Smith et al., Hydraulics Optimization Research in Large Diameter Bits Reduces Operator's Variable Costs, AASDE-05-NTCE-58 (2005).
It has also been reported that maintaining a negative potential of a few volts on the drill string assembly may liberate water at the interface between the bit and the hydrated clay. See Sanjit et al., The effect of electro-osmosis on the indentation of clays, Proceedings of the 32nd US Rock Mechanics Symposium, Norman Okla. (July 1991).
Although the art does provide remedial measures, bit balling continues to be a significant factor affecting the costs of drilling new wells. It is particularly difficult to pump pills of material to remediate the problem of bit balling, and any such measures often provide only temporary relief.
SUMMARY
The present instrumentalities overcome the problems outlined above and advances the art by providing a compact and easy to use article of manufacture for introducing treatments to a drilling mud system.
In one embodiment, the article is formed as a solid body that contains a combination of nut hulls and a surfactant that are bound together with an optional carrier. As used herein the term “solid” also encompasses a gel unless specifically noted otherwise. The carrier may be a soft wax, such as beeswax, having a melting temperature much less than is expected at the bit. Beeswax generally melts at a temperature of 144° to 149° F. Thus, in an area where there exists a geothermal gradient of 1.8° F. per 100 feet of well, it may be expected that a well in excess of 8000 feet of depth will reach this temperature. A plasticizer, such as glycerol or castor oil, may be added to reduce the melting temperature. Alternatively, a water soluble polymer may be used as the carrier. This may be, for example, an ethylene/vinyl alcohol copolymer with a de-structured starch composition and a plasticizer, such as glycerin, with urea as a de-structuring agent. Suitable compositions are reported in EP0400532A1 to Bastioli et al., which is incorporated by reference to the same extent as though fully disclosed herein. The carrier is nonessential, since the surfactant itself may bind the nut hulls.
In dissolved form, the solid body forms a pill. A “pill” is hereby defined as any relatively small quantity, less than 200 bbl, of a special drilling fluid that is provided to accomplish a specific task that the regular drilling fluid cannot perform. Examples of conventional pills include the use of high-viscosity pills to help lift cuttings out of a vertical well bore, pipe-freeing pills to destroy filter cake and relieve differential sticking forces and lost circulation material pills to plug a thief zone. The pill that is formed of the dissolved solid body is used against bit balling.
The surfactant may be any surfactant; which may be a detergent, a wetting agent, or an emulsifier. Detergents are preferred. The detergent may be a soap, such as a sodium soap of a fatty acid. The detergent may also be classified as an ionic, anionic, or cationic detergent depending upon the mode of action. Sulfonates are especially preferred, and particularly linear alkyl sulfonates for their biodegradability. Soaps may be particularly useful, as a saponification reaction may be used to react and harden a glycerol ester as a soap during the casting process. In some embodiments, a potassium or sodium lye may be used to saponify a C15 to C20 fatty acid. The C18 fatty acids are particularly preferred where, for example, the resultant soap may be a saponified castor oil comprised mostly of ricinoleic acid, or oleic acid.
The nut hulls may be any nut hulls, but the use of walnut hulls is particularly preferred. Crushed walnut hulls that have been screened through −30/+60 US mesh are commonly purchased on commercial order and used to remediate lost circulation in wells. These may be mixed with other hull materials, including similarly sized cottonseed hulls, pecan shells, and almond shells. Use of the walnut hulls in the present instrumentality differs in that the walnut hulls are generally hard and lightweight, and may be used to blast hydrated clay from the bit and bottom hole assembly, once softened by the surfactant.
The article of manufacture may be used in a method of treating a drilling mud system to overcome bit balling
The following disclosure makes these and other advantages are apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a solid body that may be used to provide a pill for the treatment of bit balling;
FIG. 2 is a cross-sectional view taken along line 2 - 2 ′ of FIG. 1 ;
FIG. 3 shows another embodiment of the solid body;
FIG. 4 shows the solid body being inserted into a drill string;
FIG. 5 is a top view of the solid body inserted into the drill string;
FIG. 6 shows an improvement in a rate of penetration obtained form use of a pill that contains a combination of a detergent and crushed nut hulls;
FIG. 7 shows a system for molding the solid body;
FIG. 8 provides additional detail for the molding system of FIG. 7 ; and
FIG. 9 shows an alternative embodiment that contains the pill in a prepackaged amount that is contained in a plastic bottle using a liquid surfactant for make a slurry with the crushed nut hulls.
DETAILED DESCRIPTION
There will now be shown and described an article for use in treating a bit balling problem. FIG. 1 shows an article 100 that is formed as a generally cylindrical tube having a diameter D and a length L. A center hole 102 presents a diameter D′. A wall 104 is made of a surfactant, crushed hulls, and a dissoluble carrier. FIG. 2 presents a sectional view taken along line 2 - 2 ′ of FIG. 1 .
Dimensions are not critical, except the diameter D must be sufficiently small to pass through the interior of a drill pipe. Hole 102 is provided to assist circulation of mud through the article 100 , in order to facilitate dissolution. By way of example, suitable dimensions for most applications include a diameter D of 1 to 1.5 inches, a length L of about 20 to 30 inches, with 27 inches being most preferred, and a diameter D′ of about 1/16 to ½ inch.
Article 100 contains a combination of nut hulls and a surfactant that are bound together with a carrier. The carrier may be a soft wax, such as beeswax, having a melting temperature much less than is expected at the bit. Beeswax generally melts at a temperature of 144° to 149° F. Thus, in an area where there exists a geothermal gradient of 1.8° F. per 100 feet of well bore, it may be expected that a well in excess of 8000 feet of depth will reach this temperature. A plasticizer, such as glycerol, may be added to reduce the melting temperature suitably for shallower depths. Alternatively, a water soluble polymer may be used as the carrier. This may be, for example, an ethylene/vinyl alcohol copolymer with a de-structured starch composition and a plasticizer, such as glycerin. Urea may be used as a de-structuring agent. Suitable polymeric compositions for this use are reported in EP0400532A1 to Bastioli et al.
In some cases, the carrier may be a soap. It is possible to combine the nut hulls with the glycerol ester of a fatty acid, or another ester, pour the mixture into a mold, and cast the article 100 to saponify and harden the mixture, then release from the mold. In this case, the resultant soap holds together the nut hulls.
FIG. 3 shows another embodiment as article 300 with center hole 302 . In this case, half of the article 300 is a surfactant 304 and the other half 306 contains nut hulls bound with a carrier, as described above in context of the wall 104 that is shown in FIG. 1 . The respective halves 304 , 306 are cast together in a common mold.
FIG. 4 shows article 100 in use. Drill pipe 400 is retained by slips 402 in a rotary table 404 . The drill string, as represented by drill pipe 400 , is broken to make a new connection. Tongs 406 are in position for use in assembling the next connection, as is required to advance the drill pipe 400 down the well-bore as the well is drilled. The article 100 is being placed into a female joint 408 that will receive a male pin of the next piece of drill pipe (not shown) as the connection proceeds. Any number of articles 100 may be manually placed in the drill pipe 400 in this manner.
FIG. 5 shows the article 100 positioned in the female joint 408 . A threaded surface 500 transitions to a curved wall 502 and conduit 504 . Article 100 resides within conduit 504 . From this position, the connection may be assembled with joint 408 , and active drilling may recommence. The recommencement of drilling necessarily entails the pumping of mud through conduit 504 . The mud drives article 100 down hole towards the bit. As article 100 proceeds down hole the water in the mud and/or temperature of the mud tends to dissolve article 100 to release the surfactant and the nut hulls, providing what is known in the art as a ‘pill’. The surfactant and the nut hulls pass through the nozzles of a drilling bit and enter the annulus of the well-bore where they work against bit balling. The hole 102 and the space between article 100 and the walls of conduit 504 assures that mud pumped through conduit 504 is able to bypass article 100 , in order that article does not fully obstruct conduit 504 if article 100 has not completely dissolved by the time it reaches the drill bit (not shown) at the bottom of the hole.
FIG. 6 shows an improvement in rate of penetration that was obtained using a pill of this nature where the pill contained 0.1 gallons of crushed walnut hulls and 0.3 gallons of liquid soap. The “after” penetration rate shows comparatively that a bit balling problem has been overcome.
FIG. 7 shows a system 700 that may be used to make article 100 . An injection system 702 disburses liquid material through line 704 into to mold system 706 . A nut hull hopper 708 provides nut hull material for combination with the liquid in the mold system 706 . The injection system 702 may be, for example, a screw extruder system for the liquefaction of water soluble polymer material, as described above in context of EP0400532A1. The injection system 702 may also be a metering system for pumping a soap precursor that may be saponified in the mold system 706 . Initially cast with a liquid, the articles 100 , 300 harden in the mold system 706 .
FIG. 8 provides additional detail with respect to one embodiment of the mold system 706 . A bivalve mold 800 is formed of respective halves 802 , 804 , which are notched as at 806 , 808 to accommodate line 704 . Upon opening of the mold 800 , a robotic arm 810 imparts motion 812 , 814 to swing the halves 802 , 804 away from line 704 . With the mold 800 removed in this way, a pneumatic cylinder 816 is mounted on line 704 , and is capable of extending head 818 in direction 820 to release cast articles 100 from line 704 . The arm 810 then positions the mold 800 as shown in FIG. 8 for receipt of nut material from nut hopper 708 (not shown in FIG. 8 ). With the mold 800 subsequently closed, line 704 receives liquid material from the injection system 702 and disburses the same into mold cavity 822 through perforations 824 . The mold halves 802 , 804 may be configured with a heating structure, such as resistive electrical coils or a water jacket (not shown) to heat materials in the mold, for example, to perform a saponification reaction.
FIG. 9 shows a plastic bottle 900 having a screw-on lid 902 and a body that is formed of wall 904 leading to a tapered shoulder 906 . The bottle may be used to package a liquid or slurry form of the pill. For example, ground walnut hulls may be combined with a liquid detergent and packaged within bottle 900 . The bottle 900 may be shaken to more or less evenly disperse the contents. The cap 902 is then unscrewed, and the bottle 900 is inverted over the open end of the top pipe in a drill string (not shown) to pour the contents of bottle 900 into the drill string. If needed, the shoulder 906 may form a temporary seal to facilitate the pouring operation.
EXAMPLES
Table 1 provides various formulations of materials that may be used as articles 100 or 300 : A 1.5″ diameter stick that is 27″ long contains 0.27 gallons of material. Although this is less than the total of 0.4 gallons used in actual testing reported herein two or more sticks may be used at one time in a stacked sequential order. The calculations below are based on a total stick volume of 0.27 gallons.
TABLE 1
Example compositions
Article
Material
Amount
Processing Comments
A
Saponified Castor Oil
0.2 gal
Heat to 115°. Mix .01 gal
(SCO)
of the SCO together with
Crushed walnut hulls
0.07 gal
the walnut hulls. Inject
sized - 30/+60 US mesh
remainder of the SCO into
one end of the mold and
the SCO/Walnut hull
mixture into the other end.
Cool for 360 minutes.
Remove from mold.
B
Beeswax
.01 gal
Heat Beeswax to 144°
Saponified Castor Oil
0.19 gal
and mix with walnut hulls.
(SCO)
Heat SCO to 115°. Inject
Crushed walnut hulls
0.07 gal
each mixture into opposite
sized - 30/+60 US mesh
ends of the mold. Cool for
360 minutes. Remove
from mold.
C
Oleic Acid
0.14 gal
Add Lye to water. Mix
Lye
0.02 gal
lye/water solution into
Crushed walnut hulls
0.07 gal
Oleic Acid. Stir until
sized - 30/+60 US mesh
thick. Mix .01 gal of this
solution together with the
walnut hulls. Inject
remainder of the solution
into one end of the mold
and the Walnut hull
mixture into the other end.
Cool for 360 minutes.
Remove from mold.
Water
0.04 gal
Those skilled in the art appreciate that the foregoing instrumentalities teach by way of example, and not by limitation. Accordingly, what is claimed as the invention also encompasses insubstantial changes with respect to what is claimed. The inventor hereby states his intention to rely upon the Doctrine of Equivalents to protect the scope and spirit of the invention.
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A solid body contains a surfactant and crushed walnut hulls. The solid body is shaped to predetermined dimensions that permit passage through the central interior opening of drill pipe. The solid body dissolves in drilling mud for delivery of a pill to the annulus through the drill bit nozzles. The pill is an effective treatment against bit balling.
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TECHNICAL FIELD OF THE INVENTION
The present invention relates to the general art of swimming accessories, and to the particular field of scuba diving accessories.
BACKGROUND OF THE INVENTION
The problem of conveniently carrying, accessing, and using a camera under various operating conditions has existed since the beginning of hand-held photography. With the spread of digital photography, which allows inexpensive photograph storage and capture, more individuals are exposed to the inherent limitations that camera securement imposes during periods of activity. Fast-paced and strenuous physical activities such as surfing, jogging, mountain climbing, snowboarding, and skydiving often require the individual to fully concentrate on the activity rather than on capturing photographs or video. Furthermore, such activities often leave the participant without a free hand to operate the camera.
The problem of conveniently carrying, accessing, and using a camera under various operating conditions has existed since the beginning of hand-held photography. It has become even more of a problem in recent years as a growing number of photographers attempt to take action photographs while participating in fast-paced physical activities such as surfing, snorkeling, skiing, mountain biking, kayaking, rafting and so on. Activities such as these often leave a photographer without pockets, purses, or even enough time to fetch a camera from such a place if he or she hopes to get a photo of the action while it is occurring.
Even in the event that a photographer is able to quickly access a camera during such an activity, an accidental fall or change of circumstances could make it difficult for the photographer to hold on to the camera. The camera could be damaged, broken or lost altogether in the event that the photographer might quickly need both of his or her hands free to ensure his or her safety. It is possible that people would take more photographs, and even better photographs, during their favorite physical activities if there was a convenient way for them to carry, quickly access, and then securely use a camera at such a time.
Another problem with taking photographs during fast-paced physical activities is the question of what to do with the camera after a photograph has been taken. For example, a surfing photographer taking a photograph of a breaking wave might quickly need his or her hands free to push their surfboard under the wave after taking the photograph. Perhaps a rafting photographer wants to photograph the harrowing view of the rapids just before entering them, but he or she might immediately thereafter need both hands free to brace themselves or to steer the raft. In either case, the photographer may not have enough time to securely store the camera after taking a photograph.
Additionally, the photographer might just prefer to have the camera immediately out of the way so that he or she can enjoy the given activity without the hassle of stowing their camera. Whatever the circumstance, there is currently no solution that solves the problems associated with conveniently carrying, quickly accessing, securely using and then quickly stowing a camera during periods of physical activity such as surfing, snorkeling, kayaking, rafting, etc.
There have been attempts to provide a solution to these problems. For years, rubber bands and wrist or neck ropes have been included with new cameras in an effort to provide the photographer with a convenient way to carry the camera. While this may suffice for a walk in the park, surfing a wave or rafting the rapids with a camera swinging wildly from one's wrist or neck is a less than ideal or safe way to carry a camera while participating in such an activity. Either the photographer, the camera, or people nearby may be harmed by the swinging camera.
The camera could be easily lost if the photographer is unable to adequately clutch the rubber band or nylon strap draped around their wrist. And while this method of carrying a camera does provide for immediate access to the camera, it unfortunately does not allow the user to have both hands free for participating in the given activity when the camera is not needed. In this way, a simple rubber band or nylon strap solution handicaps the photographer's participation in and enjoyment of the given activity and to a certain extent sacrifices their own safety and the safety of the camera.
Hence, conventional devices or solutions fail to provide adequate means for a photographer to conveniently carry, access, securely hold and use, and then quickly stow away a camera while participating in a physical activity. Therefore, there is a need for a solution that allows for carrying a camera in a further secured position, provides quick access to for holding and using the camera while still remaining secured to the user, and then quickly stowing the camera into the aforementioned further secured position.
Under water photography has become popular in recent years, especially with the introduction of inexpensive, one time use, waterproof cameras such as Kodak's “Max Sport” camera. During the process of swimming it is necessary for a person to use both hands and arms to help propel him or herself through the water. Carrying a camera becomes problematic because it forces the user to relinquish one hand to the job of carrying the camera. The camera may be carried in a pocket on the user's swimming outfit, or may be retained by means of a lanyard that attaches to the camera at one end and wraps around the users wrist or neck, unfortunately, these retaining means tend to be problematic in that the user must pull the camera out of a pocket or must retrieve that camera from its lanyard and position the camera for taking a photo, a time consuming process that may cause the user to be too slow in taking a photo of a moving object such as a fish. Additionally, there may be other applications for a wrist mounted camera holder under other conditions such as during sports activities or other applications where the user wants to use a camera for quick photo opportunities while having both hands free when not using the camera.
Therefore, there is a need for a means for mounting a camera, such as a GoPro® camera, on a swimmer or diver in a secure manner which is convenient for use and does not unduly interfere with the swimming activity.
SUMMARY OF THE INVENTION
The above-discussed disadvantages of the prior art are overcome by a GoPro® pivoting/swivel mount that is securely integrated with high quality Mechanix® type gloves that are used for diving.
The preferred form of the device embodying the present invention will co-operate with a GoPro® camera mount that is attached to gloves, thus enabling a diver to film left or right handed, and be able to move the camera easily during a dive or any activity. The mount in the preferred form of the invention is a 360° swivel GoPro® mount.
The device of the present invention can be used for any activity that doesn't require the use of one's hands. There are limitless uses of the device when diving, climbing, surfing, skating, skydiving, cycling, hunting, shooting, etc. The device will provide protection against chaffing and will offer a feasible way to film while doing activities.
The preferred form of this invention is a tool for scuba diving. Typically, GOPRO® cameras are mounted to the top of a user's head. When scuba diving, there is no way to know exactly what the diver is filming when under water. By mounting the camera to a glove since the swimmer is swimming with arms fully extended the swimmer always have direct visual contact to what he is filming. For the fact the swimmer's arms are fully extended anyway, this product is perfect for the scuba diver to continually see what he is filming.
Other systems, methods, features, and advantages of the invention will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the different views.
FIG. 1 shows a GoPro® camera and mount which will be mounted on a glove using the unit embodying the present invention.
FIG. 2 shows the GoPro® camera in combination with a glove to which it will be mounted using the unit embodying the present invention
FIG. 3 is a shows the unit embodying the present invention.
FIG. 4 shows a support brace that can be used in conjunction with the unit embodying the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the figures, it can be understood that the present invention is embodied in a unit 10 for mounting a GoPro® camera unit 20 on a glove 30 which is worn by a swimmer, such as a SCUBA diver to record his or her surroundings during the swim. The GoPro® camera unit is well known and therefore will not be discussed in detail. Unit 20 includes a mount 40 having an adhesive surface 42 for securely mounting camera support 44 on a chosen surface. Mount 40 is an accessory commonly supplied by GoPro® and support 44 is also an accessory commonly supplied by GoPro® for mounting the camera. Those skilled in the art will understand how mount 40 cooperates with camera support 44 to support a camera; therefore, these details will not be provided.
Referring to FIGS. 2 and 3 it can be understood that glove 30 has a palm portion 31 , a back portion 32 , a thumb portion 33 , a finger portion 34 , an inside surface 35 , and an outside surface 36 . The unit 10 for mounting a GoPro® camera on the glove comprises a base 50 which is securely mounted on the inside surface of the glove on the back portion of the glove adjacent to the thumb portion. An arcuate rail 60 has a bottom rim 62 securely affixed to the base, a top rim 64 spaced apart from the base and from the top surface of the back portion of the glove. The rim extends for 360°, but only a portion of the rim is shown in FIG. 3 for the sake of clarity.
A spring-biased locking pin 70 is mounted on the rail. The locking pin has a body 72 which extends through the rail and a proximal end 74 located within the perimeter of the rail and a distal end 76 located outside the perimeter of the rail. A head 78 is on the distal end of the locking pin. The locking pin includes a spring element 80 which at one end engages the rail and at another end engages an abutment 82 on the body of the pin and biases the pin radially inwardly of the arcuate rail as indicated by arrow 84 . The pin is withdrawn by pulling on the head against the bias of the spring for a purpose which will be understood from the teaching of this disclosure.
A swivel element 100 is rotatably mounted on the base to rotate inside the circumference of the arcuate rail. The swivel element extends through the glove and has a plurality of angularly spaced-apart grooves thereon, such as groove 110 . The grooves are located on the swivel element to cooperate with the proximal end of the locking pin to lock the swivel element in a chosen position by engaging the locking pin in a chosen groove. In this manner, the orientation of the camera can be selected and adjusted in two planes: in the horizontal plane by using unit 10 and in the vertical plane by using the GoPro®-supplied adjustment accessory.
A mounting element 120 is located on the swivel element having a top surface on which the mount 40 of the GoPro® camera can be affixed. Adhesive 130 can be located on mounting element 120 to secure mount 40 to mounting element 120 .
The glove can include a reinforcing brace 140 shown in FIG. 4 , integrated with the body and material of the glove to provide extra support for the unit 10 with the base of the unit being secured to the brace. The brace is X-shaped and includes a main portion 142 located to support base 50 on the back of the wearer's hand, a first strap portion 144 which extends around the hand between the first digit 145 of the fingers and thumb 146 , a second strap portion 147 which extends around the hand adjacent to the fingers opposite to the thumb to extend between the third digit 148 and fourth digit 149 (with the fourth digit being commonly known as the little finger and the third digit being the digit immediately adjacent to the little finger), a third strap portion 150 which extends around the hand between the base of the thumb and the wrist, and a fourth strap portion 152 which extends between the fourth digit 149 (the little finger) and the wrist 154 on the heel of the hand 156 . The brace is X-shaped with the base engaging portion in the middle and the straps defining the X-shape. The reinforcing brace can be formed of any suitable material.
While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of this invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.
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A GoPro® pivoting/swivel mount that is securely integrated with high quality Mechanix® type gloves that are used for diving.
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[0001] This is a national stage of PCT/AT2010/000316 filed Sep. 1, 2010 and published in German, which has a priority of Austria No. GM 552/2009 filed Sep. 3, 2009, hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for connecting a plurality of elements of a printed circuit board, comprising the steps of
providing with mutually matching contours the elements to be connected of a printed circuit board, arranging with mutually complementary contours in a close spatial relationship on at least one peripheral region the elements to be connected, while keeping a distance between the mutually facing peripheral regions, and mechanically connecting, particularly bonding or gluing, the mutually facing peripheral regions over at least portions thereof, for connecting the elements to be connected of the printed circuit board.
[0006] The invention relates furthermore to a printed circuit board comprising a plurality of interconnected elements, as well as the use of such method for the production of a multi-part circuit board.
PRIOR ART
[0007] In the context of the production of printed circuit boards, it is known to produce a plurality of printed circuit boards or printed circuit board elements on a common plate-shaped element, such printed circuit boards, as a rule, being each comprised of a plurality of conductive and insulating layers and/or of components integrated in such a printed circuit board. According to known production methods of this type, a substantially full-surface assembly of a plurality of printed circuit boards on the common plate-shaped element is effected, whereupon, after the completion of the printed circuit boards, the latter are separated from one another. In those cases, each of the printed circuit boards has a respective edge region about its periphery, and hence outside a substantially central region forming an actual printed circuit board element, in which the structures for the formation of the printed circuit board and/or the electronic component are integrated. Said edge region is provided for carrying out further printed circuit board processing steps, for instance, in the context of the insertion of components to be fixed to at least one surface and/or the installation into an electric or electronic device, in order to enable the manipulation and, in particular, the automatic seizure of such a printed circuit board during subsequent treatment or processing steps. According to presently known process controls, it is thus to be anticipated that the peripheral region to be provided for the frame or the peripheral region of the printed circuit board is likewise produced of a usually expensive material in accordance with the usually multi-layered printed circuit board. Such an edge or peripheral region, which is not required for the functioning of the printed circuit board, will however, result in elevated costs of such a printed circuit board, considering the usually multi-layered structure made of expensive materials. In addition, in the context of known production methods of printed circuit boards, regions or areas located between individual printed circuit board elements, of the common plate-shaped element are discarded as waste such that elevated costs for the production of printed circuit boards or printed circuit board elements will also occur in this respect.
[0008] In connection with the production of printed circuit boards it is, moreover, known to remove individual defective printed circuit boards from a common plate-shaped element if they are recognized as defective in the course of tests or checks, and to insert individual printed circuit boards in place of such removed, defective printed circuit boards.
[0009] In addition, methods for collectively processing and handling printed circuit boards are known, according to which several printed circuit boards or printed circuit board elements are usually inserted into frame elements each surrounding the printed circuit boards about their entire peripheries, and fixed to them, for instance, by bonding or gluing. In this respect, it is, for instance, referred to DE-A 1906 00 928, U.S. Pat. No. 4,689,103, U.S. Pat. No. 5,044,615, U.S. Pat. No. 5,866,852 or WO 2009/068741. Those known methods for inserting printed circuit boards into a frame element each completely surrounding the printed circuit boards, in particular, involve the drawbacks that the reception openings to be provided in the frame element for the arrangement and press-fitting of the printed circuit boards have to be precisely adapted to the dimensions and shapes of the printed circuit boards to be inserted, while observing small manufacturing tolerances, and the proper positioning and fixation, for instance by bonding, on the peripheral edges of the printed circuit boards and frame elements, which usually have comparatively small thicknesses, are therefore extremely difficult and complex.
[0010] It is, moreover, known to assemble individual printed circuit boards of a plurality of elements produced, for instance, according to the above exposition, such elements having, for instance, been produced in different methods steps or production processes, as can, for example, be taken from US 2008/0144299 A1 or US 2009/0014205 A1.
[0011] For the simultaneous processing of printed circuit boards or printed circuit board elements, it is further known to temporarily connect printed circuit boards lying on a common transport path in a processing line, as can, for instance, be taken from WO 03/005785, wherein, after the completion of the processing of such several printed circuit board elements arranged in a common transport plane, the separation of the interconnected printed circuit boards or printed circuit board elements is effected.
SUMMARY OF THE INVENTION
[0012] The invention aims to prevent or minimize the problems of known configurations, particularly in the context of a precisely fitting connection of several printed circuit board elements. The present invention, in particular, aims to provide a method, and a printed circuit board, of the initially defined kind, in which the connection of at least two elements to a common printed circuit board can be realized in a simplified manner while avoiding tight and precise production tolerances, favorably in a largely automated fashion.
[0013] To solve these objects, a method for connecting a plurality of elements of a printed circuit board according to the kind mentioned-above is substantially characterized in that the printed circuit board elements to be connected are arranged or supported on a carrier element for carrying out the connecting procedure, that the printed circuit board elements to be connected are kept secured to the carrier element during the connecting procedure by applying a vacuum, by clamping, by elevations or pins projecting from the carrier element entering complementary recesses of the elements, or the like and that the surface of the carrier element facing the elements to be supported is formed by, or coated with, an antiskid material, e.g. silicone, rubber or the like.
[0014] Due to the fact that, after having provided with mutually matching contours the printed circuit board elements to be connected, the elements to be connected are arranged while keeping a distance between the mutually facing peripheral regions to be connected and are subsequently mechanically connected, particularly bonded or glued, it is ensured that a reliable connection of printed circuit board elements to be connected will be achievable even when observing smaller production tolerances, and hence by a simpler and quicker element production. It will, thus, for instance, also be possible to simply and reliably provide printed circuit board elements produced, or to be produced, in different methods steps with regard to the contours of peripheral regions to be connected, so that it will not be necessary to observe the tight and precise production tolerances essential for press fitting, as required in the initially mentioned embodiments according to the prior art. By keeping a distance, the appropriate space or clearance required, in particular, for the introduction of an adhesive will, moreover, be provided, which, while again simplifying processing and connecting operations, will ensure or enable a quicker connecting operation of such printed circuit board elements and, in particular, the automation of such a connecting operation. For a reliable support of the elements to be connected as well as for supporting an automation, it is proposed according to the invention that the printed circuit board elements to be connected are arranged or supported on a carrier element for carrying out the connecting procedure. In order to secure the at least temporary positioning of individual elements on the carrier element prior to realizing the final connection of elements to be connected, it is proposed according to the invention that the printed circuit board elements to be connected are kept secured to the carrier element during the connecting procedure by applying a vacuum, by clamping, by elevations or pins projecting from the carrier element entering complementary recesses of the elements, or the like. For the at least temporary securing or positioning on the carrier element, of the printed circuit board elements to be connected, it is alternatively or additionally proposed according to the invention that the surface of the carrier element facing the elements to be supported is formed by, or coated with, an antiskid material, e.g. silicone, rubber or the like.
[0015] Considering the usually small-dimensioned elements of a printed circuit board as well as the production tolerances to be observed, which have to be complied with even in the context of automated production processes, it is proposed according to a preferred embodiment that the distance between the mutually facing peripheral regions to be connected is selected to be 500 μm at most and, in particular, 200 μm at most. By keeping such a distance between the peripheral regions to be connected, it will be ensured that a reliable and relative positioning of individual such printed circuit board elements will be achievable even in an automated fashion, such a distance being safely achievable and keepable even when observing comparatively large production tolerances. In addition, the selection of such a distance proposed by the invention will also enable the quick and reliable introduction of, for instance, an adhesive into at least portions of peripheral regions to be connected, of the elements to be connected. Furthermore, the keeping of such a small distance proposed by the invention, between elements to be connected will also permit the consideration of requirements in view of a miniaturization of the printed circuit boards or printed circuit board elements to be produced.
[0016] For the proper relative positioning of elements to be connected, it is proposed according to a further preferred embodiment that elements to be connected are arranged and connected with reference to at least one aligning or registering element provided on one of the elements to be connected. Such an aligning or registering element can, for instance, be formed by an opening or passage provided on at least one of the elements to be connected. When treating or processing a plurality of printed circuit boards each optionally comprised of several elements, it is, moreover, known to provide an appropriate plurality of aligning or positioning elements for such plate-shaped or panel-shaped arrays of several printed circuit boards, in order to enable the reliable positioning of a plurality of elements.
[0017] For the reliable and rapid connection of printed circuit board elements to be connected, it is, moreover, proposed that a thermally or chemically or UV or IR curable adhesive is used for bonding, as in correspondence with a further preferred embodiment of the method according to the invention.
[0018] Considering the elements of a printed circuit board and, in particular, insulating or plastic layers of such a, particularly multilayer, printed circuit board, which, as a function of the selected materials, must not be subjected to extremely high temperatures during subsequent processing steps, it is proposed according to a further preferred embodiment that thermal curing of the adhesive is carried out at temperatures between 80° C. and 300° C.
[0019] In order to achieve a reliable and targeted arrangement of the adhesive used for connecting the elements to be connected, it is proposed according to a further preferred embodiment that a high-viscosity adhesive is used. Such a high-viscosity adhesive can be appropriately introduced into the distances or clearances between the printed circuit board elements to be connected while, in particular, preventing flowing or excessive spreading in the region of the distances, even when taking into account the comparatively small distances of the elements to be connected.
[0020] For a particularly reliable application or arrangement of the adhesive in the distances of elements to be connected, it is, moreover, proposed that the adhesive is applied by the aid of a dispensing device or dispenser, template printing, screen printing or the like, as in correspondence with a further preferred embodiment of the method according to the invention.
[0021] In order to avoid spreading of the adhesive, particularly below elements to be connected, it is proposed according to a further preferred embodiment that the adhesive is merely introduced or arranged over a portion of the vertical extension of side edges of the peripheral regions to be connected. Particularly by selecting the appropriate viscosity of an adhesive and whilst taking into account the comparatively small distance between adjacent peripheral regions to be connected, of the elements to be connected, the adhesive will be safely prevented from filling-up and penetrating over the entire vertical extension of the gap or distance between elements to be connected.
[0022] For a, particularly temporary, positioning, for instance in the presence of a plurality of elements to be connected, wherein curing of the adhesive is, for instance, carried out after the arrangement of a plurality of such elements, it is proposed according to a further preferred embodiment that a temporary connection of peripheral regions to be connected is formed by using a removable adhesive tape or label. Such removable adhesive tapes or labels can be easily and reliably positioned and even after the arrangement of elements to be connected will additionally permit at least minor corrections of the respective mutual positions prior to realizing the final connection.
[0023] Particularly when using a carrier layer or carrier element, it is proposed, in order to avoid adherence during the introduction of an adhesive, particularly at an inadvertent passage of the adhesive through the entire clearance between the mutually facing peripheral regions, that a removable protective element, for instance a removable sheet of paper, is arranged below the peripheral regions to be connected, of the elements to be connected, as in correspondence with a further preferred embodiment of the method according to the invention. Such a protective element and, in particular, removable sheet of paper can be readily and reliably arranged at least in areas where peripheral regions to be connected are arranged during the connecting procedure, and can again be readily removed from the printed circuit board elements connected with one another upon completion of the connection.
[0024] By providing a distance between printed circuit board elements to be connected, which will not only be advantageous in view of the automated positioning of individual elements to be connected but also enable the simplified production of the same, an optionally required separation of elements to be connected or already connected may also be effected along the distance to be kept between the same. In this context, it is proposed according to a further preferred embodiment that connected elements of a printed circuit board can be separated along the interconnected peripheral regions, e.g. for repair purposes, particularly by using a cutter or laser. In this manner, expensive elements of a printed circuit board can thus, for instance, be removed from such a printed circuit board in case of damage and replaced with new elements, so that a printed circuit board need not be completely exchanged at a locatable damage of merely a portion thereof.
[0025] While substantially linear peripheral regions of printed circuit board elements to be connected can be reliably connected by the mechanical connection, particularly bonding, provided by the invention, it is proposed according to a further preferred embodiment, particularly for enabling the mutual engagement of portions of the peripheries to be connected, of individual elements, that elements to be connected in a manner known per se are each formed with at least one relatively complementary coupling element on peripheral regions to be connected. Such complementary coupling elements can likewise be produced in a simplified manner with accordingly large production tolerances while taking into account the distances to be kept between elements to be connected, and likewise allow for the substantially automated fitting-in of elements to be connected, said complementary coupling elements facilitating positioning and enhancing the mechanical strength of the connection.
[0026] In this context, it is proposed according to a further preferred embodiment that the at least one coupling element of an element to be connected is formed by a profiled coupling element projecting from the peripheral region of said element and received in a complementary recess of the element to be connected therewith, while keeping said distance. By providing appropriate coupling elements, the mechanical stability of the connection of the elements to be connected will thus, in particular, be further improved or enhanced.
[0027] Particularly when arranging or providing frame or carrier elements for receiving or holding elements of a printed circuit board which are, for instance, made of more cost-effective materials and can be used for treating or processing purposes, it is proposed according to a further preferred embodiment that a substantially rectangular element of a printed circuit board, on respectively opposite peripheral regions, is each provided with at least one coupling element each connected with a coupling element of a frame or carrier element cooperating therewith.
[0028] As already pointed out above, it is possible to produce several elements to be used for the production of a printed circuit board and to be connected with one another, in, for instance, different production steps and at, for instance, different construction expenditures, so that it is, moreover, preferably proposed according to the invention that a plurality of elements of a printed circuit board are connected with one another in a spaced-apart relationship.
[0029] To solve the initially mentioned objects, a printed circuit board comprised of a plurality of interconnected elements is essentially characterized in that at least two elements to be connected of the printed circuit board are mechanically connected, particularly bonded or glued, with one another on at least one peripheral region thereof while keeping a distance and being supported on a carrier element. As pointed out above, an automation of the production of such printed circuit boards comprised of at least two elements will also be feasible in a favorable manner whilst observing accordingly large production tolerances for the elements to be connected.
[0030] For a proper mechanical connection in compliance with the requirements, for instance with regard to a miniaturization of such printed circuit boards, it is, moreover, proposed in a preferred manner that the distance between the mutually facing peripheral regions to be connected is selected to be 500 μm at most and, in particular, 200 μm at most.
[0031] For the proper mutual positioning of individual elements to be connected, it is, moreover, proposed that elements to be connected are arranged, and connected with one another, with reference to at least one aligning or registering element provided on one of the elements to be connected, as in correspondence with a further preferred embodiment of the printed circuit board according to the invention.
[0032] For a reliable and simple connection, it is, moreover, proposed in a preferred manner that a thermally or chemically or UV or IR curable adhesive is used for bonding, adhesives curing in such a manner being known per se in the context of the production of printed circuit boards.
[0033] For a reliable connection, it is, moreover, proposed that the adhesive is merely introduced or arranged over a portion of the vertical extension of side edges of the peripheral regions to be connected, as in correspondence with a further preferred embodiment of the printed circuit board according to the invention.
[0034] For an optionally required separation, particularly upon detection of a damage of a portion of the printed circuit board according to the invention, it is, moreover, proposed that connected elements of a printed circuit board are separable along the interconnected peripheral regions, e.g. for repair purposes, particularly by using a cutter or laser, as in correspondence with a further preferred embodiment of the invention.
[0035] For the simple positioning and mechanically stable coupling or connection of elements to be connected, it is, moreover, proposed in a preferred manner that elements to be connected, in a manner known per se, are each formed with at least one relatively complementary coupling element on peripheral regions to be connected, wherein, in this context, it is proposed according to a further preferred embodiment that the at least one coupling element of an element to be connected is formed by a profiled coupling element projecting from the peripheral region of said element and received in a complementary recess of the element to be connected therewith, while keeping said distance.
[0036] In addition, the use of the method according to the invention for the production of a multi-part circuit board is proposed.
SHORT DESCRIPTION OF THE DRAWINGS
[0037] In the following, the invention will be explained in more detail by way of exemplary embodiments schematically illustrated in the drawing. Therein:
[0038] FIG. 1 illustrates schematic top views on different embodiments of connected elements of a printed circuit board, using the method according to the invention, an element of a printed circuit board partially encompassing a further element in FIG. 1 a , a printed circuit board element being completely encompassed by a further element in the embodiment according to FIG. 1 b , several printed circuit board elements being encompassed or surrounded by a common element in the embodiment according to FIG. 1 c , and several printed circuit board elements being connected with one frame or carrier element each on respectively opposite edges in the embodiment according to FIG. 1 d;
[0039] FIG. 2 on an enlarged scale depicts schematic views of different configurations of coupling elements between printed circuit board elements to be connected;
[0040] FIG. 3 schematically illustrates the course of procedure of connecting printed circuit board elements to be connected, FIG. 3 a depicting the side-by-side arrangement of elements to be connected, FIG. 3 b depicting the application of an adhesive for connecting the elements to be connected; and FIG. 3 c depicting the state after having applied the adhesive;
[0041] FIG. 4 is a schematic top view on the relative arrangement of a plurality of elements of a printed circuit board relative to one another with reference to at least one aligning or registering element;
[0042] FIG. 5 is a schematic top view of a carrier element for arranging a plurality of printed circuit board elements to be connected, with a negative pressure or vacuum being generated and applied for temporary fixation;
[0043] FIG. 6 is a schematic illustration of a modified embodiment of the arrangement of a plurality of elements on a carrier element, FIG. 6 a depicting a schematic partial section and FIG. 6 b being a schematic top view;
[0044] FIG. 7 is a schematic view of a configuration of a temporary fixation of two elements to be connected, using an adhesive tape; and
[0045] FIG. 8 schematically illustrates the course of procedure of connecting and subsequently separating two elements, for instance for repair purposes and for an exchange of one of such interconnected elements.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0046] In respect of the Figures, it is initially noted that in some cases only portions of elements of a printed circuit board to be produced are shown in the region of fixation of elements to be fixed to one another or connected with one another. Furthermore, the relative dimensions, particularly in regard to a distance to be provided between the individual elements, are not illustrated true to scale. Moreover, for a simplified illustration, no patterning is indicated and no components optionally attached or to be received are illustrated on the individual elements of a printed circuit board to be produced.
[0047] In the illustration according to FIG. 1 , different options for connecting printed circuit board elements to be connected are schematically indicated, the indicated options merely showing exemplary embodiments not to be interpreted in a limiting sense.
[0048] In the embodiment according to FIG. 1 a , a substantially rectangular or square element 1 , on two peripheral sides, is surrounded by an element 2 to be connected therewith as will be discussed in more detail below, a distance or gap 3 being indicated between the elements 1 and 2 to be connected with each other. Mutually facing peripheral regions of the elements 1 and 2 are denoted by 28 and 29 , respectively.
[0049] In the embodiment according to FIG. 1 b , an again substantially square element 1 is surrounded by a likewise substantially square element 4 , the square element 1 being, for instance, taken up on substantially all peripheral sides while substantially again keeping a distance or gap 3 .
[0050] In the embodiment according to FIG. 1 c , a plurality of elements again schematically indicated by 1 are received in a common element 5 , a distance or gap 3 being again provided between the individual elements 1 .
[0051] The different elements 1 , 2 , 4 and 5 of a printed circuit board, which are illustrated in FIGS. 1 a to 1 c , can, for instance, be produced by different production methods of a particularly multilayer printed circuit board and, upon completion of the same, can be connected or coupled with each other for providing a finished printed circuit board comprising different portions or elements, as will be discussed in more detail below.
[0052] In the embodiment according to FIG. 1 d , it is indicated that a plurality of elements 6 , on respectively opposite peripheral regions or side edges 7 , are each provided with coupling elements schematically denoted by 8 , said coupling elements 8 cooperating, or being connected, with complementary coupling elements 9 provided on frame or carrier elements 10 . It is apparent, also from the embodiment according to FIG. 1 d , that a distance or gap 3 is each provided or maintained in the regions of the coupling elements 8 and 9 as well as the adjoining peripheral regions 7 of the elements 6 and the peripheral regions 11 of the frame elements 10 .
[0053] FIG. 2 schematically depicts different embodiments of coupling elements, which, irrespective of their geometric shapes, are again denoted by 8 for the sake of simplicity, which cooperate with complementary recesses 9 . As is apparent from the illustration according to FIG. 2 , a distance or gap 3 is each again provided in the region of the mutually cooperating coupling elements 8 and 9 .
[0054] While, in the illustration according to FIG. 1 , coupling elements 8 and 9 are merely indicated in the embodiment according to FIG. 1 d , it should be noted that such coupling elements 8 and 9 of elements to be connected, as are, for instance, indicated in FIG. 2 may also be used on the respective peripheral regions 28 and 29 in the embodiments illustrated in FIGS. 1 a to 1 c.
[0055] Moreover, the embodiments of coupling elements 8 and complementary recesses 9 illustrated in FIG. 2 are merely exemplary and not to be interpreted in a limiting sense.
[0056] A connection procedure of two elements to be connected will be discussed in more detail below with reference to the illustration of FIG. 3 , wherein, for instance, for a configuration as illustrated in FIG. 1 d using coupling elements 8 and 9 according to FIG. 2 a , only portions of the elements to be connected are each shown in FIG. 3 . In FIGS. 3 a , 3 b and 3 c , a schematic top view on such a portion of a connection of mutually cooperating coupling elements 8 and recesses 9 is, furthermore, each indicated on the left-hand sides of the illustrations, while sections along lines A-A, B-B and C-C are additionally indicated for the individual method steps on the right-hand sides of the illustrations.
[0057] From the method step illustrated in FIG. 3 a , it is apparent that elements to be connected, which are again denoted by 6 and 10 as in correspondence with the illustration according to FIG. 1 d , in the region of their mutually complementary coupling elements are positioned relative to each other in such a manner as to each keep a distance 3 substantially over the entire periphery of the coupling elements 8 and 9 as well as in the region of the mutually facing peripheral regions 7 and 11 for the subsequent introduction of an adhesive.
[0058] The distance 3 is chosen to have a maximum width of 500 μm, favorably 200 μm, so as to allow the elements to be connected, which are optionally provided with additional coupling elements 8 and 9 , to be produced with large production tolerances. The maintenance of such a distance of, for instance, 200 μm at most, moreover, also allows for the arrangement of a plurality of elements optionally forming a plurality of printed circuit boards on a common carrier element to be used for further processing, e.g. for inserting components, as will be discussed in more detail particularly with reference to FIG. 4 , wherein relative orientation tolerances between such a plurality of elements to be arranged, of ±50 μm, in particular ±30 μm, are attainable or can be observed. By providing a maximum distance of 200 μm for the subsequent introduction of an adhesive, the automated assembly and connection of printed circuit board elements to be connected in this manner will be feasible such that cumbersome fitting procedures of elements, which will, in particular, have to be performed manually, can be obviated.
[0059] After having arranged in a spatially close relationship the elements to be connected, as is illustrated in FIG. 3 a , the application of an adhesive 12 is, for instance, effected in the method step according to FIG. 3 b by the aid of a doctor blade 13 using a template 14 such that, after having applied the adhesive 12 and removed the template 14 , as is illustrated in the method step according to FIG. 3 c , the adhesive 12 was introduced into the gap 13 for connecting the elements 6 and 10 to be connected.
[0060] As is apparent from the illustration according to FIG. 3 c , the adhesive 12 , which has a high viscosity, in a favorable manner is merely introduced over a portion of the vertical extension of the gap 3 so as to avoid a penetration of the adhesive 12 to the lower side of the elements 6 and 10 , and hence the adherence of the elements to a carrier elements, particularly when supporting the elements 6 and 10 to be connected, as will be discussed in more detail with reference to FIG. 5 . It is further apparent from the illustration according to FIG. 3 c that, in particular as a function of the thickness of the template 14 employed, the adhesive 12 only slightly projects beyond the surfaces of the elements 6 and 10 such that, in particular, subsequent processing steps will not be impaired or affected.
[0061] The application of the adhesive as indicated in FIG. 3 c is, for instance, followed by the curing of the same, using heat or UV light. When using a thermally curing or setting adhesive 12 , temperatures between 80° C. and 200° C. are, for instance, selected in order to particularly avoid impairment to the already finished printed circuit board elements.
[0062] To simplify subsequent method steps, an adaptation of the expansion coefficient of the adhesive 12 to that of the adjoining elements 6 and 10 , respectively, is moreover effected.
[0063] Instead of using the template printing process indicated in FIG. 3 c , the adhesive 12 may, for instance, be applied by screen printing or by dispensing in the zones of the mutually facing peripheral regions 7 and 11 of the elements 6 and 10 to be connected.
[0064] From the illustration according to FIG. 3 , it is, moreover, apparent that an arrangement of the adhesive 12 , and hence a mechanical connection between the elements to be connected, is merely provided in the region of the coupling elements 8 and 9 . Alternatively, a substantially full-area connection over the entire peripheral regions 7 and 11 of the elements 6 and 10 to be connected may be provided in order to, in particular, increase the strength of the connection of the elements 6 and 10 to be connected.
[0065] Such a method, particularly when increasing or improving the strength of a connection between adjacent elements 6 and 10 by supporting the coupling elements 8 and 9 will, for instance, enable the provision of a load-carrying capacity of, for instance, 2 kg, which will be sufficient for the further use or processing of such printed circuit boards. It will, moreover, also be ensured that no changes of the mechanical connection produced between the elements 6 and 10 to be connected will occur, for instance, in subsequent treatment or processing steps such as, e.g., reflow or soldering processes, for instance for fixing components.
[0066] FIG. 4 schematically indicates that, when positioning a plurality of elements 15 in a common element 16 , particularly by departing from an aligning or registering element 17 formed, for instance, by a bore or passage, while keeping a respective maximum distance 3 of, for instance, 200 μm, the alignment of such neighboring elements 15 will be achievable with reference to aligning elements 18 and 19 additionally provided on the individual elements 15 , while observing a tolerance of ±50 μm, in particular ±30 μm. The observance of such small tolerances of a relative alignment is especially necessary or beneficial for subsequent treatment or processing procedures such as the insertion of components, in order to fix components not illustrated in detail on such elements 15 in a likewise particularly automated fashion.
[0067] From the schematic illustration according to FIG. 5 , it is apparent that a plurality of elements to be each connected with one another, which are again denoted by 6 and 10 as in correspondence with the embodiment of FIG. 1 d , are arranged on a carrier element schematically indicated by 20 , which is formed with a plurality of openings or passages 21 for generating or applying a negative pressure or vacuum from a vacuum source not illustrated in detail.
[0068] In order to prevent the penetration of an adhesive in the region of the connection of the elements to be connected, and hence an adherence to the carrier element 20 , it is, moreover, indicated in FIG. 5 that a protective layer, for instance a removable paper sheet 22 , is arranged in the region of the bonding sites, which protective layer can be easily removed again after having connected the elements 6 and 10 to be connected, even after a penetration of the adhesive over the entire vertical extension of the peripheral regions to be connected, thus preventing the adherence to the carrier element 20 and, in particular, the contamination of the same by the adhesive.
[0069] In the embodiment according to FIG. 6 , a carrier element is denoted by 30 , wherein elevations or pins 31 project from the carrier element 30 , which, through openings or passages schematically indicated at 32 , enter an element again denoted by 6 for at least temporarily securing elements to be connected with one another. With the element 6 , which is temporarily secured to the carrier element 30 by the pins or elevations 31 cooperating with the openings 32 , are subsequently connected elements again denoted by 10 , in particular frame or carrier elements, which, also via pins again schematically indicated by 31 , are secured on the carrier element 30 in their respective positions relative to the element 6 to be connected therewith, which has been omitted from FIG. 6 b for the sake of clarity. An aligning or registering element again denoted by 17 is indicated for positioning or aligning.
[0070] In the same manner as described in respect to the preceding embodiments, an adhesive is again introduced into the gap 3 between the elements 6 and 10 for connecting elements 6 and 10 .
[0071] In the illustration according to FIG. 6 , the coupling elements which are, for instance, additionally provided in preceding Figures for connecting elements 6 and 10 are, moreover, not illustrated and can be omitted.
[0072] Instead of, and/or in addition to, holding or securing the elements to be connected by applying a vacuum as illustrated in FIG. 5 as well as by the positioning pins 31 and the respective openings or passages 32 for receiving the same as in accordance with FIG. 6 , temporary securement on the carrier element 20 or 30 can, for instance, also be provided by clamping the individual elements to the carrier element until the application and, in particular, curing of the adhesive to be introduced into the distance or gap 3 between elements 6 and 10 to be connected has been completed.
[0073] In addition, or as an alternative, the surface of the carrier element 20 and/or 30 facing the elements 6 and 10 to be connected may be formed by an antiskid material such as silicone, rubber or the like, or coated with such material, in order to secure the relative positioning of the elements 6 and 10 to be connected. In this manner, an at least temporarily secured positioning of the elements 6 and 10 to be connected will be ensured, in particular, without additionally providing the application of a vacuum as indicated in FIG. 5 or using additional positioning pins 31 and respective recesses or passages 32 as indicated in FIG. 6 .
[0074] In the illustration according to FIG. 7 , it is schematically indicated that elements to be connected, which are again denoted by 6 and 10 , are temporarily secured to each other by an adhesive tape or adhesive label 23 , said adhesive tape 23 being removable again upon connection of the elements 6 and 10 .
[0075] The distance or gap 3 provided between printed circuit board elements to be connected, which not only renders feasible the simplified production as well as the automated assembly and connection of the same, also enables, for instance, defective printed circuit board elements and, if necessary, printed circuit board elements loaded with expensive components to be separated again, particularly along the connection site or line, and, in particular, expensive elements of a printed circuit board to be replaced accordingly.
[0076] FIG. 8 schematically indicates such an exchange or repair process.
[0077] Departing from two printed circuit board elements I and II according to FIG. 8 a , which are connected with each other according to FIG. 8 b as is, for instance, illustrated in more detail in FIG. 3 , the method step according to FIG. 8 c comprises the separation of the interconnected printed circuit board elements I and II along the connection site 25 using, for instance, a cutter or laser.
[0078] After a separation along the coupling elements 8 and 9 as illustrated in FIG. 8 c , the defective element II can be detached from element I as indicated by arrow 26 in FIG. 8 d , whereupon a new element III is inserted in the sense of arrow 27 in FIG. 8 e and connected with element I by a bond or glued connection again denoted by 12 .
[0079] Thus, printed circuit board elements which are simple to produce with large processing tolerances can be safely and reliably connected with one another at reduced operating expenditures and, in particular, with the option of automated arranging and connecting procedures.
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The invention relates to a method for connecting a plurality of elements for a circuit board, comprising the following steps:
providing the elements of a circuit board to be connected to each other, the elements having contours adapted to each other; arranging the elements to be connected to each other in close proximity in at least one of two peripheral areas that have complementary contours, while maintaining a distance between opposing peripheral areas; and mechanically connecting the opposing peripheral areas by means of at least one sub-area thereof in order to connect the elements of the circuit board to be connected to each other.
Furthermore, a circuit board produced from a plurality of elements connected to each other is provided.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 60/428,672 entitled FOOT OPERATED TOILET SEAT filed in the name of Steve Stewart on Nov. 25, 2002, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present disclosure relates to a toilet seat adjusting mechanism for residential or commercial toilets, and more specifically relates to a foot-operated mechanism for raising a toilet seat that results in improved sanitation and convenience to all users of the toilet.
BACKGROUND OF THE INVENTION
[0003] Most toilets in the developed western world have a seat. The typical seat is a moveable device, to be manually lifted when using the toilet as a urinal. Seat design, however, has never favored this fact, and it is very common to this day to fumble for a finger-hold on the bottom edge of toilet seats in both public and residential bathrooms in order to lift them to the raised position. This is both unsanitary and inconvenient.
[0004] Other numerous attempts to produce a commercially viable toilet seat lifting device have encompassed designs that are ungainly or involve mechanisms that require considerable manufacturing cost and complexity and user maintenance. U.S. Pat. No. 4,103,371 to Wilson, U.S. Pat. No. 5,014,367 to Gamblin, U.S. Pat. No. 5,448,782 to Ratajac and U.S. Pat. No. 6,112,335 to Gaston all involve hydraulic and pneumatic cylinders and complicated levers and linkages necessitating manufacturing complexity and undue expense, along with user assembly and maintenance issues associated with hydraulic and pneumatic designs. U.S. Pat. No. 5,404,595 to Carmel involves two levers, a floor-mounted base and numerous linkages, as well as an electrical motor option to lift the seat. This too, is overly complex to manufacture and difficult for the end user to install and maintain.
SUMMARY OF THE INVENTION
[0005] The present disclosure provides a simple, easy to manufacture, and cost effective solution to the age-old problem of lifting the toilet seat in order to use the toilet as a urinal in a sanitary and convenient manner. The present disclosure will overcome this problem by utilizing a very simple foot-operated mechanism to lift the seat while using the toilet as a urinal. It can be inexpensively mass produced and can be easily fitted to new and existing popular toilet models.
[0006] Instead of fumbling for a finger-hold around the bottom of the toilet seat, a foot-operated device is more convenient and keeps a user's hands away from the toilet bowl. Using a robust two geared shaft design and a single lever, this invention can be installed quickly on new toilets, and can easily replace or supplement conventional toilet seats on popular existing toilet models.
[0007] The present disclosure is operated by means of a mechanical assembly near the rear base of the toilet seat, mounted near the rear edge of the toilet bowl, in front of the toilet tank, and consisting of a pair of geared shafts, one attached to the toilet seat and the other attached to an adjustable lever that extends down one side of the toilet bowl, at an angle, toward the floor, terminating in a foot pedal a few inches above the floor itself Downward pressure on the foot pedal causes the rear shaft to rotate toward the front of the toilet bowl, with the gearing then forcing the front shaft to rotate in the opposite direction. This front shaft is connected to the toilet seat at its rear base, causing it to lift up from the toilet bowl as the shaft is rotated. Its maximum travel is almost 90 degrees from the closed position, resulting in unfettered access to the toilet bowl. Releasing pressure on the pedal reverses the process, with gravity causing the seat to lower back into the horizontal position, resting on the toilet bowl. A set of friction bushings on each end of the front shaft can be adjusted to control the amount of resistance necessary for smooth operation in both raising and lowering the seat, and will eliminate the seat from being dropped too quickly into the lowered position. A toilet seat cover will ride on top of the toilet seat and will rise with the toilet seat from the pressure of the toilet seat rising beneath it and lower by force of gravity, resting on top of the toilet seat. The toilet seat cover may also be left in the open (upright) position by rotating it beyond 90 degrees from the toilet bowl (so it rests against the toilet tank) if so desired, with the toilet seat moving up and down independently.
[0008] The present disclosure will increase sanitation when using the toilet by eliminating the need to touch the toilet seat to raise it. It would also make it easier for young male children, the elderly, handicapped or those with bad backs to raise the toilet seat and will eliminate the need for men to hold the toilet seat in a raised position while urinating. The present disclosure would also serve to eliminate the common problem of male household members forgetting to put the toilet seat down after use.
[0009] The present disclosure overcomes the problems associated with prior technologies by retaining a simple design for both manufacturing and use. This simplicity equates to lower production costs (and thus, lower retail prices) and ease of installation and use by the consumer. The robust structure of the mechanism and the small number of moving parts involved translates into a high level of durability for the end user. The present disclosure is also easily retrofitted to existing toilets, and doesn't require special tools, electricity, drilling, floor-mounted brackets or floor-mounted pedals to install or use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a side view of a foot-operated lever mounted on a typical toilet with the toilet seat in a lowered position.
[0011] [0011]FIG. 2 is a side view of the foot-operated lever depressed to adjust the toilet seat to a raised position.
[0012] [0012]FIG. 3 is a perspective view of a mechanism for raising the toilet seat in response to a depression of the foot-operated lever.
[0013] [0013]FIG. 4 is a second perspective view of the mechanism of FIG. 3.
[0014] [0014]FIG. 5 is a top view of the mechanism of FIG. 3.
[0015] [0015]FIG. 6 is a perspective view of a decorative plastic cover for the mechanism of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring to FIG. 1, a foot-operated mechanism 10 is shown in a side perspective, mounted on a typical toilet, just in front of the tank, on the rear edge of the toilet bowl. In a lowered position, the toilet seat 11 rests on the edge of the toilet bowl, with the foot pedal 12 in a normal position above the floor. The lower lever 13 to which the foot pedal 12 is attached is slightly smaller in diameter than an upper lever 14 , allowing for an adjusting friction screw 15 to be used to adjust the extension length of the lower lever 13 , and thus the distance from the foot pedal 12 distance above the floor. A toilet seat cover 16 is mounted on a hinge 17 just to the rear of the toilet seat and on top of a metal flange 18 .
[0017] [0017]FIG. 2 depicts the foot-operated mechanism 10 shown in a side perspective with the toilet seat 11 in a raised position. Note that as the foot pedal 12 is depressed, the toilet seat 11 and toilet seat cover 16 are lifted into the raised position.
[0018] [0018]FIG. 3 depicts a front, right perspective view of the foot-operated mechanism 10 with the toilet seat 11 and toilet seat cover 16 in the lowered position. FIG. 4 depicts a front, left perspective view of the foot operated mechanism 10 with the toilet seat 11 and toilet seat cover 16 in the lowered position.
[0019] [0019]FIG. 5 depicts a top perspective view of the foot-operated mechanism 10 . The foot-operated mechanism 10 includes a base plate 20 that may be constructed of a metal or other durable material. The base plate 20 includes a left mounting bracket 21 and a right mounting bracket 22 that may also be constructed of a metal or other durable material. The base plate 20 is secured to the toilet between the bowl and the tank with two lock nuts 23 and 24 , or other useful fasteners. This positioning of the base plate allows the mechanism 10 to be positioned where it is less likely to be damaged and does not interfere with normal use of the toilet, than for example previous devices that are disposed on the floor or a side of the bowl of the toilet.
[0020] A metal rear geared shaft 25 is mounted between the left 21 and right 22 mounting brackets with a steel rear threaded bolt 26 running through the left mounting bracket 21 and a left rear bearing 27 . The rear threaded bolt 26 continues through the center of the rear geared shaft 25 and then through a right rear bearing 28 and right mounting bracket 22 , threading into the upper lever's 14 threaded recess. A left rear bearing 27 is recessed in the left mounting bracket 21 and a right rear bearing 28 is recessed into the right mounting bracket 22 for supporting the rear geared shaft 25 . The rear geared shaft 25 features a female geared recess on the right side, where a male end of the upper lever 14 fits into it, such that a depression of the foot pedal 12 provides torque to the rear geared shaft 25 .
[0021] The rear geared shaft 25 meshes with a metal front geared shaft 29 , such that a rotation of the rear geared shaft 25 causes rotation of the front geared shaft 29 . The front geared shaft 29 is mounted in front of the rear geared shaft 25 and between the left and right mounting brackets 21 and 22 by a steel front threaded bolt 30 . The front threaded bolt 30 runs through the left mounting bracket 21 and a left front bearing 31 , then through a left friction bushing 32 . The front threaded bolt 30 then continues through the front geared shaft 29 , through a right friction bushing 33 , a right front bearing 34 and then the right mounting bracket 22 , terminating in a lock nut 35 . The left front bearing 31 is recessed in the left mounting bracket 21 and the right front bearing 34 is recessed in the right mounting bracket 22 for supporting the front geared shaft 29 . The left 32 and right 33 friction bushings can be constructed of plastic or polyurethane, or any compressible and durable substance or other known apparatus that will provide a damping effect to or friction against the rotation of the metal front geared shaft 29 . In certain embodiments, the friction is adjustable by tightening or loosening the front threaded bolt 30 .
[0022] The toilet seat 11 is connected to the front geared shaft 29 by the metal flange 18 . The metal flange 18 is secured to the front geared shaft 29 in a position that does not interfere with the rear geared shaft 25 . The toilet seat 11 is mounted on top of the flange 18 , which is welded to a position on the front geared shaft 29 . The flange 18 is secured by providing two self-tapping screws 37 and 38 , or other useful fasteners or attachment methods, into the bottom of the toilet seat 11 . The toilet seat cover's hinge 17 is secured to the top of the flange 18 with two machined screws 39 and 40 , or otherwise fastened or attached thereto.
[0023] The described components cooperate together in the following manner to facilitate raising and lowering the toilet seat. As the user applies foot pressure to the foot pedal 12 , the lower lever 13 and upper lever 14 cooperatively provide torque to cause the rear geared shaft 25 to rotate in a direction toward the front geared shaft 29 . Due to the engagement of the rear geared shaft 25 with the front geared shaft 29 , this rotation causes the front geared shaft 29 to rotate in the opposite direction toward the rear geared shaft 25 , thus lifting the metal flange 18 and the toilet seat 11 into the raised position, substantially 90 degrees from the toilet bowl. When the user releases foot pressure to the foot pedal 12 , gravity causes the toilet seat 11 to move back to its lowered position, dampened by the left friction bushing 32 and the right friction bushing 33 on both sides of the front geared shaft 29 . The toilet seat cover 16 , rides on the toilet seat as it is lifted into the raised position and lowered back to the lowered position. It may also be left in a raised position by lifting it beyond 90 degrees from the toilet seat 11 . With the toilet seat cover 16 in this position, the toilet seat 11 will raise and lower independently of the toilet seat cover 16 .
[0024] [0024]FIG. 6 depicts a decorative plastic cover 41 that fits over the foot operated mechanism 10 with adequate apertures for the upper lever and toilet seat 11 and toilet seat cover 16 to operate. The cover is constructed to fit snuggly over the left 21 and right 22 mounting brackets, utilizing a pair of plastic clips 42 and 43 built into the underside of the top and aligned with the top centers of the left 21 and right 22 mounting brackets to hold it in place.
[0025] The foot operated mechanism 10 may be manufactured in a left side version where the foot pedal 12 is disposed on the left side of the toilet, as opposed to the right side as shown in FIGS. 1 - 5 . In addition, a foot pedal 10 , lower lever 13 and upper lever 14 may simultaneously be provided on both the left and right sides of a toilet.
[0026] The rear geared shaft 25 and front geared shaft 29 may be provided in a 1:1 gear ratio, or in certain embodiments may be provided in a 2:1 ratio, or other useful gear ratio, to lessen the force needed to raise the toilet seat 16 with the foot pedal 12 .
[0027] Various alternate embodiments are readily contemplated. For example, it is contemplated that bearings 27 , 28 , 31 , 34 and/or screws 38 , 39 may be omitted, or that alternate equivalent components may be substituted therefore. Also, a single lever may be provided in place of lower lever 13 and upper lever 14 .
[0028] In a further alternate embodiment, the rear geared shaft 25 and/or the front geared shaft 29 may not be geared continuously across its length as shown in FIGS. 3 - 5 . In such embodiments, one or more individual gears may, for example, be cooperatively disposed along the length of the threaded bolts 26 , 30 . Such individual gears may have a threaded opening in the center thereof for engaging the threaded bolts 26 , 30 , thus allowing the gears to be spun along the length of a bolt 26 , 30 to a desired position. The flange may then be welded or otherwise secured to the individual gear or gears disposed in place of the front geared shaft 29 .
[0029] In another alternate embodiment, the rear threaded bolt 26 may be disposed in the opposite direction than as shown in FIGS. 4 and 5, while the front threaded bolt 30 remains in the orientation shown. In this exemplary embodiment, the upper lever 14 may be welded or otherwise secured directly to the head of the rear threaded bolt 26 .
[0030] The components described herein can be constructed of any material that is both strong and durable. The base plate 20 , flange 18 , threaded bolts 26 , 30 , two geared shafts 25 , 29 , screws 37 , 38 , nuts 24 , 35 , bearings 28 , 34 and upper lever 14 should be constructed of metal, as these parts support the weight of the toilet seat and will require strength. The lower lever 13 and foot pedal 12 may be constructed of metal or a composite material with high strength. The toilet seat 11 and seat cover 16 may be constructed of plastic or any other lightweight high strength material. The decorative cover 41 may be constructed of plastic or other lightweight material. The present disclosure may be finished in any color or powder coat finish to match any décor. Brushed metal and chromed finishes are also possible. Other minor decorative changes and derivatives that do not affect the operation of the present disclosure are possible are well.
[0031] Although the best methodologies of the invention have been particularly described in the foregoing disclosure, it is to be understood that such descriptions have been provided for purposes of illustration only, and that other variations both in form and in detail can be made thereupon by those skilled in the art without departing from the spirit and scope of the present invention, which is defined first and foremost by the appended claims.
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A mechanism for raising a toilet seat includes two geared shafts that are cooperatively engaged while mounted on a toilet. A foot-operated lever attached to a first of the geared shafts provides torque thereto, causing a rotation of the first geared shaft upon depressing the lever. This, in turn, causes a rotation of the second of the geared shafts. The second geared shaft includes a metal flange or other connector that secures a toilet seat thereto over the bowl of the toilet. As the two geared shafts rotate, the toilet seat raises and lowers with the movement of the metal flange on the second geared shaft.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/138,490, filed on Aug. 25, 2011, which is a National Stage application of International Application No. PCT/CH2010/000023, filed on Feb. 1, 2010, which claims priority of Swiss application Serial Number 00287/09, filed on Feb. 26, 2009, all of which are incorporated herein by reference in their entireties.
FIELD OF INVENTION
[0002] The present invention relates to a method for preserving food, in which the food is heated in a moist state in a container, which has a venting opening and is suited as transport and retail packaging, by way of microwaves for a limited time, however at least until hot steam forms in the container and exits through the venting opening. After the heating process, a gas is injected into the container using a cannula, and for this purpose a container wall made of a plastic film is pierced with the cannula. After the gas injection, the venting opening and the pierced hole formed by the cannula in the plastic film are closed.
BACKGROUND
[0003] A method of the aforementioned type is known from WO 2006/084402 A1. In this method the injection of the gas, in particular, serves to avoid the formation of a significant vacuum in the container as a result of condensing steam once said container has been closed.
[0004] Reference is made in WO 2006/084402 A1 to EP 1 076 012 A1 with regard to the design of the container. The containers known from EP 1 076 012 A1 have a flat deep-drawn shell made of polypropylene with a peripheral edge. A peripheral weld seam is used to weld a cover film onto this edge, for which 12 μm polyester is covered over approximately 90-100 μm polypropylene. It is this multi-layered plastic film which is pierced by the cannula in order to inject the gas.
[0005] It is further known from WO 2006/084402 A 1 to use a gas which is low in oxygen or free from oxygen and to use this to flush the container in order to reduce the content of oxygen in the container which could be particularly harmful to the shelf life of the food.
[0006] It is also known from WO 2006/084402 A1 to seal the pierced hole produced with the cannula during the injection process and to simultaneously seal the venting opening by applying an adhesive label.
SUMMARY
[0007] The present invention aims to improve the known method. In particular it has been found that the above-mentioned plastic film is not sufficiently stable, bulges too much when subjected to high temperature and pressure during the heating process, and tends to become rippled as a result of shriveling once the heating process has finished.
[0008] In contrast to EP 1 076 012 A1, where the container is opened after the heating process in order to remove the food for consumption and the cover film is no longer important, the plastic film remains on the container for a longer period of time in the method according to the invention and significantly determines the look and appearance of the container during the retail phase.
[0009] The behavior of the known cover film is also unfavorable for the piercing by the cannula and the injection process. Ultimately, its rippling impairs the application of the adhesive label.
[0010] In accordance with the present invention, as is characterized in claim 1 , the plastic film that is used is less than 100 μm thick, at least one layer of the plastic film consisting of polyethylene terephthalate (PET) with a thickness greater than 19 μm.
[0011] Although even thinner on the whole than the film known from EP 1 076 012 A1, this film is substantially less ductile under the prevailing temperature and pressure owing to its thicker layer of PET, and returns practically completely back to its original flat form. The aforementioned problems are thus avoided.
[0012] In the plastic film used the layer of PET is oriented biaxially, in particular by corresponding stretching. The layer of PET is preferably 23 μm thick. However, it could be up to 40 μm thick.
[0013] A multi-layered plastic film in which a second layer consists of polypropylene and the layer of polypropylene is preferably only 2 to 2.5 times thicker than the layer of PET is preferably further used as a plastic film.
[0014] In order to improve tightness a barrier layer may also be provided between the two layers, wherein silicon oxide, aluminum oxide and/or ethylene vinyl alcohol is/are used, in particular, for the barrier layer in order to achieve an OTR value of approximately 1.
[0015] In accordance with the preferred embodiment of WO 2006/084402 A1, a shell-like container made of plastic is also preferably used as a container within the scope of the present invention, onto which the plastic film is welded in a planar manner as a cover film. The shell-like container may be round, have a diameter of 15-17 cm and a height of 2.5-3.5 cm for a content of approximately 300 g. Oval, rectangular or square shells can also be used.
[0016] A multi-layered plastic film in which a second layer consists of a connection layer which enables a connection between the plastic film and the shell can be used as a cover film. For example the above-mentioned layer of polypropylene can be used as a connection layer and can be welded in an effective manner to a shell made of polypropylene.
[0017] Before consumption, the food which has been preserved with the aid of the described method is heated in the packaging to consumption temperature, typically in a microwave oven. The use of microwave ovens is not possible or desired in some locations, for example in aircraft. In order to make it possible to heat the food preserved in the packaging in a conventional oven at relatively high temperatures a crystalline polyethylene terephthalate (C-PET) with a higher melting point than amorphous polyethylene terephthalate for example can be used for the shell and the at least one layer of plastic film made of polyethylene terephthalate. An adhesion promoter which enables a connection between the plastic film and the shell can be used as a connection layer. Such a container is therefore more resistant to high temperature and the preserved food contained therein can be heated in a conventional oven at temperatures of approximately 230° C.
[0018] With regard to the method, it has been found that it is sufficient to inject the gas at an overpressure of 0.05-0.8 bar, preferably of 0.2-0.4 bar, more preferably of 0.3 bar. A tearing of the plastic film starting from the pierced hole produced by the cannula as a particular weak point is thus simultaneously avoided.
[0019] A cannula with a stop collar which is set back slightly compared to the tip of said cannula is used to inject the gas. The cannula is guided in such a way that the stop collar rests at least temporarily against the outer face of the plastic film when the gas is injected.
[0020] When driven in a force-controlled manner the cannula can be prevented by the stop collar from penetrating too deeply into the container. The cannula should also not come into contact with the food where possible so it can immediately be used for a further injection of gas in a further container without having to be subjected to an expensive cleaning process. In addition, the risk of any bacteria present in a container being shifted into the subsequent gassed container is thus reduced.
[0021] If the plastic film expands again and puffs out due to the injection of the gas at the aforementioned overpressure, it presses against the stop collar, which provides additional protection against tearing of the pierced hole and produces a specific seal around the tip of the cannula. It may be advantageous to withdraw the cannula again slightly after the piercing action so as not to locally block the expansion of the plastic film at the point of piercing.
[0022] As is already known from WO 2006/084402 A1, the gas used within the scope of the present invention is also low in oxygen or free from oxygen and the container is flushed with this gas, expelling oxygen through the venting opening. This is preferably carried out until the oxygen content in the container is less than 0.2%, preferably 0.1%.
[0023] As is already provided in WO 2006/084402 A1, the venting opening and the pierced hole are then sealed by applying an adhesive label to the plastic film. In order for this to be possible, the two openings cannot of course be distanced too far from one another.
[0024] The venting opening and the pierced hole should be closed after the injection process, but not before a waiting time of at least 3 seconds has elapsed. During this waiting time the plastic film puffed out by the gas injection can be relieved again, at least in part, and can again adopt its preferably flat form, which facilitates the application of the adhesive label. In addition, the adhesion of the adhesive label is improved by the cooling of the plastic film, and this cooling is continued further after the waiting time. Having said that, however, the waiting time should not last any longer than 10 seconds.
[0025] During the waiting time the content of oxygen previously reduced by the flushing with the gas which is low in oxygen or free from oxygen increases slightly again in the container, at least if said container is arranged in ambient air for example. Although the presence of oxygen is detrimental to the shelf life of the food, an oxygen content of 4-5% is by all means favorable and sometimes even required in order to prevent the formation of botulinum toxin in the container, which requires anaerobic conditions.
[0026] In order to ensure a sufficiently long shelf life of the food, the heating should be carried out in such a way that a temperature of 90-98° C. is produced in the core of the food for 30-90 seconds.
[0027] The weight loss caused by steam exiting from the container can be determined as a criterion for whether these values have been achieved and can be compared with a predetermined threshold value in order to ascertain whether this has been exceeded.
[0028] As already emphasized in WO 2006/084402 A1, it is important for the venting opening to be of a defined size and therefore to have a defined flow resistance which also stays the same when subjected to the stresses during the heating process. In this regard, it has been found that suitable holes, which effectively satisfy these requirements, with a diameter typically of 0.5-10 mm can be formed in the plastic film by hot-needle perforation or flame perforation, but in particular by laser perforation. In this method a fusion bulge is produced around the formed hole as an edge reinforcement. The contactless laser perforation process is carried out, for example, by the use of a high-energy light which is generated by a CO 2 gas laser, wherein the material of the plastic film is plasticized and vaporized, in part, in the lens focus of the laser light.
[0029] With geometrically complex packagings, for example a cup packaging with a height of 80 to 140 mm and a small diameter of 60 to 200 mm, the steam generated during heating may possibly be insufficiently displaced by the injected gas owing to the geometry of the packaging. In the case of gas injection into the upper region of a cup packaging steam may remain in the lower third of the packaging, despite the flushing with the injected gas, and the packaging may become dented during the cooling phase.
[0030] In order to nevertheless ensure sufficient flushing argon may be used as a flushing gas. The greater density of argon compared to nitrogen leads to improved flushing, even in the lower third of a cup packaging, and thus to reduced denting of the packaging in the cooling phase. However, it has been found that a remaining oxygen content in the container of 4-7% is produced when flushing with argon in contrast to approximately 0.1% when flushing with nitrogen. However, this affords the advantage that the aforementioned formation of botulinum toxin is prevented.
[0031] A further option for preventing excessive denting after the heating process in the case of geometrically unfavorable packagings consists in carrying out a second gas injection as well as a cooling step between the first and second gas injection. The first gas injection is carried out as already described. After the first gas injection the venting opening and the pierced hole are sealed by applying an adhesive label. The adhesive label is provided with an adhesive which firmly closes the two openings and no longer opens, even at high pressure and temperature, such that the adhesive does not detach during the second gas injection owing to the slight overpressure and the possible residual heat, and no further gas can escape. The two openings remain firmly closed. The packaging is then cooled in a first cooling step. The packaging constricts slightly during this process. After the first cooling process gas is injected for a second time, the packaging not being flushed this time but merely puffed out to approximately the original form.
[0032] The pierced hole of the second gas injection is sealed by an adhesive label which ensures a hermetic seal during the storage period, but opens automatically under the effect of heat, steam and/or pressure when the product is re-heated by the consumer.
[0033] In the above-mentioned method the container can also be actively cooled externally during the first gas injection. This cooling process can be achieved, for example, by a water bath or a cooling tunnel. Such a cooling process results in an additional cooling of the food provided in the packaging, in particular if liquid has collected at the bottom of the packaging, and thus assists the cooling by the first gas injection. Such a cooling also leads to a cooling of the side walls of the packaging and thus to an increased condensation of the steam on the side walls.
FIGURES
[0034] The invention will be explained hereinafter in greater detail with reference to an embodiment in conjunction with the drawings, in which:
[0035] FIG. 1 shows a container, which is suitable for use within the scope of the method according to the invention, with a venting opening and food before said food is preserved;
[0036] FIG. 2 shows the container of FIG. 1 during heating by means of microwaves;
[0037] FIG. 3 shows the container comprising a cannula piercing into the cover film of said container;
[0038] FIG. 4 shows the injection of a gas with the cannula into the container;
[0039] FIG. 5 shows the sealing of the venting opening and of the pierced hole formed by the cannula by means of an adhesive label;
[0040] FIG. 6 shows the sealed container with the food preserved in accordance with the invention; and
[0041] FIG. 7 a shows a suitable cup packaging for use within the scope of the method according to the invention comprising with two injection steps;
[0042] FIG. 7 b shows the cup packaging of FIG. 7 a during a heating process by means of microwaves;
[0043] FIG. 7 c shows the cup packaging during a first injection of a gas with a piercing cannula;
[0044] FIG. 7 d shows the sealing of the venting opening and of the pierced hole, formed by the first cannula, by means of a permanent adhesive label;
[0045] FIG. 7 e shows the contracted cup packaging during a cooling step;
[0046] FIG. 7 f shows the cup packaging during a second injection of a gas with a piercing cannula;
[0047] FIG. 7 g shows the cup packaging sealed by a second adhesive label with the food which has been preserved in accordance with the invention.
DETAILED DESCRIPTION
[0048] FIG. 1 shows a shell-like container 10 made of polypropylene comprising a peripheral edge 11 onto which a cover film 12 , which is likewise peripheral, is welded. The weld connection is preferably peelable.
[0049] The cover film is a multi-layered plastic film less than 100 μm thick, wherein one layer consists of biaxially oriented polyethylene terephthalate (PET) and a second layer consists of polypropylene, and wherein the layer of polypropylene is 50 μm thick and the layer of PET is 23 μm thick. A high barrier which consists of silicon oxide, aluminum oxide or ethylene vinyl alcohol may be present between the two layers.
[0050] A venting opening 20 with a diameter of approximately 2.5 mm is provided in the cover film 12 and is formed by laser perforation and thus comprises a small fusion edge.
[0051] Food 30 is provided in air in the container 10 and has a specific inherent moisture and, for example, is still present in the raw/fresh state.
[0052] FIG. 2 shows the container 10 during heating with microwaves M to preserve the food 30 , wherein steam D has formed from the moisture contained in the food 30 and has caused an overpressure P> in the container 10 . Under the action of said overpressure P>, steam D together with the air which was originally present flows out from the container 10 through the venting opening 20 . The cover film 12 has also expanded and bulged under the action of the overpressure P>.
[0053] The pressure in the container 10 rapidly decreases, above all by condensing steam D, after the heating process and with cooling, in such a way that the cover film 12 can also return, at least approximately, back to its original flat form. In this phase the cover film 12 is pierced in the vicinity of the venting opening 20 by means of a cannula 40 , as shown in FIG. 3 .
[0054] The cannula 40 is provided with a stop collar 41 , which is slightly set back relative to the tip of said cannula, and is preferably inserted until said stop collar 41 rests against the outer face of the cover film 12 . The stop collar 41 , which may have a diameter of 10-20 mm, in particular of 14 mm, prevents excessively deep penetration of the cannula 40 into the container 10 . Its tip only protrudes to such an extent beyond the stop collar 41 , in particular only approximately 5-15 mm, preferably 7 mm, that it does not contact the food 30 where possible. The tip is ground to form three cutting edges which are offset from one another by 120° and are inclined by approximately 22° to the axial direction.
[0055] As is shown in FIG. 4 , a gas G is then injected via the cannula 40 into the container 10 at an overpressure of approximately 0.3 bar. The necessary gas feed to the cannula 40 is not shown in FIG. 4 , similarly to the other figures. The gas G emerges radially at a plurality of openings distributed over the periphery between the tip and the stop collar 41 of the cannula 40 . The cover film 12 expands slightly again owing to the renewed overpressure and bulges upwardly. It presses against the stop collar 41 of the cannula 40 , whereby the pierced hole denoted by 13 in FIG. 5 is additionally stabilized against tearing and a certain sealing effect is also experienced. In order to ensure that the cover film 12 is not pressed in too excessively by the cannula 40 and the stop collar 41 thereof, it is pulled back again slightly during the gas injection, for example by 1-3 cm, as is also shown in FIG. 4 .
[0056] The container 10 is flushed with the gas G, thus expelling steam D and any air still present through the venting opening 20 , and this occurs until no significant vacuum can form as a result of further steam condensation in the container after the aforementioned sealing of the container, or until the content of any oxygen contained in the container has decreased to approximately 0.1%. The injected gas must, of course, itself be free from oxygen where possible.
[0057] FIG. 5 shows the container 10 after the injection of the gas G, wherein the cannula 40 has already been withdrawn again fully from the container 10 . The container 10 must now still be sealed.
[0058] In order to close the container 10 the pierced hole 13 and the venting opening 20 in the cover film 12 are sealed by applying an adhesive label 50 . A plunger 60 which picks up the adhesive label 50 , for example from a label dispenser (not shown) and holds it, for example by suction, until it is applied on the container 10 is used to apply the adhesive label 50 .
[0059] A specific period of time between approximately 0.5 and 10 seconds elapses between the end of the gas injection and the withdrawal of the cannula 40 on the one hand, and the application of the adhesive label 50 on the other hand. During this period the overpressure generated in the container 10 by the injection of the gas G may decrease again, at least in part, owing to the venting opening and the pierced hole 13 formed in the cover film 12 by the cannula 40 , wherein the film returns to its flat form. In addition, the oxygen content in the container may advantageously increase to 4-5% owing to a specific backflow or back-diffusion of external air. Lastly, the temperature may decrease again slightly, which is advantageous in order to support the adhesive label on the film.
[0060] FIG. 6 shows the container 10 with the food 30 preserved in accordance with the invention in the gas atmosphere G and with the adhered adhesive label 50 at ambient pressure. The cover film 12 is easily drawn in under the influence of a certain subsequent condensation of residual steam once the adhesive label has been applied, but this is not detrimental to the food contained in the container and helps to ensure that the cover film is stretched tight and also remains in place in the long term. In this form the container is suitable as a transport and retail packaging and is further preferably supplied to a conventional cooling chain with cooling temperatures in the range of 1-8° C.
[0061] For sufficient preservation of the food 30 it is important that a temperature of 90-98° C. is reached for 30-90 seconds in the core of the food during the heating process. As a criterion for this the container 10 can be weighed before the heating process and after the sealing process, and from this the weight loss caused by the escape of steam can be ascertained. If it is too low, it means that a sufficient temperature has not been reached or was only reached for an insufficient period of time. The relevant container 10 can then be rejected.
[0062] Before consumption of the food preserved by the described method, it is heated in the packaging, typically in a microwave oven, to consumption temperature. In order to enable heating in conventional ovens at relatively high temperatures, the shell-like container 10 and the polyethylene terephthalate layer of the cover film 12 can consist of crystalline polyethylene terephthalate (C-PET) with a melting point above 230° C. The second layer of the plastic film is a connection layer which consists of an adhesion promoter. The cover film can thus be adhered to the edge of the shell-like container after activation of the adhesion promoter.
[0063] It may be that the gas flushing is insufficient with the use of cup-like packagings for example, and that the packaging contracts significantly after being sealed during cooling. In order to avoid this, a cooling step and a second gas injection are carried out after the gas flushing, as is shown in FIGS. 7 a - g.
[0064] FIG. 7 a shows a suitable cup packaging 70 for use within the scope of the method according to the invention with two injection steps. Food 30 in air is provided in the cup packaging 70 . The cup packaging 70 with a height of 80 to 140 mm and a diameter of 60 to 200 mm also has a cover film 12 and a venting opening 20 . It differs from the container 10 mentioned above merely in shape.
[0065] FIG. 7 b shows the cup packaging 70 of FIG. 7 a during a heating process by means-of microwaves M in order to preserve the food 30 , as has already been described for the container 10 of FIG. 2 . Steam D has formed from the moisture contained in the food 30 and the cover film 12 has expanded and bulged under the action of the overpressure P> produced. Some of the steam D, together with the air originally present in the cup packaging 70 , escapes through the venting opening 20 .
[0066] FIG. 7 c shows the cup packaging 70 during a first injection of a gas G with a cannula 40 which has pierced through and comprises a stop collar 41 . This process is also carried out in the manner as already described for the container 10 of FIG. 3 and FIG. 4 . Owing to the geometry of the cup packaging it may be that the cup packaging 70 is not sufficiently flushed and steam D remains in the lower third of the cup packaging, as shown in FIG. 7 d.
[0067] FIG. 7 d also shows the sealing of the venting opening 20 and of the pierced hole 13 , formed by the first injection, by a permanent adhesive label 80 . In this case the permanent adhesive label 80 is still retained by the plunger 60 . This permanent adhesive label 80 has an adhesive which no longer detaches, even when subjected to pressure and increased heat.
[0068] Once the permanent adhesive label 80 has been affixed, the cup packaging 70 is cooled in a cooling step from the pasteurization temperature to approximately 65° C. Depending on requirements, it can also be cooled further, for example to 2-4° C. As the cooling takes place the pressure in the cup packaging 70 decreases and the cup packaging 70 constricts under the vacuum P< produced. The cover film 12 is drawn inwards. FIG. 7 e shows the cup packaging 70 which is drawn in during a cooling step.
[0069] FIG. 7 f shows the cup packaging 70 during a second injection of a gas G with a cannula 40 which has pierced through and comprises a stop collar 41 . The second injection is carried out at a point which is offset from the first injection site. During the second injection, gas G 2 is injected until the constricted cup packaging 70 has been puffed out again to its original form. During the second injection it is suffice to apply a lower overpressure than that during the first injection. The overpressure during the second injection may be approximately 0.2 bar.
[0070] FIG. 7 g shows the cup packaging 70 , which is sealed by an adhesive label 50 , with the food 30 preserved in accordance with the invention. The adhesive label 50 is applied to the cup packaging 70 in the manner already described above for the container 10 .
[0071] Alternatively to the above-described design of the plastic film and irrespectively thereof, the design of the cannula described above could be considered as an independent inventive concept to improve the method known from WO 2006/084402 A1, in particular in terms of the stop collar and/or movement of said cannula. The same also applies at least to the waiting period between the end of the gas injection and the sealing of the container and/or to the method with an intermediate cooling step and a second gas injection.
[0072] What has been described above are preferred aspects of the present invention. It is of course not possible to describe every conceivable combination of components or methodologies for purposes of describing the present invention, but one of ordinary skill in the art will recognize that many further combinations and permutations of the present invention are possible. Accordingly, the present invention is intended to embrace all such alterations, combinations, modifications, and variations that fall within the spirit and scope of the appended claims.
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A method for preserving food. The food is heated in a moist state in a container, which has a venting opening and is suited as transport and retail packaging, by way of microwaves (M) for a limited time, however at least until hot steam (D) from in the container and exists through the venting opening. After the heating has ended, a gas (G) is injected into the container using a cannula, and a container wall made of plastic film is pierced with the cannula. The plastic film that is used has a thickness of less than 100 μm. At least one layer of the plastic film is made of polyethylene terephthalate having a thickness of greater than 19 μm.
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FIELD OF THE INVENTION
The present invention relates generally to switching power supply circuits. In particular, the invention relates to circuits that supply power to loads in continuous conduction mode and discontinuous conduction mode.
BACKGROUND OF THE INVENTION
Portable electronic devices typically require the application of a regulated DC voltage in a predetermined range of voltages for satisfactory operation. Many electronic devices rely on unregulated DC supplies such as lithium-ion batteries as a power source. Batteries generally provide a voltage that is substantially fixed over short time periods but slowly decreases throughout its useful lifetime. Consequently, battery voltage is often transformed to a regulated supply voltage having a different voltage value to ensure proper operation of the electronic device.
The prior art teaches many ways to accomplish this conversion. For example, some portable electronic devices use arrays of capacitors (e.g., charge pumps) to convert the source voltage into a voltage with a different polarity or magnitude. Other devices use switching power supplies to provide a regulated voltage for proper operation. Switching losses inherent in such supplies can limit the power efficiency.
Certain portable electronic devices utilize unregulated DC supplies that are sensitive to current backflow. For example, lithium-ion batteries can experience heating problems or can be damaged if current flows back into the battery. Therefore, it is desirable to provide a switching power supply that prevents current backflow and minimizes switching losses.
SUMMARY OF THE INVENTION
The present invention relates to a circuit and method for powering DC devices using DC voltage sources. The present invention provides an improved switching power supply that has reduced switching losses and prevents load current reversal under light load conditions. The circuit operates using constant ripple current regulation in continuous and discontinuous mode operation. In discontinuous mode, this is accomplished using pulse-frequency mode modulation. A rectifier circuit prevents current backflow into the DC voltage source, which otherwise can cause overheating and device failure.
In one aspect, the invention relates to a circuit for generating a regulated output voltage. In one embodiment, the circuit includes an inductor, a first switch, a pulse generator and a rectifier circuit. The inductor has a first terminal and a second terminal. The first switch has a first terminal to receive a first reference voltage, a second terminal in communication with the first terminal of the inductor, and a control terminal for receiving a first control signal. The pulse generator has an input terminal and an output terminal, which provides the first control signal, in communication with the control terminal of the first switch. The rectifier circuit has a first control input terminal in communication with the output terminal of the pulse generator, a second control input terminal in communication with the second terminal of the second switch and a third control input terminal to receive the second reference voltage.
In one embodiment, the rectifier includes a first comparator, a logic module, and a second switch. The first comparator has a first terminal in communication with the second control input terminal, a second terminal in communication with the third control input terminal, and an output terminal. The logic module has a first input terminal in communication with the first control input terminal, a second input terminal in communication with the output terminal of the first comparator, and an output terminal to provide a second control signal. The second switch has a first terminal to receive a second reference voltage, a second terminal in communication with the first terminal of the inductor, and a control terminal to receive the second control signal. In another embodiment, the second terminal of the first comparator receives a small negative voltage.
In another embodiment, the pulse generator includes an adaptive pulse generator and an OR gate. The adaptive pulse generator has an input terminal in communication with the input terminal of the pulse generator and an output terminal. The OR gate has a first input in communication with the output terminal of the adaptive pulse generator, a second input in communication with the input terminal of the pulse generator, and an output terminal in communication with the output terminal of the pulse generator. In yet another embodiment, the pulse generator also includes a comparator. The comparator has a first terminal in communication with the second terminal of the inductor, a second terminal to receive a third reference voltage, and an output terminal connected with the input terminal of the adaptive pulse generator. In still another embodiment, the pulse generator includes an overcurrent detector having an input terminal connected to the first inductor terminal and an output terminal connected to the first switch control terminal.
In still another embodiment, the logic module includes a flip-flop and a NOR gate. The flip-flop has an input terminal in communication with the output terminal of the first comparator, a reset terminal in communication with the first control input terminal, a data terminal to receive the first reference voltage, and an output terminal. The NOR gate has a first NOR input terminal in communication with the first control input terminal, a second NOR input terminal in communication with the output terminal of the flip-flop, and an output terminal in communication with the control output terminal.
In another embodiment, the second terminal of the second comparator is in communication with the second terminal of the inductor through a voltage divider network. In one embodiment, the voltage divider network includes a first resistor and a second resistor. The first resistor has a first terminal coupled to the second terminal of the second inductor, and a second terminal. The second resistor has a first terminal coupled to the second terminal of the first resistor and a second terminal to receive the second reference voltage.
In another aspect, the present invention relates to a method for generating a regulated output voltage. The method includes the step of applying a first reference voltage to a series combination of an inductor and a load if an elapsed time is less than a predetermined time or if a voltage across a load is less than a first predetermined voltage. A second reference voltage is applied to the series combination of the inductor and the load if the elapsed time is greater than the predetermined time and if the load voltage is not less than the first predetermined voltage. The application of the second reference voltage is terminated if the voltage across the series combination of the inductor and the load exceeds a second predetermined voltage or if the voltage across the load does not exceed the first predetermined voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will become apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings. The drawings are not necessarily to scale, emphasis instead being placed on illustrating the principles of the present invention.
FIG. 1 is a functional block diagram of one embodiment of the circuit of the present invention;
FIG. 1A is a functional block diagram of another embodiment of the circuit of the present invention.
FIG. 2 is a chart of sample waveforms produced during the operation of the circuit of FIG. 1;
FIG. 3 is a block diagram of an embodiment of the rectifier circuit of FIG. 1;
FIG. 4 is a block diagram of an embodiment of the pulse generator of FIG. 1;
FIG. 5 is a block diagram of an embodiment of the logic module of FIG. 3;
FIG. 6 is a schematic diagram of the overcurrent detector of FIG. 4;
FIG. 6A is a schematic diagram of one embodiment of voltage divider network 19 ;
FIG. 7 is a schematic diagram of the adaptive pulse generator of FIG. 4; and
FIG. 8 is a flowchart representation of one embodiment of the method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In brief overview, the present invention relates to a circuit and method for providing a regulated DC voltage from a DC source. By maintaining a constant magnitude ripple component in the output current in both continuous and discontinuous conduction modes, regardless of the magnitude of the load, the present invention reduces switching losses under light load conditions. Additional functionality prevents current backflow into the DC source under light load conditions.
FIG. 1 depicts one embodiment of the circuit of the present invention. The circuit includes a pulse generator 20 , a switch 28 , a rectifier circuit 32 , an inductor 40 , and a capacitor 46 . In one embodiment, the switch 28 is a field-effect transistor (FET). The circuit is designed to deliver regulated DC power to a load 10 having one terminal 12 connected to capacitor terminal 44 and a second terminal 16 connected to ground 14 .
The load voltage V o is applied to terminal 18 of pulse generator 20 . In one embodiment, illustrated in FIG. 1A, the load voltage V o is applied to terminal 18 through a voltage divider network 19 . The voltage divider network 19 provides a proportionately-scaled voltage representative of the voltage V o . The pulse generator 20 compares the voltage V o to the predetermined reference voltage and generates a signal CHG indicative of whether the voltage across load 10 is less than the reference voltage. This variable pulse width signal CHG is asserted (e.g., changed to a logical HIGH or logical 1 state) at pulse generator output terminal 24 for at least a predetermined time period. If the voltage V o across load 10 fails to reach the predetermined reference voltage in the predetermined time period, then the pulse generator 20 maintains the variable pulse width signal CHG in the asserted state. The variable pulse width signal CHG is deasserted when excessive current is detected in the inductor, or when the predetermined time period has elapsed and the voltage V o has increased to the reference value.
The variable pulse width signal CHG is applied to switch terminal 26 to control closure of switch 28 and, therefore, application of DC supply voltage V cc to the inductor terminal 38 . A change in the magnitude of the current I L flowing through inductor 40 occurs when the switch 28 is closed. Thus, energy is stored in the inductor 40 and the voltage V 0 across load 10 increases. If the load voltage V 0 increases to match the value of the reference voltage and if the predetermined time period has expired, then the pulse generator 20 deasserts the variable pulse width signal CHG , thereby opening switch 28 . Until both conditions are satisfied, the pulse generator 20 continues to assert the variable pulse width signal CHG.
When the variable pulse width signal opens switch 28 , the rectifier circuit 32 couples the first inductor terminal 38 to V GNG 15 , a ground or negative voltage, at substantially the same time. As inductor 50 discharges, the inductor current IL decreases in magnitude and capacitor 46 releases its stored charge and provides current to load 10 . At first, the current provided by capacitor 46 maintains the voltage V o across load 10 near the reference voltage. When the inductor current I L and the charge in capacitor 46 sufficiently decrease, the load voltage V o drops below the reference voltage value. Consequently, the pulse generator 26 initiates a new charging cycle to maintain the load voltage V o in regulation.
As long as the average load current is greater than one half of the ripple component of the load current, then the current flow I L through the inductor 40 remains positive. This mode of operation is referred to as continuous conduction mode (CCM) because there is an uninterrupted current flowing through the inductor 40 . A complementary operating mode, referred to as discontinuous conduction mode (DCM), occurs if the current through the inductor 40 decreases to zero for a finite time during operation, such as during sleep mode. During sleep mode, only a small average current is required to maintain the load voltage V 0 in regulation. As a result, the magnitude of the ripple component of the load current exceeds the average value of the inductor current I L . Thus, the current I L through the inductor 40 reverses direction during part of the discharge period. To avoid this backflow current that can damage some DC sources, the rectifier circuit 32 interrupts the current path to the inductor 40 shortly before reversal of the inductor current I L can occur. Interrupting the current path allows capacitor 46 to discharge directly into load 10 , maintaining the load voltage V 0 in regulation. This mode of operation is referred to as discontinuous conduction mode (DCM) because the current flow through the inductor 40 is discontinuous.
FIG. 2 illustrates the current and voltage waveforms of the circuit of FIG. 1 . The waveforms on the left depict the circuit powering a load in CCM operation. The waveforms on the right depict the circuit in DCM operation. I L depicts the current flowing through inductor 40 . During CCM operation, the inductor current IL exhibits a ripple about an average current value I o . V 0 represents the value of the voltage across the load 10 . During DCM operation, the inductor current I L includes periods during which its magnitude is zero. V olow represents the result of the comparison of the magnitude of the load voltage V o and the predetermined reference voltage. During CCM operation, V olow is true (logic HI or logic 1 ) when the load voltage V o is less than the predetermined reference voltage. T on represents a signal having a substantially fixed predetermined duration that is generated in the pulse generator 20 . CHG represents the variable pulse width signal provided at the pulse generator output terminal 24 that maintains switch 28 closed during its asserted state. CHG is asserted for at least the predetermined minimum period, and can remain asserted for a longer period if necessary to increase the load voltage V o to the predetermined reference voltage. DCHG represents a signal generated within the rectifier circuit 32 that is used to control the coupling of the first inductor terminal 38 to V GNG 15 . UCT represents a signal generated within the rectifier circuit 32 that is used to terminate the coupling of the first inductor terminal 38 to V GNG 15 . Initiation of the asserted state for signal UCT occurs when the inductor current I L decreases to near zero to avoid current reversal.
FIG. 3 depicts one embodiment of the rectifier circuit 32 of FIG. 1 . The rectifier circuit 32 includes a switch 62 , a comparator 68 , and a logic module 78 . The switch 62 includes a first terminal 64 in communication with input terminal 36 of the rectifier circuit 32 , a second terminal 66 connected to ground 14 , and a control terminal 60 . The comparator 68 has one input terminal 70 connected to rectifier terminal 36 and a second input terminal 72 connected to rectifier terminal 34 . By comparing the voltages at the comparator input terminals 70 and 72 , the polarity f the inductor current I L is determined and is represented by a signal generated at the output terminal 73 of the comparator 68 . The logic module has one input terminal 74 connected to input terminal 30 of the rectifier circuit, a second input terminal 76 connected to the comparator output terminal 73 and an output terminal 80 in communication with the control terminal 60 of switch 62 . The logic module 78 generates a signal DCHG at its output terminal 80 for controlling switch 62 in response to the output signal CHG from the pulse generator 20 and the output signal UCT from the comparator 68 . During CCM operation, control signal DCHG is substantially complementary to the pulse generator output signal CHG. During DCM operation, the combination of control signal DCHG and signal UCT is complementary with the output signal CHG.
FIG. 4 depicts one embodiment of the pulse generator 20 of FIG. 1 . The pulse generator 20 includes a comparator 94 , an adaptive pulse generator 98 , an OR gate 106 , an AND gate 114 and an overcurrent detector 116 . The comparator 94 has an input terminal 90 to receive a reference voltage V REF , a second input terminal 92 in communication with input terminal 18 of the pulse generator 20 , and an output terminal 93 . The adaptive pulse generator 98 has an input terminal 96 in communication with the output terminal of comparator 94 . The OR gate 106 has an input terminal 102 in communication with output terminal 100 of the adaptive pulse generator 98 , a second input terminal 104 in communication with comparator output terminal 93 , and an output terminal 108 . The AND gate 114 has a first input terminal 110 in communication with OR gate output terminal 108 , a second complemented input terminal 112 and an output terminal 113 connected to terminal 24 of the pulse generator 20 . The overcurrent detector 116 has an input terminal 115 connected to input terminal 22 of the pulse generator 20 and an output terminal 117 connected to the complemented input terminal 112 of the AND gate 114 .
In operation, comparator terminal 90 receives a reference voltage V REF representative of a desired load voltage V 0 during regulated operation and comparator terminal 92 receives a voltage representative of the instantaneous load voltage V 0 . The comparator 94 generates a signal at its output terminal 93 indicating whether the load voltage V 0 is less than the reference voltage V REF . In one embodiment, a proportionately-scaled voltage representative of the load voltage V 0 is applied to comparator terminal 92 from a voltage divider network (not shown) coupled to load terminal 12 and comparator terminal 92 .
Comparator 94 provides an output signal V olow to the adaptive pulse generator input terminal 96 and OR gate input terminal 104 . If V olow indicates that the load voltage V 0 is less than reference voltage V REF , the adaptive pulse generator 98 asserts a signal at its output terminal 100 for a predetermined minimum time. The OR gate 106 provides an asserted signal at output terminal 108 if at least one of the signals applied to its input terminals 102 and 104 is asserted. Thus, OR gate 106 continues to assert a logical HI or logical 1 signal at terminal 108 beyond the predetermined minimum time if the comparator output signal V olow indicates that load voltage V 0 is still less than the desired voltage V REF .
The output signal from OR gate 106 is applied to AND gate input terminal 110 . The output of overcurrent detector 116 is applied to complemented AND gate input terminal 112 . When there is no excess inductor current I L , the output signal from overcurrent detector 116 is low. Consequently, the signal CHG generated by AND gate 114 is determined by the output signal from the OR gate 106 . If the inductor current I L increases to an unacceptable level, the output signal from the overcurrent detector 116 is asserted. As a result, the pulse generator output signal CHG is deasserted or held low to reduce the inductor current I L .
FIG. 5 depicts an embodiment of the logic module 78 of FIG. 3 . The logic module 78 includes an edge-triggered D flip-flop 138 and a NOR gate 144 . The D flip-flop 138 has an input terminal 132 in communication with logic module input terminal 76 , a reset terminal R 130 in communication with logic module input terminal 74 , a data terminal D 134 adapted to receive a reference voltage V cc and an output terminal Q 136 . The NOR gate 144 has one input terminal 142 in communication with logic module input terminal 74 , a second input terminal 140 in communication with the output terminal 136 of the D flip-flop 138 , and an output terminal 143 in electrical communication with logic module output terminal 80 .
In CCM operation, while inductor 40 is charging, the asserted output signal CHG from the pulse generator 20 resets the flip-flop 138 so that terminal Q 136 is set low. Consequently, the output signal DCHG from NOR gate 144 is low and switch 62 is maintained in an open state. When output voltage V 0 is greater than the desired load voltage represented by V REF and the minimum time on has expired, the output signal CHG from the pulse generator 20 is deasserted and the output signal DCHG is asserted.
In DCM operation during the discharge period, the signal UCT received at input terminal 76 is asserted when the inductor current I L decreases to zero (or a small positive value). Consequently, the signal at the output terminal Q 136 of the flip-flop 138 is asserted and the output signal DCHG of the logic module is deasserted. Switch 62 is thereby open for the remainder of the discharge period.
FIG. 6 depicts one embodiment of the overcurrent detector 116 of FIG. 4 . The overcurrent detector 116 includes a current monitor 160 , a comparator 162 , and a pulse generator 164 . The current monitor has an output terminal 168 . The comparator 162 has a first input terminal 170 connected to overcurrent detector input terminal 115 , a second input terminal 172 connected to current monitor output terminal 168 , and an output terminal 174 . Pulse generator 164 has an input terminal 176 connected to comparator output terminal 174 and an output terminal 178 connected to complemented AND gate input terminal 112 .
The current monitor 160 applies a reference voltage at comparator terminal 172 representative of the maximum current density allowable through switch 28 . Comparator terminal 170 receives the voltage at inductor terminal 38 . When the voltage at terminal 170 decreases so that it equals the voltage representative of the maximum allowable current density while the inductor 40 is charging, the output signal of comparator 162 is asserted at output terminal 174 . Pulse generator 164 receives the comparator output signal and consequently generates a logical HIGH pulse of a predetermined minimum time at overcurrent detector output terminal 117 to indicate excess inductor current I L .
FIG. 6A is a schematic diagram of one embodiment of voltage divider network 19 . In this embodiment, voltage divider network 19 includes a first resistor 180 having a first terminal electrically coupled to the second terminal of the inductor 40 and a second terminal. The voltage divider network 19 also includes a second resistor 182 having a first terminal electrically coupled to the second terminal of the first resistor 180 and a second terminal adapted to receive a second reference voltage.
FIG. 7 depicts one embodiment of the adaptive pulse generator of FIG. 4 . The adaptive pulse generator 98 includes a first inverter 190 , a second inverter 192 , a first D flip-flop 194 , a second D flip-flop 196 , a delay module 198 , a current source 200 , a transistor 202 , a capacitor 204 , a current mirror 206 , an inverter 208 , and an inverter 210 . As signal V olow is asserted, inverters 190 and 192 provide triggers to the first flip-flop 194 , thereby asserting its START signal output. Flip-flop 196 is cleared, asserting the adaptive pulse generator output signal T on and causing the BUSYN signal output to be deasserted. Deasserting BUSYN opens switch 202 , allowing current source 200 to charge capacitor 204 . After sufficient charging of the capacitor 204 , current mirror 206 is activated so that inverters 208 and 210 trigger flip-flop 196 such that adaptive pulse generator output signal T on is deasserted.
FIG. 8 is a flowchart representation of a method for generating a regulated output voltage in accord with the present invention. A first reference voltage is applied across a series combination of an inductor and a load (Step 10 ). If a predetermined time T has elapsed (Step 12 ) and the voltage V 0 across the load is not less than a first predetermined voltage V 1 (Step 14 ), then a second reference voltage is applied across the series combination of the inductor and the load (Step 16 ). In one embodiment, the second reference voltage is ground. Application of the second voltage is terminated (Step 22 ) if the voltage across the series combination of the inductor and the load exceeds a second predetermined voltage (Step 18 ) or if the voltage V 0 across the load decreases to less than the first predetermined voltage (Step 20 ). In one embodiment, the second predetermined voltage is equal to the second reference voltage. In another embodiment, the method includes the additional step of terminating the application of the first reference voltage if the inductor current exceeds a predetermined current limit.
While the invention has been particularly shown and described with reference to specific preferred embodiments, it should 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 as defined by the appended claims.
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A circuit and method for powering DC devices using DC voltage sources. The present invention provides an improved switching power supply that has reduced switching losses and prevents current backflow under light load conditions. The circuit operates using pulse-frequency modulation in discontinuous conduction mode for powering small loads. A rectifier circuit prevents current backflows into the DC voltage source to prevent overheating and device failure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to automotive boots and, more particularly, to a boot having a fixed end and a floating end to seal an encircled element against foreign matter while accommodating axial translation and limited rotational and pivotal movement between the fixed and floating ends.
2. Description of the Prior Art
Tube like flexible boots have been used in various automotive, industrial and other applications to protect extensible members from environmental contaminants. Often, the extensible members effect a combination of axial and rotational movements between the elements to which they are attached. In such prior applications, both ends of the boot may be fixedly attached to the respective encircled shaft and housing to form a seal. Similarly, boots used to protect the junction between telescoping members where there is no relative rotational or pivotal movement between the members, may be fixedly secured at both ends. However, when both ends of a boot are fixedly secured to two elements which reciprocally rotate with respect to one another, substantial twisting stresses are imposed upon the boot and its lifespan is a function of the ability of the boot material to withstand the stresses imposed. When there is compression and expansion of the boot in combination with a twisting motion, the boot will fatigue more rapidly or not function at all. A boot split or torn as a result of fatigue induced non compliance will expose the protected elements to foreign matter and thus defeat the purpose for which a boot was installed. Such exposure will quickly cause corrosion and damage with a possible resulting failure of the elements and jeopardy to operability of the vehicle. These problems are particularly prevalent in automotive applications in general and for MacPherson struts in particular.
Various mechanisms have been developed in an attempt to float one end of a boot to accommodate relative rotational and pivotal movement between the points of attachment of the ends of the boot. In one embodiment of a boot, a radially inwardly oriented channel is formed in a floating end of the boot for receiving the edge of a disk like element. To accommodate rotation, the channel must be in sufficiently loose engagement with the disk to permit rotation of the boot about the disk and avoid translation of twisting forces upon the boot. In practice, it has been found that to avoid twisting sufficient looseness of the fit must exist which fit will permit particulate matter and liquids to enter the boot through the floating end. In another embodiment, one end of the boot is rigidly secured to a collar. The collar includes a radially inwardly oriented channel for receiving an annular ridge in sliding engagement. To prevent unwanted restraint of rotational movement of the channel relative to the ridge, a substantial space therebetween must be provided, which space is also sufficient to prevent a substantial inflow of particulate matter and liquid into the boot. Modified versions of such radially inwardly oriented channels cooperating with radially extending ridges or disks have also been employed. In each of such configurations, a common problem is present. A certain amount of radially oriented space must exist to permit sufficient segregation and lack of frictional resistance to permit independent rotation therebetween. Since the radial width of this space is a function of the sealing capability of the interconnection, a dichotomy exists. Either the radial space must be sufficient to permit independent relative rotation between the parts, in which case an inflow of particulate matter and liquid occurs or the radial space must be minute enough to provide a seal against intrusion of particulate matter and liquids, in which case independent relative rotation between parts is inhibited. Furthermore, looseness of the fit will be noisy during operation of the vehicle, which noise is unacceptable. A further ongoing problem with boot designs in general is that of providing a means for air outflow and inflow as the boot compresses and extends.
SUMMARY OF THE INVENTION
One end of a tube like accordion shaped flexible boot is secured to the cylinder of a shock absorber. The other end of the boot is secured to a point proximate the end of a plunger extending from the cylinder with a floating point of attachment to accommodate axial displacement of the plunger and relative rotation between the plunger and the cylinder. The floating point of attachment includes a radially inwardly oriented flange formed in the boot, which flange includes a plurality of concentric ridges disposed on opposed sides. A plunger associated radially outwardly oriented channel receives and maintains the flange. A seal between the channel and ridges is formed by the ridges exerting pressure axially upon opposed sides of the channel.
It is therefore a primary object of the present invention to provide a floating attachment for providing a measure of sealing for one end of a boot while permitting air outflow and inflow as the boot member compresses and extends and yet permitting rotational movement between elements of the boot protected extensible member.
Another object of the present invention is to provide apparatus for attaching a boot to protect the junction between two elements which are axially and rotationally displaceable with respect to one another.
Still another object of the present invention is to provide an effective seal against intrusion of foreign matter into a boot having one fixed end and a floating end.
Yet another object of the present invention is to provide a seal between a boot and an element rotatable with respect thereto which is a function of opposed axially oriented forces.
A further object of the present invention is to provide a floating seal between one end of a boot and a rotating element which seal accommodates radial displacement of the sealed end of the boot without affecting the integrity of the seal.
A still further object of the present invention is to provide a boot for effectively sealing a MacPherson strut of a vehicle.
A yet further object of the present invention is to provide a low noise floating seal between a non rotating boot and a rotating and axially displaceable element.
A yet further object of the present invention is to provide a means for exchanging air out of and into a boot as the boot compresses and extends.
These and other objects of the present invention will become apparent to those skilled in the art as the description thereof proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described with greater clarity and specificity with reference to the following drawings, in which:
FIG. 1 illustrates a floating boot seal incorporated with an automotive suspension element of the type sometimes referred to as a MacPherson strut;
FIG. 2 is a partial cross sectional view illustrating the floating boot seal;
FIG. 3 is a cross sectional view taken along line 3--3, as shown in FIG. 2; and
FIG. 4 is a partial view showing a variant configuration of the ridges on the flange.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A MacPherson strut is a particular strut used as part of the front end suspension system of certain automotive vehicles. This strut is, in essence, a shock absorber mounted and oriented in a particular relationship which results in both axial displacement of the plunger with respect to the cylinder and incremental rotation of the plunger about its axis with respect to the cylinder. Foreign matter, whether particulate or liquid, disposed upon the plunger will tend to corrode the plunger and will affect the seal between the plunger and the cylinder. Moreover, particulate matter forced between the plunger and the cylinder will cause scoring and will damage the seals of the cylinder and render the shock absorber functionally inadequate. It is therefore mandatory that the plunger be protected in an effective manner. Because any shroud or boot disposed about the plunger must be capable of accommodating not only axial displacement of the plunger but also rotational displacement of the plunger relative to the cylinder while providing an effective seal against particulate matter and liquid, a severe problem has existed. Finally, the seal must not clatter or otherwise be noisy.
Referring to FIG. 1, there is shown, in representative form, a MacPherson strut 10. The strut in one sense functions in the manner of a coil spring encircling a conventional shock absorber to suspend the automobile frame and body while dampening the relative movement between two interconnected parts. However, because of its position and angular orientation along with the associated suspension components, it is identified by the name of the inventor of this type of suspension. The MacPherson strut, or shock absorber, includes a plunger 12 secured to an element 14 of the automotive chassis. A tab 16, or like element, may be used to attach the strut body or cylinder 18 to an arm of a wheel supporting assembly. The coil spring and coil spring supporting elements normally used with a MacPherson strut are not shown for reasons of clarity; moreover, further elements associated with the suspension system but not a part of the present invention have been omitted for the sake of clarity.
A boot 20 is a flexible tube like element having an accordion like round wall to accommodate axial compression and extension. Fixed end 22 of the boot includes a cylindrical section 24 sized to circumscribe cylinder 18 in contacting relationship. A band 26 encircles the cylindrical section to compressively maintain the cylindrical section fixed to cylinder 18 in sealed relationship. A bead or lip 28 may be employed to discourage withdrawal of the cylindrical section from within band 26. Thereby, lower end 22 of boot 20 is affixed to cylinder 18 in sealed relationship.
Referring jointly to FIGS. 1, 2 and 3, the floating attachment point of upper end 36 of boot 20 will be described. A nut 40, in combination with a washer 42, threadedly engages threaded section 44 of plunger 12 to secure the plunger to chassis element 14. Plunger 12 may include a shoulder 46 for this purpose. A member 48 includes an aperture 50 for penetrably receiving threaded section 44 of plunger 12. Upon tightening of nut 40, member 48 is drawn against the under surface of chassis element 14 by shoulder 46 bearing against the member. It is to be understood that other mechanisms for attaching member 48 as well as the location of the member with respect to the chassis element or the plunger may be varied or otherwise modified.
Member 48 includes a radially outwardly oriented channel 56. This channel may be formed by the combination of a disk 58 secured to a circular offset element 60. Alternatively, it may be a single piece pulley like element having a deep annular channel.
Upper end 36 of boot 20 includes a radially inwardly oriented flange 66 positionable within channel 56. Preferably, the interior radius of flange 66 is greater than the minimum radius of channel 56 to permit upper end 36 of the boot to be displaced laterally to a certain extent without contact with the inner extremity of the channel.
A seal 64 between upper end 36 and member 48 is provided by a plurality of concentric ridges 68, 70 and 72 disposed upon exterior surface 74 of the flange and a further plurality of concentric ridges 76, 78 disposed upon interior surface 80 of the flange. These ridges are dimensioned to bear against the respective radial walls of channel 56 and create a seal therewith. The cross section of the ridges may be semicircular, triangular, rectangular or of any other configuration.
It may be noted that radial excursion of upper end 36 relative to the axis of plunger 12 will result in the ridges being displaced radially inwardly with respect to one part of the channel but radially outwardly with respect to the diametrically opposed part of the channel. Any such displacement, to the extent accommodated by the radial dimension of flange 66 and the innermost wall of the channel, will have no effect upon the sealing engagement between the ridges and the respective radial walls of the channel. It will therefore become evident that the integrity of the seal between upper end 36 of the boot and member 48 is not a function of any radially oriented force therebetween. Instead, the sealing effectiveness is a function of the degree of axial compression between the radial walls of channel 56 and the engaged ridges. Because the line of contact between each of the ridges and the respective radial wall can be very narrow, only a very small amount of force is required to produce a high sealing pressure. Thus, the amount of friction between member 48 and boot 20 due to rotational displacement therebetween about the axis of plunger 12 will be minimal. There will therefore exist a tendency for upper end 36 of the boot not to rotate relative to member 48 in response to relative rotation between cylinder 18 and plunger 12. The effective lack of rotational movement of upper end 36 of boot 20 with respect to fixed end 22 will minimize the stresses imposed upon the boot due to relative rotation between the fixed end and the upper end; and, the useful life of the boot will be enhanced.
Because upper end 36 of the boot is in ongoing and continuing contact with element 48, there will be little noise producing motion therebetween. Accordingly, the floating interconnection is relatively quiet and essentially unnoticeable to an occupant of the vehicle.
While flange 66 is illustrated and described as being oriented radially inwardly, it is to be understood that the flange could be radially outwardly oriented. In such case, member 48 would be adapted to provide a radially inwardly extending channel to receive the flange. By incorporating the concentric ridges discussed above in such radially oriented flange, the sealing effectiveness described above would be maintained. A further consideration for the effectiveness of the seal is that of the spacing between the planar surfaces of flange 66 and the opposing radial sides of channel 56.
Since the combination of flange 66 and channel 56 provides a convoluted path into upper end 36 of the boot, a deterrent to flow of particulates and liquids into the boot exists. Because of such preexisting deterrent, a sufficient seal may be effected even if the ridges are segmented, instead of continuous, and whether such segmented ridges are overlapping or not.
FIG. 4 illustrates a variant flange 66a having segments 68a, 70a, 70b, 72a and 72b of ridges 68, 70 and 72 formed thereon. These segments are in radially aligned overlapping relationship and provide a clear airway into and out of boot 20 for venting purposes. However, the segments contribute to the convoluted passageway into and out of the boot and restrain flow of particulate matter and liquid therepast.
As boot 12 compresses and extends in response to the protected MacPherson strut or extensible member, air must be permitted to flow out of and into the boot. A vent for this purpose can be provided by seal 64. That is, by appropriate dimensioning of ridges 68, 70, 72, 76 and 78 with respect to the corresponding radial walls of channel 56, sufficient space can be provided for air flow therebetween and venting of the boot. Even though the resulting seal will not prevent gaseous flow therepast, the convoluted pathway provided by the flange within the channel and the ridges extending from the flange will be very effective in precluding particulate matter or fluids from passing therepast. Should the ridges be segmented as discussed above and whether or not radially overlapped, venting for the airflow into and out of the boot will be provided.
From the above description it will be apparent that boot 12, due to its accordion like wall, can accommodate axial displacement between the two points of attachment. Moreover, it is well known that the accordion like wall of the boot will accommodate at least a limited degree of lateral displacement between the two points of attachment. The floating seal engagement of one end described above accommodates relative rotation between the points of attachment of the opposed ends of the boot without imposing a like degree of rotation on twisting of the boot. Accordingly, the configuration of boot 12 and the structure for attaching the opposed ends thereof, as described above, can and will accommodate rotational displacement as well as axial and lateral displacement between the points of attachment at the opposite ends of the boot.
While the principles of the invention have now been made clear in an illustrative embodiment, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, elements, materials and components used in the practice of the invention which are particularly adapted for specific environments and operating requirements without departing from those principles.
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A protective accordion configured tubular boot has one end fixedly secured to and sealed about the cylinder of a shock absorber and the boot extends upwardly about a plunger protruding from the cylinder. The other end of the boot includes an inwardly extending radial flange having a plurality of circular concentric ridges disposed on opposed sides. An outwardly radially extending channel fixedly secured proximate the end of the plunger receives the radial flange to form a floating vented seal at the other end of the boot to prevent particulate matter and liquids from entering the boot.
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FIELD OF THE INVENTION
The present invention relates to microphones in general, and in specific, relates to microphones having feedback suppression.
BACKGROUND OF THE INVENTION
The audio feedback effect, also called microphone feedback, occurs when a sound wave enters a microphone having a frequency that is the same as the frequency of a sound wave at an output of the microphone.
Feedbacks could happen on the electronic equipment which receives and broadcasts sounds. When the External Feedback Path is formed, where sound waves generated by the broadcast point are received by the collecting point, sound waves are thus constantly repeatingly amplified.
There are 2 major impacts of feedbacks.
1. When feedback sounds are mixed with the original sounds, it would cause acoustic distortion.
2. When feedbacks of the same frequency repeatingly accumulate, and volume gain is too large, piercing whistles occur.
Cancellations in High Fidelity Acoustics:
(1) A microphone cannot determine whether the incoming sounds or signals are from an objective sound source or from noises, such as background noises or internal microphone generated noises. When objective sounds are interfered with by noises, their sound waves are changed, and thus the acoustic quality is affected.
(2) Traditional noise filters can solve this issue by treating the frequency of the incoming signals. If the noise and the sound source's frequencies are different, a high-pass filter (which allows only sounds below certain frequency to pass), a low-pass filter (which allows only sounds above certain frequency to pass), or a range-pass filter (which allows only sounds within certain frequency range to pass) can be used to filter out the noise.
(3) However if the noise and the objective sound's frequencies are the same, or are close (such as multiple reflections of the objective sound), the objective sounds and noises are similar, and the filter cannot delete the noise.
(4) In addition, irrespective of whether digital or analogue filters are used, or if frequency or time-domain filters are used, all are more-or-less subjected to mathematical transformations. The transformations result from distortion and time delay issues. Thus the better a filter is, the more complex design and mathematical conversions are required. For example the latest Wavelet filter could be used, but it is very expensive.
SUMMARY OF THE INVENTION
A major difference between an objective, desirable sound signals and noise signals are in their incoming direction and energy. Objective sounds have a fixed direction and a stronger energy. The noises that originate from other sources and their various directions usually have a weak energy. A purpose of the present invention is to cause the objective sound signals to predominate over the noise signals.
The present invention provides a mechanical solution to the feedback problem by shifting the phase of the input sound wave to the microphone. The phase shifting is done physically by separating the sound wave into at least two secondary waves and then re-combining them before they are impact on the microphone.
A microphone module according to the present invention includes a body, an opening or area to receive sound waves, and a transducer diaphragm. The module also includes a film or diaphragm that extends over and is spaced from the sound wave receiving area of the microphone body. The film has at least one slit or cut through it which in one embodiment is located in a central portion of the film. The slit allows the sound wave to pass through it and results in the formation of at least two distinct acoustic waves, one generated by a film portion on each side of the slit.
The structure of the film slit of the present invention allows sound waves from the directly ahead with a stronger energy to pass, but adds a filter effect to cancel out or reduce the effect of sound waves from other directions or with lower energy. In this way, there is no or only a little variance for the objective/target sound source's wave, and accordingly the acoustic quality is increased.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded, perspective, diagrammatic view of a microphone according to a presently preferred embodiment having a casing with a top that has a slit therein.
FIG. 2 is a perspective, diagrammatic view of the microphone casing showing the slit location.
FIG. 3 is a cross sectional diagrammatic view taken along lines A-A of FIG. 2 , of a microphone surrounded by the microphone casing and showing a top portion with a slit and the internal chamber.
FIG. 4 is a top plan view of the microphone casing.
FIG. 5 is a diagrammatic cross sectional view showing schematically the division of an incident sound wave by the split in the film cover.
FIG. 6 is a plan view of a film showing a presently preferred split or cross cut pattern.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to FIGS. 1-5 , the present invention will be described with respect to a presently preferred embodiment in which like numerals designate like elements throughout the several views.
In describing an embodiment of the present invention, only diagrammatic representations will be used, at least because the present invention is subject to a large number of particular implementations, which those skilled in the art would recognize.
Now, with a particular reference to FIGS. 1, 2, 3 and 4 , there is depicted a microphone module 100 which comprises a diagrammatically depicted microphone 110 and a housing, guide tube or casing 120 . Microphone 110 can be, for example, a conventional condenser microphone.
Guide tube 120 has an exterior surface 121 and an interior bore or chamber 122 extending completely there through. Chamber 122 , as depicted in FIG. 1 , has a longer, upper section 124 (sometimes called the first section so that the orientation of the chamber is not at issue) and a contiguous lower, wider section 126 (sometimes called the second section). Lower chamber section 126 has a diameter and bore configuration so as to be able to receive the top or sound receiving part of microphone 110 , and to snuggly encompass microphone 110 , as depicted in FIG. 3 . The area where upper chamber section 124 and lower chamber section 126 meet, bottom 129 of upper chamber section 124 , marks the end of the sound collecting space and thus its length. As discussed below, the length of upper chamber section 124 has an effect on the filtering characteristics and quality of microphone module 100 .
Casing 120 as shown in FIG. 1 has a top audio receiving end 128 and a bottom end 130 . The bottom audio transmitting end is depicted at 129 , as mentioned above.
The interior shape of upper chamber 124 is depicted as being cylindrical, but it could be ovular or even rectangular. Although chamber 122 is depicted as having only one bore, casing 120 can be in more than one part and upper chamber 124 can be mounted directly to the end of microphone 110 . Also, an outer elastic housing (not shown) can surround casing 120 so as to better isolate casing 120 from external sounds and vibrations.
Exemplary dimensions of casing 120 , for two different embodiments are:
Microphone diameters (lower section 126 ): 9 mm and 6 mm; Sound hole diameter of microphone: 4 mm and 2 mm; Upper section 128 internal diameter: 4 mm and 2 mm; and Upper section 128 length: 4 mm and 2 mm.
Securely mounted on top end 128 of casing 120 , such as by an adhesive or some mechanical connection such as a screw or nail, is a disk-shaped thin film 140 . Film 140 has a minimum diameter so that it can completely close the upper end of chamber upper section 124 and is stretched tight across chamber 120 . In FIGS. 1 and 2 , film 140 has the same diameter as does the upper end of casing 120 . In the present embodiment, film 140 is depicted and described as having only one sheet, but in other embodiments, film 140 could be comprised of a plurality of sheets or of a laminate having a plurality of layers.
Located in the central portion of film 140 is a single thin slit 142 , which when film 140 is mounted on casing 120 fully extends across top end 128 of casing 120 . Slit 142 divides film 140 into a first section 144 and a second section 146 .
Film 140 can be made of any flexible, but unbreakable or untearable material, such as a plastic film (e.g. PET, PEEN and OPP). Also, film 140 can be comprised of a flexible and thin metallic film. Further, although film 140 is depicted as being comprised of a single material sheet, film 140 could also be comprised a multipart, multi material sheet in which the parts could be concentric, or could be coplanar with slit 142 dividing the different materials. Obviously, this later design provides different sound reproduction effects as the produced waves will have different qualities (e.g. phase, amplitude, vibration)
Film 140 has a thickness dimension in the range of about 0.01 mm to about 0.1 mm. The length of slit 142 can be as long as, or slightly longer than the diameter of the top of chamber 122 or it could be a length as short as one-half to nine-tenth the diameter of the top of chamber 122 . Slit 142 is preferable a simple, thin cut.
The length of slit 142 that is equal to or larger than the diameter of end of upper chamber section 124 is preferred. Preferably, slit 142 is straight or linear, but it could have an arcuate shape that if extended would have a radius of 100 s of millimeters to a few centimeters, somewhat depending upon the length of slit 142 . Also, as discussed above, slit 142 can actually be multiple slits that preferably intersect, such as depicted in FIG. 6 . Obviously, a more complex plurality of signals would be generated. Also, slit 142 can be comprised of a plurality of cuts that do not intersect, such as parallel cuts that result in a plurality of vibrating separate film sections. Further, in the embodiment in which there are plural films, such as two or more axially spaced apart films, each film can have a slit that is aligned and located above the other, or they can be in different parts of the film body so as not to be vertically aligned.
A slit 142 in a harder film 140 , is presently preferred to comprise or have a cross shape, and a slit 142 in a softer film 140 is presently preferred to comprise a straight line slit or parallel slits.
Different locations of slit 142 with respect to the center of chamber upper section 124 has different results for piercing feedback suppression. If slit 142 is not in the center, there is a different size in first and second film sections 144 and 146 and a resultant different time shift of the sound wave. A slit 142 located in the center over chamber 122 is better than if it is not in the center of film 140 . Thus for either a single slit 142 , or for multiple slits, whether cross slits or parallel slits, the slits should be arranged symmetric to the center.
The diameter of film 140 is related to the size of the microphone, and should be slightly wider than the size range of the sound receiving hole or holes in the microphone body (on the top and sound collecting end). The thickness of film 140 will affect the result of sounds passing through film 140 . When sounds are generated, high pitch sounds and low pitch sounds have the same level of energy. But as sounds spread away from the sound origin, high pitch sounds have more decay than the low pitch sounds. Thus when reaching a film 140 that is spaced from the sound origin, the low pitch sounds have more energy than the high pitch sounds. Thus, low pitch sounds are better able to pass (vibrate) a thicker film than high pitch sounds. Therefore, for the same film material, the thicker the film, the worse mid- and high-pitch sounds that would reach the microphone and that microphone design has a poorer performance at the mid- and high-pitch fields will not be good. For the same thickness of film, the softer the film material is, the better is the performance and results from mid- and high-pitch sounds. Films have a preferable thickness varying from 0.01 mm to 0.1 mm with material such as PET, PEEN and OPP. Various hardness of the film material is used to tune the microphone's performance for the desired result.
Casing 120 is preferably only a few centimeters long and a few centimeters in width. Although casing 120 is shown as a cylinder, any exterior shape can be utilized. Casing is preferably made of an elastic or soft material that is slightly compressible, but could also be made of a solid hard material, such as a plastic or metal. Casing 120 can also be comprised of a ceramic material that is resistant to cracking or breaking. Casing 120 can also be comprised of two or more materials, but it is preferably that the interior walls forming upper chamber 24 be non-resilient and be reflective so as not to introduce any interferences into the passing sound waves.
Similar as the ranges in the diameter of film 140 diameter, the length of chamber 122 affects the performance of microphone module 100 with various frequencies. If the length of chamber 122 is equal to or close to the inner diameter of chamber 122 , there will be a good result for high, mid and low pitch sounds, and good piercing feedback suppression from the sound source and microphone. When the length of chamber 122 is smaller than the inner diameter thereof, there will be a better result for mid- and high-pitch sounds, but the feedback suppression of piercing sounds is worse (i.e. at a closer distance from the sound source to the microphone). When the length of chamber 122 is longer than the inner diameter thereof, there will be a worse result for mid- and high-pitch sounds, but the feedback suppression of piercing sounds is better (i.e. at a closer distance from sound source to the microphone).
Casing 120 can be made of a plastic, metal, ceramic material. The harder the material, the better are the isolation of possible vibrations from the casing material.
In the operation of microphone module 100 , as depicted in FIG. 5 , a sound wave 150 reaches the surface of film 140 and film sections 144 and 146 independently vibrate resulting in the generation of two sound waves, 152 and 154 . Sound waves 152 and 154 have the same frequency and if film sections 144 and 146 have substantially the same surface area, will have the same phase, but the amplitude will be reduced to half. There can also a phase difference (i.e. a time difference) between original sound wave 150 and sound waves 152 and 154 . Sound waves 152 and 154 pass through chamber 122 and are united and regenerated as a new sound wave at the bottom thereof. Due to the time difference between original sound wave 150 and generated sound waves 152 and 154 , there are small differences between the new and the original sound waves, which is sufficient to suppress any feedback. Obviously, the greater the number of generated sound waves, such as by the slits in FIG. 6 , the greater the cumulative differences will be between the original sound wave and the reconstituted sound wave, and the created the feedback suppression.
The present invention operates in theory as follows.
A. Noise Cancellation
Film 140 cancels feedback noises based on the following principles and reasons.
(1) Noises come from the reflections of the objective sound source, from non-objective sound sources and reflection from non-objective's sound source, and white noises (which in general refers to all multiple reflections, refractions, and dispersions at a sound source's surrounding).
(2) Orientation/Directional: Film 140 generates a large uni-directional effect, which filters out non-objective sound sources and white noises. Reflections of objective sound sources, non-objective sound sources, and white noises incident onto film 140 perpendicularly (i.e. in a normal direction) are not filtered.
(3) The critical energy which drives the film and the energy transformation of the above processes are not linearly transformed. The film vibrates only when the incident sound wave has minimum amount strength. For example, those noises which come from an objective sound source's reflection, non-objective sound source's reflection, and white noises which are reflected or multiply reflected have energy decay after transfers and spherical spreading. Thus these low energy noises are thus filtered by film 140 .
(4) By using the structure of guide tube 120 , a wind must pass through film 140 before reaching the microphone diaphragm. Thus wind pressure will not cause the microphone diaphragm to vibrate back and forth, but only to shift or move. Film 140 transfers sound energy by vibration. The shifting and movement of the film does not generate sound energy and thus noises because the energy is attenuated, absorbed, or reflected by the film.
(5) There are 2 conditions which could still result in the generation of sound from a wind striking film 140 : the strength of the wind or the direction changes of the wind. When the wind's strength or direction changes, it changes the tightness of film 140 , which could cause an effect that is similar to vibration. This is especially true when there are more severe changes in the wind's strength or directions, which is a situation more like vibrations. This type of noise is more serious.
When the wind blows toward the film 140 at a direction nearly parallel to the surface of film 140 , the slight angle variation causes a large sound pressure variation, and generates noises. The power of the wind pressures is much larger than sound waves. Thus, a wind component with film 140 resulting in less than 5% energy can make film 140 vibrate, and generate noises. Thus, when a wind blows nearly parallel to film 140 , there would be noises. (This phenomenon is similar to when wind flow a flag, the flag waves within small angles, and makes sounds.)
A physical method of lowering feedbacks for microphone by using films has been described for various types of sound waves impacting on microphone module 100 . There is an elastic film at the input end of the microphone, and there is at least one cut in the film, as shown in FIGS. 1 and 2 . Sound waves are energy that is transmitted by directional vibrations. A perpendicular component to film 140 makes film 140 vibrate and a parallel component does not. When film 140 is not cut film 140 is sealed tight and it is hard to make a contribution to the vibrations. Only small portion of can pass through film 140 and forms a penetrating wave while the rest is reflected and forms a perpendicular reflex wave.
When film 140 is cut, the opening edges are free ends and the resulting film portions can easily vibrate, and form penetrating waves. When the generated sound waves reach microphone 110 , and are collected by microphone 110 , there is a time difference, but the time difference is small, and the distortion is usually acceptable. When there is no film 140 , as in traditional microphone, at the opening of the sound collecting end, though the incident wave comes parallel to the opening, some sound waves will enter the sound collecting end due to the diffraction effect. Thus certain sounds are still collected, and it is possible to totally block out the sounds.
When there is no film, as in a the traditional microphone, at the opening of the sound collecting end, sound waves enter the sound collect opening in the transmission path which is not parallel with the sound collecting tube. There would be multiple reflections and other disturbances occur on the tube's wall. Various frequencies of reflections will cause various disturbances, and cause sound distortions.
The invention's structure employs one or more films, but for the purpose of the following explanation, only a single film will be discussed. With respect to a film and its vibrations, sound waves enter the tube in the transmitting path which is nearly parallel to the tube's wall, produces less multiple reflections, thus there are no sound distortions.
When sound waves from a sound source comes at an incident angle “theta” to the surface of film 140 , its sound wave arrives film A and B at difference time, and the 2 films vibrate independently. They could be seen as 2 new sound waves (see FIG. 5 ), which have the same wave form with but half amplitude of the sound source, and there is the time difference and phase difference between the two new sound waves. The 2 new waves combine as one sound wave in inner chamber 122 . Because of the phase difference between the 2 sound waves, there is a slight difference between the new formed sound wave and the source's sound wave. The new formed sound wave is collected by the microphone, and outputted from the speaker. When the outputted sound wave returns to film 140 , the new wave arrives with a time difference from the original wave, and again new sound wave is formed in the tube with phase. And the accumulated phase difference increases,
With the present invention, each time the wave feedbacks, it accumulates phase differences, and decreases the accumulation results, thus suppressing the feedback noises or whistles. For microphone feedback from microphones not employing the present invention, theoretically, the more times sound waves with same frequencies at zero phase difference feedback, the stronger will be the piercing whistles. However, with the present invention, the more times sound waves feedback, the phase difference increases, the accumulated difference of the wave form increases, thereby increasingly suppressing the piercing whistles.
Other embodiments, alternatives, modifications, variations to the presently disclosed embodiments, as well as other dimensions, are obvious to those skilled in the art, and the scope of the present invention is determined by the attached claims.
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A microphone module and method for suppressing feedback in a microphone. The module has a casing with a hollow bore therethrough and a microphone mounted in one end of the bore. The other end of the bore is completely covered by a film mounted onto the top of the casing. The film has at least one slit therethrough in the film portion that covers the other end of the bore. The method includes introducing a sound wave to a film having at least one slit therethrough that separates the film into at least two parts; generating a sound wave from each film part; and conveying the generated sound waves in a sound tube to a microphone as a rejoined sound wave.
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BACKGROUND OF THE INVENTION
This invention generally relates to garment cleaning apparatuses, and is specifically concerned with a water wash apparatus for both washing the garments worn by maintenance personnel in nuclear power facilities, and radioactively decontaminating them.
Machines for cleaning radioactively contaminated clothing are known in the prior art. Such prior art machines may use either a dry cleaning technique or a water wash technique to achieve the desired end. Of the two techniques, dry-cleaning with the use of fluorocarbon solvents such as freon is presently preferred over known water wash type machines due to the generally superior penetrating ability of fluorocarbon solvents. However, before the relative advantages and disadvantges of these two types of machines can be fully appreciated, some background as to the nature of the clothing cleaned and the environment wherein it is used is necessary.
Present-day nuclear power facilities require various maintenance and operating personnel to work in areas which may be contaminated with radioactive particles. To prevent these radioactive particles from coming into contact with the skin of such personnel, protective clothing in the form of frocks, hoods, and shoe coverings (known as "duck feet" in the art) are worn. After use, it is essential that the clothing be cleaned in such a way that remove substantially all of the radioactive particulates, and all or at least most of the conventional soils, sweats and body salts than can also accumulate therein. The removal of certain rare but highly radioactive particulates, such as the "fuel fleas" which can be generated by the cracking of a fuel rod, is particularly important as such particles are capable of exposing a small, pinpoint area of skin to a dangerous level of radioactivity. However, the cost of performing such a cleaning must be substantially less than the cost of replacing the garment if it is to be cost-effective. If the cost of cleaning approaches the cost of disposing of the old garment and replacing it with another, then garment replacement becomes preferable to garment cleaning.
Dry-cleaning techniques for cleaning such radioactively contaminated clothing are generally preferred over water wash techniques due to the inherently lower surface tension and hence generally superior penetrating ability of the fluorocarbons used in such techniques. While the use of such fluorocarbons has proven effective in removing substantially all of the radioactive particulates from such clothing, such dry-cleaning techniques are not without shortcomings. For example, the fluorocarbons used in such dry-cleaning techniques tend to dissolve the elastomers in certain synthetic rubbers that form parts of boots and other shoe coverings used in maintenance operations. The dissolution of these elastomers causes the synthetic rubbers to become brittle and crack, thereby damaging and ultimately destroying the particular article of clothing containing the synthetic rubber. Other materials used in protective gloves and shoes such as Neoprene® tend to soak up and absorb the fluorocarbons used until unacceptable levels of these fluorocarbons build up in the articles of clothing. While the excess fluorocarbons might be evaporated out of the clothing by the application of additional amounts of heat, such extra or protracted steps in the cleaning process adds to the overall expense of cleaning, and may tend to heat damage the plastic and rubber portions of the clothing, thereby defeating the purpose of the extra dry-out. Still another shortcoming associated with dry-cleaning techniques is the limited ability of fluorocarbons to dissolve sweat and body salts. While he fluorocarbons may succeed in removing substantially all of the radioactive particulates, the accumulation of such sweat and body salts will ultimately give the garment a cumulative "locker room" odor. Moreover, the fluorocarbons used in such dry-cleaning techniques presently cost about $13.00 per gallon, which is not an inconsiderable expense where many gallons are required. Finally, the fluorocarbons used in these techniques are limited (as are most organic solvents) in their ability to dissolve and remove radioactive contaminants in the form of metallic salt, such as cesium 137.
While wet washing techniques avoid many of the shortcomings associated with dry-cleaning techniques in that they are highly effective in dissolving and removing sweat and body salts as well as salts of cesium 137 they, too, have their drawbacks, the most serious being the generation of a water effluent which contains the radioactive particles removed from the clothing. The transportation and disposal of such an effluent significantly contributes to the cost of the wash notwithstanding the fact that the effluent qualifies as a low radiation level waste. While most nuclear facilities have on-site demineralizer systems which are capable of radioactively decontaminating such water, the inconveniences and expenses associated with the use such on-site demineralizer systems also add substantially to the overall cost of such prior art water wash techniques. Still another problem is the relatively lower efficiency of the water used in such systems in penetrating the fabrics that form such clothing and removing radioactive particulates. The relatively lower penetrating ability of water, coupled with the greater effort needed for dry-out due to its lower volatility as compared to freon, generally has the effect of increasing the time necessary to effectively water wash a contaminated garment.
Clearly, what is needed is an apparatus and method for cleaning radioactively contaminated clothing which removes all of the radioactive particulates, and cleans the clothing of sweat, body salts and radionucleide salts without damaging or destroying any of the synthetic rubbers or artificial fibers forming such clothing. Ideally, such an apparatus should be mobile to obviate the need for the transportation of radioactively contaminated garments, which would require the use of special containers and procedures. Finally, such an apparatus should be capable of quickly cleaning a large volume of such clothing at a cost which is substantially lower than the disposal and replacement costs of the garments being cleaned.
SUMMARY OF THE INVENTION
Generally speaking, the invention is both an apparatus and method for water washing garments and removing radioactive contaminates therefrom without the generation of liquid effluents. The apparatus generally comprises a washing machine for washing the garments which includes a wash water inlet, a rinse water inlet, a water outlet, a reservoir of surfactants and suspension agents. The apparatus also comprises a hydraulically closed wash water system that includes a reservoir of polished water connected to the wash water inlet of the washing machine, a particulate filtration unit connected to the outlet of the machine, and a water polishing unit connected between the filtration unit and the wash water inlet for resupplying the reservoir with filtered and polished water. The use of high-purity, polished water in combination with surfactants and suspension agents greatly improves the solvency and penetrating ability of the wash water, thus rendering it comparable in efficiency to known dry-cleaning solvents when the ability of such water to easily dissolve perspiration and salts is considered. Moreover, the generation of liquid effluents is avoided by the use of a hydraulically closed wash water system which recirculates and re-polishes the water while trapping radioactive particulates in filter units that utilize conveniently disposable cartridge-type filter members.
The wash water system may further include a wash water diverter conduit connected at one end between the filtration unit and the polisher, and at the other end directly to the wash water inlet of the washing machine. This conduit includes a value for selectively diverting water which has been filtered by the filtration unit, but not yet polished by the polisher directly back into the washing machine during the initial washing cycles implemented by the apparatus, thereby avoiding the removal of any surfactants and suspension agents which were initially mixed into the wash water while at the same time protracting the life of the carbon and ion-exchange columns used in the wash water polisher.
The apparatus may further include a closed rinse water system connected between the outlet of the washing machine and the rinse water inlet. This rinse water system includes its own particulate filtration unit and polisher for removing any residual particulates and dissolved impurities in the rinse water discharged from the washing machine water outlet. To maintain the wash and rinse water systems in hydraulic isolation with one another, the apparatus preferably also includes a pair of valves for selectively connecting the washing machine outlet to the wash water system to the exclusion of the rinse water system, and vice versa. The provision of a hydraulically separate rinse water system insures that the last water to immerse the garments is of the purest form and highest quality.
The polisher of both the wash water system and the rinse water system each include a pair of polishing banks connected in parallel for reducing the pressure drop associated with such polishers. Each of the polishing banks preferably has a column of particulate carbon for removing dissolved gases and organic impurities, as well as a mixed cationic-ionic exchange column serially connected downstream from the carbon column. The polisher of the wash water system additionally includes a cationic exchange column and ionic exchange column serially connected between the column of particulate carbon and the mixed cationic-ionic column. In both the rinse and wash water polishers, isolation valves are provided for hydraulically isolating one or the other of the two polishing banks so that repairs may be made on one or the other of the banks without disrupting the operation of the apparatus.
To kill any microorganisms which may be present in the water flowing through the outlet of the washing machine, the outlet may be connected to an outlet conduit which includes an ultraviolet sanitizer. To prevent relatively large particles from clogging the filtration units of both the wash and rinse water systems, the outlet conduit may further include a bag-type filter.
Finally, the washing machine preferably includes a drum capable of spin-drying the garments fast enough to centrifugally remove at least 80% of all of the water absorbed therein. Such high-efficiency spin drying minimizes the number of wash and rinse cycles necessary to effectively clean the garments, and also minimizes the amount of make-up water which must be periodically added to the closed wash and rinse water systems to compensate for water losses.
BRIEF DESCRIPTION OF THE SEVERAL FIGURES
FIGS. 1A and 1B together form a hydraulic schematic diagram of the wash water apparatus of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
General Description Of The Apparatus And Method Of The Invention
With reference now to FIGS. 1A and 1B, the water wash apparatus 1 of the invention generally comprises a washing machine 3 having a wash water inlet 6, a rinse water inlet 8, an outlet conduit 12, and a surfactant and suspension agent supply reservoir 14. A hydraulically closed wash water system 64 is connected to the wash water inlet 6 at one end and the outlet conduit 12 at the other end. A hydraulically closed rinse water system 68 is connected between the rinse water inlet 8 and the outlet conduit 12. Solenoid operated check valves 62 and 66 connect the outlet conduit 12 of the washing machine 3 either to the wash water system 64 to the exclusion of the rinse water system 68, or vice versa.
The wash water system 64 includes a five-micron particulate filtration unit 74 serially connected upstream to a one-micron particulate filtration unit 76. A water polisher 93 is in turn connected downstream with respect to both filtration units 74 and 76. As will be described in detail hereinafter, most of the radioactive contaminants in the clothing being washed are in the form of particulates of which about 95% are captured by the filtration units 74 and 76. In order to conserve the surfactants and suspension agents which the supply reservoir 14 introduces into the washing machine 3 during the initial washing cycles, the wash water system 64 includes a diverter conduit 94 having a solenoid-operated valve 165. The diverter conduit 94 allows the operator of the apparatus to "short-circuit" water around the water polisher 93 and back into the washing machine 3 which has been filtered by filtration units 74 and 76, but which still contains surfactants and suspension agents by closing valve 96 (leading to the water polisher 93), and opening diverter conduit valve 165. Such operation and use of the diverter conduit 94 advantageously obviates the need for introducing surfactants and suspension agents to the wash water at the beginning of each wash, and further advantageously protracts the life of the various carbon and ion exchange columns of the water polisher 93.
The rinse water system 68 also contains a five-micron particulate filtration unit 190 which is serially connected to a one-micron particulate filtration unit 192. Downstream of these filtration units is a rinse water polisher 210 for insuring the purity of the rinse water circulated through the system 68. The use of polished water in both the wash and rinse water systems 64 and 68 significantly increases the solvency and hence washing effectiveness of the water. Because water from the rinse water system 68 is the last water to touch the garments in the washing machine 3, and because the wash water and rinse water system 64 and 68 are hydraulically isolated from one another, the apparatus insures that the last water to immerse the garments is of the highest quality.
Specific Description Of The Apparatus And Method Of The Invention
With reference again to FIGS. 1A and 1B, the washing machine 3 of the apparatus 1 includes an agitating and spin-dry drum 5 that is preferably capable of handling at least 50 pounds of garments or other fabrics. Additionally, wash and rinse water solenoid-operated intake valves 7 and 9 control the amount of wash or rinse water introduced into the washing machine 3 from either the wash water inlet 6 or the rinse water inlet 8. To control the amount of surfactants and suspension agents introduced into the machine 3, the reservoir 14 has an intake conduit 16 connected to the machine 3 which is provided with solenoid-operated valve 18. Finally, the machine 3 includes a high-water pressure switch 19 for closing the wash and rinse water intake valves 7 and 9 when the water level of the machine 3 reaches a selected height. In the preferred embodiment, the washing machine 3 is a UNIWASH Model No. FB84/8610No.210 manufactured by D'Hooge machine is capable of not only thoroughly agitating any garments placed therein in order to effectively clean them, but is also capable of spin-drying the garments quickly enough to squeeze 82% of all the water absorbed therein during either a wash or a rinse cycle. This last feature is important, because it helps to prevent any residual radioactive particles from remaining in the clothing at the end of the wash cycle. It also minimizes the amount of make up water necessary to keep the apparatus 1 in operation.
The outlet conduit 12 includes on its upstream end a bag filter 21 for removing relatively large particles and pieces of debris from the wash or rinse water expelled from the machine 3. The removal of such large particles and chunks of debris not only avoids the fouling of the pumps 54 and 58 (to be described in more detail hereinafter), but further reduces the load on the particulate filtration units 74, 76, and 190, 192 of both the wash and rinse water systems 64 and 68. Located downstream of the bag filter 11 is a solenoid-operated drain valve 23. Unless indicated as being controlled by a pressure switch or some other local controller, all of the solenoid-operated valves in the apparatus 1 are controlled by a programmable central processor unit (not shown) having a timer which implements the method of the invention.
Downstream of the solenoid-operated drain valve 23 is the washer drain collecting tank 25. In the preferred embodiment, tank 25 is formed of stainless steel and has approximately a 30 gallon capacity. The tank 25 of outlet conduit 12 allows either wash water or rinse water to be rapidly drained from the washing machine 3. Such rapid draining facilitates effective cleaning of the garments within the machine 3 by helping to maintain all of the debris and particulate contaminants in suspension as the water is effectively dumped from the machine 3. By contrast, slow drainage would encourage such suspended debris and particulates to deposit themselves on the internal walls of the machine 3, thereby impairing the washing operation. The washer drain collecting tank 25 is provided with a gas-type drain valve 27 that is used when the entire apparatus 1 is drained-down incident to decommissioning, as well as high and low water pressure switches 29 and 31. These switches can actuate and deactuate a self-priming, single impeller pump 54 located downstream of the tank 25. Finally, the tank 25 includes a make-up water inlet 33 that is connected to both an internal make-up water supply 35 by way of a conduit 37 having a ball valve 39, as well as to an external make-up water supply 41 by way of another conduit 43 which extends through the wall 45 of a trailer which contains the apparatus 1. This last conduit 43 of the external make-up water supply 41 includes a serially connected ball valve 47, solenoid valve 49 and ball check valve 51 as indicated. The ball check valve 51 insures that no radioactively contaminated water from the washer drain collecting tank 25 can back up into the external makeup water supply 41.
While it is possible to introduce makeup water at other points in the apparatus 1, the connection of the internal and external makeup water supplies 35 and 41 to the washer drain collecting tank 25 has two advantages. First, because the tank 25 is hydraulically connectable via solenoid-operated valve 62 and 66 to either the wash water system 64 on the rinse water system 68, the hydraulic connection of the makeup water supplies 35 and 41 to the tank 25 allows a single makeup water tap-in to serve the make-up water needs of both the wash and rinse water systems 64 and 68. Secondly, the location of these makeup water supplies 35 and 41 upstream of the water polishers 93 and 210 of the wash and rinse water systems 64 and 68 allows the makeup water used to be undemineralized and unpolished if desired.
Located downstream of the washer drain collecting tank 25 is the previously mentioned self-priming, single impeller pump 54, as well as an ultraviolet sanitizer 56, and a high-pressure pump 58. Preferably, the high-pressure pump 58 is a staged impeller booster pump capable of generating between 55 to 60 pounds per square inch. Such pressure is necessary to push either the wash or the rinse water through the particulate filtration unit 74, 76 and 190, 192 of the wash and rinse water systems 64 and 68 in a reasonably short time. Such pumps are available from Webber Industrial, Inc., located in St. Louis, Mo. 63123, and are sold under the name "Webtrol." While such a staged impeller booster pump is safely capable of generating the pressures necessary for the expeditious circulation of the wash and rinse water in the apparatus 1 without rupturing or jeopardizing the integrity of the CPBC type of piping that is preferably used the conduits in the apparatus 1, it is unfortunately not self-priming. However, this problem is solved by the provision of the single impeller pump 54 located upstream. Pump 54 is capable of creating a pressure of approximately 15 to 20 pounds in the conduit 12, which in turn provides the necessary priming needed for pump 58.
The purpose of the ultraviolet sanitizer unit 56 is to kill any microorganisms which might be present in either the wash or rinse water drained out of the tank 25. This is important, since such bacteria, fungi, and other microorganisms can lodge in the carbon and ion exchange columns of the polishers 93 and 210 and reproduce, thereby lowering quality of the wash and the the efficacy of the polishers 93 and 210 and accelerating the need for the replacement of columns. In the preferred embodiment, the ultraviolet sanitizer unit 56 (as well as all the other ultraviolet units used in apparatus 1) is either a Model No. UV8G478 or MP2-5L type unit manufactured by Aquafine Corp. for Cullingan. Aquafine Corporation is located in Valencia, Calif. 91355.
Located at the end of the outlet conduit 12 is a T intersection 61 which couples the washing machine outlet 11 to both the wash water system 64 and the rinse water system 68. As has been previously mentioned, solenoid-operated check valves 62 and 66 are provided on either side of the T intersection 61 for admitting water from the outlet conduit 12 to either the wash water system 64 to the exclusion of the rinse water system 68, and vice versa. As such, the solenoid-operated check valve 62 serves as an inlet valve to the wash water system 64, while valve 66 serves the same function with respect to the rinse water system 68.
With respect now to the wash water system 64, the previously mentioned five-micron and one-micron particulate filtration units 74 and 76 are located downstream of the inlet valve 62 as shown. The upstream location of the five-micron filtration unit relative to the one-micron filtration unit has the effect of extending the lifetime of the filtration element used in the one-micron filtration unit 76. In the preferred embodiment, disposal, cartridge-type filter elements (shown in phantom) are used in both of the filtration units 74 and 76 to expedite filter element changes. As has been previously indicated, such filtration units 74 and 76 have proven to be extremely effective in removing radioactive particulate contaminates from the wash water used in the apparatus 1, and together are responsible for approximately 95% of such particulate removal. Water sampling taps 77 and 79 regulated by needle valves 78 and 80 are provided in each of the particulate filtration units 74 and 76 for monitoring purposes. Additionally, pressure gauges 82, 84, and 86 are connected between the inlets and outlets of the particulate filtration units 74 and 76 so that the operator of the apparatus might readily ascertain when the cartridge filter elements used in the units have become saturated and need replacement. Finally, a pair of union ball valves 87 and 88 are disposed upstream and downstream of the particulate filtration units 74 and 76 to facilitate the assembly of the apparatus 1.
Located upstream of union ball valve 88 is T connection 90. One branch of the T connection 90 leads to water polisher conduit 92, which in turn flows into the water polisher 93, while the other branch of the T joint 90 is connected to the previously mentioned wash water diverter conduit 94. Solenoid-operated valves 96 and 165 are disposed at the inlet ends of both the water polisher conduit 92 and the diverter conduit 94, respectively.
Downstream of the solenoid-operated polisher inlet valve 96, the polisher conduit 92 bifurcates into two parallel conduits, 97a and 97b, each of which is 100a and 100b of the polisher 93, respectively. Each of the polishing banks 100a and 100b includes a granulated carbon column 100a, 100b, a cation exchange 104a, 104b, an ion exchange column 106a, 106b, and mixed cation-anion exchange column 108a, 108b. In each of the banks 100a, 100b the granulated carbon column 102a, 102b serves to remove organic contaminates and dissolved gases, while the cation, ion and mixed exchange beds 104a, 104b, 106a, 106b and 108a, 108b each serve to remove dissolved radioactive nucleides from the wash water. Each of these columns preferably contains about three cubic feet of either particulate carbon or an appropriate ion exchange resin. Sampling provided between the various columns so that the water quality at every point within the polisher 93 may be monitored. To help the operator determine whether or not any flow-blocking stoppages have occurred at any point within the polisher 93, pressure gauges 114a, 114b and differential pressure gauges 115a, 115b are provided at the points indicated between the carbon and various ion exchange columns, as well as between the polishing banks 100a, 100b themselves. Finally, ohmic water quality sensors 116a, 116b are provided in the middle of each bank 100a, 100b for monitoring purposes. The use of two separate polishing banks 100a, 100b connected hydraulically in parallel advantageously lowers the back pressure that otherwise would exist across the polisher 93 if only serial connections were used. Moreover, because of the presence of isolation valves 119a, 119b and 120a, 120b both upstream and downstream in each of the separate polishing banks 100a, 100b, the polisher 93 is capable of operating during the repair or the replacement of any of the component parts of the banks 100a, 100b. This redundant capacity is an important advantage, as it avoids the need for a complete shut-down of the apparatus 1 whenever a particular column is repaired or replaced.
Downstream of the water polisher 93 is another union ball valve 122 for assembly purposes, an additional ohmic water quality sensor 124, and finally a wash water holding tank 126. The purpose of the wash water holding tank 126 is to "park" the filtered and polished water produced by the wash water system 64. High and low water switches 128 and 130 are provided in this wash water holding tank 126 for sounding high and low water alarms respectively. In the preferred embodiment, tank 126 has approximately 150 gallons of holding capacity, and serves as a reservoir of polished and filtered water for use in the washing machine 3. The tank 126 includes a water level indicator tube 132 which may be hydraulically isolated from the tank 126 by way of isolation valves 134a, 134b. For water quality monitoring purposes, the indicator tube 132 is also hydraulically connected to a water testing tap 136 having a needle valve 138. Tank 126 further has a fill port 140 for the addition of filtered and polished makeup water therein, as well as a gate-type drain valve 144 used during a general drain-down of the apparatus 1.
Located downstream of the wash water holding tank 126 is solenoid-operated valve 142 which controls the admission of wash water from the reservoir provided by the tank 126 into a single impeller, self-priming pump 146. For water testing purposes, pump 146 is hydraulically connected to a water sampling tap 147 by way of ball valve 148. The output of the pump 148 is connected to the water inlet 6 of the washing machine 3 by way of a second ultraviolet sanitizer 149 flanked by union ball valves 150a, 150b, a ball check valve 154, another union ball valve 156, and a solenoid-operated close-off valve 159. This last valve 159 prevents water that may have been contaminated in the washing machine 3 from backing up from the machine 3 into the purified water present in the wash water holding tank 126. An additional pressure gauge 162 is provided upstream of the water inlet 6 of the washing machine 3 so that the pressure and hence the flow rate of recycled wash water can be monitored.
Turning back to the wash water diverter conduit 94 and a description of the components therein, a wash water interim holding tank 167 is connected to this conduit 94 upstream of the previously mentioned conduit inlet valve 165. In the preferred embodiment, tank 167 is preferably formed from stainless steel and has about 40 gallon capacity. High and low water switches and 171 are provided therein, as well as a water level indicator tube 173 which maybe isolated from the tank 167 by means of isolation valves 175a, 175b. For quality monitoring purposes, a water sampling tap 177 having a needle valve 179 is connected to the indicator tube 173. The tank 167 also includes a gate-type drain valve 181 to facilitate a general drain-down of the apparatus 1. Downstream of the wash water interim holding tank 167 is another self-priming single impeller centrifugal pump 183. Pump 183 is actuated and deactuated by high and low level water pressure switches 169 and 171. Upstream of pump 183 is a ball-type check valve 185 for preventing the backup of any water from the washing machine 3 back into the tank 167.
The rinse water system 68 includes components which operate in very much the same fashion as the previously described components of the wash water system 64. Specifically, the rinse water system 68 includes a five-micron particulate filtration unit 190 and a one-micron particulate filtration unit 192 serially connected as shown. Each of these filtration units uses disposable, cartridge-type filter elements (shown in phantom). Sample water taps 193 and 196 having needle valves 194 and 197 are provided in each of the particulate filtration units 190 and 192 for water quality testing. Additionally, pressure gauges 199, 201, and 203 are provided upstream and downstream in each of the particulate filtration units 190 and 192 in order to determine the relative extent to which the filter elements in the particulate filtration units 190 and 192 have become saturated. For assembly purposes, all the aforementioned components are flanked by union ball valves 204 and 205.
The rinse water polisher 210 is located downstream of the union ball valve 207, and is comprised of two separate polishing banks 212a, 212b hydraulically connected in parallel via conduits 214a, 214b. Each of the banks 212a, 212b of the rinse water polisher 210 includes a carbon column 216a, 216b and a mixed cation anion column 218a, 218b. Water testing taps 220 having needle valves 222 are located between the columns of each of the polisher banks 212a, 212b for testing purposes. Additionally, pressures gauges 224 and differential pressure gauges 226a, 226b are installed at various junctions in and between the rinse water polishing banks 212a, 212b for determining the location of flow-blocking stoppages which may occur in the polisher 210. In order to achieve the same redundant capacity as the wash water polisher 93, isolation valves 228a, 228b and 230a, 230b are provided in the locations indicated.
Downstream of the rinse water polisher 210 is a union ball valve 232 for assembly purposes, and an ohmic water quality tester 234. A rinse water holding tank 236 is provided downstream of the rinse water polisher 210 for parking a reservoir of filtered and polished rinse water for use in the washing machine 3. The tank 236 is again preferably formed from stainless steel and has at least a 40 gallon capacity. The tank 236 preferably also includes both high and low water pressure switches 238 and 240 which serve to actuate and deactuate a centrifugal pump 256 located downstream thereof. Finally, the rinse water holding tank 236 includes a water level indicator tube 242 for visually monitoring the level of water therein, a water sampling tap 244 having a needle valve 246, and a pair of isolation valves 248a, 248b for isolating the water level tube 242 from the tank 336. A fill port 250 and gate-type drain valve 254 are provided as indicated. The outlet of the centrifugal pump 256 located downstream of the tank 236 is connected to a water sampling port 257 by way of a ball valve 258, as well as to the rinse water inlet 8 by way of a ultraviolet sanitizer 260 which is flanked on either side by union ball valves 262a and 262b. Another union ball valve 264 and a pressure gauge 266 are disposed between the ultraviolet sanitizer 260 and the rinse water inlet 8 as shown. The entire system 1 is preferably contained within a trailer 270 (indicated by the phantom brackets in FIGS. 1A and 1B) to advantageously render it mobile.
In the method of the invention, approximately 50 pounds of soiled and radioactively contaminated garments are disposed in the agitating and spin-dry drum 5 of the washing machine 3. The washing machine 3 is actuated and wash water inlet valve 7 is opened. To supply wash water to the washing machine 3, solenoid-operated valves 142 ad 159 are opened and centrifugal pump 146 is actuated until the high water pressure switch 19 of the machine 3 indicates that a sufficient amount of wash water has been admitted therein. At this juncture, inlet valve 7 is closed, as are valves 142 and 159. Additionally, centrifugal pump 146 is deactuated.
Next, surfactants and suspension agents are added to the wash water that has been admitted into the washing machine 3 from the surfactant and suspension agent reservoir 14 via conduit 16 and solenoid-operated valve 18. In the preferred method of the invention, approximately a 50/50 mix of type A (for particulates) and type B (for oil and grease) surfactants are used along with a sufficient amount of a commercially available suspension agent to prevent the particulates dislodged from the clothing to become reentrained in the clothing at the end of the washing cycle. The clothes are then thoroughly washed in the machine 3 for approximately 5 minutes.
After the end of the first 5 minute wash, solenoid-operated outlet valve 23 is opened and the wash water is rapidly dumped through a four inch drain first through the bag filter 11 to rid it of all large particulates and pieces of debris, an then into the washer drain collecting tank 25. As soon as high water pressure switch 29 is closed by the rising level of the wash water in the washer drain collecting tank 25, pumps 54 and 58 are actuated. At the same time, solenoid-operated check valve 66 loading into the rinse water system 68 is closed, while wash water system inlet valve 62 is opened so that the wash water proceeds through the five- and one-micron particulate filtration units 74 and 76.
At this juncture, the wash water can either flow through the polisher conduit 92, or through the diverter conduit 94 depending upon whether solenoid-operated valves 96 and 165 are opened and closed, respectively, or vice versa. In the preferred method of the invention, the garments in the washing machine 3 are subjected to three separate washes before being rinsed, although more washes could be added if the garments were heavily soiled. In the first two of the three separate washes, polisher inlet valve 96 is closed while the diverter conduit valve 165 is opened in order to divert the filtered but unpolished wash water into the wash water interim holding tank 167. As soon as the water level in the tank 167 is high enough to actuate the high water switch 169, centrifugal pump 183 is actuated, and wash water inlet valve 7 is opened while close-off valve 159 is closed. As has been mentioned hereinbefore, such hydraulic short-circuiting of the wash water obviates the need for the addition of new surfactants and suspension agents to the wash water with every wash while advantageously extending the lifetimes of the carbon and ion-exchange columns in the wash water polisher 93. Still another advantage associated with such short-circuiting is the expedition of the wash cycle as a whole.
In the last wash of the wash cycle, the conduit diverter valve 165 is closed and the polisher inlet valve 96 is opened so that all dissolved radionucleides, body salts, organic solvents, and dissolved gases are completely removed from the wash water. The resulting purified wash water flows through the union ball valve 122 and into the wash water holding tank 126, where it is "parked" for use in the next wash cycle.
At the end of the last wash of the washing cycle, the drum 5 of the washing machine 3 executes a high-speed extraction by rotating the garments so that they experience centrifugal forces on the order of 400 to 500 Gs. Such large centrifugal forces has the effect of squeezing out approximately 82% of all of water entrained in the garments, even if they are made from highly absorbent material such as cotton. The large degree of water extraction achieved at this juncture by the spin-drying step advantageously removes virtually all of whatever residual particulate contaminates which may have been dislodged by the wash water in the last wash of the cycle in the preferred method, the spin-drying step lasts approximately four minutes.
In the preferred method of the invention, two separate rinses complete the rinse cycle. Each of the rinses commences with the introduction of rinse water into the rinse water inlet of the machine 3 via inlet valve 9. After the high water level switch 19 of the washing machine 3 has been actuated, the inlet valve 9 is shut off, along with the centrifugal pump 256. The drum 5 then agitates the garments for approximately seven minutes whereupon the rinse water is dumped out through the outlet conduit 12 in virtually the same manner as has been previously described with respect to the wash water system 64. Of course, as the rinse water is being dumped, wash water system inlet valve 62 has been closed and rinse water system inlet valve 66 has been opened, so that the rinse water flows through the five-micron and one-micron particulate filtration units 190 and 192 of the rinse Water system 68. From there, the filtered rinse water flows through the rinse water polisher 210 and into the rinse water holding tank 236. When the high level pressure switch of the rinse water holding tank 236 is actuated, centrifugal pump 256 is again actuated, thereby commencing the reintroduction of recycled rinse water into the washing machine 3 and the commencement of the second rinse cycle.
At the end of the second rinse, another spin-drying, high speed extraction step is implemented by the drum 5, which again lasts approximately four minutes. This last spin-drying step not only gives the high-purity water of the rinse water system 68 one last chance to dislodge and remove particulate contaminates from the garments, but also serves to minimize the need for make-up water in the apparatus 1.
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Both an apparatus and method for water washing garments and removing radioactive contaminates therefrom without the generation of liquid effluents is disclosed herein. The apparatus comprises a washing machine unit having a wash water inlet, a rinse water inlet and an outlet conduit, and a hydraulically closed wash water system. The wash water system in turn includes a reservoir of filtered and demineralized water connected to the wash water inlet, a particulate filter unit connected to the outlet conduit for removing particulate impurities from the wash water discharged through the conduit, and a water polisher connected between the particulate filtration unit and the reservoir for supplying the reservoir with filtered and demineralized and chemically purified water. To conserve surfactants and suspension agents added to the wash water in the washing machine unit, the wash water system further includes a diverter conduit connected between the filtration unit and the wash water inlet of the washing machine unit. The apparatus further has a hydraulically closed rinse water system which likewise includes a particulate filtration unit, as well as a water polisher. The apparatus avoids the generation of radiocative liquid effluents by trapping substantially all of the radioactive nucleides in disposable, cartridge-type filter elements that are used in the filtration unit of the wash water system. Moreover, the use of polished water in both the wash and rinse water systems renders the resulting water wash more effective.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not Applicable
CROSS REFERENCES TO RELATED APPLICATIONS
Not Applicable
TECHNICAL FIELD
The present invention relates to a printer label media cartridge, and more particularly to a cartridge having a pivotally mounted label media spool.
DESCRIPTION OF THE BACKGROUND ART
There are a number of U.S. patents that disclose electronic apparatus for printing indicia on labels, some of these are restricted to hand held units and others that disclose tabletop units. Hand held label printers, such as disclosed in U.S. Pat. No. 6,113,293, and tabletop printers, such as disclosed in U.S. Pat. Nos. 6,266,075 and 5,078,523, include the same general combination of elements, a print head, means for feeding label media to be printed past the print head, a microprocessor, a read only memory programmed with appropriate instructions to operate the microprocessor, a random access memory, a keyboard with letter, number, and function keys for the entry of alphanumeric information and instructions concerning the indicia to be printed, and a visual display such as a light emitting diode (LED) or liquid crystal display (LCD) unit to assist the operator in using the printer. In a hand held printer, these components may all be enclosed in a single housing.
The label media comprises a series of labels that are attached to a carrier strip. The carrier strip is fed through the printer and legends, alphanumeric characters, and other indicia, are printed on the labels. The labels are then removed from the carrier and attached to the objects needing identification. As there are many types of label applications, there are many combinations of labels and carrier strips that provide labels of varying sizes, colors and formats.
A particular type of print head employs thermal transfer printing technology. Thermal transfer printing uses a heat generating print head to transfer a pigment, such as wax, carbon black, or the like, from a thermal transfer ribbon to a label media. By using digital technology, characters are formed by energizing a sequence of pixels on the print head which in turn melts the wax or other pigment on the ink ribbon transferring the image to the label media.
In a known thermal transfer printer such as a label printer, label media and ink ribbon are simultaneously fed past the print head by a platen roller in an overlay relationship between the print head and the platen roller. The platen roller is rotatably driven by a drive mechanism that may also rotatably drive ink ribbon take up and supply spools to maintain tension in the ink ribbon.
In a cartridge-based printing system, such as disclosed in U.S. Pat. No. 6,113,293, it is desirable to have a consistent label media path. In order to accomplish this, many cartridge-based printing systems have the label media path defined by a point tangent to the outside diameter of a roll of label media. This method, however, presents a problem as the label media is consumed. In particular, as the label media is consumed the diameter of the roll decreases and the beginning point of the label media path changes.
This problem becomes even more critical if the printing system prints on label media having die cut labels. In order to minimize wasting the die cut labels, it is necessary to feed the label media in a reverse feed direction to align the die cut label with the print head once the previously printed label has been dispensed. The changing beginning point of the label media path caused by the decreasing roll diameter makes it difficult to accurately align the label media with the print head. Therefore, a need exists for a printing cartridge which can be used in a cartridge-based printing system that defines a consistent beginning of the label media path.
Another problem with cartridge-based printing systems is that the cartridges are typically formed to accommodate a single label media width. As a result, a cartridge manufacturer must maintain an inventory of cartridges for each label media width. Therefore, a need exists for a label media cartridge that can be used for a variety of label media widths.
SUMMARY OF THE INVENTION
The present invention provides a printer cartridge suitable for use in a cartridge-based printer. The printer cartridge houses and dispenses a roll of label media, and includes a housing having a top wall and a bottom wall. A yoke pivotally mounted between the top and bottom walls for pivotable movement about a pivot axis includes a label media supply shaft for holding a roll of label media. The label media supply shaft has a longitudinal axis spaced from, and parallel to, the pivot axis. A label media drive roller is rotatably mounted between the top and bottom walls, and a biasing means biases the yoke toward the label media drive roller to maintain the roll of label media in contact with the label media drive roller and define a beginning of a media path. In one embodiment, the yoke is adjustable to accommodate different label media widths.
A general objective of the present invention is to provide a cartridge that can house a roll of label media and define a consistent beginning of the label media path as the diameter of the roll of label media decreases. This objective is accomplished by providing a cartridge having a pivotally mounted yoke that maintains label media supported by the yoke in contact with a label media drive roller to define a consistent beginning of the label media path.
Another objective of the present invention is to provide a cartridge that can accommodate label media having different widths. This objective is accomplished by providing a yoke having a movable media guide that accommodates different label media widths.
The foregoing and other objectives and advantages of the invention will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown by way of illustration a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention, however, and reference is made therefore to the claims herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a hand held label printer incorporating the present invention;
FIG. 2 is a perspective view of the printer of FIG. 1 with the cartridge and top portion, keyboard, and display removed;
FIG. 3 is a top perspective view of the cartridge of FIG. 1 ;
FIG. 4 is a bottom perspective view of the cartridge of FIG. 1 ;
FIG. 5 is a top view of the cartridge of FIG. 1 received in the cartridge receptacle with the top wall of the cartridge removed;
FIG. 6 is a top perspective view of the base of the cartridge housing of FIG. 3 ;
FIG. 7 is a top perspective view of the cartridge of FIG. 3 with the cover removed;
FIG. 8 is a bottom perspective view of the cover of the cartridge housing of FIG. 3 ;
FIG. 9 is a bottom perspective view of the cartridge of FIG. 3 with the base removed;
FIG. 10 is a perspective view of the yoke of FIG. 7 ;
FIG. 11 is a perspective view of the first media guide of FIG. 10 ;
FIG. 12 is a perspective view of the second media guide of FIG. 10 ;
FIG. 13 is a detailed perspective view of the pivot shaft interfacing with the second media guide of FIG. 10 ; and
FIG. 14 is a detailed perspective view of the pivot shaft and torsion spring of the first media guide of FIG. 10 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring particularly to FIGS. 1–5 , a hand held thermal printer 10 employing a preferred embodiment of the present invention includes a molded plastic housing 2 that supports a keyboard 4 on its front surface and a display 6 positioned above the keyboard 4 . An opening 8 formed in the housing 2 above the display 6 receives a cartridge 12 containing label media 14 and an ink ribbon 16 . The cartridge 12 is inserted through the opening 8 into a cartridge receptacle 18 housed in the printer housing 2 . The label media 14 and ink ribbon 16 from the cartridge 12 are threaded through a printer mechanism assembly 20 . The printer mechanism assembly 20 includes a print head 22 and a platen roller 24 for printing indicia on labels forming part of the label media 14 . The printed labels pass through a cutter mechanism 26 which cuts the label media 14 to separate the printed labels from unprinted labels.
The label media 14 is known in the art, and generally comprises a carrier web which supports a series of adhesive labels. The size, width, color, and type of web material varies depending upon the particular print application. The label media 14 is dispensed from the cartridge 12 , and urged along a web path as it is consumed by the printer 10 .
Referring to FIGS. 3–9 , the cartridge 12 includes a cartridge housing 28 having a top wall 30 and a bottom wall 32 joined by a periphery wall 34 . The periphery wall 34 defines a label media and ink ribbon container for housing the label media and ink ribbon on spools. The label media 14 and ink ribbon 16 from the cartridge housing 28 pass out of the cartridge housing 28 through an exit slot 29 and into a printing area 38 external to the cartridge housing 28 for engagement with the platen roller 24 and print head 22 . The used ink ribbon 16 reenters the cartridge housing 28 , and is wound onto an ink ribbon take up spool 40 rotatably mounted in the cartridge housing 28 .
The cartridge housing 28 disclosed herein is formed from a base 68 joined to a cover 70 . The base 68 includes the cartridge housing bottom wall 32 and a lower portion 72 of the periphery wall 34 . Ribs 74 spaced along the lower portion 72 of the periphery wall 34 include guide holes 76 . Each guide hole 76 is formed in the free end of each rib 74 adjacent the free edge of the periphery wall lower portion 72 for receiving guide pins 78 extending from the cover 70 . A pair of catches 80 are formed in an outwardly facing surface 82 of the periphery wall lower portion 72 for engaging latches 84 extending from the cover 70 to lock the base 68 and cover 70 together.
Drive shaft openings 86 formed in the bottom wall 32 receive drive shafts 92 , 96 , 100 therethrough for driving an ink ribbon supply spool 48 , ink ribbon take up spool 40 , and a label media drive roller 46 rotatably mounted in the cartridge housing 28 . A circular recess 88 is formed around each drive shaft opening 86 in the inwardly facing surface 90 of the bottom wall 32 . Each recess 88 receives a drag washer 95 for inducing drag during rotation of the ink ribbon supply spool 48 , ink ribbon take up spool 40 , and the label media drive roller 46 . A smaller opening 99 formed through the bottom wall 32 adjacent the periphery wall lower portion 72 receives one end of a pivot shaft 103 forming part of the yoke 42 supporting the label media 14 .
The cover 70 includes the cartridge housing top wall 30 and an upper portion 104 of the periphery wall 34 . Cover ribs 106 spaced along the upper portion 104 of the periphery wall 34 are aligned with the base ribs 74 and include the guide pins 78 received in the guide holes 76 formed in the base ribs 74 . Each guide pin 78 extends from each cover rib 106 adjacent the free edge of the periphery wall upper portion 104 . The pair of latches 84 extend from the free edge of the periphery wall upper portion 104 for engaging the catches 80 formed in the base 68 . An inwardly extending boss 108 formed in the cartridge housing top wall 30 receives the other end of the pivot shaft 103 forming part of the yoke 42 .
First, second, and third cylindrical support columns 110 , 112 , 114 extend inwardly from the cartridge housing top wall 30 . Each support column 110 , 112 , 114 rotatably supports either the ink ribbon supply spool 48 , ink ribbon take up spool 40 , or the label media drive roller 46 . A coil spring 116 wrapped around each support column 110 , 112 , 114 urges the respective spool 48 , 40 and label media drive roller 46 toward the cartridge housing bottom wall 32 and into engagement with a drag washer 95 received in the respective recess 88 .
Unused ink ribbon 16 is housed in the cartridge housing 28 on the ink ribbon supply spool 48 and, once the ink ribbon 16 travels past the print head 22 , is wound onto the ink ribbon take up spool 40 . The ink ribbon supply and take up spools 48 , 40 are both rotatably supported in the cartridge housing 28 on the second and third columns 112 , 114 , respectively. The ink ribbon take up and supply spools 40 , 48 are selectively rotatably driven by an ink ribbon rewind shaft 100 and ink ribbon unwind shaft 96 , respectively, which form part of a drive mechanism to maintain tension in the ink ribbon 16 in the forward and reverse feed directions.
The ink ribbon supply spool 48 is rotatably mounted on the second support column 112 between the cartridge housing top and bottom walls 30 , 32 , and has a roll of ink ribbon 16 wound thereon. In the forward feed direction, the ink ribbon 16 unwinds from the ink ribbon supply spool 48 and passes out of the cartridge 12 with the label media 14 through the printing area 38 between the print head 22 and platen roller 24 . The print head 22 engages the ink ribbon 16 to transfer ink on the ink ribbon 16 onto the label media 14 . Once the ink has been transferred, the ink ribbon 16 reenters the cartridge 12 , and is wound onto the ink ribbon take up spool 40 supported between the top and bottom walls 30 , 32 .
The ink ribbon take up spool 40 is rotatably mounted on the third support column 114 between the cartridge housing top and bottom walls 30 , 32 , and, as described above, winds used ink ribbon 16 thereon in the forward feed direction. In the reverse feed direction, the ink ribbon 16 unwinds from the ink ribbon take up spool 40 and passes out of the cartridge 12 through the printing area 38 between the print head 22 and platen roller 24 , and is wound onto the ink ribbon supply spool 48 .
The label media drive roller 46 is rotatably mounted on the first support column 110 between the cartridge housing top and bottom walls 30 , 32 , and engages the label media 14 to define the beginning of the label media path. The beginning of the label media path is defined as the point of contact between the label media drive roller 46 and the label media 14 on the roll supported by the yoke 42 . Preferably, the label media drive roller 46 is rubber coated, and in a forward feed direction provides a constant tension in the label media 14 between the label media drive roller 46 and the print head 22 and platen roller 24 . In a reverse feed direction, a label media drive shaft 92 forming part of the drive mechanism drives the label media drive roller 46 to maintain tension in the label media 14 between the label media drive roller 46 and platen roller 24 and print head 22 .
Each drag washer 95 is received in one of the circular recesses 88 formed around each drive shaft opening 86 of the cartridge housing 28 , and frictionally engages one of the ink ribbon supply spool 48 , take up spools 40 , and label media drive roller 46 to induce a drag, or torque level, on the rotating spools 48 , 40 and roller 46 in order to maintain tension in the label media 14 and ink ribbon 16 . The coil springs 116 urge the spools 48 , 40 and roller 46 against the drag washers 95 to provide the desired drag. The drag can be adjusted to a desired level using methods known in the art, such as texturing the washers, changing the spring constant of the coil springs, and the like, without departing from the scope of the invention. Of course, other methods for inducing drag can be used, such as introducing a drag in the spools and roller through the drive mechanism, frictionally engaging the spools and/or roller with the cartridge, a spring, or other structure, without departing from the scope of the invention.
The label media 14 engaging the label media drive roller 46 is housed in the cartridge housing 28 in the form of a roll rotatably mounted on the yoke 42 . Advantageously, in the embodiment disclosed herein, the yoke 42 is pivotally mounted to maintain a consistent beginning of the label media path as the diameter of the roll of label media 14 decreases. The yoke 42 pivots so that the label media drive roller 46 engages the roll of label media 14 at a point of tangency to the outside diameter of the roll of label media 14 to provide a constant beginning of the label media path regardless of the roll diameter.
As shown in FIGS. 5–14 , the yoke 42 disclosed herein includes first and second label media guides 118 , 120 joined by the pivot shaft 103 and label media supply shaft 122 . Each end of the pivot shaft 103 is received in either the boss 108 formed in the cartridge housing top wall 30 or the opening 99 formed in the cartridge housing bottom wall 32 to pivotally mount the yoke 42 in the cartridge housing 28 . The label media supply shaft 122 mounts the roll of label media 14 , either alone, or on a core 123 . Advantageously, the label media guides 118 , 120 square the label media 14 relative to the cartridge exit slot 29 to prevent the label media 14 from jamming as it exits the cartridge housing 28 .
Preferably, the first label media guide 118 is fixed to, or formed as an integral part of, one end of the pivot shaft 103 and label media supply shaft 122 . The second label media guide 120 includes a pivot shaft opening 124 for slidably receiving the pivot shaft 103 and a label media supply shaft opening 126 for slidably receiving the label media supply shaft 122 . Advantageously, the second label media guide 120 is slidable along the pivot shaft 103 and label media supply shaft 122 to accommodate rolls of label media 14 having different widths.
The second label media guide 120 disclosed herein is positionable at a plurality of preset positions for accommodating rolls of label media 14 of predetermined widths. Although providing a yoke 42 having preset positions defining different widths is preferred, a yoke having infinite adjustability for accommodating any label media width between a minimum and a maximum, such as by sizing the pivot shaft and/or label media supply shaft to frictionally engage the pivot shaft opening and/or label media supply shaft opening, respectively, can be provided without departing from the scope of the invention.
In the embodiment shown in FIGS. 9–14 , the preset positions are defined by notches 128 formed in the pivot shaft 103 and label media supply shaft 122 . Latches 130 extending from the second label media guide 120 toward the first label media guide 118 engage the notches 128 to fix the second label media guide 120 relative to the first label media guide 118 at the desired preset position. Advantageously, this arrangement simplifies assembly of the cartridge 12 and minimizes the number of parts necessary for different widths of label media 14 because the same yoke 42 can be used to accommodate different label media widths.
The yoke 42 is pivotally biased by a torsion spring 44 toward the label media drive roller 46 rotatably mounted between the cartridge housing top and bottom walls 30 , 32 . The torsion spring 44 is wrapped around the pivot shaft 103 , and has one end 132 engaging the first label media guide 118 and an opposing end 134 engaging the cartridge housing periphery wall 34 to urge the yoke 42 , and thus the roll of label media 14 , toward the label media drive roller 46 . Advantageously, the torsion spring 44 maintains the label media drive roller 46 in contact with the roll of label media 14 as the diameter of the roll of label media 14 decreases during use. Although a torsion spring is disclosed, any biasing means for biasing the yoke toward the label media drive roller, such as leaf springs, coil springs, elastomeric members, resilient media guides, or arms, and the like, can be used without departing from the scope of the invention.
Referring back to FIGS. 1–5 , the cartridge 12 is received in the cartridge receptacle 18 housed in the printer housing 2 . The printer housing 2 is, preferably, formed from at least two portions 50 , 52 , and houses printer components, such as the cartridge receptacle 18 , the keyboard 4 , display 6 , the cutter mechanism 26 , a printed circuit board 54 having printer circuitry, and the like. The opening 8 formed in the housing top portion 50 provides access to the cartridge receptacle 18 for insertion of the cartridge 12 into the cartridge receptacle 18 . A slot 56 formed in the housing 2 adjacent the cutter mechanism 26 provides an exit for label media 14 which has passed through the cutter mechanism 26 .
Referring to FIGS. 2 and 5 – 9 , the cartridge receptacle 18 has a periphery wall 58 generally shaped to conform with the cartridge periphery wall 34 , and a bottom wall 60 that supports the cartridge 12 therein. The cartridge receptacle periphery wall 58 surrounds the printer mechanism assembly 20 which is fixed in the printer housing 2 relative to the cartridge receptacle 18 .
The printer mechanism assembly 20 fixed relative to the cartridge receptacle 18 in the printer housing 2 includes the pivotable print head 22 and stationary platen roller 24 . The print head 22 cooperates with the ink ribbon 16 and the label media 14 such that the print head 22 can print characters or symbols on the label media 14 . This is described in greater detail in U.S. Pat. No. 5,078,523 which is incorporated herein by reference. The platen roller 24 also forms part of the drive mechanism.
The drive mechanism drives the label media 14 and ink ribbon 16 past the print head 22 , and includes the platen roller drive shaft 62 , label media drive shaft 92 , ink ribbon rewind drive shaft 100 , and ink ribbon unwind drive shaft 96 . The drive mechanism selectively drives the rollers 24 , 46 and spools 40 , 48 to drive and tension the label media 14 and ink ribbon 16 in the forward and reverse feed directions. Preferably, the platen roller 24 , label media drive roller 46 , ink ribbon supply spool 48 , and ink ribbon take up spool 40 are all rotatably driven by a dual feed direction drive mechanism mounted to the bottom of the cartridge receptacle 18 , such as disclosed in a copending U.S. patent application Ser. No. 10/639,548. Although the drive mechanism disclosed in the copending patent application is preferred, any drive mechanism known in the art that can feed the label media and ink ribbon in one or more feed directions can be used without departing from the scope of the invention.
The label media 14 and ink ribbon 16 passing through the printing area 38 are advanced past the print head 22 in the forward feed direction and reverse feed direction by the platen roller 24 which maintains the ink ribbon 16 and label media 14 in close cooperation with the print head 22 . The platen roller 24 is mounted on a platen roller drive shaft 62 which is rotatably mounted in the cartridge receptacle 18 by a bracket 66 . The print head 22 is pivotally mounted relative to the platen roller 24 in the cartridge receptacle 18 to provide space between the print head 22 and platen roller 24 when threading the label media 14 and ink ribbon 16 therebetween.
As the label media 14 and ink ribbon 16 are driven in the forward and reverse feed directions by the platen roller 24 , tension is maintained in the ink ribbon 16 and label media 14 by the label media drive shaft 92 , ink ribbon rewind drive shaft 100 , and ink ribbon unwind drive shaft 96 . The label media drive shaft 92 , ink ribbon rewind drive shaft 100 , and ink ribbon unwind drive shaft 96 are each received through one of the drive shaft openings 86 formed in the cartridge housing bottom wall 32 and into one of the first, second, and third support columns 110 , 112 , 114 . The drive shafts 92 , 96 , 100 extend through the support columns 110 , 112 , 114 , and engage inner surfaces 94 , 98 , 102 of, and rotatably drive, the label media drive roller 46 , ink ribbon supply spool 48 , and ink ribbon take up spool 40 , respectively.
Referring to FIGS. 1–14 , in use, the cartridge 12 is inserted into the cartridge receptacle 18 with the label media drive shaft 92 received in the label media drive roller 46 , the ink ribbon unwind drive shaft 96 received in the ink ribbon supply spool 48 , and the ink ribbon rewind drive shaft 100 received in the ink ribbon take up spool 40 to properly position the cartridge 12 in the cartridge receptacle 18 and thread the label media 14 and ink ribbon 16 between the platen roller 24 and print head 22 . The print head 22 is then urged toward the platen roller 24 to sandwich the label media 14 and ink ribbon 16 therebetween.
Once the cartridge 12 is locked in place, the printer 10 is ready to produce printed labels. When printing on the labels, the label media 14 and ink ribbon 16 are fed past the platen roller 24 and print head 22 by the platen roller 24 in the forward feed direction by driving the platen roller 24 in a first direction of rotation. The ink ribbon take up spool 40 is rotatably driven in the first direction of rotation to take up the used ink ribbon 16 fed past the print head 22 and maintain tension in the ink ribbon 16 . The label media drive roller 46 and ink ribbon supply spool 48 are not rotatably driven. The drag induced on the label media drive roller 46 and ink ribbon supply spool 48 by the drag washers 95 creates a tension in the label media 14 and ink ribbon 16 to prevent jams.
When a desired character is input by an operator or other means, the printer circuitry of the printer 10 energizes pixels on the print head 22 as the label media 14 and ink ribbon 16 advance past the print head 22 . The head pixels are variously energized to imprint the character on the label media 14 . This is described in greater detail in U.S. Pat. No. 5,078,523 which has been incorporated herein by reference.
As label media 14 is unwound from the roll of label media 14 , the diameter of the roll of label media 14 is reduced. Advantageously, the yoke 42 pivots about the pivot axis defined by the pivot shaft 103 in the cartridge housing 28 to maintain the label media in contact with the label media drive roller 46 and define the consistent beginning of the label media path from the roll of label media 14 .
When a label has been printed, the platen roller 24 continues to drive the label media 14 and ink ribbon 16 in the forward feed direction to advance the label for removal by the user, such as by cutting the label media 14 using the cutter mechanism 26 . Once the portion of the label media 14 containing the printed label is removed, the remaining label media 14 and ink ribbon 16 are fed in the reverse feed direction by the platen roller 24 to position the next available label in position for printing without wasting the label media 14 and ink ribbon 16 .
The label media 14 and ink ribbon 16 are fed past the platen roller 24 and print head 22 in the reverse feed direction by driving the platen roller 24 , label media drive roller 46 , and ink ribbon supply spool 48 in a second direction of rotation. The platen roller 24 drives the label media 14 and ink ribbon 16 past the print head 22 while the ink ribbon 16 is wound onto the ink ribbon supply spool 48 and the label media 14 is urged onto the roll by the label media drive roller 46 . The pixels on the print head 22 , however, remain deenergized to avoid printing on the label as it is being repositioned for printing. The ink ribbon take up spool 40 is not rotatably driven, and the drag induced on the ink ribbon take up spool 40 by the drag washer 95 creates a tension in the ink ribbon 16 to prevent jams.
While there has been shown and described what is at present considered the preferred embodiment of the invention, it will be obvious to those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention defined by the appended claims. For example, the cartridge disclosed herein is for use with a roll of label media, however, any type of media in a roll and useable in a printer can be used without departing from the scope of the invention.
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A printer cartridge suitable for use in a cartridge-based printer houses and dispenses a roll of label media. The cartridge includes a housing having a top wall and a bottom wall. A yoke pivotally mounted between the top and bottom walls for pivotable movement about a pivot axis includes a label media supply shaft for holding a roll of label media. The label media supply shaft has a longitudinal axis spaced from, and parallel, to the pivot axis. A label media drive roller is rotatably mounted between the top and bottom walls, and a biasing means biases the yoke toward the label media drive roller to maintain the roll of label media in contact with the label media drive roller and defines a beginning of a media path. In one embodiment, the yoke is adjustable to accommodate different label media widths.
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FIELD OF THE INVENTION
This invention relates generally to pet bandannas and, more particularly, to a method and apparatus for tying a bandanna around the neck of a pet.
BACKGROUND OF THE INVENTION
It is well known to hang a piece of cloth around the neck of an animal and, in particular, the neck of a pet such as a dog, cat, potbelly pig, or rabbit as an accessory or a fashion statement. The cloth is usually triangular in shape and, besides being colorful, may include a design or picture. The cloth is usually referred to as bandanna or neckerchief.
Pet, and in particular canine, bandannas are well known. For example, U.S. Pat. No. DES 423,150 to Vignere discloses an ornamental design for a dog scarf. Retail outlets, for example, pet superstores, sell pet bandannas.
In some instances, the bandannas can be impregnated with a chemical insecticide or perfume to achieve a desired effect (i.e., as a flea and tick repellent and/or to cover the smell of a pet). For example, U.S. Pat. No. 5,465,689 to Winder discloses a flea and tick repellant bandanna for pets.
SUMMARY OF THE INVENTION
The present invention is a method and apparatus for quickly attaching a bandanna around the neck of a pet. The method involves the use of the apparatus. In addition, the apparatus may also complement the bandanna by manipulating the shape or appearance of the apparatus. For example, the apparatus can be shaped into a well-known object. In the drawings, the apparatus is shown as a bone (an item typically associated with dogs). However, this apparatus can be shaped into virtually any object (e.g., a pumpkin or bat if the bandanna has a Halloween theme associated with it). Further, the apparatus can be painted a particular color. For instance, the pumpkin can be painted orange to further complement and for keeping with a particular theme.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the following description, serve to explain the principles of the invention. For the purpose of illustrating the invention, embodiments which are presently preferred are shown in the drawings, it being understood, however, that the invention is not limited to the specific instrumentality or the precise arrangement of elements or process steps disclosed.
In the drawings:
FIG. 1 is a top view of the apparatus in accordance with the present invention;
FIG. 2 is a front side view of the apparatus illustrated in FIG. 1 taken along lines 2 — 2 ;
FIG. 3 is a right side view (from the perspective of the reader) of the apparatus illustrated in FIG. 1 taken along lines 3 — 3 ;
FIG. 4 shows a pet scarf or bandanna which is designed to be tied around a pet's neck and illustrates the first step in a method of securing the bandanna about the pet's neck in accordance with the present invention;
FIG. 5 illustrates the second step of the method;
FIG. 6 illustrates the third step of the method;
FIG. 7 illustrates the fourth step of the method;
FIG. 8 illustrates the fifth step of the method; and
FIG. 9 is an isometric view of the bandanna as it hangs from the neck of a dog with the ends of the bandanna secured in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In describing a preferred embodiment of the invention, specific terminology will be selected for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings in which an apparatus for securing the ends of a bandanna in accordance with the present invention is generally indicated at 10 .
As illustrated in FIG. 1, an apparatus 10 for assisting in tying a bandanna 25 around the neck of a pet is illustrated. Although the apparatus may be scaled up or down in size to accommodate a particular sized bandanna (or pet), in a preferred embodiment, the apparatus 10 is approximately 3½″ long to accommodate a large breed of dog and approximately 2¼ long to accommodate a small breed dog.
The apparatus 10 includes three apertures arranged substantially at the vertices of an inverted triangle. The apertures go completely through the apparatus. The aperture 12 at the upper left vertex and the aperture 14 at the upper right vertex are preferably slightly smaller in diameter than the bottom or lower aperture 16 . In a preferred embodiment, the two upper apertures 12 , 14 are {fraction (9/32)} of an inch in diameter and the lower aperture 16 is {fraction (5/16)} of an inch in diameter.
As illustrated, the apparatus 10 is shaped like a dog bone. However, it would be obvious to one skilled in the art, after reading the subject specification, that the general shape is not particularly important to the operation of the apparatus and is only meant to be pleasing to the eye of the pet's owner. The apparatus only needs to be large enough to have the three apertures positioned there through. As indicated previously, the apparatus 10 may be shaped like a geometric figure (e.g. a circle or square), pumpkin, a dog or other animal, or virtually any object. The shape of the apparatus is merely for aesthetics.
The three apertures are shown centered on the apparatus. It would be clear to a person skilled in the art, after reading this disclosure, to offset the three apertures to complement the shape or design of the apparatus.
In a preferred embodiment, the apparatus 10 is manufactured from plastic and preferably acrylic. This provides a number of options in the manufacturing and appearance of the apparatus. For example, the apparatus may be made of different colors during the manufacturing process by changing the color of the plastic or even painted, if desired. Further, plastics may be injection molded to lower the cost of manufacturing (i.e., the apertures will be pre-formed without drilling them out in a separate manufacturing step). However, the apparatus may be made from wood or metal (particularly a metal that does not oxidize and is relatively light in weight like aluminum).
FIG. 2 illustrates a front side view of the apparatus 10 illustrated in FIG. 1 taken along line 2 — 2 , and FIG. 3 illustrates a right side view of the apparatus illustrated in FIG. 1 taken along line 3 — 3 .
As illustrated, the apparatus 10 is relatively flat. This keeps the weight down and allows the ends to pass through the apertures with relative ease. In the dog bone embodiment, illustrated herein, the apparatus is approximately 3½ inches long, approximately 1 inch high and approximately ¼ inch thick.
Referring now to FIG. 4, a typical pet bandanna 25 is shown. Although the bandanna is illustrated as triangular in shape, it is commonly a square piece of cloth that is folded in half along a diagonal to generally form a triangle.
Depending on the size of the bandanna 25 , the method according to the present invention may be initiated without placing the bandanna around the subject pet's neck. However, in most instances, the large portion of cloth (i.e., near the apex of the triangular shaped cloth) is placed on the back of the pet with first 20 end and the second 22 end of the cloth hanging down on the sides of the pet's neck.
The method is further illustrated in FIGS. 5-8. Although a pet is not shown, the bandanna is preferably hung around the neck of a pet with the left or first end 20 guided from the back of the apparatus 10 through upper left aperture 12 . (The perspective when referring to the directions “left” and “right” is taken from the person practicing the invention.) The first end 20 may be pulled through aperture 12 from the front side and it is then guided back through bottom aperture 16 . The right or second end 22 of the bandanna is guided from the back through upper right aperture 14 to the front of the apparatus 10 . The second end 22 is then overlaid over first end 20 and through the bottom aperture 16 as shown in FIG. 8 .
It is clear now why the lower aperture 16 is slightly larger than the upper apertures 12 , 14 because it must secure both ends of the bandanna Moreover, the friction caused by the apertures holds the bandanna securely, thereby preventing it from falling off the pet.
The method may be practiced if the right end 22 of the bandanna 25 is drawn through the upper right aperture 14 first and then through bottom aperture 16 , followed by guiding the left end 20 of the bandanna through its respective apertures.
The apparatus 10 may be adjusted by sliding the ends 20 , 22 of the bandanna 25 through the apertures thereby making the bandanna looser or more snug around the neck of the pet as shown in FIG. 9 .
Although this invention has been described and illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made which clearly fall within the scope of this invention. The present invention is intended to be protected broadly within the spirit and scope of the appended claims.
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A method and apparatus used in the method for securing at least two ends of a triangularly-shaped bandanna. The apparatus includes a generally flat article having three apertures there through. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical diclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72( b ).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is concerned with a control method for a tufting machine used to weave carpets.
2. Description of the Prior Art
Generally in the control of a conventional tufting machine, the number of stitches in a unit length of woven carpet is visually counted, the length of yarn to be fed is calculated from the weighted amount of yarn being used, and it is judged if the woven carpet is made to the required color pattern. These factors have then been controlled as necessary by changing a spiked roller or a yarn roller in the conventional tufting machine. However, such operations have led to very complicated control of the tufting machine, which are accompanied by the disadvantage of inability of making fine adjustment to cope with the requirements of color pattern, and the requirement of having higher highly skilled and experienced personnel for the operation of the machine.
SUMMARY OF THE INVENTION
Accordingly, one object of this invention is to provide a novel method for controlling a tufting machine, which corrects the stated disadvantages of conventional methods for controlling such machines.
The object of the invention is achieved by providing a quite practical and convenient control method for tufting machines characterized by measuring the number of stitches and feeding yarn length for a unit feed length of the ground fabric, and automatically controlling the feeding of ground fabric and/or yarn. The method results in uniform and continuous finishing of a carpet to a required color pattern merely by selected setting of standard values depending on the color pattern of the carpet to be woven, and allows fine control without requiring highly skilled personnel.
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 schematic drawing indicating the principle of the control method of a tufting machine related to an exemplary embodiment of this invention;
FIG. 2 is a block diagram showing the control circuit of the control panel; and
FIG. 3 is a plan view of a control panel for practicing the control method of the invention.
DETAILED 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, the numeral 1 refers to a ground fabric, the numeral 3 refers to yarn fed by a yarn roller 2 and driven into the ground fabric 1 by means of a needle 5. The needle 5 is driven by stitch shaft 4 to form pile 6. The yarn 3 is stitched to a tufted fabric of carpet 7 and is devised to be sent out by a spiked roller 8.
Letter A is a yarn feed detector which detects the speed of yarn being fed by way of a photoelectric contactless switch, and generates a definite number of pulses for a certain length of yarn feeding.
Letter B designates a stitch number detector which detects the number of the strokes of needle 5 corresponding to stitch number by way of magnetic contactless switch, and generates a definite number of pulses for a stroke of the needle 5.
Letter C designates a ground fabric feed detector, which detects the speed of ground fabric feeding and generates a definite number of pulses for a certain length of ground fabric feeding. Now, numeral 9 designates a control device, which receives pulses issued from yarn feed detector A, stitch number detector B and ground fabric feed detector C respectively; and determines the number of stitches and yarn feed length corresponding to a unit ground fabric feed; then compares this value with a preestablished standard value, and generates an output signal when the value deviates outside an allowable limit, changing the ratio of PIV 10 and 11, causing pilot motors 12 and 13 to increase or decrease the rotation of yarn roller 2 and spiked roller 8 to control and correct the tufting machine.
FIG. 2 is a block diagram indicating the control circuit of above described control device 9, of which the structure and function are now described.
In FIG. 2, letter A designates the yarn feed detector, letter B designates the stitch number detector and letter C designates the ground fabric feed detector. Numeral 14 designates a standard value setting device, which is set to the predetermined standard stitch number and standard yarn feed length for a unit ground fabric feed length corresponding to the color pattern of the carpet to be tufted by way of a digital switch, and the set signal of the standard value is applied to a synchronous counter 15. The synchronous counter 15 receives and counts the number of pulses issued from the ground fabric feed detector C, synchronizing with the rotation of the skid roller 8, and is arranged to give a standard set-signal as derived from the standard value setting device 14 to counters 17 and 18, via gate 16 which opens a gate when the synchronous counter 15 completely counts the number of pulses corresponding to the unit ground fabric feed length set by standard value setting device 14.
The counter 17 counts the pulse number corresponding to the unit ground fabric feed length counted by synchronous counter 15, and the pulses issued from yarn feed detector A during the time between successive gate pulses, and thereby measures the yarn feed length corresponding to the unit ground fabric feed length. The obtained pulse number is latched by a latch relay 19, and converted to the length of pile 6 by decoder 20, with the pile length expressed digitally by a scale factor on a ratio indicator 21. The counter 17 is devised to compare the measured value of yarn feed length for a unit ground fabric feed length with its standard value, and determine their difference as plus or minus percentage error, and to issue an error signal 22 corresponding to the error value.
Numeral 23 designates an upper control limit setting apparatus and numeral 23 designates a lower control limit setting apparatus, which are respectively set to plus or minus allowable percentage discrepancy value ranges of the difference of yarn feed length from the standard yarn feed value for unit ground fabric feed length. When the error signal 22 exceeds the plus side allowable value, upper limit control 23 functions to initiate the issuance of a signal from command signal generator 25 which causes the issuance of a speed reducing command signal 27 through the relay 26. Conversely, when the error signal exceeds the minus allowable limit, lower limit control 24 operates to initiate issuance of a corresponding signal from command signal generator 28 which causes the issurance of a speed increasing command signal 30 through relay 29. Then the above described speed reducing command signal 27 or speed increasing command signal 30 is sent to the pilot motor 12, and changes the ratio of PIV (stepless transmission) 10 and increases or decreases the rotation speed of yarn roller 2 resulting in the automatic control and correction of the rotation speed of the yarn roller until the error signal 22 returns to the allowable range of plus and minus deviation.
Numeral 31 designates an upper stop limit setting apparatus and numeral 32 designates a lower stop setting apparatus respectively, and are devised to issue a signal when error signal 22 largely exceeds the plus or minus allowable range to actuate stop signal generator 33 which causes issuance of a stop signal 35 through a relay 34 to open the main switch of the tufting machine and prevent the occurrence of failure of the tufting machine.
Counter 18 counts the pulse number corresponding to the unit ground fabric feed length counted by the synchronous counter 15 and the pulses issued from the stitch number detector B during the period between successive gate pulses, and measures the number of stitches for a unit ground fabric feed length. The output of counter 18 corresponding to the number of stitches is latched by a latch relay 36, whose output is coupled to decoder 37 devised to indicate the stitch number digitally for display by a stitch number indicator 38.
The counter 18 compares the measured value of stitch number for a unit ground fabric feed length with the standard number, determines the deviation as a plus or minus percentage error, and issues error signal 39 corresponding to the error value.
Numeral 40 designates a control upper limit setting apparatus and numeral 41 designates a control lower limit setting apparatus which are respectively previously set to the plus or minus percentage allowable value of the deviation of stitch number for unit ground fabric feed length from its standard value. Control upper limit setting apparatus 40 operates whenever the error signal 39 exceeds the plus allowable value to initiate the issuance of a signal from command signal generator 42 and which in turn initiates generation of a speed reducing command signal 44 through relay 43.
Conversely, when the error signal 39 exceeds the minus allowable limit, control lower limit setting apparatus 41 operates to initiate the issuance of a signal from a command signal generator 45, which in turn initiates generation of a speed increasing command signal 47 through a relay 46. The above stated speed reducing command signal 44 or speed increasing command signal 47 is fed to the pilot motor 13 to change the ratio of PIV (stepless transmission) 11, which increases or decreases the rotating speed of the spiked roller 8 to control and automatically correct the rotating speed of the spiked roller 8 until the error signal 39 falls within the plus or minus allowable range.
Numerals 48 and 49 designate an upper stop limit setting apparatus and a lower stop limit setting apparatus respectively, are devised to issue a signal when the error signal 39 largely exceeds the plus or minus allowable value respectively, to to operate stop signal generator 33 to cause generation of a stop command signal 35 through relay 34 to open the main switch of the tufting machine and prevent the occurrence of the failure of tufting machine.
Manual operation switches 50, 51, 52 and 53 are installed between each command signal generator and relay, such as between 25-26, 28-29, 42-43 and 45-46, such that it is possible to increase or decrease rotational speed of yarn roller 2 and spiked roller 8 optionally, by independently issuing speed reducing command signal 27 and 44 or speed increasing command signal 30 and 47 separately without any relation to automatic control corrections.
Numeral 54 designates a production quantity preset counter, which is set with a ground fabric length corresponding to a predetermined production quantity by way of a digital switch. Counter 54 counts the number of gate pulses received, and indicates the number of gate pulses and ground fabric length determined from the unit ground fabric feed length digitally, to issue a signal when the measured ground fabric length corresponds to the preset production quantity to operate stop signal generator 33, open the main switch of the tufting machine by sending stop signal 35 through relay 34 and preset the production quantity.
FIG. 3 is a plan view of the control panel, in which numeral 55 designates a manual main switch of the tufting machine. Numeral 56 designates a reset switch to be operated when the standard value is to be changed, numeral 57 designates a starting button and numeral 58 designates a power source input lamp respectively.
Referring to the Figure, numeral 38 designates a stitch number indicator, numeral 21 designates a ratio indicator and numeral 54 designates a production quantity preset counter respectively, corresponding with identical symbols in FIG. 2.
Numeral 23 designates a control upper limit setting apparatus, numeral 24 designates a control lower limit setting apparatus, numeral 31 designates a lower stop limit setting apparatus respectively.
Further, numeral 40 designates a control upper limit setting apparatus, numeral 41 designates a control lower limit setting apparatus, numeral 48 designates an upper stop limit setting apparatus, numeral 49 designates a lower stop limit setting apparatus and numeral 14 designates a standard value setting device respectively. The above stated apparata on the control panel with numerals 38, 21, 54, 23, 24, 31, 32, 40, 41, 48, 49 and 14 are made to be visually observed by digital indication.
In the drawing, numerals 23', 24', 31', 32', 40', 41', 48' and 49' respectively are alarm lamps attached to 23, 24, 31, 32, 40, 41, 48 and 49 respectively devised to light on and indicate what error value was occurred and what kind of control operation or stop control is being performed when the error value corresponds to error signal 22 or 39 has exceeded the permissible value.
In the drawing, numerals 50 and 51 designate manual switches to decrease or increase yarn roller speed and numerals 52 and 53 designate manual switches to decrease or increase spiked roller speed respectively.
The operation of the above control panel is described as follows:
Firstly, the manual main switch 55 of the tufting machine is turned on and the standard stitch number and the standard yarn feed length are preset by means of the standard value setting device, depending on the color patterns to be woven.
Secondly, the control upper limit setting apparata 23 and 40, control lower limit setting apparata 24 and 41, upper stop limit setting apparata 31 and 48 and lower stop limit setting apparata 32 and 49 are respectively set.
Further, the planned production quantity is set on the production quantity preset counter 54, and the starting button 57 is pushed "on", so that the tufting machine starts operation. Thereafter, the production quantity is continuously indicated on the production quantity preset counter, and the tufting machine stops when the preset production quantity is attained. During this period, if and when the measured value of the stitch number and standard yarn feed length for a unit ground fabric feed length departs from the standard value, either of alarm lamp 23', 40' or 24', 41' corresponding to control upper limit setting apparatus 23, 40 or control lower limit setting apparatus 24, 41 are lighted to indicate the status, and automatically control and correct the rotation speed of yarn roller 2 or spiked roller 8.
If the above measured value largely departs from the standard value, either of the alarm lamps 31', 48' or 32', 49' correspond to upper stop limit setting apparatus 31, 48 or lower stop limit setting apparatus 32, 49 are lighted to indicate the fact and the tufting machine is made to stop operation. In this case, if the cause of failure is investigated and repaired, the tufting machine can be reoperated by pushing starting button 57 on. Naturally, the rotation speed of yarn roller 2 and spiked roller 8 can be controlled by operation of manual switch 50, 51, 52 and 53 without any relation to the standard value.
Correction or change of the standard value can be performed by pushing reset switch 56 to reset each set value starting from zero.
As explained above in detail, this invention devises to preset a standard stitch number and standard yarn feed length for the unit ground fabric feed length, determine stitch number and yarn feed length for unit ground fabric feed length with each detected value of ground fabric feed detector, yarn feed detector and stitch number detector; compare the measured value with the standard stitch number and standard yarn feed length; and automatically control and correct the rotating speed of the spiked roller and yarn roller; and has great advantage in comparison to the conventional method as follows:
(1) The tufting machine can be controlled quite easily and fully automatically, because the rotation speed of the spiked roller and yarn roller are automatically controlled and corrected, if the measured value departs from the standard value.
(2) Because control and correction of a tufting machine is performed automatically, the tufting machine is not required to be watched as in the case of conventional machine, and there is no fear of personnel inattention or fault, which results in a great saving of man-power.
(3) Because the only required operation is to preset the standard stitch number and the standard yarn feed length for a unit ground fabric feed length, operation is quite simple requiring no skill, can be handled by unskilled personnel easily, and a uniform finish of products can be expected.
(4) Because the rotation speeds of the spiked roller and yarn roller are controlled and corrected independently or parallelly, good response of correction control is obtained, and the correction control is finished in a short time.
(5) Because control and correction can be performed without stopping the tufting machine, long hours of continuous operation can be performed which leads to a great increase of production capacity.
(6) Because the accuracy of correction can be set freely by changing the range of allowable limit, fine controls in accordance with color design is possible.
The method of this invention is far more functional compared with the conventional method, and provides a quite practical and convenient control method for a tufting machine.
Although an embodiment was explained for the example of applying this invention for the control of one tufting machine, it is evident that the invention can be embodied for the control of many tufting machines parallelly or independently, for example by collective control by way of employing a mini-computer.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claim, the invention may be practiced otherwise than as specifically described herein.
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A method of controlling a tufting machine including preestablishing a selected stitch number and a selected yarn feed length for a predetermined unit feed length of ground fabric, determining stitch number and yarn feed length for the unit feed length of ground fabric by means of measured values respectively obtained from a ground fabric feed detector, a yarn feed detector and a stitch number detector, comparing the measured values with the preestablished stitch number and the preestablished yarn feed length, and automatically controlling the rotation speeds of a spiked roller and a yarn roller respectively to correct the ground fabric feed and the yarn feed to the preestablished values whenever the measured values depart from a predetermined tolerance from the selected values.
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BACKGROUND OF THE DISCLOSURE
The invention relates to an FM-receiver comprising a frequency-locked loop which includes, in succession, a voltage-controlled oscillator, a mixer circuit connected to an aerial input, an IF-portion comprising an IF-filter, an FM-detector, a loop filter and a loop amplifier for adjusting the transfer characteristic of the frequency-locked loop. The loop amplifier is connected to a control input of the voltage-controlled oscillator for feedback of the modulation signal of the received FM-signal, the filter comprising a first low-pass filter.
Such an FM-receiver is known from the Netherlands Patent Application No. 7906602 which has been laid open to public inspection.
In the known FM-receiver, when being correctly tuned to a wanted transmitter signal, the FM-aerial signal having an average frequency RF is amplified and mixed down in the mixer circuit to a low, average intermediate frequency IF by means of the oscillator signal which has an average frequency OF. Simultaneously, by the feedback of the modulation in the frequency-locked loop, the frequency deviation of the received FM-aerial signal is compressed, for example by a factor of 5 from 75 KHz to 15 KHz. This reduces considerably the foldover distortion of the FM-signal in the IF-portion, which is the result of the comparatively low average intermediate frequency IF.
The low intermediate frequency IF in combination with the compression of the frequency deviation makes it possible to realize the known FM-receiver in integrated circuit form. However, for an adequate signal processing a number of requirements must be satisfied. For a selectivity which is effective in the most critical circumstances, and an adequately wide FM-IF-passband the IF-filter must be of a higher order, for example of the 4 th order. In addition, in practice the stability of the frequency-locked loop is guaranteed only when, within the passband of the closed loop--that is to say the frequency range in which the loop gain is equal to one--the phase shift of the modulation signal in the loop is less than 180°. This phase shift is predominantly effected in the IF-filter, the FM-detector and the first low-pass filter and limits significantly the number of choices as regards the order, the bandwidth and the class of the filters. A further restraint is the requirement that for an effective compression of the frequency deviation the bandwidth of the open loop, that is to say the bandwidth of the first low-pass filter must include at least a considerable portion of the modulation signal.
In practice these requirements can only be satisfied by a certain choice of filter parameters, when the bandwidth of the modulation signal is of the order of magnitude of that of an FM-mono signal.
With modulation signals having a bandwidth of the order of the stereo multiplex signal (53 KHz) the requirements as regards compression of the frequency swing deviation, selectivity and stability result in conflicting filter parameters. Thus, for an effective compression of the frequency deviation of FM-stereo signals, the bandwidth of the first low-pass filter shoulld amount to 40 to 45 KHz and the open loop gain within this bandwidth must be approximately 12 dB. This results in a passband of the closed loop of 160 to 180 KHz when the first low-pass filter has a first order roll-off of 6 dB/octave. Owing to the first low-pass filter the phase shift within the pass-band of the closed loop is at its maximum at the 160 to 180 KHz limit frequency of this passband. With the given order and loop gain this maximum phase shift amounts to approximately 90°. In order to satisfy the stability requirement the phase shift produced by the IF-filter and the FM-detector within this 160 to 180 KHz passband must be less than approximately 90°. For a 4 th or higher order IF-filter this is only realizable at very large bandwidths. Such very large bandwidths are impermissible for an effective IF-selectivity. Consequently, the prior art FM-receiver is not suitable for receiving and processing FM-stereo signals.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an FM-receiver, which is realizable as an integrated circuit and suitable for processing both FM-mono and FM-stereo signals, and is at least comparable to conventional, non-integrable high grade receivers as regards selectivity, sensitivity and harmonic distortion.
An FM-receiver according to the invention, is characterized in that a first low-pass filter selects the audio-frequency stereo sum signal from a stereophonic FM-multiplex signal, and the loop filter also comprises a bandpass filter circuit arranged in parallel with the first low-pass filter for a selection of the stereo difference signal being amplitude-modulated on a suppressed stereo sub-carrier from a stereophonic FM-multiplex signal. The phase shift of the first low-pass filter and the phase shift of the bandpass filter circuit is, at least within the passband of the frequency-locked loop, not more than approximately 90°.
The invention is based on the recognition that in the processing of FM-stereo signals an adequate compression of the frequency deviation is achieved when only a portion of the audio-frequency stereo sum signal (0-15 KHz) and a portion of the double sideband amplitude-modulated stereo difference signal (23-53 KHz) of the demodulated stereo multiplex signal is adequately amplified and applied to the voltage-controlled oscillator. Consequently, the selection of the stereo multiplex signal in the loop filter need not be of a wideband nature, that is to say be effected over one consecutive frequency range, but may be effected over several, separate frequency ranges of the stereo multiplex signal by means of a like number of parallel filters. This results in the possibility of limiting the passband of the closed loop to a considerable extent, for example to 60 KHz, by using simple filters with a relatively low quality-factor (Q) effecting only a slight phase shift, while maintaining an effective compression of the frequency deviation.
When the invention is used, a phase shift of 90° or more is permissible in the IF-filter and the FM-detector at a much lower frequency (for example 70 KHz) than is possible with the prior art FM-receiver (160 to 180 KHz) without introducing instabilities. As a result thereof the bandwidth of the IF-filter can be chosen to be sufficiently narrow to realize an effective selectivity.
In a preferred embodiment of an FM-receiver the first low-pass filter is a first order filter having a bandwidth of the order of 5 KHz and the band-pass filter circuit is of the second order having a bandwidth of the order of 10 KHz.
In a further preferred embodiment of an FM-receiver in accordance with the invention that the bandpass filter circuit comprises, in succession, a first mixer stage for demodulating the stereo difference signal of a stereophonic FM-multiplex signal, which stereo difference signal is amplitude-modulated on a stereo carrier, a second low-pass filter for selecting the demodulated baseband stereo difference signal, and a second mixer stage for remodulating the baseband stereo difference signal. These two mixer stages are connected to an output of the stereo subcarrier regenerator. The second low-pass filter has or approaches a first order frequency characteristic.
When this technique in accordance with the invention is used, noise components which may cause instability in the closed loop because of their frequency position which generally is asymmetrical relative to the stereo carrier, are reduced by 6 dB, which improves the stability of the receiver. In addition, the availability of the demodulated audio-frequency stereo difference signal enables, in combination with the already available audio-frequency stereo sum signal, a simple decoding of the left and right stereophonic signals.
A still further preferred embodiment of an FM-receiver includes between the output of the stereo subcarrier regenerator and at least one of the two mixer stages a phase shifting circuit for producing a phase shift of the regenerated stereo sub-carrier. The absolute magnitude of this phase shift is at least substantially equal to the phase shift of the received stereo sub-carrier in the IF-filter and the FM-detector.
By using this technique it is possible to compensate for unwanted phase shifts introduced in the IF-filter and/or the FM-detector by an adequate phase adjustment in the phase shifting circuit. This reduces the harmonic distortion, when keeping the dimensioning of the circuits used unchanged or improves the IF-selectivity, at an unchanged distortion rate.
In a further preferred embodiment of such an FM-receiver the stereo sub-carrier regenerator comprises a phase-locked loop, a control input of which is coupled to the connection between the output of the FM-detector and an input of the loop filter.
This measure advantageously uses the stereo pilot signal between the FM-detector and the loop filter, the amplitude thereof being comparatively large, because of the compression of the frequency deviation being smaller for the stereo sum and stereo difference signal than for the stereo pilot signal.
The invention will now be further described by way of example with reference to the Figures shown in the accompanying drawing.
DESCRIPTION OF THE FIGURES
FIG. 1 shows a prior art FM-receiver for processing FM-mono signals;
FIG. 2 shows the frequency characteristic of a fourth-order IF-low-pass filter in said FM-mono receiver;
FIGS. 3a and b show transfer characteristics of the frequency-locked loop;
FIGS. 4a and b show transfer characteristics of the frequency-locked loop after an adaptation of some filter parameters of the prior art FM-receiver for processing the FM-stereo signals;
FIGS. 5a and b show some characteristics which represent the magnitude of three desired and some foldover sideband components of the FM-IF-signal as a function of the modulation frequency for two values of the frequency deviation;
FIG. 6 shows a FM-receiver in accordance with the invention;
FIGS. 7a and b show transfer characteristics of the frequency-locked loop in the FM-receiver of FIG. 6;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a prior art FM-receiver comprising, connected to an aerial A, an aerial-input, to which a frequency-locked loop 2-14 is coupled through an RF-input stage 1. The frequency-locked loop 2-14 comprises, successively connected, a voltage-controlled oscillator 8, a mixer circuit 2 connected to the RF-stage 1, an IF-portion 3 comprising an IF-low-pass filter 9, an amplifier/limiter 10 and an amplifier 11, an FM-quadrature detector 4 comprising a frequency-phase converter 12 and a multiplier circuit 13, a loop filter 5 which comprises a first low-pass filter 14, an amplifier/limiter 6, and an adder circuit 7 connected to a control input of the voltage-controlled oscillator 8. The adder circuit 7 is connected to a tuning voltage input V t to which a tuning voltage can be applied. An output of the amplifier/limiter 6 is connected to an audio output stage 15 and a loudspeaker 6 through a modulation signal output V m .
The operation of this prior art FM-receiver is described in the above-mentioned Netherlands Patent Application No. 7906602, which has been laid open to public inspection. In this prior art receiver the following problems require a solution.
The use of a low intermediate frequency (for example 80 KHz) require a compression of the frequency deviation of the received signal. This is illustrated by the curves I 1 -I 3 and I 1c -I 3c , in FIG. 5a and FIG. 5b, respectively. These curves show the amplitude of the standardized, 1 st to 3 rd order Bessel-function for an average intermediate frequency IF of 80 KHz as a function of modulation frequencies (f mod ) varying between 10 and 50 KHz at a frequency deviation Δf of 15 KHz (weak deviation compression) and of 3 KHz (strong deviation compression), respectively. The fold-over of particularly the higher order Bessel-function at high modulation frequencies is considerably reduced by compression. An adequate frequency-deviation compression is achieved by applying the modulation signal from the output of the FM-quadrature detector 4 after amplification to the voltage-controlled oscillator 8.
For a modulation signal having a bandwidth of the order of the bandwidth of an FM-mono-signal (15 KHz), this is realized when the transfer characteristic of the open and closed loop, respectively corresponds to the curves shown in FIG. 3b by means of curve f 1 and f 2 , respectively. These curves are predominantly determined by the low-pass filter 14 of the loop filter 5, which is of the first order and has a band-width of approximately 5 KHz. As a result thereof, the frequency deviation compression is at its maximum (12 dB open loop gain of the modulation signal) for modulation frequencies up to 5 KHz, while the frequency deviation compression for modulation frequencies from 5-15 KHz decreases by a 6 dB/octave first order roll-off.
As a result thereof the 3 dB passband of the closed loop is 20 KHz and comprises the whole modulation signal. The maximum phase shift produced by the above-mentioned first low-pass filter within said passband for which the phase shift at the 20 KHz limit or edge frequency (f k ) is decisive, is approximately 90°. Consequently, the phase shift in the IF-filter and the FM-detector being permissible for stability at the 20 KHz 3 dB edge frequency (f k ) may not exceed 90°. This can be realized by means of a 4 th order IF-lowpass filter 9 whose transfer characteristic translated to the basic frequency domain is illustrated in FIG. 3a by curve f 3 . The translated 3 dB edge frequency thereof is located at 50 KHz.
The transfer characteristic of this IF-low-pass filter in the real frequency domain is illustrated in FIG. 2 by curve f 4 . The real 3 dB edge frequency is approximately 100 KHz, while over a frequency spacing of approximately 160 KHz relative to the selected intermediate frequency IF=70 KHz the attenuation increases to 30 dB. From this it can be seen that with such an IF-low-pass filter a satisfactory IF-selectivity is obtainable.
For further information about the translation of filter characteristics from one domain into another reference is made to the dissertation "Analysis of the FM-receiver with frequency feedback", by F. G. M. Bax, published on Oct. 23, 1970 at Eindhoven.
For an adequate frequency deviation compression of modulation signals having a bandwidth of the order of extent of a stereo multiplex signal (53 KHz) the open loop pass band must be, as mentioned already in the foregoing, 40 to 45 KHz and the open loop gain approximately 12 dB. This results, after adaptation of the filter parameter, in transfer characteristics as shown for the first low-pass filter in FIG. 4b by f 5 (open loop) and f 6 (closed loop) and for the IF-lowpass filter in FIG. 4a by curve f 7 .
Because of the stability requirement, the translated 3 dB edge frequency now amounts to 200 KHz, which, in the real frequency domain, corresponds to 3 dB edge frequency of some hundreds of KHz. For reasons of selectivity such a wide-band IF-filter is impermissible.
FIG. 6 shows an FM-receiver in accordance with the invention, in which the circuits corresponding to circuits of the prior art FM-receiver of FIG. 1 have been given the same reference numerals.
The FM-receiver in accordance with the invention differs from the prior art FM-receiver predominantly in the construction of the loop filter 5. In the embodiment shown the loop filter 5 comprises a band-pass filter 17-19 arranged in parallel with the first-order low-pass filter 14. The band-pass filter circuit 17-19 comprises, successively connected to the FM-quadrature detector 4, a first mixer stage 17, a second, first order low-pass filter 18 and a second mixer stage 19. A 38 KHz stereo sub-carrier is applied from a stereo sub-carrier regenerator 21 to the two mixer stages 17 and 19, a phase shifting circuit 50 being arranged between the stereo sub-carrier regenerator 21 and the first mixer stage.
As a result thereof, the stereo-difference signal of the stero multiplex signal at the output of the FM-quadrature detector 4, which stereo-difference signal is double-sideband amplitude-modulated on a suppressed 38 KHz stereo sub-carrier is demodulated in the first mixer stage 17 to the baseband, selected in the second, first order low-pass filter 18 and remodulated in the second mixer stage 19 on a suppressed 38 KHz stereo sub-carrier. As a result thereof, the bandpass filter circuit 17-19 operates as a second order band-pass filter having a central frequency of 38 KHz and a bandwidth and (first order) frequency characteristic determined by the low-pass filter 18. In a practical embodiment this bandwidth may optionally be chosen equal to the bandwidth of the first low-pass filter 14, that is to say equal to approximately 5 KHz. The stereo multiplex signal thus selected in the bandpass filter circuit 17-19 is adjusted to an amplitude level as indicated in FIG. 7b by curve f 8 and, after having been applied to the voltage-controlled oscillator 8, causes compression of the frequency deviation of the received FM-aerial signal. This compression is at a maximum in the frequency range up to approximately 5 KHz (12 dB open loop gain for both the stereo sum signal and the stereo difference signal) and decreases with a first order slope, that is to say 6 dB/octave for the frequency range from 5 to 15 KHz.
The transfer characteristic of the closed loop is illustrated in FIG. 7 by curve f 9 . As a result of the chosen filter parameters of the bandpass filter circuit 17-19 (central frequency 38 KHz; first order roll-off after 5 KHz), the pass-band of the closed loop is approximately 58 KHz. This passband comprises the whole stereo multiplex signal and is significantly smaller than the passband of the closed loop which is obtained after adaptation of the filter parameters of the prior art FM-receiver, as illustrated in FIG. 4 by the curve f 6 . As a result of the function of the band-pass filter circuit 17-19 the phase shift at the 58 KHz 3 dB edge frequency f k is approximately 90°. Because of this, a phase shift ocurring in the IF-filter and the FM-detector is permissible, which, without introducing instabilities, reaches the value of 90° already at a much lower frequency (for example 60 KHz) than with the prior art FM-receiver. The transfer characteristic of a suitable 4 th -order IF-low-pass filter, which characteristic is translated to the base-band domain, may therefore vary as illustrated in FIG. 7a by curve f 10 . An effective IF-selectivity is obtained by means of such an IF-bandpass filter.
The realization of the bandpass filter circuit 17-19 with the aid of the first and second mixer stages 17 and 19 as shown also offers the possibility to compensate for the errors which are introduced at the demodulation and remodulation of the stereo difference signal annd which are produced by signal delays which may occur in the IF-filter and the FM-detector. Such errors may result in instabilities. To compensate for these errors in the embodiment as shown, the phase shift of the regenerated 38 KHz stereo sub-carrier in the phase shifting circuit 50 is chosen to be equal but opposite to the phase shift of the suppressed 38 KHz stereo sub-carrier of the IF-filter 3 and the FM-detector 4. As a result thereof the regenerated 38 KHz stereo sub-carrier, which is applied to the input of the second mixer stage 19, has the same phase as the received 38 KHz stereo sub-carrier at the input of the mixer circuit.
In an embodiment, not shown, wherein the regenerated 38 KHz stereo sub-carrier at the output of the stereo sub-carrier regenerator 21 has the same phase as the received 38 KHz stereo sub-carrier at the input of the mixer circuit, the phase shifting circuit 50 must be arranged between the output of the stereo sub-carrier regenerator 21 and the input of the first mixer stage 17 to obtain the same compensation as above. In that case the phase shift of the phase shifting circuit 50 must be equal to the phase shift of the 38 KHz stereo sub-carrier which occurs in the IF-filter and the FM-detector.
For a person skilled in the art such phase shifting circuits are simple to realize, for example by means of a delay network, and a further description is therefore not necessary. In practice it has been found that the phase shift of the 38 KHz stereo sub-carrier in the IF-portion and the FM-detector is approximately 90°, so that the phase shifting circuit 50 should preferably effect a -90° phase shift of the regenerated 38 KHz stereo sub-carrier in the embodiment shown and a 90° phase shift in the last-mentioned embodiment, not shown.
The regeneration of the (38 KHz) stereo sub-carrier for the demodulation and remodulation of the stereo difference signal in the band-pass filter circuit 17-19 is effected in the stereo sub-carrier regenerator 21, which comprises a phase locked-loop (PLL) 22-25. Therein the 19 KHz stereo pilot of the stereo multiplex signal at the output of the FM-quadrature detector 4 is multiplied in known manner in a mixer stage 22 by the output signal of an 38 KHz voltage-controlled oscillator 24, the frequency of which output signal is halved by a frequency divide-by-two divider 25. The output signal of the mixer stage 22 is applied as a phase control signal through a low-pass filter 23 to the voltage-controlled oscillator 24. As a result thereof, the 38 KHz oscillator signal is phase-coupled to the received 19 KHz stereo pilot and is applied as a mixing signal to the first and second mixer stages 17 and 19 of the band-pass filter circuit 17-19.
The 38 KHz oscillator signal whose frequency is halved in the frequency divide-by-two divider 25 is applied in the FM-receiver in accordance with the invention to a mixer stage 26 of a stereo pilot detector 26, 27. The received 19 KHz stereo pilot is also applied to the mixer stage 26. The output signal of the mixer stage 26 is filtered in a low-pass filter 27 and provides an indication about the presence of the stereo pilot in the received FM-signal. The stereo indication signal thus obtained is thereafter applied through a bistable multivibrator 28 to a stereo indicator 29 for an optical stereo indication.
The stereo indication signal is also applied as a mono/stereo switching signal to a control input of a switch 30, through which the demodulated baseband stereo difference signal is applied, in the case of stereo reception, from the output of the second low-pass filter 18 of the bandpass filter circuit 17-19 to a variable-gain amplifier 31. By means of selection in a filter and tuning circuit 34, the baseband stereo sum signal is filtered from the output of the loop rectifier 6 from the fedback stereo multiplex signal and applied to a matrix circuit 32, 33 through an amplifier 35. Also the baseband stereo difference signal of the variable gain amplifier 31 is applied to the matrix circuit 32, 33. In the matrix circuit 32, 33 the left and right stereophonic signal, respectively decoded by addition and subtraction, respectively, the signal being reproduced through the respective amplifier 15, 15' in loudspeakers L and R.
The variable-gain amplifier 31 controls by means of a stereo control signal the amplitude of the baseband stereo difference signal applied to the matrix circuit 32, 33. As a result thereof the stereophonic effect of the reproduction is controllable, for example in dependence on the signal-to-noise ratio of the received FM-stereo signal. In the case of a stereo difference signal amplitude which increases from zero the stereophonic effect can increase from a mono reproduction (L-R=0) via stereo reproduction (L-R and L+R have equal amplitudes) to a so-called "enhanced" stereo reproduction, wherein the spacing between the left and right sound sources seems larger than in normal stereo reproduction.
It will be obvious that the invention is not limited to the embodiment shown. It is very well possible, while maintaining the advantage of the invention, to omit the phase shifting circuit 50, to replace the bandpass filter circuit 17-19 by a simple and optionally passive bandpass filter, and to change the bandwidth of the pass-band region of the open loop and/or the open loop gain. The invention is also not limited to the use of a low-pass filter as the IF-filter or an FM-quadrature detector as the FM-detector. Those skilled in the art will recognize yet other embodiments defined by the claims which follow.
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FM-receiver including a frequency-locked loop (2-14), which loop includes, successively connected, a voltage controlled oscillator (8), a mixer circuit (2) connected to an aerial input, an IF-portion comprising an IF-filter (9), an FM-detector (4), a loop filter (5) and a loop amplifier (6) for adjusting the transfer characteristic of the frequency locked loop (2-14), which loop amplifier (6) is connected to a control input of the voltage-controlled oscillator (8) for a feedback of the modulation signal of the received FM-signal. The loop filter (5) comprises a first low-pass filter (14). The FM-receiver being realizable in integrated circuit form and suitable for processing FM-stereo signals. The receiver is at least comparable to conventional FM-stereo receivers as regards selectivity, harmonic distortion and stability, the conventional FM-stereo receivers not being realizable in integrated circuit form. The stereo sum and the stereo difference signal are selectively and separately fedback by two simple, comparatively less selective parallel-arranged filter circuits (14; 18).
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FIELD OF THE INVENTION
The present invention relates to a roll for a paper/board machine or for a paper/board finishing device and a method for fastening an inner tube in the interior of a roll of a paper/board machine or a paper/board finishing device.
BACKGROUND OF THE INVENTION
Polymer-coated rolls arranged in calenders require cooling so that they will operate optimally. By means of such cooling, attempts are made to keep the end and lateral areas of the roll at a uniform temperature so that the effect of crown formation by the effect of heat is minimized.
For cooling, a so-called displacement tube technique has been applied.
The principle of the displacement tube technique is briefly as follows: water at the required temperature is passed to the end of the roll by means of a water coupling, water circulates in the interior of the roll along a space between an inner tube and an outer tube to the opposite end of the roll, and at the opposite end of the roll there is a water coupling through which the water is passed out of the roll. The space between the inner tube and the outer tube in the roll is usually quite small. In this manner, even though the amounts of water are quite small, attempts are made to keep the flow sufficiently large in order to meet the requirement of a uniform temperature in the end and lateral areas of the roll.
It has been laborious and difficult to fit the inner tube and the outer tube one inside the other. First, it has been necessary to measure and to manufacture the inner tube separately for each roll because the diameters of the outer tube vary from roll to roll. Then, in the installation stage, it has been necessary to cool the inner tube with nitrogen in order to fit the tube into the interior of the outer tube. Thus, manufacturing rolls with inner tubes has been typically a time-consuming and technically and economically unfavorable procedure.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention is to provide a solution for installing an inner tube in a roll by whose means the difficulties related to the prior art methods are overcome.
It is another object of the present invention to provide new and improved rolls for a paper/board machine or for a paper/board finishing device.
It is another object of the present invention to provide new and improved methods for fastening an inner tube in an interior of a roll, especially for use in a paper/board machine or paper/board finishing device.
It is yet another object of the present invention to provide an inner tube for a roll which is able to be arranged in the inside of rolls having different diameters so that the inner tube does not have to be roll-specific.
In order to attain these objects and others, in a roll in accordance with the present invention, the inner tube, by whose means the water is forced to flow along the inner face of the mantle of the roll body, is fastened to the body mantle by fastening pistons which are installed on the inner tube with a necessary spacing in the longitudinal direction whereby three pistons are arranged in the direction of the circumference. Of the pistons in the direction of the circumference, two are fixedly installed at a proper height in connection with the installation, and one is freely moving and spring-loaded. The spring-loaded piston is constructed so that, by means of hydraulics, the piston is pressed down for the time of installation of the inner tube. The pipe systems required by the hydraulics are passed along the outer face of the inner tube, preferably to the tending-side end of the roll. The pressure required by the hydraulics is produced by means of a normal hydraulic pump (the same pump by whose means the bearing is removed/fixed). After the inner tube has been installed in the correct position, the hydraulic pressure is released, and the disk springs of the spring-loaded piston press the piston against the body mantle. By means of the fixed and the spring-loaded pistons, the inner tube is kept in its position, and vibration and bending of the inner tube are prevented. The fastening at the ends is arranged either so that separate rings attached to the flange shafts by means of hexagonal socket-head bolts, on which rings the inner tube is installed with glide fitting, or, in new projects, so that alterations are made to the cast models of the flange shaft, and the end fastening face is provided directly on the flange shaft. In this manner, separate rings are not needed.
Thus, one general embodiment of a roll for a paper/board machine or finishing device comprises a roll mantle defining an interior and having an inner face, an inner tube arranged in the interior of the roll mantle and having an outer face arranged at a distance from the inner face of the roll mantle, and a plurality of fastening elements (or simply fastenings) for securing the inner tube to the roll mantle. At least one fixed fastening is positioned radially in a certain predetermined position (fixed in that it includes a piston which is not movable during the installation procedure) and a displaceable fastening is arranged to be displaceable in a radial direction of the inner tube (displaceable in that it includes a component which is movable during the installation procedure). The inner tube may comprise apertures at first and second ends and the roll further comprises first and second shafts arranged at first and second ends of the roll mantle. Each shaft includes a flow passage communicating with a space between the inner face of the roll mantle and the outer face of the inner tube via the apertures in the inner tube.
The displaceable fastening comprises a spindle part having a head part and biasing means, e.g., a spring unit of one or more springs, for urging the head part against the inner face of the roll mantle. It may also comprise an interior space receivable of pressure fluid defined adjacent the spindle part. The biasing means are thus arranged such that upon removal of pressure fluid from the interior space (which occurs after the inner tube is installed in the interior of the roll), the head part is urged against the inner face of the roll mantle. The displaceable fastening may also comprise a piston part, whereby the interior space is defined between the piston part and the spindle part, and a sleeve defining a first interior space and a second interior space having a diameter smaller than a diameter of the first interior space and having an edge portion in the vicinity of an inlet opening of the first interior space. The sleeve defines an inside shoulder between the first and second interior spaces. The spindle part may include a rod connected to the head part and surrounded by the spring(s) of the spring unit. An intermediate disk may be arranged on the shoulder and a cotter ring may be provided to lock the disk against the shoulder. The disk includes a central opening through which the rod of the spindle part passes. The piston part includes an inner bore having threading and the rod includes a threading in engagement with the threading of the piston part. Further, the fastening may include an end disk arranged at an end of the inner bore of the piston part, and a cotter coupled to the piston part for preventing rotation of the piston part. The cotter is guided in a hole in the sleeve of the fastening. In some embodiments, the sleeve includes a duct for allowing passage of pressure fluid into and from the interior space in the fastening.
There are preferably two fixed fastenings. Each fixed fastening comprises a sleeve and a screw arranged in the sleeve and having an outer face adapted to be pressed against the inner face of the roll mantle. The screw is rotatable relative to the sleeve to provide adjustable extension of the screw from the sleeve, which rotation is effected prior to installation or insertion of the inner tube into the interior of the roll mantle. The screw is then locked in its position and then the inner tube is inserted into the interior of the roll. In some embodiments, the screw has a spindle part having a threaded outer surface and a backup part wider than the spindle part. The interior of the sleeve defines a wide recess and an end bore having a threading. The spindle part of the screw threadingly engages with the threading of the end bore of the sleeve. The backup part includes a curved outer face adapted to be pressed against the inner face of the roll mantle upon rotation of the screw relative to the sleeve.
In the method for fastening an inner tube into an interior of a roll for a paper/board machine or finishing device, at least one first fastening is arranged in the inner tube at a location along an axis of the inner tube, each first fastening having an extension projectable above the outer face of the inner tube and designed to be fixed in position during installation of the inner tube into the interior of the roll. A second fastening is arranged in the inner tube at the same axial location as the first fastening(s), the second fastening having a displaceable spindle part movable between first and second position whereby the spindle part projects further above the outer face of the inner tube in the second position (although in the first position, the spindle part does not necessarily have to project above the outer face of the inner tube). The position of the extension of each first fastening is adjusted and preferably fixed at a desired radial projecting position prior to installation of the inner tube in the interior of the roll. The inner tube is then inserted into the mantle of the roll while maintaining the spindle part of the second fastening in the first position. The spindle part of the second fastening is then displaced into the second position and urged against the inner face of the mantle, e.g., by the decompression of springs in a spring unit.
The spindle part of the second fastening may be maintained in the first position by coupling a pipe to the second fastening, extending the pipe to one of the ends of the inner tube and directing a medium through the pipe to cause displacement of the spindle part of the second fastening to the first position such that control of the displacement of the spindle part of the second fastening is effected from the end of the inner tube. Similarly, the spindle part of the second fastening may be maintained in the first position and caused to be displaced into the second position by coupling a pipe to the second fastening, arranging a piston part and a stationary disk in the second fastening, arranging at least one spring between a head part of the spindle part and the disk, and controlling the flow of pressure fluid through the pipe into and from a space between the disk and the piston part. When the pressure fluid flows into the space, the spindle part is moved to the first position and the at least one spring is compressed, and when the pressure fluid flows from the space, the spindle part is moved to the second position upon decompression of the at least one spring.
In the following, the invention will be described in detail with reference to some exemplifying embodiments of the invention illustrated in the figures in the accompanying drawing. However, the invention is by no means strictly confined to the details of the illustrated embodiments alone.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings are illustrative of embodiments of the invention and are not meant to limit the scope of the invention as encompassed by the claims.
FIG. 1 is a longitudinal sectional view of a roll in accordance with the invention.
FIG. 2 is a sectional view taken along the line I—I in FIG. 1 .
FIG. 3A is a sectional view of one of the two fastenings in the arrangement of three-point fastening.
FIG. 3B shows the third fastening in the arrangement of three-point fastening, which third fastening comprises a hydraulic/spring-operated spindle.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the accompanying drawings wherein the same reference numerals refer to the same or similar elements, FIG. 1 is a longitudinal sectional view of a roll 10 in accordance with the invention. The fastening between the roll 10 and an inner tube 11 installed in the interior of the roll 10 is accomplished in accordance with the invention by means of piston elements, fastening elements or fastenings 13 a 1 , 13 a 2 and 13 a 3 placed in certain fastening planes, each at a respective location in the axial direction of the inner tube 11 . The fastenings 13 a are arranged preferably at the ends and in the middle of the roll so that each fastening arrangement in a plane at a point of the length of the roll 10 comprises a three-point fastening arrangement. The fastenings 13 a 1 , 13 a 2 and 13 a 3 are arranged at a uniform angular spacing, i.e., at an angular spacing of 120°, in relation to one another on the inner tube 11 that has been installed inside the roll 10 . The fastenings 13 a 1 , 13 a 2 and 13 a 3 in each fastening plane T 1 , T 2 and T 3 fasten the inner tube 11 in the interior space O in the roll mantle 10 a of roll 10 against the inner face 10 a 1 of the roll mantle 10 a , i.e., secure the inner tube 11 to the roll mantle 10 a . The inner tube 11 comprises a closed inner space O 2 and closing plates E 1 and E 2 passing across the tube 11 and placed in the vicinity of the ends of the tube 11 (but not at the end of the tube 11 so that a portion of the roll mantle 10 a remains outside of inner space O 2 ). At the ends of the tube 11 , spaces O 3 and O 4 are thus formed on the other side of plates E 1 and E 2 and the roll mantle 10 a includes flow passages such that water or any other heat transfer medium, preferably a cooling medium, can be passed from space O 3 along the roll mantle 10 a and then into space O 4 . More particularly, the heat transfer medium can be passed in the axial direction of roll 10 through a flow passage J 1 in the center of a shaft 10 b 1 , and shaft flange 10 c into the space O 3 , from space O 3 through the flow passages N 1 formed at one end of the inner tube 11 into the space O 1 between the outer mantle face 11 a of the tube 11 and the inner mantle face 10 a 1 of the roll 10 and then through the tubular space O 1 in an axial direction of the roll 10 (arrows L 1 ). The heat transfer medium is able to flow from space O 1 through the flow passages N 2 formed at the other end of the tube 11 into the space O 4 . From space O 4 , the medium may be passed through a central flow passage J 2 in the center of the shaft flange 10 c and shaft 10 b 2 of the roll 10 . The flow can also take place in the opposite direction, in which case the heat transfer medium, such as water, is initially passed into the other end of the roll 10 through the central flow passage J 2 in the shaft 10 b 2 .
In FIG. 1, the flow of water in connection with the roll 10 and with its inner tube 11 is indicated by the arrows L 1 .
The roll 10 comprises shafts 10 b 1 , 10 b 2 which are attached to the roll mantle 10 a from their shaft flanges 10 c by means of screws R,R 1 . An end ring 10 d is attached to the flange 10 c by means of screws R 2 , and the end of the tube 11 is fitted around the end ring 10 d . The arrangements are similar at each end of the roll 10 .
FIG. 2 is a sectional view taken along the line I—I in FIG. 1 . As shown in FIG. 2, the fastenings 13 a 1 , 13 a 2 and 13 a 3 are arranged in the fastening plane T 1 so that they are coupled (engaged) both with the inner tube 11 and with the inner face 10 a 1 of the roll mantle 10 a of the roll 10 . There is an angle of about 120° between each of the fastenings 13 a 1 , 13 a 2 and 13 a 3 , i.e., thus, the fastening are situated with uniform angular spacing on the circumference of the inner tube 11 . As shown in FIG. 2, the two fastenings 13 a 1 and 13 a 2 are identical, and the construction of the third fastening 13 a 3 differs from the fastenings 13 a 1 and 13 a 2 .
FIG. 3A illustrates the construction of the fastening 13 a 1 , which is also the construction of fastening 13 a 2 , and is referred to herein as a fixed fastening. The fastening 13 a 1 comprises a sleeve 14 having an interior space D in which a screw 15 is mounted. The interior space D comprises a wider recess D 1 and an end bore D 2 (having a diameter smaller than the diameter of the wider recess D 1 ) and an inner threading N 1 on the end bore D 2 . The screw 15 is brought into engagement with inner threading N 1 by means of an outer threading N 2 of an extension or spindle part 15 a of the screw 15 . In addition to the spindle part 15 a , the screw 15 also comprises a wider backup or head part 15 b having a curved outer face 15 b 1 . On the face of the backup part 15 b , there is a groove U into which a seal ring U 1 has been fitted. The sleeve 14 comprises an edge widening 14 a at the mouth of the space D. When the inner tube 11 is arranged in the space O inside the roll 10 , the fastenings 13 a 1 , 13 a 2 on the inner tube 11 are placed in a certain position by rotating the screw 15 into a certain position in relation to the sleeve 14 so that a suitable degree of projection over the outer face 11 a 1 of the inner tube 11 is obtained for the head part 15 b of the screw 15 from the space D 1 in the sleeve 14 . It is only after this is done that the tube 11 is locked in the interior of the roll 10 by using the third fastening 13 a 3 for the locking so that when the third fastening 13 a 3 is released from the pressure of hydraulic fluid, it presses the head of a released spindle against the inner face 10 a 1 of the roll 10 by means of the spring force of its springs (discussed below with reference to FIG. 3 B).
FIG. 3B illustrates the construction of the third fastening 13 a 3 . It is a so-called freely displaceable fastening in which the spindle part 16 of the fastening can be displaced by means of the pressure of a medium in the radial direction via remote control, i.e., from a location other than that at which the fastening 13 a 3 is situated. The fastening 13 a 3 comprises a sleeve 14 and an edge portion 14 a in the vicinity of the inlet opening of its interior space D 1 . Thus, the sleeve 14 comprises an interior first space D 1 and, at its end, a second interior space D 2 having a smaller diameter than first space D 1 and between which spaces, an inside shoulder i remains. The spindle part 16 comprises a rod 16 a and a head part 16 b which is connected with the rod 16 a and operates as a backup part and is coupled with the inner face 10 a 1 of the roll mantle 10 a of the roll 10 . An intermediate or backup disk 17 is situated on the shoulder i and is locked by means of a cotter ring 18 so that it is stationary. The intermediate disk 17 comprises a central opening B through which the rod 16 a of the spindle part 16 is passed freely. A seal 20 a is arranged in the opening B in the intermediate disk 17 between the intermediate disk 17 and the rod 16 a of the spindle part 16 . A seal 20 b is placed between the intermediate disk 17 and the inner face of the sleeve 14 .
The head part 16 b of the spindle part 16 is provided with a groove U, in which there is a seal ring U 1 . The rod 16 a of the spindle part 16 is provided with a threading N 2 at its end, which threading N 2 is brought into engagement with the threading N 3 on an inner, central bore 21 a in a piston part 21 . The end of the central bore 21 a in the piston part is provided with an end disk 21 b . A cotter 22 which prevents rotation is arranged in engagement with the piston part 21 and to be guided freely in an end hole T in a portion of the space D 2 . The pressure fluid can be passed through a pipe 40 (see FIG. 1) into and from duct 41 in the sleeve 14 and further into and from the space D 2 between the piston part 21 and the intermediate disk 17 . In this manner, when the pressure fluid is passed into the space D 2 , a force acts upon the piston part 21 of the spindle part 16 and the spindle part 16 is pressed and moved in the direction S 1 against the spring force of the spring disks 22 a 1 , 22 a 2 in the spring unit 22 . In this manner, the fastening 13 a 3 can also be installed freely into the interior of the roll 10 since it will not engage the inner surface of the roll mantle 10 a . Once the inner tube 11 is in its desired position, the effect of the pressurized fluid is discharged from the space D 2 and the springs 22 a 1 , 22 a 2 , . . . in the spring unit 22 press with a force between the backup disk 17 and the head part 16 b of the spindle part 16 so that the spindle part 16 and its head part 16 b are displaced in the direction S 2 . As such, the curved backup face 16 b 1 of the head part 16 b is urged against the inner face 10 a , of the roll mantle 10 a 1 of the roll 10 .
When the inner tube 11 is installed into the interior O of the roll 10 , first the fastenings 13 a 1 , 13 a 2 provided on the tube 11 in each fastening plane T 1 , T 2 , . . . are installed so that their screws 15 have been rotated and locked, for example, by means of a locking glue in the threading of the sleeve 14 in a certain position. Thereafter, when the tube 11 is in a precise position in the space O in the interior of the roll mantle 10 a , the fastening 13 a 3 is made free from the pressure of the hydraulic fluid (i.e., the hydraulic fluid is removed from interior space D 2 ), and the springs in the spring unit 22 of the fastening 13 a 1 are thereby allowed to act with a force so that the head part 16 b of the spindle part 16 of the fastening 13 a 3 is pressed by the spring force of the springs 22 a 1 , 22 a 2 , . . . against the inner mantle face 10 a 1 of the roll mantle 10 a of the roll 10 .
A pipe/hose 40 (FIG. 1) can be connected to the fluid duct 41 of the fastening 13 a 3 . Pipe/hose 40 can be passed from the end of the inner tube 11 on the outer face of the inner tube 11 to the fastening 13 a 3 . In this manner, the operation of the fastening 13 a 3 can be remote-controlled from the end of the roll 10 and the inner tube 11 . The pressure fluid is passed from an actuator, for example from an actuator of a reversing cylinder, to the pipe 40 and further to the fastening 13 a 3 .
By means of the present invention, the arrangement of the tubes one inside the other becomes clearly easier, as compared with prior art procedures. The mode of fastening also permits a larger play in respect of the measures of the outer and the inner tubes. Thus, inner tubes with equal diameter can be arranged in outer tubes with different diameters. Roll-specific tailoring is no longer needed, but inner tubes of standard diameter can be used. In this way, quicker installation and shorter delivery terms can be achieved.
The examples provided above are not meant to be, exclusive. Many other variations of the present invention would be obvious to those skilled in the art, and are contemplated to be within the scope of the appended claims.
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Roll for a paper/board machine or finishing device having an interior in which an inner tube is installed and a method for fastening the inner tube in the roll interior. The inner tube is arranged so that its outer face is spaced from the inner face of the mantle of the roll whereby a heat transfer medium can be passed into the interior of the roll and through this space in an axial direction of the roll. The inner tube includes fastenings arranged at one or more axial locations. At each axial location, at least one fastening can be positioned radially in a certain predetermined position and another fastening can be displaced freely in the radial direction.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This non-provisional application claims the benefit of U.S. Provisional Patent Application No. 60/891,900, entitled “Control Module,” filed on Feb. 27, 2007, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Many outdoor utility vehicles include electrical or electronic control systems that disable operation of the vehicle's engine, ignition system, or power takeoff when certain operating conditions are not met. For example, the control system may prevent operation of the ignition circuit if the presence of an operator is not detected by a sensor, such as, for example a seat switch. Because outdoor utility vehicles are subject to relatively extreme environmental conditions, including moisture, control circuits are protected against the elements by such measures as sealed housings.
SUMMARY
[0003] The disclosed control systems and methods for an electrical device include features that protect against operation of the electrical device based on false data produced by malfunctioning components. The control system , in one embodiment may include a controller that controls operation of an electrical device based on the present state of one or more sensors. In a more specific embodiment, the controller generates an AC device enable signal when the outputs of each of the sensors indicates that operation of the device is appropriate. The control system prevents operation of the device in the absence of the AC device enable signal. The control system may alternatively or additionally provide a sensor integrity check component that polls a present state of the one or more sensors. The sensor integrity check component outputs a validation signal when the sensor exhibits an acceptable sensor state. The control system prevents operation of the device in the absence of the validation signal. The control system may alternatively or additionally monitor a current draw of the electrical device and disable operation of the device when the current draw exceeds predetermined current amounts for predetermined durations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a functional block diagram of a control system constructed in accordance with an embodiment of the present invention;
[0005] FIG. 2 is a functional block diagram of a control system constructed in accordance with an embodiment of the present invention; and
[0006] FIGS. 3-6 are electrical schematics, that illustrate in their entirety an exemplary circuit constructed to implement a control system in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0007] FIG. 1 illustrates a prior art simple tractor control system 10 . The control system includes a controller 14 that may be implemented in many different ways, including but not limited to a microprocessor, discrete components including analog or digital hardwired control circuits, or any other appropriate components and circuits. The controller 14 monitors the outputs of various sensors 12 that are located on the tractor. These sensors may include, for example, a seat switch that closes when an operator is present in the seat, a power brake switch that closes when the parking brake is engaged, a start switch that is closed when the key is turned to the start position, and a power takeoff (“PTO”) switch that is closed when the operator calls for operation of the PTO. When a present state of these sensors indicates that the tractor is in a proper condition for operation of one or more various electrical devices (not shown) on the tractor the controller 14 produces DC enable signals 16 that enable operation of each of those devices. The DC enable signals may, for example, trigger a relay to connect power to a given device. For example, the electrical devices that are enabled by the enable signals 16 may include a starter solenoid, a power takeoff (PTO), and a deck lift mechanism. The enable signals are input to power control circuits 18 to enable to flow of device power 19 , which may be supplied by a tractor battery (not shown), to the enabled device.
[0008] The sensors 12 may be implemented as, for example, two position switches that present an open or closed state or two distinct output states. Due to the harsh environment in which they are used, the sensors 12 are susceptible to malfunction caused by contamination. For example, water may short or lower the impedance between the terminals of the switch and produce a false closed signal. Alternatively, foreign matter may interfere with a closed switch to produce a false open signal. Contamination may also produce faulty enable signals, which as noted above, are generally DC signals. The contamination in the control system may produce a DC signal that mimics an enable signal. In order to protect against faulty signals, many control systems are located in sealed modules and sensors are sealed against moisture and foreign material entry. As will be seen with reference to FIGS. 2-6 , the control system described herein includes various measures that are taken within the control system to protect against faulty signals caused by contamination of the system by moisture and foreign material. While the control system described herein is within the context of a tractor control system, it will be apparent to one of skill in the art that the control system described herein could also be advantageous when used in any control environment in which it is desirable to protect against enabling operation of a device in response to a faulty signal that is generated by a control system component malfunction.
[0009] Referring now to FIG. 2 , a function block diagram depicts a control system 20 . The control system 20 functions in a similar manner to the control system 10 but includes features that are directed to discerning between signals that are generated by false signals caused by contamination and signals that are properly generated by the controller and/or sensors. To check the signals from sensors, the control system 20 includes a signal integrity check 40 that pulls current from a normally open sensor or pushes current through a normally closed sensor to verify that signal from the sensor 45 results from the closing or opening of a sensor and not a signal caused by contamination. The controller 60 receives validation signals 47 (corresponding to normally open sensors) and 147 (corresponding to normally closed sensors) from the signal integrity check 40 . Based on the validation signals 47 , 147 , the controller 60 outputs DC and AC enable signals 62 and 66 .
[0010] The signal integrity check 40 may be controlled by the controller 60 to poll and validate the various sensors 45 and pass the status of the various sensors by way of a validation signal 47 , 147 to the controller. To this end, the controller 60 sends a sequence of sets of selection signals 49 to a decoder 65 . In response, the decoder 65 outputs an enable single on one sample enable line 41 from the decoder. Each sample enable line 41 selects a sensor 45 to be connected by a connection 46 to the integrity circuit 43 . The integrity circuit 43 verifies that the output of the sensor 45 is the result of a proper operational state, for example an open or closed switch position. The integrity circuit outputs a validation signal 47 , 147 that indicates that the sensor state is proper and the validation signal is passed back to the controller 60 . The controller matches the validation signal 47 , 147 to the selection signals 49 to determine which sensor's signal was polled by the integrity check 40 . While the integrity check 40 is shown as part of an overall control system 20 , it will be understood that the integrity check 40 may be used alone or in combination with the other features described herein.
[0011] To protect against false enable signals, the controller 60 outputs two AC enable signals 66 (only one shown in FIG. 2 ) that enable passage of electrical power 67 to two selected electrical devices, such as, for example, the starter solenoid and PTO clutch (not shown). The AC enable signals 66 are readily distinguishable from a signal caused by contamination, which would likely be DC. If an AC enable signal 66 is not present, the control system prevents power from passing to the starter solenoid or PTO clutch. In the described embodiment, the controller 60 also outputs DC control signals 62 to other tractor devices such as the fuel pump or deck lift mechanism. It will be apparent to one of skill in the art that any number of the enable signals generated by the controller may be AC.
[0012] The controller 60 outputs the DC control signals 62 and AC enable signals 66 based on the validation signal 47 , 147 from the signal integrity check 40 . Each AC enable signal 66 is detected by an enable signal check 70 that, functionally speaking, allows passage of electrical power 67 to the electrical device from a vehicle power source, generally indicated as 64 , when the AC enable signal is present. The enable signal check 70 may condition the AC signal to allow it to be better processed by other components in the control system. For example, as will be described below, the AC enable may be transformed into a pulse train prior to use of the enable signal to enable power being passed to the device. The controller 60 operates according to an algorithm that specifies which combinations of past and present sensor states should result in the output of the AC enable signal. Of course, the controller may be implemented as a hard wired control circuit or any other appropriate means. The use of AC enable signals is shown in conjunction with many different features, however, it will be apparent to one of skill in the art that an AC control signal may be used alone or in connection with any number of features.
[0013] FIG. 2 also functionally illustrates circuit protection measures taken to limit the heating effects of high current draw during operation. These protective measures facilitate implementation of the control system using solid state components. A surge protector 87 prevents the flow of current in the event of high current draw, such as, for example, a starter solenoid current draw of over 20 A for longer than a relatively short period of time. The controller 60 monitors device power sources 64 of the various devices as shown functionally in FIG. 1 by a monitoring line 73 . The controller 60 monitors the device power with internal timing mechanisms and counters. These timing mechanisms monitor a duration of time during which power is being provided to the electrical device. If power is provided for a longer period of time than allowed, the AC enable signal corresponding to the device is interrupted and a counter is incremented. If the AC enable signal is interrupted by the controller a predetermined number of times, such as, for example, three times, the control system 20 disallows the flow of power to the electrical device by ceasing to output the AC enable signal 66 until the controller resets after a predetermined amount of time.
[0014] FIGS. 3-6 are circuit schematics illustrating an exemplary circuit implementation of the control system 20 . These schematics will be described in functional terms, without detailing component values or exhaustively describing the function of each component. Referring first to FIG. 3 , in the described embodiment, the controller 60 is a microprocessor that has among its inputs: validation signals 47 , 147 , PTO clutch monitor and starter monitor signals 75 , and a current monitor 73 that is used for circuit protection. The controller 60 outputs four DC control signals (described in more detail with reference to FIG. 7 ). The DC control signals control such devices as, for example, a magneto interrupt signal, a diagnostic LED signal, a fuel solenoid enable signal, and a deck lift enable signal. The controller 60 also outputs the AC enable signals 66 (described in more detail with reference to FIG. 5 ), one for the starter solenoid and one for the PTO clutch. The PTO clutch monitor and starter monitor signals 75 are used as the controller as part of a diagnostic check. As will be described in more detail with reference to FIG. 5 , these signals should indicate that power is flowing to the PTO clutch and/or starter solenoid when the AC enable signal 66 is being generated and operation of the PTO clutch and/or starter solenoid is called for. If these signals indicate that power is not flowing, an error condition is detected by the controller.
[0015] To conduct the polling of the status sensors 45 ( FIG. 2 ), the controller 60 outputs the selection signals 49 to two decoders 65 . Based on the selection signals, each decoder 65 outputs a single sample enable signal 41 that selects one of four sensor outputs to be connected to the signal integrity check circuits 43 . Referring now to FIGS. 4 a and 4 b , an exemplary circuit embodiment of the validation check 40 is shown. The circuit shown in FIG. 4 b is analogous to that shown in FIG. 4 a except that it processes the outputs of four different sensors not processed by the circuit of FIG. 4 a . In FIG. 4 a , output signals from four sensors 45 , a left steering arm switch and a right steering arm switch, a deck lift switch, and a PTO stop switch are each input to the integrity check circuit 43 through an enable circuit 44 . Each enable circuit 44 connects the sensor 45 to which it is connected to the signal integrity check circuit 43 for validation when the corresponding sample enable signal 41 is present. Hence, based on the input to the decoder 65 ( FIG. 1 and 2 a ), at any given time, the output of one of the four sensors 45 is connected to the signal integrity check circuit 43 .
[0016] The signal integrity check circuit 43 checks for the presence of foreign material, such as moisture, bridging the terminals of the sensor 45 and producing a false closed signal. When the sensor is connected to the signal integrity check circuit 43 , the signal integrity check circuit attempts to sink sufficient current out of the sensor to discern whether the sensor is truly closed or merely shorted by foreign material. In general, a first leg 43 a of the signal integrity check circuit 43 is set up as a constant current sink by virtue of a zener diode 144 that maintains a constant voltage across a resistor 148 connected to the emitter of a first transistor 145 . In the disclosed embodiment, the first leg of the circuit sinks about 35 mA. A second leg of the circuit 43 b produces the validation signal 47 when a second transistor 146 is turned on by current in excess of 35 mA passing through a second resistor 149 connected to its base. When the sensor is producing a closed output caused by the switch being closed, the sufficient current can be pulled through the sensor to turn on the second transistor 146 and produce the validation signal. When the sensor is shorted by foreign material, it is unlikely that sufficient current can be pulled through the shorted sensor and the validation signal will not be produced. FIG. 4 b illustrates a second signal integrity check circuit 43 that tests inputs from a start switch, a PTO switch, a seat switch, and a parking brake switch. The circuit of FIG. 4 b operates in the same manner just described for FIG. 4 a.
[0017] Referring now to FIG. 5 , an exemplary circuit is shown that includes the enable signal check circuit 70 that processes the AC enable signals 66 and allows passage of power 67 to the starter solenoid and PTO electromagnetic clutch. The exemplary circuit also includes an embodiment of the surge protector 87 . FIG. 5 includes two exemplary circuits, a top circuit that outputs power 67 to the starter solenoid and a bottom circuit that outputs power to the PTO electromagnetic clutch. As both circuits function in substantially the same manner, only the top circuit will be described in detail here. The AC enable signal 66 is input to the enable signal check 70 . The various circuit components filter and rectify the AC signal to transform the AC signal into a DC pulse train. The DC pulse train is the gate input to a MOSFET 165 that closes when a pulse train is present to form an enable signal along line 61 for the remainder of the circuit. When a pulse train is not present, an AC enable signal has not been generated by the controller, and the MOSFET 165 opens to disable the circuit. In this manner, a false enable signal caused by a shorted component likely cannot enable the flow of power to the starter solenoid.
[0018] A start voltage 64 is connected to the surge protection 87 portion of the circuit when the key is turned to the start position. During normal operating conditions, the start voltage is essentially passed through to the starter solenoid at output 67 . When the AC signal is present and MOSFET 165 is conducting current between its drain and base, a voltage is present across resistor 172 . This voltage is input to a comparator 178 that in response to the presence of a voltage on this input produces an output that enables passage of power to the starter solenoid. When the MOSFET 165 is conducting, a MOSFET 166 is turned off so that the output of the comparator 178 is not grounded through the MOSFET 166 . In this state, the output of the comparator 178 turns on a MOSFET 169 that in turn turns on a MOSFET 167 to allow the passage of current through the output 67 to the solenoid. When the AC enable signal 66 is not present, the MOSFET 165 turns off causing the MOSFET 166 to turn on and pull the output of the comparator to ground. With the output of the comparator grounded, the MOSFET 169 is off as is the MOSFET 167 and current cannot pass through the MOSFET 167 to power the starter solenoid.
[0019] The surge protector 87 is implemented in the circuit shown in FIG. 5 by virtue of a timed shut off feature that is dependent upon the amount of current that flows through a resistor 191 . Two capacitors, 193 , 173 are initially charged to a specific level. When a high current surge is present for more than a preset amount of time, the capacitor 173 discharges. When the voltage of the capacitor 173 reaches that of the other capacitor 193 , the output of the comparator 178 will be switched to ground. As already discussed, when the output of the comparator is grounded, the MOSFET 167 will be turned off and power cannot pass to the output 67 . In the described embodiment, the output of the comparator will switch to ground when a current of 30 A is present for longer than approximately 0.1 seconds.
[0020] A secondary surge protection mechanism is also present in the circuit. When the drain of the MOSFET is shorted to ground and the circuit is enabled, the voltage that develops across the resistor 191 will be imposed across the emitter to base junction of a transistor 195 . This will cause the transistor to turn on and allow current to flow from emitter to collector. This current flow will cause the voltage across the capacitor 193 to increase at a rapid rate. When the voltage of the capacitor 193 reaches that of the other capacitor 173 , the output of the comparator 178 will switch to ground. As already discussed, when the output of the comparator 178 is grounded, the MOSFET 167 will be turned off. This part of the circuit operates at a speed approximately 1000 times faster than the circuit operation described in the previous paragraph.
[0021] FIG. 6 illustrates various circuits that are enabled by the DC enable signals 62 a - 62 e that are generated by the controller (also shown in FIG. 1 ). A diagnostic LED enable signal 62 a is passed to a diagnostic LED illumination output 110 to cause the LED to flash in various patterns depending on operating conditions detected by the controller. A deck lift enable signal 62 b controls a relay 125 that switches 12V to a deck lift actuator 120 in the presence of the enable signal 62 b . Similarly, a fuel pump enable signal 62 c controls a relay 132 that switches 12V to the fuel pump 130 in the presence of the enable signal 62 c . When a magneto disable signal 62 d is present, magneto power 150 is allowed to flow to the magneto during normal operating conditions. Also shown in FIG. 6 is a signal integrity check circuit 43 ′ that acts on an engine over-temperature sensor. Since this is a normally open sensor, the signal integrity check circuit 43 ′ acts as a current source that pumps current through the over temperature sensor to detect a false open condition. The validation output 147 is output when current cannot be passed through the sensor.
[0022] As can be seen from the foregoing description, a control system that includes a signal integrity check on input signals to the controller and/or an AC enable output helps protect against faulty control based on false signals caused by component malfunction. It should be understood that the embodiments discussed above are representative of aspects of the inventions and are provided as examples and not an exhaustive description of implementations of an aspect of one or more of the inventions.
[0023] While various aspects of the inventions are described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects may be realized in many alternative embodiments, either individually or in various combinations and subs combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects and features of the inventions, such as alternative materials, structures, configurations, methods, devices, software, hardware, control logic and so on may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the aspects, concepts or features of the inventions into additional embodiments within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present inventions however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated.
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A control system for an electrical device includes a controller that outputs an AC device enable system when one or more monitored sensors are in a proper state for operation of the electrical device. The control system may also include a sensor signal integrity checking circuit that outputs a validation signal when the sensor is one of a discrete set of acceptable sensor states. The control system may also include a current monitor that monitors the current draw of the electrical device and compares the current draw to a range of acceptable current draw levels and durations and disables operation of the electrical device when the current draw falls outside of the range.
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FIELD OF INVENTION
[0001] In general, the invention relates generally to optical systems and nanocrystal-in-glass materials. In more detail, the invention relates to a nanocrystal-in-glass material for providing fiber optics telecommunications functionality.
BACKGROUND
[0002] It is critical to test the optical signal transmission characteristics of fiber optic communication lines at various points along the line. Conventional optical fiber consists of a core and a cladding and as such may be utilized as an optical waveguide.
[0003] Conventional optical test ports utilize a tapered fiber approach, which introduces some amount of optical loss for light that traverses the testing port. In particular, conventional optical test ports require mounting a certain section of the fiber such that the fiber is stretched rendering the core and cladding much thinner compared to rest of fiber. When the optical light passes through the stretched section, because the diameter of fiber is thinner in that area it results in optical loss in the propagated signal. A photodetector is introduced to measure the leakage light.
[0004] Applicants have identified significant shortcomings with conventional approaches to optical testing of waveguides. In particular, a major limitation of conventional approaches such as the tapered fiber approach, is that there is no way to turn the optical test functionality “on” or “off” in an active manner.
SUMMARY OF INVENTION
[0005] The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
[0006] According to one embodiment an optical test port for testing an optical waveguide comprises a nanocrystal-in-glass member coupled to the optical waveguide, the nanocrystal-in-glass member comprising a transmission portion and a testing portion, at least one electrode coupled to the nanocrystal-in-glass member such that an optical transmission through at least one of the transmission portion and the testing portion is varied continuously based upon a voltage established on the electrode, and a photodetector coupled to the testing portion, the photodetector receiving a light signal from the testing portion and indicating a transmission characteristic of the optical waveguide.
[0007] According to an alternative embodiment, an optical test port for testing an optical waveguide comprises a nanocrystal-in-glass member coupled to the optical waveguide, a first electrode and a second electrode coupled to the nanocrystal-in-glass member and a detector coupled to the first electrode for measuring electrons generated by absorbed photons passing through the nanocrystal-in-glass member.
[0008] According to an alternative embodiment, an optical test port for testing an optical waveguide comprises a nanocrystal-in-glass member coupled to the optical waveguide, the nanocrystal-in-glass member comprising a transmission portion and a testing portion, at least one electrode coupled to the nanocrystal-in-glass member such that an optical transmission through at last one of the transmission portion and the testing portion is varied continuously based upon a voltage established on the at least one electrode, and a detector coupled to the testing portion, the detector measuring an electromagnetic property of the testing portion.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1 depicts a cross-section of an electrochromic material structure for use in an optical test port according to one embodiment.
[0010] FIG. 2A depicts an optical test port incorporating an electrochromic material according to one embodiment.
[0011] FIG. 2B depicts an optical test port incorporating an electrochromic material in which the test port is in an “off” state according to one embodiment.
[0012] FIG. 2C depicts an optical test port incorporating an electrochromic material in which the test port is in an “on” state according to one embodiment.
[0013] FIG. 3 depicts an alternative embodiment of an optical test port incorporating an electrochromic material in which an induced photo-voltage is utilized to monitor an optical transmission characteristic according to one embodiment.
[0014] FIG. 4 depicts an optical test port incorporating an electrochromic material that combines a splitting structure and an induced photo-voltage measuring approach according to one embodiment.
DETAILED DESCRIPTION
[0015] Applicants have developed a technique that allows for active tuning of optical test ports and makes use of electrochromic materials, which may be optically tuned by an applied electric field. The optical test port is arranged to include a transmission portion and a testing portion, both of which are comprised of electrochromic materials. If testing is desired, a voltage signal may be applied to the electrochromic material associated with the testing portion to cause a portion of the light to propagate through the testing portion. If no testing is desired, no voltage is applied so that all of optical signal will pass through the transmission portion with a minimum of optical loss and interruption to optical transmission line.
[0016] FIG. 1 depicts a cross-section of an electrochromic material structure 100 for use in an optical test port according to one embodiment. According to one embodiment, electrochromic material structure 100 comprises electrode 102 ( 1 ), electrode 102 ( 2 ) and a nanocrystal-in-glass material 104 . According to one embodiment electrochromic material structure 100 incorporates a nanocrystal-in-glass material. According to alternative embodiments, an electro-optic material such as a semiconductor material (i.e., gallium arsenide or lithium niobate) may also be used to control light transmission via an applied voltage. Other materials may be substituted so long as their optical transmission properties may be varied based upon application of a control signal.
[0017] For example, light transmission properties of nanocrystal-in-glass material 104 may be modulated by application of a voltage to nanocrystal-in-glass material 104 via electrodes 102 ( 1 ) and 102 ( 2 ), which form a pair. The voltage applied may be obtained from a voltage source and vary over a range. Nanocrystal-in-glass material 104 may incorporate nanocrystals covalently bonded in amorphous material and may enable dynamic control of near-infrared and visible light transmission depending upon an applied voltage to the material.
[0018] FIG. 2A depicts an optical test port incorporating an electrochromic material according to one embodiment. Electrochromic optical test port 200 comprises waveguide 202 , testing portion 204 ( 1 ) and transmission portion 204 ( 2 ). Testing portion 204 ( 1 ) comprises nanocrystal-in-glass material 104 ( 1 ) and electrodes 102 ( 1 ) and 102 ( 2 ), which form a pair. Transmission portion 204 ( 2 ) comprises nanocrystal-in-glass material 104 ( 2 ) and electrodes 102 ( 3 ) and 102 ( 4 ), which form a pair. Testing portion 204 ( 1 ) and transmission portion 204 ( 2 ) are coupled to waveguide 202 . As shown in FIG. 2A , the coupling is arranged through a Y-Junction. However, other arrangements are possible in other embodiments.
[0019] Upon arriving at the Y-Junction, a portion of light propagating through waveguide 200 will travel through transmission portion 204 ( 2 ). As will become evident with respect to FIGS. 2B-2C , upon arriving at the Y-Junction, a portion of light propagating through waveguide 200 will travel through testing portion 204 ( 1 ) depending upon whether a voltage is applied to electrodes 102 ( 1 ) and 102 ( 2 ). Electrodes 102 ( 1 )- 102 ( 4 ) may be made of indium tin oxide (ITO) or other conductive material suitable for optical applications. The light transmission through testing portion 204 ( 1 ) may be measured by photodetector 210 .
[0020] Electrochromic optical test port 200 provides a distinct advantage over convention optical test port methodologies such as those that utilize a tapered fiber approach in that it allows active tuning of the transmission properties of the testing portion 204 ( 1 ) in relation to the transmission portion 204 ( 2 ). This use of electrochromic material allows active tuning of the light transmission properties, which results in a higher signal-to-noise ratio (SNR) for induced light absorption when desired.
[0021] FIG. 2B depicts an optical test port incorporating an electrochromic material in which the test port is in an “off” state according to one embodiment. As shown in FIG. 2B , voltage source 208 is applied to electrode 102 ( 1 ) of testing portion 204 ( 1 ). In this configuration, nanocrystal-in-glass material 104 ( 2 ) in transmission portion 204 ( 2 ) does allow transmission of light from waveguide 202 . However, in this configuration, nanocrystal-in-glass material 104 ( 1 ) in testing portion 204 ( 1 ) does not allow transmission of light from waveguide 202 .
[0022] FIG. 2C depicts an optical test port incorporating an electrochromic material in which the test port is in an on state according to one embodiment. As shown in FIG. 2C , voltage source 208 is applied to electrode 102 ( 1 ) of transmission portion 204 ( 2 ) while electrode 102 ( 2 ) of transmission portion 204 ( 2 ) is grounded. In this configuration, nanocrystal-in-glass material 104 ( 2 ) in transmission portion 204 ( 2 ) allows transmission of a portion of the light from waveguide 202 . In addition, in this configuration, nanocrystal-in-glass material 104 ( 1 ) in testing portion 204 ( 1 ) also allows transmission of a portion of the light from waveguide 202 . The proportion of light passing through testing portion 204 ( 1 ) relative to transmission portion 204 ( 2 ) will depend upon the voltage applied to electrode 102 ( 1 ). The light transmission through testing portion 204 ( 1 ) may be measured by photodetector 210 .
[0023] FIG. 3 depicts an alternative embodiment of an optical test port incorporating an electrochromic material in which an induced photo-voltage is utilized to monitor an optical transmission characteristic according to one embodiment. Electrochromic optical test port 200 comprises waveguide 202 , electrode 102 ( 1 ) and electrode 102 ( 2 ) which form a pair, and nanocrystal-in-glass material 104 . Further, as shown in FIG. 3 , an ammeter or voltmeter 302 is applied to electrode 102 ( 1 ). As an optical signal passes from waveguide 202 through nanocrystal-in-glass material 104 , a small portion of the passing photons may be absorbed by nanocrystal-in-glass material 104 and converted to electrons, which generates a photo-current or photo-voltage that may be measured by ammeter/voltmeter 302 for diagnostic purposes. An advantage of the approach shown in FIG. 3 is that it does not require a splitting structure nor a photodetector, which thus yields a lower cost design.
[0024] FIG. 4 depicts an optical test port incorporating an electrochromic material that combines a splitting structure and an induced photo-voltage measuring approach according to one embodiment. As shown in FIG. 4 , rather than utilizing a photodetector as shown in the embodiment in FIG. 2A , voltmeter/ammeter 302 is coupled to electrode 102 ( 2 ) while electrode 102 ( 1 ) is grounded. Voltage source 208 coupled to electrode 102 ( 4 ), which is coupled to nanocrystal-in-glass material 104 ( 2 ) in transmission portion 204 ( 2 ), allows modulation of light transmission through testing portion 204 ( 1 ). As an optical signal passes from waveguide 202 through nanocrystal-in-glass material 104 ( 1 ) in testing portion 204 ( 1 ), a small portion of the passing photons may be absorbed by nanocrystal-in-glass material 104 ( 1 ) and converted to electrons, which generates a current or voltage that may be measured by ammeter/voltmeter 302 coupled to electrode 102 ( 2 ) for diagnostic purposes.
[0025] These and other advantages maybe realized in accordance with the specific embodiments described as well as other variations. It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.
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An electrochromic test port provides an actively tunable system for building an optical test port for an optical waveguide with enhanced SNR properties over conventional approaches.
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FIELD OF THE INVENTION
The present invention generally relates to the field of tissue characterization. More specifically, the invention pertains to the filed of ultrasonic signal processing for tissue characterization using ultrasonic waves.
BACKGROUND DISCUSSION
Heretofore, there have widely been used ultrasonic diagnosing apparatus for diagnosing arteriosclerosis and performing a preoperative diagnosis and a postoperative check for coronary intervention using a dilatation catheter or a high-functionality catheter such as a stent or the like.
One example of ultrasonic diagnosing apparatus discussed below is intravascular ultrasound (IVUS) diagnosing apparatus. Generally, intravascular ultrasound diagnosing apparatus are constructed to include an ultrasonic probe that makes radial scans in an artery of the patient and receives an echo (reflected wave) reflected from a reflecting object in the artery. The echo signal is amplified and detected to convert the echo intensity into an image signal on a gray scale for thereby displaying a B-mode image.
B-mode images on the gray scale can display a large lipid in plaque deposited in the blood vessel. However, it is difficult for B-mode images to display a small lipid that may be present in an initial phase of plaque growth.
Since the rupture of vulnerable plaque in an artery is considered to be responsible for acute coronary syndromes such as an acute myocardial infarction, it is clinically desirable to diagnose plaque with a relatively high degree of accuracy. Specifically, when plaque in a blood vessel ruptures, the lipid contained in the plaque blows out into the blood vessel, leading to acute coronary syndromes. Therefore, an indication of the amount of lipid contained in plaque can serve as an important diagnostic marker.
Consequently, it is desirable in the art to develop ultrasonic diagnosing apparatus capable of sufficiently displaying tissue characters and allowing the user to easily determine whether or not plaque is relatively lipid-rich.
Efforts have been made with respect to ultrasonic diagnosing apparatus to increase the frequency of a transmitted ultrasonic signal in order to increase the resolution of the B-mode image or to analyze an RF signal obtained by receiving a reflected echo for tissue characterization. For example, a ROI (Region of Interest) is established in an analytic section, some parameters are calculated from the spectrum of an RF signal in the ROI, and tissue characters are displayed by a multivariable analysis.
It might be possible to attempt to display a smaller lipid by increasing the frequency for higher resolution. However, with this possibility, the range that can be diagnosed is limited because the depth that the ultrasonic wave can reach is reduced. Ultrasonic probes that are commercially available at present emit ultrasonic waves at a frequency of about 40 MHz and it is not clear at present whether high-frequency ultrasonic probes can generally be used for tissue characterization in blood vessels.
The process of analyzing an RF signal for tissue characterization is still under development at present and established procedures are not yet available. The process of displaying tissue characters by way of a multivariable analysis requires time-consuming calculations because the number of parameters involved is quite large as is the amount of analyzed data, and so this requires calibration of each ultrasonic probe to be used, a task not easy to perform.
SUMMARY
An apparatus for processing an ultrasonic signal comprises IB value calculating means for calculating IB values by extracting RF signals in predetermined time regions respectively from a plurality of RF signals which are produced when an examinee is scanned by an ultrasonic wave, variance value calculating means for calculating a variance value of the IB values calculated by the IB value calculating means, and output means for outputting information based on the variance value calculated by the variance value calculating means.
With the above arrangement, the existence of small foreign matter in an examinee can relatively easily determined in diagnosing tissue characters of the examinee with ultrasonic waves.
According to another aspect, an apparatus for processing an ultrasonic signal comprises IB value calculating means for extracting RF signals in predetermined time regions respectively from a plurality of RF signals produced when an examinee is scanned by an ultrasonic wave and calculating respective IB values in the time regions, linear average calculating means for calculating linear averages of the IB values calculated by the IB value calculating means in IB value groups with respect to mutually related time regions, variance value calculating means for calculating a variance value of the linear averages of the IB values calculated by the linear average calculating means, and output means for outputting information based on the variance value calculated by the variance value calculating means.
Another aspect pertains to a method of processing an ultrasonic signal comprising extracting RF signals in predetermined time regions respectively from a plurality of RF signals which are produced when an examinee is scanned by an ultrasonic wave, calculating respective IB values in the time regions, calculating a variance value of the calculated IB values, and outputting information based on the calculated variance value.
In accordance with another aspect, a method of processing an ultrasonic signal comprises scanning an examinee by an ultrasonic wave, extracting RF signals in predetermined time regions respectively from a plurality of RF signals which are produced by the scanning of the examinee by an ultrasonic wave, calculating respective IB values in the time regions, calculating linear averages of the calculated IB values in IB value groups with respect to mutually related time regions, calculating a variance value of an additive averages of the calculated IB values, and outputting information based on the calculated variance value.
Further aspect involve a control program for enabling a computer to perform the disclosed methods and a recording medium storing a control program for enabling a computer to perform the disclosed methods.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a block diagram of an ultrasonic signal processing system for performing an intravascular ultrasonic diagnosis in which the ultrasonic signal processing system incorporates an ultrasonic signal processing apparatus according to a first embodiment.
FIGS. 2( a ) and 2 ( b ) are somewhat schematic views illustrating the manner in which a catheter operates in an intravascular ultrasonic diagnosis.
FIGS. 3( a )-( c ) are diagrams illustrating a general process for processing an ultrasonic signal during intravascular ultrasonic diagnosis.
FIG. 4 is a diagram showing a B-mode image.
FIG. 5 is a block diagram of the ultrasonic signal processing apparatus according to the first embodiment.
FIG. 6 is a flowchart of a processing sequence of the ultrasonic signal processing apparatus according to the first embodiment for performing an intravascular ultrasonic diagnosis.
FIG. 7 is a flowchart of a processing sequence of an ultrasonic signal processing apparatus according to a second embodiment for performing an intravascular ultrasonic diagnosis.
FIGS. 8( a ) and 8 ( b ) are cross-sectional views illustrating a process of specifying region of interest (ROI) lines.
FIGS. 9( a ) and 9 ( b ) are cross-sectional views illustrating another process of specifying ROI lines.
FIGS. 10( a ) and 10 ( b ) are cross-sectional views illustrative of a process of placing regions of interest (ROIs) on ROI lines.
DETAILED DESCRIPTION
Configuration of an Ultrasonic Signal Processing System
FIG. 1 schematically illustrates an ultrasonic signal processing system 100 for performing an intravascular ultrasonic diagnosis. The ultrasonic signal processing system 100 incorporates an ultrasonic signal processing apparatus 130 according to one disclosed embodiment.
As shown in FIG. 1 , the ultrasonic signal processing system 100 for performing intravascular ultrasonic diagnosis comprises a catheter 101 and an ultrasonic signal processing apparatus 130 .
The catheter 101 has an ultrasonic transducer 105 disposed in its tip end. When the catheter 101 is inserted in a blood vessel, the ultrasonic transducer 105 transmits an ultrasonic wave in the cross-sectional direction of the blood vessel based on a pulse signal sent from an ultrasonic signal transmitter/receiver 110 through signal lines 104 , 103 , receives a reflected wave (echo) of the transmitted ultrasonic wave, and sends an ultrasonic signal (as an electric signal) representative of the echo through the signal lines 104 , 103 to the ultrasonic signal transmitter/receiver 110 .
The ultrasonic signal processing apparatus 130 includes a motor 102 , the ultrasonic signal transmitter/receiver 110 , a signal processing circuit 113 , a monitor 114 , and a motor controller 120 .
The ultrasonic transducer 105 is rotatably mounted in the catheter 101 for being rotated by a motor 102 that is detachably connected to the catheter 101 . When the ultrasonic transducer 105 is rotated circumferentially in the blood vessel, it can detect an ultrasonic echo signal to be used for tissue characterization of the blood vessel in the circumferential direction at a certain cross section of the blood vessel. The operation of the motor 102 is controlled by the motor controller 120 based on a control signal that is sent from the signal processing circuit 113 through a signal line 121 .
The ultrasonic signal transmitter/receiver 110 has a transmitting circuit 111 and a receiving circuit 112 . The transmitting circuit 111 supplies a pulse signal to the ultrasonic transducer 105 in the catheter 101 based on a control signal that is sent from the signal processing circuit 113 through a signal line 115 .
The receiving circuit 112 receives an ultrasonic signal sent from the ultrasonic transducer 105 in the catheter 101 . The ultrasonic signal received by the receiving 112 is sent to the signal processing circuit 113 ,which processes the ultrasonic signal and outputs the processed ultrasonic signal to the monitor 114 .
The monitor 114 displays images based on various signals output from the signal processing circuit 113 . The signal processing circuit 113 is capable of outputting an RF signal, i.e., a signal produced by converting an ultrasonic signal into a digital signal, and a B-mode signal used to generate a B-mode image, to the monitor 114 . The signal processing circuit 113 is also capable of processing such an RF signal and a B-mode signal for performing an intravascular ultrasonic diagnosis and outputting the processed signals to the monitor 114 .
Operation of the Catheter In an Intravascular Ultrasonic Diagnosis
FIGS. 2( a ) and 2 ( b ) illustrate the manner in which the catheter 101 operates in an intravascular ultrasonic diagnosis. FIG. 2( a ) is a cross-sectional view of a blood vessel with the catheter 101 inserted therein, and FIG. 2( b ) is a perspective view of the blood vessel with the catheter 101 inserted therein.
As seen in FIG. 2( a ), the ultrasonic transducer 105 mounted in the tip of the catheter 101 is rotated by the motor (the motor 102 shown in FIG. 1) in the direction indicated by the arrow 202 .
The ultrasonic transducer 105 transmits and receives an ultrasonic wave at each of the angular positions thereof in the blood vessel. Specifically, the ultrasonic transducer 105 transmits an ultrasonic wave along respective radial lines 1 , 2 , . . . , 1024 at different angular positions as illustrated by way of example in FIG. 2( a ). While the ultrasonic transducer 105 is rotating 360 degree in the blood vessel cross section 201 , it intermittently transmits and receives an ultrasonic wave a total of 1024 times. The number of times that the ultrasonic transducer 105 transmits and receives an ultrasonic wave while it is rotating 360 degree is not limited to 1024 as this is merely described by way of example. The number of times the ultrasonic transducer 105 transmits and receives an ultrasonic wave while it is rotating 360 degree may thus be selected as desired.
The ultrasonic transducer 105 transmits and receives an ultrasonic wave along the radial lines 1 , 2 , . . . , 1024 while it is traveling in the direction indicated by the arrow 203 (see FIG. 2( b )) in the blood vessel. The scanning process in which ultrasonic transducer 105 repeatedly transmits and receives an ultrasonic wave in each blood vessel cross section while traveling in the direction indicated by the arrow 203 is referred to as the “radial scanning process.”
General Ultrasonic Signal Processing
A general process of processing an ultrasonic signal in the intravascular ultrasonic diagnosis will be described below with reference to FIGS. 3( a )-( c ). FIG. 3( a ) shows an RF signal representing a reflected ultrasonic wave that is received by the ultrasonic transducer 105 . In FIG. 3( a ), the horizontal axis represents time and the vertical axis the intensity of the RF signal.
FIG. 3( b ) shows a B-mode signal that is produced when the RF signal is amplified and detected by the signal processing circuit 113 to convert the echo intensity into an image signal on a gray scale. In FIG. 3( b ), the horizontal axis represents time and the vertical axis the gray scale. The B-mode signal shown in FIG. 3( b ) represents a signal along one line in the blood vessel cross section 201 .
FIG. 3( c ) shows a B-mode image that is generated from a circumferential array of B-mode signals along the lines 1 through 1024 in the blood vessel cross section 201 . In FIG. 3( c ) the B-mode image includes a blood vessel 301 and plaque 302 deposited in the blood vessel 301 .
Arrangement of the Signal Processing Circuit
An arrangement of the signal processing circuit 113 will be described below with reference to FIG. 5 . FIG. 5 shows in block form the arrangement of the signal processing circuit 113 according to this embodiment.
As shown in FIG. 5 , the signal processing circuit 113 has a central processing unit (CPU) 501 , a control memory (ROM) 502 , and a memory (RAM) 503 . The signal processing circuit 113 also has an output device 504 connected to the monitor 114 for outputting a signal such as a B-mode image signal to the monitor 114 , an input/output interface (I/F) device 505 for sending signals to and receiving signals from the transmission wave circuit 111 and the motor controller 120 , an input device 506 including a track ball, a mouse, a keyboard, etc. for entering signals, a storage device 507 such as a HDD or the like, and a bus 508 .
Control programs for performing ultrasonic signal processing functions according to this embodiment and data used by the control program are stored in the storage device 507 (representing functions 507 - 1 through 507 - 8 to be described in more detail later). The control programs and data are loaded through the bus 508 into the memory 503 under the control of the CPU 501 , and executed by the CPU 501 .
Processing of the Ultrasonic Signal Processing Apparatus for an Intravascular Ultrasound Diagnosing
FIG. 6 shows a processing sequence of the ultrasonic signal processing apparatus 130 according to this embodiment for performing an intravascular ultrasonic diagnosis. The processing sequence of the ultrasonic signal processing apparatus 130 for performing an intravascular ultrasonic diagnosis will be described below with reference to FIG. 6 . The processing sequence will be described below while referring to a B-mode image shown in FIG. 4 . The processing sequence shown in FIG. 6 is premised on the ultrasonic scanner 507 - 1 having been operated and the radial scanning process having been completed.
In step S 601 shown in FIG. 6 , a B-mode image display unit 507 - 2 operates to display a B-mode image 400 (see FIG. 4 ) on the monitor 114 . In step S 602 , a plaque region setting unit 507 - 3 recognizes a plaque area 401 that is designated by the user based on the displayed B-mode image 400 , and sets the plaque area 401 in an IB (integrated backscatter) value calculator 507 - 5 .
For allowing the user to make various designations or indications on the B-mode image displayed on the monitor 114 , it is assumed that a UI (User Interface) unit 507 - 7 has operated to allow the user to make such various designations or indications through the input device 506 .
In step S 603 , the user designates M ROI Lines (lines for specifying a direction in which to array ROIs) from the center of the catheter 101 within the designated plaque area 401 .
In step S 604 , the user designates N ROIs for each of the designated M ROI Lines. A ROI setting unit 507 - 4 recognizes the designated ROIs and sets the recognized ROIs in the IB value calculator 507 - 5 .
FIG. 4 shows that 10 ROI Lines (arranged circumferentially) multiplied by 5 layers (arranged radially)=50 ROIs are set in the plaque area 401 . For illustrative purposes, the 10 ROI Lines are referred to as ROI Line 1 , ROI Line 2 , . . . , ROI Line 10 , respectively. Of the ROIs designated on the ROI Lines, a ROI group that is closest to the catheter 101 is referred to as ROI Layer 1 . ROI groups that are positioned progressively farther from the catheter 101 are referred to as ROI Layer 2 , ROI Layer 3 , ROI Layer 4 , ROI Layer 5 .
Each ROI is defined by a ROI Line and a ROI Layer. For example, a ROI on ROI Line 2 in ROI Layer 1 is defined as ROI [ 2 ] [ 1 ], and a ROI on ROI Line 3 in ROI Layer 1 is defined as ROI [ 3 ] [ 1 ].
As shown in FIG. 4 , a ROI has a certain radial width and a certain circumferential width. It is assumed in the present embodiment that all the 50 ROIs have the same size. The radial width corresponds to the time region of the RF signal. An encircled region 402 is illustrative of the size of each ROI. According to the present embodiment, one ROI contains 8 lines, 32 samples.
If an ultrasonic signal is converted into a digital signal at a frequency of 240 MHz, then the 32 samples correspond to about 0.1 mm as calculated according to 1.530×10 6 (mm/sec)/2 (reciprocated)×32 (samples)/240×10 6 (samples/sec)=0.102 mm. If the ultrasonic transducer 105 intermittently transmits and receives an ultrasonic wave a total of 1024 times per rotation, then the eight lines correspond to 2.8 degree as calculated according to 1024 (lines/rotation)×360 (degree/rotation) =2.8 degree.
As the frequency of the ultrasonic wave emitted by the ultrasonic transducer is higher, a more detailed analysis, i.e., an analysis at a higher resolution, is possible, and a smaller lipid in the plaque can be detected. Therefore, the ultrasonic wave emitted by the ultrasonic transducer should preferably have a frequency of 50 MHz or higher.
In step S 605 shown in FIG. 6 , the IB value calculator 507 - 5 operates to calculate an IB (Integrated Backscatter) value for each ROI. In the present embodiment, the IB value calculator 507 - 5 calculates the IB value (total) of the eight lines in each ROI.
Specifically, the IB value calculator 507 - 5 calculates an FFT (fast Fourier transform) of an RF signal that is produced by converting an ultrasonic signal into a digital signal, thereby determining a power spectrum P(f) which is a function of the frequency f. If it is assumed that the ultrasonic transducer which is used has a bandwidth [f 1 , f 2 ], then an IB value for each ROI is determined by integrating the power spectrum in the range from f 1 to f 2 , dividing the integral by the number of samples (32 samples in the present embodiment) of the RF signal, and standardizing.
Specifically, the IB value on a line m in a ROI is calculated according to the following equation:
IB Line m =∫ f1 f2 P Line m ( f )/32 (32 is the number of samples)
By determining linear average of the IB values on all the lines in the ROI, the IB value for each ROI is determined. Specifically, the IB value for ROI [M] [N] is calculated as follows:
IB ROI[M][N] =ΣIB Line m /8 (8 is the number of lines)
In step S 606 , a variance value calculator 507 - 6 operates to calculate a variance of the IB values for all the ROIs according to the following equation:
σ
=
∑
M
∑
N
(
IB
ROI
(
M
)
(
N
)
-
average
(
IB
ROI
(
M
)
(
N
)
)
)
2
/
(
10
×
5
-
1
)
(10 is the number of ROI Lines, and 5 is the number of ROI Layers)
In the above equation,
average
(
IB
ROI
(
M
)
(
N
)
)
=
∑
M
∑
N
IB
ROI
(
M
)
(
N
)
/
(
10
×
5
)
(10 is the number of ROI Lines, and 5 is the number of ROI Layers)
In step S 609 , a diagnosing unit 507 - 8 operates to compare the calculated variance value with a predetermined threshold value (e.g., 32). If the calculated variance value is greater than the threshold value, the diagnosing unit 507 - 8 judges that the plaque 401 is a lipid rich plaque, and displays “Lipid” or the like in the B-mode image.
According to the above embodiment, as described above, the variance value of the IB values of the ROIs in the plaque area is calculated and compared with the threshold value to determine whether the plaque to be analyzed is lipid rich or not. It is also possible to determine whether the plaque to be analyzed is stable or unstable. According to the above embodiment, furthermore, the processing sequence has a shorter calculation time for an easier analysis than the conventional process.
In the first embodiment described above, after the IB values for the ROIs have been calculated, the variance value of the IB values for all the ROIs is calculated and compared with the threshold value to determine whether or not the plaque to be analyzed is lipid rich. However, the present invention is not limited to this embodiment.
According to a second embodiment, a linear average of IB values for a group of every M ROIs in the same ROI layer is determined, and a variance value of the average IB value is calculated and compared with a threshold value to determine whether or not the plaque to be analyzed is lipid rich.
FIG. 7 shows a processing sequence of an ultrasonic signal processing apparatus according to a second embodiment of the present invention. Of the processing sequence shown in FIG. 7 , steps S 601 through S 605 are identical to those shown in FIG. 6 , and will not be described in detail again.
In step S 607 , a linear average of IB values of every M ROIs in the ROI layer N is determined. Specifically, the linear average is calculated according to the equation:
IB ROI Layer N = ∑ M IB ROI ( M ) ( N ) / 10
(10 is the number of ROI Lines)
In step S 608 , a variance value of the average IB values of each ROI layer is calculated as follows:
σ = ∑ N ( IB ROI Layer N - average ( IB ROILayerN ) ) 2 / ( 5 - 1 )
(5 is the number of ROI Layers)
In the above equation,
average
(
IB
ROI
Layer
N
)
=
∑
N
IB
ROI
Layer
N
/
5
(5 is the number of ROI Layers)
In step S 609 , the diagnosing unit 507 - 8 compares the variance value determined in step S 608 with a predetermined threshold value. If the variance value is greater than the threshold value, the diagnosing unit 507 - 8 judges that the plaque 401 is a lipid rich plaque, and displays “Lipid” or the like in the B-mode image.
In the first and second embodiments, processes for the user to designate or specify a ROI have not been described. However, the ultrasonic signal processing apparatus according to the present invention allows a ROI to be designated or specified by any of various processes. A ROI may be specified by specifying the position of a ROI Line and specifying the position of the ROI on the specified ROI Line. A process of specifying the position of a ROI Line and a process of specifying the position of the ROI on the specified ROI Line is described below.
Process of Specifying the Position of a ROI Line:
FIGS. 8( a ) and 8 ( b ) show by way of example a process of specifying the position of a ROI Line. According to the illustrated process, the number of ROI Lines to be specified is predetermined, and the user specifies only a range in which ROI Lines are positioned. Specifically, as shown in FIG. 8( a ), when the user specifies a ROI Line 801 and a ROI Line 802 , eight equally spaced radial lines are automatically specified between the ROI Line 801 and the ROI Line 802 , as shown in FIG. 8( b ).
Since the user specifies only a range in which ROI Lines are positioned, the user can specify ROI Lines quickly without a lot of trouble.
FIGS. 9( a ) and 9 ( b ) show by way of example another process of specifying the position of a ROI Line. According to this other process, the user specifies all ROI Lines that the user wants to be specified. Since the user can specify any desired number of ROI Lines at any desired positions while seeing a B-mode image, it is expected that the user can conduct a diagnosis with increased latitude.
Process of Specifying the Position of a ROI on a Specified ROI Line:
A process of specifying the position of a ROI on a specified ROI Line will be described below. It is assumed that the process is performed when ROI Lines have been specified according to the specifying process shown in, for example, FIGS. 8( a ) and 8 ( b ). However, the process may also be applicable when ROI Lines have been specified according to the specifying process shown in, for instance, FIGS. 9( a ) and 9 ( b ).
FIGS. 10( a ) and 10 ( b ) show by way of example a process of specifying the position of a ROI on a specified ROI Line. According to the process, it is assumed that the number of ROIs to be placed on each ROI Line is predetermined (5 ROIs/ROI Line), and the user specifies a range in which ROIs are positioned on the ROI Lines. Specifically, as shown in FIG. 10( a ), the user places ROI [ 1 ] [ 1 ], ROI [ 1 ] [ 5 ], . . . , ROI [ 10 ] [ 1 ], ROI [ 10 ] [ 5 ]in order to specify a range in which to position ROIs on ROI Lines 1 through 10 . Then, as shown in FIG. 10( b ), three new ROIs (e.g., ROIs [ 1 ] [ 2 ] through [ 1 ] [ 4 ]) are automatically placed at equal intervals between the specified ROIs on each ROI Line (e.g., ROI [ 1 ] [ 1 ] and ROI [ 1 ] [ 5 ] on ROI Line 1 ).
Since the user can specify any desired range in which to place ROIs on ROI Lines, it is expected that the user can specify the positions of ROIs quickly without a lot of trouble.
The principles and preferred embodiments have been described in the foregoing specification. However, the invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. Variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations, changes and equivalents which fall within the spirit and scope of the present invention as defined in the claims, be embraced thereby.
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RF signals in predetermined time regions are extracted respectively from a plurality of RF signals which are produced when an examinee is scanned by an ultrasonic wave, and respective IB values are calculated in the time regions. A variance value of the calculated IB values is calculated, and information based on the calculated variance value is output.
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RELATED APPLICATIONS
This application is a continuation in part of U.S. patent application Ser. No. 09/436,177 which was filed on Nov. 8, 1999 and issued as U.S. Pat. No. 6,189,828 on Feb. 20, 2001. This application also claims the benefit of U.S. Provisional Patent No. 60/183,906 which was filed on Feb. 22, 2000. This application hereby incorporates by reference the above two applications.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to paper roll dispensers and, more specifically, concerns a more robust sanitary paper dispenser that inhibits the introduction of particle matter into the internal portion of the dispenser and provides a uniform and flat surface for easy cleaning.
2. Description of the Related Art
It has long been appreciated physically challenged persons have a difficult time installing paper rolls into conventional paper roll dispensers. Conventional dispensers often comprise a cylindrical shaft that fits into the hollow inner diameter of the paper roll, and the shaft often includes a smaller diameter knob at both ends. Usually, one knob is spring biased outward along the axis of the shaft and, when biased into a cavity in the wall, retains the cylinder along with the paper roll. This installation process requires the use of two hands and fine motor skills. In particular, one must hold onto the paper roll with one hand, insert the cylinder with the other hand, then gather the two components in one hand, bias the knob into the cylinder with the other hand, and then insert the knobs into the two receiving recesses in the wall. However, for many people, like the thousands of people suffering from arthritis, this procedure is too painful or difficult to perform. Hence, there is a need for a toilet paper roll dispenser allowing for quick and easy installation and removal of the paper roll.
It has also long been appreciated that germs can cause illness in humans. Germs are especially prevalent in restrooms on toilet paper dispensers, mainly because bodily waste products are within close proximity and because persons touching the dispensers often do so with unwashed hands. These germs can be passed on to the next person touching the dispenser and cause illness in the recipient. Also, dispenser designs often include recesses and other inaccessible features making cleaning very difficult. Hence, there is an on-going problem of paper dispensers that retain germs and are difficult to clean.
Various dispensers have been developed which retain the roll of paper with a pair of pivoting support members. These dispensers allow the user to install and remove the paper roll with one hand in one easy upward motion. For example, U.S. Pat. No. 4,553,710 discloses several types of paper roll dispensers which retain the roll of paper with a pair of pivoting support members. In particular, U.S. Pat. No. 4,553,710 discloses paper roll dispensers utilizing a pair of support members biased to pivot and enter the hollow section of the paper roll. Furthermore, the support members shown in U.S. Pat. No. 4,553,710 can retract into the main structure of the dispenser when either removing or inserting a roll of paper. In fact, products have become marketed, like those distributed by Rubbermaid, that include retractable support members similar to the members disclosed in U.S. Pat. No. 4,553,710.
While the dispensers disclosed in U.S. Pat. No. 4,553,710 and the Rubbermaid product have been particularly effective in reducing the time and effort needed to remove or insert a roll of paper, these dispensers are susceptible to the retention of germs and foreign particles. More specifically, when the support members are pivoted outward, the design leaves open apertures when the paper roll is installed. These apertures provide a path to the internal portion of the dispenser, and these are prime locations for germs and foreign particles to accumulate and potentially cause illness to all coming in contact with the dispenser. Also, the affected areas are difficult to clean because they are inaccessible inner surfaces.
The dispensers disclosed in U.S. Pat. No. 4,553,710 and the Rubbermaid product can also be difficult to assemble. For instance, the Rubbermaid product comprises two springs, two pivoting members, and two halves of a dispenser shell housing. Neither the springs nor the pivoting members can be rigidly attached to the shell housing during assembly. Instead, during assembly, the pivoting members swing freely on flanges extending from one half of the shell housing, and one end of the springs resides inside the hollow of the pivoting member. Then, the other half of the shell housing must be lowered onto the first half of the shell housing as the springs are bent and lined up with retainer posts on the lowered half. Hence, assembly of this Rubbermaid product can be time consuming and expensive.
Last, the Rubbermaid product is not a robust design because the pivoting members are prone to failure. More specifically, the springs bend from inside the pivoting members, around the base of the pivoting members, to the base of the dispenser shell housing. The bending of the spring results in a lateral offset of the spring, and this lateral offset actually biases the spring to eject out of the pivoting members where they can no longer bias the pivot members. If the springs bias out of the pivoting member, then the pivoting member will not bias and will not be able to support a paper roll. To account for this weakness, Rubbermaid designers have utilized overly long and overly stiff springs. Unfortunately, even these springs are still prone to bias out of the pivot members, and the overly stiff springs may actually impair the user's ability to install a roll of paper. Hence, the robustness of the Rubbermaid product could be significantly improved.
From the foregoing, it will be appreciated that there is a need for an improved paper roll dispenser that keeps germs from entering the dispenser assembly and is easy to clean. It will also be appreciated that there is a need for an improved paper roll dispenser that is easy and inexpensive to assemble. Last, it will be appreciated that there is a need for a more robust paper roll dispenser.
SUMMARY OF THE INVENTION
The aforementioned needs are satisfied by the paper roll dispenser of the present invention which, in one aspect, comprises a base member adapted to mount the apparatus onto a wall and a first and second arm having an inner and outer face wherein the first and second arms extend outward from the mounting plate so as to be spaced a first distance apart, the first distance being selected to be larger than the width of the roll of paper. The arms also have apertures formed on the outer surfaces of the first and second arm members.
This aspect of the present invention also includes a first and a second pivoting member each defining an outer perimeter and an apex where the first and second pivoting members are respectively mounted in the apertures in the first and second arms. The first and second pivoting members are biased inward into the space between the first and second arms in a first orientation such that the apex of the first and second pivoting arms are positioned a second distance apart that is less than the length of the roll of paper such that the roll of paper can be retained on the first and second pivoting members. The first and second pivoting members can be moved into a second orientation such that the apex of the first and second pivoting members are spaced a third distance apart that is greater than the length of the roll to permit removal of the roll.
This aspect of the present invention also includes a first and second cavity shield respectively mounted about the outer perimeter of the first and second pivoting members so as to extend outward therefrom a distance that is selected such that the first and second cavity shield contact the inner surface of the first and second arms when the first and second pivoting members are in the first orientation such that the first and second cavity shields substantially seal the first and second apertures.
In one embodiment, the first and second pivoting members are biased and have an angled surface that is angled such that positioning a roll of paper against the angled surface and exerting pressure against the roll of paper such that it exerts pressure against the first and second pivoting member results in the pivoting members moving from the first orientation to the second orientation to permit installation of the roll of paper. Similarly, to remove the roll of paper, the first and second pivoting members are biased such that moving the roll of paper away from the angled surface results in the first and second pivoting members moving into the second orientation.
In this way, installation and removal of the roll of paper is greatly simplified as the person simply has to grasp the roll of paper and push it against the pivoting members. For individuals with infirmities, this apparatus reduces the need for using both hands and compressing springs and the like to install the paper. Further, since the cavity shields extend outward from the outer perimeter of the first and second pivoting member, the entry of debris and particulate matter into the interior of the apparatus can be reduced thereby resulting in a more sanitary apparatus.
In another aspect, the present invention comprises a base member adapted to mount the apparatus onto a wall and a first and second arm having an inner and outer face wherein the first and second arms extend outward from the mounting plate so as to be spaced a first distance apart, the first distance being selected to be larger than the width of the roll of paper. The arms also have apertures formed on the outer surfaces of the first and second arm members.
This aspect of the present invention also includes a first and a second pivoting member each defining an outer perimeter and an apex where the first and second pivoting members are respectively mounted in the apertures in the first and second arms. The first and second pivoting members are biased inward into the space between the first and second arms in a first orientation such that the apex of the first and second pivoting arms are positioned a second distance apart that is less than the length of the roll of paper such that the roll of paper can be retained on the first and second pivoting members. The first and second pivoting members can be moved into a second orientation such that the apex of the first and second pivoting members are spaced a third distance apart that is greater than the length of the roll to permit removal of the roll. In this aspect, the first and second pivoting members are biased by springs that extend from an interior surface of the first and second arms respectively into the first and second pivoting members. Moreover, the springs are retained in contact with the interior surface and the interior of the pivoting member by retainers such that repeated operation of the pivoting members is less likely to result in the spring being dislodged.
In one specific embodiment, the first and second arms are hollow and the springs are mounted so as to extend laterally across the arms so as to be adjacent the pivoting members. In another embodiment, the springs extend from a bottom surface of the arms to a position adjacent the pivoting members. The use of the retainers in both embodiments results in a more easily assembled, more robust design.
Hence, the paper roll holder of the present invention is more sanitary, more robust and easier to assemble than similar dispensers of the prior art. These and other objects and advantages will be more apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are isometric views illustrating a paper roll dispenser assembly incorporating two pivoting retainer members with cavity shields;
FIG. 2 is an isometric view of a pivoting member included in the paper roll dispenser shown in FIGS. 1A and 1B;
FIGS. 3A and 3B are cross-sectional views of the paper roll dispenser assembly of FIG. 1B taken along the lines of 3 A— 3 A and 3 B— 3 B;
FIG. 4 is a front view of the paper roll dispenser assembly of FIG. 1B taken along the lines of 4 — 4 ; and
FIG. 5 is another cross-sectional view illustrating another embodiment of the paper roll dispenser of FIGS. 1 A and 1 B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made to the drawings wherein like numerals refer to like parts throughout. Referring to FIGS. 1A and 1B, one embodiment of a paper roll dispenser assembly 100 is illustrated. As shown, the paper roll dispenser assembly 100 is generally a U-shaped shell 138 comprising a base member 104 , the portion that will attach onto a wall, and a first and second side arm 102 a , 102 b . The first and second side arms 102 a , 102 b extend perpendicularly from the base member 104 . Also, the first and second side arms 102 a , 102 b are separated by a first distance 103 . Preferably, the arms define a space 101 having a width of the first distance 103 . The first distance 103 is wider than the paper roll 106 so that the paper roll 106 can fit in the space 101 between the first and second side arms 102 a , 102 b and be retained in a manner to be discussed in further detail below.
In the preferred embodiment, the shell 138 comprises an upper half shell 141 and a lower half shell 145 . When the upper half shell 141 and the lower half shell 145 are joined, the shell 138 is hollow, making room for a first and second pivot member 108 a , 108 b to protrude perpendicularly from an aperture 127 in the first and second side arms 102 a , 102 b and point toward the center of the space 101 . The pivot members 108 a , 108 b are assembled into the side arms 102 a , 102 b in a manner to be described below. The first and second pivot members 108 a , 108 b are spaced apart a second distance 105 . Preferably, the second distance 105 is less than the length of the paper roll 106 so that the paper roll can be held up by the pivoting members 108 a , 108 b . More specifically, the pivoting members 108 a , 108 b will fit inside a cylindrical hollow core 107 around which the paper 109 of the paper roll 106 is wound. In this way, the first and second pivot members 108 a , 108 b support the paper roll 106 .
In one embodiment, the shell 138 and the pivot members 108 a , 108 b are made from a lightweight plastic known in the art. It will be appreciated that the overall form of the base member 104 , the first and second arms 102 a , 102 b , and the pivot members 108 a , 108 b can take on a variety of shapes without departing from the spirit of the present invention.
FIG. 2 illustrates an isometric view of the first pivot member 108 a . It will be appreciated that the second pivot member 108 b shares the same features with the first pivot member 108 a . In the embodiment shown, the pivot member 108 a comprises various thin-walled surfaces. More specifically, the pivot member 108 a comprises a top face 118 which provides a surface for a paper roll 106 to sit in a manner to be discussed in further detail below. A front face 120 extends at an acute angle from the top face 118 so as to provide a surface for the paper roll 106 to push on and bias the pivot member 108 a to thereby induce the pivot member 108 a to pivot in a manner to be discussed in further detail below. Also, a first side 114 perpendicularly connects both the top face 118 and the front face 120 . Similarly, a second side 116 perpendicularly connects the other side of the top face 118 and the front face 120 .
The pivot member 108 a also includes a cavity shield 110 that extends ninety degrees from the top face 118 and from the first and second sides 114 , 116 . This cavity shield 110 performs two functions, both of which will be discussed in further detail below. First, the cavity shield 110 prevents germs and foreign particles from entering the paper roll dispenser 100 through the aperture 127 . Second, the cavity shield limits the rotation of the pivoting member 108 a.
Also, connected to both the first and second sides 114 , 116 is a half-circle protrusion 122 . Centered on the protrusion 122 is a cylinder 112 . As is illustrated in FIG. 2, the protrusion 122 is located at the bottom of the pivot member 108 a adjacent the rear surface. In the preferred embodiment, the cylinder 112 is short—approximately twice the thickness of the protrusion 122 . The cylinder 112 provides a means of supporting the pivoting member 108 a when installed into the paper roll dispenser 100 as will be described in greater detail below.
More specifically, FIGS. 3A and 3B illustrate the assembly of the first pivot member 108 a into the first side arm 102 a , and also reveal inner features of the pivot member 108 a and the side arm 102 a . It will be appreciated that the second pivot member 108 b is assembled into the second side arm 102 b in the same manner.
As shown in FIGS. 3A and 3B, a first support mount 130 is located inside a cavity 121 of the pivoting member 108 a on the bottom interior wall of the first side arm 102 a . The first support mount 130 is a cylindrical outgrowth that defines a lip 131 and a recessed surface 139 . In the preferred embodiment, the end of the first support mount includes a collar 134 . The collar 134 is an extremely short cylinder of a slightly larger diameter than the first support mount 130 . The combination of the first support mount 130 and the collar 134 provide a mechanism of retaining a spring 128 in a manner to be discussed in greater detail below.
Also located on the bottom interior wall of the first side arm 102 a is a support 124 . The support 124 is a thin, rectangular outgrowth that extends from the bottom surface 191 of the cavity 143 of the side arm 102 almost to the base of the aperture 127 . The support 124 supports the pivoting member 108 a . Specifically, the support 124 includes a pair of grooves 140 which are cut to a diameter greater than the diameter of the cylinders 112 . The grooves 140 provide a location to seat the cylinders 112 of the pivoting member 108 a into the support 124 ; thus, the grooves 140 prevent the pivoting member 108 a from dislocating from the support 124 .
FIGS. 3A and 3B illustrate a second support mount 132 located on the interior wall of the top face 118 of the pivot member 108 a . The second support mount 132 is a cylindrical outgrowth of the same diameter as the first support mount 130 . Likewise, the second support mount includes a collar 134 as described above. The combination of the second support mount 132 and the collar 134 provide a means of retaining the spring 128 in a manner to be discussed in greater detail below.
As shown in FIGS. 3A and 3B, the cylinders 112 of the pivot member 108 a fit into the grooves 140 atop the supports 124 in a manner that supports the pivot member 108 a . The grooves 140 also permit the pivot member 108 a to pivot around the axis of the cylinder 112 . As shown, the spring 128 further connects the pivot member 108 a to the rest of the side arm 102 a . A first end 133 of the spring 128 attaches to the side arm 102 a by way of the first support mount 130 . Preferably, the diameter of the first support mount 130 is larger than the inner diameter of the spring 128 so as to create an interference fit between the spring 128 and the support 130 . Similarly, a second end 135 of the spring 128 attaches to the second support mount 132 in the same manner.
It should be noted that the collars 134 on the support mounts 130 , 132 further retain the spring 128 . This is because the diameter of the collar 134 is such that it creates a ridge that rides over and holds the ends 133 , 135 of the spring 128 in the recesses 139 to either the pivot member 108 a or the first side arm 102 a . Hence, the spring 128 is retained because of the interference force between the spring 128 and the first support mount 130 , and the spring 128 is further retained due to the hold down force that the collar 134 exerts on the spring 128 .
Advantageously, the force of the collar 134 on the spring 128 provides a rigid attachment for the spring 128 and prevents the spring 128 from shifting excessively when the pivot member 108 a is biased. Thus, the paper roll dispenser 100 is robust because the spring 128 is more likely to stay in position and remain functional for the life of the paper roll dispenser 100 . The collar 134 also allows for easy assembly of the paper roll dispenser 100 because, during assembly, the ends 133 , 135 of the spring 128 can be rigidly attached to the spring mounts 130 , 132 , leaving the person assembling the paper roll free to manipulate other features of the paper roll dispenser 100 .
As shown in FIG. 3B, when force is applied to the front face 120 of the pivot member 108 a , the pivot member 108 a pivots toward the inside of the side arm 102 a thereby compressing the spring 128 . Then, once the force is removed, the spring 128 force biases the pivot member 108 a outward from the side arm 102 a . The pivot member 108 a rotates outward until the cavity shield 110 makes contact with the wall of the aperture 127 . Preferably, the position of the cavity shield 110 stops the pivot member 108 a when the top face 118 of the pivot member 108 a is perpendicular to the plane of the aperture 127 .
FIG. 4 illustrates the pivot member 108 a assembled into the first side arm 102 a from a vantage point looking directly into the aperture 127 . The pivot member 108 a is shown rotated to a position where it is at rest. As shown, the pivot member 108 a has come to rest because the cavity shield 110 has made contact with the walls of the aperture 127 . Also illustrated in FIG. 4 is the cavity shield 110 covering the open portion of the aperture 127 lying above the top face 118 of the pivot member 108 a . The cavity shield inhibits foreign particles from entering the side arm 102 a through the aperture 127 . As is also illustrated in FIGS. 2 and 4, the cavity shield preferably includes portions 126 that extend outward along the side walls 114 , 116 of each of the pivoting members 108 a , 108 b so as to inhibit the entry of foreign particles in the gap between the wall of the apertures 127 and the walls 114 , 116 of the pivoting members 108 a , 108 b . Advantageously, by sealing off the aperture 127 , the cavity shields prevent the growth and spread of germs inside the hollow side arm 102 a . Thus, the cavity shields reduce the accumulation of waste and germs.
Ordinarily, the pivot members 108 a , 108 b will be pivoted when the paper roll 106 is inserted and removed. To insert the paper roll 106 , the user can turn the paper roll 106 horizontally and raise the paper roll 106 into the first distance 103 between the two side arms 102 a , 102 b . Then, as the paper roll 106 is raised, the paper roll 106 will make contact with the angled front face 120 of the pivot members 108 a , 108 b . This urges the pivot members 108 a , 108 b to retract into the first and second side arms 102 a , 102 b and thereby compress the springs 128 . Once the paper roll 106 is centered in the paper roll assembly 100 , the pivot members 108 a , 108 b are then urged outward again by the springs 128 so as to be centered on the hollow core of the paper roll 106 . The springs 128 bias the pivot members 108 a , 108 b into the hollow core of the paper roll 106 such that the paper roll 106 is supported by the pivot members 108 a , 108 b . Then, the paper roll 106 is free to turn along its axis and paper can be dispensed.
To remove a paper roll 106 from the paper roll dispenser 100 , the user grabs the paper roll 106 and moves it upwards normal to the top face 118 of the pivot members 108 a , 108 b . As the paper roll 106 moves, the bottom of the paper roll 106 contacts the front face 120 of the pivot members 108 a , 108 b , and the pivot members 108 a , 108 b pivot into the side arms 102 a , 102 b in the manner described above. Then, when the paper roll 106 clears the pivot members 108 a , 108 b , the pivot members 108 a , 108 b are urged out toward the center of the paper roll dispenser 100 by the springs 128 until the cavity shields 110 make contact with the sides of the aperture 127 in the side arms 102 a , 102 b . Advantageously, both the insertion and removal of the paper roll 106 can be achieved using only one hand. Hence, people can insert and remove paper rolls 106 easily and quickly, even if they are physically challenged.
FIG. 5 illustrates another embodiment of the paper roll dispenser 100 . As shown, a spring mount 230 with a collar 234 resides on an inner side wall 229 of the side arm 202 a at a height above the bottom surface 241 of the cavity 243 that is approximately equal to the height of the pivot arm 108 . In this way, the spring 228 extends laterally across the cavity 243 such that the force of the spring in compression and extension is directly exerted against the pivoting member 108 . The use of the retaining spring mount 230 retains the spring in this orientation during operation of the apparatus. The spring 228 connects to the spring mount 230 in the same manner as described above in relation to spring mount 130 . Also shown is a pivot member 208 a that is essentially the same as the pivot member 108 a described above. As shown, an opposite end 235 of the spring 228 rests inside a cavity 221 of the pivot member 208 a . It should be noted that all features shown in FIG. 5 are the same structurally and perform the same function as the features described above. The only difference between the configuration shown in FIG. 5 and the configuration shown in FIGS. 3A and 3B is the location of the spring mount 230 and the absence of a spring mount inside the cavity 221 of the pivot member 208 a.
This configuration of the paper roll dispenser 100 is advantageous for several reasons. First, the location of the spring mount 230 allows the axis of the spring 228 to remain essentially straight, even when the pivot member 208 a is biased into the side arm 202 a . Because the spring 228 remains straight, the forces in the spring 228 are primarily axial forces, and the amount of lateral forces on the spring 228 are minimal. This reduces the chances of the spring 228 dislodging from either the cavity 221 of the pivot member 208 a or the spring mount 230 . Thus, this would be a more robust configuration.
It should be noted that the spring mount 230 or collar 234 may not be needed inside the cavity 221 for retaining the end 235 of the spring 228 in all implementations. Extra retention force may not be needed at the end 235 of the spring 228 because the spring 228 remains essentially straight and has little chance to dislodge from the cavity 221 of the pivoting member 208 a . Since no feature, like the spring mount 230 or collar 234 , is needed, the paper roll dispenser 100 is easy to assemble because the spring 228 can be inserted into the cavity 221 without having to retain it further. In this implementation, assembly is simplified through the lack of a retainer. Also, this configuration may allow a less stiff spring to be used; other designs, like the routing of the spring 128 described above, require an overly-stiff spring to prevent the spring from dislodging due to its offset. A less stiff spring means that the user will need less force to insert and remove a paper roll 206 . Another advantage is that a shorter spring 228 may be used because the spring mount 230 is closer to the hollow 221 as compared to the spring routing described above. A shorter spring 228 would be a less costly for the manufacturer.
The embodiment shown in FIG. 5 would be easier to assemble as well. This is because placing the spring mounts 230 in the position shown in FIG. 5 provides a more accessible location for mounting the spring as compared to the spring mount position described above. Assembly time is further reduced if the lower half shell 145 is shaped such that the entire periphery of the aperture 127 is encompassed by the lower half shell 145 . In this instance, assembly would involve the installation of the pivoting members 208 a , 208 b and their corresponding springs 228 into the lower half shell 145 . The springs 228 would be rigidly attached at this point, and the pivoting members 208 a , 208 b would remain in their first position, with the cavity shields making contact with the inside of the lower half shell 145 . Then, the upper half shell 141 would be attached to the lower half shell 145 . Thus, assembly time is reduced because the person assembling the dispenser would have an not have to hold the pivoting members 208 a , 208 b in a biased position while the upper half shell 141 is attached to the lower half shell 145 .
The use of the retainers in both implementations makes the apparatus significantly more robust as the springs are less likely to be dislodged from their desired orientations. Assembly is also simplified as the springs can be positioned on one of the retainers and retained in their desired orientation when the other components of the apparatus, such as the pivot arms, are assembled. The springs can then be positioned on the other retainer by simply forcing the spring end over the collar. The use of the retainers also allows for a less strong spring to be used as less biasing is required to prevent the spring from being inadvertently dislodged. The reduced spring bias allows for easier installation and removal of paper rolls particularly by physically challenged persons.
Although the illustrated embodiments of the present invention have shown, described, and pointed out the fundamental novel features of the invention, as applied to these embodiments, it will be understood that various omissions, substitutions and changes in the form of the detail of the device illustrated may be made by those skilled in the art without departing from the present invention. Consequently, the scope of the invention should not be limited to the foregoing description, but should be defined by the appended claims.
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An apparatus for holding a roll of paper having a mounting section with two arms extending outward therefrom. Each arm is hollow and includes an aperture on the inner surface of the arms. Pivoting members are mounted within the arms and are spring biased into a first position where the pivoting members support the roll of paper. The pivoting members includes cavity shields that prevent the entry of debris into the arms and the springs are secured to the pivoting members and the arms so as to inhibit the springs from being dislodged. The pivoting members are further biased such that the pivoting members can be retracted into a second position as a result of a user moving the roll of paper against the pivoting members in a first direction.
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BACKGROUND OF THE INVENTION
This invention relates to a charge-coupled memory and, more particularly, relates to a charge-coupled line-addressable random-access memory (LARAM) which incorporates a uniphase clocking system.
The development of charge-coupled devices (CCD's) as described in the article by Gilbert F. Amelio, "Charge-Coupled Devices," Scientific American, Feb. 1974, Vol. 230, No. 2, p. 23, has made possible the fabrication of long shift registers having stages consisting of individual charge storage elements. These shift registers may be used in an interleaved format as in area-imaging devices or may be incorporated in analog delay lines. When strings of charge-coupled elements are organized in parallel format with associated addressing and date read-out circuitry, they become potentially suitable for use as random-access memories. This is true even though inherently such a collection of parallel shift registers does not allow random access to every bit in every register since the data in a given register must be circulated through a complete cycle to permit access to every bit. However, the circulation can be conducted at frequencies on the order of 5 to 10 MHz so the actual access time will be dependent only on line length and on clock frequency and will be on the order of microseconds, and access, as a practical matter, can be considered to be essentially random. Recirculating serial memories organized in parallel format have been reported to have, for example, 4096 bits of memory organized in 16 tracks of 256 bits each. See S. R. Rosenbaum and J. T. Caves, "CCD Memory Arrays with Fast Access by On-Chip Decoding," 1974 ISSCC Digest, pp. 210-211. The data continuously circulates in each track with the requirement that power be continuously supplied and with the result that the input/output circuitry must interact with a high capacitance since it has access to all lines at all times.
Charge-coupled shift registers may be designed with various clocking schemes. The most common and straight-forward schemes are four-phase, three-phase or two-phase schemes in which, respectively, every fourth, third or second electrode is tied to the same clock signal. The simplest scheme utilizes a single clock and is commonly denoted uniphase clocking. In this scheme, every second electrode is tied to the single clock while the alternating electrodes are held at a d.c. potential which lies inbetween the high and low extremes of the dynamic clock. In general, the simpler the clocking scheme, the higher the yield in fabricating the device and the more efficient the device in actual operation.
SUMMARY OF THE INVENTION
A line-addressable random-access memory (LARAM) comprises a plurality of lines of charge storage elements, means for introducing charge representing binary information to the beginning of particular ones of the plurality of lines of charge storage elements which are addressed, at least one data clock signal means for effecting the transfer of charge along those lines of the charge storage elements which are addressed, an address-selection matrix electrically coupled between the clock signal generator and the lines to permit the addressed ones of the lines to be clocked, and charge-sensor means for receiving charge from the addressed lines and, in response thereto, generating a signal which represents the data signified by the charge and for recirulating a refreshed representation of the charge to the means for introducing charge.
In one embodiment the LARAM is organized with four sections of 32 lines. A five-bit address may be used to impose the clock waveform on one line in each section. Thus, a four-bit byte can be written, read or refreshed. Each section has its own associated address decoder, charge sensor and I/O logic. Address enable, inverse read enable, inverse write enable and clocks are common to all sections.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the line-addressable random-access memory of the present invention, reference may be had to the drawings which are incorporated herein by reference and in which:
FIG. 1 is a block diagram of a generalized LARAM organization;
FIG. 2 is a block diagram of a 16,384-bit LARAM organized in four groups, each group having 32 lines with 128 bits/line;
FIG. 3 is a circuit schematic of a particular line driver and decoder for the LARAM of FIG. 2;
FIG. 4 is a circuit schematic of a particular input circuit for the LARAM of FIG. 2;
FIG. 5 is a circuit schematic of a particular write enable circuit for the LARAM of FIG. 2;
FIG. 6 is a circuit schematic for a particular sensor refresh circuit for the LARAM of FIG. 2;
FIG. 7 is a circuit schematic for a particular data output circuit for the LARAM of FIG. 2;
FIG. 8 is a circuit schematic for a particular read enable circuit for the LARAM of FIG. 2;
FIGS. 9a-9k are a series of timing diagrams for the operation of the LARAM of FIG. 2 with:
FIG. 9a illustrating the master clock;
FIG. 9b illustrating the data transmission clock;
FIG. 9c illustrating the address enable clock;
FIG. 9c' illustrating the address validity check time interval;
FIGS. 9d-9f illustrating the inverse write enable, inverse read enable and data output pulses for the Read Mode;
FIGS. 9g-9i illustrating the inverse write enable, inverse read enable and data input pulses for the Write Mode;
FIGS. 9j-9k illustrating the inverse write enable and inverse read enable for the Refresh Mode;
FIG. 10 is a circuit schematic for a particular address level converter and inverter for the LARAM of FIG. 2; and
FIG. 11 is a pictorial side view of a portion of a uniphase line of charge-coupled elements with the solid potential line showing data storage under the dynamic electrode and the dotted potential line showing data storage under the static electrode.
LARAM Organization
A generalized LARAM organization is shown in FIG. 1. It comprises a self-contained memory system with a common input bus 208 and a common output bus 217, coupled with a series of n charge-coupled lines 210, . . . 214. A clock input to any one line is coupled through a corresponding one of a plurality of line drivers (formed as part of address-selection matrix and line drivers 201), thereby to impose an input clock waveform on whichever line is addressed by the address-selection matrix 201. Unaddressed lines are maintained in a definite state. During a write cycle, a clock would be imposed on line 211 (shown to be addressed) and data would be inputted through input buffer 202 to the beginning of line 211. During a read cycle the data on addressed line 211 is dumped onto output bus 217, then is introduced to charge sense amplifier 218 and thereafter is transmitted through output buffer 219 to a data output terminal; also, the data is passed via regeneration loop 220 back to input bus 208 and into the addressed line. During a refresh cycle, data on an addressed line passes through control logic 223 via regeneration loop 220 to be reintroduced through input buffer 202 to the addressed line.
In operation, each line is like an independent storage register which shares input and output circuitry with the other lines. Such an electronic scheme has extremely low capacitive requirements on the clocks since the external clocks are buffered by line drivers (part of address-selection matrix and line drivers 201). Support circuitry is simplified because n lines share a common input bus and a common output bus; for example, a single charge sense amplifier will suffice for n lines. Since the n lines are independent, any one line can be halted and another line accessed without restoring the first line to its initial position. Furthermore, chip power dissipation is low since only one data line is clocked at a time.
The organization of a LARAM is like a random-access memory (RAM) except that lines of charge-coupled elements are accessible rather than individual bits. Although access is not perfectly random, the worse-case latency time is very short since the clock rate is on the order of MHz and the number of bits per line is on the order of 100. A particularized organization of such a memory system can be by bits or words, depending on whether the lines are coequal or are lumped together in groups. A suitable convention to describe organzation is to let M be the number of bits in a line and N be the total number of lines accessed by an address-selection matrix. The number of logic lines or address bits n required to establish a unique address for each line will be log 2 N; for example, if N = 64, n 32 6. For a word-organized LARAM, groups of lines may be employed with each group having an address-selection matrix and associated sense, refresh and output circuitry. Basic system logic such as address enable, read enable, write enable and clocks such as data transmission and precharge can be generated by circuitry common to all groups.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the description of the preferred embodiment herein, certain conventions are employed. The logic operations are performed in the binary system so that the voltage level on a given line will be stated to be "high" or "low," corresponding with the two logic states associated, respectively, with a higher and lower range of voltage levels. Similarly, the data is stored and transmitted in binary format so that a charge packet with a magnitude greater than a given reference charge will represent a digital 1, while a charge packet with a magnitude less than a given reference charge will represent a digital 0. The reverse may also be employed. In this description, therefore, when read enable or any other system logic level is high, lines connected to read enable or to the other logic level lie at a voltage within a range which signifies that the read enable or the other logic function is to be performed.
The preferred embodiment of FIG. 2 is a word-organized (4 bits/word) 16,384-bit LARAM. This embodiment is organized with four sections 10, 11, 12 and 13, each of which has 32 lines (N=32) of charge-coupled elements with 128 (M=128 ) elements per line. This organization permits a 4-bit word to be processed with a particular 4-bit word having one bit stored in a particular line of each section. A particular line in each section may be addressed by a 5-bit address, consisting of bits A O , . . . A 4 , which are introduced to level converter and inverter 30. The 5-bit address is decoded by 1/32 decoders 22, 23, 24 and 25 which each select one line from the respective associated section 10, 11, 12 or 13. Thus, when a word is to be read out, the inverse read enable RE goes low so that associated buffer 36 activates Input/Output logic modules 18, 19, 20 and 21 to receive data from the associated charge sensors 14, 15, 16 and 17 and to transmit it to the associated output buffer. At the same time, since a read function is being performed and the data must be retained, it is recirculated to the addressed line of the appropriate section. The data has been refreshed as it passed through charge sensors 14, 17 and through Input/Output logic modules 18, . . . 21 so that the recirculated data which reposes in shift registers 10, . . . 13 after refresh consists of charge packets safely within the range of charge magnitude to appropriately represent the original data. Writing of data is performed in a similar manner by introducing data through the input portions of Input/Output modules 18, . . . 21 and then transmitting the data to the beginning of the particular lines which are simultaneously addressed by the five address bits A 0 , . . . A 4 . For this operation, inverse write enable WE goes low and associated buffer 37 causes the input portions of Input/Output logic modules 18, . . . 21 to function. In the Write mode, no refreshed data is transmitted in end-around fashion to the input of the lines. In the Refresh mode, RE and WE go high so that data is refreshed and recirculated while the Input/Output logic modules inhibit a reading or writing function. The introduction of data in the form of charge packets may be accomplished as described in the copending application of Gunsagar, et al., Ser. No. 492,650, assigned to the same assignee as this application. A detailed discussion of the various operating modes of the LARAM of FIG. 2 is found in the discussion of timing diagrams of FIGS. 9a-9k in conjunction with the discussions of FIGS. 3-8 and 10.
FIG. 9a and FIG. 9b show the time relationship between the master clock P and the data transfer clock DT for proper operation of the LARAM of FIG. 2. Altough DT is an external clock signal in the specific embodiment described herein, it can easily be generated on chip from the master clock P, and, in fact, this is a more desirable approach since it ensures proper tracking of the necessary delays with process variations.
The pulse address enable (AE) of FIG. 9c is a logic signal which occurs every time there is an address change. It could, however, occur every cycle without any significant impact on device performance, except for the fact that such operation would result in an increase in power dissipation. Thus, besides serving as a gating pulse to restore internally the last address information present during AE high, it serves as a useful contrivance to save power. The address information is required to be valid for a definite period of time before the pulse AE makes its high-to-low transition, as indicated by the timing diagram of FIG. 9c'. For the proper operation of the decoding scheme employed in this specific embodiment, the master clock P has to overlap AE at both its leading and trailing edges, as indicated by the time intervals t PAE and t DS respectively.
The mode of operation is determined by the logic states of inverse write enable (WE) and inverse read enable (RE) signals as captured during the P high state. For example, referring now to FIGS. 9g and 9h, to be in the Write mode, WE is required to be low for the time interval t WMC before P falls, while RE is required to be high for the time interval t RMC , also before P falls. Similar time constraints exist on RE and WE for other modes of operation.
In the Write mode, the input data (DI) shown in FIG. 9i is valid for the time interval t DIC prior to P falling and stays valid for time interval t DTI after DT falls.
In the Read mode, Output (DO) is valid after a time delay t TOD from the rise of DT and stays valid until RE changes state indicating completion of the Read mode, or until the next valid output appears, provided the memory is in a continuous Read mode.
The specification of an address for the LARAM of FIG. 2 is accomplished by means of a 5-bit address whose bits are denominated A 0 , . . . A 4 and are introduced to level converter and inverter 30. The address bits in this embodiment will originally be at external logic, e.g., TTL levels. The address will be converted to internal or MOS chip levels in level converter and inverter 30. A particular circuit for address level converter and inverter 30 is shown in FIG. 10. The circuit functions to convert each address input A(TTL) to A(MOS) and its complement A(MOS). The address enable signal AE effectively strobes the circuit to produce an A(MOS) which reflects the instantaneous level of A(TTL). A(MOS) and A(MOS) stay valid until the next strobe by AE. In operation, when AE goes high, transistor 41 will be turned on and if the external address bit A(TTL) is low, transistor 40 will be off and no current will from V DD to ground. As a result, junction 50 will be retained at a high potential approximately equal to V DD . Since transistors 43 and 44 are tied to AE, they are also tuned on. In this case, transistor 46 will be conducting and current will flow from V DD through transistors 43 and 46 to ground. As a result, the gate of transistor 47 is maintained at a relively high potential as compared to the gate of transistor 51. Thus, the gate of transistor 42 is low and the gate of transistor 48 is high; also, the gate of transistor 45 is high and the gate of transistor 49 is low. Thus, A(MOS) is low since any charge discharges to ground through transistor 45 whereas A(MOS) is high since current is supplied from V DD through transistor 48 and is not discharge to ground through transistor 49. The reverse A(MOS) levels are obtained if A(TTL) is high and the voltage on junction 50 is low.
With a multiple-bit address it is necessary that each permutation of the address bits specify a particular line, L i , in each section of lines. This is accomplished by a network of decoders which will activate one of 32 lines, depending upon the states of the address bits. The line driver and decoder of FIG. 3 illustrates two individual line decoders which will cause line L i to be addressed if all of the address bits are zeroes, e.g., if the address is 00000, and will address line L j if the address is 11111. Any intermediate permutation will result in neither of the lines being addressed; an individual line with a suitable configuration will be addressed. In operation, when AE is high, transistors 55 and 60 are turned on so that capacitors 66 and 63 are charged to V DD . When AE goes low the address levels A 0 , . . . A 4 and A 0 , . . . A 4 have stabilized. If any one of the transistors such as 56 or 57 are turned on by any of A 0 , . . . A 4 being high, then capacitor 66 will discharge to ground. Similarly, if any one of the five transistors such as 61 or 62 are turned on by any of A 0 , . . . A 4 being high, then capacitor 63 will discharge to ground. Thus, capacitor 66 will remain charged only if the address is 00000 while capacitor 63 will remain charged only if the address is 11111. In the former case, transistor 58 will be turned on and a master clock P will be impressed on the addressed line while transistor 64 will be turned off and a high circuit voltage V DD will be maintained on the nonaddressed line. Also some thrity other lines will have a high circuit voltage V DD applied as they, too, will be nonaddressed lines. The reverse situation pertains in the latter case.
The data input is converted from external TTL levels IN(TTL) to internal MOS chip levels IN(MOS) and IN(MOS) in the Data In buffers in FIG. 2. A particular input circuit is shown in FIG. 4. When P is high, IN(MOS) and IN(MOS) are unconditionally precharged high to V DD through transistors 80 and 72, respectively. Then, when P goes low, the state of IN(MOS) and IN(MOS) will be determined in accordance with the switched state of transistors 76 and 79 and the condition of inverse read enable. Since input is permitted only in the write mode, one of the IN(MOS) or IN(MOS) will stay high while the other will discharge to ground when RE goes high. This is possible because when RE is high, transistors 78 and 77 are both conducting. If IN(TTL) is high, transistor 73 will be conducting and a current will flow from V DD through transistors 70 and 73 to ground. the voltage on node 81 will be low so that transistor 79 is off. Thus, when RE strobes transistor 78, transistor 79 will not conduct, and IN(MOS) remains high. Since node 81 is low, transistor 74 is off and node 82 remains high due to current through transistor 71. Thus, when RE strobes transistor 77, transistor 76 will be on and IN(MOS) will be low. The reverse operation occurs if IN(TTL) is low. As shown in FIG. 2, this circuit is repeated in each Data In buffer.
Similar translations are made for the write enable WE signal and the read enable RE signal as shown in FIGS. 5 and 8. When P is high, WE(MOS) and WE(MOS) are unconditionally precharged high through transistors 87 and 91, respectively. When P goes low, one of WE(MOS) and WE(MOS) will remain high and the other will go low depending on the input WE(TTL). When WE(TTL) is high, current will flow to ground through transistors 85 and 88 when the precharge clock is high. As a result, junction 94 will be low so that capacitor 93 will not be charged and the gate of transistor 92 will be held low. Thus, transistor 92 will not conduct so that WE(MOS) remains high. Since transistor 89 is turned off, current will flow through transistor 86 to charge capacitor 84. The charge on capacitor 84 keeps tansistor 90 turned on so that WE(MOS) will be discharged to a low level. The reverse situation will pertain (with capacitor 93 charged and capacitor 84 discharged) for an input of WE(TTL).
The read enable logic of FIG. 8 is a circuit for buffer 36 of FIG. 2. This circuit converts RE(TTL) to internal signals RE(MOS), RE 1 (MOS) and RE 2 (MOS). These internal signals, in conunction with the particular data output circuit of FIG. 7, permit data to be outputted with low power consumption during the Read mode. RE(TTL) is introduced to the gate of transistor 140, RE 1 (MOS) is taken from the node common with the source and drain, respectively, of transistors 144 and 135, RE 2 (MOS) is taken from the node common to transistors 139 and 147. RE(MOS) is taken from the source of transistor 165. When P is high, RE 1 (MOS) and RE(MOS) all become unconditionally low and nodes B and C are precharged high.
If RE(TTL) is low, transistor 140 is off; then current flows through transistor 130 and charges node A high. Capacitor 141 also becomes charged. When P goes low and DT occurs, transistor 142 turns on and, since capacitor 141 is charged, node B discharges. Thus, transistors 143 and 144 are turned off and the node driving the gate of transistor 135 goes high, causing RE 1 (MOS) to go high. Capacitor 129 is a bootstrap capacitor which serves to speed up the rise of the node driving transistor 135. Now, since RE 1 (MOS) is high, transistor 145 is turned on and node C discharges to ground. The low potential on node C turns transistors 146 and 147 off so that RE 2 makes the low to high transition in a manner similar to RE. Since node A is high, transistor 156 is on and capacitor 157 does not become charged. Thus, transistor 159 is turned off and node D reposes at a high potential. The high potential on node D keeps transistors 164 and 165 on so that the RE(MOS) stays low. The respective circuits function essentially in an inverse manner if RE(TTL) is originally high.
The data output of FIG. 7 is controlled by the read enable voltages RE 1 (MOS), RE 2 (MOS) since data is provided as output only in the Read mode. The output O is introduced to the gate of transistor 113 in the top leg of the circuit while the inverse output O is introduced to the gate of transistor 118 in the bottom leg of the circuit. Essentially, the data output line tied to the source of transistor 112 and the drain of transistor 119 will be high if output O is high and will be low if the inverse output O is high. The gating scheme is employed to reduce power consumption. In operation, if output O is high, transistor 113 will be turned on and a current will flow to ground when RE 1 (MOS) is high. Thus, the gate of transistor 114 will be low and, when RE 2 is high and RE is low, the gate of transistor 112 will be high. Transistor 119 will be off because transistor 120 is on and current flows to ground, thereby leaving transistor 119 off. The reverse logic pertains if the inverse output O is high, i.e., the data output line will be low.
The charge-sensor modules 14, 15, 16 and 17 (FIG. 2) function to sense the magnitude of the charge packets received from addressed lines within sections 10, 11, 12 and 13. The output of the charge-sensor modules is introduced to the Input/Output modules 18, 19, 20 and 21 to be recirculated through the addressed lines in the Read and Refresh modes and to be gated to the output terminals in the Read mode. The operation of the charge-sensor circuit of FIG. 6 is described in detail in the copending U.S. application of Gunsagar, et al., Ser. No. 448,771, now abandoned, assigned to the same assignee as this application. Briefly, the data charge packet is introduced at S 1 at the terminal connected to the gate of transistor 106. A reference charge packet with a magnitude midway between the expected charge representing a digital 1 and the expected charge representing a digital 0 is introduced as S 2 at the terminal connected to the gate of transistor 107. This referance charge may have a fixed value but preferably is generated dynamically and tracks the value of the data signal as described in copending patent application of Amelio et al., Ser. No. 492,649, now U.S. Pat. No. 3,955,101. In the LARAM of FIG. 2, it is possible for each group of lines to include a dedicated line of reference charge-coupled elements alongside the addressable lines of data charge storage elements with the charge-storage capacity of the reference elements being one-half that of the data elements. The flip-flop consisting of cross-coupled coupled transistors 99 and 100 will set up in accordance with the relative magnitude of the data charge and the reference charge. The transistor network with transistors 102, 104 103 and 105 functions as a buffer between the signal representing the state of the flip-flop and the Data Output or Input circuitry.
In the preferred embodiment, each of the charge-coupled lines comprises a series of charge-coupled elements clocked in a uniphase manner. A memory cell capable of storing one bit of data consists of the conductive elements 234 and 234' tied to a d.c. voltage (and called the static electrode) and the conductive elements 236 and 236' tied to the clock 0 L (and called the dynamic electrode). In an unaddressed line, charge will either be stored under the static electrode as shown by potential profile b if the clock 0 L is maintained low or under the dynamic electrode as shown by potential profile b if the clock 0 L is maintained high. In either case, one complete cycle of the clock 0 L will move the stored charge from one memory cell to the next.
The principles of this invention are also applicable to MOS shift registers. In particular, the CCD shift registers shown in FIG. 1 can be replaced by MOS shift registers.
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A line-addressable random-access memory (LARAM) comprises a plurality of lines of charge storage elements, means for introducing charge representing binary information to the beginning of particular ones of the plurality of lines of charge storage elements which are addressed, at least one data clock signal means for effecting the transfer of charge along those lines of the charge storage elements which are addressed, an address-selection matrix electrically coupled between the clock signal means and the lines to permit the addressed ones of the lines to be clocked, and charge-sensor means for receiving charge from the addressed lines and, in response thereto, generating a signal which represents the data signified by the charge and for recirculating a refreshed representation of the charge to the means for introducing charge.
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TECHNICAL FIELD
The present invention generally relates to wire fabrics and structures. More particularly, this invention relates to tire beads and their methods of manufacturing.
BACKGROUND OF THE INVENTION
A tire bead is that part of a tire which anchors the tire onto a wheel's rim. It is essentially an annular tensile member or inextensible hoop. Every tire has two such beads which are located within the rubber which makes up the inner-most circumference on each side of the tire.
In the usual procedure for manufacturing tire beads, the ends of individual wires, the exteriors of which are often rubber coated, are fed into a tire bead making machine. Machines of this type are old and well known in the tire building art.
Typical machines of this type are disclosed in U.S. Pat. Nos. 1,913,336, 2,902,083 and 5,385,621. These machines comprise a rotating drum about which the wire is wrapped a predetermined number of turns, dependent upon the strength and/or cross-sectional area of the tire bead desired. Standard equipment on such machines includes the means for automatically introducing the leading end of the wire into a gripper on the drum, intermittently operated means for rotating the drum, a stacking device which moves the incoming wire so as to control and build-up the cross-sectional shape of the resulting tire bead, and a knife to sever the incoming wire at the end of each building cycle. During the pause in the rotation of the drum, the finished tire bead is ejected laterally from the drum.
One deficiency of conventional tire bead making machines is their relatively slow operating speeds and consequently the amount of time required to fabricate a tire bead. To overcome this deficiency, various methods have been attempted to feed such tire bead machines a strap comprised of four parallel wires held together by a coating of rubber or other elastomeric material. A rectangular cross-sectional shaped tire bead formed using a standard style strap is shown in FIG. 1 .
However, because such straps are not pliable, their use has been seen to severely limit the range of cross-sectional shapes of the tire beads which can be built-up by using them. For example, a conventional hex cross-sectional shaped tire bead, see FIG. 2, which is commonly used in the tire industry, cannot be built up using the types of straps shown in FIG. 1 . Also, by increasing the number of wires forming each bead, the strength of the bead is reduced.
Another deficiency of conventional tire bead making machines is the problem associated with how to deal with the cut ends of the resulting tire bead. The springback nature of the wire ends can result in their coming loose and causing wire misalignments which can result in an unacceptable number of manufacturing interruptions in order to restring and realign the wires.
Thus, despite the prior art, there still exists a need for more efficient tire bead manufacturing processes.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a more efficient tire bead manufacturing process as defined in one or more of the appended claims and as such, having the capability of accomplishing one or more of the following subsidiary objects.
An object of the present invention is to provide a method of constructing a tire bead with a strap containing two parallel wires enmeshed in an elastomeric material.
Still another object of the present invention is provide a new and improved type of tire bead formed of the strap of two parallel wires.
Other objects and advantages of this invention will become readily apparent as the invention is better understood by reference to the accompanying drawings and the detailed description that follows.
SUMMARY OF THE INVENTION
The present invention is generally directed to satisfying the needs set forth above and the problems identified with prior tire bead manufacturing processes. Prior problems, associated with low operating efficiencies for tire bead machines are resolved by the present invention.
In accordance with one preferred embodiment of the present invention, the foregoing need can be satisfied by providing a method of making a tire bead characterized by the steps of forming a tape composed of a plurality of parallel wires coated with a resilient elastomeric material, the elastomeric material connecting adjoining parallel wires by a web formed between the wires, the web being of a predetermined size so as to yield the tape sufficiently pliable so as to allow the tape to be positioned to build up a tire bead having the same cross-sectional areas that can be built using individual wires, and forming a tire bead by winding such a tape a predetermined number of superimposed convolutions.
In another preferred embodiment, the present invention is seen to take the form of the above described method wherein the winding of the tape proceeds with the convolutions of the tape being laid in side by side relation and in successive superposed layers of predetermined widths to provide a tire bead of predetermined cross-sectional area.
In another preferred embodiment, the present invention is seen to take the form of a tire bead formed by any of the above described methods.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure, operation, and advantages of the invention will become further apparent upon consideration of the following description taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is the cross-sectional view of a conventional tire bead fabricated by layering four straps, each of which consists of six parallel wires enmeshed in a rubber coating;
FIG. 2 is a cross-sectional view of a conventional hex cross-sectional shaped tire bead;
FIG. 3 is a side view of a tire bead manufacturing process according to the present invention;
FIG. 4 is a cross-sectional view of a tire bead tape according to the present invention; and
FIG. 5 is a cross-sectional view of a hex tire bead made from a tape according to the present invention.
DEFINITIONS
“Bead” or “Bead Core” generally means that part of the tire comprising an annular tensile member of radially inner beads that are associated with holding the tire to the rim; the beads being wrapped by ply cords and shaped, with or without other reinforcement elements such as flippers, chippers, apexes or fillers, toe guards and chafers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein are shown preferred embodiments of the present invention and wherein like reference numerals designate like elements throughout, there is shown in FIG. 3 a side view of a tire bead manufacturing process according to the present invention.
This embodiment is seen to comprise the steps of providing a tape 10 , as shown in FIG. 4, composed of a plurality of parallel wires 12 a , 12 b coated with a resilient elastomeric material. The elastomeric material connects the adjoining parallel wires by a web 14 formed between the wires. The web 14 is of a predetermined size so as to yield the tape sufficiently pliable to allow the tape to be bent to build up the same cross-sectional areas that can be built up using individual wires. Tire beads 16 are formed by winding the tape 10 a predetermined number of superposed turns around the drum 18 of the tire bead machine 20 .
The tire bead manufacturing process of FIG. 3 is seen to comprise a plurality of large creels 22 which supply individual wires 12 a , 12 b . These creels are arranged side-by-side so that only one shows in FIG. 3 . The individual wires 12 a , 12 b are drawn from the creels 22 and passed into a spacing device 24 , such as a grooved guide roller, which serves to bring the wires into parallel alignment in a single horizontal plane, this being the basis for the eventual tape which these wires will comprise. The wires are next drawn through a tubing machine 26 where a coating 28 of elastomeric material, as shown in FIG. 4, is forced around and between the separate wires 12 a , 12 b to coat the wires while forming a web 14 of predetermined size between the adjoining wires. A set of dies and inserts for the tubing machine's extruder are used to create the web's precise dimensions. The tubing machine is of any standard make and does not make up a part of the present invention.
See FIG. 4 for a cross-sectional view of the resulting tape 10 after it has passed through a cooling section 27 which is used set the elastomeric material. The tape 10 has a coating 28 about the wires 12 a , 12 b and a web 14 interconnecting the coated wires 12 a , 12 b . The web 14 has a thickness “t” and a width “w” which depends on the specific application. While tape 10 as shown, can be formed with two parallel wires, it is also within the terms of the present invention to form the tape of more wires, such as 6 or 8 , embedded in elastomeric material and then slice the tape into a plurality of tapes of two wires embedded in rubber having a web therebetween.
In order to permit continuous operation of this process, a festooning storage device 30 is placed after the cooling section 27 . The tape from the festooning device 30 is wound upon the drum 18 of the tire bead making machine 20 . The tire bead making machine 20 has all the standard equipment usually included on such machines, including the mechanical components 32 for automatically introducing the leading end of the tape 10 into a gripper (not shown) on the drum 18 , and for intermittently rotating the drum. A stacking device 34 of conventional design moves the incoming tape 10 so as to control and build-up the cross-sectional shape of the resulting tire bead. A knife 36 severs the incoming tape at the end of each building cycle. During the pause in the rotation of the drum 18 , the finished tire bead 16 is ejected laterally from the drum.
Table I below shows preferred parameters for the webs 14 formed when various sizes of round steel wires are used in manufacturing the tapes 10 from which the tire beads are formed:
TABLE I
Wire
Coating
Web
Web
Diameter
Elastomeric
Thickness
Thickness
Width
(in)
Material
(in)
(in)
(in)
0.050
Rubber
0.005
0.020-0.025
0.010
0.072
Rubber
0.005
0.025-0.030
0.010
Using such web sizes, it has been found that the resulting tapes 10 can be positioned at between 135 to 150 degree angles with respect to the majority of tape layers applied to a cylindrical drum in order to allow the tapes to be optimally configured to make the full range of cross-sectional shapes used in various tire bead configurations. For example, FIG. 5 shows a cross-sectional view of a hexagonal shaped tire bead 16 formed by using a tape 10 having two parallel wires 12 a , 12 b embedded in an elastomeric coating. In this example, a tape 10 is wound about a drum 18 so as to form twelve convolutions 10 a , 10 b , . . . 10 L of the single tape about the drum 18 . These convolutions typically are wound side to side within layers which are build up around the drum to yield the desired cross-sectional shape such as is the hexagonal shaped tire bead 16 .
Typically, the tape 10 is wound in a groove 40 formed in the outer circumference of drum 18 . First the tape is wound onto the drum 18 at one end of the groove followed by an adjacent winding convolution 10 b . Then, the stacking device positions the next convolution 10 c above and slightly to the right of convolution 10 b so that the left side of the web rests above the web section of convolution 10 b . After convolution 10 d is applied in the manner just described, the convolution 10 e is applied so that one wire is adjacent the second layer and the second wire of convolution 10 e begins the third layer. After convolutions 10 f and 10 g are applied, the convolution 10 h is applied to end the third layer and begin the fourth layer. The construction process continues to form the bead shown in FIG. 5 . The ability of the tape 10 with the double wires to straddle two layers provides the flexibility for forming a bead having any desired shape including but not limited to a triangular, pentagonal or hexagonal shape. The outside convolutions 10 c , 10 h in the second, third and fourth layers have half convolutions oriented so that a line a—a between the centers of the convolution's parallel wires is at an angle α with respect to comparable line b—b between the centers of the adjoining convolutions in the same layer. While a might be sixty degree for a hexagonal shaped bead, any other angle can be used depending on the final bead shape.
While the invention has been described in combination with embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing teachings. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.
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The present invention provides a method of making a tire bead ( 16 ) with a tape ( 10 ) composed of two parallel wires ( 12 a , 12 b ) having a coating ( 28 ) of resilient elastomeric material and connected by a web ( 14 ). The tire bead ( 16 ) can be built by winding the tape ( 10 ) in side by side relation and in successive superposed layers of predetermined widths and with convolutions spanning superposed layers to provide the tire bead ( 16 ) of predetermined cross-sectional area.
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TECHNICAL FIELD
This invention relates to flywheels for automotive engines and the like. More particularly, the invention relates to sound generating vibration damping means for reducing or modifying sound transmitted to flexplate flywheels and possibly to associated components to reduce starting noise.
BACKGROUND
It is known in the art relating to flexplate engine flywheels to provide a thin annular ring fixed as by projection welding to the flexplate inwardly of an associated starter ring gear to reduce engine generated flexplate vibrations that may result in undesirable sound transmitted from the flywheel and/or engine. One such prior art arrangement which has been used commercially in automobiles for connecting the engine with a transmission is shown in FIGS. 1 and 2.
In these Figures, numeral 10 indicates the prior art flywheel which comprises a circular disc 11 of rotatably stiff but axially flexible relatively thin sheet metal. The disc 11 is of generally constant axial thickness although variable thickness discs could be provided if desired. The disc 11 has a generally flat outer annulus 12 contacted with a slightly dished central portion 14 having a central guide opening 15 surrounded by a plurality of smaller openings 16 for attaching the disc 11 to a flanged end 18 of an engine crankshaft 19. The degree of dishing is optional and depends primarily upon the space available between the crankshaft 19 and an associated transmission input member such as a fluid coupling 20.
Beyond the outer annulus 12, the disc 11 has a short axial flange 21 to which is intermittently welded at 22 a steel ring gear 23 having outwardly facing teeth 24 adapted to be engaged by a starter drive gear 26 for starting the engine. (Some prior art arrangements omit the flange 21 and weld the ring gear directly to the flat outer annulus 12 of the disc.)
Between the flange 21 and the central portion 14 a damping ring 27 formed as a thin generally flat annulus is fixed at radially and annularly spaced locations 28 by projection welding or the like to the flat outer annulus 12. Annularly spaced mounting openings 30 extend through the outer annulus 12 and damping ring 27. One opening 30A may be nonround for balancing alignment of the engine and transmission upon assembly. Additional openings 31 may be provided through the disc 11 for controlling its stiffness and lightening the flywheel 10.
The prior arrangement as described for FIGS. 1 and 2 has been effective in reducing or altering engine generated sound vibrations to provide quieter or more pleasing engine and vehicle noise transmission within and outside the vehicle. However, a further reduction in starter drive generated noise to obtain an improved perception of transmitted sound was also desired.
SUMMARY OF THE INVENTION
The present invention provides an improved flexplate flywheel construction which advantageously reduces both the vibration level or sound power and the effective frequency of transmitted sound caused by engine starter induced vibrations during engine starting. The improved structure differs substantially from the prior art in providing direct welding, preferably continuous, of the ring gear to a damping ring to directly reduce ring gear transmitted starting induced vibrations.
This modification is preferably accomplished by connecting the flat outer annulus directly and preferably continuously by welding to the ring gear. However, it is believed that intermittent welding of the damping ring to ring gear will provide some reduction of starting noise.
It is not required to also spot weld the damping ring to the flexplate but, in a preferred embodiment, the outer edge of the flexplate central portion and the outer edge of the damping ring are both welded to an annular inner face of the ring gear by the same continuous welding bead, simplifying manufacturing.
These and other features and advantages of the invention will be more fully understood from the following description of certain specific embodiments of the invention taken together with the accompanying drawings.
BRIEF DRAWING DESCRIPTION
In the drawings:
FIG. 1 is a face view of a prior art flexplate flywheel;
FIG. 2 is a cross-sectional view from the line 2--2 of FIG. 1;
FIG. 3 is a face view of a flexplate flywheel according to the invention;
FIG. 4 is a cross-sectional view from the line 4--4 of FIG. 3;
FIGS. 5a and 5b are graphs comparing frequency vs sound pressure of prior and current devices; and
FIG. 6a and 6b are graphs comparing time during starting vs overall sound pressure for the same devices.
DETAILED DESCRIPTION
Referring now to the drawings in detail, FIGS. 3-4 show an embodiment of modified flexplate flywheel 40 having starting vibration damping means according to the invention. The flywheel has several features similar to those previously described for the prior art. These include a circular disc 41 with a flat outer annulus 42 and slightly dished central portion 44 with a central guide opening 45 surrounded by smaller openings 46 for attaching to the end 18 of a crankshaft 19 (not shown in these figures).
The outer annulus 42 of the disc 41 has a radial outer edge 52 to which is welded a steel ring gear 53 with teeth 54 for engaging a starter drive gear 26 (FIG. 1) Mounting openings 60 are provided, one of which 60A is nonround, for attaching the outer annulus to a transmission fluid coupling 20 or the like. Openings 61 may also be provided in the disc 41. These items are similar to the prior art.
The flywheel 40 also has a flat annular damping ring 62 mounted against the face of the outer annulus 42. It differs significantly from the prior art in that it is welded directly to the ring gear 53 by a continuous weld bead 63. While a continuous bead is preferred, an intermittent welding pattern may also be acceptable. Preferably, a single weld 63 is used to connect the ring gear 53 to both the damping ring 62 and the outer edge 52 of the disc 41 because this simplifies assembly and minimizes weight. Optionally, the disc and damping ring could be connected to the ring gear by separate welds. Also the disc and damping ring could additionally be projection welded together as long as both are also welded to the ring gear.
The result of this change wherein the ring gear is welded directly to the damping ring is to significantly enhance the damping of ring gear vibrations which are caused by gear rotation during engine starting. Evidence of this is seen in FIGS. 5a, 5b, 6a and 6b which compare the results of tests made on (1) an undamped flywheel, (2) one having a flexplate mounted damper as in the prior art and (3) a damper according to the invention.
FIGS. 5a and 5b compare the sound pressure across the frequency spectrum of sound readings at left and right ear positions inside a vehicle. Long dashed lines 64, 66 show the results for an undamped flexplate flywheel. Short dashed lines 67, 68 represent a prior art flywheel with damped flexplate and solid lines 70, 71 show a flywheel with damped ring gear according to the invention. The left ear results are in general greater than those of the right ear.
FIGS. 6a and 6b compare total sound pressure at similar left and right ear positions over a time period of seconds, indicated, of starter cranking. Again the left ear results are greater. Long dashed lines 72, 74 show the undamped flywheel, short dashed lines 75, 76 show the damped flexplate and solid lines 78, 79 show the damped ring gear of the invention.
While the invention has been described by reference to a preferred embodiment, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly it is intended that the invention not be limited to the disclosed embodiments, but that it have the full scope permitted by the language of the following claims.
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A flexplate flywheel has an annular damper ring welded directly to the associated ring gear to substantially reduce starter associated vibrations and the level of sound perceived by the driver of an associated automotive vehicle during engine starting.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to radio frequency mixers and, more particularly, to balanced mixers.
2. Prior Art
In the context of a communication device, such as a mobile phone, there is a need to combine the RF input signal with a local oscillator signal to generate an intermediate frequency signal for filtering. This function is performed in a mixer and it is this circuit component to which this application is directed.
A singly balanced mixer is shown in FIG. 3, and includes a differential pair of transistors connected to a collector of an RF-amplifier transistor. The local oscillator signal is connected to the bases of the differential switching pair and the RF input is connected to the base of the common emitter amplifier transistor. The RF-amplifier converts input RF-voltage to current at its collector. LO switching transistors alternate the routing of this current to either of the loads.
FIG. 4 shows a double balanced mixer, commonly known as a Gilbert cell mixer. A differential RF transistor pair converts differential RF input voltage to differential current. Two sets of LO switching transistor pairs are used to alternate the routing of the current at the output. The mixer operates as a sign-switcher. The double balanced mixer was designed, among other things, to eliminate the need, in the case of the singly balanced mixer, to cancel out. the local oscillator component from the IF signal. The proliferation of components over the singly balanced mixer, however, creates a sensitive matching challenge. For optimum performance, double balanced mixers require that the component pairs, be matched as close as possible in order to maximize port to port isolation and to reduce undesirable distortion. Conventional integrated double balanced mixer circuits may need compensation for any imbalance by either electrical means or even laser tuning.
It is a purpose of this invention to design a mixer having many of the attributes of the double balanced mixer, while minimizing matching problems. This is accomplished with a reduction in the number of components.
SUMMARY OF THE INVENTION
A mixer is provided for mixing radio frequency signals in a communications device. A single pair of matched transistors comprise the core of the mixer. Each of the transistors have their drain port connected to the in phase local oscillator signal(LO) through matching resistance loads and their source port connected to a reverse phase local oscillator signal(−LO) through a resistor acting as a current source. No DC bias is applied between such ports. The gate ports of each of the transistors in the pair receive the differential radio frequency signal. The intermediate frequency output is obtained from the drain ports of the matched transistors. In the positive half cycle of the local oscillator signal the mixer will operate as a differential pair having inverting power gain, while in the negative half cycle of the local oscillator signal, the mixer circuit will operate as two source followers, i.e. two non-inverting amplifiers having current gain. In this manner a mixer is provided with port to port isolation, low noise, and high linearity. This is accomplished with only two sets of matched components.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and other features of the present invention are explained in the following description, with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a mobile station and a cellular communication system to which the mobile station is bidirectionally coupled through a wireless RF link;
FIG. 2 is a block diagram of the mobile station shown in FIG. 1 that is constructed and operated in accordance with this invention;
FIG. 3 is a circuit diagram of a typical singly balanced mixer;
FIG. 4 is a circuit diagram of a typical double balanced mixer; and
FIG. 5 is a circuit diagram of a two transistor balanced mixer illustrating one embodiment of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A wireless user terminal or mobile station 10 is shown in FIGS. 1 and 2, in which the subject invention may be used. The mobile station 10 includes an antenna 12 for transmitting signals to and for receiving signals 10 from a base site or base station 30 . Base station 10 generally would include a base station sub-system (BSS) as well as a base transceiver station (BTS). For simplicity, these two components are collectively referred to simply as the base station 30 . The base station 30 is a part of a cellular network 32 that includes a mobile switching center (MSC) 34 or similar apparatus. The MSC 34 provides a connection to landline trunks when the mobile station 10 is involved in a call.
The mobile station includes a modulator (MOD) 14 A, a transmitter 14 , a receiver 16 , a demodulator (DEMOD) 16 A, and a controller 18 that provides signals to and receives signals from the transmitter 14 and receiver 16 , respectively. These signals include signaling information in accordance with the air interface standard of the applicable cellular system, and also user speech and/or user generated data. The air interface standard may be based on TDMA as used in the GSM system, although the use of this invention is not intended to be limited to a particular type of system.
The present invention could be used with any suitable type of radio telephone system or suitable electronic device. With general regard to GSM mobile stations and networks, reference can be had to “The GSM System for Mobile Communications”, by Michel Mouly and Marie-Bernadette Pautet, 1992, the disclosure of which is incorporated by reference in its entirety.
Controller 18 also includes the circuitry required for implementing the audio and logic functions of the mobile station. By example, the controller 18 may be comprised of a digital signal processor device, a microprocessor device, and various analog to digital converters, digital to analog converters, and other support circuits. The control and signal processing functions of the mobile station are allocated between these devices according to their respective capabilities.
A user interface may include a conventional earphone or speaker 17 , a conventional microphone 19 , a display 20 , and a user input device, typically a keypad 22 , all of which are coupled to the controller 18 . The keypad 22 includes the conventional numeric ( 0 - 9 ) and related keys (#,*) 22 a, and other keys 22 b used for operating the mobile station 10 . These other keys 22 b may include, by example, a SEND key, various menu scrolling and soft keys, and a PWR key. The mobile station 10 also includes a battery 26 for powering the various circuits that are required to operate the mobile station. The mobile station 10 also includes various memories, shown collectively as the memory 24 , wherein are stored a plurality of constants and variables that are used by the controller 18 during the operation of the mobile station. Certain TDMA timing related parameters that are transmitted from the base station 30 to the mobile station 10 are typically stored in the memory 24 for use by the controller 18 . It should be understood that the mobile station 10 can be vehicle mounted, handheld, or a stationary device. It should be further appreciated that the mobile station 10 can be capable of operating with one or more air interface standards, modulation types, and access types, and may thus be dual (or higher) mode device.
The receiver 16 also includes circuitry required for implementing the well known process of multiplexing a signal with a periodic signal to obtain a new center frequency, i.e., mixing. Mixing generally occurs immediately before multiple filter stages and receives the radio frequency (RF) signal, combines it with a periodic signal, the local oscillator (LO) signal to obtain an intermediate frequency (IF) signal which is filtered.
An embodiment of the two transistor mixer circuit 20 incorporating features of the present invention is shown in FIG. 5 . As seen in FIG. 5 the circuit comprises a pair of active semiconductor devices 21 and 22 . Semiconductors 21 and 22 are shown as a pair of transistors such as JFETS. However any suitable pair of matched semiconductors could be used, e.g., BJT, or MOSFETs.
The gates 23 and 24 of transistors 21 and 22 respectively are the differential signal input paths for the RF signals. The LO signal is received at node 27 and is passed to drains 25 and 26 of transistors 21 and 22 respectively, through matched load resistors R L1 and R L2 Source terminals 28 and 29 of transistors 21 and 22 respectively are connected to receive the LO signal through the current source resistor R s . The differential output for the IF signal is taken from drains 25 and 26 .
The transistors 21 and 22 of mixer 20 will operate in a reversible bias mode depending upon the half cycle of the LO signal. The supply voltage for this transistor pair 21 and 22 is a large LO AC signal. For positive half cycles of the LO signal, the transistor terminals 25 and 26 connected to their respective loads R L1 and R L2 are at a higher potential than the terminals 28 and 29 connected together and to the current source resistor R s . The circuit operates as a differential pair having inverting power gain. In this part of the LO signal cycle, the terminals 25 and 16 connected to the loads R L1 and R L2 are identified as the drains, while the terminals 28 and 29 are identified as the sources. For negative LO half cycles the biasing of the circuit is reversed and the operation is different. Now the transistor terminal designations are interchanged i.e., the terminal previously identifiable as a drain is now the source. Therefore, during the negative half cycle of the LO signal, mixer circuit 20 operates as two source followers, that is, two non-inverting amplifiers having current gain. At the IF outputs 30 and 31 there is present an amplified RF signal having its phase inversion triggered by the LO signal.
Thus, the mixer circuit 20 performs the function of a double balanced mixer, in the sense that it operates as a sign-switcher and the LO-signal is balanced out from both the RF and IF ports. The RF-signal is not balanced out from the IF output unlike in a true double balanced mixer. In addition, in the two transistor mixer of this invention, there can be some difference in gain between differential pair and dual source-follower modes. The mixer function is accomplished with fewer matched parts, namely, one matched pair of transistors and one matched pair of resistors. Additionally, compared to most known double balanced mixers the present invention does not have dedicated LO switch devices which in turn makes the present invention less noisy than conventional mixers.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. For example, all or some of the resistors, shown in FIG. 5, could be replaced by inductor or resonant circuits. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
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A two transistor mixer for mixing radio frequency signals in a communications device. A mixer core section comprised of a pair of matched semiconductor devices having their drain ports connected to a first common node through matched load resistors and their source ports connected to a second common node end. A local oscillator (LO) signal input connected to the first and second nodes, wherein the connection to the second node is through a current source. A radio frequency (RF) signal input connected to the gate ports of said pair of semiconductor devices and an intermediate frequency (IF) output obtained from the drain ports of said pair of semiconductor devices.
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PRIORITY/CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/926,689, filed Jan. 13, 2014, the disclosure of which is incorporated by reference.
TECHNICAL FIELD
[0002] The presently disclosed and claimed technology generally relates to an apparatus for warming a cold vehicle, and more particularly to a fitting for exchanging fluid between a warm vehicle and a cold vehicle.
BACKGROUND
[0003] Liquid cooled engines become problematic in cold climates. The cold weather can cause the oil and coolant to become more viscous. The more viscous fluids can provide less lubrication as well as making it more difficult for the engine to start. In this cold weather the batteries are also much less effective. In extreme climates this can even result in the inability of the vehicle to start.
[0004] Systems have been developed that utilize electricity to heat the vehicle fluids or the entire engine to make starting them in cold weather easier. One solution is just to keep the engine running at all times. This is not cost effective, especially for a fleet of vehicles. Electric engine heating systems require installation of the system on the vehicle and then connecting the system to an electrical source, such as a regular a/c outlet at a home or shop. These systems are typically unworkable in some operations where the vehicles are kept in remote locations. This can happen in a number of situations including farming, ranching, construction and other operations where more than one vehicle is being used. In the situations where the vehicles are in remote locations, the electrical heating solution is not available due to the distance from the nearest outlet.
SUMMARY OF THE DISCLOSURE
[0005] The purpose of the Summary of the Invention is to enable the public, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection, the nature and essence of the technical disclosure of the application. The Summary of the Invention is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
[0006] Still other features and advantages of the claimed invention will become readily apparent to those skilled in this art from the following detailed description describing preferred embodiments of the invention, simply by way of illustration of the best mode contemplated by carrying out my invention. As will be realized, the invention is capable of modification in various obvious respects all without departing from the invention. Accordingly, the description of the preferred embodiments are to be regarded as illustrative in nature, and not as restrictive in nature.
[0007] Disclosed is an engine warming system for a water cooled vehicle. The system allows for the exchange of warm fluid (coolant) from a warmed vehicle or portable tank of warmed coolant, into a cold vehicle while returning fluid from the cold vehicle to a second vehicle or fluid exchanging vessel. The system is made up of a fluid exchange fitting in one vehicle that has two positions, one for normal circulation of fluid in the vehicle cooling system, and one position for sending the coolant of the first vehicle to a second vehicle or coolant reserve tank, for replacement by warmed coolant from a second vehicle or coolant tank. On one version, identical fluid exchange fittings are in a first and a second vehicle, and the two fittings are connected by fluid transfer hoses. There is a conduit between the left and right half allowing for fluid to flow between the two halves as well as a conduit valve located within the conduit for closing or opening the conduit for the fluid flow. This fitting is installed in at least a first vehicle that will require heating.
[0008] The fluid exchange fitting has a first inlet port, a first outlet port, a second inlet port, and a second outlet port. The fluid exchange fitting has either one or three valves to switch between the first position and the second position.
[0009] The fluid exchange tank can be of several configurations. One option is to have a second fluid exchange fitting mounted on a second vehicle, where the second vehicle provides the heated fluid from its own cooling system. The second vehicle is started at a location remote from the cold vehicle and driven to the cold vehicle. A second option is to have the fluid exchange tank as a standalone unit allowing for direct connection to the fluid exchange fitting on the cold vehicle. The standalone unit could be placed on a truck bed or ATV and driven to the cold vehicle.
[0010] A typical configuration in which one vehicle is equipped with a first fluid exchange fitting and a second vehicle is equipped with a second fluid exchange fitting. The two fluid exchange fittings are connected by a first fluid transfer hose and a second fluid transfer hose. These can connect using quick release fittings, for ease of connection. The first fluid transfer hose is connected to the second outlet port of the fluid exchange fitting at one end, and at the other end is attached to the second inlet port of the second fluid exchange fitting. The second fluid exchange hose in this configuration would be attached from the second outlet port of the second fluid exchange fitting to the second inlet port of the first fluid exchange fitting. In this way, coolant fluid could pass from the first vehicle to the second vehicle, and warm fluid from the second vehicle would pass into the cooling system of the first vehicle.
[0011] Each of the cooling systems of the two vehicles could operate as normally configured by moving the valve or valves of each fluid exchange fitting to a first position. In the first position, coolant enters the fluid exchange fitting at the first inlet port, and exits at the second inlet port and continues on through the cooling system of the vehicle. The cooling system of the vehicle would include a heater, a radiator, a water pump and fluid exchange passages in the block of the engine. If both the first and the second vehicle are set so that the fluid exchange fittings are in the first position, both vehicles' cooling system would operate normally. If the two fluid exchange fittings are connected by a first and a second fluid transfer hose, and the valve or valves of the fluid exchange fittings were set to a second position, then coolant would circulate between the two vehicles.
[0012] The fluid exchange fittings can take several configurations. One of these configurations utilizes a single valve and has a disc shaped hub which is mounted in a fluid exchange fitting body. The disc shaped hub has three passages, a first, a second and a third passage. The first passage connects the first inlet port with the first outlet port, and supports normal circulation of coolant within the vehicle's cooling system. By turning the valve, the disc shaped hub is also turned, and a second and a third passage is rotated into the second position so that the first inlet port sends coolant to the second outlet port. Fluid from the second vehicle returns to the fluid exchange fitting through the second inlet port and exits the fluid exchange fitting out the first outlet port, and continues on through the rest of the cooling system of the first vehicle.
[0013] Other designs for fluid exchange fitting are foreseeable. One alternative embodiment utilizes a single valve having a first passage, a second passage and a third passage. The valve further provides for a first position and a second position. In the first position the second passage creates a fluid path between the first outlet port and the first inlet port. As in the previously described embodiment, this allows the cooling system of the vehicle to function as originally designed. In the second position the first passage creates a fluid path between the second inlet port and the first outlet port. Additionally, in the second position, the third passage creates a fluid path between the first inlet port and the second outlet port. When placed in the second position with the coolant hose and the first transfer hose and second transfer hose connected as previously described the fluid exchange fitting functions to allow external heated fluid to pass through second inlet port through the first passage through the first outlet port and then through the vehicle heater hose. Vehicle coolant hose then returns the displaced fluid to fluid exchange fitting into first inlet port through third passage and out second outlet port then through second transfer hose and then is returned to fluid exchange tank for reheating. The fluid exchange fittings can be mounted in a heater house, a flexible rubber coolant hose, on in a rigid metal tube which is part of the cooling system of a vehicle.
[0014] Fluid exchange tank can be of several designs. One potential design is to have a second fluid exchanging fitting connected to a second vehicle. The second vehicle is driven into proximity of the cold vehicle that is to be heated and then the first transfer hose and second transfer hose are connected prior to changing valves to allow for fluid communication between the vehicles. Another potential design is to have a standalone fluid heater. This system could be located on the bed of a truck, 4 wheeler, cart, or other vehicle and could potentially have the first transfer hose and second transfer hose permanently attached. The standalone unit could be powered by a variety of sources including gasoline, diesel or electrical power provided by a battery or by the transportation vehicle. Further, the transfer hoses 36 & 38 can be connected in different ways such as by a quick disconnect fitting or similar devices. The heater hose can be connected to the first outlet port and first inlet port by thread slip fittings or other fittings that are configured for connecting the fluid exchange fitting 12 and the heater hose 28 .
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a flow diagram depicting the fluid flow through two vehicles in accordance with an embodiment of the inventive concepts.
[0016] FIG. 2 is a top view of a fluid exchange fitting in accordance with an embodiment of the inventive concepts.
[0017] FIG. 3 is a perspective view of a fluid exchange fitting in accordance with an embodiment of the inventive concepts.
[0018] FIG. 4 is a cross-sectional view of fluid exchange fittings illustrating first and second positions of a valve setting on the fluid exchange fitting.
[0019] FIG. 5 is a side view fluid exchange tank and heater mounted in a second vehicle, in accordance with an embodiment of the inventive concepts.
[0020] FIG. 6 is a perspective view fluid exchange fitting in accordance with an embodiment of the inventive concepts.
[0021] FIG. 7 is a schematic view of the connection between two vehicles each having a fluid exchange fitting.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] While the presently disclosed inventive concept(s) is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the inventive concept(s) to the specific form disclosed, but, on the contrary, the presently disclosed and claimed inventive concept(s) is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the inventive concept(s) as defined in the claims.
[0023] Certain preferred embodiments of the disclosed technology are shown FIGS. 1 through 7 .
[0024] Disclosed in FIG. 1 is a diagram of an engine warming system 10 for use on liquid cooled vehicles such as cars, trucks and machinery that is stored in a cold environment. This could include heavy equipment such as earth movers, graders, dump trucks, tracked vehicles, tractors, combines, harvestors, loaders, tractor trailer rigs, as well as boats, snow mobiles, snow vehicles, 4 wheelers, generators, or other equipment using water cooled internal combustion engines.
[0025] FIG. 1 shows a first vehicle 34 and a second vehicle 66 connected to each other for coolant exchange. The first vehicle 34 would typically be cold and therefore hard to start, and the second vehicle 66 would be warm and provide warm or hot coolant to first vehicle 34 . A typical automobile system is “warmed up” when the coolant is heated to above 212 F. in a pressurized system. This “warmed” coolant would be exchanged with a cold vehicle's coolant in the disclosed system. The system 10 could optionally include a loop of heated coolant for heating the battery 68 of the cold vehicle, by use of a coolant filled jacket or box, or by use of one or more tubes which surround the cold battery and transfer heat into the cold battery.
[0026] Shown in FIG. 1 is a cooling system 36 in each of the vehicles, which includes a coolant hose 32 . Coolant is circulated through the cooling system by a water pump 70 , with coolant circulating through a radiator 72 and from there through the coolant hose 32 , which could be a heater hose. The coolant hose 32 would return coolant to the cooling system 36 , or as shown in FIG. 1 could route coolant adjacent to or surrounding a battery 68 , to warm up the battery for more powerful starting. This system includes a first fluid exchange fitting 12 in the first vehicle 34 , and a second fluid exchange fitting 48 in the second vehicle 66 .
[0027] Also shown is a first fluid transfer hose 44 and a second fluid transfer hose 46 , which are used to transfer fluid from the warm vehicle 66 to the cold vehicle 34 and vice versa.
[0028] FIG. 2 shows one configuration of the fluid exchange fitting which would be installed in the coolant hose 32 of the first or the second vehicle. The fluid exchange fitting 12 shown in FIG. 2 includes a first conduit 54 which is a straight piece of pipe which has a first valve 56 in the approximate center of the first conduit 54 . At one end of the first conduit 54 is a first inlet port 14 and at the other end is a first outlet port 16 . Attached to the first conduit 54 is a second conduit 58 , which has a second valve 60 . Also attached to the first conduit 54 is a third conduit 62 , with a third valve 64 . When attached to a coolant hose 32 , coolant would enter at the first inlet port 14 and if the second valve 60 and the third valve 64 were in a closed position and the first valve 56 was in an open position, then fluid would flow directly from first inlet port 14 to first outlet port 16 and circulate in a normal manner through the cooling system of the vehicle. The position described above is called the first position. The second position would be when the first valve 56 is closed, and the second and third valve 60 and 64 are open. When this occurred, if the second fluid exchange fitting 48 in a second vehicle is also in the second position and has transfer hoses attached, then the two systems would cause hot coolant from the second vehicle to flow into the cooling system of the cold first vehicle, and cold coolant from the first vehicle would flow into the warmed up and running second vehicle.
[0029] FIG. 3 shows a perspective view of the same version of the fluid exchange fitting as shown in FIG. 2 .
[0030] FIG. 4 shows an alternate embodiment of fluid exchange fitting 12 , which is identical to the fluid exchange fitting 48 found in the second vehicle. Also shown in FIG. 4 is the fluid exchange fitting 12 in the first position 22 and a second position 24 . In the embodiment shown in FIG. 4 , the fluid exchange fitting has a fitting body 50 and a disc shaped hub 52 . The fitting body 50 has the same inlet and outlet ports as shown in the previous figures, which includes a first inlet port 14 , a first outlet port 16 , a second inlet port 18 and a second outlet port 20 . The disc shaped hub 52 includes a first passage 26 , a second passage 28 , and a third passage 30 , which are hollow openings inside the disc shaped hub. When connected as shown in the upper view of FIG. 4 , the fluid exchange fitting 12 is in the first position 22 , and fluid from the coolant hose 32 goes directly through the first passage 26 and out the first outlet port 16 and back into the coolant hose 32 , to continue circulating through the cooling system of the vehicle. In the lower view in FIG. 4 , the disc shaped hub 52 is turned to the second position 24 and the second passage 28 aligns with the first inlet port 14 so that coolant passes through the fluid exchange fitting 12 and exits through the second outlet port 20 . In this position, the third conduit 30 alligns with the second inlet port 18 and routes fluid through the third passage 30 to exit out the first outlet port 16 , to reenter the coolant hose 32 .
[0031] FIG. 5 shows a configuration of the device in which the fluid to be warmed and exchanged is in a fluid exchange tank 38 . It is connected to the first vehicle with a first fluid transfer hose 44 and a second fluid transfer hose 46 and further includes a heater 74 and a pump 76 . The fluid exchange tank 38 could be on any vehicle, such as a pickup, a 4 wheeler, a snowmobile, or a non-motorized dolly or wagon. The fluid exchange tank includes a receiving port 40 , and a discharge port 42 , with the receiving port connected to 1 st transfer hose 44 , and the discharge port 42 connected to 2 nd fluid transfer hose 46 . This configuration is simply a different version of the system which uses a second vehicle as the fluid exchange tank, and illustrates a system which does not require use of a second fluid exchange fitting.
[0032] FIG. 6 shows a perspective view of the fluid exchange fitting 12 shown in FIG. 4 , in which the fitting body 50 encloses a rotatable disc shaped hub 52 , in which are found a first passage 26 , second passage 28 and third passage 30 . Shown in FIG. 6 is a first inlet port 14 , a second outlet port 20 , a second inlet port 18 and indicated, but not visible is a first outlet port 16 . Shown is a first valve 56 which is used to turn the disc shaped hub to a first position or a second position.
[0033] FIG. 7 shows a more detailed version of how the fluid exchange fittings are connected to each other in two separate vehicles. FIG. 7 is a different view of the same set up in FIG. 1 , but the fluid exchange fittings 12 and 48 are shown in greater detail. Both of these fittings could be set up with the fluid exchange fittings of FIG. 4 or the fluid exchange fittings of FIGS. 2 and 3 .
[0034] While certain exemplary embodiments are shown in the figures and described in this disclosure, it is to be distinctly understood that the presently disclosed inventive concept(s) is not limited thereto but may be variously embodied to practice within the scope of the following claims. From the foregoing description, it will be apparent that various changes may be made without departing from the spirit and scope of the disclosure as defined by the following claims.
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A system for warming the engine of a water-cooled vehicle by exchanging coolant with a warm vehicle or a storage tank of warmed coolant. The system utilizes a fitting that, in one position, allows for normal function of the cooling system of a vehicle, and in another position the fitting allows for fluid exchange with an outside source, such as another vehicle. The outside source can be a second vehicle equipped with a fitting or a standalone heater. Fluid transfer hoses are connected to each fitting to exchange coolant between vehicles.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/260,754 entitled “Headgear for Protection Against Environmental Effects” and filed on 12 Nov. 2009 for Devra Wathen, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to hats and headpieces and more particularly relates to hats and headpieces for protection against environmental effects.
BACKGROUND
[0003] Science has shown that the rays of the sun negatively affect a person's skin. While the skin has some natural protection from the sun, like melanin, the sun's radiation still damages the skin, causing the skin to tan, burn, freckle, develop moles, and form life-threatening cancers. While the sun can damage the skin all over a person's body, nowhere is the skin as susceptible to these harms as a person's face and in particular left side of their body from driving a car. Covering the head like one would the rest of the body with greasy sunscreens is unfeasible. Further, chemicals and lotions that block the sun's radiation are inconvenient and wear off, needing constant reapplication to fully protect one's skin. Furthermore most broad-spectrum sunscreens tout miss-leading SPF protection levels and do not protect your skin from both UVA & UVB rays. Skin cancer is on a dramatic rise leading all other forms of cancer and the only way to truly protect oneself is to cover up with clothing.
SUMMARY
[0004] While people have developed some methods to protect the face and head from the sun's radiation, because of the head's visibility to others, many of these methods negatively impact the appearance of the wearer. Coverings designed to protect the head should be fashionable so that a person is not dissuaded from protecting their head from the sun out of the fear of feeling unfashionable. Further, many other methods for skin protection don't allow a user to determine their desired level of protection. For example, a sun hat may protect the ears but neglect the neck and side of face, or the sun hat may protect the ears and neck but not allow a user to solely protect the neck and side of face. As such, the present disclosure describes a headgear that allows a user to fashionably protect their skin from the damage of the sun, while providing choices to a user as they protect their skin.
[0005] From the foregoing discussion, it should be apparent that a need exists for an apparatus and method that protects a user from environmental effects. Beneficially, such an apparatus and method would also being fashionable and provide users with choices in how they are protected from environmental effects.
[0006] The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available environmental protection. Accordingly, the present invention has been developed to provide an apparatus, kit, and method for protecting a user from environmental effects that overcome many or all of the above-discussed shortcomings in the art.
[0007] The apparatus, in one embodiment, includes a headpiece that has opposing first and second sides. The apparatus further includes a right elongated panel having a length greater than a width and a left elongated panel having a length greater than a width. The right elongated panel and the left elongated panel are attachable to the headpiece. When attached, the right elongated panel extends from the headpiece at the first side and the left elongated panel extends from the headpiece at the second side.
[0008] The apparatus, in one embodiment, includes a single elongated panel that includes the right elongated panel and the left elongated panel. In one embodiment, the single elongated panel includes a scarf. In another embodiment, the right elongated panel and the left elongated include separate elongated panels. The separate elongated panels may each include a connection edge.
[0009] In one embodiment, one or more of the right elongated panel, the left elongated panel, and the headpiece include material that is resistant to ultra-violet radiation.
[0010] In one embodiment, the apparatus includes one or more detachable means for removable attaching one or both of the right elongated panel and the left elongated panel to the headpiece. In one embodiment, the one or more detachable means includes one or more of a grommet, a button, a clip, a snap, a hook and loop fastener, and a scarf loop. In one embodiment, the headpiece further includes an inner circumference for at least partially resting on the user's head and the one or more detachable means include a first detachable means on the first side and a second detachable means on the second side. In another embodiment, the right elongated panel and the left elongated panel are substantially permanently affixed to the headpiece.
[0011] In one embodiment, the right elongated panel and the left elongated panel have a uniform width throughout the lengths of the right elongated panel and the left elongated panel. In one embodiment, the right elongated panel and the left elongated panel each include a connection edge and a distal end and one or both of the right elongated panel and the left elongated panel taper in width from the connection edge to the distal end. In one embodiment, the taper in width includes one or more of a uniform taper and a non-uniform taper.
[0012] In one embodiment, one or more of the headpiece, the right elongated panel, and the left elongated panel are made from a disposable material.
[0013] In one embodiment, the apparatus further includes a coupling portion, the coupling portion coupling the left elongated panel to the right elongated panel.
[0014] A kit of the present invention is also presented to protect a user from environmental effects. The kit may include the materials necessary to create and/or use the described apparatus. In particular, the kit, in one embodiment, includes a headpiece having opposing first and second sides. The kit further includes a right elongated panel having a length greater than a width and a left elongated panel having a length greater than a width. The kit further includes one or more of an accessory kit for altering the headpiece to allow connection of the right elongated panel and the left elongated panel to the headpiece, and one or more clips for securing one or more of the right elongated panel and the left elongated panel to the headpiece. The right elongated panel and the left elongated panel are attachable to the headpiece. When attached, the right elongated panel extends from the headpiece at the first side and the left elongated panel extends from the headpiece at the second side.
[0015] The kit may further include one or more of lip balm, sun screen, a pair of gloves, a storage bag, and means for securing the right elongated panel to the left elongated panel. The means for securing the right elongated panel to the left elongated panel may include one or more of, a hook and loop fastener, a clasp, a brooch, and an elastic band. The accessory kit comprises one or more of thread, one or more buttons, one or more grommets, one or more scarf loops, one or more clips, and glue.
[0016] A method of the present invention is also presented for protecting a user from environmental effects. The method in the disclosed embodiments substantially includes the steps necessary to carry out the functions presented above with respect to the operation of the described apparatus and kit. In one embodiment, the method includes providing a headpiece comprising opposing first and second sides and providing a right elongated panel having a length greater than a width and a left elongated panel having a length greater than a width. The method further includes attaching the right elongated panel and the left elongated panel to the headpiece. The method further includes placing the headpiece on a user's head. When placed on the user's head the right elongated panel extends from the headpiece between the first side and a right side of the user's head and the left elongated panel extends from the headpiece between the second side and the left side of the user's head.
[0017] In one embodiment, the method further includes securing the left elongated panel, the right elongated panel, and the headpiece to the user's head by securing the right elongated panel to left elongated panel at a securing location. In one embodiment, the right elongated panel is secured to the left elongated panel using one or more of a knot, a hook and loop fastener, a clasp, a brooch, and an elastic band.
[0018] Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.
[0019] Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention.
[0020] These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
[0022] FIG. 1 is a diagram illustrating one embodiment of an apparatus for protecting a head from environmental effects;
[0023] FIG. 2A is a diagram illustrating one embodiment of an elongated panel with a non-uniform taper;
[0024] FIG. 2B is a diagram illustrating one embodiment of an elongated panel with a uniform taper;
[0025] FIG. 2C is a diagram illustrating one embodiment of an elongated panel with uniform width;
[0026] FIG. 3A is a diagram illustrating one embodiment of a connection means for connecting an elongated panel to a headpiece using snap fasteners;
[0027] FIG. 3B is a diagram illustrating one embodiment of a connection means for connecting an elongated panel to a headpiece using a hook and loop fastener;
[0028] FIG. 3C is a diagram illustrating one embodiment of a connection means for connecting an elongated panel to a headpiece using clips;
[0029] FIG. 4 is a diagram illustrating one embodiment for securing the headpiece to a wearer's head;
[0030] FIG. 5A is a diagram illustrating one embodiment for protecting a face with the elongated panels;
[0031] FIG. 5B is a diagram illustrating one embodiment for securing the headpiece around the back of the wearer's neck;
[0032] FIG. 6 is a diagram illustrating one embodiment of a kit for storing elongated panels;
[0033] FIG. 7 is a diagram illustrating one embodiment of a detailed view of the inner circumference of a headpiece;
[0034] FIG. 8A is a diagram illustrating one embodiment of an inside view of a crown with a surface for attaching a scarf loop;
[0035] FIG. 8B is a diagram illustrating one embodiment of a scarf loop; and
[0036] FIG. 8C is a diagram illustrating one embodiment of a scarf;
[0037] FIG. 8D is a diagram illustrating one embodiment of an inside view of a crown with a surface for attaching multiple scarf loops;
[0038] FIG. 9A is a diagram illustrating one embodiment of attaching an elongated panel to a headpiece with a clip;
[0039] FIG. 9B is a diagram illustrating one embodiment of attaching an elongated panel to a headpiece with a plurality of clips;
[0040] FIG. 10 is a diagram illustrating one embodiment of coupled elongated panels;
[0041] FIG. 11A is a diagram illustrating a side view of the coupled elongated panels of FIG. 10 attached to a baseball cap; and
[0042] FIG. 11B is a diagram illustrating a rear view of the coupled elongated panels of FIG. 10 attached to a baseball cap.
DETAILED DESCRIPTION OF THE INVENTION
[0043] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, refer to the same embodiment.
[0044] Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are shown to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures and materials are not shown or described in detail to avoid obscuring aspects of the invention.
[0045] FIG. 1 displays a headgear 100 for protecting a user's head from environmental effects according to at least one embodiment. Headgear 100 comprises a headpiece 110 , a right elongated panel 120 , a left elongated panel 130 , an inner circumference 140 , and a connection edge 150 . The terms, “headgear” and “headpiece”, as used herein, refer to clothing accessories that may be worn on the head. For example, headgear may include hats, caps, hoods, visors, helmets, hard hats, and the like.
[0046] In certain embodiments, headpiece 110 may comprise an inner circumference 140 . The term “inner circumference”, as used herein, refers to the section of the headpiece between the part that contacts the user's head and the part at the top of the headpiece that faces the user's scalp. In certain embodiments, the inner circumference 140 of the headpiece 110 may match the circumference of the user's head at the location where the headpiece 100 rests on the user's head. In another embodiment, the inner circumference 140 may comprise the circumference of the headpiece 110 near the top of the crown of the headpiece 110 that faces the user's head.
[0047] In at least one embodiment, the headgear 100 may comprise both a right elongated panel 120 and a left elongated panel 130 . The term “elongated panel”, as used herein, refers to a piece of flexible and/or stretchable material that is longer than its width. For example, an elongated panel may have a width of 7-8 inches and a length of 27-30 inches. Further, the material of the elongated panel may comprise one or more of a textile, plastic, paper, and the like. Further, a hem may reinforce the edges of the elongated panel. In a further embodiment, the material may be resistant to environmental effects. Environmental effects may include the sun, light, wind, rain, snow, germs, chemicals, the cold, and the like. For example, the right elongated panel 120 and the left elongated panel 130 may be constructed from wind and water resistant material that block ultraviolet radiation from the sun. In an alternative embodiment, the right elongated panel 120 and the left elongated panel 130 may not provide protection against environmental effects, but the design of the panel may augment the fashion of the headgear 100 . Also, the right elongated panel 120 and the left elongated panel 130 may be dyed to a desired color. For example, the material may be blue, red, or any other color. Further, the fabric of the right elongated panel 120 and the left elongated panel 130 may display a desired pattern. For example, the material may be plaid or exhibit a desired logo.
[0048] In a further embodiment, the right elongated panel 120 and left elongated panel 130 may comprise a connection edge 150 . The term “connection edge”, as used herein, refers to an edge of an elongated panel that connects to the inner circumference of a headpiece. For example, the connection edge 150 of the right elongated panel 120 and left elongated panel 130 may connect to the inner circumference 140 of the headpiece 110 . In at least one embodiment, the connection edge 150 may detach and reattach to the inner circumference 140 via a detachable means. The detachable means may comprise a series of press in or press on grommets, hand sewn snaps, hook and loop fasteners, clips, and the like. Further, the detachable means may allow the right elongated panel 120 and the left elongated panel 130 to be removed and laundered. By washing the elongated panels, the elongated panels may provide protection to individuals with sensitive skin issues such as rosacea, contact dermatitis, skin cancer, acute and/or severe acne, and the like. Further, by providing clean protection to the wearer, the removable panels may assist in keeping free radicals, chemicals, dirt, bacteria and germs away from the skin.
[0049] In an alternative embodiment, the connection edge 150 may permanently connect to the inner circumference 140 . When the connection edge 150 permanently connects to the inner circumference 140 , the connection edge 150 may connect to the inner circumference 140 via thread, glue, rivets, and the like. After the connection edge 150 connects to the inner circumference 140 , a user may use the right elongated panel 120 and the left elongated panel 130 to protect themselves from the negative effects of the environment.
[0050] In at least one embodiment, the headgear 100 may be disposable. The headpiece 110 , the right elongated panel 120 , and the left elongated panel 130 may be made from the same material. For example, the hat and panels may be made from paper, plastic, a textile, and the like. In an alternative embodiment, the headpiece 110 , the right elongated panel 120 , and the left elongated panel 130 may be made from different materials. For example, the headpiece 110 may be constructed of cardboard and the elongated panels may be made from paper. Further, the right elongated panel 120 and the left elongated panel 130 may permanently affix to the headpiece 110 .
[0051] In another embodiment of the disposable headgear 100 , the headpiece 110 may be worn under another hat. For example, the headgear 100 may fit inside the crown of another hat such that the wearer can wear the headgear 100 with a variety of hat styles. A disposable headpiece may allow the wearer to more cheaply or conveniently protect themselves from damaging environmental effects.
[0052] FIGS. 2A through 2C illustrate a variety of different exemplary shapes for an elongated panel. FIG. 2A illustrates one embodiment of an elongated panel with a non-uniform taper. A non-uniform taper elongated panel 200 a may comprise a connection edge 210 a, a bottom point 220 a, and a tapered length 230 a. The connection edge 210 a may comprise the location of the non-uniform taper elongated panel 200 a that connects to a headpiece. Further, the connection edge 210 a may be the widest section of the non-uniform taper elongated panel 200 a. For example, the width of the non-uniform taper elongated panel 200 a at the connection edge 210 a may be seven to eight inches.
[0053] In certain embodiments, the width of the non-uniform taper elongated panel 200 a may decrease as the tapered length 230 a moves from the connection edge 210 a towards the bottom point 220 a. For instance, the taper from the connection edge 210 a towards the bottom point 220 a may be non-uniform. For a section of the length of the non-uniform taper elongated panel 200 a that is nearest the connection edge 210 a, the tapered length may have a uniform width equal to the width of the connection edge 210 a. After a determined location on the non-uniform taper elongated panel 200 a, the non-uniform taper elongated panel 200 a may taper to the bottom point 220 a. For example, when the non-uniform taper elongated panel 200 a has a length of 27 to 30 inches, the seven to eight inches of the non-uniform taper elongated panel 200 a that are nearest the connection edge 210 a may have a uniform width of seven to eight inches. The remaining length of the non-uniform taper elongated panel 200 a with a length of 19 to 22 inches may gradually taper forming a point at the bottom point 220 a. A uniform width at the section of the non-uniform taper elongated panel 200 a nearest the connection edge 210 a may allow the non-uniform taper elongated panel 200 a to cover large areas of the face.
[0054] FIG. 2B illustrates one embodiment of an elongated panel with a uniform taper. A uniform taper elongated panel 200 b may comprise a connection edge 210 b, a bottom point 220 b, and a tapered length 230 b. The connection edge 210 b may be of substantially similar construction to the connection edge 210 a in FIG. 2A . The tapered length 230 b may uniformly taper from a width of seven to eight inches at the connection edge 210 b to a point at the bottom point 220 b.
[0055] FIG. 2C illustrates one embodiment of an elongated panel with uniform width. A uniform width elongated panel 200 c may comprise a connection edge 210 c and a bottom edge 240 . The uniform width elongated panel 200 c may have the same width at the connection edge 210 c and at the bottom edge 240 , and throughout the length of the uniform width elongated panel 200 c.
[0056] Of course, the elongated panels 200 a - 200 c may be of other shapes and tapers. For example, the elongated panels 200 a - 200 c may comprise a middle portion that has a smaller width than both end portions. Similarly, the bottom points 220 a and 220 b may be of different shapes and configurations, including a rounded configuration that is not shown.
[0057] FIG. 3A illustrates one embodiment of a connection edge 300 a using snap fasteners or grommets. The connection edge 300 a is part of an elongated panel 200 and may comprise a reinforcing fold 310 and snap fasteners 320 . The term “reinforcing fold”, as used herein, refers to a strengthened section of the elongated panel 200 that will protect the fabric of the elongated panel and add strength to the connection edge 300 a. For example, the fabric of the elongated panel may be folded over at least once to increase the strength of the fabric at the connection edge 300 a. In another example, interfacing may reinforce the fabric of the connection edge 300 a. Other materials that could reinforce the connection edge 300 a may include cardboard, plastic, metal, paper, grommets, snaps by the yard, and the like. The reinforcing fold 310 may protect the fabric from the tension applied to the elongated panel at the snap fasteners 320 while adding strength to the connection edge 300 .
[0058] In certain embodiments, the snap fasteners 320 , which may include grommets, may attach the elongated panel 200 to a headpiece 110 in FIG. 1 . The term “fasteners”, as used herein, refers to a mechanism that attaches the elongated panel 200 to the headpiece 110 . For example, the fasteners may comprise press-in press-on grommets, hand sewn snap fasteners, snaps by the yard, button holes, rivets, stitching, zippers, and the like. In one embodiment, where snap fasteners attach the elongated panel 200 to the headpiece 110 , either the stud or the socket of the snap fastener may be placed on the connection edge 300 a of the elongated panel 200 . Further, the snap fasteners may comprise either post or prong type snap fasteners. Snap fasteners may allow the elongated panel 200 to detach and reattach from the headpiece 110 . In other embodiments, the elongated panel may be permanently attached to the headpiece 110 . For example, the connection edge 300 a of the elongated panel may be sewn to the headpiece 110 . By allowing the user to attach or permanently affix the elongated panel, the user can customize their collection of headwear.
[0059] FIG. 3B illustrates one embodiment of a connection edge 300 b using a hook and loop fastener 330 . The hook and loop fasteners may more equally distribute the tension from the elongated panel 200 throughout the entire surface of the connection edge. In another embodiment, the hook and loop fastener 330 (like VELCRO brand hook and loop fasteners) may be split into small segments of separate hook and loop fasteners. For example, there may be four different hook and loop fasteners along the length of the connection edge 300 b.
[0060] Also shown in FIG. 3B is an alternative connection method employing loops 350 . The loops may be used to connect with buttons attached to the tops of the panels 200 .
[0061] FIG. 3C illustrates one embodiment of a connection edge 300 c using a plurality of clips 340 . The connection edge 300 c may further comprise a reinforcing fold 310 and an elongated panel 200 . The clips 340 may allow an elongated panel 200 to attach to a plurality of hats. In one embodiment, the clips 340 may comprise a plurality of hair extension clips. For example, there may be four different hair extension clips attached to the reinforcing fold 310 . The clips 340 may be located at equal distances along the reinforcing fold 310 .
[0062] As has been aforementioned, a headpiece with attached right and left elongated panels may be used for a variety of purposes. The elongated panels may be used to secure a hat to a wearer's head, protect the sides of the head and face from the sun, act as a facial cover, and the like. Further, the headpiece with attached elongated panels provides these protections without diminishing the stylishness of the headpiece.
[0063] FIG. 4 illustrates an implementation for securing the headpiece with attached elongated panels to a wearer's head according to one embodiment. FIG. 4 comprises a headpiece 400 , a right elongated panel 410 , a left elongated panel 420 , and a securing location 430 . The headpiece 400 , the right elongated panel 410 , and the left elongated panel 420 may be substantially similar to corresponding embodiments described above.
[0064] In certain embodiments, the right elongated panel 410 and the left elongated panel 420 may be secured to one another below a user's chin. The term, “securing location”, as used herein, refers to the location on both the right elongated panel 410 and the left elongated panel 420 where the different elongated panels are secured to one another. For example, the right elongated panel 410 and the left elongated panel 420 may be tied together at the securing location 430 . By tying the right elongated panel 410 to the left elongated panel 420 , the elongated panels secure the headpiece 400 to the wearer's head. In an alternative embodiment, the securing location on the right elongated panel 410 may connect to the securing location on the left elongated panel via a hook and loop fastener, a decorative brooch, a clasp, an elastic band, and the like. By allowing different securing options, a wearer can customize the appearance of the headpiece at the securing location 430 .
[0065] In at least one embodiment, by securing the headpiece 400 to the wearer's head, the wearer can use the elongated panels to protect the sides of the head and face from environmental effects. In one embodiment, to increase the area of the head covered by the elongated panels, the right elongated panel 410 and the left elongated panel 420 may have a uniform width from the length between the headpiece 400 and the securing location 430 . Below the securing location 430 , the right elongated panel 410 and the left elongated panel 420 may begin tapering. The taper of the right elongated panel 410 and the left elongated panel 420 may limit the bulkiness of a knot used at the securing location 430 .
[0066] FIG. 5A illustrates an embodiment where a headpiece protects a wearer's face from environmental effects. For example, headpiece 500 may comprise a right elongated panel 510 and a left elongated panel 520 . The right elongated panel 510 and the left elongated panel 520 may have sufficient length to wrap around the wearer's face such that the right elongated panel 510 and the left elongated panel 520 cover the wearer's nose and mouth. By covering the wearer's face and mouth the headpiece 500 may protect the wearer from environmental effects like dust, pollution, chemicals, airborne contaminants, smoke, and germs.
[0067] In a further embodiment, the material of the right elongated panel 510 and left elongated panel 520 may be specially designed to protect against a particular environmental effect. For example, the fabric of an elongated panel may be made of a special fabric that prevents germs, chemicals, or any other airborne contaminants from passing through the fabric. The fabric may also be designed for people with particular respiratory ailments, as it may prevent pollutants from passing through the fabric. Further, the right elongated panel 510 and the left elongated panel 520 may protect a user with a particular skin ailment. For example, a person who has had skin cancer may need extra protection from the sun. The right elongated panel 510 and the left elongated panel 520 may provide the needed protection. By wrapping around the face, the headpiece 500 , with the right elongated panel 510 and the left elongated panel 520 , may provide a plurality of benefits to the wearer.
[0068] FIG. 5B illustrates one embodiment for attaching the right elongated panel 510 to the left elongated panel 520 behind the neck of the wearer at securing location 530 . At the securing location 530 , the right elongated panel 510 may be secured to the left elongated panel 520 . For example, the securing location 520 may comprise a knot, a hook and loop fastener, a clasp, a brooch, an elastic band, and the like. By securing the elongated panels over the neck, the wearer can also protect the neck from environmental effects.
[0069] While the elongated panels may protect against environmental effects, sometimes the wearer may desire to expose themselves to the environment. Some embodiments may include elongated panels that may be removably attached to the headpiece for selective attachment and removal. For example, on a rainy day, the wearer may solely want to wear the headpiece. At these times, the wearer may remove the elongated panels from the headpiece and store the elongated panels in a kit, according to one embodiment.
[0070] FIG. 6 illustrates an embodiment of a kit for storing elongated panels. The kit 600 may store the elongated panels in a storage bag 610 . The storage bag 610 may further store other items that are useful for protecting against environmental effects. For example, the kit 600 may also include gloves 620 , sunscreen 630 , a lip balm applicator 640 , a clip 650 , and the like. Also, the kit 600 may also store items for protecting a headpiece and the elongated panels. For example, the kit 600 may further include protective tape 640 , water-proofer, and the like. Further, the kit 600 may also include a clip 650 for attaching the panels to a wide variety of hats. The clip 650 may comprise a plurality of hair extension clips that are permanently sewn to the elongated panels. The kit 600 may increase the functionality of the headpiece by giving the wearer a place to store the elongated panels when they are not being used, and also providing further materials to increase one's protection against environmental effects.
[0071] In certain embodiments, a headpiece can be altered for attaching elongated panels to the hat. FIG. 7 illustrates a detailed view of the inner circumference 700 for a headpiece. The detailed inner circumference 700 may include a sweat band 710 , a headpiece crown 720 , and fasteners 730 . To alter a normal headpiece, the fasteners 730 may be attached to the sweat band 710 . The fasteners may comprise fasteners such as snaps, grommets, hook and loop fasteners, and the like. For example, the fasteners 730 may comprise snaps sewn directly to the sweat band 710 . In one embodiment, the fasteners 730 comprise five evenly spaced snaps.
[0072] In a further embodiment, the sweat band 710 may be reinforced to the headpiece crown such that the pull of the elongated panels on the sweat band 730 will not pull the sweat band out of the hat. The fasteners that attach to the elongated panels may be installed into a wide variety of hats.
[0073] FIGS. 8A-8D illustrate other embodiments for protecting a wearer's head from environmental effects. In one embodiment, a loop may be affixed to the inside surface of the crown of a headpiece and a scarf can be threaded through the loop. After the scarf is threaded through the loop, the two ends of the scarf hang down around the user's head where they can provide substantially similar protection as the elongated panels described above. Other embodiments may include more than one loop. For example, various embodiments may include two, three, four, or any other number of loops.
[0074] FIG. 8A illustrates one embodiment of an inside view of a crown with a surface for attaching a scarf loop. For example, a detailed crown 800 may comprise a loop attachment surface 810 , an inside crown surface 820 , and a back label 830 . The inside crown surface 820 may comprise the surface of the crown of a headpiece that faces a wearer's head. The term “loop attachment surface”, as used herein, refers to a surface on the inside crown surface 820 to which a scarf loop may attach. For example, the loop attachment surface 810 may comprise a hook and loop fastener, grommets, snaps, rivets, thread, or other attachment means. Further, the loop attachment surface 810 may be oriented on the inside crown surface 820 such that the length of the scarf loop may be attached running from the back of the headpiece towards the front of the headpiece. Thus, the openings of the loop may face the left and right sides of the headpiece. When a scarf is inserted into the loop this may result in forming left and right elongated panels, which may be used as described in other embodiments described herein.
[0075] FIG. 8B illustrates one embodiment for a scarf loop. The term “scarf loop”, as used herein, refers to a loop that may be secured to an inside surface on the crown of a headpiece through which a scarf may be threaded. For example, a scarf loop 840 may comprise a crown attachment surface 850 . The scarf loop 840 may be a loop formed from fabric, plastic, rubber, string, and the like. The crown attachment surface 850 may attach to the loop attachment surface 810 in FIG. 8A . The crown attachment surface 850 may comprise a hook and loop fastener, grommets, snaps, rivets, or thread. The scarf loop 840 may be detachable from the inside crown surface 820 . Further, the scarf loop 840 may permanently attach to the inside crown surface 820 . In at least one embodiment, a headpiece may be modified such that a scarf loop 840 may attach to the inside crown of a hat.
[0076] FIG. 8C illustrates one embodiment for a scarf. A scarf 860 may be of a width substantially similar to the elongated panels. The length of the scarf 860 may be longer than the combined length of the elongated panels, such that both ends of the scarf 860 descend below the hat to a substantially similar length as that of the elongated panels when the scarf 860 is threaded through the scarf loop 840 . For example, the elongated panels may descend below the headpiece by a length of 26 inches. The scarf may be 60 inches in length so that when the scarf 860 is threaded through the scarf loop 840 both ends of the scarf 860 also descend below the hat by a length of 26 inches. One of skill in the art will understand in light of the present description that other lengths and widths may also be desirable depending on the size of the headpiece, the size of the user, use of the headpiece and scarf, etc. In an alternative embodiment, the scarf 860 may directly attach to the loop attachment surface 810 . The scarf embodiment provides substantially similar functionality as the elongated panels.
[0077] FIG. 8D illustrates an embodiment of an inside view of a crown with multiple surfaces for attaching a scarf loops. For example, a detailed crown 800 may comprise multiple loop attachment surfaces 810 , an inside crown surface 820 , and a back label 830 . In the depicted embodiment, four loop attachment surfaces 810 are shown. The inside crown surface 820 may comprise the surface of the crown of a headpiece that faces a wearer's head. Similar to the embodiment of FIG. 8A the loop attachment surfaces 810 may comprise a hook and loop fastener, grommets, snaps, rivets, thread, or other attachment means. Further, the loop attachment surfaces 810 may be oriented on the inside crown surface 820 such that the length of the scarf loop may be attached running from the back of the headpiece towards the front of the headpiece. Thus, the openings of the loop may face the left and right sides of the headpiece. When a scarf is inserted into the loops this may result in forming left and right elongated panels, which may be used as described in other embodiments described herein.
[0078] FIG. 9A illustrates one embodiment of attaching elongated panels to a headpiece with a clip. A headpiece with clipped panels 900 a may comprise a clip 910 a, a headpiece 920 , an elongated panel 930 , and a sweatband 940 . The term “clip”, as used herein, refers to a device that secures an elongated panel to a headpiece. For example, the clip 910 a may secure the connection edge of the elongated panel 930 to the sweatband 940 . The clip 910 a may be sewn onto the elongated panel 930 and attach to the inside of a hat.
[0079] In one embodiment, the clip may use spring tension between two rigid flanges where the spring tension pushes the two rigid flanges into one another. The clip 910 a may squeeze the connection edge of the elongated panel 930 and the sweatband 940 between the two rigid flanges. In a further embodiment, the clip 910 a may pin the elongated panel 930 to the sweatband 940 . Also, the clip 910 a may pin the elongated panel 930 to the crown of the headpiece 920 . Further, the clip 910 a may use a variety of means to secure an elongated panel 930 to a headpiece 920 . By securing the elongated panel 930 to the headpiece 920 , the clip 910 a may allow a wearer to attach panels to a variety of hats without altering the hat.
[0080] FIG. 9B illustrates one embodiment of attaching elongated panels to a headpiece with a plurality of clips. The headpiece with clipped panels 900 b may comprise an elongated panel 930 (shown transparent in the figure to show the attached clips 910 b ), a headpiece 920 , and clips 910 b. The clips 910 b may comprise a plurality of clips that attach to different locations along the inside of a hat. The clips 910 b may be similar to a series of hair extension clips or another type of clip that may attach to a headpiece 920 .
[0081] Turning now to FIG. 10 coupled elongated panels 1000 are shown. The coupled elongated panels 1000 include a left elongated panel 1010 having a left connection edge 1012 and a right elongated panel having a right connection edge 1022 . The left and right elongated panels 1010 , 1020 are coupled together via a coupling portion 1030 . The left and right connection edges 1012 , 1022 comprise a plurality of snap connectors 1032 for attachment to a headpiece. As will be understood by one skilled in the art and in light of the present disclosure significant variation may be possible. For example, the variations of the shapes of the left and right elongated panels 1010 , 1020 connection edges 1012 , 1022 an detachment means 1032 as set forth previously may apply to the coupled elongated panels 1000 in varying embodiments.
[0082] Significant variation is also possible with the coupling portion 1030 . According to the depicted embodiment, the coupling portion 1030 comprises a portion of the left elongated panel 1010 and the right elongated panel 1020 which have been attached using thread. In other embodiments, the elongated panels 1010 , 1020 may be attached along the coupling portion 1030 using a variety of attachment means or detachment means such as glue, rivets, snap fasteners, grommets, buttons, hook and loop fasteners, clips, and the like. For example, any of the attachment means discussed in relation to the connection edges 1012 , 1022 may also be applicable to the coupling portion 1030 .
[0083] Additionally, the coupling portion 1030 may be formed in a variety of manners. For example, the coupling portion 1030 may comprise a separate piece of material which has been connected between the left elongated panel 1010 and the right elongated panel 1020 . In other embodiments, the left elongated panel 1010 , the right elongated panel 1020 , and the coupling portion 1030 may be formed of a single piece of material. Other embodiments may include multiple pieces of material, multiple layers, and/or other configurations without limitation.
[0084] The coupled elongated panels 1000 and coupling portion 1030 may be desirable in some embodiments. For example, the left elongated panel 1010 and right elongated panel 1020 being coupled together may limit losing of one of the panels 1010 , 1020 . Additionally, the coupling portion 1030 may provide additional protection for the neck of a user. For example, if a user wears a hat that provides no protection for the neck the coupling portion 1030 may provide the protection if needed. This may be the case with baseball caps or other hats having no brim or a small brim at the rear of the hat. Because similar hats are often used for sporting activities, the coupled elongated panels 1000 may be desirable in sporting environments.
[0085] FIG. 11A-11B depicts the coupled elongated panels 1000 attached to a cap 1102 . FIG. 11A is a side view of the cap 1102 and attached coupled elongated panels 1000 . The right elongated panel 1020 and coupling portion 1030 are visible. FIG. 11B is a back view of the cap 1102 and attached coupled elongated panels 1000 . The left elongated panel 1010 , the right elongated panel 1020 , and the coupling portion 1030 are visible.
[0086] As the elongated panels may function with a wide variety of headpieces, while protecting the wearer against environmental effects. The present invention may allow the wearer to recreate safely, reducing fear of damage from the sun, germs, chemicals, or other environmental threats, while wearing a fashionable item.
[0087] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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An apparatus and method are disclosed for protecting a user from environmental effects. In one embodiment the apparatus comprises a headpiece having opposing first and second sides. The apparatus further comprises a right elongated panel and a left elongated panel, each having a length greater than a width. The right elongated panel and the left elongated panel are attachable to the headpiece. When attached the right elongated panel extends from the headpiece at the first side and the left elongated panel extends from the headpiece at the second side.
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This application is a continuation of U.S. patent application Ser. No. 09/548,563 filed on Apr. 13, 2000, now U.S. Pat. No. 6,414,494, issued on Jul. 2, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to temperature probes, or sensor tips, of the type used for the control and safety monitoring of gaseous fuel burners as used in various heating, cooling and cooking appliances. In particular, the present invention relates to flame ionization sensor probes used in gas combustion control/safety environments where contamination coating of the probe shortens the useful life of the sensor.
2. Discussion of the Related Art
Flame ionization sensing provides known methods and apparatus for monitoring the presents of a flame for a gaseous fuel burner.
It is known that hydrocarbon gas flames conduct electricity because charged species (ions) are formed by the chemical reaction of the fuel and air. When an electrical potential is established across the flame, the ions form a conductive path, and a current flows. Using known components, the current flows through a circuit including a flame ionization sensor, a flame and a ground surface (flameholder or ground rod).
FIG. 1 illustrates a flame ionization sensor system 10 with a typical sensor/burner circuit loop as may be used in accordance with the present invention. Flame ionization sensor 11 having a probe 12 , will be mounted near the burner 13 . The output 15 of sensor 11 will be fed into a computer-controller 17 . The sensor loop can provide information regarding the status of a flame 18 in the burner 13 . If there is no flame, then the sensor 11 will not generate a signal which will cause the controller 17 to instruct the system to shut off fuel flow.
In utilizing a flame sensor as previously described, a voltage, such as a 120 AC voltage 21 , will be applied across the sensor loop, with the flame holder, or burner 13 , serving as the ground electrode 20 . Flame contact between the sensor probe 12 and the burner 13 will close the circuit. The alternating current (AC) output of the sensor/ground circuit, can be rectified, if the ground electrode (flameholder or burner 13 ) is substantially larger in size than the positive electrode, since, due to the difference in electrode size, more current flows in one direction than in the other.
Flame ionization sensor probes 12 are thus electrodes, made out of a conductive material which is capable of withstanding high temperatures and steep temperature gradients. Hydrocarbon flames conduct electricity because of the charged species (ions) which are formed in the flame. Placing a voltage across the probe and the flameholder causes a current to flow when the flame closes the circuit.
Unfortunately it has been found that contaminants in the air stream of the fuel/air mixture can result in the build up of an insulating contamination layer on the probe, rendering it much less effective. At a certain level of coating, which prevents electron flow to the probe surface, the sensor is rendered useless, creating a premature or false system failure. Often these airborne contaminants are organosilicones found in personal and home care products which are oxidized by the flame 18 to silicon oxides (SiOx) which in turn build up through impact on the probe 12 providing the insulative contaminant coating.
It is thus desirable to find ways to increase the useful life of flame ionization sensor probes in spite of this insulative build up resulting from normal use of the flame ionization sensor system.
SUMMARY OF THE INVENTION
According to one embodiment of the present invention, the fact that the sensor tip, or probe, is exposed to the flame is taken advantage of and the probe is constructed and arranged according to materials and shapes which promote mechanical deformation of the sensor tip due to thermal expansion and contraction. Sufficient mechanical deformation will cause cracks to open in the contaminant layer surrounding the probe, breaking the insulative effect and allowing ions from the flame through to the probe thereby enabling the sensor to perform as intended even though insulative contaminate build up is present. The mechanical deformation may be sufficient to allow the probe to shed contaminant build up. The material of the probe will thus be selected to have a coefficient of thermal expansion (CTE) over the operating temperature range of the probe sufficient to allow such cracking or shedding of the contaminants to occur. Bimetal construction of the probe is a contemplated embodiment. Specially shaped probes such as helical, or corrugated shapes may be utilized in conjunction with material selection to further aid in contaminant layer cracking or shedding. Finally, some gain in contaminant build up prevention may also be had by specially shaping the probes to minimize SiOx particle impact on the probe.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and objects of this invention will be better understood from the following detailed description taken in conjunction with the drawings wherein:
FIG. 1 illustrates the known arrangement of components for explanation of a flame ionization sensor circuit.
FIG. 2 illustrates a regular helix shaped sensor according to the present invention.
FIG. 3 is a graph showing the improved lifespan of the probe embodiment of FIG. 2 .
FIG. 4 illustrates a conical helix shaped sensor according to the present invention.
FIG. 5 illustrates a corrugated and wing-shaped sensor according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As mentioned above, the primary cause of failure for flame ionization sensors is believed to be SiOx contamination insulation of the sensor probe, which is exposed to the flame. The SiOx contamination problem was studied by accelerated life testing of an flame ionization sensor in various furnace units by introduction of organosilicone contaminants into the burner air stream through a compressed air bubbler. Dow 344 fluid available from Dow Chemical Co., consisting of ninety percent Dow D4 fluid and ten percent Dow D5 fluid was used in the contaminant vaporization apparatus. The organosilicones are oxidized in the burner flame to silicon oxides (SiOx) which are deposited by impact on the sensor probe surfaces. The baseline probe referred to herein for comparison purposes with the present invention is a straight piece of round sensor stock material of about ⅛ inch diameter. While the results mentioned are the result of the accelerated life testing, it is believed that all results may be validly extrapolated to the real time phenomena of flame ionization sensor failure.
It has been found that a rapid deposition of an initial SiOx layer takes place. This initial SiOx contaminant layer covered, or insulated, most of the effective probe surface; i.e., SiOx contamination is locally concentrated at points where the flame front contacts the sensor. However the contaminant layer contained gaps allowing charge to flow to the conductive rod surface, thereby producing enough current flow to allow operation of the flame ionization sensor control or safety system.
A relatively high percentage of the subsequent contamination settled on the initial SiOx layer. Smaller amounts of contamination eventually find their way into the gaps of the initial contamination layer thus leading to a gradual decay in signal proportional to the rate at which the gaps were filled. Because gaps in the complete coverage of the contaminant layer allow access by charged particles to the surface of the probe, it was found that constructing a probe to affect mechanical distortion of the probe and thereby crack, or even shed, at least some of the contamination layer would allow great increase in the useful life of the sensor apparatus, necessitating many less field repairs.
Referencing FIG. 2, a sensor probe was constructed as a regular helix, or coil, 25 of straightened seven gage Kanthal D stock wire, a known probe material of about 70 percent iron with the balance being largely chromium and aluminum. Kanthal D is a trademark of Kanthal AB of Sweden. The exact material is not critical to the present invention and may be selected from the group of known probe materials such as Kanthal D, stainless, and hoskins. Gage, and overall size of the probe will, of course, be dependent on application of the probe, e.g., commercial, industrial, residential, etc. Kanthal D has a coefficient of thermal expansion (CTE) over the operating range of the burner as follows:
68-480° F. =
11 × 10−6
68-930° F. =
12 × 10−6
68-1380° F. =
14 × 10−6
68-1830° F. =
15 × 10−6
For present discussion purposes the overall figure of 15×10 −6 inches/° F. over 68-1830° F. representing a change of 0.026 or {fraction (1/40)} inch over the thermal cycle of a typical 1.5 inch coil length will be used.
FIG. 3 illustrates the 310 percent increase in time to failure of the probe of FIG. 2 as compared to a baseline sensor of straight wire and the same material used in the same in-shot type burner from a residential furnace platform. The signal line 27 of the present invention shows spikes, collectively 29 , believed to represent significant cracking of the contaminant coating allowing signal strength to jump appreciably before the cracks are refilled with new contaminants.
While testing was done with the regular diameter coil of FIG. 2, it is envisioned that other shaped probes may induce adequate mechanical distortion to produce cracking of the contaminant layer in order to increase the time to failure of the sensor unit. FIG. 4 shows an alternative embodiment of coiled probe in which the probe is a conically shaped helix 31 .
Referencing FIG. 5, the shape of the probes may also be combined with other factors, beyond CTE of the material, to produce enhanced time to failure characteristics of the sensor unit. In testing, a wing-shaped body with the leading edge width being thirty percent of the baseline probe diameter and the depth (cord) being 180% of the baseline probe diameter was tested on the theory that the wing shape would allow the SiOx contaminant particles to blow by the probe resulting in less contaminant build up per unit time. In the embodiment of FIG. 5 the wing shape sensor body 37 has been pressed to produce sine wave corrugations, collectively 39 . “Corrugations” as used herein is not meant to encompass essentially two dimensional bending such as may be done to a single wire. Testing of the wing shaped body showed a twenty five percent improvement in life of the probe. Combining the wing shape with corrugations is theorized to produce the benefits of both the mechanical distortion producing corrugation shape and the low contaminant build up shape. Additional considerations affecting contamination build up such as smooth surface finish and negative polarity of the probe within the sensing circuit may further be combined with the present invention to additionally enhance probe lifespan.
While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.
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In a flame ionization sensor type gas combustion control apparatus, the sensor tip, or probe, exposed to the flame is constructed and arranged according to materials and shapes which promote mechanical deformation of the sensor due to thermal expansion and contraction. The mechanical deformation will cause cracks to open in the contaminant layers surrounding the probe, enabling the sensor to perform as intended even though insulative contaminant build up is present.
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This is a continuation of co-pending application Ser. No. 06/935,353 filed on Nov. 26, 1986 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to controllers for machines which operate on alternating current and particularly to current fault detection systems for AC machine controllers.
2. Description of Prior Art
Machines which are powered by alternating current (AC) are used extensively in areas such as, industry, home appliances, recreation, etc. The most common of such AC machines is a motor. Many AC motors are able to use multiple phase AC power.
Most multiphase motors are equipped with controllers which alter certain motor operating parameters, such as motor speed or torque, to fit a particular motor to the demands of the load to which it is being applied. These controllers are most often electronic controlling devices which allow more or less electrical power to the motor using known power limiting methods. These electronic controlling devices are very susceptible to current overloads, and therefore severe damage, as the motor demands high levels of power to drive an extremely demanding load.
Two methods are presently used to prevent damage to electronic motor controllers during a current overload condition. One method senses the position of the assembly which is being driven by the motor, such as an actuator arm or jackshaft, and relates that to the time taken to move to the new position. The ratio of change in position to time infers whether a current overload is occurring. If the ratio becomes too small it signals that a current overload is occurring and the motor controller is shut down by the protection system.
The motor or actuator arm positioning method is inexpensive and easily adapted to most positioning applications, however, it also has shortcomings. The protection of this type of overcurrent protection is limited to the time of mechanical feedback from the actuator arm or jackshaft, and electronic overload damage often occurs before the feedback time has elapsed. Also, an overload situation may occur which is not related to the mechanical position of the load, such as, a short circuit in the wiring or a short in the winding of the motor. Due to these limitations, the mechanical feedback overload system does not provide adequate protection to electronic motor controllers.
The second method presently used to protect a motor controller from over current damage is to provide direct current measurement of each phase of the motor being controlled and to shut down the entire motor control system if any of the phase currents go above a preset safety level as provided in FIG. 1. The signals from each current sensing device are input through a logical OR gate to a digital controller. If a digital high signal is sent to the digital controller from the OR gate, the digital controller sends a system shut down signal to the motor and motor controller.
In this overcurrent protection system each current sensor communicates with the digital controller. However, the digital controller must be protected from the surges of power which commonly occur in the motor control system. The presence of these power surges demand that there be ground isolation between the each current sensing device and the digital controller. Ground isolation is usually accomplished through known opto-isolators, as shown in FIG. 1, which are expensive. Also when any of the phase currents of the motor goes above the threshold safety level the entire system is shut down until reset by an operator. Often this entire motor system down time is unnecessary because only one phase of the motor is in an overcurrent state, and a 3-phase motor can usually continue running on two phase power.
Thus it is seen that a current overload protection system for 3-phase motors is needed which does not shut down the entire motor control system in an single phase, overcurrent condition yet provides adequate protection to the motor control system in an inexpensive manner.
SUMMARY OF THE INVENTION
The present invention described herein overcomes all the prior art problems associated with the mechanical feedback and direct current measurement methods of overcurrent protection of AC motor control systems. The invention accomplishes this by providing a separate overcurrent shut down mechanism for each phase of AC power used in an AC motor.
This new overcurrent protection system provides a separate shut-down mechanism for each phase of the power supplied to the AC motor without being controlled by or sending a shut down signal to the digital controller. A single phase of the 3-phase power may be shut down by the system temporarily without shutting down the entire AC motor control system. However, the overcurrent protection system is also provided with a mechanical feedback apparatus which sends a total shut down signal to the digital controller only if the AC motor stalls to provide protection for the most severe overcurrent conditions. The operator must then reset the system manually. Thus each phase of power is protected from temporary or minor overcurrent conditions without a total system shutdown, however, the entire system is completely shutdown in the event of a severe overcurrent condition.
Thus one aspect of the invention is to provide an overcurrent protection system for AC motors which does not shut down the entire AC motor control system for a minor or temporary overcurrent condition yet shuts the entire system down for severe overcurrent conditions.
Another aspect of the present invention is to provide an overcurrent protection system for AC motors whereby each individual phase of AC power is provided with its own overcurrent protection mechanism independent of the rest of the protection system.
Yet another aspect of the present invention is to provide an overcurrent protection system for an AC motor control system whereby each independent phase overcurrent protection mechanism is in no way linked to a digital control device.
Yet another aspect of the present invention is to provide a low-cost overcurrent protection system for an AC motor control system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of a prior art direct current measurement, overcurrent protection system.
FIG. 2 is a schematic drawing of an overcurrent protection system for AC motors using an individual overcurrent protection assembly for each phase of AC power.
FIG. 3 is a schematic drawing of the individual overcurrent protection assemblies of FIG. 2.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring now to the drawings generally with particular reference to FIG. 2, a motor controller overcurrent protection system 10 is provided including a 3-phase AC motor 12, a digital control unit 14, and a 3-phase AC power system 16. The overcurrent protection system 10 further includes a mechanical feedback system 18 connected to a load 20 driven by the motor 12.
The digital control unit 14 is connected to power drivers 22,24,26 of AC power system 16 along three lines 28,30,32 respectively. The power drivers 22,24,26 are then connected to overcurrent protection assemblies 34,36,38 respectively. The overcurrent protection assemblies 34,36,38 are input to the motor 12.
The mechanical feedback system 18 includes a feedback member 40 connected to the load 20 and a feedback transducer 42 attached to the member 40. The transducer 42 is connected to an analog-to-digital convertor 44 which is in turn connected to the digital control unit 14.
In operation the digital control unit 14 sends digital pulses along lines 28,30,32 which enable each of the power drivers 22,24,26 to generate single phase alternating current. Digital control unit 14 is a known microprocessor which is able to store and execute control algorithms. The AC current produced by each power driver 22,24,26 is monitored by its own respective overcurrent protection assembly 34,36,38. The three AC currents are input to the motor 12 where together they be come the 3-phase power required to run the motor. The operation of the power drivers 22,24,26 and the overcurrent protection assemblies are discussed below.
If the AC current level of any one of the power drivers 22,24,26 surpasses a threshold safety level its respective overcurrent protection assembly 34,36,38 does not allow the power driver to produce AC current. After a preset time period the power driver 22,24,26 again begins producing AC current and if the overcurrent condition is still apparent it again is disallowed from producing AC current.
The overcurrent devices 34,36,38 operate separately allowing any of the power drivers 22,24,26 to be prevented from producing AC current while the other two power drivers are still operating. The entire system is able to maintain operation if the overcurrent condition is minor because often a 3-phase motor will continue operation on two phase power. No down time is then experienced due to a minor or temporary overcurrent condition in the controls of a single phase of the three phase power output to the motor.
If a severe overcurrent condition exists two or all three of the overcurrent assemblies 34,36,38 will prevent their respective power drivers 22,24,26 to operate. As each phase of the 3-phase motor is removed, the motor's 12 potential to stall becomes greater depending upon the magnitude of the load 20. When the motor does stall it is sensed by the transducer 42 through the cessation of movement by feedback member 40. Transducer 42 is a variable resistance potentiometer with its wiper attached to the feedback member 40. Feedback member 40 is a mechanical linkage to the load 20 such as an actuator arm attached to a damper in an airduct (not shown). The A/D convertor 44 is a known analog to digital conversion circuit which converts the position of transducer 42 to digital pulses and transmits them to the digital control unit 14.
If the feedback member 40 remains in a fixed position for a set period of time as sensed by the digital control unit 14 through transducer 42 and A/D convertor 44, indicating a stalled condition, the entire system is shut down by the digital control unit 14. This fixed period of time is usually 7 seconds. An operator then must reset the motor controller system 10 after investigating and correcting the severe overcurrent condition. This provides an entire system shutdown if the digital control unit 14 enables the motor control system 10 and the motor 12 is in a stalled condition or an extreme overcurrent condition exists in the AC power system 16.
Referring now to FIG. 3 a schematic diagram of one of the overcurrent assemblies 34,36,38 (hereafter 34) is provided along with one of the power drivers 22,24,26 (hereafter 22). In normal operation of the power driver 22 the digital control unit 14 sends the same digital pulses to an AND gate 46 and INVERTER gate 48 of the power drivers 22. Gates 46 and 48 are formed by known integrated circuits commonly found in semiconductor chips. Normally the second input of AND gate 46 is logical high, therefore the logical output of AND gate 46 is normally opposite of the logical output of INVERTER gate 48. The outputs of the gates 46 and 48 are sent to known MOSFET power switches 50 and 52, respectively. The MOSFETs 50,52 are enabled alternately by the signals sent from gates 46 and 48 creating an alternating current on line 54 from DC power supply 56 and common 58.
Overcurrent assembly 34 includes a current sensing element 60 connected to one input of a known operational amplifier comparator circuit 62. The comparator 62 is connected to a known RC timing circuit 64 which is connected to the second input of the AND gate 46. The current sensing element 60 may be any known current sensing device, such as a Hall effect sensor or a current sensing resistor.
In operation current sensing element 60 senses the level of current being output by power driver 22 and sends a voltage signal indicative of the current level to the positive input of comparator 62. The negative input of comparator 62 is connected to a safety reference voltage. If the voltage level from current sensing element 60 exceeds the safety reference voltage then comparator 62 outputs an energize signal to timing circuit 64.
In normal operation timing circuit 64 outputs a constant digital high signal to AND gate 46, enabling power driver 22, however, when timing circuit 64 is energized by comparator 62 it will output a digital low signal to AND gate 46, disabling the power driver 22. The timing circuit normally disables the power driver for 20 seconds and then the power driver goes back on line. Hence, power driver 22, which creates one phase of the 3-phase AC power, is disabled separately from the other 2 power drivers 24 and 26 without being controlled by digital controller 14.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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An overcurrent protection system for AC motor control systems which provides a separate overcurrent shut down mechanism for each phase of the AC power used in an AC motor. These separate phase shutdown mechanisms provide protection for minor overcurrent conditions without shutting down the entire motor control system. The overcurrent protection system also provides a mechanical feedback apparatus for totally shutting down the motor control system only in a severe overcurrent condition.
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FIELD
This invention relates to an apparatus for positioning a tool or the like and more particularly to an apparatus having a movable work arm.
BACKGROUND
There are many previously known devices for positioning tools, welding guns and the like for mass production machining and assembly operations.
Some previously known lift and carry workpiece transfer mechanisms have used a so-called Watts linkage drive to raise and lower the workpieces.
A Watts linkage is a three link kinematic mechanism which has three long links pivotally connected together at adjacent ends with the remaining ends of two of the links pivoted about spaced apart and fixed pivot points. The links are constructed and arranged with a geometry that produces an essentially linear reciprocating motion of the center of the middle link. It is well understood that in a Watts linkage the links must be relatively long to produce this linear motion.
Because the links do not move in a true straight line, a Watts linkage is not driven or powered by an actuator producing a straight line or rectilinear motion.
SUMMARY
Pursuant to this invention, a work arm device for positioning a tool is moved in an arc by a modified Watts linkage powered by an actuator having a true straight line motion. To provide a compact device, the Watts mechanism has relatively short links resulting in the center of the middle link following an arcuate path which is drivingly connected to a linear actuator by a pivoting coupling such as a short link or a cam.
Preferably to provide shock absorption for the work arm as it reaches its fully extended position, the modified Watts linkage also has a follower arm yieldably biased by a spring adjacent one end.
Objects, features and advantages of this invention are to provide a device having a movable work arm for positioning a tool which provides arcuate motion of the work arm utilizing a simple linear actuator, readily moves and positions a heavy or massive tool, has a smooth and yet relatively rapid accelerating and decelerating motion when moving the arm to its retracted and extended positions, and is compact, rugged, durable, of relatively simple design and economical manufacture and assembly and in service has a long useful life and requires little maintenance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a device embodying this invention with a pivotally movable arm carrying a welding gun and driven by an air actuated cylinder;
FIG. 2 is a fragmentary top view of the device in the direction of the arrow 2 in FIG. 1;
FIG. 3 is an enlarged and fragmentary side view with portions broken away of the device of FIG. 1 illustrating some of the linkage operably connecting the arm with the drive cylinder and showing the arm in its fully extended position;
FIG. 4 is a fragmentary side view with portions cut away similar to FIG. 3 and illustrating the position of the connecting linkage when the arm is in its fully retracted position;
FIG. 5 is an enlarged, fragmentary and somewhat diagrammatic top view along 5--5 of FIG. 3 illustrating some of the linkage of the device;
FIG. 6 is a diagrammatic side view illustrating the motion of the linkage of the device;
FIG. 7 is an enlarged and fragmentary side view with portions broken away of an alternative embodiment of the device shown in FIGS. 1-6 utilizing an eccentric cam to operably connect the arm with the drive cylinder, and showing the arm in the fully extended position;
FIG. 8 is an enlarged, fragmentary and somewhat diagrammatic top view along 8--8 of FIG. 7 illustrating some of the linkage of the device; and
FIG. 9 is a diagrammatic side view of the embodiment of FIG. 7 illustrating the motion of the linkage of the device.
DETAILED DESCRIPTION
FIG. 1 illustrates a device 10 embodying the invention with a work arm 12 pivotally movable to extended and retracted positions to move a clamp 14 or other tool into and out of a work station 16. In the work station, a pair of steel sheets 18 and 20 are held together by the clamp. The clamp has a pair of arms 22 and 24 providing a backup and a press foot between which the sheets are clamped. The lever arm 24 is pivotally mounted and actuated by a drive cylinder 25 to engage the steel sheets 18 and 20 and thereby hold them in the correct position for an assembly operation such as welding.
The work arm 12 is driven by a preferably air (pneumatic) actuated cylinder 28 through a linkage assembly 30 received in a housing 32 mounted on a pedestal 34. To insure smooth movement of the arm into and out of its fully advanced position, it is operably connected through the linkage to a shock absorber assembly 36.
The pedestal has an upright 38 fixed at one end to a base plate 40 and at the other end to an inclined mounting plate 42 to which the housing 32 is secured. The housing has side plates 44 and 46 joined by a base plate 48 and an H-shaped top plate 50. The top plate 50 provides clearance for articulation of the linkage assembly 30 and the shock absorber 36. The cylinder 28 is mounted on an end plate 52 attached to the side plates. The linkage 30 is carried and retained within the housing 32 by a first pivot 54 and a second pivot 56 each fixed to the side plates 44 and 46.
In accordance with this invention, the work arm 12 is moved to its extended and retracted positions by a modified Watts linkage assembly 30 having a first link 58 to which the work arm is attached for movement in unison therewith, a pair of second links 60, 62, and a pair of third links 64, 66. The first link 58 is pivotally mounted in the housing by a pivot shaft 68 journalled for rotation in a pair of bearings 70, 72 received in collars 74, 76 fixed to the side plates 44, 46. The second links 60, 62 are pivotally connected adjacent one end to the first link by a pivot pin 78 and pivotally connected adjacent the other end to the pair of third links 64, 66 by a pivot pin 80. The pin 80 is journalled for rotation in thrust bearings 82, 84, received in the second links, and is secured to the third links. Adjacent the other end, the third links are pivoted on a pin 86 journalled for rotation in bearings 88, 90 received in the third links and fixed to the housing side plates 44, 46. All three of these links are relatively short, preferably each of substantially the same length, and each has a longitudinal length between the centers of its pivots which is less than 10 inches, desirably 3 to 6 inches, and preferably about 31/2 to 41/2 inches.
To accommodate the arcuate movement of a mid point 92 of the second links 60, 62, they are operably connected to the power cylinder 28 through a fourth link 94. The fourth link is pivotally connected adjacent one end to the mid point 92 of the pair of second links by a pivot pin 96 and is pivotally connected adjacent the other end to an extension bar 98 by a pivot pin 100. The other end of the extension bar is rigidly connected to the piston rod 102 of the cylinder 28 for movement in unison therewith. The fourth link has a generally U-shape to provide clearance for the pivotal connection between the second and third links. Preferably, this fourth link is also relatively short and has a longitudinal length between the centers of its pivots which is not greater than about 8 inches, desirably 3 to 6 inches, and preferably about 31/2 to 41/2 inches.
In accordance with another feature of this invention, to insure smooth and rapid movement of the work arm 12 adjacent its fully extended position, the shock absorber 36 is operably connected to the drive linkage 30 through a fifth link, or follower arm 104, received between the third links 64, 66 and journalled on the pivot pin 86. To operably connect the drive linkage with the shock absorber upon the work arm approaching its fully extended position, the arm 104 has a T-shaped portion 106 at one end with abutment surfaces 110, 112. These abutment surfaces engage with corresponding abutment surfaces on wear blocks 114, 116 secured respectively on each third link. The abutment surfaces on the lever arm 104 and corresponding abutment surfaces on each third link are constructed and arranged to engage as the work arm 12 moves adjacent its fully extended position, as depicted in FIG. 3. As the work arm is moved away from the fully extended position, the abutment surfaces disengage, as depicted by the fully retracted position shown in FIG. 4.
As the work arm approaches the fully extended position, the lever arm 104 pivots about the pin 86 and transmits force to the shock absorber 36 through a cross pin 120 with a reduced shank received in a hole 122 and secured by a nut 124 to the arm. The pin forcibly engages a plunger 126 slidably received in a housing 128 and yieldably biased by a spring 130 toward its extended position. Rotation of the lever arm displaces the plunger and compresses the spring to provide shock absorption as the work arm 12 and clamp 14 approach their fully extended position.
FIGS. 5 and 6 provide a simplified representation of the linkage 30 of FIGS. 1-4 to better depict the arrangement and motion of its components. In FIG. 6, the linkage is shown in the fully extended position with the paths of motion of selected pivot points traced through the full range of motion of the linkage. As seen in FIG. 6, the arcuate reciprocating motion of the mid-point 92 of the second links 60, 62 between the fully extended and fully retracted positions is along the path 132. This arcuate path has a longitudinal axis of symmetry 133 which is preferably coincident with the longitudinal axis of the piston rod 102 of the cylinder 28. Rectilinear motion of the extension bar 98 and piston rod 102 of the cylinder 28 imparts pivotal and axial motion to the fourth link 94 and produces motion of the mid-point 92 of the second links along the path 132, driving the linkage and the work arm 12 as the actuator cylinder applies force to the bar 98.
In accordance with another embodiment of this invention, FIGS. 7-9 show an eccentric cam link assembly 130 and a curvilinear extension bar 131 in lieu of the pivotal fourth link 94. The cam assembly operably connects the linkage about the mid-point 92 of the second links 60, 62 to the piston rod 102 of the cylinder 28. The curvilinear extension bar is rigidly fixed to the piston rod 102, and moves along a rectilinear path 133. Pivotal motion between extension bar 131 and the linkage is produced by a cam cylinder 134 coaxially received in a bore 136 in an end portion 140 of the extension bar 131 and a follower pin 142. The follower pin 142 is received in a bore 144 offset from the center of the cam cylinder and connected to the second links 60,62 of the Watts linkage with its axis coincident with the mid point 92 of these links. Preferably, the cam cylinder is journalled in a bearing 146 and the follower pin 142 is journalled in bearings 148 and 150 in both the second links, respectively.
In use, pivotal motion of the cam cylinder 134 is produced by the offset 156 of the follower pin from the center of the cam cylinder. Preferably, the offset 156, which is the distance between the center of the follower pin and the center of the cam cylinder, is at least three times greater than the maximum transverse offset 158 between the axis of symmetry 133 and the path 132 of motion of the mid point 92 of the second links. For a given offset dimension 158 of 0.080 inches, an exemplary offset dimension 156 for the follower pin would be 0.250 inches. This 3:1 ratio provides a guideline to limit the angular rotation of the cam cylinder, and effectively limits the amount of lateral force produced between the extension bar 132 and the second links 62, 64. This lateral force produces bending moments on the curvilinear extension bar, piston rod and cylinder, when the follower pin 142 is positionally offset from the rectilinear path of the axis of the cam cylinder. Preferably, the cylinder bearing 146 is a Dixon bearing #CJ22E24-T and the second link bearings 148, 150 are a pair of Dixon bearings #CJ10E14-6.
The power work arm of this invention uses a simple and readily available rectilinear actuating means to couple and drive a modified Watts linkage having short links by using a pivotal link coupling the center of the middle link of the modified Watts linkage with the rectilinear motion of the air actuator cylinder. A follower arm with a spring cushion provides shock absorption for the smooth positioning of a work arm and tool as it moves to its fully extended position. This provides a self contained package which is compact, may be a standardized unit, and has an accurate, simplified and precise driving articulation of a work arm and tool through an economical coupling engagement with a simplified and readily available rectilinear air actuator cylinder to produce a simple arcuate motion of a tool mounted at the end of a work arm.
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A device with a pivoting work arm for carrying and positioning a tool which is moved by a modified Watts linkage powered by a linear actuator having a true straight line motion. The modified Watts linkage has relatively short links resulting in the center of the middle link following an arcuate path. The center of the middle link is drivingly connected to the linear actuator by a pivoting link or a cam. To provide shock absorption for the work arm as it reaches its fully extended position, the modified Watts linkage is coupled to a follower arm yieldably biased by a spring.
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PRIORITY CLAIM
[0001] This application claims priority to Non-Provisional patent application Ser. No. 10/852,167 entitled “DUAL FUNCTION PROSTHETIC BONE IMPLANT AND METHOD FOR PREPARING THE SAME” filed on May 25, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is related to a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, and in particular to a prosthetic bone implant comprising a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.
[0004] 2. Description of the Related Art
[0005] It is advantageous if a prosthetic bone implant is bioresorbable and is supportive at the same time. Accordingly, an article made of calcium phosphate will be preferable than that made of a metal, if the former has strength which is comparable to a human cortical bone. One way of making such a bone implant is by sintering a calcium phosphate powder, particularly a hydroxyapatite (HA) powder, into a block material at a temperature generally greater than 1000° C. Despite the fact that the high temperature-sintered HA block material has an enhanced strength, the bioresorbability of the material is largely sacrificed, if not totally destroyed, due to the elimination of the micro- and nano-sized porosity during the sintering process.
[0006] The conventional spinal fusing device is composed of a metallic cage and a bioresorbable material disposed in the metal cage, for example the one disclosed in U.S. Pat. No. 5,645,598. An inevitable disadvantage of this fusion device is the sinking of the metallic cage sitting between two vertebrae to replace or repair a defect spinal disk, because the hardness and the relatively small size of the cage wear out or break the bone tissue, and in particular the endplate of the vertebra.
SUMMARY OF THE INVENTION
[0007] A primary objective of the invention is to provide a prosthetic bone implant free of the drawbacks of the prior art.
[0008] The prosthetic bone implant constructed according to the present invention is made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which comprises a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.
[0009] The prosthetic bone implant of the present invention is made by a novel technique, which involves immersing an article molded from two different pastes of calcium phosphate cement (CPC), one of them having an additional pore-forming powder, in a liquid for a period of time, so that the compressive strength of the molded CPC article is significantly improved after removing from the liquid while the pore-forming powder is dissolved in the liquid, creating pores in a desired zone or zones of the molded article.
[0010] Features and advantages of the present invention are as follows:
[0011] 1. Easy process for different shape and size of the prosthetic bone implant of the present invention, so that the outer circumferential dense portion thereof can sit over the circumferential cortical portion of a bone and the porous portion thereof can contact the cancellous portion of the bone adjacent to a bone receiving treatment.
[0012] 2. The dense cortical portion of the prosthetic bone implant made according to the present invention exhibits a high strength comparable to that of human cortical bone (about 110-170 MPa). The strength is adjustable by adjusting process parameters.
[0013] 3. The dense cortical portion of the prosthetic bone implant made according to the present invention contains significant amount of micro- and nano-sized porosity, that improves bioresorbability thereof. Conventional high temperature-sintered HA block, on the other hand, does not possess sufficient micro/nano-sized porosity and is not bioresorbable.
[0014] 4. The porous cancellous portion of the prosthetic bone implant made according to the present invention possesses a porosity greater than 40% in volume, prepferably 40-90%, allowing rapid blood/body fluid penetration and tissue ingrowth, thereby anchoring the prosthetic bone implant.
[0015] 5. A wide range of medical application includes bone dowel, spacer, cavity filler, artificial disc and fixation devices for spine and other locations, to name a few.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIGS. 1 a to 1 d show schematic cross sectional views of four different designs of prosthetic bone implants constructed according to the present invention.
[0017] FIGS. 2 a to 2 f are schematic cross sectional views showing steps of a method for preparing a prosthetic bone implant according to one embodiment of the present invention.
[0018] FIGS. 3 a and 3 b are schematic vertical and horizontal cross sectional views of a prosthetic bone implant prepared according to another embodiment of the present invention, respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Preferred embodiments of the present invention includes (but not limited to) the following:
[0020] 1. A prosthetic bone implant comprising a cortical portion having two opposite sides, and a cancellous portion integrally disposed in said cortical portion and being exposed through said two opposite sides, wherein said cortical portion comprises a hardened calcium phosphate cement has a porosity of less than 40% in volume, and said cancellous portion comprises a porous hardened calcium phosphate cement having a porosity greater than 20% in volume, and greater than that of said cortical portion.
[0021] 2. The implant according to Item 1, wherein the cortical portion is in the form of a hollow disk, and the cancellous portion is in the form of a column surrounded by the hollow disk.
[0022] 3. The implant according to Item 2 further comprising a transitional portion between said column and said hollow disk surrounding said central cylinder, which has properties range from those of said cancellous portion to said cortical portion.
[0023] 4. The implant according to Item 1, wherein the cortical portion is in the form of a disk having one or more longitudinal through holes, and the cancellous portion is in the form of one or more columns surrounded by said one or more longitudinal through holes.
[0024] 5. The implant according to Item 1, wherein said hardened calcium phosphate cement of said cortical portion comprises an apatitic phase as a major phase giving rise to broadened characteristic X-ray diffraction peaks in comparison with a high-temperature sintered apatitic phase.
[0025] 6. The implant according to Item 5, wherein said broadened characteristic the X-ray diffraction peaks are at 2-Theta values of 25-27° and 30-35°.
[0026] 7. The implant according to Item 1, wherein said hardened calcium phosphate cement of said cortical portion is prepared without a high temperature sintering.
[0027] 8. The implant according to Item 1, wherein said hardened calcium phosphate cement of said cortical portion comprises an apatitic phase as a major phase having a Ca/P molar ratio of 1.5-2.0.
[0028] 9. The implant according to Item 1, wherein said hardened calcium phosphate cement of said cancellous portion comprises an apatitic phase as a major phase giving rise to broadened characteristic X-ray diffraction peaks in comparison with a high-temperature sintered apatitic phase.
[0029] 10. The implant according to Item 9, wherein said broadened characteristic the X-ray diffraction peaks are at 2-Theta values of 25-27° and 30-35°.
[0030] 11. The implant according to Item 1, wherein said hardened calcium phosphate cement of said cancellous portion is prepared without a high temperature sintering.
[0031] 12. The implant according to Item 1, wherein said hardened calcium phosphate cement of said cancellous portion comprises an apatitic phase as a major phase having a Ca/P molar ratio of 1.5-2.0.
[0032] 13. The implant according to Item 1, wherein said cortical portion comprises 10-90% in volume of said implant.
[0033] 14. The implant according to Item 1, wherein said cortical portion has a porosity of less than 30% in volume.
[0034] 15. The implant according to Item 1, wherein said cancellous portion has a porosity greater than 40-90% in volume.
[0035] 16. A method for preparing a prosthetic bone implant comprising a cortical portion having two opposite sides, and a cancellous portion integrally disposed in said cortical portion and being exposed through said two opposite sides, said method comprises the following steps:
a) preparing a first paste comprising a first calcium phosphate cement and a first setting liquid; b) preparing a second paste comprising a second calcium phosphate cement, a pore-forming powder and a second setting liquid; c) i) preparing a shaped article in a mold having two or more cells separated by one more partition walls comprising introducing said first paste and said second paste into said two or more cells separately, and removing said one or more partition walls from said mold, so that said second paste in the form of a single column or two or more isolated columns is integrally disposed in the first paste in said mold; or ii) preparing a shaped article comprising introducing one of said first paste and said second paste into a first mold to form an intermediate in said first mold, placing said intermediate into a second mold after a hardening reaction thereof undergoes at least partially, and introducing another one of said first paste ad said second paste into said second mold, so that said second paste as a single column or as two or more isolated columns is integrally disposed in the first paste in said second mold; d) immersing the resulting shaped article from step c) in an immersing liquid for a first period of time so that said pore-forming powder is dissolved in the immersing liquid, creating pores in said single column or said two or more isolated columns; and e) removing the immersed shaped article from said immersing liquid.
[0041] 17. The method according to Item 16 further comprising
f) drying the immersed shaped article.
[0043] 18. The method according to Item 16, wherein said pore-forming powder is selected from the group consisting of LiCl, KCl, NaCl, MgCl 2 , CaCl 2 , NaIO 3 , KI, Na 3 PO 4 , K 3 PO 4 , Na 2 CO 3 , amino acid-sodium salt, amino acid-potassium salt, glucose, polysaccharide, fatty acid-sodium salt, fatty acid-potassium salt, potassium bitartrate (KHC 4 H 4 O 6 ), potassium carbonate, potassium gluconate (KC 6 H 11 O 7 ), potassium-sodium tartrate (KNaC 4 H 4 O 6 .4H 2 O), potassium sulfate (K 2 SO 4 ), sodium sulfate, and sodium lactate.
[0044] 19. The method according to Item 16, wherein said first calcium phosphate cement comprises at least one Ca source and at least one P source, or at least one calcium phosphate source; and said second calcium phosphate cement comprises at least one Ca source and at least one P source, or at least one calcium phosphate source.
[0045] 20. The method according to Item 19, wherein said first calcium phosphate cement comprises at least one calcium phosphate source, and said second calcium phosphate cement comprises at least one calcium phosphate source.
[0046] 21. The method according to Item 20, wherein said calcium phosphate source is selected from the group consisting of alpha-tricalcium phosphate (α-TCP), beta-tricalcium phosphate (β-TCP), tetracalcium phosphate (TTCP), monocalcium phosphate monohydrate (MCPM), monocalcium phosphate anhydrous (MCPA), dicalcium phosphate dihydrate (DCPD), dicalcium phosphate anhydrous (DCPA), octacalcium phosphate (OCP), calcium dihydrogen phosphate, calcium dihydrogen phosphate hydrate, acid calcium pyrophosphate, anhydrous calcium hydrogen phosphate, calcium hydrogen phosphate hydrate, calcium pyrophosphate, calcium triphosphate, calcium phosphate tribasic, calcium polyphosphate, calcium metaphosphate, anhydrous tricalcium phosphate, tricalcium phosphate hydrate, and amorphous calcium phosphate.
[0047] 22. The method according to Item 21, wherein said first calcium phosphate cement and said second calcium phosphate cement are identical.
[0048] 23. The method according to Item 22, wherein said first calcium phosphate cement and said second calcium phosphate cement are tetracalcium phosphate.
[0049] 24. The method according to Item 16, wherein the first setting liquid and the second setting liquid independently are an acidic solution, a basic solution, or a substantially pure water.
[0050] 25. The method according to Item 24, wherein said acidic solution is selected from the group consisting of nitric acid (HNO 3 ), hydrochloric acid (HCl), phosphoric acid (H 3 PO 4 ), carbonic acid (H 2 CO 3 ), sodium dihydrogen phosphate (NaH 2 PO 4 ), sodium dihydrogen phosphate monohydrate (NaH 2 PO 4 .H 2 O), sodium dihydrogen phosphate dihydrate, sodium dihydrogen phosphate dehydrate, potassium dihydrogen phosphate (KH 2 PO 4 ), ammonium dihydrogen.phosphate (NH 4 H 2 PO 4 ), malic acid, acetic acid, lactic acid, citric acid, malonic acid, succinic acid, glutaric acid, tartaric acid, oxalic acid and their mixture.
[0051] 26. The method according to Item 22, wherein said basic solution is selected from the group consisting of ammonia, ammonium hydroxide, alkali metal hydroxide, alkali earth hydroxide, disodium hydrogen phosphate (Na 2 HPO 4 ), disodium hydrogen phosphate dodecahydrate, disodium hydrogen phosphate heptahydrate, sodium phosphate dodecahydrate (Na 3 PO 4 .12H 2 O), dipotassium hydrogen phosphate (K 2 HPO 4 ), potassium hydrogen phosphate trihydrate (K 2 HPO 4 .3H 2 O), potassium phosphate tribasic (K 3 PO 4 ), diammonium hydrogen phosphate ((NH 4 ) 2 HPO 4 ), ammonium phosphate trihydrate ((NH 4 ) 3 PO 40.3 H 2 O), sodium hydrogen carbonate (NaHCO 3 ), sodium carbonate Na 2 CO 3 , and their mixture.
[0052] 27. The method according to Item 16, wherein step c-i) further comprises allowing said first paste and said second paste undergoing a hardening reaction in said mold.
[0053] 28. The method according to Item 16, wherein step c-i) further comprises pressurizing said first paste and said second paste in said mold after removing said one or more partition walls from said mold to remove a portion of liquid from said first paste and said second paste, so that a liquid/powder ratio of said first paste and of said second paste decreases; and allowing said first paste and second paste undergoing a hardening reaction in said mold.
[0054] 29. The method according to Item 16, wherein step c-ii) further comprises allowing said intermediate undergoing a hardening reaction in said first mold, and allowing said another one of said first paste and said second paste undergoing a hardening reaction in said second mold.
[0055] 30. The method according to Item 16, wherein step c-ii) further comprises pressurizing said one of said first paste and said second paste in said first mold to remove a portion of liquid therefrom before the hardening reaction of said intermediate is completed; allowing said intermediate undergoing a hardening reaction in said first mold; pressuring said another one of said first paste and said second paste in said second mold, so that a liquid/powder ratio of said another one of said first paste and of said second paste decreases; and allowing said another one of said first paste and second paste undergoing a hardening reaction in said second mold.
[0056] 31. The method according to Item 28, wherein said pressuring is about 1 to 500 MPa.
[0057] 32. The method according to Item 30, wherein said pressuring is about 1 to 500 MPa.
[0058] 33. The method according to Item 16, wherein the immersing liquid is an acidic aqueous solution, a basic aqueous solution, a physiological solution, an organic solvent, or a substantially pure water.
[0059] 34. The method according to Item 33, wherein the immersing liquid comprises at least one of Ca and P sources.
[0060] 35. The method according to Item 33, wherein the immersing liquid is a Hanks' solution, a HCl aqueous solution or an aqueous solution of (NH 4 ) 2 HPO 4 .
[0061] 36. The method according to Item 16, wherein the immersing in step d) is carried out for a period longer than 10 minutes.
[0062] 37. The method according to Item 16, wherein the immersing in step d) is carried out for a period longer than 1 day.
[0063] 38. The method according to Item 16, wherein the immersing in step d) is carried out at a temperature of about 10 and 90° C.
[0064] 39. The method according to Item 38, wherein the immersing in step d) is carried out at room temperature.
[0065] 40. The method according Item 17 further comprising cleaning said immersed shaped article before said drying; and heating the resulting dried shaped article at a temperature between 50 and 500° C.
[0066] Four different designs of prosthetic bone implants constructed according to the present invention are shown in FIGS. 1 a to 1 d . In FIG. 1 a , the prosthetic bone implant of the present invention has a dense cortical portion D 1 in the tubular form and a porous cancellous portion P 1 formed in the central through hole of the tubular cortical portion D 1 . Both the dense cortical portion D 1 and the porous cancellous portion P 1 are made of a hardened calcium phosphate cement having an apatitic phase as a major phase. In FIG. 1 b , the prosthetic bone implant of the present invention has a dense cortical portion D 1 in the tubular form; a cylindrical porous cancellous portion P 1 in the center of the tubular cortical portion D 1 ; and an annular transitional portion P 2 connecting the tubular cortical portion D 1 and the cylindrical cancellous portion P 1 . The transitional portion P 2 is made of a hardened calcium phosphate cement having an apatitic phase as a major phase, and a porosity gradient increasing from the lower porosity of the cylindrical cancellous portion P 1 to the higher porosity of the tubular cortical portion D 1 , which may be formed in-situ during molding of two different two different CPC pastes, one of them having an additional pore-forming powder for forming the cylindrical cancellous portion P 1 , and another one being a regular CPC powder for forming the dense cortical portion D 1 . The porous cancellous portion P 1 may be in the forms of isolated columns surrounded by the dense cortical portion D 1 as shown in FIGS. 1 c and 1 d . Other designs are also possible in addition to those shown in FIGS. 1 a to 1 d.
[0067] A suitable method for preparing the prosthetic bone implant of the present invention includes placing a tubular partition wall 10 in a hollow cylindrical mold 20 , as shown in FIG. 2 a ; pouring a first paste comprising a calcium phosphate cement and a setting liquid in the annular cell and a second paste comprising the calcium phosphate cement, a pore-forming powder and the setting liquid in the central cell, as shown in FIG. 2 b ; removing the partition wall and pressing the CPC pastes before hardening, as shown in FIG. 2 c , wherein a portion of the setting liquid is removed from the gap between the mold 20 and the press 30 and/or holes (not shown in the drawing) provided on the press 30 . The CPC paste will undergo a hardening reaction to convert into apatitic phase. The hardened disk is removed from the mold and is subjected to surface finishing to expose the central portion hardened from the second paste, as shown in FIG. 2 d , followed by immersing in a bath of an immersing liquid as shown in FIG. 2 e , where the pore-forming powder is dissolved in the immersing liquid while the hardened CPC thereof gaining compressive strength. The immersing may last from 10 minutes to several days. The composite disk so formed is washed with water after being removed from the bath, and dried and heated in an oven to obtain the prosthetic bone implant as shown in FIG. 2 f . The heating is conducted at a temperature between 50 and 500° C. for a period of several hours to several days, which enhance the compressive strength of the cortical portion of the prosthetic bone implant.
[0068] An alternative method for preparing the prosthetic bone implant of the present invention from the same raw materials includes pouring the second paste in a first mold, pressing the second paste to remove a portion of the setting liquid from the second paste before the hardening reaction is completed, so that the liquid/powder ratio in the second paste decreases, and allowing the hardening reaction undergo in the mold for a period of time, e.g. 15 minutes starting from the mixing of the CPC powder, the pore-forming powder and the setting liquid, to obtain a cylindrical block having a diameter of 7 mm. Then, the cylindrical block is removed from the first mold, and placed in the center of a second mold having a diameter of 10 mm. The first paste is poured into the annular space in the second mold, and a press having a dimension corresponding to the annular shape is used to pressure the first paste to remove a portion of the setting liquid from the first paste before the hardening reaction is completed, so that the liquid/powder ratio in the first paste decreases. Again, the first paste will undergo a hardening reaction to convert into apatitic phase. The hardened cylinder having a diameter of 10 mm is removed from the second mold, followed by immersing in an immersing liquid, where the pore-forming powder contained in the second paste is dissolved in the immersing liquid while the hardened CPC thereof gaining compressive strength, to obtain the prosthetic bone implant of the present invention, as shown in FIGS. 3 a and 3 b . It is apparently to people skilled in the art that the prosthetic bone implant shown in FIGS. 3 a and 3 b can also be prepared by changing the sequence of the molding of the first paste and the second paste with modifications to the second mold used in this alternative method.
[0069] The following examples are intended to demonstrate the invention more fully without acting as a limitation upon its scope, since numerous modifications and variations will be apparent to those skilled in this art.
PREPARATIVE EXAMPLE 1
Preparation of TTCP Powder
[0070] A Ca 4 (PO 4 ) 2 O (TTCP) powder was prepared by mixing Ca 2 P 2 O 7 powder with CaCO 3 powder uniformly in ethanol for 24 hours followed by heating to dry. The mixing ratio of Ca 2 P 2 O 7 powder to CaCO 3 powder was 1:1.27 (weight ratio) and the powder mixture was heated to 1400° C. to allow two powders to react to form TTCP.
PREPARATIVE EXAMPLE 2
Preparation of Conventional TTCP/DCPA-Based CPC Powder (Abbreviated as C-CPC)
[0071] The resulting TTCP powder from PREPARATIVE EXAMPLE 1 was sieved and blended with dried CaHPO 4 (DCPA) powder in a ball mill for 12 hours. The blending ratio of the TTCP powder to the DCPA powder was 1:1 (molar ratio) to obtain the conventional CPC powder. Particles of this C-CPC powder have no whisker on the surfaces thereof.
PREPARATIVE EXAMPLE 3
Preparation of Non-Dispersive TTCP/DCPA-Based CPC Powder (Abbreviated as ND-CPC)
[0072] The TTCP powder prepared according to the method of PREPARATIVE EXAMPLE 1 was sieved and blended with dried CaHPO 4 (DCPA) powder in a ball mill for 12 hours. The blending ratio of the TTCP powder to the DCPA powder was 1:1 (molar ratio). The resultant powder mixture was added to a 25 mM diluted solution of phosphate to obtain a powder/solution mixture having a concentration of 3 g powder mixture per 1 ml solution while stirring. The resulting powder/solution mixture was formed into pellets, and the pellets were heated in an oven at 50° C. for 10 minutes. The pellets were then uniformly ground in a mechanical mill for 20 minutes to obtain the non-dispersive TTCP/DCPA-based CPC powder (ND-CPC). The particles of this ND-CPC powder have whisker on the surfaces thereof.
[0000] Dense Blocks
EXAMPLE 1
Effect of Immersion Time on Compressive Strength of CPC Block
[0073] To a setting solution of 1M phosphoric acid solution (pH=5.89) the ND-CPC powder from PREPARATIVE EXAMPLE 3 was added in a liquid/powder ratio (L/P ratio) of 0.4, i.e. 4 ml liquid/10 g powder, while stirring. The resulting paste was filled into a cylindrical steel mold having a length of 12 mm and a diameter of 6 mm, and was compressed with a gradually increased pressure until a maximum pressure was reached. The maximum pressure was maintained for one minute, and then the compressed CPC block was removed from the mold. At the 15 th minute following the mixing of the liquid and powder, the compressed CPC block was immersed in a Hanks' solution for 1 day, 4 days, and 16 days. Each test group of the three different periods of immersion time has five specimens, the compressive strength of which was measured by using a AGS-500D mechanical tester (Shimadzu Co., Ltd., Kyoto, Japan) immediately following the removal thereof from the Hanks' solution without drying. The CPC paste in the mold was compressed with a maximum pressure of 166.6 MPa, and in the course of the compression the compression speeds were about 5 mm/min during 0˜104.1 MPa; 3 mm/min during 104.1˜138.8 MPa; 1 mm/min during 138.8˜159.6 MPa: and 0.5 mm/min during 159.6˜166.6 MPa. The measured wet specimen compressive strength is listed Table 1.
TABLE 1 Compressive Immersion time (Day) strength (MPa) Standard deviation (MPa) No immersion 37.3* 0.6 1 day 149.2 12.9 4 days 122.7 6.7 16 days 116.4 7.7 *This value was measured before the compressed CPC blocks were immersed in the Hanks' solution, and it was substantially the same for the compressed CPC blocks not immersed in the Hanks' solution measured a few days after the preparation.
[0074] It can seen from Table 1 that the compressive strength of the compressed CPC blocks is increased remarkably after one-day immersion in comparison with the non-immersed block, and declines a little for a longer immersion time.
EXAMPLE 2
Effect of Whiskers on Compressive Strength of TTCP/DCPA-Based CPC Block
[0075] The procedures of EXAMPLE 1 were repeated by using the C-CPC powder prepared in PREPARATIVE EXAMPLE 2 and the ND-CPC powder prepared in PREPARATIVE EXAMPLE 3. The maximum pressure used to compress the CPC paste in the mold in this example was 156.2 MPa. The results for one-day immersion time are listed in Table 2.
TABLE 2 Compressive Standard CPC powder strength (MPa) deviation (MPa) C-CPC (no whisker) 62.3 5.0 ND-CPC (with whisker) 138.0 8.2
[0076] It can be seen from Table 2 that the compressive strength, 62.3 MPa, of the immersed compressed CPC block prepared from the conventional CPC powder (no whisker) is about 1.7 times of that (37.3 MPa) of the non-immersed compressed CPC block in Table 1, and the compressive strength, 138.0 MPa, of the immersed compressed CPC block prepared from the non-dispersive CPC powder (with whisker) is about 3.7 times of that of the non-immersed compressed CPC block in Table 1
EXAMPLE 3
Effect of Whiskers on Compressive Strength of TTCP-Based CPC Block
[0077] Ca 4 (PO 4 ) 2 O (TTCP) powder as synthesized in PREPARATIVE EXAMPLE 1 was sieved with a #325 mesh. The sieved powder has an average particle size of about 10 μm. To the TTCP powder HCl aqueous solution (pH=0.8) was added according to the ratio of 1 g TTCP/13 ml solution. The TTCP powder was immersed in the HCl aqueous solution for 12 hours, filtered rapidly and washed with deionized water, and filtered rapidly with a vacuum pump again. The resulting powder cake was dried in an oven at 50° C. The dried powder was divided into halves, ground for 20 minutes and 120 minutes separately, and combined to obtain the non-dispersive TTCP-based CPC powder, the particles of which have whisker on the surfaces thereof. A setting solution of diammonium hydrogen phosphate was prepared by dissolving 20 g of diammonium hydrogen phosphate, (NH 4 ) 2 HPO 4 , in 40 ml deionized water. The procedures in EXAMPLE 1 were used to obtain the wet specimen compressive strength for one-day immersion time, wherein the maximum pressure to compress the CPC paste in the mold was 156.2 MPa. The results are shown in Table 3.
TABLE 3 Compressive Standard CPC powder strength (MPa) deviation (MPa) TTCP (no whisker) 79.6 8.8 TTCP (with whisker) 100 4.2
[0078] The trend same as the TTCP/DCPA-based CPC powder in Table 2 of EXAMPLE 2 can be observed in Table 3.
EXAMPLE 4
Effect of Molding Pressure on Compressive Strength of ND-CPC Block (in Low Pressure Regime: 0.09˜3.5 MPa)
[0079] The procedures of EXAMPLE 1 were repeated except that the maximum pressure used to compress the CPC paste in the mold was changed from 166.6 MPa to the values listed in Table 4. The period of immersion was one day. The results are listed in Table 4.
TABLE 4 Pressure for compressing the CPC paste in mold Compressive Standard (MPa) strength (MPa) deviation (MPa) 0.09 12.3 2.0 0.35 16.0 2.3 0.7 20.7 2.5 1.4 26.4 1.4 3.5 35.2 3.7
[0080] The data in Table 4 indicate that the compressive strength of the CPC block increases as the pressure used to compress the CPC paste in the mold increases.
EXAMPLE 5
Effect of Reducing Liquid/Powder Ratio During Compression of the CPC Paste in the Mold on Compressive Strength of ND-CPC Block
[0081] The procedures of EXAMPLE 1 were repeated except that the maximum pressure used to compress the CPC paste in the mold was changed from 166.6 MPa to the values listed in Table 5. The liquid leaked from the mold during compression was measured, and the liquid/powder ratio was re-calculated as shown in Table 5. The period of immersion was one day. The results are listed in Table 5.
TABLE 5 Pressure for compressing the L/P ratio (after Compressive Standard CPC paste in a portion of strength deviation mold (MPa) liquid removed) (MPa) (MPa) 1.4 0.25 26.4 1.4 34.7 0.185 75.3 3.9 69.4 0.172 100.4 6.8 156.2 0.161 138.0 8.2 166.6 0.141 149.2 12.9
[0082] The data in Table 5 show that the compressive strength of the CPC block increases as the liquid/powder ratio decreases during molding.
EXAMPLE 6
Effect of Post-Heat Treatment on Compressive Strength of CPC Block
[0083] The procedures of EXAMPLE 1 were repeated. The period of immersion was one day. The CPC blocks after removing from the Hanks' solution were subjected to post-heat treatments: 1) 50° C. for one day; and 2) 400° C. for two hours with a heating rate of 10C per minute. The results are listed in Table 6.
TABLE 6 Compressive Standard strength (MPa) deviation (Mpa) No post-heat treatment 149.2 12.9 50° C., one day 219.4 16.0 400° C., two hours 256.7 16.2
[0084] It can be seen from Table 6 that the post-heat treatment enhances the compressive strength of the CPC block.
[0000] Porous Blocks
EXAMPLE 7
Effect of KCl Content and Immersion Time on Compressive Strength of Porous CPC Block
[0085] To a setting solution of 1M phosphoric acid solution (pH=5.89) the ND-CPC powder from PREPARATIVE EXAMPLE 3 was added in a liquid/powder ratio (L/P ratio) of 0.4, i.e. 4 ml liquid/10 g powder, while stirring. KCl powder in a predetermined amount was mixed to the resulting mixture by stirring intensively. The resulting paste was filled into a cylindrical steel mold having a length of 12 mm and a diameter of 6 mm, and was compressed with a gradually increased pressure until a maximum pressure of 3.5 MPa was reached. The maximum pressure was maintained for one minute, and then the compressed CPC block was removed from the mold. At the 15 th minute following the mixing of the liquid and powders, the compressed CPC block was immersed in a deionized water at 37° C. for 4 days, 8 days, and 16 days. The compressive strength of the specimens of the three different periods of immersion time was measured by using a AGS-500D mechanical tester (Shimadzu Co., Ltd., Kyoto, Japan) after the specimens were dry. The measured dry specimen compressive strength is listed Table 7.
TABLE 7 Dry compressive strength (MPa) Immersion time (Day) KCl/CPC ratio by weight 4 days 8 days 16 days 1 7.0 5.4 6.6 1.5 3.9 2.7 4.3 2 1.3 2.3 2.6
[0086] It can seen from Table 7 that the dry compressive strength of the porous CPC blocks decreases as the KCl/CPC ratio by weight increases.
EXAMPLE 8
Porosity and Compressive Strength of Porous CPC Blocks Prepared from Different Pore-Forming Powders
[0087] The procedures of EXAMPLE 7 were repeated by using sugar, K 1 , C 17 H 33 COONa and C 13 H 27 COOH instead of KCl. The immersion time was 14 days in deionized water. In the cases where the C 17 H 33 COONa and C 13 H 27 COOH were used, the CPC blocks were further immersed in ethanol for additional four days. The conditions and the results are listed in Table 8.
TABLE 8 Pore-forming powder S a) C.S. (MPa) b) Porosity (vol %) c) Sugar 1 4.1 58.4 KI 2 4.3 62.2 KI 3 1.7 75.5 C17H33COONa 1 8.0 56.0 C13H27COOH 2 5.9 60.1 a) S = Pore-forming powder/CPC by volume. b) C.S. = dry compressive strength (hereinafter abbreviated as C.S.). c) Porosity: Porosity (vol %) was measured by Archimedes' method, and calculated as in ASTM C830.
[0088] It can be seen from Table 8 that various powders which are soluble in water can be used in the preparation of a porous CPC block according to the method of the present invention.
[0000] Dual-Functional Block
EXAMPLE 9
[0089] To a setting solution of 1M phosphoric acid solution (pH=5.89) the ND-CPC powder from PREPARATIVE EXAMPLE 3 was added in a liquid/powder ratio (L/P ratio) of 0.4, i.e. 4 ml liquid/10 g powder, while stirring. KCl powder in a ratio of KCl powder/CPC by volume of 2 was mixed to the resulting mixture by stirring intensively. The resulting paste was filled into a cylindrical steel mold having a length of 12 mm and a diameter of 7 mm, and was compressed with a gradually increased pressure until a maximum pressure of 3.5 MPa was reached. The maximum pressure was maintained for one minute, and then the compressed CPC block was removed from the mold at the 15 th minute following the mixing of the liquid and powders.
[0090] The resulting cylinder having a diameter of 7 mm was placed in another cylindrical steel mold having a diameter of 10 mm. To a setting solution of 1M phosphoric acid solution (pH=5.89) the ND-CPC powder from PREPARATIVE EXAMPLE 3 was added in a liquid/powder ratio (L/P ratio) of 0.4, i.e. 4 ml liquid/10 g powder, while stirring. The resulting paste was filled into the gap between said cylinder and said another mold, and was compressed with a gradually increased pressure until a maximum pressure of 50 MPa was reached. The maximum pressure was maintained for one minute. At the 15 th minute following the mixing of the liquid and ND-CPC powder, the CPC/KCl composite block was immersed in a deionized water at 37° C. for 4 days. KCl powder was dissolved in the deionized water, and a dual-functional CPC block having a porous CPC cylinder surround by a dense CPC annular block was obtained.
[0091] The compressive strength of the specimen was measured by using a AGS-500D mechanical tester (Shimadzu Co., Ltd., Kyoto, Japan) after the specimens were dry. The measured dry specimen compressive strength is 68.8 MPa.
[0092] The porosities of the porous CPC cylinder and the dense CPC annular block were measured by Archimedes' method, and calculated as in ASTM C830, after the dual-functional CPC block was broken intentionally, and the results are 74% and 30%, respectively.
[0093] X-ray diffraction pattern of the powder obtained by grinding the dual-functional CPC block shows broadened characteristic X-ray diffraction peaks of apatite at 20=25-27° and 20=20-35° w ith a scanning range of 20 of 20-40° and a scanning rate of 1°/min. The results indicate that the powder is a mixture of apatite and TTCP with apatite as a major portion.
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The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.
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This application is a continuation-in-part of application Ser. No. 344,309 filed Feb. 1, 1982, which in turn is a continuation of application Ser. No. 154,132, filed May 29, 1980, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a method of convulsions, including convulsive tremors and convulsive seizures, and, in particular, epilepsy, with organic copper compounds.
BACKGROUND OF THE INVENTION
Copper is a normal component of the human brain, which contains about 370 mg of copper per gram of tissue ash. This amount of tissue copper ranks second only to that amount found in the liver, the storage organ for copper.
Normal brain development and function requires a number of copper-dependent enzymes. The following is a list of these enzymes and their role in brain function.
______________________________________Copper-Dependent Enzyme Role in Brain Function______________________________________(1) Cyctochrome c oxidase Cellular respiration(2) Cerebrocuprein (cerebral Dismutation of superoxidesuperoxide dismutase) anion radicals(3) Tyrosinase Conversion of tyrosine to DOPA(4) Dopamine-β-hydroxylase Conversion of dopamine to norepinephrine and epinephrine(5) Lysyl oxidase Conversion of procollagen to tropocollagen and proelastn to elastin in tne vasculature______________________________________
In addition, copper-dependent processes are required for the modulation of prostaglandin syntheses, lysosomal membrane permeability, the activity of histamine, and myelinogenesis.
A variety of brain pathologic disorders accompanied by convulsive seizures are associated with abnormal copper metabolism in humans. Serum copper is elevated in epileptic patients, but brain copper levels are markedly reduced in autopsied epileptics. The elevated serum copper concentrations may indicate physiologic mobilation of copper from the liver to the brain in life but depleted stores leading to copper deficiency may account for decreased brain levels postmortem. Children with severe copper deficiency due to inadequate intake or Menkes' Syndrome, which includes depleted liver copper stores and markedly decreased brain copper levels, are known to have convulsive seizures as a constant feature of their copper deficiency. In addition, neonatal copper deficiency and the copper deficiency associated with Menkes' Syndrome are also associated with severe or terminal central nervous system disorders.
Seizures as well as neuronal and cerebral degeneration also occur in copper-deficient animals. Both quaking mice and mottled mice exhibit tremors as well as neural and central nervous system degeneration as symptoms of their genetic copper deficiency. Rats which are made copper-deficient by removing copper from their diet also exhibit convulsive tremors and central nervous system degeneration. The observation of seizures and central nervous system degeneration in association with a reduction in brain copper levels and concomitant reduction in norepinephrine and epinephrine levels which have been proposed to be seizure modulators, are consistent with known copper requirements [Jobe, P. C., A. L. Picchioni and L. Chin, Role of Brain Norepinephrine in Audiogenic Seizure in the Rat, J. Pharmac. Exp. Ther., 184:1-10 (1973), hereby incorporated by reference]. Further, complexing agents which produce tremors in these animals also reduce brain copper levels [Hadzovic, S., R. Kosak and P. Stern, The Effect of Tremorigenic Substances on the Copper Content of the Rat Brain, J. Neurochem, 3:1027-29 (1966); Price, T. R. and P. Silberfarb, Convulsions Following Disulfiram Treatment, Am. J. Psychiatry, 133:235 (1976), hereby incorporated by reference]. Finally, lambs born to ewes living on copper deficient pastures have a poorly developed central nervous system and exhibit tremors. On recognition, this enzootic ataxia is prevented by injecting the pregnant ewes with copper complexes [Underwood, E. J., In: Trace Elements in Human and Animal Nutrition, 4th Ed. Academic Press, New York, pp. 56-108 (1977), hereby incorporated by reference].
Existing antiepileptic drugs have been found to be ineffective in treating many individuals with epilepsy. This is in part due to serious side effects associated with these agents which include: intolerance, sedation, gingival hyperplasia, ataxia, nystagmus, diplopia, vertigo, psychoses, lethargy, euphoria, mydriasis, headache, hyperactivity, confusion, hallucinations, peripheral neuropathy, gastrointestinal irritation, vomiting, nausea, epigastric pain, anorexia, increased appetite, hypoglycemia, glycosuria, osteomalacia, symptoms of systemic lupus erythematosus, dermatoses, hepatic necrosis, many blood dyscrasias and lymphadenopathy [Woodbury, D. M. and E. Fingl, The Pharmacological Basis of Therapeutics, 5th Ed., MacMillan Pub., New York, pp. 201-225 (1975), hereby incorporated by reference]. Ataxia, anorexia [Underwood, E. J. In: Trace Elements in Human and Animal Nutrition, Id.], peripheral neuropathy, nystagmus, lethargy, and osteomalacia are associated with copper deficiency [Danks, D. M., Copper Transport and Utilization in Menkes' Syndrome and in Mottled Mice, Inorg. Persp. Biol. Med. 1: 73-100 (1977); Sorenson, J. R. J., Therapeutic Uses of Copper, In: Copper in the Environment, Ed. by J. O. Nriagu, John Wiley and Sons, New York, pp. 83-162 (1979); Underwood, E. J., In: Trace Elements in Human and Animal Nutrition, Id., hereby incorporated by reference].
SUMMARY OF THE INVENTION
The present invention seeks to overcome the problems and disadvantages of the prior art. As pointed out, supra, existing antiepileptic drugs are ineffective in treating many individuals with epilepsy because of their toxic side-effects. If drug-induced toxicities are in part caused by the removal of copper from some copper-dependent metalloprotein or metalloenzyme via complexation as a result of therapy, then these toxicities may be avoided by treatment with a copper complex of these drugs. Because copper complexes are known to have potent antiulcer activity and lack gastrointestinal irritant activity [Sorenson, J. R. J., Copper Chelates As Possible Active Forms of the Anti-Arthritic Agents, J. Med. Chem. 19(1): 135-147 (1976); Sorenson, J. R. J., Copper Complexes, A Unique Class of Antiarthritic Drugs, Prog. Med. Chem. 15:211-260 (1978); and Walker, W. R., R. Reeves and D. J. Kay, Role of Cu 2+ and Zn 2+ in Physiological-Activity of Histamine in Mice, Search 6:134-135 (1975), hereby incorporated by reference], it is conceivable that at least the gastrointestinal side-effects of the existing antiepileptic drugs may be circumvented by using copper complexes in therapy. If copper complexes of the antiepileptic drugs or other copper complexes have increased anticonvulsant activities and do not cause gastrointestinal irritation or the other toxicities associated with the currently used drugs they would offer more effective and less toxic therapy of convulsions and epilepsy.
Broadly, the present invention is directed to a method for treating convulsions, including convulsive tremors and convulsive seizures, and epilepsy comprising administration of a therapeutically effective amount of an organic compound of copper (in the cuprous or cupric form) having anticonvulsant and/or antiepileptic activity.
Such compounds include but are not limited to copper complexes of imines, including the following specific types of imines which possess distinctive configurations when complexed with copper: bisethyleneimine Schiff bases, salicylidene-amino acid Schiff bases and pyridoxylidene-amino acid Schiff bases.
Such compounds further include but are not limited to copper complexes of carboxylic acids. Included among these carboxylic acids are aryl carboxylic acids and also branched and unbranched aliphatic carboxylic acids, for example, those carboxylic acids with aliphatic chains of one to seven carbons in length. The aryl carboxylic acids include, but are not limited to, acylsalicylic acids and benzoic acids. When complexed with copper the carboxylic acids are called copper carboxylates.
The organic copper compounds useful in the practice of this invention also include copper complexes of amino acids. Two molecules of the same or different amino acid complex with one atom of copper to form a distinctive copper coordination compound. The twenty common amino acids as well as other less common amino acids are potentially useful.
The organic copper compounds that can be used in the invention include copper complexes of salicylic acid and substituted salicylic acids. Such salicylic acids form copper salicylates.
One of the remarkable aspects of Applicant's invention is the demonstration that copper complexes of salicylates, acylsalicylates and amino acids exhibit anticonvulsant and/or antiepileptic activity. To Applicant's knowledge, no one has ever reported that salicylates, acylsalicylates, or amino acids alone, i.e., not complexed with copper, have any anticonvulsant and/or antiepileptic. On the contrary, what is known is that salicylate and acetylsalicylate (aspirin) actually cause convulsions at high doses, making Applicant's discovery that copper complexes of these compounds have anticonvulsant activity all the more remarkable. Applicant's discovery further supports the suggestion of reduced toxicity of copper complexes of existing anticonvulsant (antiepileptic) drugs.
Also suitable for use in the practice of this invention are copper complexes of known anticonvulsant/antiepileptic compounds. Such compounds are of the following classes: hydantoins, barbiturates, desoxy-barbiturates, iminostilbenes, acetylureas, succinimides, benzodiazepines, oxazolidinediones, sulfonamides and fatty acids (saturated or unsaturated) or mixtures of any of the foregoing compounds. Remarkably, it has been found that subcutaneous administration of copper complexes of certain of the known anticonvulsant drugs, specifically amobarbital, is free of side effects (hypnosis or sedation) associated with the non-copper-complexed form of the drug. The potential for elimination of side-effects associated with known anticonvulsant and antiepileptic drugs by using copper complexes thereof is a particularly important discovery.
BRIEF DESCRIPTION OF THE FIGURE
FIG. 1 graphically depicts the anticonvulsant activity versus time for Cu(II)(salicylate) 2 in preventing the Metrazol-induced seizure after giving 100 mg/kg subcutaneously (closed circles) and in preventing the Maximal Electroshock-induced seizure after giving 600 mg/kg subcutaneously (open circles).
DESCRIPTION OF THE INVENTION
Copper complexes were synthesized using reported methods [Sorenson, J. R. J., Copper Chelates As Possible Active Forms of the Anti-Arthritic Agents, Id.; U.S. Pat. No. 4,221,785 of Sorenson, J. R. J., hereby incorporated by reference].
The copper complexes were submitted to the National Institute of Neurological and Communicative Disorders and Stroke (NINCDS) which has an Antiepileptic Drug Development (ADD) program to screen compounds for anticonvulsant activity. Test compounds were either dissolved in 0.9% saline, or suspended in either 30% polyethylene glycol 400 in 0.9% saline or 0.2% suspending agent like polyoxyethylene glycol or Tween 80 in 0.9% saline prior to injection into male Carworth Farms #1 mice or Sprague-Dawley rats. Thus, compounds can be administered as solutions, suspensions or ointments. Unless otherwise specified, concentrations are percent by weight.
In Phase I identification of anticonvulsant activity, test compounds were given intraperitoneally (IP) at 30, 100, 300 and, in some cases, 600 milligrams per kilogram (mg/kg) of body weight and protection against Maximal Electroshock and/or Metrazol-induced seizures was determined 30 minutes, 4 hours, or later. Initial studies using the intraperitoneal route of administration demonstrated that copper complexes were effective as anticonvulsants but stimulation or depression (rotating rod toxicity) and lethality were occasionally observed at the highest doses given. Subsequently the routine protocol was modified and certain of the test compounds (see Tables, infra) re-evaluated following subcutaneous (SC) injection at periods of up to 8 hours post injection. Subcutaneous administration can be helpful in determining whether or not hypnotic activity can be distinguished from anticonvulsant activity based upon the decreased rate of absorption associated with this route of administration as opposed to the more rapid rate of absorption associated with IP administration. With this protocol none of the copper complexes so tested was found to be toxic in the rotating rod test and no deaths were observed, even at the highest doses given. In addition, some of these compounds were found to have anticonvulsant activity at doses less than 30 mg/kg and for prolonged periods of up to 6 to 8 hours post injection.
Compounds found to be effective only at 30 minutes are viewed as rapid in onset (due to rapid distribution to the central nervous system) and of short duration. Compounds that are effective only at 4 hours are viewed as slower in onset. Those compounds that are effective at both 30 minutes and 4 hours are viewed to be rapid in onset and of prolonged duration. Variability in onset and duration may be useful in the design of therapeutic regimens in which combinations of compounds are administered to a convulsant or epileptic patient.
Minimal anticonvulsant activity and the lack of toxicity were criteria required for Phase II studies, in which the time of peak anticonvulsant effect in the Maximal Electroshock and Metrazol-induced seizures, efficacy (ED 50 values for protection against the Maximal Electroshock and Metrazol-induced seizures), and lethality (LD 50 in 24 hours) were quantified. All statistics were obtained by probit analyses.
SEIZURE MODELS
Maximal Electroshock Seizure Test. Maximal electroshock seizures were elicited with a 60 cycle alternating current of 50 mA intensity (5-7 times that necessary to elicit minimal electroshock seizures) delivered for 0.2 seconds via corneal electrodes. A drop of 0.9% saline is instilled in the eye prior to application of the electrodes in order to prevent the death of the animal. Abolition of the hind limb tonic extension component of the seizure is defined as protection.
Subcutaneous Pentylenetetrazol (Metrazol) Seizure Threshold Test. Eighty-five mg/kg of pentylenetetrazol (produces seizures in greater than 97% of mice) was administered as a 0.5% solution subcutaneous in the posterior midline. The animal was observed for 30 minutes. Failure to observe even a threshold seizure (a single episode of clinic spasms of at least 5 seconds duration) is defined as protection.
Toxicity. The rotating rod was used to evaluate neurotoxicity. The animal was placed on a 1-inch diameter knurled plastic rod rotating at 6 revolutions per minute. Normal mice can remain on a rod rotating at this speed indefinitely. Neurologic toxicity is defined as the failure of the animal to remain on the rod for 1 minute and is due to either stimulation or depression of the central nervous system.
EXPERIMENTAL EXAMPLES
COPPER COMPLEXES OF ACYLSALICYLATES
The data obtained for a number of copper complexes of acylsalicylates following subcutaneous (SC) administration are presented in Table I. Cu(II) refers to the cupric form of the compound, that is, copper with a valency of +2. Structures I and II schematically depict the generic structure of an acylsalicylate copper complex (where R represents hydrogen, branched or unbranched lower alkyl, aryl, alkyl-aryl, or substituted alkyl or aryl groups; R" represents branched or unbranched lower alkyl, aryl, halogen, or branched or unbranched lower alkyl or aryl groups substituted with halogens or oxygen-containing substituents such as hydroxy or alkoxy or nitrogen-containing substituents such as amino or nitro; and L represents solvating or other ligands capable of bonding to copper as indicated, such as water, alcohols, amines, ethers, sulfoxides and other solvents and competing ligands). The nonsolvated form of copper complexes of acylsalicylates, i.e., in the absence of L, exhibits a central binuclear configuration (as in Structure I) characteristic of nonsolvated forms of copper complexes of carboxylic acids which associate witn copper atoms via their carboxyl groups in a 4:2 (carboxylic acid:copper atom) ratio. When L is present, the copper complex can exist in either the binuclear configuration of Structure I or the mononuclear configuration of Structure II depending on the affinity of L for copper. ##STR1##
TABLE I______________________________________ANTICONVULSANT ACTIVITY (PHASE I)OF SOME COPPER COMPLEXES OFACYLSALICYLATES Maximal % Electro-COMPLEX Copper Route shock Metrazol______________________________________Cu(II).sub.2 (adamantyl- 9 SC.sup.1 I.sup.2 A.sup.3 at 30salicylate).sub.4 and 300 mg/kg at 30 min.Cu(II).sub.2 (acetyl- 15 SC I A at 100salicylate).sub.4 and 300 mg/kg at 30 min. and 6 hrs.; A at 30, 100 and 300 mg/kg at 8 hrs.Cu(II) 11 SC I A at 300(acetylsalicylate).sub.2 mg/kg at(dimethylsulfoxide).sub.2 30 min.; A at 100 mg/kg at 4 hrs.Cu(II) 11 SC I A at 300(acetylsalicylate).sub.2 mg/kg at(pyridine).sub.2 30 min.; A at 100 and 300 mg/kg at 4 hrs.Cu(II).sub.2 (3,5-dibromo- 8.6 IP A at 100 A at 100acetylsalicylate).sub.4 mg/kg at mg/kg at 4 hrs. 30 min. SC A at 300 I mg/kg at 4 hrs.Cu(II).sub.2 (3,5-diiodo- 6.8 IP I A at 100acetylsalicylate).sub.4 mg/kg at(H.sub.2 O).sub.6 30 min. and 4 hrs. SC A at 300 A at 300 mg/kg at mg/kg at 4 hrs. 4 hrs. SC.sup.4 Not A at 105 tested mg/kg at 30 min.______________________________________ .sup.1 SC = Subcutaneous. .sup.2 Inactive at doses studied. .sup.3 Activity at doses and times indicated. .sup.4 Phase II data.
Cu(II) 2 (adamantylsalicylate) 4 was found to have anticonvulsant activity at 30 minutes following subcutaneous injection at 30 and 300 mg/kg. Cu(II) 2 (acetylsalicylate) 4 [alternatively called copper aspirinate or Cu(II) 2 (aspirinate) 4 ] was found to have activity at 30 minutes, 6 hours and 8 hours following subcutaneous injection of the entire range of doses studied. The dimethylsulfoxide and pyridine solvates of Cu(II)(acetylsalicylate) 2 were found to be effective at the higher doses studied at 30 minutes and 4 hours. None of these complexes was found to have rotating rod toxicity at any of the doses or times studied following subcutaneous injection. Cu(II) 2 (3,5-dibromoacetylsalicylate) 4 and Cu(II) 2 (3,5-diiodoacetylsalicylate) 4 were also effective in protecting against both models of seizure. ##STR2##
A group of copper complexes of salicylates with the generic structures shown schematically by structures III and IV (where R" and L represent the same groups, substituents, and described for Structures I and II) were also evaluated for their anticonvulsant activity. The nonsolvated form of copper complexes of salicylates, i.e., in the absence of L, exnibits a mononuclear configuration as in Structure III. When L is present, the copper complex can exist in either the mononuclear configuration of Structure III or tne binuclear configuration of Structure IV depending on tne affinity of L for copper.
As shown in Taole II, Cu(II)(salicylate 2 ), Cu(II)(4-tertiarybutylsalicylate) 2 and Cu(II)(3,5-ditertiarybutylsalicylate) 2 were found to be effective at the higher doses studied and for prolonged periods of up to 4 hours. Cu(II)(salicylate) 2 (pyridine) 2 had activity representative of a compound with rapid onset. The 3,5-diisopropylsalicylate, 3,5-ditertiarybutylsalicylate, 3,5-dibromosalicylate and 3,5-dichlorosalicylate complexes are of special interest because they were effective in preventing both the Maximal Electroshock and Metrazol-induced seizures in Phase I studies. All of these complexes were also found to be free of rotating rod toxicity at all of the doses and time periods studied following subcutaneous injection. Also presented in Table II are data obtained for three 4-substituted salicylates, Cu(II)(4-nitro-salicylate) 2 , Cu(II)(4-aminosalicylate) 2 and Cu(II)(4-acetylaminosalicylate) 2 , which were also effective in preventing seizures. However, administration of Cu(II)(4-nitrosalicylate) 2 at 100 mg/kg, Cu(II)(4-aminosalicylate) 2 at 300 mg/kg and Cu(II)(acetylaminosalicylate) 2 at 600 mg/kg elicited rotating rod toxicity. Moreover, administration of Cu(II) (4-nitrosalicylate) 2 at doses higher than 100 mg/kg and Cu(II)(4-aminosalicylate) 2 at doses higher than 300 mg/kg caused death in some of the test groups. These deaths may have resulted from a hypnotic overdose.
TABLE II______________________________________ANTICONVULSANT ACTIVITY (PHASE I)OF SOME COPPER COMPLEXES OF SALICYLATES Maximal % Electro-COMPLEX Copper Route shock Metrazol______________________________________Cu(II) (salicylate).sub.2 19 SC.sup.1 I.sup.2 A.sup.3 at 30, 100 and 300 mg/kg at 30 min.; A at 300 mg/kg at 4 hrs.Cu(II) (salicylate).sub.2 -- IP I A at 300(pyridine).sub.2 mg/kg at 30 min.Cu(II).sub.2 14 SC I A at 300(4-tertiarybutyl- mg/kg atsalicylate).sub.2.1/2H.sub.2 O 30 min.; A at 300 and 600 mg/kg at 4 hrs.Cu(II) (3,5-diisopro- 13 SC A at 300 A at 30,pylsalicylate).sub.2 mg/kg at 100 and 4 hrs; 300 mg/kg A at 100 at 30 min.; and 300 A at 100 mg/kg at and 300 6 hrs.; mg/kg at A at 300 4 hrs.; mg/kg at A at 100 8 hrs. mg/kg at 6 hrs.; A at - 100 and 300 mg/kg at 8 hrs.Cu(II) (3,5-ditertiary- -- IP A a 100 A at 30butylsalicylate).sub.2 mg/kg at and 100 4 hrs. mg/kg at 30 min. SC A at 300 A at 300 mg/kg at mg/kg at 4 hrs. 4 hrs.Cu(II) -- IP.sup.4 I A at(4-nitrosalicylate).sub.2 100.sup.3 mg/kg.sup.6 at 30 min.Cu(II) -- IP I A at 30,(4-aminosalicylate).sub.2 100 and 300.sup.5 mg/kg.sup.6 at 30 min.; A at 100 mg/kg.sup. 6 at 4 hrs.Cu(II) (4-acetyl- -- IP A at 600.sup.5 I.sup.7aminosalicylate).sub.2 mg/kg at 30 min.Cu(II) (5-chloro- -- IP I A at 300salicylate).sub.2 mg/kg at 30 min. and 30 mg/kg at 4 hrs. IP.sup.8 Not A at 30 tested mg/kg at 6 hrs.Cu(II) (3,5-dibromo- -- IP A at 300 A at 30salicylate).sub.2 (H.sub.2 O).sub.3 mg/kg at mg/kg at 4 hrs. 30 min. and 100 mg/kg at 4 hrs. SC A at 300 A at 600 mg/kg at mg/kg at 4 hrs. 4 hrs.Cu(II) (3,5-dichloro- -- IP A at 600 A at 100salicylate).sub.2 (H.sub.2 O).sub.2 mg/kg at mg/kg at 4 hrs. 30 min. SC I A at 600 mg/kg at 4 hrs.______________________________________ .sup.1 SC = Subcutaneous. .sup.2 Inactive at doses studied. .sup.3 Activity at doses and times indicated. .sup.4 IP = Intraperitoneal. .sup.5 Rotating Rod toxicity. .sup.6 Lethal at higher doses. .sup.7 Lethal at 100 mg/kg at 4 hours. .sup.8 Phase II data.
PHASE II EVALUATION OF Cu(II)(SALICYLATE) 2
The Phase I test data presented in Tables I, II (supra) and III (infra) were all obtained in a standardized protocol using routine doses and routine times for the qualitative evaluation of anticonvulsant effects of the compounds tested. The NINCDS-ADD Program Phase II follow-up evaluation of active compounds with low toxicity is a quantitation of the anticonvulsant activity and acute toxicity. The anticonvulsant activity is quantitated by determining the times of peak activity and ED 50 values in the Maximal Electroshock and Metrazol-induced seizures. The acute toxicity is quantitated by determining the 24-hour LD 50 value.
The first copper complex selected by the ADD Program for Phase II evaluation was Cu(II)(salicylate) 2 . The data presented in FIG. I show that the time of peak effect for the inhibition of Metrazol-induced seizures following subcutaneous administration of 100 mg/kg was 2 hours and the time of peak effect for the inhibition of Maximal Electroshock induced seizures was 7 hours following subcutaneous administration of 600 mg/kg.
These data point out that the times of peak effects were different from the time of routine evaluation in the Phase I tests and that the dose required to protect against the Maximal Electroshock-induced seizure was larger than the largest dose used in the routine Phase I test. The data plotted in FIG. I also show that there was a rapid onset of protection against the Metrazol-induced seizure which decreases over the extrapolated period of 7 hours. The onset of protection against Maximal Electroshock-induced seizure was slower but the activity was prolonged over the 24-hour period (37% inhibition at 24 hours) and beyond. The ED 50 values for protection against Maximal Electroshock and Metrazol-induced seizures were 360 mg/kg and 38 mg/kg, respectively. The LD 50 value for this compound was 441 mg/kg. This value was not much different from the ED 50 for protection against Maximal Electroshock-induced seizures but it was over 10 times the ED 50 for the prevention Metrazol-induced seizures.
These data show that while Cu(II)(salicylate) 2 was inactive in protecting against tne Maximal Electroshock-induced seizure in routine Phase I studies, it was found to be active in protecting against this seizure when higher doses were used and the activity was evaluated at different time periods. As a result, inactivity in Phase I studies cannot be taken as evidence of no activity at any time period or higher doses. The possibility exists that these apparently inactive compounds may be active in protecting against seizures when the treatment protocol is modified to include prolonged pretreatment (i.e., longer periods of time after administration of a copper complex but before inducement of the seizure) and/or higher doses.
COPPER COMPLEXES OF AMINO ACIDS
A series of copper complexes of bidentate amino acid generically depicted by Structure V (where R represents the alpha substituents of the D or L amino acids, wherein D and L represent the configuration of the alpha carbon and where two of the same or two different amino acids form the complex and L represents solvating or other ligands such as water, alcohols, amines, ethers, sulfoxides and other solvents and competing ligands) and a copper complex of a tridentate amino acid (glutamic acid) were evaluated as anticonvulsants. The results are presented in Table III. ##STR3##
TABLE III______________________________________ANTICONVULSANT ACTIVITY (PHASE I)OF SOME COPPER COMPLEXES OF AMINO ACIDS Maximal % Electro-COMPLEX Copper Route shock Metrazol______________________________________Cu(II) 22 IP.sup.1 NT.sup.2 A.sup.3 at(L-threoninate) 30,100 and(L-serinate) 300 mg/kg at 30 min. and 4 hrs.Cu(II) 24 IP NT A at 30,(L-threoninate) 100 and(L-alaninate) 300 mg/kg at 30 min. and 4 hrs.Cu(II) 20 IP NT A at 30,(L-valinate).sub.2 H.sub.2 O 100 and 300 mg/kg at 30 min. and 4 hrs.Cu(II) 20 IP NT A at 30,(L-threoninate).sub.2 H.sub.2 O 100 and 300 mg/kg at 30 min. and 4 hrs.Cu(II) 27 IP NT A at 30,(L-alaninate).sub.2 100 and 300 mg/kg at 30 min. and 4 hrs.Cu(II) 16 IP NT At at 30,(L-phenylalaninate).sub.2 100 and 300 mg/kg at 30 min.Cu(II) 20 IP NT At at 100(L-cystinate).sub.2 H.sub.2 O and 300 mg/kg at 30 min.Cu(II) -- SC.sup.1 NT A at 30,(L-serinate).sub.2 100 and 300 mg/kg at 30 min. and 4 hrs..sup.6Cu(II) -- IP I.sup.5 A at 300(L-tryptophanate).sub.2 and 600 mg kg at 30 min. and 4 hrs.Cu(II) -- SC I A at 600(L-glutamate).sub.2 mg/kg at 4 hrs. IP I A at 100.sup.7 mg/kg at 30 min; A at 30 and 100 mg/kg at 4 hrs.Cu(II) -- SC I I(L-leucinate).sub.2 IP I A at 100 mg/kg at 30 min. and A at 30 and 100 mg/kg at 4 hrs.Cu(II) -- SC I A at 300(L-isoleucinate).sub.2 and 600 mg/kg at 30 min. and 600 mg/kg at 4 hrs.Cu(II) (L-isoleucinate).sub.2 TP A at 600.sup.6 A at mg/kg at 100.sup.6 30 min. mg/kg at 30 min.______________________________________ .sup.1 Not Tested. .sup.2 Active at doses and times indicated. .sup.3 Rotating red toxicity observed with 300 mg/kg at 4 hrs. .sup.4 Inactive at 30, 100, 300 and 600 milligrams per kilogram at 30 min and 4 hrs. .sup.5 Rotating rod toxicity. .sup.6 Lethal at higher doses.
Cu(II)(L-threoninate)(L-serinate), Cu(II) (L-threoninate)(L-alaninate), Cu(II)(L-valinate) 2 , Cu(II)(L-threoninate) 2 and Cu(II)(L-alaninate) 2 were found to be effective against the Metrazol-induced seizure at all doses studied and at both time intervals, 30 minutes and 4 hours. Rotating rod toxicity was observed with the first four of these compounds but only at the highest dose studied (300 mg/kg) at the end of the 4-hour observation. Cu(II)(L-phenylalaninate) 2 and Cu(II)(L-cystinate) 2 were also effective against the Metrazol-induced seizure at all three doses studied but only at the shorter time period.
Cu(II)(L-serinate) 2 , Cu(II)(L-tryptophanate) 2 , Cu(II)(L-glutamate) 2 , Cu(II)(L-leucinate) 2 and Cu(II)(L-isoleucinate) 2 have also been found to have anticonvulsant activity. In all cases these compounds were found to be more effective following IP than SC administration but they were also more toxic following IP administration. This is consistent with a more rapid absorption of greater amounts of these compounds following IP administration. The lethality associated with higher doses of some of the compounds is consistent with the possibility that these animals had been given hypnotic overdoses. The isoleucine complex was unique because it inhibited both the Maximal Electroshock and Metrazol-induced seizures in these Phase I tests.
COPPER COMPLEXES OF IMINES
Copper complexes of imines were evaluated for the anticonvulsant activity. The types of imine compounds tested included copper complexes of the following: (a) salicylidene-amino acid Schiff bases, the generic structure of which is depicted by Structure VI (where R represents the alpha substituents of the D or L amino acids, D and L denoting the configuration of the alpha carbon; R" represents branched or unbranched lower alkyl, aryl or halogen groups, or branched or unbranched lower alkyl or aryl groups substituted with halogens, oxygen-containing groups, e.g., hydroxy or alkoxy, or nitrogen-containing groups, e.g., amino or nitro; and L represents solvating or other ligands capable of bonding to copper as indicated, such as water, alcohols, amines, ethers, sulfoxides, and other solvents and competing ligands); (b) bisethyleneimine Schiff bases, the generic structures of which are depicted by Structures VII and VIII (where R and R" represent branched or unbranched lower alkyl, aryl or halogen groups, or branched or unbranched lower alkyl or aryl groups substituted with halogens, oxygen-containing groups, e.g., hydroxy or alkoxy, or nitrogen-containing groups, e.g., amino or nitro; and L represents solvating or other ligands capable of bonding with copper as indicated such as water, alcohols, amines, ethers, sulfoxides, and other solvents and competing ligands); and (c) pyridoxylidene-amino acid Schiff bases, the generic structure of which is depicted by Structure IX (where R represents the alpha substituents of the D or L amino acids; D and L denoting the configuration of the alpha carbon; and L represents solvating or other ligands capable of bonding with copper as indicated such as water, alcohols, amines, ethers, sulfoxides, and other solvents and competing ligands). ##STR4##
TABLE IV______________________________________ANTICONVULSANT ACTIVITY (PHASE I)OF SOME COPPER COMPLEXES OF SALICYLIDENE-AMINO ACID AND BISETHYLENEIMINE SCHIFF BASES Maximal Electro-COMPLEX Route shock Metrazol______________________________________Cu(II) SC I A (slight) at 100Salicylidene-L- and 300 mg/kg.sup.2valinate at 4 hrs. IP I A at 100 mg/kg.sup.2 at 30 min. and 30 mg/kg.sup.2 at 4 hrs.Cu(II) SC I A (slight) at 600Salicylidene-L- mg/kg at 30 min.histidinate IP I ICu(II) SC A at 100 A at 100, 300'Bisacetylacetonethyl- mg/kg at and 600' mg/kgeneimine 30 min.; at 4 hrs. A at 100, 300' and 600' at 4 hrs.Cu(II) SC I Ibissalicylato- IP I A (marginal) atethyleneimine 300 and 600 mg/kg at 4 hrs.______________________________________ A = Active. I = Inactive at doses studied. IP = Intraperitoneal. SC = Subcutaneous. .sup. 1 Rotating rod toxicity. .sup.2 Lethal at higher doses.
The data obtained with copper complexes of salicylidene-amino acid Schiff bases and bisethyleneimine Schiff bases are presented in Table IV. The majority of these copper complexes had weak activity. The salicylidene-L-valinate complex also caused lethality at higher doses. The bisacetylacetonethyleneimine complex was effective in preventing both Maximal Electroshock and Metrazol-induced seizures, but rotating rod toxicity, which may also have been due to hypnotic activity, was found at the higher doses studied.
The data obtained with copper complexes of pyridoxylidene-amino acid Schiff bases are presented in Table V. These data show that the pyridoxylideneglycinate complex protected against both types of seizure. The serinate, tryptophanate and threoninate complexes were more effective but only protected against the Metrazol-induced seizure. The phenylalaninate and valinate complexes had no activity.
Some of these complexes are as active or more active than existing antiepileptic drugs. Other potentially useful copper complexes of pyridoxylideneamino acid Schiff bases include complexes of the following: tyrosine, dihydroxyphenylalanine (DOPA), 5-hydroxytryptophan, glutamic acid, gamma aminobutyric acid, aspartic acid, and beta-alanine.
TABLE V______________________________________PHASE I ANTICONVULSANT DATA OFPYRIDOXYLIDENEAMINOACID COPPER COMPLEXES Challenge Seizure Model.sup.1Complex Route Time MES Metrazol______________________________________Cu(II)Pyridoxylidene- IP 30 min 300 100glycinate(H.sub.2 O).sub.1.5 4 hrs I ICu(II)Pyridoxylidene-L- IP 30 min I 100serinate(H.sub.2 O) 4 hrs I 100Cu(II)Pyridoxylidene-L- IP 30 min I 30tryptophanate(H.sub.2 O).sub.2 4 hrs I 30Cu(II)Pyridoxylidene-L- IP 30 min I 30threoninate(H.sub.2 O).sub.2 4 hrs I 30Cu(II)Pyridoxylidene-L- IP 30 min I Iphenylalaninate(H.sub.2 O).sub.2 4 hrs I ICu(II)Pyridoxylidene-L- IP 30 min I Ivalinate(H.sub.2 O) 4 hrs I I______________________________________ .sup.1 The numerical values are the lowest active doses in mg/kg of body weight; I = Inactive; MES = Maximal Electroshock.
COPPER COMPLEXES OF CARBOXYLIC ACIDS
Several copper complexes of carboxylic acids have been tested for their anticonvulsant activity. The carboxylic acids include branched and straight chain alipnatic carboxylic acids as well as aryl carboxylic acids. In their nonsolvated state (i.e., in the absence of L), such carboxylic acids form a characteristic binuclear complex of copper as schematically depicted by Structure X (where R represents alkyl, aryl, aryl-alkyl groups wherein substituents may be hydrogen, halogen, oxygen-containing, e.g., hydroxy or alkoxy, or nitrogen-containing, e.g., amino or nitro substituents; and L represents solvating or other ligands capable of bonding to copper as indicated such as water, alcohols, amines, ethers, sulfoxides, and other solvents and competing ligands). When L is present, the copper complex of the carboxylic acid can exist in either the binuclear configuration of Structure X or the mononuclear configuration of Structure X-A depending on the affinity of L for copper. It should be recalled from the section on copper complexes of acylsalicylates, supra, that these compounds are also carboxylic acids that complex with copper in the nonsolvated state to form a binuclear coordination compound and, when in the solvated state, complex with copper in either the binuclear or mononuclear configurations shown by Structures I and II, respectively. Similarly, fatty acids, which include saturated and unsaturated monocarboxylic acids of up to about C 19 in length, can complex in either the binuclear or mononuclear configurations in their solvated states. ##STR5##
Copper acetate, Cu(II) 2 (acetate) 4 , a binuclear copper complex of a C 2 , straight chain, aliphatic carboxylic acid, was evaluated for anticonvulsant activity in a test in which aspirin (not complexed with copper) was also evaluated. It is known that in high doses aspirin (and other salicylates) have toxic effects on the central nervous system, including convulsions [Goodman and Gilman (Eds.), The Pharmacological Basis of Therapeutics (1980), 6th ed., MacMillan, New York, p. 689].
As shown in Table VI, aspirin was found to be inactive at 30, 100, 300 and 600 mg/kg in both seizure models at both time intervals, 30 minutes and 4 hours. Because it was thought that a copper-containing compound injected subcutaneously at the same site as the site of subcutaneous Metrazol injection might somehow, through a direct interaction with Metrazol perhaps, prevent the induction of seizures with Metrazol, and as a result cause an apparent anticonvulsant effect, this aspect of administration was investigated.
TABLE VI______________________________________ANTICONVULSANT ACTIVITY OF ASPIRIN ANDCOPPER ACETATE Seizure Model MaximalCompound Route Electroshock Metrazol______________________________________Aspirin IP I.sup.1 I.sup.1Cu(II).sub.2 (acetate).sub.4 SC* I.sup.1 A at 30, 100, 300 and 600 mg/kg at 30 min. and 4 hrs.Cu(II) (Metrazol)Cl.sub.2 IP I A at 30 mg/kg at 30 min. SC I A at 300 mg/kg at 4 hrs.Cu(II).sub.2 (acetate).sub.4 SC NT I.sup.1Cu(II).sub.2 (acetate).sub.4 IP I.sup.1,2,3 A at 30 mg/kg at 30 min..sup.4,3Cu(II).sub.2 (acetate).sub.4 IP NT A at 10 and 20 mg/kg at 30 min. and A at 5, 10 and 20 mg/kg at 4 hrs.Cu(II).sub.2 (acetate).sub.4 IG I.sup.1 I.sup.1______________________________________ A = Active; NT = Not Tested. IP = Intraperitoneal. SC = Subcutaneous at site different from injection of Metrazol. IG = Intragastric. *Same injection site used for injection of Metrazol. .sup.1 Inactive 30, 100, 300 and 600 mg/kg at 30 min. and 4 hrs. .sup.2 Rotating rod toxicity at 30, 100, 300 and 600 mg/kg. .sup.3 Lethal at 30, 100, 300 and 600 mg/kg at 4 hrs. .sup.4 Lethal at 100, 300 and 600 mg/kg at 30 min.
As shown in Table VI, Cu(II) 2 (acetate) 4 was active when injected at the same site as the site of Metrazol injection and the copper complex of Metrazol, Cu(II)(Metrazol)(Cl 2 ), had some anticonvulsant activity when injected at a site different from the site of Metrazol injection. In addition, the Metrazol complex produced no rotating rod toxicity at doses up to 600 mg/kg, which is remarkable since Metrazol is a potent central nervous system stimulant accounting for its seizure producing capacity. Such stimulation produces marked rotating rod toxicity.
The lack of anticonvulsant activity of Cu(II) 2 (acetate) 4 when it is given subcutaneously at an alternate site of injection is consistent with the lack of anticonvulsant effect following subcutaneous injection of either copper acetate or copper chloride at a site different from the site of Metrazol injection as reported previously [Sorenson et al., Anticonvulsant Activity of Some Copper Complexes, In: Trace Substances in Environmental Health-XIII, D. D. Hemphill, ed., University of Missouri Press, Columbia, Mo., pp. 360-367 (1979); U.S. patent application Ser. No. 344,309 filed Feb. 1, 1982]. There it was reported that no anticonvulsant activity was found with either copper acetate or copper chloride using doses of 50, 100 and 300 mg/kg at 0.75, 1.5 and 3 hours post subcutaneous injection at a site different from the site of Metrazol injection.
On the other hand, the observation of anticonvulsant activity at a very low dose, 5 mg/kg, following intraperitoneal administration of Cu(II) 2 (acetate) 4 at a site different from the subcutaneous administration of Metrazol, suggests that copper acetate is effective in inhibiting Metrazol-induced seizures by some mechanism other than a direct interaction with Metrazol when the rate of absorption and the amount of compound absorbed from the site of administration is increased, as it is with intraperitoneal administration. Consistently, copper acetate was found to be inactive when administered orally, the route which is likely to provide the slowest rate of absorption and the smallest amount of compound absorbed, in comparison with the subcutaneous and intraperitoneal routes of administration. It may, however, be that a method of oral dosing can be developed to produce anticonvulsant activity following oral treatment with copper complexes using prolonged treatment or facilitating oral absorption.
Other copper complexes of carboxylic acids which have been tested for anticonvulsant activity are the following: (1) Cu(II) 2 (valproate) 4 , also known as Cu(II) 2 (dipropylacetate) 4 , which is the binuclear copper complex of valproic acid, a known anticonvulsant drug (valproic acid is a C 7 , branched chain, aliphatic carboxylic acid); (2) Cu(II) 2 (phenylacetate) 4 , a binuclear copper complex of an aliphatic carboxylic acid; and (3) Cu(II) 2 (benzoate) 4 , a binuclear copper complex of an aryl or aromatic carboxylic acid. The data obtained with these compounds are presented in Table VII. Cu(II) 2 (valproate) 4 and Cu(II) 2 (phenylacetate) 4 were effective in protecting against Metrazol-induced seizures while Cu(II) 2 (benzoate) 4 was effective in protecting against both Maximal Electroshock and Metrazol-induced seizures.
TABLE VII______________________________________ANTICONVULSANT ACTIVITY OFCOPPER COMPLEXES OF CARBOXYLIC ACIDS Seizure Model MaximalComplex Route Electroshock Metrazol______________________________________Cu(II).sub.2 IP I A at 100 mg/kg(valproate).sub.4 at 30 min. SC I A at 600 mg/kg at 4 hr.Cu(II).sub.2 IP I A at 300 mg/kg(phenylacetate).sub.4 at 4 hr..sup.1Cu(II).sub.2 IP A at 300 A at 30, 100.sup.1(benzoate).sub.4 mg/kg at and 300.sup.1 mg/kg 30 min..sup.1 at 30 min.______________________________________ .sup.1 Rotating rod toxicity at 300 mg/kg.
COPPER COMPLEXES OF KNOWN ANTICONVULSANT AND ANTIEPILEPTIC DRUGS
Numerous compounds are known to have anticonvulsant and antiepileptic activity. Some of the better known therapeutic agents, listed in Table VIII, fall into the following classes: hydantoins, barbiturates, desoxybarbiturates, iminostilbenes, acetylureas, succinimides, benzodiazepines, oxazolidinediones, sulfonamides and fatty acids. [See K. W. Leal and A. S. Troupin, Clinical Pharmacology of Anti-epileptic Drugs: A Summary of Current Information, Clin. Chem. 23: 1964-1968 (1977), hereby incorporated by reference.] Copper complexes of the foregoing anticonvulsant and antiepileptic drugs can be used in the practice of the present invention.
TABLE VIII______________________________________KNOWN ANTICONVULSANT AND ANTIEPILEPTICDRUGSClass Example______________________________________Hydantoins Phenytoin (Dilantin) Desmethylmephenytoin Desethylethotoin 5-Ethyl-5-phenylhydantoinBarbiturates Phenobarbital Mephobarbital MetharbitalThiobarbiturates ThiopentalDesoxybarbiturates PrimidoneIminostilbenes CarbamazepineAcetylureas PhenacemideSuccinimides Desmethylmethsuximide Ethosuximide Desmethylphensuximide α-Methyl-α-phenylsuccinimideBenzodiazepines Chlorazepam Desmethyldiazepam Diazepam Chlorazepate Chlordiazepoxide OxazepamOxazolidinediones Desmethyltrimethadione DesmethylparamethadioneSulfonamides AcetazolamideFatty Acids Sodium Valproate______________________________________
The general structure of hydantoins, barbiturates and thiobarbiturates is depicted schematically by Structure XI. ##STR6##
For hydantoins, X represents --NH--, R and R' are branched or unbranched lower alkyl groups, aryl groups or branched or unbranched lower alkyl or aryl groups, which may be substituted with halogen or oxygen-containing (e.g., hydroxy or alkoxy) and nitrogen-containing (e.g., amino or nitro) substituents. L represents solvating or other ligands capable of bonding with copper as indicated such as water, alcohols, amines, ethers, sulfoxides and other solvents and competing ligands.
For barbiturates, X represents ##STR7## and R, R' and L are as described for hydantoins.
For thiobarbiturates, sulfur replaces oxygen in bonding to copper as illustrated for barbiturates.
For oxazolidinediones, X represents --O-- and R, R' and L are as described for hydantoins.
For succinimides, X represents CH 2 -- and R, R' and L are as described for hydantoins.
For acetylureas, X represents NH 2 and is not bonded to carbon-5 to give an acyclic ligand. R, R' and L are as described for hydantoins.
For desoxybarbiturates the general structure is ##STR8## and R, R' and L are as described for hydantoins.
For iminostilbenes the general structures may be ##STR9## where R and R' are the same or as described for hydantoins and L is as described for hydantoins.
For benzodiazepines the general structure may be ##STR10## where R and R' are hydrogen, halogen or nitro substituents, R" is hydrogen, alkyl, or the amide group ##STR11## is replaced by a group yielding an amide group on hydrolysis in vivo, and L is as described for hydantoins. The bonding atom in Structure XV may be replaced with N-oxide, ##STR12## In Structure XVI, X may be an oxygen of an N-oxide. The C-3 carbon may also be substituted with a carboxyl or hydroxyl group.
For Sulfonamides, the general structure is ##STR13## where R represents aryl, alkyl-aryl, a heterocycle or substituted aryl, alkyl-aryl or heterocycle wherein the substituents are halogen or oxygen-containing (e.g., hydroxy or alkoxy) or nitrogen-containing (e.g., amino or nitro) substituents. R' may be H or the same as R. L is as described for hydantoins.
With the hypothesis that copper complexes of the antiepileptic drugs might be the active metabolites of these drugs, several copper complexes of known antiepileptic drugs were synthesized and tested for their anticonvulsant activity. The first series of tests were performed with the copper complex of amobarbital and the results indicated that the copper complex of this known anticonvulsant drug was a more potent anticonvulsant than sodium (Na) amobarbital. The data are presented in Table IX.
TABLE IX______________________________________COMPARISON OF THE SODIUM AND COPPERAMOBARBITAL ANTICONVULSANT IN THE MAXIMALELECTROSHOCK SEIZURE MODEL FOLLOWINGINTRAPERITONEAL INJECTION Number Average Pro- of Sleep tection.sup.1 Animals Dose in Time, AgainstCompound Treated mg/kg minutes Seizure______________________________________Na amobarbital 5 65 0 0Cu(II) (amobarbital).sub.2 5 65 16.sup.2 100______________________________________ .sup.1 Percent protected. .sup.2 All animals slept.
Subsequently, the anticonvulsant activity of copper complexes of dilantin, valproate, phenobarbital (and pyridine and imidazole solvates thereof), amobarbital, lorazepam, α-methyl-α-phenylsuccinimide, carbamazepine, clonazepam, oxazepam, 5-ethyl-5-phenylhydantoin, thiopental and diazepam was investigated in Phase I testing, and for those compounds found to be active, Phase II testing. The results are presented in Table X.
TABLE X__________________________________________________________________________PHASE I AND SOME PHASE II ANTICONVULSANT DATAFOR COPPER COMPLEXES OF ANTIEPILEPTIC DRUGS Challenge Seizure Model.sup.1Compound Route.sup.2 Time MES Metrazol__________________________________________________________________________Cu(II) (Dilantin).sub.2 IP 30 min 30 100(H.sub.2 O).sub.3 4 hrs 30 100Cu(II) (Dilantin).sub.2 IP.sup.3 4 hrs.sup.4 13 NT.sup.5(H.sub.2 O).sub.3Dilantin IP.sup.3 1 hr.sup.4 7 Potentiates Metrazol seizuresCu(II).sub.2 (Valproate).sub.4 IP 30 min I 100 4 hrs I ICu(II).sub.2 (Valproate).sub.4 SC 30 min I I 4 hrs I 600Valproic Acid IP.sup.3 15 min.sup.4 272 149Cu(II) (Phenobarbital).sub.2 IP 30 min 30 5(H.sub.2 O).sub.5.5 4 hrs 30 5Cu(II) (Phenobarbital).sub.2 SC 30 min 30 30(H.sub.2 O).sub.5.5 4 hrs 30 30Cu(II) (Phenobarbital).sub.2 IP 30 min 30 5(H.sub.2 O).sub.3 4 hrs 30 5Cu(II) (Phenobarbital).sub.2 SC 30 min 30 30(H.sub.2 O).sub.3 4 hrs 30 30Cu(II) (Phenobarbital).sub.2 IP.sup.3 2 hrs.sup.4 16 10(H.sub.2 O).sub.3Cu(II).sub.n (Phenobarbital).sub.n SC 30 min 100 30(H.sub.2 O).sub.2n (H.sub.2 O).sub.3n 4 hrs 30 30Phenobarbital IP.sup.3 1 hr.sup.4 22 13Cu(II) (Phenobarbital).sub.2 IP 30 min 100 30(pyridine).sub.2 4 hrs 100 30Cu(II) (Phenobarbital).sub.2 SC 30 min I I(pyridine).sub.2 4 hrs 30 30Cu(II) (Phenobarbital).sub.2 IP.sup.3 2 hrs.sup.4 17 9(pyridine).sub.2Cu(II).sub.n (Phenobarbital).sub.n SC 30 min 100 30(pyridine).sub.2n (H.sub.2 O).sub.3n 4 hrs 30 30Cu(II).sub.n (Phenobarbital).sub.n SC 30 min 30 30(pyridine).sub.2n (H.sub.2 O).sub.3n 4 hrs 100 30Cu(II) (Phenobarbital).sub.2 IP 30 min 100 300(imidazole).sub.2 4 hrs 100 30Cu(II) (Phenbarbital).sub.2 SC 30 min I 100(imidazole).sub.2 4 hrs 100 100Na.sub.2 [Cu(II) (Pheno- IP 30 min 30 30barbital).sub. 4 ](H.sub.2 O).sub.2 4 hrs 100 100Na.sub.2 [Cu(II) (Pheno- SC 30 min 30 30barbital).sub.4 ](H.sub.2 O).sub.2 4 hrs 30 100Na.sub.2 [Cu(II) (Pheno- IP.sup.3 6 hrs.sup.4 25 20barbital).sub.4 ](H.sub.2 O).sub.2Cu(II) (Amobarbital).sub.2 IP 30 min 300 30(H.sub.2 O).sub.2.5 4 hrs I ICu(II) (Amobarbital).sub.2 IP 30 min 100 100(H.sub.2 O).sub.2 4 hrs I ICu(II) (Amobarbital).sub.2 SC 30 min 300 100(H.sub.2 O).sub.2 4 hrs I ICu(II) (Amobarbital).sub.2 IP.sup.3 30 min.sup.4 87 87(H.sub.2 O).sub.2.5Amobarbital IP 30 min 30 100 4 hrs I IAmobarbital IP.sup.3 15 min.sup.4 45 53Cu(II) (Amobarbital).sub.2 IP 30 min 300 100(pyridine).sub.2 4 hrs 300 30Cu(II) (Amobarbital).sub.2 SC 30 min I 600(pyridine).sub.2 4 hrs 100 600Cu(II) (Amobarbital).sub.2 IP 30 min 600 300(imidazole).sub.2 4 hrs I ICu(II) (Amobarbital).sub.2 SC 30 min I I(imidazole).sub.2 4 hrs I 600Cu(II) (Lorazepam).sub.2 IP 30 min 20 I(Cl).sub.2 H.sub.2 O 4 hrs 30 ICu(II) (Lorazepam).sub.2 SC 30 min 20 I(Cl).sub.2 H.sub.2 O 4 hrs 100 ILorazepam IP.sup.3 1 hr.sup.4 24 0.02Cu(II) (Diazepam).sub.2 (Cl).sub.2 IP 30 min 30 30 4 hrs 30 30Diazepam IP.sup.3 1 hr.sup.4 19 0.17Cu(II)α-methyl-α-phenyl- IP 30 min 100 100succinimide(H.sub.2 O).sub.0.75 4 hrs I 100Cu(II)α-menthyl-α-phenyl- SC 30 min 30 30succinimide(H.sub.2 O).sub.0.75 4 hrs 100 600Cu(II) Carbamaze- IP 30 min 10 30pine(H.sub.2 O).sub.2 4 hrs 100 ICu(II)Carbamaze- SC 30 min 30 300pine(H.sub.2 O).sub.2 4 hrs 100 300Carbamazepine IP.sup.3 -- 9 Potentiates Metrazol seizuresCu(II) (Clonazepam).sub.2 (Cl).sub.2 IP 30 min 10 1 4 hrs I 1Cu(II) (Clonazepam).sub.2 (Cl).sub.2 SC 30 min 1 1 4 hrs 30 1Cu(II) (Clonazepam).sub.2 (Cl).sub.2 IP.sup.3 30 min.sup.4 25 0.05 (30 min).sup.4 1Clonazepam IP.sup.3 -- 19 0.2Cu(II) oxazepam IP 30 min 10 1 4 hrs I 10Cu(II)5-ethyl-5-phenyl- IP 30 min 100 300hydantoin(H.sub.2 O).sub.2.5 4 hrs 100 100Cu(II)5-ethyl-5-phenyl- SC 30 min 100 30hydantoin(H.sub.2 O).sub.2.5 4 hrs 30 100Cu(II)5-ethyl-5-phenyl- IP 30 min 100 100hydantoin(CH.sub.3 OH) 4 hrs 100 ICu(II)5-ethyl-5-phenyl- SC 30 min 100 100hydantoin(CH.sub.3 OH) 4 hrs 30 300Cu(II)5-ethyl-5-phenyl- IP 30 min 30 30hydantoin(HO) (Cl) (CH.sub.3 OH) 4 hrs I ICu(II) (N--thiopental).sub.2 IP 30 min I I(H.sub.2 O).sub.2.5 4 hrs I ICu(II) (N--thiopental).sub.2 SC 30 min I I(H.sub.2 O).sub.2.5 4 hrs I 30Cu(II) (S-thiopental).sub.2 IP 30 min I I(H.sub.2 O).sub.2 4 hrs I ICu(II) (S-thiopental).sub.2 SC 30 min I I(H.sub.2 O).sub. 2 4 hrs I I__________________________________________________________________________ .sup.1 The numerical values are the lowest doses in milligrams per kilogram of body weight, I = inactive, MES = maximal electroshock. .sup.2 IP = intraperitoneal, SC = subcutaneous. .sup.3 Phase II data. .sup.4 Time of peak activity in Phase II studies and ED.sub.50 values for inhibition of seizures. .sup.5 Clonic seizures inhibited but animals stimulated by Metrazol (continuous running).
The data provided in Table X for the inhibition of Maximal electroshock and Metrazol-induced seizures are the lowest effective doses (mg/kg). If a compound is found to be effective and nontoxic in Phase I evaluations, which are done to detect anticonvulsant activity, it is further examined in Phase II studies to determine time of peak effect and ED 50 . Since Phase II evaluations are done only after Phase I, there are Phase II data for a smaller number of compounds. There are no Phase I data for the known anticonvulsant drugs since the NINCDS had no need to attempt to detect anticonvulsant activity for these established anticonvulsant agents. Phase II-ED 50 data for some of the compounds are included in Table X. Table X also contains Phase II time of peak effect data for the parent anticonvulsant drugs.
The copper complex of dilantin was found to have a rapid onset and prolonged duration in inhibiting only Maximal Electroshock-induced seizures. Dilantin is also known to only inhibit Maximal Electroshock-induced seizures but it potentiates Metrazol-induced seizures. The copper complex did not potentiate but did block both types of seizures. Phase II data for Cu(II)(dilantin) 2 indicate that it has a time of peak effect of 4 hours, which is longer than the time of peak effect for dilantin (1 hour).
In phase I studies, Cu(II) 2 (valproate) 4 appeared to be ineffective against Maximal Electroshock seizures, but had some inhibitory activity against Metrazol-induced seizures. This compound had a rapid onset and short duration of activity following intraperitoneal administration and, consistently, a prolonged onset of activity at a higher dose following subcutaneous administration. The parent compound (valproic acid) was also weakly effective against Maximal Electroshock-induced seizures and more effective against Metrazol-induced seizures.
With few exceptions the phenobarbital complexes were also found to have rapid onset and prolonged durations of activity in both models of seizure. Although the data do not allow a rigorous comparison of these compounds, it is of interest that the pyridine and imidazole complexes were somewhat less effective than the aquo complexes. All three solvates had prolonged onsets of action following subcutaneous administration. The aquo phenobarbital complexes were most effective regardless of the route of administration and recent data show that the tri- and penta-aquo complexes are effective in preventing the Metrazol-induced seizure at a dose much lower than the lowest dose routinely used as the lowest dose in Phase I studies, 30 mg/kg. Activity at 5 mg/kg would appear to indicate greater activity than phenobarbital which has an ED 50 of 13 mg/kg.
Copper (II)(amobarbital) 2 complexes also appear to have rapid onsets and short durations of activity following intraperitoneal administration, which appears to be reversed with subcutaneous administration.
The copper complex of lorazepam appears to have a rapid onset of action and prolonged duration following intraperitoneal and subcutaneous administration. This complex appears to be quite active. However, this complex involves complexation at the 4-nitrogen and its stability may not be as high as others. The copper complex of diazepam also appears to have a rapid onset of action and prolonged duration following intraperitoneal administration.
Cu(II)α-methyl-α-phenylsuccinimide and Cu(II)5-ethyl-5-phenylhydantoin complexes were also effective in preventing both types of seizure with rapid onsets of action and prolonged durations of action following subcutaneous and intraperitoneal administration.
Cu(II)oxazepam also protected against both types of seizure and seems to be more prolonged in its action against Metrazol induced seizures.
The Cu(II)carbamazepine complex was also an effective anticonvulsant. However, it did not potentiate Metrazol seizures while the parent drug is known to be a seizure-inducing agent.
Cu(II)(clonazepam) 2 was found to be a very potent anticonvulsant. Doses less than those used in routine Phase I studies were required to obtain the lowest effective doses in both models of seizure. In addition, the results of Phase II studies with this complex show that the complex is four times as effective as the parent drug.
The copper complexes of thiopental were tested at lower doses than usually used in Phase I studies. It is anticipated that higher doses of these complexes will evidence anticonvulsant activity.
Since all of the foregoing drugs (parent compounds or ligands) are known to be active anticonvulsants, simultaneous comparisons of the ligands and their copper complexes are ultimately required to determine whether or not these complexes are more active than the ligands, as suggested by some of the data. Nevertheless, the data in Table X do indicate that all the copper complexes tested have anticonvulsant activity. Even if some of the copper complexes are not more active than the parent compound, they may nonetheless prove useful in therapy regimens alone or in conjunction with other complexes, especially if their time of peak effect differs from that of the parent and also especially if the copper complexes are less toxic and associated with fewer side effects than the parent compounds.
The foregoing experiments with copper complexes of acylsalicylates, salicylates, amino acids, imines, carboxylic acids and known anticonvulsant and antiepileptic drugs demonstrate that such complexes have anticonvulsant activity. That the intact copper complex may play a key role in the observed anticonvulsant activity is consistent with the observation that inorganic copper salts, which contain much more copper on a weight percentage basis, do not have anticonvulsant activity, or have less anticonvulsant activity based upon copper content, and also with the observation that there is a lack of an apparent direct correlation between the observed anticonvulsant activity of copper complexes and the amount of copper in them.
The organic compounds of copper or their solvates and other chemical modifications useful in the present invention can be administered as solid, solution, suspension, or ointment-dosing formulations in a concentration range of between about 0.01 to about 600 mg/kg of body weight and preferably between about 0.01 to about 100 mg/kg of body weight. The compounds can be administered orally, topically or parenterally, that is, intraperitoneally, subcutaneously or intravenously.
Having described the invention with particular reference to the preferred form thereof, it will be obvious to those skilled in the art to which the invention pertains after understanding the invention, that various changes and modifications may be made therein without departing from the spirit and scope of the invention as defined by the claims appended hereto.
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Copper-dependent enzymes are required for normal brain development and function. Copper deficiency can result in pathological disorders accompanied by convulsive seizures or tremors in man and animals. The present invention is directed to a method for treating convulsions or epilepsy comprising administration of a therapeutically effective amount of an organic compound of copper having anticonvulsant activity. Those compounds include copper complexes of carboxylic acids, acylsalicylates, salicylates, amino acids, imines and known anticonvulsant and antiepileptic drugs.
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BACKGROUND
[0001] The invention relates to a safe securing system for a person, a carabiner useable for such a system and an assembly for securing a person comprising such a system.
[0002] It is known, in particular from Document EP 2 637 747-A1, to provide a safe securing system for a person, comprising two carabiners intended to receive at least one securing element, each of said carabiners comprising:
a hook for receiving said securing element, said hook being generally in an inverted J-shape when seen from the side, the ascender of the J forming a lower gripping part and the curved part of the J forming an upper reception part for receiving said securing element, said upper reception part including an opening so that said securing element can pass into it, a gate—particularly a generally V-shaped gate—comprising a first branch forming a door and a second branch that activates said door, said gate being mounted on said hook at the intersection between said first and second branches, said gate being free to rotate about a rotation axis located between said lower gripping part and said upper reception part, said gate being moveable into:
Firstly, an angular reception configuration for receiving said securing element between said first and second branches, in which said opening is closed off by said second branch, and wherein said first branch can be closed by applying an upwards pressure (particularly by said element) on said second branch, and Secondly, an angular retaining configuration for retaining said securing element inside said upper reception part between said first and second branches, in which said opening is closed off by said first branch,
a first means for locking said gate in the angular retaining configuration, a transmission device connecting said carabiners to each other, said device being arranged to ensure that at least one carabiner is always secured to a securing element.
[0009] The securing element may for example be a cable, a ladder rung or a scaffolding bar.
[0010] Such a system is integrated particularly into an assembly also including a harness for securing a person, the carabiners being attached to said harness by straps or ropes.
[0011] Such a system can be used particularly to secure site operators working at a height or persons performing “via ferrata” (climbing path) or tree-to-tree activities.
[0012] The fact of having two carabiners connected by the transmission device enables the user to change from one securing element to another while remaining in a safe condition, since he or she is always in a situation in which at least one of the carabiners is attached to a securing element.
[0013] In construction activities, the securing element is often a scaffolding bar or a metal angle or a similar metal element that consequently has a large cross-sectional dimension—for example a diameter of between 50 and 70 mm.
[0014] In order to achieve optimal ergonomics, it is essential that a carabiner does not have any projection that could hinder its attachment when it is moved in translation downwards, therefore along a vertical direction or a direction with a vertical component.
[0015] However, when the carabiner is intended to be secured to a securing element with a large cross-section, a large opening and therefore a door with a corresponding size are essential.
[0016] Consequently, when the gate is in the reception configuration, the door can form a projection that may hinder the securing of the carabiner on the securing element.
[0017] The purpose of the invention is to mitigate this disadvantage.
SUMMARY
[0018] To that effect, a first aspect of the invention discloses a safe securing system for a person, comprising two carabiners intended to receive at least one securing element, each of said carabiners comprising:
a hook for receiving said element, said hook being generally in an inverted J-shape when seen from the side, the ascender of the J forming a lower gripping part and the curved part of the J forming an upper reception part for receiving said securing element, said upper reception part including an opening so that said securing element can pass into it, a gate—particularly a generally V-shaped gate—comprising a first branch forming a door and a second branch that activates said door, said gate being mounted on said hook at the intersection between said first and second branches, said gate being free to rotate about a rotation axis located between said lower gripping part and said upper reception part, said gate being moveable into:
Firstly, an angular reception configuration for receiving said securing element between said first and second branches, in which said opening is closed off by said second branch, and wherein said first branch can be closed by applying an upwards pressure (particularly by said element) on said second branch; and Secondly, an angular retaining configuration for retaining said securing element inside said upper reception part between said first and second branches, in which said opening is closed off by said first branch,
a first means of locking said gate in the angular retaining configuration, a transmission device connecting said carabiners to each other, and comprising two cables ( 14 ) each sliding in a sheath, each of said cables being connected:
on one side, to a gate ( 10 ), at a distance from its rotation axis ( 12 ); on the other side, to the first means for locking the other gate ( 10 ),
such that placing a gate ( 10 ) in the angular retaining configuration causes deactivation of the first means for locking the other gate ( 10 ), whereas placing a gate ( 10 ) in the angular reception configuration causes activation of the first means for locking the other gate ( 10 ), so as to ensure that at least one carabiner ( 2 ) is always secured to a securing element ( 3 ),
said lower gripping part comprising for each carabiner a reception face facing said first branch when said gate is in its angular reception configuration, said reception face extending over all or some of the height of said lower gripping part.
[0027] Note that throughout this description, unless mentioned otherwise, positioning terms in space (upper, lower, under, bottom, top, vertical, horizontal, etc.) are considered with reference to a carabiner in its normal working situation, its lower gripping part extending vertically.
[0028] When it is said that the transmission device is arranged to ensure that at least one carabiner is always secured to a securing element, reference is made to normal conditions of use of the system, in other words without using a tool or a complex manoeuvre in order to achieve emergency unlocking.
[0029] Indeed, in some systems it is possible to unlock one carabiner although the other carabiner is not secured, said unlocking making use of a tool or activation of an access device that is not practical for the user's hand.
[0030] With the proposed arrangement, there is a system in which there are no projecting parts from the carabiners that could hinder their securing manoeuvre by downwards translation, therefore along a vertical direction or including a vertical component, for example inclined at the order 45° from the vertical.
[0031] Indeed, the invention takes advantage of the fact that the gripping part is wide (particularly corresponding to the width of a hand) to bring the door (that is also wide) facing said part, such that said door does not form a projection that hinders the securing of the carabiner when the gate is in the angular reception configuration.
[0032] A second aspect of the invention relates to a carabiner that can be used for such a system.
[0033] A third aspect of the invention discloses an assembly for securing a person comprising such a system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Other special features and advantages of the invention will become clear after reading the following description given with reference to the appended figures in which:
[0035] FIG. 1 is a diagrammatic perspective view of an assembly for securing a person comprising a system according to the invention.
[0036] FIGS. 2 a to 2 h are transparent side views of a carabiner according to one embodiment, and a securing element, the first branch of said carabiner being shown:
open ( FIG. 2 a ), during its closing with the lock in the locked position ( FIG. 2 b ) and in the release position ( FIG. 2 c ), closed with the first and second latches in the locked position ( FIG. 2 d ), closed with the first latch in the locked position and the second latch in the unlocked position ( FIGS. 2 e , 2 f in which the gate that has turned to its angular reception configuration is blocked in rotation because the first latch is locked), closed with the first and second latches in the unlocked position ( FIG. 2 g ), closed with the first latch in the unlocked position and the second latch in the locked position ( FIG. 2 h.
[0043] FIGS. 3 a and 3 b are diagrammatic side views of another embodiment of a carabiner, with the first branch closed ( FIG. 3 a ) and open ( FIG. 3 b ).
DETAILED DESCRIPTION
[0044] A safe securing system 1 for a person is described with reference to the figures, comprising two carabiners 2 intended to receive at least one securing element 3 , each of said carabiners comprising:
a hook 4 for receiving said securing element, said hook being generally in an inverted J-shape when seen from the side, the ascender of the J forming a lower gripping part 7 and the curved part of the J forming an upper reception part 5 for receiving said securing element, said upper reception part including an opening 6 so that said securing element can pass into it, a gate 10 (particularly a generally V-shaped gate) comprising a first branch forming a door 8 and a second branch 11 that activates said door, said gate being mounted on said hook at the intersection between said first and second branches, said gate being free to rotate about a rotation axis 12 located between said lower gripping part and said upper reception part, said gate being movable into:
Firstly, an angular reception configuration for receiving said element between said first and second branches, in which said opening is closed off by said second branch, and wherein said first branch can be closed by applying an upwards pressure (particularly by said securing element) on said second branch; and Secondly, an angular retaining configuration for retaining said securing element inside said upper reception part between said first and second branches, in which said opening is closed off by said first branch,
a first means for locking said gate in the angular retaining configuration, a transmission device 9 connecting said carabiners to each other, said transmission device being arranged to ensure that at least one carabiner 2 is always secured to a securing element 3 ,
said lower gripping part comprising a reception face 31 facing said first branch when said gate is in its angular reception configuration, said reception face extending over all of the height or some of the height of said lower gripping part.
[0051] According to the embodiment shown in FIG. 3 , the lower gripping part 7 is provided with an orifice 30 into which a user's hand will fit.
[0052] With such an arrangement, the user's hand does not interfere with the first branch 8 , when it extends in front of the reception face 31 , when the gate 10 is rotated towards its retaining configuration.
[0053] Furthermore, the presence of such an orifice 30 enables the user to optimise his or her grip on the carabiner 2 making it possible to hang from a securing element 3 .
[0054] Finally, such an orifice 30 provides protection for the user's fingers.
[0055] A protection cover (not shown) can be provided extending laterally from the orifice 30 to surround at least a part of the user's fingers not protected by the walls of said orifice.
[0056] The protection cover can be in the form of a part associated with the hook 4 , for example attached by screws, said part particularly being made of a moulded plastic material to be lightweight, or being derived from the material of said hook.
[0057] According to the embodiments shown in FIGS. 2 and 3 , when the first branch 8 extends facing the reception face 31 , said first branch is at least partially inserted in a complementary shaped housing 13 formed in the lower gripping part 7 .
[0058] In the embodiments shown, the housing 13 is in the form of a cavity.
[0059] In one variant not shown, the housing 13 is in the form of a recess that opens up laterally on each side of the wall 31 .
[0060] In the embodiment shown in FIG. 3 , the housing 13 is in the form of a cavity delimited partly by the reception face 31 and by a wall 32 integrated into a projection 33 located at the bottom of said reception face.
[0061] According to the embodiment shown in FIG. 3 , the first branch 8 is entirely inserted into the cavity such that said first branch does not form a projection that would hinder the securing of the carabiner 2 .
[0062] According to the embodiment shown in FIG. 3 , the projection 33 includes an inclined face 34 designed to guide the securing element 3 between the first 8 and second 11 branches of the gate 10 in the angular reception configuration when the carabiner 2 is positioned above said securing element.
[0063] Thus, the projection 33 does not at all hinder maneuvers to insert a securing element 3 into a carabiner 2 .
[0064] It can be seen that with the embodiment shown in FIG. 3 , a securing element 3 can be inserted along a direction inclined at about 45° from the vertical, while with the embodiment in FIG. 2 a securing element 3 can be inserted along an approximately vertical direction.
[0065] With the embodiments shown, the transmission device 9 comprises two cables 14 each sliding in a sheath not shown, usually called “Bowden cables”, each of said cables being connected:
on one side, to a gate 10 , at a distance from its rotation axis 12 , on the other side, to the first means for locking the other gate 10 ,
[0068] such that placing a gate 10 in the angular retaining configuration ( FIGS. 2 d to 2 h ) causes deactivation of the first means for locking the other gate 10 ( FIGS. 2 g , 2 h ), whereas placing a gate 10 in the angular reception configuration ( FIG. 2 ) causes activation of the first locking means for locking the other gate 10 ( FIGS. 2 d to 2 f ).
[0069] According to the embodiments shown, the first locking means comprises:
a first latch 15 fitted in rotation on the hook 4 between a locked position ( FIGS. 2 d to 2 f ) and an unlocked position ( FIGS. 2 g , 2 h ), a first spring 16 for moving said first latch to the locked position, a first tooth 22 located on said gate, to contain said first latch in the locked position.
[0073] According to the embodiments shown, placing a gate 10 in the angular reception configuration applies a tension on the corresponding cable 14 , the effect of said tension being to release the first latch 15 from the first tooth 22 on the other gate 10 .
[0074] According to the embodiments shown, the system 1 also includes a second locking means, said second locking means comprising:
a second latch 18 mounted in rotation about the rotation axis 19 of the first latch 15 between a locked position ( FIGS. 2 d and 2 h ) and an unlocked position ( FIGS. 2 e to 2 g ), said second latch having a zone 20 for allowing the user to move said second latch to the unlocked position (in this case by pressing it), a second spring 21 (in this case taken from the first spring 16 that is based on metal wire comprising two tabs separated by a spiral, each of said tabs bearing on a latch 15 , 18 respectively) for moving said second latch to the locked position, a second tooth 17 (in this case offset axially and angularly relative to the first tooth 22 ) for holding said second latch in the locked position.
[0078] The presence of the second locking means obliges the user to perform a voluntary manoeuvre to detach a carabiner 2 from a securing element 3 .
[0079] According to the embodiments shown, a carabiner 2 also comprises a spring 35 for moving the gate 10 to the angular reception configuration.
[0080] Opening of the first branch 8 is thus assisted, that facilitates removal of a securing element 3 from the carabiner 2 .
[0081] According to one embodiment, the system 1 comprises a device for guaranteeing that a carabiner 2 will be attached to a securing element 3 , said guaranteeing device including:
a lock 23 mounted (in this case in rotation) on the reception part 5 and moveable between a locked position ( FIG. 2 b ) for preventing the gate 10 to move to said angular retaining configuration and a release position ( FIG. 2 c ) allowing said gate to move to said angular retaining configuration, a third spring, not shown, for moving said lock to the locked position, a magnet 24 mounted on said lock to move said lock to the release position when a material that can be attracted by a magnet (said material forming particularly a part of a securing element 3 ) is placed below said lock.
[0085] There is thus a safety device that prevents the securing of a carabiner 2 on a securing element 3 that is not made of a material (metallic in that case) that can be attracted by a magnet.
[0086] According to one variant embodiment, the system 1 comprises a device for guaranteeing that a carabiner 2 will be attached to a securing element 3 , said guaranteeing device including:
a lock 23 mounted (in this case in rotation) on the upper reception part 5 and moveable between a locked position ( FIG. 2 b ) for preventing the gate 10 to move to the angular retaining configuration and a release position ( FIG. 2 c ) for allowing said gate to move to said angular retaining configuration, a third spring, not shown, for moving said lock to the locked position, a component 24 made of a material that can be attracted by a magnet, said component being mounted on said lock to enable said lock to move to the release position when a magnet is located below said lock, a magnet, not shown, intended to be mounted on a securing element 3 to enable said lock to move to the release position when said magnet is located below said lock.
[0090] There is thus a safety device that prevents the securing of a carabiner 2 on a securing element 3 that has not been identified as suitable for such a securing, a securing element 3 being fitted with a magnet facing which said carabiner 2 must be placed to that it can be secured.
[0091] We will now describe a carabiner 2 that can be used for such a system, said carabiner comprising:
a hook 4 for receiving a securing element 3 , said hook being generally in an inverted J-shape when seen from the side, the ascender of the J forming a lower gripping part 7 and the curved part of the J forming an upper reception part 5 for receiving said securing element, said upper reception part including an opening 6 so that said securing element can pass into it, a gate 10 —particularly a generally V-shaped gate—comprising a first branch forming a door 8 and a second branch 11 that activates said door, said gate being mounted on said hook at the intersection between said first and second branches, said gate being free to rotate about a rotation axis 12 located between said lower gripping part and said upper reception part, said gate being moveable into:
Firstly, an angular reception configuration for receiving said securing element between said first and second branches, in which said opening is closed off by said second branch and wherein said first branch can be closed by applying an upwards pressure (particularly by said securing element) on said second branch; and Secondly, an angular retaining configuration for retaining said securing element inside said upper reception part between said first and second branches, in which said opening is closed off by said first branch,
a first means for locking said gate in the angular retaining configuration,
[0097] said lower gripping part comprising a reception face 31 facing which said first branch extends when said gate is in the angular reception configuration, said face extending over all or some of the height of said lower gripping part.
[0098] According to the embodiments shown in FIGS. 2 and 3 , when the first branch 8 extends facing the reception face 31 , it is at least partially ( FIG. 2 ) or completely ( FIG. 3 ) inserted in a housing 13 formed in the lower gripping part 7 , so as not to inconvenience the user.
[0099] According to the embodiment shown in FIG. 3 , the gripping part 7 is provided with an orifice 30 into which the user's hand will fit.
[0100] With such an arrangement, the user's hand does not interfere with the first branch 8 , when it extends in front of the reception face 31 , when the gate 10 is rotated towards its angular retaining position.
[0101] Furthermore, the presence of such an orifice 30 enables the user to optimise his or her grip on the carabiner 2 making it possible to hang from a securing element 3 .
[0102] Finally, such an orifice 30 provides protection for the user's fingers.
[0103] A protection cover (not shown) can be provided extending laterally from an orifice 30 to surround at least a part of the user's fingers not protected by the walls of said orifice.
[0104] The protection cover can be in the form of a part associated with the hook 4 , for example attached by screws, said part particularly being made of a moulded plastic material to be lightweight, or being derived from the material of said hook.
[0105] In the embodiments shown, the housing 13 is in the form of a cavity.
[0106] In one variant not shown, the housing 13 is in the form of a recess that opens up laterally on each side of the wall 31 .
[0107] In the embodiment shown in FIG. 3 , the housing 13 is in the form of a cavity delimited partly by the reception face 31 and by a wall 32 integrated into a projection 33 located at the bottom of said reception face.
[0108] According to the embodiment shown in FIG. 3 , the first branch 8 is entirely inserted into the cavity such that said first branch does not form a projection that would hinder securing of the carabiner 2 .
[0109] The projection 33 includes an inclined face 34 designed to guide the securing element 3 between the first and second branches 8 , 11 of the gate 10 in the angular reception configuration when the carabiner 2 is positioned above said securing element.
[0110] According to the embodiments shown, a carabiner 2 also comprises a spring 35 for moving the gate 10 to the angular reception configuration.
[0111] Opening of the door 8 is thus assisted, that facilitates removal of a securing element 3 from the carabiner 2 .
[0112] Obviously, such a carabiner 2 can be used alone, without being integrated into a system 1 as described above, the planned arrangement making it possible to have a carabiner without a projecting part that could hinder its securing manoeuvre when it is moved in downwards translation.
[0113] Note that the orifice 30 described above can also apply to carabiners of types other than that described above.
[0114] To achieve this, the invention also relates to a carabiner comprising:
a hook for receiving a securing element, said hook having a gripping part and a reception part for receiving said securing element, said reception part having an opening through which said securing element can pass, a door for closing said opening,
said gripping part being provided with an orifice into which a user's hand will fit.
[0117] Finally, an assembly 25 for securing a person is described comprising such a system 1 , said assembly also comprising a harness 26 for securing a user and two straps 27 connecting the carabiners to said harness.
[0118] According to the embodiment shown in FIG. 1 , the harness comprises a belt 28 and two loops 29 into which the user's thighs fit and an adjustment loop (not shown).
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A safety restraint system for a person comprising two carabiners configured to receive at least one restraint element, each of the carabiners comprising a hook for receiving the element, a gate comprising a first branch forming a door and a second branch for actuating the door, a first means for locking the gate in a holding configuration. The system further comprising a transmission device connecting the carabiners together, the device arranged to make it impossible to switch from a state in which each of the carabiners is secured to an element to a state in which neither of the carabiners are secured to an element.
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FIELD OF THE INVENTION
The present invention relates to microorganisms for preventing or treating obesity or diabetes mellitus, which are capable of reducing an amount of monosaccharides or disaccharides that can be absorbed into the intestine by converting those mono or disaccharides into polymeric materials that cannot be absorbed in the intestines. The present invention also relates to use of the microorganisms for preventing or treating obesity or diabetes mellitus and a pharmaceutical composition containing the microorganisms.
BACKGROUND OF THE INVENTION
Obesity is well known as a chronic disease caused by various factors whose origins have not yet been clearly discovered. It is understood that obesity induces hypertension, diabetes mellitus, coronary heart disease, gall bladder disease, osteoarthritis, sleep apnea, respiratory disorder, endomerial, prostate, breast and colon cancer and the like.
According to the NIH Report (THE EVIDENCE REPORT: Clinical Guideline on the Identification, Evaluation, and Treatment of Overweight and Obesity in Adults, 1999, NIH), about 97,000,000 Americans suffer from overweighting and obesesity, and the number of patients of type II diabetes mellitus associated with obesity, reaches about 15,700,000. Moreover, it is reported that about 200,000 people die of diseases associated with obesity each year (Dan Ferber, Science, 283, pp 1424, 1999).
Diabetes mellitus is one of the most widespread chronic diseases in the world, which impose a substantial expense on the public as well as on patients of diabetes mellitus and their families.
There are several types of diabetes mellitus that are caused by various etiological factors and whose pathogenesis is different from each other. For example, genuine diabetes mellitus is characterized by high level of blood glucose and glycosuria, and is a chronic disorder of carbohydrate metabolism due to a disturbance of the normal insuline mechanism.
Non-Insulin-Dependent Genuine Diabetes Mellitus (NIDDM), or the type II diabetes mellitus is found in adults who have insulin-resistance in a peripheral target tissue, despite of normal generation and function of insulin. Non-Insulin-Dependent Genuine Diabetes Mellitus(NIDDM) can be caused by three important metabolic disorders, i.e., insulin-resistance, fucntional disorder of insulin secretion stimulated by nutrients, and overproduction of glucose in liver. Failure to treat NIDDM, resulting in losing control of blood glucose levels, leads to death of patients from diseases such as atherosclerosis, and/or may cause late complications of diabetes, such as retinopathy, nephropathy or neuropathy.
Accompanying diet-exercise therapy, NIDDM therapy uses sulfonylurea and biguanidine compounds to control blood glucose levels. Recently, therapeutic compounds such as metformin or acarbose have been used for treating NIDDM. However, diet-exercise therapy alone or even combined with chemotherapy using such compounds fails to control hyperglycemia in some of the diabetes mellitus patients. In such cases, these patients require exogenous insulin.
Administration of insulin is very expensive and painful to patients, and furthermore, may cause various detrimental results and various complications in patients. For example, incidences, such as, miscalculating insulin dosage, going without a meal or irregular exercise, may cause insulin response (hypoglycemia) and sometimes the insulin response occurs even without any particular reasons. Insulin injection may also cause an allergy or immunological resistance to insulin.
There are several methods for preventing or treating obesity or diabetes mellitus, including diet-exercise therapy, surgical operation and chemotherapy. Diet-exercise therapy involves a low-calorie and low-fat diet accompanying aerobic exercise, but this therapy requiring a regular performance is hard to continue until achieving the goal.
Despite of instant effects, a surgery for physically removing body fat has limitations due to the risk and cost involved in a surgical operation and insufficient durability of the effects.
As one of the most promising therapies currently developed, pharmacotherapy can reduce blood glucose level, inhibit absorption of glucose, strengthen the action of insulin or induce the decrease of appetite. The medicines that have been developed so far use various physiological mechanisms for the prevention and the treatment of obesity and diabetes mellitus.
Some medicines, such as, sulfonylurea, metformin, pioglitazone or thiazolidindione derivatives and the like have been developed to enhance the function of insulin. Although sulfonylurea stimulates insulin-secretion from β-cells in the pancreas, it may accompany side effects, such as hypoglycemia resulting from lowering blood glucose levels under normal levels.
Metformin is mainly used for insulin-nondependent diabetes mellitus patients who fail to recover after diet-exercise therapy. This medicine inhibits hepatic gluconeogenesis and enhances glucose disposal in muscle and adipose tissue. However, it suffers from side effects, such as, nausea, vomiting and diarrhea.
Pioglitazone developed by Takeda in Japan, enhances the function of insulin through increasing susceptibility of cells to insulin (Kobayashi M. et al., Diabetes, 41(4), pp 476-483, 1992).
Beta 3-adreno receptor inhibitor (BRL-35135) known as a medicine that stimulates the decomposition of body fats and that convert body fats into heat with a specific action on adipose cells, also suffers from lowerings blood glucose level.
The inhibitor of a pancreatic lipase (Orlistat produced by Roche of Switzlend) inhibits and/or reduces absorption of body fats by inhibiting pancreatic lipase. It, however, accompanies undersirable inhibition of absorption of fat-soluble vitamin and may also cause breast cancer.
Generally, medicines that decrease appetite affects catecholamine in the brain. However, dexfenfluororamine and fenfluoroamine have side effects of nerve toxicity and valvular heart disease. Also, sibutramine has side effects of increasing heart rate and blood pressure.
α-Glucosidase inhibitor (Acarbose produced by Bayer of Germany), is known as a glucose absorbing inhibitor. Acarbose is pseudo-monosaccharide which competitively inhibits the action of various a-glucosidases existing in microvilli of the gastrointestinal tract. However, taking a large amount of these may induce diarrhea. (W. Puls et al., Front. Horm. Res. 2, 235, 1998).
Amylase inhibitor that inhibit converting carbohydrates into oligosaccharides has been developed to prevent imbalance of metabolism originated from excessive uptake of nutrient. (Sanches-Monge R. et al. Eur. J. Biochem., 183, 0037-40, 1989).
Dietary fiber using diet with a large amount of vegetable fiber is the easiest way to obtain inhibitory effect on obesity by lowering glucose and/or fat amounts absorbed in the intestine. However, such method also involves problems in requiring facility and manpower for the production of dietary fiber with low productivity.
Polymeric materials, such as, isomaltotriose, dextran and pullulan, inhibit the increase of blood glucose level originated from glucose. However, such materials also cause severe side effects. For example, dextran may induce excessive bleeding by delaying a blood coagulation time.
Among said various medicines, dietary fibers are the most useful medicine for prevention or treatment of obesity because no damage to the human metabolism-balance and use natural substances.
Microorganism dietary fiber is produced using microorganisms, such as, Gluconobacter sp., Agrobacterium sp., Acetobacter xylinum, A. hansenil, A. pasteurianus, A. aceti, Rhizobium sp., Alcaligenes sp., Sarcina sp., Streptococcus thermophilus, Lactococcus cremoris, Lactobacillus helveticus, Lactobacillus bulgaricus, Lactobacillus sake, Lactobacillus reuteri, Lactobacillus lactis, Lactobacillus delbrueckii subsp., Lactobacillus helveticusglucose var. jugurti, Leuconostoc dextranicum, Bulgariscus sp., Campestris sp., Sphingomonas sp.
Dietary fiber produced by these microorganisms is used as stabilizer, thickening agent, emulsifier, hygroscopic agent of various foods and raw materials of cosmetics and pharmaceuticals. Microorganism cellulose, xanthan, acetan, guar gum, locust bean gum, carrageenan, alginate, and agar obtained from seaweed are commercialized.
Lactobacillus sp. strain is the major component of normal microbial flora in the human intestines. Its significant roles for maintaining digestive organ and for healthy environment of the vagina, have been well known. [Bible, D. J., ASM News, 54:661-665, 1988; Reid G. and A. W. Bruce, In H Lappin-Scott (de.), Bacterial biofilms, Cambridge University Press, Cambridge, England, p. 274-281, 1995; Reid G., A. W. Bruce, J. A. McGroarty, K. J. Cheng, and J. W. Costerton, clin. Microbiol. Rev., 3:335-344, 1990]. Generally, Lactobacillus strain inhabits in digestive organs ( L. acidophilus, L. intestinalis, L. johnsonii, L. reuteri et al.,), muscosa of the vagina ( L. vanginals, L. gasseri ), food (wine- L. hilgardii ), lactobacillus beverage ( L. kefir, L. kefiranofaciens ), cheese ( L. casey ), vinegar ( L. acetotolerance ), the oral cavity ( L. oris ), yeast ( L. sake, L. homohiochi ), fruit juice ( L. kunkeei, L. mali, L. suebicus ), fermented sausages or fish ( L. farciminis, L. alimentarious ) et al.
Many people take health complementary food containing a Lactobacillus sp. strain in order to maintain healthy intestines and to prevent urogenital tract infection. Recently, in addition to the prevention of the diarrhea, constipation and urogenital tract infection; various probiotic activities of Lactobacillus, such as, control of immunity, control of cholesterol level in blood, prevention of cancer, treatment of rheumatism, alleviation of sensitivity on lactose or effect for atopic dermatitis, have been reported and thus, have attracted more attention.
According to the U.S. Public Health Service Guideline, all of the 262 Lactobacillus deposited in ATCC are classified as “Bio-safety Level 1,” which stands for no potential risk, which has been known up to now, causing diseases in human or animals. There is no harm to human body among approximately 60 strains of Lactobacillus.
Recently, there has been a rapid progress in the research for an extracellular dietary fiber produced by Lactobacillus. It has been reported that a process of producing dietary fiber in these strains are very complicated because a lot of genes are mediated in the process, and the amount of dietary fiber thus produced are very low (Int. J. Food Microbiol., Mar 3 40:1-2, 87-92, 1998; Current Opinion in Microbiology, 2:598-603, 1999; Appl. Environ. Microbiol., Feb 64:2, 659-64, 1998; FEMS Microbiol. Rev. Apr 23:2 153-77, 1999; FEMS Microbiol. Rev. Sep 7:1-2, 113-30, 1990).
Also, various researches on the synthesis of cellulose by Acetobacter sp. which is well known as a microorganism producing dietary fiber, have been performed (Aloni Y., cohen R., Benziman M., Delmer D, J Biological chemistry, 171:6649-6655, 1989; Ascher M., J. Bacteriology, 33:249-252, 1937; Benziman M., Burger-Rachamimv H., J., Bacteriology, 84:625-630, 1962; Brown AM. Journal of Polymer science, 59:155-169, 1962; Brown AM, Gascoigne JA, Nature, 187:1010-1012, 1960; Calvin JR, Planta DP, Benziman M., Padan E, PANS USA, 79:5282-5286, 1982; Dehmer DP. Brown RM Jr., Cooper JB, Lin FC, Science, 230:82-825, 1985).
Acetobacter is a strict aerobe but has characteristics of surviving and living under the condition of infinitesimal oxygen, and of being floated to seek for oxygen by means of synthesizing cellulose dietary fiber itself under this condition of infinitesimal oxygen. According to the research regarding the amount and rate of converting glucose into cellulose dietary fiber by Acetobacter (Brown et al.: Proc. Natl. Acad. Sci. USA, Vol73 (12), 4565-4569), Acetobacter converts glucose into cellulose with the speed rate of 400 mol/cell/hour. This is equivalent to the rate that about 200 g glucose can be converted into cellulose dietary fiber by 4×10 15 cells per an hour.
Although Acetobacter that can metabolizes saccharose is rare, Acetobacter converting sacchores in glucose, exists in nature (PNAS, 9: pp14-18). Presently, FDA of the United States has approved Acetobacter xylinum for synthesizing acetic acid and sorbose, and has classified it as generally safe microorganism (GRAS: Generally Recognized As Safe).
As mentioned above, although there have been various researches and efforts to develop drugs for treatment or prevention of obesity and diabetes mellitus, their results were not satisfactory. Various chemical substances mentioned above, have been developed for treatment of obesity and diabetes mellitus, but still suffer from various side effects. These drugs forcibly discharge body fat together with valuable proteins. Consequently, any one single drug for treatment or prevention of obesity and diabetes mellitus at the origin thereof does not exist yet.
SUMMARY OF THE INVENTION
Therefore, the object of the present invention is to provide microorganisms capable of living within the intestines and converting oligosaccharides produced by the digestive enzymes into non-digestable polysaccharides, and thereby remarkably reducing the amount of oligosaccharide absorbed into the intestines.
Another object of the present invention is to provide a pharmaceutical composition comprising at least one of said microorganisms in an amount effective to prevent or treat obesity and diabetes mellitus and a pharmaceutically acceptable carrier. Another object of the present invention is to provide a method for preventing or treating obesity, diabetes mellitus comprising administering to a subject in need thereof capable of pharmaceutical comprising a method for reducing weight gain, controlling blood glucose level and control absorption of blood lipod.
The microorganisms that can be used for the pharmaceutical composition of the present invention preferably fall within Acetobacter genus, Gluconobacter genus, Lactobacillus genus, and Acrobacterium genus, which are capable of living in the intestine and not harmful to human body, and are capable of converting oligosaccharides into polysaccharides that cannot be absorbed into human body. Specifically, the following microorganisms can be used as microorganisms of the pharmaceutical composition of the present invention, such as, Acetobacter xylinum, A. hansenii, A. pasteurianus, A. aceti, Lactococcus cremoris, Lactobacillus helveticus, L. bulgaricus, L. sake, L. reutari, L. lactis , the subspecies of L. delbrueckii, L. delbrueckii subsp., and a variant form of L. helveticusglucose . Preferably, the microorganisms can be used as an active principle of the pharmaceutical composition of the present invention is Lactobacillus sp. BC-Y009 (KCTC0774BP) strain or Acetobacter sp. BC-Y058 (KCTC0773BP) strain.
The pharmaceutical composition of the present invention may be administered in a form of tablet, capsule, suspension or emulsion, which comprises excipients, pharmaceutically acceptable vehicles and carriers which are selected depending on administration routes. The pharmaceutical formulation of the present invention may further comprises supplemental active ingredients.
Lactose, dextrose, sucrose, sorbitol, mannitol, starch, acacia gum, calcium phosphate, alginic acid salt, treguhkense latex, gelatin, calcium silicate, finecrystalline cellulose, polyvinylpyrolidon, cellulose, water, syrup, methylcellulose, methylhydroxybenzoate and prophylhydroxybenzoate, talc, magnesium stearate or mineral oil may be used as carriers, exipients or diluents in the pharmaceutical composition of the present invention.
In addition, the pharmaceutical composition of the present invention may further comprises lubricants, moisturizer, emulsifier, suspension stabilizer, preservative, sweetener and flavor. The pharmaceutical composition of the present invention may be in a form of an enteric coating formulation produced by various methods which have been publicly known, in order to deliver the active ingredients of the pharmaceutical composition, ie., microorganisms, to the small intestines without degradation by gastric juices in stomach.
Furthermore, microorganisms of the present invention may be administered in a form of capsule prepared by conventional process. For example, standard vehicles and lyophilized microorganisms of the present invention are mixed together and prepared to pellets and then, the pellets are filled into hard gelatin capsules. In addition, the microorganisms of the present invention and pharmaceutically allowable vehicles, for example, aqueous gum, cellulose, silicate or oil are mixed to produce a suspension or emulsion and then, this suspension or emulsion may be filled into soft gelatin capsule.
The pharmaceutical composition of the present invention may be prepared as an enterically coated tablets or capsules for oral administration. The term “the enteric coating” of this application includes all conventional pharmaceutically acceptable coating that has resistance to gastric juice, however, in the small intestines, can disintegrate sufficiently for a rapid release of the microorganisms of the present invention.
The enteric coating of the present invention can be maintained for more than 2 hours in synthetic gastric juice, such as HCl solution of pH 1 at the temperature of 36° C. to 38° C. and desirably, decomposes within 0.5 hours in synthetic intestinal juice, such as KH2PO4 buffer solution of pH 6.8.
The enteric coating of the present invention applies to each tablet with the amount of about 16 to 30 mg, desirably 16 to 25 mg, more desirably 16 to 20 mg. The thickness of enteric coating of the present invention is 5 to 100 μm, desirably 20 to 80 μm. The components of the enteric coating are selected appropriately from common polymeric materials which have been publicly well known. The polymeric materials which may be employed for enteric coating of the present invention are enumerated and described in the flowing articles [The Theory and Practices of Industrial Pharmacy, 3rd Edition, 1986, pp. 365-373 by L. Lachman, Pharmazeutische Technologie, thieme, 1991, pp. 355-359 by H. Sucker, Hagers Handbuch der Pharmazeutischen Praxis, 4th Edition, Vol. 7, pp. 739, 742, 766, and 778, (SpringerVerlag, 1971), and Remington's Pharmaceutical Sciences, 13th Edition, pp. 1689 and 1691 (Mack Publ., Co., 1970)]. For example, cellulose ester derivative, cellulose ether and copolymer of acryl and methyl acrylate or maleic acid or phthalic acid derivative may be used in enteric coating of the present invention.
The preferred enteric coating of the present invention are prepared from polymers of cellulose acetate phthals or trimelitate and methacrylic copolymer (for example, copolymer of more than 40% of methacrylic acid and methacrylic acid which contains hydroxyprophyl methylcellulose phthalate or derivatives from ester thereof).
Endragit L 100-55 manufactured by Rohm GmbH of Germany may be used as a raw material for the enteric coating of the present invention.
Cellulose acetate phthalate employed in the enteric coating of the present invention, has about 45 to 90 cP of viscosity, 17 to 26% of acetyl contents and 30 to 40% of phthalate contents. The cellulose acetate trimelitate used in the enteric coating, has about 15 to 21 cS of viscosity, 17 to 26% of acetyl contents, and 25 to 35% of trimelityl contents. The cellulose acetate trimelitate which is manufactured by the Eastman Kodak Company may be used as a material for the enteric coating of the present invention.
Hydroxyprophyl methylcellulose phthalate used in the enteric coating of the present invention has molecular weight of generally 20,000 to 100,000 dalton, desirably 80,000 to 130,000 dalton and has 5 to 10% of hydroxyprophyl contents, 18 to 24% of metoxy contents, and 21 to 35% of phthalyl contents. Cellulose acetate phthalate manufactured by the Eastman Kodak Company can be used as a material for the enteric coating of the present invention.
Hydroxyprophyl methylcellulose phthalate used in the enteric coating of the present invention is HP50 which is manufactured by the Shin-Etsu Chemical Co. Ltd., Japan. The HP50 has 6 to 10% of hydroxyprophyl contents, 20 to 24% of metoxy contents, 21 to 27% of prophyl contents, and molecular weight is 84,000 dalton. Another material for enteric coating manufactured by the Shin-Etsu Chemical Co. Ltd., is HP55. HP55 can also be used as material for the enteric coating of the present invention. The HP55 has 5 to 9% of hydroxyprophyl contents, 18 to 22% of metoxy contents, 27 to 35% of phthalate contents, and molecular weight is 78,000 dalton.
The enteric coating of the present invention is prepared by using conventional methods of spraying the enteric coating solution to the core. Solvents used in the process of the enteric coating are alcohol such as ethanol, ketone such as acetone, halogenated hydrocarbon such as dichloromethane, or the mixture thereof. Softeners such as Di-n-butylphthalate and triacetin are added to the enteric coating solution in the ratio of 1 part coating material to about 0.05 or to about 0.3 part softner.
A spraying process is preferably performed continuously, and the amount of materials sprayed may be controlled depending on the condition of the coating process. Spraying pressure may be regulated variously and, generally, desirable result can be obtained under the pressure of average 1 to 1.5 bar.
“The effective amount” of this specification means the minimum amount of the microorganisms of the present invention, which can reduce the amount of oligosaccharide absorbed into the body through the intestines of mammalian animals. The amount of microorganisms administered into a body with the pharmaceutical composition of the present invention may be adjusted depending on the administration method and the administration subject.
The composition of the present invention may be administered once or more per day on the subject. The unit of administration amount means that it is separated physically and thus is suitable for the unit administration for the human subjects and all other mammalian animals. Each unit contains a pharmaceutically acceptable carrier and the amount of the microorganisms of the present invention which are effective in therapy.
An oral administration unit of an adult patient contains microorganisms of the present invention in an amount, desirably, 0.1 g or more, and the composition of the present invention contains 0.1 to 10 g per one time administration, desirably 0.5 to 5 g. The effective amount of microorganisms of the present invention is 0.1 g per 1 day.
However, the administration amount can vary depending on the weight and the severity of obesity of the patient, supplemental active ingredients included and microorganisms used therein. In addition, it is possible to divide up the daily administration amount and to administer continuously, if needed. Therefore, range of the administration amount does not limit the scope of the present invention in any way.
The “composition” of the present invention means not only as medicinal products but also to serve as functional foods and health complementary foods.
In case of taking the composition of the present invention periodically, microorganisms form colony within the intestines and interrupt absorption of oligosaccharide in the body competitively. Also, non-digestable fibers produced by microorganisms make a healthy condition for other useful microorganisms within the intestines and stimulate the intestinal activity. Consequently, the composition of the present invention functions to treat and prevent obesity and diabetes mellitus.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and other advantages of the present invention will become more apparent by describing in detail a preferred embodiment thereof with reference to the attached drawings, in which:
FIG. 1 is the graph illustrating the absorption rate of glucose by the microorganisms of the present invention.
FIG. 2 is the graph illustrating the change of blood glucose level after taking the microorganisms of the present invention.
FIG. 3 is the graph illustrating the change of energy metabolism efficiency of obese mouse that has taken the microorganism of the present invention.
FIG. 4 is the graph illustrating the change of energy metabolism efficiency of control mouse that has taken the microorganism of the present invention.
FIG. 5 is the graph illustrating the change of the body weight of obese mouse induced by pharmacological prescription.
FIG. 6 is the graph illustrating the change of the metabolic efficiency of obese mouse induced by pharmacological prescription.
FIG. 7 is the phylogenetic analysis diagram of Lactobacillus BC-Y009 based on 16s rRNA nucleotide sequence of the present invention.
FIG. 8 is the phylogenetic analysis diagram of Lactobacillus BC-Y058 based on 16s rRNA nucleotide sequence of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be described more in detail.
The microorganisms which can be used in the pharmaceutical composition of the present invention for preventing and treating obesity and diabetes mellitus, or in a method therefore, should satisfy the requirements of 1) being capable of proliferating within the intestinal layers, 2) being capable of absorbing oligosaccharide rapidly and of converting them into non-digestable or hardly digestable high molecular weight materials, such as fibrous materials, and 3) being harmless to human body and animals. All microorganisms that can satisfy the above requirements can be used as active principles of the pharmaceutical composition of the present invention and for use of the pharmaceutical composition, and may be obtained from the numerous microorganism depository institutions in the world.
Therefore, the microorganisms of the pharmaceutical composition of the present invention are Acetobacter xylinum , Acetobacter BC-YO58, Acetobacter hansenii, Acetobacter pasteurianus, Acetobacter acetic Leuconostoc sp., Bacillus sp., Lactobacillus BC-Y009, Lactobacillus brevis, Lactobacillus helveticus, Lactobacillus bulgaricus, Lactobacillus casei, Lactobacillus kefir, Lactobacillus keriranofaciens, Lactobacillus bifidus, Lactobacillus sake, Lactobacillus reuteri, Lactobacillus lactis, Lactobacillus delbrueckii, Lactobacillus helveticusglucos var. jugurti., Lactococcus cremoris, Bifidobacterium bifidium, Streptococcus thermophilus or Pediococcus sp. Bacteria, which produce polysaccharide. These microorganisms are described in the following Articles:
Bart Degeest and Luc De Vuyst,
“Indication that the Nitrogen Source Influences Both Amount and Size of Exopolysaccharides Produced by Streptococcus thermophilus LY03 and Modelling of the Bacterial Growth and Exopolysaccharide Production in a Complex Medium”
( Appl. Envir. Microbiol. 1999, 65: 2863-2870);
Stacy A. Kimmel, Robert F. Roberts and Gregory R. Ziegler,
“Optimization of Exopolysaccharide Production by Lactobacillus delbrueckii subsp. bulgaricus RR Grown in a Semidefined Medium”
( Appl. Envir. Microbiol. 1998, 64: 659-664.);
P. L. Pham, I. Dupont, D. Roy, G. Lapointe and J. Cerning,
“Production of Exopolysaccharide by Lactobacillus rhamnosus
R and Analysis of Its Enzymatic Degradation during Prolonged Fermentation”
( Appl Envir. Microbiol. 2000, 66: 2302-2310.);
Petronella J. Looijesteijn, lngeborg C. Boels, Michiel Kleerebezem and Jeroen Hugenholtz,
“Regulation of Exopolysaccharide Production by Lactococcus lactis subsp. cremoris by the Glucose Source”
( Appl Envir. Microbiol. 1999, 65: 5003-5008);
G. H. Van Geel-Schutten, E. J. Faber, E. Smit, K. Bonting, M. R. Smith, B. Ten Brink, J. P. Kamerling, J. F. G. Viegenthart and L. Dijkhuizen,
“Biochemical and Structural Characterization of the Glucan and Fructan Exopolysaccharides Synthesized by the Lactobacillus reuteri Wild-Type Strain and by Mutant Strains”
( Appl. Envir. Microbiol. 1999, 65: 3008-3014.);
G. J. Grobben, I. Chin-Joe, V. A. Kitzen, I. C. Boels, F. Boer, J. Sikkema, M. R. Smith and J. A. M. de Bont,
“Enhancement of Exopolysaccharide Production by Lactobacillus delbrueckii subsp. bulgaricus NCFB 2772 with a Simplified Defined Medium”
( Appl. Envir. Microbiol. 1998, 64: 1333-1337.);
Sandrine Petry, Sylviane Furlan, Marie-Jeanne Crepeau, Jutta Cerning and Michel Desmazeaud,
“Factors Affecting Exocellular Polysaccharide Production by Lactobacillus delbrueckii subsp. bulgaricus Grown in a Chemically Defined Mediums”
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which are hereby incorporated by reference in their entirety, including any drawings, as if fully set forth herein.
In addition, the present inventors have isolated and obtained novel microorganisms which can be used as an active principle of the pharmaceutical composition of the present invention.
In order to isolate and obtain novel microorganisms which satisfy the requirements for an active principle of the pharmaceutical composition of the present invention, the present inventors have researched as follows:
Samples of microorganisms collected from the glucose factory sewage and other locations were inoculated in MRS and BHS agar mediums containing cycloheximide, and then cultured. Colonies formed in agar medium were then inoculated into MRS and BHS liquid medium and incubated without shaking. Microorganisms that formed a matrix or a membrane shape on top layers of the medium were selected. Formed membranes were separated and tested for whether or not the separated membranes were decomposed by the intestinal digestive enzyme. The results determined whether non-digestable (or hardly digestable) high molecular-weight compounds were produced or not. Among the microorganisms, BC-Y009 and BC-Y058 were selected for their high productivity of extracellular polysaccharide (dietary fiber).
Upon observing the morphology of BC-Y009 and BC-Y058 and comparing with 16s rRNA's partial DNA sequences, it was confirmed that each showed high percentage of homology sequence when compared with Lactobacillus and Acetobacter. Based on the phenotype and 16s rRNA DNA sequence analysis, it was ascertained that BC-Y009 is a novel microorganism which falls within the Lactobaccilus genus and BC-Y058 as a novel microorganism of Acetobacter genus.
Lactobacillus BC-Y009 and Acetobacter BC-Y058 of the present invention were administered into a mouse which was induced to have obesity and diabetes mellitus. The blood glucose level of a subject mouse had been decreased approximately 70% after administration.
According to these results, it was confirmed that microorganisms of the present invention has an effect in decreasing blood glucose level and thus it is effective for treating and preventing against diabetes mellitus.
When microorganisms of the present invention, BC-Y009 and BC-Y058 were administered into a mouse induced to have diabetes mellitus and obesity, the feed consumption rate increased 17 to 24% upon comparison with a control mouse. However, weight gain versus feed consumption amount was decreased. The result thus indicates that the microorganism composition of the present invention allows for humans to consume without worrying about obesity or diabetes mellitus.
From the observation that a blood lipid level is also lower than that of control group in case of taking these microorganisms, the microorganisms of the present invention is found to be capable of controlling the occurrence of diabetes mellitus, obesity and circulatory diseases, for example, arteriosclerosis or myocardial infarction. Additionally, in case of a normal mouse, mouse administered with the composition of the present invention consumed more feed, thus energy efficiency had been decreased in comparison with a control mouse. However, it was confirmed that there was no side effects led from the administration upon observing that the change of lipid content was negligible.
Hereinafter, the present invention will be further explained with reference to the following examples. The examples are given only for illustration of the invention and are not intended to limit the scope of the present invention.
EXAMPLE 1
Selecting of microorganism which produces extracellular polysaccharide from samples
In order to isolate microorganisms which produce dietary fibers, samples were collected from glucose factory sewage and other locations. 10 g of the mixture thus collected were disrupted and suspended in 90 ml of physiological saline solution (0.85% NaCI). The said suspended samples were diluted to 10 −2 , 10 −4 , and 10 −6 in physiological saline solution. These diluted samples then smeared on MRS agar medium containing 1 mg of cycloheximide per 100 ml medium (1% Peptone, 1% beef extract, 0.5% yeast extract, 2% glucose, 0.1% Tween-80, 0.2% Citric Acid Ammonium, 0.5% Sodium Acetate, 0.01% MgSO 4 , 0.005% MnSO 4 , 0.2% Sodium Phosphate pH6.5) and on BSH agar medium (2% glucose, 0.5% Peptone, 0.5% yeast extract, 0.27% Na2HPO4, 0.115% Citric Acid pH 5.0)(Hestirin and Schramm, J. Gen. Microbiol., 11:123, 1954) and cultured in 30° C. for 72 hours. Approximately 2,000 colonies were selected and were initially inoculated in 5 ml MRS liquid medium and BSH liquid medium at 30° C. for 72 hours and cultured without shaking. The microorganism which form a membrane shape on upper layer of the liquid medium and the microorganism which form capsule-shaped extracellular polysaccharide and of which medium was transparent, were selected. These microorganisms were inoculated again in 5 ml of MRS liquid medium and BSH liquid medium and stirred at 30° C. and the absorbance thereof was measured at 600 nm by spectrophotometer. Microorganisms were diluted with BSH liquid medium until the absorbance thereof reached to 0.2. 10 ml of microorganism thus diluted was inoculated into 100 ml of BSH liquid medium at 30° C. for 72 hours and cultured without shaking.
In order to measure the amount of extracellular polysaccharide (dietary fibers) thus produced, each medium were centrifuged at 6,000 rpm in 4° C. to obtain the precipitation of microorganisms. Cell membrane were disrupted by alkali lysis in 0.1 N NaOH solution and left alone in 800° C. for 30 minutes and centrifuged at 6,000 rpm in 4° C. and repeated multiple times, the above process in entirety. Extracellular polysaccharide entangled like white strings were isolated and lyophilized to be measured the amount thereof. Microorganisms with high extracellular polysaccharide productivity were selected and extracellular polysaccharide productivity was compared with each other (Table 1).
TABLE 1
Comparison of extracellular polysaccharide productivity
Amount of produced extracellular
Selection Number
polysaccharide (dry weight g/l BSH)
BC-Y 009
3.8
BC-Y 002
4.2
BC-Y 015
3.2
BC-Y 026
4.1
BC-Y 058
4.8
BC-Y 112
3.0
BC-Y 130
3.4
BC-Y 201
3.3
EXAMPLE 2
The morphological determination and characteristics of the selected BC-Y009 and BC-Y058
Microorganisms which show high polysaccharide productivity selected from the Example 1 were BC-Y009, BC-Y002, BC-Y01 5, BC-Y026, BC-Y058, BC-Y112, BC-Y130, and BC-Y201. Upon observing partial DNA sequences, BC-Y009, BC-Y002, BC-Y015 and BC-Y026 were microorganisms of Lactobacillus genus, and BC-Y058, BC-Y112, BC-Y130 and BC-Y201 were microorganisms of Acetobacter genus.
Among these bacteria, BC-Y009 and BC-Y058 which show high polysaccharide productivity were inoculated in MRS and BSH liquid mediums at 30° C. for 72 hours and cultured in suspension. Cultured mediums were centrifuged at 6,000 rpm in 4° C. to obtain microorganisms and the nucleic acids thereof were isolated by means of using the CTAB/NaCl method. By using 16s rRNA consensus primer, 16s rRNA was amplified by means of PCR method, and the sequence thus obtained, was determined. BLAST analysis (NCBI, USA) on the sequence thus determined, was performed and its result showed high percentage of sequence homology with sequence of Lactobacillus hilgardii, Acetobacter xylinum, Gluconobacter sp., numerous other Lactobacillus sp. and Acetobacter sp. (Tables 2 and 3).
TABLE 2
Comparison of 16S rRNA nucleotide sequence of Lactobacillus
sp. BC-Y 009
L.delbrueckii
Lactobacillus
sub sp.
L.helveticus
L.acidophillus
L.hilgardii
sp.
BC-Y009
ATCC9649
NCDO2712T
ATCC4356
NCDO264
ATCC13133
BC-Y009
—
145
136
146
3
4
L.delbrurckii sp.
88.93
—
76
73
142
143
ATCC9649
L.helveticus
89.16
93.94
—
21
134
134
NCDO2712T
L.acidophillus
88.85
94.43
98.33
—
144
144
ATCC4356
L.hilgardii
99.77
89.07
89.26
88.93
—
1
NCDO264
Lactobacillus sp.
99.69
88.97
89.21
88.90
99.92
ATCC13133
Among 1,400 base pairs which are included in comparison, top right of table indicates number of base pairs which show difference, bottom left of table indicates % homology
TABLE 3
Comparison of 16S rRNA nucleotide sequence of Acetobacter
sp. BC-Y 058
BC-Y 058
A.diazotrificus
A.liafaciens
A.hansenii
A.xylinum
A.europaeus
BC-Y 058
—
37
34
10
13
14
A.diazotrificus
97.20
—
17
37
35
36
A.liafaciens
97.42
98.71
—
34
32
33
A.hansenii
99.24
97.20
97.42
—
15
16
A.xylinum
99.02
97.35
97.58
98.86
—
3
A.eurapaeus
98.94
97.27
97.50
98.79
99.77
—
Among 1,320 base pairs which are included in comparison, top right of table indicates number of base pairs which show difference, bottom left of table indicates % homology
BC-Y009 is a gram-positive bacteria and 0.5 to 3.0 μm in size. It is a non-motile & short-rod shaped bacteria. It does not form spores and is facultative anaerobic. The growth temperature is between 20° C. to 37° C. and pH level is 2.0 to 8.0 and optimal pH level is 4.0 to 7.0. The experimental results showed that this microorganism was condensed in milk and was negative (non-reactive) to catalase and formed white colored colony in complex medium. It was precipitated in MRS liquid medium and BSH liquid medium in form of white colored capsule. The turbidity of the liquid medium was clear and the microorganism produced extracellular polysacchardie in clear medium and in case liquid medium was shaken, the extracellular polysacchride (dietary fiber) were broken into small particles.
BC-Y058 is a gram-negative bacteria, rod shaped bacteria and 0.6 to 0.8 μm in size and exists as single or a pair. It is also a non-motile and does not form spores. Growth rate thereof is slow, therefore 5 to 7 days of incubation time is needed and colonies formed are small and hard. In liquid medium, clear cellulose pellicle is formed. Ethanol, acetic acid, or lactic acid can be used as substrates and showed positive response to catalase. This microorganism produces acid by using glucose and in Hoier medium, it can not grow.
Upon consideration of the result of analysis of phenotype and 16s rRNA DNA sequence, BC-Y009 was named as Lactobacilus sp. BC-Y009 and BC-Y058 as Acetobacter sp. C-Y058. They were deposited in KCTC(Korean Collection for Type Cultures, locate at Korea Research Institute of Bioscience and Biotechnology (KRIBB), #52, Oun-dong, usong-ku, Taejon, 305-333, Republic of Korea) on May 30, 2000, and the deposit num er was granted as KCTC BC-Y009, KCTC BC-Y058, respectively.
EXAMPLE 3
The degree of decomposition of extracellular polysacchride (dietary fiber) by intestinal digestive enzymes
In order to determine whether or not dietary fiber produced by said microorganisms is decomposed by intestinal digestive enzyme, 1 g of porcine pancreatin that shows the activity of 3×U.S. Pharmacopia (manufactured by Sigma) and comprises amylase, lipase, protease and nuclease, was suspended in buffer solution (pH7.5) of 1 g of dried dietary fiber. This suspension was incubated for 7 days at 40° C. and the suspension was collected once a day and the glucose therein was analyzed quantitatively by using DNS(3,5-dinitrosalicylic acid). The result thereof showed that dietary fibers has never been decomposed at all.
Therefore, it was confirmed that the dietary fibers produced by the microorganisms of the present invention do not decompose within the intestine.
EXAMPLE 4
Glucose absorption rate of bacteria
Glucose absorption rates of Lactobacillus acidophilus (KCTC3140), L. hilgardii (KCTC3500) known as probiotics, and the said Lactobacillus BC-Y009, Acetobacter BC-Y002, Acetobacter BC-Y058 and E. coli ., were measured in the condition of the intestine. The results are represented in FIG. 1 and Table 4.
As illustrated in FIG. 1 and Table 4, the microorganisms of the present invention are superior to the other lactic acid bacteria in terms of glucose absorption rate.
TABLE 4
Glucose concentration decreased by the bacteria
of unit O.D. per unit time.
glucose
concentration
glucose
decreased per
initial glucose
concentration
unit time and
initial
concentration
after 1
unit
O.D. 600 nm
(mM)
hour (nM)
O.D. (mM/hr/O.D.)
E.coli
3.0 ± 0.1
110
85 ± 0.5
8.3 ± 0.44
BC-Y009
3.0 ± 0.2
110
50 ± 0.3
20 ± 1.5
BC-Y002
3.0 ± 0.1
110
30 ± 0.7
26.6 ± 1.1
BC-Y058
3.0 ± 0.2
110
38.6 ± 0.3
23.8 ± 0.1
KCTC3500
3.0 ± 0.2
110
67.2 ± 0.3
14.2 ± 0.4
KCTC3140
3.0 ± 0.1
110
65.2 ± 0.4
14.4 ± 0.1
EXAMPLE 5
Concentration and survival rate of microorganisms in the intestine after adminstering microorganisms
Mouse C57BL/6J Lep ob ob/ob genetically induced of obesity and diabetes mellitus (hereinafter,“OB Mouse”), was starved for 18 hours and fed the composition of the present invention (the number of microorganism of the composition was 1.0×10 13 CFU/g) containing 1% of Lactobacillus BC-Y009 , Acetobacter BC-Y058 (w/w, drying weight) for 7 days, and then the bacterial concentration in the duodenum, the jejunum, and the large intestine of these mice were analyzed. In addition, the bacterial concentration in the duodenum, the jejunum, and the large intestine of the control OB mouse that had been fed the feed without containing the microorganisms of the present invention, was analyzed.
In order to measure the amount of Lactobacillus, the duodenum, the jejunum, and the large intestine of the mouse that had been fed Lactobacillus feed and the control mice were cut out. Each surfaces of the organs were rinsed with physiological saline solution and the contents were suspended in physiological saline solution. Then, inoculated in MRS agar medium and incubated at 37° C. Three (3) days later, the amount of bacteria was measured by counting floc and by subtracting the amount of Lactobacillus in the control group to determine the change of the amount of bacteria (Table 5).
In order to confirm the existence of Acetobacter, the each organs of mouse were cut out, then rinsed the surfaces of the organs with physiological saline solution. The contents were suspended in physiological saline solution, then inoculated in BSH liquid medium and cultured at 37° C. for 3 days. By checking the pellicle appeared on top layer of the liquid medium, the existence of fiber-producing Acetobacter was confirmed (Table 6).
According to the results represented in Table 5 and Table 6, the said two kinds of microorganisms were both able to proliferate in the intestine.
TABLE 5
The amount of Lactobacillus sp. in the duodenum, the jejunum,
and the large intestine of mouse
Existence of
the region of
bacterial
membrane
intestine
weight (g)
number (CFU/g)
formation
Duodenum
0.18 ± 0.03
83 ± 20
no
Jejunum
0.29 ± 0.05
1.2X10 3 ± 50
no
large intestine
0.36 ± 0.07
5.1X10 3 ± 30
yes
TABLE 6
The amount of Acetobacter sp. in the duodenum, the jejunum,
and the large intestine of mouse
existence of
the region of intestine
weight (g)
membrane formation
duodenum
0.20 ± 0.02
no
jejunum
0.28 ± 0.04
yes
large intestine
0.35 ± 0.03
yes
EXAMPLE 6
The change in blood glucose level upon feeding of BC-Y009 and BC-Y058
100 g of mouse feed purchased from SAMYANG Co. and 400 g of Korean rice were mixed to make a composition in which carbohydrate content was 60%, then 5 g of dried Lactobaccillus BC-Y009 or Acetobacter BC-Y058 were added thereto to prepare a lyophilized tablet. Mice were fed this tablet with water.
All mice tested in this Example were female and OB mice. Acetobacter feed group (OB-058), Lactobacillus feed group (OB-009), and the control group (OB-con, which has no microorganism of the present invention in the feed) were bred separately. The breeding condition was that there was light every 12 hour intervals(9:00-21:00 lighted, 21:00-9:00 no lighted) and maintained 20 to 24° C. and 40 to 60% humidity.
Additionally, enteric coating solution was sprayed on dried Lactobacillus BC-Y009 or Acetobacter BC-Y058 to produce the compostion of the present invention which comprises enteric coated microorganisms. The weight of the enteric coating of material on the composition was approximately 16 to 30 mg or less per tablet. The materials for the enteric coating were selected from common high molecular weight materials, such as, cellulose acetate phthalate, trimelitate, copolymer of methacrylic acid (Methylacrylic acid 40% or more, especially methylacrylic acid including hydroxypropyl methylcellulose phthalate and its ester derivatives), or mixture thereof.
Methylacrylate used in the Example was Endragit L 100-55 manufactured by Rohm GmbH(Germany), cellulose acetate phthalate with about 45 to 90 cP of viscosity, 17 to 26% of acetyl content and 30 to 40% of phthalate content, or cellulose acetate trimelitate manufactured by the Eastman Kodak Company (approximately 15 to 20 cS of viscosity, 17 to 26% of acetyl content and 25 to 35% of trimelityl content).
The enteric coating was produced by a conventional coating process wherein the enteric coating solution was sprayed on a core. Ethanol and acetone mixture was used as solvent and a softening agent was added to the coating solution in a ratio of 1 to approximately 0.005 or 0.3.
The enteric coating composition of the present invention produced by means of the process was provided to the mice with water for unrestricted taking. The blood glucose level of the mouse which has taken the enteric coating composition, was measured.
Before measuring the blood glucose level of each mouse group, each mouse was starved for 18 hours. Following 60 minutes after starvation, sufficient amounts of feed were provided and after a 60 minute period, serum was collected from the retroorbital venous plexus by using anti-coagulating agent-free capillary tubes.
The blood glucose level was measured by absorbance at 505 nm, using the Trinder kit (Cat. 315-500, Sigma, USA) which employs enzyme coloring method. The statistical error of the results was indicated by average ± standard deviation per experimental group, and statistical significance of the average difference in each group was tested through ANOVA (p<0.02).
Data for blood glucose level are illustrated in FIG. 2 . As illustrated in the FIG. 2, the blood glucose level for OB-con group is approximately 500 mg/dl, whereas OB-058 blood glucose level is low. Additionally, due to administration of Acetobacter BC-Y058 and Lactobacillus BC-Y009, the blood glucose levels of each mouse had been decreased to approximately 70% and 53% each (Table 7).
TABLE 7
The change of blood glucose level after administration of
Acetobacter BC-Y058 and Lactobacillus BC-Y009
OB-009
OB-058
OB-con
Blood glucose
229 ± 16
141 ± 19
492 ± 60
level(mg/dl)
EXAMPLE 7
The change of weight and amount of diet due to taking BC-Y058 and BC-Y009 and in metabolic efficiency
Mice were classified as OB-058 group, OB-009 group, OB-con group, and Acetobacter BC-Y058 and Lactobacillus BC-Y009 were administered on each group and the weight of each mouse was measured in weekly intervals. Along with the measuring of changes in weight, the weight of feed consumed by the mice was also measured, therefore changes of metabolic efficiency of each group were investigated.
The difference of weight change was apparent in each species whose genetic characteristics were different, but the difference of weight change, within the group having the same genetic characteristics was negligible.
As indicated in Table 8, the weight change of OB mice within the period of 7 weeks, regardless of the administration of Acetobacter BC-Y058 or Lactobacillus BC-Y009, was approximately 47% increase of weight. However, on the contrary, as indicated in Tables 9 and 10, feed consumption percentage, depending on microorganism administration, increased 17 to 24% in OB mice group.
That is, the weight increase of the mice fed feed which comprises the microorganisms of the prevent invention was the same as that of the mice fed that does not contain the microorganism of the prevent invention. The results indicate that because Acetobacter BC-Y058 and Lactobacillus BC-Y009 suppress increase of blood glucose levels after meal, increase of feed consumption occurs as its compensation. In other words, with the same amount of feed, increase of weight can be decreased by feeding the microorganism of the present invention without causing no further weight increase because of lower metabolic efficiency. Because of the conversion of glucose into dietary fiber by BC-Y058 and BC-Y009 microorganism, metabolic efficiency has changed.
According to the formula represented below, the change of energy efficiency depending on feed consumption, was calculated and represented in Table 10.
energy metabolic efficiency =(weight gain(g)/amount of feeding(g)) ×1,000
As represented in Table 10, when microorganisms were administered to OB mouse, the energy metabolic efficiency was from 75 to 85% (FIG. 3) compared to that of the control group which was not administered with the microorganisms of the present invention (FIG. 4 ).
TABLE 8
Change of the mouse weight (g)
1 week
2 week
3 week
4 week
5 week
6 week
7 week
OB-009
21.5 ± 3.21
26.53 ± 2.72
31.52 ±3.01
34.91 ± 2.5
37.6 ± 2.53
40.1 ± 1.74
41.4 ± 1.47
OB-058
21.95 ± 5.3
26.75 ± 4.60
31.65 ± 2.33
35.8 ± 1.27
38.25 ±0.78
40.35 ± 0.64
41.25 ± 0.21
OB-con
21.4 ± 2.83
26.3 ± 1.56
31.9 ± 0.99
35.8 ± 2.12
38.35 ± 2.33
40.1 ± 2.69
41.75 ± 3.61
TABLE 9
Change of amount of feed consumption according to the
administration of Acetobacter BC-Y058, Lactobacillus BC-Y009 (g)
0-16 days
16-21 days
21-34 days
34-41 days
Total
OB-009
146.3
32.4
110.7
38.6
328
OB-058
157.4
34.3
115.3
41
348
OB-con
128.1
34.8
80.3
36.5
279.7
TABLE 10
Energy metabolic efficiency
Amount
weight
rate of
of
gain
energy
average
weight
feed (g)
(g)
metabolicefficiency
weight (g)
increase
OB-009
328
19.9
121
41.4
0.48
OB-058
348
19.3
111
41.25
0.47
OB-con
279.7
20.35
146
41.75
0.49
EXAMPLE 8
Change of weight and diet amount of obesity mouse induced by GTG and subsequent change in metabolic efficiency
Before feeding Acetobacter BC-Y058 and Lactobacillus BC-Y009, each mouse was administered with 1 g/kg of goldthioglucose (Cat. A-0632, Sigma, USA) in order to induce obesity. And every 3 or 4 weeks, weight change was measured and only obesity-induced mice were selected. For accuracy of the experiment, a mouse of which weight increase was too great or too little relatively, was excluded from the experiment.
The target was female C57BL/6J mice and breeding environment and conditions were the same as those in Example 6. The test subjects were classified into BC-Y058 group, KCTC3140 group, KCTC3500 group, and BC-Y009 group depending on microorganisms.
The weight changes of mice depending on microorganisms administered with, are illustrated in FIG. 5 and it is confirmed that when Acetobacter BC-Y058 and Lactobacillus BC-Y009 were administered, the weight increase rate has decreased.
Additionally, as represented in Table 11 and FIG. 6, in case that KCTC3140 and KCTC3500 which consume glucose but do not produce dietary fibers, were administered, the energy efficiency of obesity-induced mice was higher than that of the control group which was not administered with the microorganisms of the present invention. However, the mouse group which was administered with BC-Y009 and BC-Y058 which produce dietary fibers, showed relatively low energy efficiency, especially in case of BC-Y058. That is the energy efficiency decreased to 55% compared with that of the control group (Table 12).
TABLE 11
Metabolism efficiency of obese mouse induced
with drug administration (g)
energy metabolic
Weight gain (g)
amount of feed (g)
efficiency
Carbohydrate
5.43
103.7
52
KCTC3140
6.65
92.4
72
KCTC3500
5.67
102.2
55
BC-Y009
4.38
104.4
42
BC-Y058
2.98
102.7
29
EXAMPLE 9
Lipid level changes when BC-Y058 and BC-Y009 were administered
After administration of the microorganisms of the present invention, the change of blood lipid, especially cholesterol change, was analyzed and confirmed whether or not the microorganisms affected the circulatory disease, such as, artheriosclerosis and myocardial infarction besides diabetes mellitus and obesity.
Lipid analysis was performed by means of enzyme coloring method as in Example 6, using TG-glycezyme-V (Young-Yeoun Chemical Co., Japan), HDL-zyme-V (Young-Yeoun Chemical Co., Japan), Cholestezyme-V (Young-Yeoun Co., Japan), LDL cholesterol (Cat. 61532, BioMeriux, France), to measure the absorbance at 505 to 570 nm with standard solution, and the amount of lipid in blood was calculated.
As represented in Table 12, lipid concentration before feed administration did not show any differences in obese mouse. However, after Acetobacter BC-Y058 and Lactobacillus BC-Y009 were administered, as indicated in Table 12, the change of lipid concentration was apparent after 7 weeks.
In case of obese mice that have taken the microorganism, the lipid level did not change in comparison with the data of early steps in the present experiment and however, in case of control mouse which had not been administered with the microorganisms, overall lipid content in blood was increased.
TABLE 12
Lipid amount in blood before administration of
feed (mg/dl)
total cholesterol
TG
HDL-C
LDL-C
OB-009
130.22 ±
98.1 ± 11.4
98.73 ± 9.7
4.13 ± 2.36
4.11
OB-058
129.37 ±
101.6 ± 10.36
113.52 ±
3.35 ± 2.08
4.24
15.47
OB-con
127.57 ±
97.13 ± 14.64
96.86 ± 7.61
6.62 ± 2.78
4.32
n = 4
TG: Triglyceride
HDL-C: High Density Lipoprotein Cholesterol
LDL-C: Low Density Lipoprotein Cholesterol
TABLE 13
Lipid amount in blood after administration of
feed (mg/dl)
Total cholesterol
TG
HDL-C
LDL-C
OB-009
167.04 ±
100.76 ± 3.2
157.71 ± 2.4
4.2 ± 2.08
1.12
OB-058
*135.25 ±
98.5 ± 2.83
135 ± 1.41
3.36 ± 1.31
2.47
OB-con
*174 ± 1.41
110.5 ± 1.06
165.25 ± 1.06
3.19 ± 0.36
n = 4, *p < 0.05
TG: Triglyceride
HDL-C: High Density Lipoprotein Cholesterol
LDL-C: Low Density Lipoprotein Cholesterol
The industrial applicability of the present invention
The microorganisms of the present invention are capable of living within the intestine and converting monosaccharides and disaccharides into high molecular weight materials which cannot be absorbed and hardly digestible in the intestine, thereby remarkably reducing the amount of monosaccharide to be absorbed. Therefore, the energy required for metabolic activity is provided from lipids and protein accumulated in the body, thus effectively suppressesing obesity and diabetes mellitus. In addition, the microorganisms of the present invention produce dietary fibers within the intestine and excreting harmful materials along with these dietary fibers, to prevent appendicitis or large intestinal cancer, to suppress cholesterol absorption and to clean the intestine.
While the present invention has been particularly shown and described with reference to particular examples thereof, it will be understood by those skilled in the art that various changes in form and details may be conceived therefrom without departing from the spirit and scope of the present invention as defined by the appended claims.
This application claims priority from the Korean Patent Application Nos. 10-2000-0026379 (filed May 17, 2000) and 10-2000-0049805 (filed Aug. 26, 2000), the contents of which are hereby incorporated by reference in their entirety, including the specification, drawings and claims.
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The present invention relates to microorganisms for the treatment or the prevention of obesity or diabetes mellitus, which reduce the amount of monosaccharide or disaccharide which may be absorbed into human body by converting monosaccharides such as glucose, fructose, galactose et al. and disaccharides into polymeric materials which cannot be absorbed by the intestine, and relates to a pharmaceutical composition containing the said microorganisms. Preferred microorganisms are Lactobacillus sp. BC-Y009 and Acetobacter sp. BC-Y058.
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TECHNICAL FIELD
The present invention is directed to the field of flame detection, particularly to a flame detection device for conducting flame detection as to a high-temperature and high-pressure furnace chamber under an explosive gas atmosphere.
BACKGROUND
A typical flame detection means at present includes a flame scanner or an industrial camera. Although flame scanners have advantages of high sensitivity and automaticity, there also exit several problems of “miss report, false report and peeking” or the like due to the complexity of the flame detection. Therefore, flame detection by combining an industrial camera with a flame detector could be employed on account of different conditions. A current flame scanner mainly includes an infrared flame scanner and an ultraviolet flame scanner. The infrared flame scanner is typically applied to detecting coal flame, while the ultraviolet flame scanner is typically applied to detecting gas flame and oil flame.
Most furnace burners nowadays adopt a multi-step ignition, and during different phases of the operation, the burning substance is changed. For example, some furnace burners ignite fuel gas or fuel oil and next boost pressure, and then introduce coal for normal operation. Since the characters of radiation spectrums of flames generated by burning different fuel are different, a single infrared or ultraviolet flame scanner cannot meet the requirements of flame detection as to the different operation phases of the burners. Typically, a solution to this problem is to install the infrared and ultraviolet flame scanners simultaneously. However, this will need a very large space to receive a plurality of flame detectors as well as their accessorial lines and conduits, which is rather difficult for those compact furnaces to provide such large spaces.
In addition, the currently used flame scanners and industrial cameras require relatively strict working environments on temperature and pressure. They typically require that the working temperature is below 70° C. and the working pressure is atmosphere or micro negative pressure, otherwise, failure of or damaged to the flame scanner occurs when going beyond above working environments. However, the current flame scanners have to directly face the gas environment inside the furnace chamber. For those high furnace temperature and pressure furnaces, in which the temperature could reach above 1000° C. and the furnace pressure would reach a magnitude of several MPa, the current flame scanners cannot meet the operation requirements under such a high temperature and pressure.
A flame detecting probe is disclosed in Chinese patent publication CN101398183A, which comprises a phototube, an anti-explosion junction cassette, a quartz glass sheet located between a cover for a phototube protecting sleeve and the phototube protecting sleeve, and a cooling venting passage for cooling the phototube and the quartz glass sheet. Such a flame detector probe is mounted inside the furnace chamber. Although the phototube is separated from the high temperature environment inside the furnace via the quartz glass sheet and the cooling venting passage is provided for cooling the phototube, the quartz glass sheet contacts directly with the environment inside the furnace such that the quartz glass sheet and thus the phototube is prone to be damaged by high temperature. Moreover, the furnace has to be shut down when such a flame detector probe is to be replaced.
SUMMARY OF THE INVENTION
The primary object of the present invention is to overcome the defects in the prior arts and to provide a flame detection device which is able to conduct flame detection as to a high temperature and pressure furnace and has a relatively long service life.
For the reason above, the present invention provides a flame detection device comprising a flame signal receiver, a flame signal passage and a flame signal transmitting mechanism; wherein the flame signal passage passes into an inner of a furnace through a furnace shell and comprises an outside-furnace passage portion and an inside-furnace passage portion; and wherein a pressure-resistant optical mechanism is arranged at an outermost end of the outside-furnace passage portion, said pressure-resistant optical mechanism hermetically and transparently separates the flame signal receiver from the flame signal passage.
Preferably, the inside-furnace passage portion comprises a cooling mechanism, which not only plays a role in preventing the inside-furnace passage portion from being damaged by the high temperature, but also could decrease the temperature of high-temperature gas which is from inner of the furnace before it gets into the outside-furnace passage portion of the flame signal passage such that the gas contacting with the pressure-resistant optical mechanism has a temperature lower than that inside the furnace, so as to increase the service life of the pressure-resistant optical mechanism. In the present invention, the cooling mechanism is configured to have a structure of multi-layer jacket or coil pipes which is provided with a coolant inlet and a coolant outlet. It should be appreciated that the cooling mechanism could be any suitable structure and the coolant may include water, gas or any other suitable fluid.
According to one aspect of the present invention, it is preferred that a protective gas inlet is provided on one side of the outside-furnace passage portion for introducing protective gas, such as inert gas, into said outside-furnace passage portion in order to further lower the temperature of the gas from the inside-furnace passage portion, so as to prevent the pressure-resistant optical mechanism from coming into exposedly contact with the high-temperature gas and thus to maintain a relative low temperature of the surface of the optical mechanism and to protect the surface from corrosion by the gas.
In order to improve the safety of the flame detection device and facilitate servicing and replacing the flame signal detector, a valve mechanism is also arranged between the pressure-resistant optical mechanism and the outside-furnace passage portion, which can be configured, upon opening, together with the flame signal passage and the pressure-resistant optical mechanism, to form a light passage through which the light is able to pass. It is preferred that the valve mechanism is a ball valve in the present invention, however, it is appreciated for those skilled in the art that any suitable valve mechanism which allows flame signals to pass through upon opening could be adopted. According to a preferred aspect of the present invention, the valve mechanism includes a pneumatic ball valve and a manually operated ball valve connected to the pneumatic ball valve. Furthermore, such a valve mechanism should guarantee that light can pass through when it opens and it can be rapidly closed or opened. Furthermore, it should also guarantee that the furnace chamber under the high temperature and pressure is sealed upon closing. Said valve mechanism should also endure the temperature and pressure involved.
Furthermore, in order to improve the safety of the flame detection device, it is preferred that a pressure-resistant protective enclosure which hermetically connects to the pressure-resistant optical mechanism is arranged outside of the flame signal receiver. In the event of damage to the pressure-resistant optical mechanism by accident, the pressure-resistant protective enclosure would keep the high-temperature gas, which is bursting out of the furnace chamber, from escaping out of the enclosure in order to gain time for further measures. It should be understood herein that the pressure-resistant protective enclosure could be any suitable protection mechanism as well known to those skilled in the art.
According to an aspect of the present invention, the flame signal receiver detachablely connects with the pressure-resistant optical mechanism by a joint, and the flame signal transmitting mechanism comprises a signal wire connected to the flame signal receiver and extending from an electric connector which is arranged on the pressure-resistant protective enclosure and is preferably capable of enduring high temperature and pressure. A flameproof enclosure which hermetically connects to the pressure-resistant protective enclosure is arranged on the outside of the electric connector, such that the flame detection device can be operated in an explosive gas atmosphere. Said flameproof enclosure can isolate the electric components from the external explosive gas atmosphere, such that the flame detection device can be used safely in the flammable and explosive gas environment, such as in a chemical plant or the like. It is appreciated for the person skilled in the art that both the electric connectors and the flameproof enclosures are well-known components in the art.
In the aspect, the electric connector can be configured as a plug-in structure having a male connector member and a female connector member. The signal wire extending from the flame signal receiver is attached to the female member on the inside of the pressure-resistant protective enclosure. The male connector member at one end is inserted in the female member and at the other end a cable is connected. The cable transmits electrical signals to a control system. The flameproof enclosure isolates the electric connector from the external explosive atmosphere, such that the electric sparks generated by the electric connector is prevented from igniting the external potentially explosive gas. It is further preferred that the combination of the pressure-resistant protective enclosure and the flameproof enclosure also could isolate the flame signal receiver from the external explosive gas atmosphere so as to prevent the electric sparks generated by the flame signal receiver from igniting the flammable and explosive gas in the external environment.
In an aspect of the present invention, the pressure-resistant optical mechanism includes a mounting flange, a compressing flange, and a transparent member and a sealing member which are arranged between the mounting flange and the compressing flange, such that the pressure-resistant optical mechanism is capable of hermetically and transparently separating the flame signal receiver from the flame signal passage. In this embodiment, the transparent member for example can be a quartz lens. It should be understood that, however, any kind of transparent material which has a certain level of resistance to heat and pressure can be used.
In addition, in the present invention, the flame signal receiver can be selected from one in the following group: an infrared/ultraviolet dual sensor flame scanner, an infrared flame scanner, an ultraviolet flame scanner or an industrial camera. Since such a flame detection device is arranged outside the high temperature and pressure environment in the furnace, the flame signal receiver can be easily detached without shutting down the furnace. Therefore, different flame signal receivers, such as the infrared/ultraviolet dual sensor flame scanner which can meet various detection requirements for combustion flames of different burning substances, such as coal-flame, gas-flame, oil-flame or the like, can be selected depending on the specific flame in the furnace. With respect to the burners employing a multi-step ignition, one such flame detection device can fulfill the detection task, such that the space for arranging the flame detection devices and the cost can be decreased.
The flame detection device according to the present invention is capable of conducting flame detection on a high temperature and pressure furnace chamber under an explosive gas atmosphere. Since such a flame detector is mounted outside the furnace, it also allows to select and to install an appropriate kind of flame detectors or industrial cameras depending on the specific conditions, so as to fulfill various flame detection requirements. Moreover, the flame signal receiver of such a flame detection device would not contact directly with the high temperature and pressure gas, thereby greatly increasing the service life and adaptability thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention would be explained in detail in the following description in conjunction with the attached drawings, in which the same reference number represents the same components, wherein:
FIG. 1 is a cross-sectional view of one embodiment of the flame detection device according to the present invention.
FIG. 2 is a cross-sectional view of another embodiment of the flame detection device according to the present invention.
REFERENCE NUMERALS LIST
1 —flame signal receiver
2 —joint
3 —compressing flange for transparent member
4 —transparent member
5 —packing
6 —gasket
7 —spacer
8 —mounting flange
9 —valve mechanism
9 a —pneumatic ball valve
9 b —manually operated ball valve
10 —pressure-resistant optical mechanism
11 —flame signal passage
11 a —the outside-furnace passage portion
11 b —the inside-furnace passage portion
12 —furnace shell
14 —pressure-resistant protective enclosure
15 —electric connector
16 —flameproof enclosure
17 —cable
17 a —signal wire
18 —protective gas inlet
19 —cooling mechanism
19 a —coolant inlet
19 b —coolant outlet
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an embodiment of the flame detection device according to the present invention which comprises a flame signal receiver 1 , a pressure-resistant optical mechanism 10 and a flame signal passage 11 . The pressure-resistant optical mechanism 10 includes a transparent member 4 , a mounting flange 8 and a compressing flange 3 . The transparent member 4 is placed into the mounting hole of the mounting flange 8 with spacers 7 being positioned on its upside and downside. A gasket 6 surrounding the transparent member 4 is also positioned in the mounting hole, and is filled with packing 5 (i.e., a temperature-resistant sealing member). In this embodiment, the compressing flange 3 and the mounting flange 8 is connected with each other, e.g., via bolts or the like, thereby sealing the pressure-resistant optical mechanism 10 by tightening the compressing flange 3 to jam the packing 5 .
In this embodiment, the flame signal receiver 1 is mounted on joint 2 , which is in turn mounted on the compressing flange 3 , and the mounting flange 8 finally attaches to a valve mechanism 9 via an adapter flange. Herein, the valve mechanism 9 preferably includes a pneumatic ball valve 9 a which is attached to the pressure-resistant optical mechanism 10 , and a manually operated ball valve 9 b which is attached to an outside-furnace passage portion 11 a of the flame signal passage 11 positioned on the furnace shell 12 . An inside-furnace passage portion 11 b of the flame signal passage 11 is positioned inside the furnace wall of the furnace shell 12 . It should be understood for those skilled in the art that, although the valve mechanism 9 is a ball valve in this embodiment, other types of valve mechanisms could be adopted as long as the valve mechanism on one hand allows the flame signals to pass through when it opens, and on the other hand it can be rapidly closed or opened if necessary, and also ensures that the high temperature and pressure furnace chamber is isolated when said valve mechanism closes meanwhile can endure working temperature and pressure involved.
It is advantageous that the inside-furnace passage portion 11 b further comprises a cooling mechanism 19 having a coolant inlet 19 a and a coolant outlet 19 b . In the present invention, the cooling mechanism 19 can be configured to have a structure of multi-layer jacket or coil pipes or any other suitable structure. In this embodiment, the coolant in cooling mechanism 19 is water. However, it could be appreciated for the person skilled in the art that, any suitable coolant, such as air, may provide a desired cooling effect, can also be used. The inside-furnace passage portion 11 b of the flame signal passage and the cooling mechanism herein can be made of a material that is resistant to the high temperature and corrosion. Such a cooling mechanism for cooling the inside-furnace passage portion not only prevents the inside-furnace passage portion from being damaged by the high temperature, but also decreases the temperature of high-temperature gas inside the furnace before the gas gets into the outside-furnace passage portion of the flame signal passage, such that gas contacts with the pressure-resistant optical mechanism in a lower temperature than that inside the furnace. As a result, the service life of the pressure-resistant optical mechanism is increased.
Preferably, in this embodiment a protective gas inlet 18 is positioned outside the passage portion 11 a , through which protective gas, such as inert gas, is fed into said outside-furnace passage portion 11 a in order to further cool down the high temperature gas from the inside-furnace passage portion and thus to prevent the transparent member 4 from contacting with the high temperature gas directly, such that the pressure-resistant optical mechanism 10 keeps at a relative lower temperature and is prevented from corrosion caused by gas as well. To achieve the effect of isolating the high temperature gas, the protective gas should be fed continuously. When feeding the protective gas, the flow rate and pressure of the protective gas should be controlled such that a portion of the protective gas is allowed to get into the furnace. In this case, the composition and flow rate of the protective gas on one hand should meet the requirements of protection, but on the other hand would have no obvious impact on normal reactions and the composition of the gas within the furnace. For example, the protective gas can be carbon dioxide or nitrogen depending on the products to be prepared. In this embodiment, the transparent member 4 is made from quartz glass which is not prone to be corroded by the gas. The primary function of the protective gas is to obstruct the high temperature gas from the furnace chamber. However, if other transparent materials are used, the protective gas also could advantageously protect them from corrosion.
In order to improve the safety of the flame detection device, a pressure-resistant protective enclosure 14 , which is hermetically connected to the mounting flange 8 for fixing the transparent member 4 , is arranged outside of the flame signal receiver 1 . In the event of transparent member 4 broken by an accident, the pressure-resistant protective enclosure 14 would hold the high-temperature gas which is bursting out of the furnace chamber, and avert the high-temperature gas escaping out of the enclosure in order to gain time for taking further measures. It should be understood for the person skilled in the art that the pressure-resistant protective enclosure could be any other suitable protection mechanism.
In this embodiment, a signal wire 17 a from the flame signal receiver 1 is led out the pressure-resistant protective enclosure 14 via an electric connector 15 . Herein, the electric connector 15 is configured as a plug-in structure having a male member and a female member. The signal wire 17 a from the flame signal receiver 1 is attached to the female member on the inside of the pressure-resistant protective enclosure 14 , the male connector member at one end is inserted in the female member and at the other end a cable 17 is led out for transmitting electric signals to the control system. For the operation of flame detection device in an explosive gas atmosphere, a flameproof enclosure 16 is arranged outside and encloses the electric connector 15 . The flameproof enclosure is fixedly attached to the outer wall of the pressure-resistant protective enclosure 14 , e.g. by means of welding or the like, and the cable 17 extends from the top of the flameproof enclosure 16 . Moreover, the combination of the pressure-resistant protective enclosure 14 and the flameproof enclosure 16 also could isolate the flame signal receiver 1 from the external explosive gas atmosphere so as to prevent the electric sparks potentially generated by the flame signal receiver 1 from igniting the flammable and explosive gas in the external environment.
In addition, since the flame detection device in the present invention is arranged outside the furnace, this facilitates the detachment and replacement of the flame signal receiver 1 . In this embodiment, the flame signal receiver 1 is an infrared/ultraviolet dual sensor flame scanner so as to meet the detection requirements for different burning substance, such as coal-flame, gas-flame, oil-flame or the like. With respect to burners employing the manner of multi-step ignition, one such flame detection device can fulfill the detecting task, which will save the space for receiving the flame detection devices and thus cut down the cost. However, depending on the specific applications, it is possible to select any of one from the following group: an infrared/ultraviolet dual sensor flame scanner, an infrared flame scanner, an ultraviolet flame scanner or an industrial camera
The operation of the flame detection device of the present invention will be described in detail as follows: during the running of the boiler or gasifier, if there is a need to conduct a flame detection, an operator will open the pneumatic ball valve 9 a and the manually operated ball valve 9 b in sequence, and start the working of the cooling mechanism 19 ; wherein a cooling water is supplied through the coolant inlet 19 a , and outflows from the coolant outlet 19 b to provide cooling protection for the inside-furnace passage portion 11 b of the flame signal passage 11 . Meanwhile, an inert gas through the protective gas inlet 18 is introduced to provide protection for the pressure-resistant optical mechanism 10 , particularly for the transparent member 4 . The flame radiation signals in the furnace chamber received by the inside-furnace passage portion 11 b of the flame signal passage 11 pass through the inside-furnace flame passage portion 11 b , the outside-furnace flame passage portion 11 a , the manually operated ball valve 9 b and the pneumatic ball valve 9 a as well as the transparent member 4 in sequence and then are received by the flame signal receiver 1 . After processed by the flame signal receiver 1 , the received flame radiation signals are transmitted out of the pressure-resistant protective enclosure 14 by the signal wire 17 a and the electric connector 15 and then to a post-processing system or safety system via the cable 17 extending through the flameproof enclosure 16 . When the boiler runs stably or stops, the manually operated ball valve 9 b and the pneumatic ball valve 9 a are closed in sequence.
FIG. 2 illustrates another embodiment of the flame detection device, the main structure of which is same as that of the preceding embodiment except that the electric connector 15 and the flameproof enclosure 16 are arranged on a side of the pressure-resistant protective enclosure 14 .
In the flame detection device mentioned above, if there is a damage to the transparent member 4 by accident, which will cause a leakage of the high temperature and pressure gas, the sealing system formed of the pressure-resistant protective enclosure 14 and the electric connector 15 will restrict the high temperature and pressure gas from the furnace chamber within the pressure-resistant protective enclosure 14 . At this moment, there need to emergently close the pneumatic valve 9 a for following emergency measures. Furthermore, the two combined valves make it possible that the valves could be closed rapidly when flame detection is finished or other critical situations occur, so as to improve safety of the entire device. In addition, the use of the high temperature- and pressure-resistant electric connector and the flameproof enclosure isolates the electrical components from the external explosive gas atmosphere, which enables the flame detection device to be used in the flammable and explosive gas environment such as in chemical plants or the like.
The present invention has been generalized and described in detail via embodiments. It should be understood for those skilled in the art that the present invention is not limited to these exemplary embodiments. There would be various alterations and modifications made within the spirit and scope of the present invention as defined by the claims or any equivalents thereof.
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The present invention is directed to a flame detection device comprising a flame signal receiver ( 1 ), a flame signal passage ( 11 ) and a flame signal transmitting mechanism, characterized in that, the flame signal passage ( 11 ) passes through a furnace shell ( 12 ) into inner of the furnace and comprises an outside-furnace passage portion ( 11 a ) and an inside-furnace passage portion ( 11 b ); wherein a pressure-resistant optical mechanism ( 10 ) is arranged at the outermost end of the outside-furnace passage portion, said pressure-resistant optical mechanism hermetically and transparently separate the flame signal receiver from the flame signal passage; and wherein the inside-furnace passage portion ( 11 b ) is provided with a cooling mechanism ( 19 ). Such a flame detection device is to be arranged on a furnace shell, and it could not only conduct a flame detection on the furnace under high temperature and high pressure, but also has a selection of the proper flame signal receivers installed for different stages of operation as desired.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] None applicable
REFERENCES TO SEQUENCE LISTINGS, TABLES OR COMPUTERS
[0003] None
PROGRAM LISTINGS, COMPACT DISK APPENDIX
[0004] None
BACKGROUND OF THE INVENTION
[0005] In recent years people with antisocial aberrations have undertaken lethal hijackings of aircraft resulting in severe losses of life and property. Among the solutions to this problem which have been advanced are strengthened physical security at airports, various baggage security techniques, the introduction of armed air marshals on flights, arming of pilots, and strengthening of cockpit doors. The latter procedure has proven effective in incidents which have occurred since the recent emphasis on the process of “hardening” aircraft doors, but it is apparent that the brute force solution of requiring a plurality of iron bars to be built into the doors for hardening, while effective against a frontal assault, does not protect against missiles tossed into the cockpit, and adds an undesirable amount of unproductive weight to the aircraft, inhibiting performance and reducing the potential payload.
DISCUSSION OF THE PRIOR ART
[0006] Security doors and cells (robber traps) are well known in the patent literature with respect to static structures such as financial and retail institutions, with variations on the theme of two remotely controlled lockable doors, or revolving doors which lock in position to prevent a robber's escape. Given terrestrial installation, the design of such cells is usually dominated by commercial considerations to disguise the cell to appear as open and inviting as possible so as not to discourage the entry of the general public who wish to do business with the establishment. Precluding claustrophobia is a major terrestrial design consideration since the very idea of a security cell tends to inhibit people from coming through the cell on their way into a store or bank. Illustrative of the terrestrial security cylindrical cell art, see U.S. Pat. No. 6,073,394, to Uhl, and U.S. Pat. No. 5,181,018, to Cowie.
SUMMARY OF THE INVENTION
[0007] This invention relates to a cylindrical module which may be retrofit into the passageway of an aircraft which communicates between the cockpit and the passenger cabin. The cylindrical module, installed as fixed to the aircraft structure, is provided with two apertures, one facing into the cockpit and the other facing into the passenger cabin. A pair of arcuate doors (i.e. arcuate conformably to the cylindrical arc of the module) are slidably mounted into the apertures on tracks and are connected to remotely-controlled driving means which enable the doors to slide back along the cylinder walls. The doors are normally closed. In operation the captain of the aircraft in the cockpit opens the aft door from the passenger cabin in response to a request from a candidate for entrance, whereupon the candidate enters the interior of the cylindrical module and the aft door closes behind the candidate. The module would be equipped with a variety of readers, sensors and detectors to examine the candidate for identity and absence of weapons. When the captain is content that the candidate has cockpit business and is authorized for entry, the forward door is opened and the candidate is permitted to enter the secure cockpit.
[0008] Transplanting the security cell into an aircraft presents a number of special considerations. Unlike the terrestrial application, the weight of the airborne security cell must be carried for the entire duration of flight as a continuing drain on the power supplied by the aircraft engines, so it must be lightweight. Space is at a premium since the aircraft has already been designed and configured to use virtually all the space between the cockpit and the passenger cabin, so a retrofit module must be capable of fitting into a narrow, predetermined space and shape. Crew are themselves chosen in part for their compact size and shape and are typically subject to weight limits. It is desirable that the chamber defined by the cylinder be small enough to admit only one person at a time, thereby discouraging hostage taking and contributing to the compactness of the design. Even for aircraft designs with ample space in the passageway to the cockpit, it is preferred that the cylindrical security module of our invention be kept small enough to permit passage through the cell of only one person at a time. The aircraft may be operated in abnormal attitudes so the direction of verticality may be, or seem to be, displaced. Even in normal operations, the mechanisms of the cell may be subjected to abnormal gravitational, centrifugal and centripetal forces, but they must nevertheless continue to work effectively and without delays. Finally, given the rigors of aircraft operation, failure of the security system cannot be tolerated and hence immediately-operable manual overrides must be provided to permit prompt ingress and egress.
[0009] Thus it is an object of this invention to provide an easily retrofittable module for effective secure access control for aircraft cockpits.
[0010] It is a further object of this invention to provide a security module for aircraft which has simple and uncomplicated design and construction.
[0011] It is a further object of this invention to provide a lightweight security module for use in aircraft.
[0012] It is a further object of this invention to provide a security module for aircraft with minimal to moderate power consumption requirements.
[0013] It is a further object of this invention to provide a security cell for aircraft which fits into space which is available within the existing configuration of the aircraft.
[0014] It is a further object of this invention to provide a security cell for aircraft which blocks line-of-sight openings between the cockpit and the passenger cabin during operation of the aircraft.
[0015] It is a further object of this invention to provide a security cell for aircraft which, although small enough to be retrofit, nevertheless offers ample space for readers, sensors and detectors to test the acceptability of a candidate who presents for admission.
[0016] It is a further object of this invention to provide a security cell for aircraft, which adapts proven security techniques and design considerations for airborne use.
[0017] It is a further object of this invention to provide a security cell for use in aircraft which can be relied upon to be operable despite being subjected to abnormal gravitational, centripetal or centrifugal forces.
[0018] It is a further object of this invention to provide a power operated airborne security cell which has manual override features to permit quick and convenient egress in case of power failure.
[0019] It is a further object of this invention to provide a retrofittable aircraft security module which, when designed for retrofit into a specific aircraft model, can be quickly installed during routine maintenance so as to minimize the time delay in getting the aircraft back into service.
[0020] It is a further object of this invention to provide a security module for aircraft made from bullet-resistant materials and which is resistant to other forms of mechanical attack.
[0021] It is a further object of this invention to provide a cylindrical airborne security module with rack and pinion drive means for selectively and smoothly driving arcuate doors for opening and closing access apertures in the cylindrical module.
[0022] It is a further object of this invention to provide a cylindrical security module for aircraft which may serve as an entrapment mechanism for hijackers seeking entry to the cockpit, and which is tamper resistant to preclude escape of a hijacker so entrapped.
[0023] It is a further object of this invention to provide a security module for airborne application which is readily and easily serviceable by maintenance and security personnel.
[0024] It is a further object of this invention to provide an airborne security module with identification and testing means, of sufficiently small size as to preclude easy admission to the interior of the module by more than one person at a time.
[0025] Those skilled in the art will readily appreciate that many of the substantial and distinguishable structural functional abilities and advantages disclosed herein represent significant advances over the prior art and that individual features disclosed herein may be applicable in the field of secure access control for ground applications as well as for airborne applications.
[0026] The foregoing and other objects of the invention can be achieved with the present invention, device and system which is a cell door system principally for aircraft security.
[0027] The invention, in a broad sense, is provided as a security cell system having mechanical drive means, two door panels and a selectively operable geared disconnect assembly, for engaging and disengaging the door panels in relation to the drive means; therefore providing respective opening and closing movements along a displacement path and selective access to the cockpit secured area. The invention may be installed and utilized in an aircraft, or similar, structure, such as an adjacent or proximately located support structure for an aircraft of other structure close to or for use while servicing an airplane.
[0028] The security cell system is provided with a cylindrical containment cell area having two substantially parallel partitioned inner compartment walls that form a short internal hallway between the two arcuate sliding door panels. The door panels are secured in place between two semicircular grooved tracks, one such grooved track that supports the bottom of both door panels while the other grooved track secures the tops of the door panels. The tracks may be thought of as circular for convenience only, since they might as easily be two semicircular tracks, each of which permits excursion of a door panel through a 180° arc, and there is no need for the two semicircular track sections to be coextensive as a 360° circle, nor that the two semicircular track members share a common central axis. The bottom ends and the top ends of the two arcuate doors are v-shaped along the curved surface to match the grooves in the (semi-) circular tracks, the upper track and the lower tracks having substantially the same arcuate radii as the corresponding door panels.
[0029] The doors 14 are fabricated preferably from bullet-resistant material such as Kevlar™ or other lightweight, composite, bullet-resistant material, to preclude attempts to deliver bullets or other missiles from the passenger cabin into the cockpit.
[0030] Each of the two door panels is provided with one lower arcuate rack and one upper arcuate rack attached to the inside of each door. Each door is provided with a long, vertical shaft having upper and lower pinions mounted thereon to mesh with the lower and upper arcuate racks for driving the doors respectively to their open and closed positions. The vertical shaft, with pinions, is provided to assure that the doors are driven at both the top and bottom for even driving pressure to prevent the doors from binding in the course of their opening/closing excursions. Reference here to vertical, top, or bottom, assumes the cell, and the aircraft, are at rest on the ground. Since, in flight, the cell will be in whatever attitude the aircraft is in, the G forces acting on the cell and its components, may be varied and strong.
[0031] The interior of the security cell has substantially parallel sides, substantially flat panels which extend generally from the top of the interior chamber to the bottom. A top down cutaway view would show that the inside of the flat panels define a chamber, or an equipment bay, with the inside wall of the module, and within the equipment bay, an assortment of readers, sensors and detectors may be installed, as well as an array of gas dispensers, electronic stun apparatus, or other means for subduing a hijacker. The vertical shafts which carry the pinions which drive the doors to their open and closed positions, are also concealed behind these flat panels.
[0032] The opening and closing power derives from small electric motors powered by the aircraft's electric power system, and mounted advantageously in a ceiling chamber of the module. The power is transmitted to the drive shaft through a power train which includes a worm gear, an arrangement which is very difficult to reverse, and thereby making the system virtually impervious to attempts by the person inside the cell to open or reopen the door once inside by pushing on the door. The door is smoothly formed, precluding handholds which might give purchase in an attempt to move the door sideways. The module has therefore additional utility in being useful as a detainment cell pending landing of the aircraft so that the inhabitant of the cell can be turned over to ground security personnel.
[0033] The module may be further arranged to keep at least one of the doors closed at all times while the aircraft is in operating mode, i.e., loading, taxiing, flying, landing, and unloading. This feature prevents an attacker from having an opportunity to present missiles, e.g., bombs, explosives, gas canisters, gunfire or other hazardous items from being thrown or delivered from the passenger compartment into the cockpit during critical moments in the operation of the aircraft.
[0034] The pilot has total control of the security module, as all control mechanisms are operable solely from the cockpit, including emergency releases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 : A plan view of the front section of an aircraft giving an overall view of how a security module after our invention would be retrofit into the passageway between the cockpit and the passenger cabin of an aircraft.
[0036] FIG. 2 . Enlarged view of the center portion of FIG. 1 , showing a cross section of our module with both doors closed and a candidate for admission approaching the rear door of the module.
[0037] FIG. 3 . Same as FIG. 2 , but the rear door has opened and the candidate has taken station inside the module.
[0038] FIG. 4 . Same as FIG. 3 , but the rear door has closed around the candidate.
[0039] FIG. 5 . Cutaway cross section side view showing the motor, drive shaft, disengagement lift, upper track, door with upper arcuate rack engaged with the upper pinion, and in the lower portion of the drawing, the lower part of the door with the lower arcuate rack engaged with the lower pinion, and the lower track.
[0040] FIG. 6 . An enlarged portion of the upper part of FIG. 5 showing the driver clutch lifted out of engagement with drive shaft.
[0041] FIG. 7 ( a ) Vertical section through the emergency door release showing the spline sleeve coupling fully engaged with the lower shaft gear for normal operation.
[0042] FIG. 7 ( b ) Similar to (a) but with the spline sleeve coupling raised to disengage from the lower shaft gear, leaving the doors free to rotate for manual operation in emergency door release mode.
[0043] FIG. 7 ( c ) Horizontal section of FIGS. 5 and 6 showing the lifting fork which disengages the spline sleeve coupling from the lower shaft gear.
[0044] FIG. 7 ( d ) Detail of spline sleeve coupling shown in vertical and horizontal cross section.
[0045] FIG. 7 ( e ) Detail of the drive line components from the upper drive shaft to the lower drive shaft showing the respective parts which achieve smooth engagement/disengagement of the drive mechanism.
[0046] FIG. 8 . Illustration of a candidate inside the module with both doors closed, waiting for the cockpit (forward) access door to be opened for admission into the secure cockpit space.
[0047] FIG. 9 Horizontal section showing the configuration of the left and right door frames when the door is closed.
[0048] FIG. 10 . Horizontal section showing the floor plate. Both doors are shown partly open for clarity, but in practice at least one door would be fully closed while the aircraft is operational.
[0049] FIG. 11 . Horizontal section with the top cover plate removed, showing the location of the two drive motors and the emergency manual door release cables, which are controllable solely from the secure portion of the aircraft.
[0050] FIG. 12 . Like FIG. 10 , but with cutouts showing the lower drive pinions engaged with the arcuate racks on the lower edge of the doors. One door is shown partly open for clarity.
[0051] FIG. 13 . Horizontal section of the sub floor plate, beneath the floor plate shown in FIG. 10 . Shows the bearing assemblies which support the long vertical drive shafts. Also shows the central support members provided for stability of the unit in its connection to the floor of the aircraft.
[0052] FIG. 14 . Vertical schematic sectional view (not to scale) through the security module showing the general juxtaposition of the respective major portions of the module.
[0053] FIG. 15 . Schematic diagram of the electrical control system of the security module.
[0054] FIG. 16 . Horizontal section illustrating a single door version of the security module in open and closed positions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0055] The retrofittable security door module of our invention is preferably installed in the passageway between the cockpit and the passenger cabin of an airliner as shown in FIG. 1 .
[0056] The module is attached to the aircraft by custom brackets, or even wall sections 53 which are fabricated as necessary to interface with a particular aircraft configuration. These brackets will typically be consistent over a plurality of individual aircraft of the same model, thereby affording a measure of repetitivity in manufacturing of the brackets. Other components of the module are designed to be interchangeable over substantially all aircraft into which they might be installed.
[0057] In operation, a candidate 56 for admission to the cockpit, is shown in FIG. 2 approaching the security module rear door 14 . The candidate 56 is admitted to the module when a pilot activates the control which opens the arcuate door 14 , causing the door 14 to be driven into a recess between in inner and outer walls of the module, permitting the candidate 56 to enter the module, as seen in FIG. 3 . Once inside the module, the door 14 closes, as shown in FIG. 4 . While enclosed in the module, the candidate may be examined by a plurality of instruments which are installed in the equipment bays 51 . These may include video, card readers, retina scanners, magnetic weapons detectors, fingerprint readers, and such other scanning and reading devices as may be appropriate for identification and authentication of the candidate 56 , or as might be required to fulfill the security protocols of the organization which operates the aircraft. In addition to identification apparatus, the equipment bays may contain apparatus for gaseous discharges or electronic stun equipment for disabling the candidate 56 if that person should prove to be an attacker.
[0058] With reference now to FIG. 5 , it may be seen that the doors 14 are held in place between upper 15 door frame guides and lower 44 door frames. Both the frame members 15 and 44 are provided with V-shaped edges which are cooperatively positioned into the inverted V-shapes formed in the upper 16 and lower 45 track members and are rollably separated from them by the bearings 36 .
[0059] The lower frame member 44 is provided with a groove into which the closure plate 43 fits to provide a loose seal sufficient to prevent substantial particles from falling through into the track and drive mechanisms below.
[0060] Both the door frames 15 and 45 are provided with arcuate rack sections 1 conforming to the arcuate shape of the doors 14 . The rack sections 1 are meshed cooperatively with pinion gears 2 which are mounted respectively at the upper and lower portions of drive shaft 3 , at locations which are respectively above the ceiling and below the floor of the candidate reception chamber. Drive shafts 3 are held in position at the upper end by stabilizing bearings 33 which are attached to the upper door tracks 16 , and are held at the lower end by the bearing assemblies 38 which are attached to the base of the module.
[0061] Colinear with each lower drive shaft 3 and above it, are upper drive shafts 4 , driven by a worm 26 and worm gear arrangement powered by motors 5 . The upper drive shaft 4 is held in decoupleable engagement with the lower drive shafts 3 by springs 7 and splines 10 . The decoupling mechanisms will be explained in greater detail below with respect to FIG. 7 ( a ) to ( e ). The decoupling mechanism is activated in the absence of power by the manually operated release cable 19 , or if power is available by the door release cable 20 which operates the solenoid 21 .
[0062] FIG. 6 shows the upper part of the same sectional view as FIG. 5 , but the mechanism is in reaction to a power-on door release signal. Upon receipt of an electrical charge delivered through the electric cable 20 , solenoid 21 is activated, drawing the shift fork sleeve 25 upward along the shift fork sleeve shaft 22 and carrying the shift fork 9 upward to lift the spline sleeve coupling 10 up and clear of the lower shaft gear 13 , thereby leaving the lower drive shaft 3 free to turn and permitting the door to slide freely to any desired position. The shaft 22 and solenoid 21 are securely affixed to the support bracket 23 which is secured to the exterior wall 17 . Also held by the bracket 23 is the sleeve 27 which guides the travel of the shift fork sleeve shaft 22 . The solenoid 21 is held in its normal position, when not activated, by the spring 24 .
[0063] Alternatively, manual activation of the release cable 19 can draw the lifting fork 9 upward to achieve disengagement of the spline sleeve coupling 10 from the lower shaft gear 13 , with the same result.
[0064] It may be seen in FIG. 7 ( a ) that when operationally coupled together, collinear drive shafts 3 and 4 are connected by means of the upper shaft gear 11 which is attached to shaft 4 to rotate as shaft 4 rotates. When coupled, shaft 4 is received in the lower shaft gear 13 by the pilot bearing 32 . The upper shaft gear 11 is attached to the spline sleeve coupling 10 and the splines of the coupling 10 fit down over the teeth of the lower shaft gear 13 . As seen in FIG. 7 ( b ), when the lifting fork 9 raises the spline sleeve coupling 10 to disengage from the lower shaft gear 13 , the coupling connection between the upper drive shaft 4 and the lower drive shaft 3 is broken and the associated door 14 is free to move.
[0065] Operation of the lifting fork 9 is best understood with reference to FIG. 7 ( c ) where the fork 9 is engaged with the coupling sleeve 10 . The fork 9 is carried by the hollow square cross sectioned shift fork sleeve 25 which rides on the shift fork sleeve shaft 22 , separated from it on all four sides by the sleeve bushing 28 .
[0066] The spline sleeve coupling 10 is illustrated in FIG. 7 ( d ), where the coupling 10 holds the spring retainer 6 and the bumper rings 8 are provided to form a groove to securely receive the lifting fork 9 .
[0067] In FIG. 7 ( e ) the arrangement for driveable connection between drive shafts 4 and 3 is illustrated. Note from comparison of FIGS. 7 ( a ) (engaged) and 7 ( b ) (disengaged), the shafts 3 and 4 are in collinear, tandem juxtaposition, and the engagement is achieved through the spline sleeve 10 which is moved up to disengage and down to engage. Even when disengaged, the shaft 4 spins fruitlessly in the pilot bearing 32 which is secured within the lower shaft gear 13 to maintain the colinearity between the shafts 3 and 4 .
[0068] FIG. 8 shows a candidate for admission to the cockpit secure area standing in the interior of the security cell with orientation arrows identifying the location of the cross sectional view of FIG. 9 . The arcuate doors are shown for convenience in FIG. 9 as thought they were planar rather than arcuate. The doors 14 fit into a door frame 47 . When fully driven to the end of its excursion, the door frame, comprising an after section 47 and leading section 54 , which is shaped to complement the shape of the door stop 50 , comes to rest against the door stop 50 . The door frame 47 is lightly in contact with door spacer 49 which is adhered to the exterior cylinder wall 17 on one side, and is similarly lightly in contact with the angle door spacer 48 on the other side. The angle door spacer 48 is adhered on one side to the intermediate wall 46 and on the other to the interior wall panel 41 . It may be seen that the interior wall panel 41 defines a cavity in which the lower drive shaft 3 is enclosed.
[0069] With reference now to FIG. 14 , it may be seen that the next series of drawings, FIGS. 10, 11 , 12 , and 13 , are cross sections of the module of our invention at the respective levels and from the respective directions therein indicated.
[0070] FIG. 10 is a cross section through the lower central portion of the security module looking down. The doors 14 are shown in their true arcuate configuration, and are depicted partially open for clarity. It will be appreciated that while the aircraft is in operation at least one of the doors 14 will be in the closed position at all times. The doors 14 are driven into and out of the recessed pockets which are defined between the exterior walls 17 and the intermediate walls 46 , by the rack and pinion arrangement previously discussed, under the positive drive forces transmitted through the lower drive shaft 3 . The interior walls 41 define the equipment bays 51 in which may be mounted such readers, sensors, detectors, dispensers and other security apparatus as may be chosen for the security design of the aircraft owner.
[0071] FIG. 11 is the view down upon the ceiling plate 52 , showing the motors 5 which, through a worm mechanism, drive the pinions 2 to activate the racks 1 which are attached to the doors 14 so as to propel them along their respective tracks in their excursion from fully closed (as is the door at the top of FIG. 11 ) through a partially open position (as is the door at the bottom of FIG. 11 ) to the fully open position when the door 14 is drawn to its maximum extent into the recess defined between the outer wall 17 and the intermediate wall 46 . Also shown in FIG. 11 are the door stops 50 and the manual emergency release cables 19 .
[0072] FIG. 12 is the view down on the floor plate 39 with part of the plate 39 cut away to show the lower drive shaft 3 carrying the lower pinion 2 which is engaged with the lower rack section 1 for driving the doors. The cut away view also shows the sub floor plate 37 and the floor support channel 40 , which supports part of the floor plate 39 .
[0073] FIG. 13 provides a view down upon the sub floor plate 37 showing the bearings 38 which support the lower drive shafts 3 . The sub floor plate 37 is also supported by the floor support channel 40 and the floor support plates 55 .
[0074] FIG. 14 provides a diagrammatic cross section, not to scale, of the cell fully assembled. From top to bottom, we see the top cover plate 18 , the interior ceiling 52 , the floor plate 39 and the sub floor plate 37 . The door 14 is held in a frame 47 ( FIG. 9 ) which has arcuate upper 15 and lower 44 members, and to which are attached the rack sections 1 . The upper portion of the arcuate upper frame member 15 is V-shaped to fit cooperatively with the inverted V of the arcuate upper track 16 , while the lower portion of the arcuate lower frame member 44 , is similarly V-shaped to fit cooperatively with the inverted V of the arcuate lower track 45 . The frame members and track members are separated by small bearings 36 ( FIG. 5 ) for smooth, positive movement throughout the excursions of the doors 14 .
[0075] FIG. 15 is an illustration of the Door Control Panel and Related Circuitry. The two push button switch for O 1 , 102 , (Open first door), C 1 , 104 , (Close first door), is a unit with two single contacts designed to operate alternately from close door to open door and vice-versa, contacts are normally open. The two push button switch for O 2 , 106 , (open second door) and C 2 , 108 , (close second door) is similar. The “E” Emergency control, 110 , is DPDT with normally closed contacts that are in series with the two closed door solenoids C 1 , 112 , and C 2 , 114 . It has a large push button and when pressed in, will lock in, in the on position, for both doors to fully open until the Door Limit Switches, 116 , 118 , are contacted. The emergency switch is released by a slight turn of the button and it returns to normal position. This also reconnects the circuit so the doors can be closed. Arrows, 120 , 122 , indicate the direction for the doors to close. The emergency button is protected with a hinged cap lid designed to prevent accidental emergency button engagement.
[0076] The On-Off switch, 124 , is a DPST which activates solenoid “P”, 126 , that connects current to the door motor controls. Each door has 3 limit switches. Two are SPST and one is DPST. The DPST D 1 LO, 128 , and D 2 LO, 130 , are for limiting door opening travel and individual door circuitry. The SPST D 1 LC, 132 , and D 2 LC, 134 , are for limiting the door closing travel. The other SPST switches, 136 , 138 , are close tolerance to the door opening preventing the other door from opening when one door is already open.
[0077] Except for the emergency switch, all push buttons are below the panel surface to inhibit accidental activation. Fuses or circuit breakers, 140 , 142 , are provided for Line 1 and similar mechanisms, 144 , 146 , are provided for Line 2 and also for the solenoid circuitry. Door motors M 1 , 148 , and M 2 , 150 , are reversible by the O 1 , 152 , and C 1 , 112 , and 02 , 154 , and C 2 , 114 , solenoids. These motor controls are interlocking so that only one set of contacts at a time can close. No part of the circuitry is dependent upon any particular gravitational angle so that the door controls remain operable irrespective of G forces acting upon the aircraft.
[0078] FIGS. 16 ( a ) and ( b ) respectively show a single door version of our invention in the closed FIG. 16 ( a ) and in one of the open FIG. 16 ( b ) positions. As shown, the door 14 extends through 270° of arc, whereas each of the two doors 14 as illustrated at FIGS. 2, 3 , 10 , 11 , and 12 , extend only through substantially 90° of arc. The exterior cylinder wall 17 is provided with two apertures in the same way as the two-door version above described, but the controls are arranged to drive the door 14 to three different positions: open to the cockpit, FIG. 16 ( a ), closed, FIG. 16 ( b ), and open to the cabin which is like FIG. 16 ( a ) but with the door 14 rotated 180° from the position shown in FIG. 16 ( a ). To admit a candidate, the door would be rotated so as to be open to the cabin, the candidate would enter the interior of the module and the door would be rotated to the closed position as shown in FIG. 16 ( b ). After satisfactory examination of the candidate, the door would be rotated to the cockpit-open position and the candidate would be admitted to the cockpit.
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A generally cylindrical security door module is designed for retrofit into the passageway of an aircraft leading to the cockpit. Two doors, forward and aft, are provided which are mounted for opening and closing upon commands emanating from the cockpit. Both doors are normally closed and only one normally opens at a time. A candidate for entrance to the cockpit is permitted to enter the module when the cockpit personnel open the aft door, which is then closed. Sensing apparatus may be employed to establish the identity and clearance of the candidate. Upon approval, the cockpit personnel open the forward door to admit the candidate. Emergency release apparatus is also described.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of U.S. provisional application 61/724,942 filed on Nov. 10, 2012 which is incorporated by reference herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] This invention describes structural elements comprised of functionalized material in a rapidly setting resin.
DESCRIPTION OF RELATED ART
[0004] Rapidly deployable structures for military and civilian use typically are in the form of tents and structures that provide minimal protection from enemy or natural forces. These temporary or permanent structures are typically time demanding to assemble and do not provide much protection for personnel and equipment. More protective structures are constructed from difficult to transport materials such as concrete and steel, and these are labor intensive and expensive to build.
SUMMARY OF THE INVENTION
[0005] This invention is rapidly deployable structures that provide ballistic and impact resistance. The structures are fabricated using specific molds that shape a specific rapid cure resin-filler mixture. The fillers are typically sand, silica, ceramic, silica fume, silica flower, nano powders, metal fibers, plastic fibers, Kevlar fabrics and the like, that are plasma functionalized. Plasma functionalization or activation involves subjecting the filler to a high power atmospheric pressure plasma to remove weak boundary layers and improve the adhesion properties of the surface and opening the pores. When blended with the proper resin, the resultant composite structure is extremely tough. For this invention, a preferred resin is pDCPD (poly-Dicyclopentadiene). pDCPD has exceptional toughness, is about 25% lighter than typical epoxies and has good ballistic penetration resistance. Any resin of interest also should have a low viscosity, catalyze quickly and be nano-sized to fit into places where longer chain polymers cannot.
[0006] In a preferred embodiment, the resin and functionalized filler are blended together and a catalyst added and the mixture is pumped into a bladder that acts as a mold for the structure. The filler could be made from material found at the site, such as silica sand, or from a wide variety of materials that can be selected based upon their mechanical properties and ability to be functionalized by the plasma. The catalyst and amount of catalyst used is selected carefully such that is provides a rapid cure, but without causing an overly exothermic reaction. In addition, the bladders or molds used must be made of a material compatible with the catalyst.
[0007] In one embodiment, the filled nano-resin composite is used to fill bladders that act as molds for structural components arranged as ballistic or impact resistant shelters. In a preferred embodiment, the bladder molds are made of ripstop nylon coated urethane or rigid pre-cast molds. In a preferred embodiment, the bladders are further supported and separated by wall dividers that the bladders are hot welded to maintain their shape without ballooning and structural integrity while the resin is curing. In another embodiment, these structural components are further arranged with high performance concrete and optionally woven polypropylene to provide for even greater ballistic protection. In a further configuration, thermal insulation is interspersed with the structural components. In another embodiment, the filled nano-resin composite is used as protective surface material for a balloon antenna or air ship in a ball in ball configuration. In a preferred embodiment, the ball inside a ball is configured with two bladders, where the inner bladder is filled with air and the outer bladder contains the resin composite with resin, concrete or a foam material. An electric control valve and bleeder valve connect the interior air filled chamber with the exterior.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] While some embodiments of this invention describe a unique mixture of resin and a functionalized filler, the drawings are used to demonstrate the embodiments of this invention in which the resin-filler composite is used for structural applications.
[0009] Drawing 1 shows tubular wall channels.
[0010] Drawing 2 shows dividers and joints in tubular channels.
[0011] Drawing 3 shows a half dome constructed of tubular channels.
[0012] Drawing 4 shows a sphere constructed of tubular channels.
[0013] Drawing 5 shows double wall dividers in tubular channels.
[0014] Drawing 6 shows a stack of divided tubular channels.
[0015] Drawing 7 is another configuration of stacked divided tubular channels.
[0016] Drawing 8 is a frame of a structure constructed of tubular channels.
[0017] Drawing 9 shows walls covering a tubular channel frame.
[0018] Drawing 10 is the exterior view of the shelter of Drawing 9 .
[0019] Drawing 11 shows a configuration of offset channels of a structural member.
[0020] Drawing 12 is a cross-section view of Drawing 11 .
[0021] Drawing 13 shows the stacking of the structural members of Drawing 11 .
[0022] Drawing 14 is a ball mold for a spherical structure.
[0023] Drawing 15 is the detail of the valve and wall configuration of the ball mold.
[0024] Drawing 16 shows the structure of Drawing 13 as configured for ballistic protection.
[0025] Drawing 17 is a zig zag sheet of composite material
[0026] Drawing 18 is stacked zig zag sheets
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] In FIG. 1 , the bladder used as a mold for the composite is stiffened and the segments separated by stiff polymer dividers. The bladder material, which may be comprised of ripstop nylon coated urethane, are welded to the dividers. The dividers are not meant to keep the segments contents separated but just to provide structural stiffness and thus they are perforated to prevent the bag from ballooning. FIG. 2 shows a close up view of the divider and the bladder wall.
[0028] FIG. 3 shows a configuration in which the molds are used to make cylindrical segments that are curved and arranged to form a half dome structure. This structure can be a rapidly deployed structure to protect men or materials. FIG. 4 shows the further use of the cylindrical segments as arranged in a full spherical configuration.
[0029] For greater stiffness, double wall dividers can be used and shown in FIG. 5 . The cylindrical segments are typically constructed as a series of segments and these series could be stacked as shown in FIG. 6 for additional protection. FIG. 7 shows how the stacked series could also be interspersed with thermal insulation segments and that concrete or resin could be used to fill some segments instead of a composite if desired.
[0030] The cylindrical segments could also be used as structural beams. FIG. 8 shows these beams arranged as a frame for a rapidly deployable structure. In a cutaway view, FIG. 9 shows the beams being used to support exterior walls to form an enclosed structure. These walls may be made from resin or other materials. A view of the enclosed structure is provided in FIG. 10 .
[0031] Various configurations of segments could be used and one with good structural stiffness is shown in FIG. 11 and FIG. 12 . The arches and dividers are set up in a kind of truss system to ensure that the structure can handle high applied loads. The use of these type of series of segments is shown in FIG. 13 where the outer layers can be filled with concrete or resin. In this stacked configuration, the offset of the segments provide good ballistic protection as the weakest path through the dividers is backed up by the composite. In another configuration, these segmented series are stacked and further surrounded by high performance concrete and woven polypropylene material for further ballistic protection as shown in FIG. 16 .
[0032] The exterior of a ball mold is shown in FIG. 14 , where a bleeder valve and an air fill valve are also shown. In the detail of FIG. 15 , the bleeder/filler valve configuration is visible as are the two bags or bladders. This is a ball in ball type of mold where the interior is filled with air and covered with a resin composite or concrete layer. This exterior layer is both structural and provides protection, including ballistic resistance to the interior. Such a structure could be used for many purposes including airships or ball antennae.
[0033] FIG. 17 shows another configuration of how the molds can be used to shape the composite material. The zig zag pattern increases ballistic resistance by providing a longer path that a projectile would have to travel through. This pattern could be made in sheets for easy construction and could be stacked as shown in FIG. 18 .
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Structural elements comprised of functionalized material in a rapidly setting resin. The structural elements are rapidly deployable and arranged as structures that provide ballistic and impact resistance. The structures are fabricated using specific molds that shape a specific rapid cure resin-filler mixture.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for preparation of white liquor in a chemical recovery process of the kraft process. It affects the total system lay out of the causticizing process between input of raw green liquor and final production of a clear white liquor.
BACKGROUND OF THE INVENTION
[0002] The causticizing process has conventionally used a lot of different process steps for;
reception of the green liquor; separation of dregs from green liquor; washing and drying dregs obtained from the previous separation step; mixing of clear green liquor and burnt lime in order to slake lime and start the causticizing reaction; tanks for completion of the causticizing reaction; separation of lime mud from white liquor; lime mud washing and drying.
[0010] A typical conventional causticizing process is shown in FIG. 1 . The raw green liquor RGL is first received in an equalizing tank EQT and from there pumped to a first green liquor separation process, here shown as a green liquor pressurized disc filter GLF. The green liquor filter separates dregs from the raw green liquor and produces clear green liquor which is sent to a green liquor storage tank GLT. The clear green liquor is then sent, most often via a green liquor cooler GLC, to the slaker SL where burnt lime is mixed into the green liquor. The cooler is needed to reduce temperature ahead of the slaker to keep the slurry in the slaker under boiling point as the reactions occurring in and after the slaker are exothermic. Grits, i.e. unreacted fractions of the burnt lime, are also separated out from the slaker. After mixing in the slaker, the slurry is sent to a series of causticizing vessels CT 1 -CT 2 -CT 3 , often named the causticizing train, wherein the chemical causticizing reactions are completed. Once these causticizing reactions are completed, the slurry is pumped to a white liquor separation process, here shown as white liquor pressurized disc filter WLF. The white liquor filter separates lime mud from the caustiziced liquor and produces clear white liquor, which is sent to a white liquor storage tank WLT. The clear white liquor is then sent directly to be used in the kraft cooking or bleaching line, or alternatively via a polysulfide modification process to said kraft cooking. The lime mud, which still may have a residual content of alkali, is sent to a lime mud washing and drying stage, here shown as a lime mud pressurized disc filter LMF.
[0011] Once the lime mud is washed and dried it may be passed to the lime kiln in order to convert it to burnt lime to be used in the slaker again.
[0012] In these conventional causticizing processes as shown in FIG. 1 , a specific start up procedure for the green liquor separation process has been used. During start up, the green liquor filter has initially been filled with causticizised liquor from the causticizing train CT 1 -CT 2 -CT 3 in order to build up a precoat of lime mud on the surface of the filter cloth. The reason for this formation of lime mud precoat is that this precoat exhibit a far better separation efficiency than the cloth itself and has a better filterability than would a precoat formed by dregs from green liquor. The filterability improves by a factor of 6 if a precoat is formed by lime mud instead of green liquor mud (dregs). However, this short establishment of the precoat using causticizised liquor from the causticizing train CT 1 -CT 2 -CT 3 has never been used for longer periods than about 5% of the total cycle time of the green liquor filter, and as soon as this precoat has been formed, the major part of the operating time for the green liquor filter has been used for green liquor filtering, and the main part of the white liquor produced, typically more than 90% of the total amount, is obtained from the dedicated white liquor filter.
[0013] However, usage of pressurized disc filters, one for white liquor filtration and one for green liquor filtration, are expensive as the costs for these filters are high. Filtering techniques are often better as cleaner product liquors could be obtained with small amounts of suspended solids in the product liquors, typically with content less than 20 ppm, as compared with typical green liquor having more than 1500 ppm. Another advantage is that dregs or lime mud separated from these filters could be obtained at very high dryness in the range 40-60% and 60-75% respectively. Alternative techniques has therefore been considered, and usage of conventional settling tanks for green liquor has once again been considered simply due to less investment costs, even though the amount of suspended solids often are much higher, typically four times more.
[0014] Another problem with these conventional processes is that so many different and dedicated separation apparatuses are needed, requiring a lot of free building area. This will be problematic when trying to increase capacity of the causticizing plant, as most often no available room is at hand for additional apparatuses increasing the capacity.
SUMMARY OF THE INVENTION
[0015] The invention is based upon the surprising finding that using a common separation process apparatus for white and green liquor separation will maintain a very efficient green liquor separation process as of reduced content of suspended solids, low residual alkali in dregs separated as well as high dryness in dregs. There is thus no need for a multitude of dedicated separation processes for white and green liquor.
[0016] The present invention also shows a method for simplification of the recausticizing process using far less separation apparatuses and thus may provide a solution for increasing capacity in any given available area not having the possibility of increasing the building area of the causticizing plant.
[0017] Another objective is to reduce the risk for down time. Normally the MTBF (mean time between failures) for the causticizing process will increase as the numbers of apparatuses needed in sequence in the process flow are decreased.
[0018] The invention will enable replacement of two separate and dedicated separation processes for white- and green liquor separation with only one separation process used for both the entire white- and green liquor separation. The new separation apparatus will have a slightly larger footprint area than one of the previously used separation apparatuses, but require far less foot print area than the two previous separation apparatuses put together. Even though buffer tanks preceding the common separation apparatus will increase in size, would the net foot print area be reduced in the system.
[0019] The method according to the invention is intended for preparation of white liquor in a chemical recovery process of the kraft process. Here the raw green liquor is first fed to a green liquor separation process wherein dregs are separated out and clear green liquor is obtained. Thereafter burnt lime is added to the clear green liquor in a slaker, followed by a causticizing train with a number of causticizing vessels wherein the causticizing process is finished producing causticized liquor. Thereafter the causticized liquor is sent to a white liquor separation process wherein lime mud is separated out and a clear white liquor is obtained to be used as cooking liquor in the kraft process either in form of the clear white liquor or as modified by polysulfide modification in a polysulfide process. The separated lime mud is sent to a lime mud washing and drying process before feeding the washed lime mud to a lime kiln. In this type of process the method is characterized in that the green liquor separation process and the white liquor separation process takes place in the same common filter apparatus with no dedicated green liquor separation apparatus nor any dedicated white liquor separation apparatus, and where the white liquor separation process and the green liquor separation process are conducted in sequence in the same filter apparatus and where the white liquor separation process has a part of the cycle time in the range 20-50% of the total cycle time in the same filter apparatus.
[0020] In order to maintain the flexibility of the process the method is further characterized in that an equalizing buffer tank is preceding the green liquor separation process and where the equalizing buffer tank has a storage capacity holding raw green liquor for at least 5 hours in said equalizing buffer tank, and where a last buffer tank in the causticizing train has a storage capacity holding a causticized liquor for at least 2 hours in said last buffer tank in the causticizing train. With this embodiment could the causticizing process be maintained even in case of any interruption in the dissolving tank (where green liquor is formed) or any interruption in the causticizing reaction process following the slaker operation.
[0021] In order to further improve the flexibility of the process, the method is further characterized in that the equalizing buffer tank is filled with raw green liquor while emptying the buffer tank in the causticizing train when performing the white liquor separation in the common filter apparatus, and thereafter emptying the equalizing buffer tank of raw green liquor while filling the buffer tank in the causticizing train when performing the green liquor separation in the common filter apparatus. By this alternating filling and emptying the buffer tanks the separation process can be in continuous operation producing the necessary volumes of both separated green and white liquors.
[0022] In order to use the buffer tanks as much as possible the method is further characterized in that the level of liquors in the buffer tanks are controlled within 20-95% of the total retention capacity during white and green liquor separation. A certain minimum content of liquor is needed to maintain a stabilizing volume in the equalizing tank as well as a minimum level for agitation in the buffer tank, and filling of buffer tanks should not reach a full 100% filling degree which may risk overflow of liquors and special handling actions for such overflow.
[0023] In order to improve formation of an optimal lime mud precoat with a minimum of residual dregs content, which content of dregs may reduce filterability, is the method further characterized in that the green liquor separation process in said common filter apparatus is ended by a complete emptying of raw green liquor and addition of an intensified wash out process using a volume of washing liquid of at least 5% of the liquor volume held in the common filter apparatus, said washing liquid not containing any dregs or lime mud particles, said intensified wash out process also entailing intense agitation in the liquid volume held in the common filter apparatus. In this context it would be beneficial for the volume of washing liquid used during the intensified wash out process to exceed 3 m 3 in most typical processes having a capacity of over 5300 m 3 green liquor per day and over 5000 m 3 white liquor per day. The wash liquid should be clean in such aspects that any content of dregs are less than 1/100 of the content in the green liquor to be filtered.
[0024] According to one further aspect of the inventive method is also a cake of precoat maintained on the filter surface during the intensified wash out process. The wash out process ending each cycle after green liquor separation is intended to flush out the vat of the separating apparatus with the objective to flush out any dregs accumulated in the vat, while maintaining the precoat so that the following white liquor separation process could start immediately after termination of the wash out process.
[0025] According to yet a further embodiment of the inventive method is also a total removal of the precoat on the common filter apparatus including a filter cloth wash activated after two or more green liquor separation cycles and wherein a total new precoat is established in subsequent white liquor separation process in said common filter apparatus. In some cases could as many as up to 3 - 4 green liquor separation cycles be performed in sequence, interrupted by white liquor separation cycles in between, before a total removal of the precoat is activated. The number of green liquor cycles possible is dependent on the current status of the green liquor or the causticized white liquor as of impurities and is very much specific for each mill and current type of kraft pulping operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a schematic representation of a conventional causticizing process;
[0027] FIG. 2 is a schematic representation of the causticizing process according to the invention;
[0028] FIG. 3 is showing the liquor flows during the white liquor cycle according to the invention;
[0029] FIG. 4 ; is showing the liquor flows during the green liquor cycle according to the invention;
[0030] FIG. 5 ; is showing a typical sequence with white- and green liquor cycles according to the invention;
[0031] FIG. 6 ; is showing the usage in buffer tanks during green and white liquor cycles according to the invention;
[0032] FIG. 7 ; is showing precoat removal on filter surfaces of the common filter apparatus;
[0033] FIG. 8 ; is showing a typical disc filter apparatus preferably used for the common filter apparatus.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The inventive method is described in connection with a system set up as shown in FIG. 2 . In here is one single common filter apparatus GLF/WLF used for the green and white liquor cycles.
[0035] The raw green liquor RGL is first received in an equalizing tank EQT and from there pumped to the green liquor separation process when the feed valve for green liquor FV GL is open and the feed valve for white liquor FV WL is closed (black valves indicate closed status). The separation process is here shown implemented in a pressurized disc filter GLF/WLF. The common filter apparatus GLF/WLF now operating as a green liquor filter separates out dregs from the raw green liquor and produces clear green liquor sent to a green liquor storage tank GLT when the output valve for green liquor OV GL is open and the output valve for white liquor OV WL is closed. The clear green liquor is then sent, most often via a green liquor cooler GLC, to the slaker SL where burnt lime is mixed into the green liquor. The cooler is needed to reduce temperature to well below boiling point as the reactions occurring in and after the slaker are exothermic. Grits, i.e. unreacted components from the burnt lime, are also separated out from the slaker. After mixing in the slaker the mixture is sent to a series of causticizing vessels CT 1 -CT 2 -CT 3 , often named the causticizing train, wherein the chemical causticizing reactions are completed. As the feed valve for white liquor FV WL is closed the vessels CT 1 -CT 2 -CT 3 , preferably only the last vessel CT 3 , are used as storage vessels for the causticizised liquor when the common filter apparatus GLF/WLF is used as a green liquor filter during the green liquor cycle.
[0036] When the storage vessel CT 3 is reaching the upper storage capacity limit, the common filter is switching to white liquor filtration. During the white liquor filtration the feed valve for green liquor FV GL is closed and the feed valve for white liquor FV WL is opened, while the output valve for green liquor OV GL is closed and the output valve for white liquor OV WL is opened. During the white liquor cycle the liquid is pumped from storage vessel CT 3 to a white liquor separation process in the common filter apparatus GLF/WLF, here shown as a white liquor pressurized disc filter. During the white liquor cycle the filter separates out lime mud from the caustiziced liquor and produces clear white liquor sent to a white liquor storage tank WLT. The clear white liquor is then sent directly to be used in the kraft cooking or bleaching line, or alternatively via a polysulfide modification process to said kraft cooking. The lime mud, which still may have a residual content of alkali, is sent to a lime mud washing and drying stage, here shown as a lime mud pressurized disc filter LMF. Once the lime mud is washed and dried it may be passed to the lime kiln in order to convert it to burnt lime to be used in the slaker again.
[0037] In FIG. 3 only the flows during the white liquor cycle are shown when operating the common filter apparatus GLF/WLF. This cycle is preferably initiated during 1.5-2 hours, during which the equalizing tank EQT for receiving raw green liquor RGL is only used as buffering tank, i.e. with no outflow of any raw green liquor. As no filtered green liquor is produced, the green liquor tank GLT is in an emptying process, feeding clear green liquor to the slaker and onwards via the causticizing train CT 1 -CT 2 -CT 3 to the common filter apparatus GLF/WLF. The resulting filtered white liquor is fed from the common filter apparatus GLF/WLF to the white liquor tank WLT.
[0038] In FIG. 4 only the flows during the green liquor cycle are shown when operating the common filter apparatus GLF/WLF. This cycle is preferably initiated during 2 . 5 - 3 hours, during which the causticizing train CT 1 -CT 2 -CT 3 for receiving causticizised liquor is only used as buffering tank, i.e. with no outflow of any causticizised liquor. As no filtered white liquor is produced, the white liquor tank WLT is in an emptying process, feeding clear white to the cooking or bleaching process in the kraft pulping process. Raw green liquor RGL is fed from the equalizing tank EQT to the common filter apparatus GLF/WLF. The resulting filtered green liquor is fed from the common filter apparatus GLF/WLF to the green liquor tank GLT.
[0039] In FIG. 5 are shown a number of white and green liquor cycles in sequence operated according to the inventive method. Typically within a 10 hour total cycle there are preferably a first white liquor cycle during 1.8 hours followed by a first green liquor cycle during 2.8 hours, and repeated with a subsequent second white liquor cycle during 1.8 hours followed by a second green liquor cycle during 2.8 hours. After the white liquor cycles there are preferably only an emptying of the common filter apparatus GLF/WLF from causticizised white liquor during the time interval A. But after the green liquor cycles there are preferably not only an emptying of the common filter apparatus GLF/WLF from raw green liquor during the time interval B, but also an improved addition of an intensified wash out process using a volume of washing liquid of at least 5% of the liquor volume held in the vat of the common filter apparatus during filtering. As indicated before, the washing liquid should not contain any larger amounts of dregs, as the objective is to flush out any dregs that may have settled into the vat of the filter apparatus, whose presence may have a negative impact during the start of the white liquor cycle and formation of a precoat with only lime mud on the filter cloth of the filtering apparatus. If any dregs are still kept in the common filtering apparatus when filling it up with causticized liquor, these dregs residuals may be suspended in the causticized liquor and then remain in the precoat formed, thus reducing the filtering capacity. In order to flush out any dregs should preferably also said intensified wash out process be complemented by intense agitation in the liquid volume held in the common filter apparatus. This could be implemented by any intense recirculation inside the vat of the common filtering apparatus or adding the washing liquid trough so called mammoth pumps located in the bottom area of the vat. The mammoth pumps are during filtering operations fed with pressurized air in order to prevent settling in the vat, and looks like an educator nozzle that is driven by the air flow and which induce a suction effect around the nozzles at the bottom wall of the vat.
[0040] As indicated in FIG. 5 is also a total renewal of the precoat including a thorough cloth wash implemented after a last green liquor cycle, here indicated as a 30 minutes cloth wash.
[0041] In FIG. 6 are shown how the equalizing tank EQT and the last tank CT 3 in the causticizing train CT 1 -CT 2 -CT 3 are used as buffer tanks during the white liquor cycle (left hand part of figure) and the green liquor cycle/right hand side of figure). During the white liquor cycle the liquid level in the equalizing tank EQT is rising from a level of 20% and up to about 95%, while the liquid level in CT 3 is dropping from a level of 95% and down to about 20%. In the subsequent green liquor cycle the opposite effect occurs, i.e. the liquid level in the equalizing tank EQT is dropping from a level of 95% and down to about 20%, while the liquid level in CT 3 is rising from a level of 20% and up to about 95%.
[0042] In FIG. 7 is shown a filter disc section used in a disc filter apparatus as shown in FIG. 8 . Knives located on each side of the rotating disc, are scraping off an outer layer of the precoat. In FIG. 7 is shown the principle constitution of the precoat after a green liquor cycle, where an outermost layer of dregs has been caught on top of the lime mud base precoat. The knives advance a little bit into the lime mud base precoat and create a clean lime mud surface for the following white liquor cycle. During the white liquor cycle the knives are retracted allowing the lime mud base precoat to build up again in thickness.
[0043] In a preferred mode of operation, the knives are located about 12 mm from the filter cloth during start of WL filtration and is retracted to position about 22 mm when a precoat of lime mud is built up on the filter cloth. At the end of the WL filtration period a lime mud precoat with a thickness of 22 mm is thus established. When GL filtration is started, the knives are successively moved towards the filter cloth and when reaching a distance of 12 mm the GL filtration stops. WL filtration starts by moving the knives to a distance of 10 mm in order to expose a fresh lime mud precoating and rebuilding a new lime mud precoat with 22 mm thickness.
[0044] In a test of the inventive method using a cycle sequence as shown in FIG. 5 , the total cycle time was about 619 minutes (the “10 h” in figure). In this total cycle the WL filtration was about 230 minutes, i.e. 37% of the total cycle, and the GL filtration about 330 minutes, i.e. 53% of the total cycle. The rest of the total cycle, about 10%, is non productive time (A, B and 30 min cloth wash in FIG. 5 ). In the test a common filter apparatus was used with a pressurized disc filter, see FIG. 8 , having a total filter area of 280 m 2 and a vat holding some 55 m 3 liquor to be filtered, producing 5 100 m 3 WL/day and 5 350 m 3 GL/day.
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The method is for preparation of white liquor in a chemical recovery process of the kraft process. The green liquor separation process and the white liquor separation process are taking place in the same common filter apparatus with no dedicated green liquor separation apparatus or any dedicated white liquor separation apparatus. The white liquor separation process and the green liquor separation process are conducted in sequence in the same filter apparatus. The white liquor separation process has a part of the cycle time in the range 20-50% of the total cycle time in the same filter apparatus.
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BACKGROUND OF THE INVENTION
The invention relates to a compound block kit of edge-toothed concrete blocks.
Compound block kits consisting of concrete are known in many forms. Such kits are composed of concrete plaster compound blocks which have an identical or different surface area configuration as well as a uniform height and which are used to cover paths, streets, yards or the like with a continuous compound block surface. If it is desired to provide e.g. lateral borders for a thus covered surface, different elements which are not associated and cannot be engaged with the compound blocks, for example border walls, fences, palisades or the like must be used. This results in transitions from the block-covered surface to e.g. a surrounding palisade wall which are optically not particularly attractive, especially since the individual elements of such a wall are frequently only inadequately position stabilized. It must be taken into account that such palisade borders often must absorb not insignificant lateral earth thrusts, which leads to substantial supporting problems. Further, in the case of a compound block covering, it is not readily possible to integrate within the covered area other elements serving other purposes, for example in form of anti-entry bollards, and to do so in a position stabilized manner. In this context it is known to interrupt the block-covered area by removing one or more of the compound blocks and to put in their place for example a limiting concrete column, concrete rod or the like. If a particularly good position stabilization is desired, this element must be concreted in place. It is thus evident that such compound block kits are relatively limited with respect to their applicability and flexibility and that substantial problems occur if a transition from the blocks to other elements is to be made.
SUMMARY OF THE INVENTION
It is the purpose of the invention to provide a compound block kit of the type in question which on the other hand is highly variable with respect to creative possibilities while offering non-problematic position stability of the individual compound blocks within the compound, and on the other hand, is relatively light and can be produced economically.
To solve the problem it is proposed in a compound block kit of the type in question, that according to the invention it be composed of a plurality of compound blocks which are coordinated relative to their cross-sectional shape and size and have cobblestone blocks to palisade blocks of various heights and that all cobblestone blocks and palisade compound blocks be provided with edge-teeth extending around the entire block circumference and engageable with one another.
Thus, the thought behind the invention is to unite similar compound blocks of different heights to a kit and thus to open the possibility to combine cobblestone compound blocks and palisade compound blocks which are usable for the greatest variety of different applications, into an integrated position-stabilized block compound in which there are no transition problems between the compound blocks of different heights. Since the compound blocks differ essentially only by their height, they can be produced simply and inexpensively. The similar edge-teeth largely prevent a relative shifting of the blocks and because of the identical cross-sectional shapes and sizes permit any desired insertion and exchanges of compound blocks at any desired position.
The inventive compound block kit is highly versatile, and for example, it is possible to provide in a fully non-problematic manner a position stabilized palisade fence around a block-covered area, whereby due to the intimate connecting effect even lateral earth thrusts of various forces, can be absorbed without positional changes of the compound blocks. Furthermore, the higher palisade compound blocks of the kit permit the erection of any desired embankments, support walls, and fence walls which may be straight, angular or curved and have different height dimensions. Lower palisade compound blocks may for example be used as surrounds for trees, flowers, lamps, water basins and the like in position-stabilized manner. The lower palisade compound blocks may also be used to make stair steps to which they are associated at the lateral sides higher than support palisade compound blocks. It is also possible to integrate within a block-covered area lower and/or higher palisade compound blocks in individual or adjoining manner as elements which prevent the entry of vehicles, which prevent parking or as fencing elements. For this purpose, it is simply necessary to omit a cobblestone block or to remove it and to replace it with a correspondingly higher palisade which itself is maintained in position stabilized condition by the block compound. Aside from the aforementioned possibilities of use there are many other modifications and applications, as for example for outdoor grills, benches, tables and the like. In all cases, the inventive compound block kit permits a largely freely selective and always position stabilized combining of lower and higher edge-toothed compound blocks of identical cross-sectional form and size.
While in principle other cross-section are possible, for example a quadratic form, it has been found to be particularly advantageous and esthetically pleasing to make all compound blocks of a hexagonal cross-section of essentially identical edge lengths. Compared to a quadratic shape this has for example the essential advantage that not only right angular but also inclined palisade delimitation angles are possible.
A particularly advantageous embodiment relative to the compound block teeth and thus the position stabilization is obtained if at each circumferential side of the block there is provided at least one edge tooth composed of a convex edge projection--round bar--a thereto adjoining outwardly inclined straight edge portion--rod--and a thereto adjoining concave edge recess--hollow. Such edge teeth may very easily be moved into mutual engagement during laying of the compound blocks, and assure a good position fixation of the compound blocks which in such engagement can be neither shifted nor turned relative to one another.
Basically, it is sufficient if the edge teeth extend over the height of the mutual block engagement region. For the higher palisade compound blocks this means that they need be edge toothed only in the lower area. However, to provide the manufacture as economical as possible and to make the kit as versatile as possible, it is of advantage if the edge teeth extend over the entire block height. This is in any case advantageous in the higher palisade compound blocks which for example are to be used for supporting adjacent ground and thus must have mutually position stabilizing engagement over the entire block height.
In principle the compound block dimensions may be selected at will and accommodated to the requirements of a particular application. For manufacturing and handling reasons it has been found advantageous, however, that the maximum height ratio between the palisade compound blocks and the cobblestone compound blocks is approximately 10:1 to 15:1. The palisade compound blocks of different heights may have a maximum height of approximately 100-120 cm and a minimum height of approximately 20 cm and the cobblestone compound blocks may have a height of approximately 8 cm. In the case of hexagonal compound blocks it has been found advantageous if the spacing between oppositely located hexagonal edge teeth is approximately 20 cm. These dimensions, which are preferred for many applications, may however be largely changed at will in dependance upon the particular requirements.
Preferably the palisade compound block is provided on an edge face with a depression having a circumferentially extending margin. The depression is advantageously a planting depression of round cross section and preferably has a diameter of about 10 cm and a depth of about 10-20 cm. Such a depression, provided in an edge face, permits the use of the compound blocks in one position as a normal palisade and in a position turned through 180° as a palisade with an uppermost depression which is primarily usable for planting. This has the great advantage that the block compound can be planted without the need for additional plant receptacles or bare-earth spaces. This is particularly advantageous in the case of a large palisade compound, for example if a steep incline is to be supported with several palisade rows arranged one behind another between which due to the intimate connection no interspaces remain for ground in which planting can be made. By means of the planting depressions the planting can in effect grow directly out of the palisade itself. The preferred dimensions listed for the planting depression are adequate but may be increased or decreased as required.
It is preferred that the circumferential margin of the depression for planting is provided in the region of its bottom with at least one passage. This extends preferably approximately radially outwardly and is inclined in downward direction. In this passage a venting or dewatering tube may be embedded in the concrete. The passage prevents over watering of the ground placed into the depression and permits venting sufficient for the plantings. The venting or dewatering tube need not absolutely be cast in place, but can be subsequently inserted into the passage. For many applications such a tube could be entirely omitted.
A further possibility of variation is obtained in that the palisade compound block is constructed as a fountain element and is penetrated in longitudinal direction by at least one channel opening at one of its end faces. In this manner it is for example possible to provide within a palisade compound, such as a palisade hill with differently high palisades, one or more palisades which are constructed as fountain elements and to connect them at their underside with a water supply so that the water can exit at the upper open side and for example flow off over adjacent lower palisades. In this manner very appealing water-flooded palisade hills respectively steps can be formed. If desired, passages or channels of adjacent lower palisades can be used as water draining channels.
The palisade compound block may be provided in the opening region of the channel with an end face depression or with a convex protrusion. In the case of the depression a water collecting effect occurs in the same, so that a kind of fountain is formed. If the channel is a water outflow channel, then the depression can be used as a water outflow funnel. A convex protrusion in the opening region of the channel, on the other hand, can supply for a more reliable draining-off of the water without any residual water being entrapped.
In principle it is possible for the palisade compound block to be provided with water outlet openings on its circumference also. In this manner particularly a higher palisade can be used as a fountain device which sprays in all directions. To supply the outlet at the end and/or outlets at the circumference with water, it is advantageous for a tube or hose element to be arranged in the channel. After being connected to the supply in the ground this can be inserted into the channel when the palisade is erected. It is also possible for the tube or hose element to be previously placed into the channel and to be connected on erection of the palisade with a water supply in the ground area. And finally, a tubular element can already be cast into the concrete palisade during the manufacture of the same, in which case the channel is formed without any additional means.
The inventive compound block kit is, as already explained in detail, suitable for a great many applications since different-height palisades can be integrated in many different ways in a cobblestone compound in position-stabilized manner without any transition problems. For example, the compound block kit can be used for providing fountains, plantings, tables or benches, with or without palisade bannisters, anti-vehicle boundaries, more or less dense palisade fences, palisade pyramids or hills with or without plantings, and the like, all within the context of an area covered by compound blocks. Such a compound-block covered area can also be provided with a center region serving for grill purposes and which is surrounded by palisade seats. The greatly variable block compound has a good connection not only in the region of the ground, but also in the higher block engagement region located above and constituted by palisade compound blocks. This is particularly important for palisade surrounds which are adjacent to the ground and which are prevented from sliding or turning by the compound effect.
The invention will hereafter be described in more detail with reference to several embodiments in the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing two different-height compound blocks of one embodiment of the inventive compound block kit,
FIG. 2 shows a compound block of the kit according to the embodiment of FIG. 1 in an end view,
FIG. 3 is a partly sectioned side view of a palisade compound block of the kit provided in an end phase with a planting depression,
FIG. 4 shows an end view of the compound block in FIG. 3,
FIG. 5 is a partly sectioned side view showing another embodiment of a palisade compound block with a channel extending in longitudinal direction,
FIG. 6 is an embodiment which is modified with respect to FIG. 5 and has an end phase depression provided in the region of the opening of the channel,
FIG. 7 is an embodiment modified with respect to FIG. 5 and having a protrusion provided in end phase in the region where the channel opens,
FIG. 8 is a perspective simplified view showing a block compound of compound blocks of different heights, the compounds being of hexagonal cross section and of identical length sides and being shown for purposes of simplicity without edge teeth, and with different-height palisade compound blocks delimiting an area covered with lower cobblestone compound blocks, and
FIG. 9 is a perspective simplified view of a block compound of compound blocks in which also the individual compound blocks are shown without edge teeth for reasons of simplification and in which different-height palisade compound blocks are arranged as a palisade hill within a region which is covered with compound blocks.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The compound blocks of the inventive compound block kit have, according to FIG. 1, an identical cross sectional form and size, but a different height. For reasons of simplification FIG. 1 shows only two different height dimensions, with a cobblestone compound block 10 having a lower height H 1 of e.g. approximately 8 cm and a palisade compound block 12 having a greater height H 2 of e.g. 20 cm up to approximately 120 cm. Other dimensions, particularly stepped heights of the palisade compound blocks 12, are possible. According to FIGS. 1 and 2 the compound blocks 10, 12 have a hexagonal cross sectional shape of identical-length sides, and each side of the hexagon is provided with an edge tooth 14 composed of a convex projection 16 (round rod), a thereto adjacent outwardly inclined straight edged portion 18 (rod) and a thereto adjacent concave edge depression 20 (hollow). At the edges of the block there is always an edge depression of one block side located opposite an edge projection of the adjacent block side. This assures that the hexagonal compound blocks 10 can have any desired sides placed into meshing engagement in a very simple and position stabilizing manner. The edge projections 16 of one compound block always engage in the edge depressions 20 of the adjacent compound block and the straight edge portions 18 of the compound blocks move into engagement with one another. The distance D between oppositely located edge teeth 14 of each compound block 10, 12 is approximately 20 cm according to a preferred embodiment, but even this dimension may be changed and accommdated to the requirements of a particular application.
An embodiment of the type shown in FIGS. 3 and 4 is suitable for the higher compound blocks 12, which are primarily used as palisades. It is shown that the compound block 12 is provided in one end phase with a depression 22 which is surrounded everywhere by a margin 24. This depression primarily serves for planting purposes and ground to be planted is placed into it. To avoid overwatering and/or assure sufficient venting, the lower region of the depression 22 is provided with a passage 26 extending through the circumferential border 24 and which may be defined according to FIG. 3 by a venting or dewatering tube 28. This can subsequently be inserted into the passage 26 or else may be cast into the same during the manufacture of the compound block 12. Taking into account the dimension which is preferred in connection with the spacing D of FIG. 1, the depression 22 which according to FIG. 4 is of circular cross section may, e.g., have a diameter of approximately 10 cm and a depth of approximately 10-20 cm. In this event a still sufficient material strength is obtained for the circumferential margin 24, and on the other hand sufficient space is provided for planting purposes. If desired, other dimensions may be selected for the depression 22.
FIGS. 5-7 show different embodiments of a higher compound block 12 constructed as a fountain element. In all embodiments a channel extends in longitudinal direction through the compound block 12. In the embodiment of FIG. 5 the compound block 12 has at both sides planar delimiting phases. In addition, a tube or hose element 36 is placed into the channel 30 which can be inserted after the manufacture of the compound block 12 or else can be cast into the compound block 12 during the manufacture thereof. The channel 30 respectively the tube or hose element 36 serve to guide water supplied from the underside of the compound block 12 to the upper side of the same and to let it emerge in the outlet region. In contradistinction to the embodiment of FIG. 5 the compound block 12 of FIG. 6 is provided in the upper outlet region of the channel 30 with a depression 32. When operated as a fountain element here also a hose or tube element can be inserted into the channel 30 as in FIG. 5, and may for example enter into the depression 32 or project beyond the same. The embodiment of FIG. 6 can also be used as a water run-off element, in which case the depression 32 functions as a funnel-shaped water collecting basin. In the embodiment of FIG. 7 the upper end of the compound block 12 is provided, in contradistinction to the one in FIG. 6, in the opening region of the channel 30 with a concave protrusion 34 rather than a depression 32. This permits the uniform run-off of the water emerging from the channel 30 without leaving any residues. The palisade compound block may have water outlet openings 30a in the circumferential region also.
In FIG. 8 it is shown in an exclusively exemplary manner how low cobblestone compound blocks 10 and palisade compound blocks 12 of different height, all forming a part of the inventive kit, may be installed to form a block compound. In the present instance the palisade compound blocks 12 serve as a border for a region which is covered with cobblestone compound blocks 10. Some or all palisade compound blocks 12 may be provided at the upper end phase with depressions 22 according to FIGS. 3 and 4 and planted with plantings which hang down over the compound blocks and partially obscure them.
FIG. 9 shows a further example of a block compound, wherein a palisade hill composed of palisade compound blocks 12 of different height is arranged within a region covered with low cobblestone compound blocks 10. One or more palisade compound blocks 12, particularly the highest compound block 12, may be constructed as fountain elements with a channel 30 according to FIGS. 5-7. The water which is supplied to the channel 30 from below can be supplied fountain-like under pressure or else largely without pressure and can run off in steps along the palisade hill in downward direction, in order to drain into the earth between the compound blocks or else to be collected at certain locations and to be conveyed away, for example with the aid of a compound block 12 according to the embodiment of FIG. 6. Other compound blocks 12 may be provided with depressions 22 for planting purposes, as is shown in FIG. 9.
Many modifications relative to the form, size, edge teeth and detail configuration are possible within the scope of the invention. What is important is that all different-height compound block of the kit are exchangeable for one another and can be intermeshed with one another. This assures multiple applicabilities for a block compound which can be erected readily but with the highest possible position stability and which can be varied at will.
Particularly advantageous results are obtained if the palisade compound blocks 12 are of tubular configuration with a closed end phase to save material, costs and weight. The tubular form can be produced by means of a removable core and be formed by the depression 22 itself which in this case, in contradistinction to the preceding explanations, has a depth that is slightly smaller than the height H 2 of the palisade compound blocks 12. This depression 22 may also serve for planting purposes. These substantially less costly palisade compound blocks can also be more readily transported and installed because of the lower weight.
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A compound block kit of edge-toothed concrete blocks, in which the compound blocks are coordinated relative to their cross-sectional shape and size and have cobblestone blocks to palisade blocks of various heights. The cobblestone compound blocks and palisade compound blocks are provided with edge-teeth extending around the entire block circumference and are engageable with one another. The similar edge-teeth prevent a relative shifting of the blocks. The identical cross-sectional shapes and sizes permits any desired insertion and exchange of compound blocks at any desired position.
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RELATED APPLICATION
This application is the non-provisional filing of provisional application No. 60/157,687, filed Oct. 5, 1999.
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for scheduling and bandwidth allocation in a telecommunications network and a system incorporating the same.
BACKGROUND TO THE INVENTION
A key requirement of a broad band telecommunications network is that of scheduling bandwidth allocation in response to user demand to ensure efficient operation of the network and to maximise the revenue earning traffic that may be carried. Typically, this task is performed by the use of a scheduling algorithms.
Many scheduling algorithms are known, based on fundamental Weighted Fair Queuing concept. However, the basic Weighted Fair Queuing algorithm that is commonly used suffers from a number of disadvantages including:
computational complexity is high, it does not provide fairness when the output bandwidth fluctuates, it requires length of packets to be known it exhibits higher unfairness it causes higher delay to low throughput applications.
In an attempt to mitigate those disadvantages, some workers have employed Start Time Fair Queuing algorithm. This however, has the specific limitations that:
instantaneous nature of congestion is not accounted for and inter-packet delay can grow very large.
OBJECT OF THE INVENTION
The invention seeks to provide an improved method and apparatus for scheduling and bandwidth allocation in a telecommunications network.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention there is provided a method of scheduling packets from a plurality of queues onto a outgoing link comprising the steps of: associating a start time with each of said queue s; selecting queues in turn responsive to said start times until a non-empty queue is selected; sending a packet from said selected queue; measuring the length of said packet; and associating a new start time with said selected queue responsive to said length of said packet.
In a preferred embodiment the method additionally comprises the step of: associating a weight with each of said queues; and the step of associating a new start time is additionally responsive to the weight associated with said selected queue.
Advantageously this
supports partitioning of the output bandwidth according to bids, supports provision of quality of service guarantee and fairness even with variable capacity, does not need prior knowledge of the length of packet, supports incorporation of forward strategies based on policies, supports efficient use of bandwidth when scheduled flow gets blocked, mitigates the instantaneous nature of congestion, is adaptable to operate in hierarchical systems.
In a further aspect of the present invention there is provided a method of reserving bandwidth for a traffic flow in a telecommunications network comprising the steps of associating a minimum bandwidth reservation level with said flow; and if actual flow falls below said reservation level sending an indication of a difference between said actual level and said minimum reservation level as part of said actual flow.
In a first preferred embodiment said indication comprises a volume of dummy traffic indicative of said difference.
In a further preferred embodiment said indication comprises a packet containing an indication of said difference.
In this case the packet indicating the ‘potential’ flow may be sent to the control network.
The method may additionally comprise the steps of monitoring actual traffic flows including said indication; and dynamically allocating bandwidth to a traffic flow in the network responsive to a characteristic of said actual traffic flows.
The invention also provides for a system for the purposes of digital signal processing which comprises one or more instances of apparatus embodying the present invention, together with other additional apparatus.
In particular, there is provided apparatus for scheduling packets from a plurality of queues onto a outgoing link comprising the steps of: a start time associator for associating a start time with each of said queues; a queue selector for selecting queues in turn responsive to said start times until a non-empty queue is selected; a packet sender for sending a packet from said selected queue; a measure for measuring the length of said packet; a new start time for associator for associating a new start time with said selected queue responsive to said length of said packet.
In a preferred embodiment, the apparatus additionally comprises: a weight associator for associating a weight with each of said queues; and the new start time associator associates a new start time additionally responsive to the weight associated with said selected queue.
The invention is also directed to software for a computer, comprising software components arranged to perform each of the method steps.
In particular there is provided a program for a computer on a machine readable medium for scheduling packets from a plurality of queues onto a outgoing link and arranged to perform the steps of: associating a start time with each of said queues; selecting queues in turn responsive to said start times until a non-empty queue is selected; sending a packet from said selected queue; measuring length of said packet; associating a new start time with said selected queue responsive to said length of said packet.
There is also provided a program for a computer on a machine readable medium for reserving bandwidth for a traffic flow in a telecommunications network and arranged to perform the steps of: associating a minimum bandwidth reservation level with said flow; and, if actual flow falls below said reservation level sending an indication of a difference between said actual level and said minimum reservation level as part of said actual flow.
The preferred features may be combined as appropriate, as would be apparent to a skilled person, and may be combined with any of the aspects of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to show how the invention may be carried into effect, embodiments of the invention are now described below by way of example only and with reference to the accompanying figures in which:
FIG. 1 shows the overall functional architecture of the dynamic resource control system;
FIG. 2 shows in more detail the system diagram for the ingress control gateway; and
FIG. 3 shows further detail of the arrangement of FIG. 2 ;
FIG. 4 shows a modified arrangement;
FIG. 5 illustrates the use of dummy packets internal to the ingress gateway;
FIG. 6 illustrates dummy packets being injected into the network along the data path;
FIGS. 7 and 8 are graphs illustrating smoother packet flow according to the present invention;
FIG. 9 shows how dummy packet flow is seen by Dynamic Resource Control (DRC) system as part of the real data traffic flow in accordance with the present invention; and
FIG. 10 shows how the dummy packet data can be sent to the management system and used to dynamically modify the set points in accordance with the present invention.
DETAILED DESCRIPTION OF INVENTION
Referring now to FIG. 1 , there is shown an example of a network architecture in accordance with the present invention. The network comprises a number of interconnected core routers CR and edge routers ER.
An ingress gateway within each edge router controls incoming traffic flows 10 received from a source network SN. The incoming traffic flows are derived from micro flows 18 received by the source network; the micro flows being controlled by explicit or implicit (e.g. packet loss) signalling 17 from the edge router ER.
Traffic received at edge routers is routed across the network along paths comprising one or more links 11 - 13 to its destination, network DM via further link 14 .
A Dynamic Resource Control (DRC) System 15 comprises an aggregate controlled traffic flow monitor 151 which measures aggregate controlled traffic flows at each resource CR, ER in the network.
It also comprises a resource ‘cost’ calculator 152 which calculates ‘n-price’ of each resource as a function of the measured traffic and set control level.
It further comprises a path ‘cost’ calculator 153 which calculates ‘n-price’ of each path as a function (e.g. sum) of the n-price of each resource on the path.
The DRC system may be centralised or distributed according to the response time required from the system.
A management system 16 may be coupled to the DRC system 15 (e.g. via the resource ‘cost’ calculator) and provide set control levels for each resource in the system.
In this part of the system architecture the rate of flow of high priority elastic (TCP) traffic from each of a set of buffers is controlled by an output port scheduler. Note that for this high priority elastic traffic the TCP traffic ingress flow is controlled by packet discard in the RED queue. This has been chosen as a good example of an elastic traffic flow. The demonstration is aimed at showing that we can feed back remote link ‘congestion n-price’ information to the rate control element determining the rate of the aggregate TCP flows along each path. Using DRC algorithms we aim to demonstrate that high priority traffic can be controlled to less than 100% utilisation in all the remote links, and yet the overall user utility will be maximised. Typically there are four classes of traffic:—
Class one is high priority (inelastic) real-time traffic to be treated with the expedited forwarding per hop behaviour or top priority assured forwarding in the core routers. (Top buffer in FIG. 1 output scheduler) The volume of this type of traffic is separately controlled by earlier admission controllers. (Being inelastic these flows prefer a yes/no admission decision to being allocated less bandwidth than they requested.) The admission controller operates in such away that the aggregate class one traffic in any link in the network is less than the pre-set control level for total high priority (class one plus class two) traffic (say 10% to 60%) of any link capacity.
For high priority elastic traffic (class two), the aggregate flow rate x ci scheduled onto each output path is controlled by a controlled weighting factor w ci (where the subscript ‘i’ denotes the path number and the subscript ‘c’ denotes the class number). The path is the complete path shown in FIG. 1 from the ingress node to the egress node. Note there are many paths per output port. (They could be implemented for instance as MPLS paths).
Class three is traditional best efforts traffic and is scheduled on a per port basis with packet discard controlling the ingress rate in overload.
Class four is a dummy packet stream that may occasionally be necessary to achieve the desired scheduler behaviour. (discussed in more detail later)
Below we describe a method of calculating and continuously updating the value of w ci in such a way that maximum use of the remote links is made within the constraint that the total high priority traffic (class one plus class two) must not exceed the management system defined pre-set link occupancy. In this way this high priority elastic traffic is treated in such a way that it is guaranteed never to be delayed significantly by congestion beyond this ingress controller gateway. The paths form ‘dynamic elastic trunks’ that breathe in and out in bandwidth in such a way as to maximise end user utility and network revenue. We are effectively automating the traffic engineering of a VPN carrying the high priority traffic by applying carefully devised sets of policies. Remote congestion information is returned to the ingress controller in the form of a path source n-price p i s . The term n- price is a DRC term to indicate that the price is a network control signal price and not a real price that anyone gets charged for. This price p i s is the sum of all the link n-prices p i in the path i. Each link n-price increases when the aggregated high priority traffic passing through it exceeds pre-set link control level and decreases when it is less. To minimise stability issues, we prefer a time constant, say 1 second on the rate at Which link n-price, path n-price, and w ci can vary. This negotiation time can be as long or short as chosen, limited at the short end by about two round trip times (RTTs).
Offset Adjusted Fair Scheduler:
The scheduler is designed such that it is constantly trying to schedule traffic fairly according to their weights using the following method.
Let p f j , l f i and r f i denote the j th packet of flow f, its length and its bid respectively. Let A(p f j )denote the time at which the j th packet is requested (comes to the head of the queue). If the flow remains runnable, it is the time at which its previous packet finishes.
The following assignments hold:
1. Virtual time,
v ( t ) = S ( p f IN - SERVICE j )
when CPU is busy
max { F ( p f j ) }
when CPU is idle
2. Virtual start time,
S ( p f j ) = max { v ( A ( p f j ) ) , F ( p f j - 1 ) }
3. Virtual finish time,
F ( p f j ) = S ( p f j ) + I f j r f j
Service the flows in the increasing order of virtual start time. Ties are broken either arbitrarily or according to a policy. The bid can be changed, if required, by the ingress controller to take care of the instantaneous nature of congestion.
The algorithm is invoked once per packet transmitted.
The virtual start time of a blocked flow is updated in the background and is carried along the running flow. This is done for the following purpose:
Assume flow B is being served and flow P is scheduled for a time in future, t r Assume flow B got blocked. Now the bandwidth will be taken over by flow P. When flow B becomes runnable, it captures the service. But flow P will now be scheduled for a time later than t r Four things are to be noted here:
Flow P gets expedited service when flow B is blocked
Flow P relinquishes control on demand from flow B Overall fairness is maintained. Flow B does not give away the effective bandwidth share even though it was not ready on time. Bandwidth can be ‘stolen’ from B when it has no traffic. Bandwidth stealing can be achieved by assuring service to flow P at the previously scheduled time t r In this case, flow B will have to give away the service time allotted to it when it gets blocked. This share of time will not be given back to flow B.
This can be achieved by updating the virtual start time of B when it is blocked, as follows:
S ( p B i ) = S ( p B i - 1 ) + ( F ( p P j ) - F ( p P j - 1 ) ) + l P j r B i
where i is the virtual packet count for flow B for each packet of flow P.
The technique can be modified to achieve near ideal fairness, at the cost of increased computation:
In this case the adjacent flow gets the bandwidth share absolutely free. This could fairly be distributed among all the flows by incrementing the start time of this adjacent flow by an amount that would spread the slot evenly. A simple case would be to increment it by
( l f j r f j ) / number_of _flows .
The scheduler is such that providing one or more packets are always available in all of the buffers of that feed into the output scheduler.
The average aggregate flow on each path:
x ci = C L w ci ∑ ci w ci bytes / second ( 1 )
Where C L is the output link capacity and
∑ ci w ci
is the sum of all the weights of all the queues.
For this high priority elastic class of traffic (class 2 here) we want the flows x ci to be proportional to the weights w ci . There is a problem with this type of scheduler if other flows are blocked so that some of the scheduler's queues are empty. In its basic form this scheduler leaps to next highest priority packet if it finds a queue empty. If a queue stays empty for long then the average rate of the remaining active queues increases to fill the total output port capacity. This is called a work conserving scheduler. This ingress controller application requires that the output scheduler is not work conserving for class two traffic. We want to modify the algorithm so that for every fully active class two queue, x ci is always proportional to the weights w ci irrespective of which other flows are fully or partially blocked. In this way the weight w ci is acting as the key parameter in an ingress traffic flow controller controlling the sustained byte transmission rate on each path (referred to henceforth as the committed information rate on the path or CIR).
Lower classes of traffic such as best efforts traffic (class 3) can be scheduled in a work conserving manner because it does not matter if such traffic overloads distant routers.
A simple embodiment to the algorithm is to always give unused ‘virtual time credit’ from blocked class two packet time slots to class three, if there are no class three packets give it to class four. Where virtual time credit is the defined in the accompanying description of the basic scheduling algorithm. The dummy packets can either be real packets that carry arbitrary data, but are marked in some way to enable a packet discard unit after the scheduler to delete such packets. (see FIG. 5 ) Alternatively it is simply a conceptual mechanism for telling the scheduler to idle for a period equivalent to that at which a dummy packet was sent. The length of dummy packet is not important as the scheduler algorithm will arrange that the amount of idle time is appropriate. The weighting allocated to the dummy (class four) packet stream is such as to keep
∑ ci w ci
constant. Where this represents the sum of the weightings for all the queues of all the classes. (No packet discard unit shown in FIG. 2 )
Consider first the case where there is overall network congestion and plenty of TCP traffic on each path. Controlled by packet loss from the RED queues, user TCP algorithms will have allowed the flows on each path to increase until the average flow on each path is as high as the link scheduler algorithm allows. That is to say every path flow is saturated with TCP traffic up to the path scheduled committed information rate (CIR). The rate of this will be set by the scheduler algorithm as defined in Equation (1) The flow of class 2 traffic/path:
x 2 i = CIR 2 i = C L w 2 i ∑ ci w ci bytes / second ( 2 )
The question is how to set w 2i to optimise resource usage.
In DRC work a perfectly elastic source states its willingness to pay WtP (the units are arbitrary but for clarity referred to here as n-cents/sec). The network carries out the DRC optimisation for all the WtPs on all the paths and returns an n-price/unit bandwidth (in units of (n-cents/sec)/(byte/sec)=n-cents/byte say) to the source. The source is then permitted to transmit a flow at a rate:—
x 2 i = WtP 2 i p i s ( n - cents / sec ) / ( n - cent / byte ) = bytes / sec ( 3 )
The actual trunk flow rates can then be managed by managing the WtPs on each path. The DRC optimisation that sets path price ensures that the resources are shared in a proportionally fair manner across the whole network. Network management can easily control the way the resources are shared by adjusting the WtPs along each path, confident that the DRC automated n-price setting will ensure that no resource is overloaded. It is easy for instance to allocate a greater share of the total WtP to a particular set of paths exiting a particularly important set of users such as a set of servers or a highly paying business access site.
For simplicity, we assume that the network manager wishes to treat all users of this class two traffic service equally. In the first case let us assume that we want to manage the resource allocation for this high priority class of traffic according to the following simple policies.
All ingress flows considered equal at the path level—irrespective of how many TCP flows or users are using the path
Total willingness to pay constant on a per ingress node basis.
In the case that all the n paths leaving the ingress node are saturated with TCP traffic These two policies translate into:—
WtP 2 i = WtP TOT2 / n ( 4 )
where
WtP TOT2 = ∑ i = 1 → n WtP 2 i
is the total willingness to pay for this ingress node for class 2 traffic.
Taking equations 2,3 and 4 together it is deduced that the weighting factor to apply to the output port scheduler is
w 2 i = WtP TOT2 n × p i s × ∑ ci w ci C L ( 5 )
This equation says that the scheduler output port weighting is inversely proportional to path price (similar to the multiplicative rate decrease of TCP in response to congestion) and proportional to the total weighting given to class two traffic.
In cases where all weights are equal, scheduling is no longer dependent on the weights but rather on the start times of the queues alone.
These concepts can be further extended to improve the overall performance of the system.
FIG. 3 shows a modification in which the weighting of class two traffic on a path is continuously adjusted so that the sum of class one and class two traffic varies only slowly with time. Sudden jumps on(e.g. on millisecond to second timescales of premium traffic flow are compensated by momentary reductions in the class two elastic traffic so that the sum of the high priority (class One and two traffic on the path changes only slowly. This is to keep traffic flow rate change within the within the frequency response of the DRC negotiation feedback control mechanism time response. (taken as 1 second in this example, but all these suggested times could be scaled down or up without changing the principle.) NB the correction only need to be approximate say 10% accuracy as there is margin for error in the control mechanism at the routers.
In FIG. 4 the scheduling algorithm is modified so that the sum of premium plus HP Elastic traffic is approximately smoothed to fluid flow along path. The resulting smoothed flows is illustrated in FIG. 7 .
FIG. 5 shows the use of dummy packets, as described earlier, for ensuring that the scheduler control packet flows of an absolute rather than relative level. In this case dummy packets are discarded after the scheduler. This converts a proportional rate scheduler (work conserving) into an absolute rate scheduler (non-work conserving)
In the arrangement of FIG. 4 Dummy Packets are added purely to enable the scheduler to control per path flows independently of sum of packet flows. That is, to convert proportional rate scheduler (work conserving) into an absolute rate scheduler (non-work conserving)
FIG. 6 shows the use of dummy packets that are not discarded and are used to ‘fill in packet flows’ that consist of arbitrary mixtures of premium and high priority elastic traffic as illustrated in FIG. 7 , the reason the user may choose to send such packets is to ensure that the simple core routers, which are measuring traffic flow to set n-price, are not misled into thinking the traffic flow is lower than a certain control value that the edge router can set. Using this mechanism the Edge Router can maintain, increase or decrease its ‘reserved bandwidth’. When it subsequently receives a burst of high priority traffic it can then substitute some or all of the dummy stream of traffic and hence produce less unexpected jump in total high priority traffic at the core routers.
FIG. 7 thus shows how the Dummy Packet flow can be added so that sum of premium plus HP elastic plus dummy traffic is approximately smoothed to fluid flow approximation. (dummy packets not discarded). Simple metering in the subsequent standard routers gives the sum of real and dummy packet flows. The dummy packet flows can then be used to reserve bandwidth (by using it) on the DRC bandwidth negotiation timescale (e.g. 10 sec down to a few RTTs).
An example of the overall view of such a DRC control system carrying real plus dummy data traffic on each path is shown in FIG. 9 . This figure emphasises how the DRC feedback control system cannot distinguish between real and dummy flows in setting the n-price of each resource and behaves as if the control data stream were a single flow. This single flow however consists of the real data plus the dummy packet flow.
FIG. 8 shows the case where there is sufficient elastic (e.g. high priority TCP traffic) to smooth the total flow without the necessity of adding dummy packets. This is clearly less ideal than the case shown in FIG. 7 but it is none the less better than not smoothing the HP-TCP traffic.
In a further refinement it is proposed to use virtual dummy packets in network with special routers that recognise their symbolic significance e.g. as 500 packets. The spare bandwidth then can be used by local best efforts traffic in core routers. These virtual dummy packets are for instance suitably modified versions of ATM or MPLS resource management packets or IP control packets. The modification would include an indication that they are a special type of packet that represents a number of real packets and a field to indicate the number and size of the real packets they represent, perhaps measured as total number of bytes they represent.
In FIG. 10 we show an alternative arrangement for achieving a similar overall system performance. In this case instead of adding the dummy data stream to the real data packet stream, the dummy data is sent to the part of the management control system that sets the control levels in each resource. The management control system then dynamically adjusts the control set point of each resource to allow for the magnitude of the aggregated dummy packet flow that it calculates flowing thorough each resource. To achieve this, the management system needs to be aware of the network topology so it can allocate ingress flows to the correct core router resources. This system requires a larger amount of signalling traffic than the system of FIG. 9 which dummy packets go with the data flows. In a further refinement it may be desirable to ‘smooth’ the dummy flow data to a slower response speed and send information that represents this smoothed version of the dummy flow rate data at longer time intervals. This will minimise signalling traffic to the management system but obviously not allow the overall control system to track and control the changes in demand so accurately and rapidly. It will be an engineering compromise to decide what the optimum configuration, control and smoothing time constants are. It should be noted that these two systems of FIGS. 9 and 10 are conceptually very similar: in one case the dummy traffic is added to the data traffic and the control set points is fixed; in the other the dummy traffic is subtracted from a fixed reference control level by the management system and used to dynamically adjust the actual control set point of each resource.
It should be noted that in both systems more or less sophisticated modifications can be made to the instantaneous assumed dummy traffic load in order to make more efficient use of the resource available. So for a system with a measured aggregate 10 Mbit/sec dummy traffic flow through a resource, a policy may be employed to count it as much less so that more real traffic can be allowed through. This would then start to risk the possibility of unexpected surges in traffic that the ingress controllers think is ‘guaranteed’ causing momentary overload at certain resources.
The network operator could monitor the occurrence of such overloads and adjust the policies to suit his business aims.
Any range or device value given herein may be extended or altered without losing the effect sought, as will be apparent to the skilled person for an understanding of the teachings herein.
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A packet scheduling scheme schedules packets from a plurality of queues onto outgoing link. The scheme associates a weight and a virtual start time with each of the queues. Queues are selected, in order of the virtual start time, until a non-empty queue is selected. One or more packets are sent from the selected queue and then the virtual start time is updated, based on the length of the transmitted packet and the weight associated with the selected queue.
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BACKGROUND OF THE INVENTION
(a) Field of the Invention
This invention relates to tongs used, for example, in the drilling industry for connecting and disconnecting lengths of pipe, e.g. drill pipe, and more particularly to an attachment for such a tong incorporating means to measure the torque being applied through the tong when a force is applied to the tong arm by means of a cable or rope.
(B) Description of the Prior Art
By definition, the torque applied through a tong is the product of the force applied, i.e. the tension in the line, and the moment arm, which is the perpendicular distance between the center of the pipe being connected and the line of action of the force It is known to incorporate a tension indicator in the cable to indicate the force being applied to the tong arm. However, because of the change of position of the tong arm as the pipe is turned, the length of the moment arm as above defined changes, being equal to the length of the connection line, i.e. the line from the center of the pipe to the point of connection of the cable to the tong arm only when such connection line is perpendicular to the cable. In general, the moment arm is equal to such distance multiplied by the sine of the angle (X) between the cable and the connection line.
It is desirable to provide a device overcoming the problem of the variation of the angle (X), whereby torque is correctly indicated by a force measuring device regardless of the angle (X). A search of certain areas of classification of United States patents revealed the following U.S. patents as relevant to the problem:
U.s. pat. No. 2,183,633 -- Zimmermann,
U.s. pat. No. 2,801,539 -- Swenson,
U.s. pat. No. 3,589,179 -- Nicolau,
U.s. pat. No. 3,693,727 -- Bell.
The Zimmerman patent discloses a wrench employing two arms, both to be positioned with one end centered on a nut to be turned but extending in different directions, with a force indicator therebetweeen perpendicular to one arm. Force applied at any angle to the other arm is transmitted perpendicularly through the force indicator to the one arm. However, as the spring type force indicator employed shortens with application of force, the force indicator is no longer precisely perpendicular to the one arm so that the force indicator scale needs to be nonlinear in order to indicate torque.
The Swenson patent shows pipe tongs and cable with a force measuring unit in the cable. The cable end connected to the tongs passes over an arcuate support mounted on the tongs, whereby the angle between the cable and the connection line is constant, so that a torque gage connected to the force measuring unit can be linearly calibrated. The angle through which the tongs can be turned while the torque gage gives a correct reading is limited by the length of the arcuate support.
The Nicolau patent shows a pipe tong to be actuated by a cable and incorporating a torque indicator which gives a true torque indication regardless of the cable's angle to the tong arm. This is achieved by passing the cable through an eye in the torque arm, the end of the cable then extending perpendicular to the arm to a force measuring unit, so that only the component of cable tension perpendicular to the arm is applied to the force indicator. To compensate for the reaction of the tong at its eye where the cable passes through, the force measurer is mounted so that the torque effective component of the reaction force is also applied to the force measuring unit. The mounting of the force measuring unit includes relatively movable yoke and U shaped support members which must remain free to move in order that the torque indicator will give correct readings.
The Bell patent shows a pipe tong to which force is applied by a cable and which includes a torque indicator. To overcome the problem of variable angle between cable and tong, a special connection between them is employed. A lever is pivotally mounted on the tong arm. The cable is attached to one end of the lever. A load cell is positioned between the other end of the lever and the tong with the load cell axis perpendicular to the lever arm. It is said that the load cell measures the true torque applied to the lever and since the tong torque must be equal and opposite, the load cell measures the true torque applied to the tong arm.
It will be seen that all of the foregoing U.S. patents which are intended to give a linear indication of torque involve a mounting including some form of relatively moving parts, i.e. a sector on which the cable winds (Swenson), relatively slidable yoke and U shaped members (Nicolau), and a pivotally mounted lever (Bell).
It is an object of the present invention to provide a torque indicator for attachment to a tong arm that will give a correct reading independent of the angle of the cable employed to apply force to the tong arm and which will be inexpensive to manufacture and simple and reliable in operation, involving few moving parts.
SUMMARY OF THE INVENTION
According to the invention, there is provided a true torque indicator unit for attachment to or manufacture integral with a pipe tong. The unit comprises a U section attachment bracket adapted to encompass a tong arm and to be secured thereto. A support tube lying in the open side of the bracket and closing same about the tong arm is releasably secured to the bracket by bolts. A gusset plate welded to the tube extends in a direction away from the tube and bracket perpendicular to the tong arm. A pair of bars are each pivotally connected at one end to the upper and lower sides respectively of the end of the plate. The other ends of the bars are pivotally connected to the ends of a U shaped bar forming means for making connection to a cable. The two bars form one link of a toggle. The other link of the toggle is provided by a transducer pivotally connected at one end to the tube and at the other to the two bars where they join the U shaped bar. The transducer is of the type that converts force to an electric signal. Preferably the toggle link formed by the transducer is disposed with its axis perpendicular to the radius from the center of the pipe gripping means of the tong to the point of connection of the transducer to the tong arm, so that all force transmitted to the tong arm by the transducer creates torque. The toggle link formed by the two bars lies on a radius from the center of the pipe gripping means of the tong, so that the force transmitted by the bars to the tong arm exerts no torque. In other words, the toggle divides the force of the cable applied to the tong arm into two components, with the entire component perpendicular to the connection line (moment arm) being applied through the transducer. The transducer converts force to an electric signal to give an indication of the torque applied by the tong arm which is correct regardless of the angle of the cable. Variations in the toggle angles with applied force are minimal due to the fact that the force-to-electric signal transducer, e.g. a strain gage welded onto a solid steel body, responds to a wide range of force with a change of dimensions of only molecular magnitude, and also due to the fact that the toggle link formed by the two bars is short compared to the transducer link, e.g. less than half the length, whereby even a large change in length of the transducer would not shift it far from perpendicularity to the moment arm.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals and wherein:
FIG. 1 is a plan view of the invention applied to a tong arm;
FIG. 2 is a plan view of the invention similar to FIG. 1 but to a larger scale;
FIG. 3 is a section taken at 3--3 of FIG. 2; and
FIGS. 4 and 5 are fragmentary views similar to FIG. 2 showing modifications.
The parts are all made of steel except for the transducer and electrical instrument connected thereto, and the usual convention for showing metal in elevation and in section have been employed.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring now to FIGS. 1-3, especially FIG. 1, there is shown a pipe 11 to which is applied the gripping means 13, 15 and 17 on one end of arm 19 of pipe tong 21.
A torque indicator unit according to the invention includes support means having a U shaped support bracket 23 secured about arm 19 and support tube 25 bolted thereto. A gusset support plate 27 is welded to the tube. A force dividing toggle is attached to the support means. The toggle includes a short link comprising two bars 29 (see also FIG. 2) pivotally connected at 33 to plate 27. The toggle also includes a second link having a force-to-electric signal transducer 31. One end of said force-to-electric signal transducer 31 is pivotally connected at 35 to the other ends of bars 29, and the other end of the transducer is pivotally connected at 34 to the support tube.
As indicated by broken line 36, the center 37 of pipe 11, and of the gripping means 13, 15, 17 when in the closed position around the pipe 11, and the centers 33, 35 (see FIG. 2) of the pivotal connections of bars 29 with plate 27 and transducer 31, are in alignment. The axis of transducer 31, indicated by broken line 41, is at right angles to the connection line indicated by broken line 42, the connection line being a line through pipe gripping means center 37 and pivot 34, the latter being the point of application of force to the tong arm.
A rope or cable 43 has an eye 45 (see FIG. 3) connected to U shaped bar 47. Bar 47 is pivotally connected at 35 to the juncture of transducer 31 and bars 29. By this means, force can be applied to the tong arm. The resulting torque is visually indicated by galvanometer 49 connected by electric cable 51 to transducer 31. A sounder 53 connected to the galvanometer can be set to sound whenever a desired torque is achieved or exceeded.
Referring now particularly to FIGS. 2 and 3, in order to allow bracket 23 and support tube 25 to both grip arm 19 tightly, the four openings 61, (only three are visible in the drawings) through which pass attachment bolts 63 are elongated to allow for adjustment. This insures that the line through the axes of pivots 33, 35 will be properly positioned to pass through center 37 of the closed pipe gripping means 13, 15, 17. It is the dimensioning of bars 29, plate 27, tube 25, and transducer 31 which determine the position of the center of pivot 35 relative to the center of pivot 34 so that the line joining centers 34, 35 is perpendicular to the line joining centers 34, 37, as required to effect the desired resolution of the force from the third toggle link provided by U shaped bar 47.
It is to be noted that while support bracket 23 and support tube 25 are tightly held together by bolts 63 and the four nuts 65 (only one appears on the drawings) screwed thereon, nut 67 on pivot bolt 35 and the like nuts (not appearing in the drawings) screwed onto pivot bolts 33, 34, do not bind bars 29 and transducers 31 to plate 27 and tube 25, whereby the transducer and bars transmit forces along their lengths, but no bending moment. Any desired means can be employed to keep the relatively loose nuts from coming unscrewed, e.g. lock nuts 69 may be employed.
While a preferred embodiment of the invention has been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit of the invention.
Referring now to FIG. 4, the support bracket 23 and support tube 25 could be omitted and plate 27' and transducer 31 could be secured directly to tong arm 19, thereby making the tong and torque indicator one assembly. To avoid repetition of the description, in FIG. 4 like parts are given the same reference number as in FIGS. 1-3, and analagous parts are given the same reference number except primed. The operation is the same.
While the transducer axis is preferably at right angles to the connection line 42, this is not essential. For example, as shown in FIG. 4, if the axis 41 of transducer 31 was disposed at right angles to centers line 36, the force measured by transducer 31 would include a component directed radially through pipe gripper center 37. Such component exerts no torque on the pipe. However the ratio of such component to the torque exerting component perpendicular to the connection line would be constant and independent of the cable angle. Therefore, the galvanometer could be calibrated to read true torque independent of the cable angle.
It will be apparent therefore, that, in the FIGS. 1-3 embodiment, the disposition of transducer axis 41 could be as in FIG. 4 or any other desired angle. This is illustrated in FIG. 5. The angle shown in FIG. 1 is preferable, however, because it minimizes the required force transmitting capacity of the transducer. For this reason, the FIG. 1 disposition of transducer 31 would be preferable also in the FIG. 4 embodiment.
In view of the large forces employed in making up drill pipe connections and the minimal movement of the links 29, 31 of the force dividing toggle, it will be apparent that any slight friction at pivot points 33, 34, 35 of the toggle such as would occur if the nuts 67 were drawn up fairly tight on bolts 33, 34, 35 would have little adverse effect, since not much torque would be transmitted by such friction compared to the large torque applied to the tong arm. It is also to be noted that the transducer can pivot freely regardless of the degree of make up of the nuts on pivot bolts 34, 35, since the bolt tension is taken by tube 25 and U bar 47 respectively.
Although the preferred embodiment and preferred method of operation as described in detail have been found to be most satisfactory, many variations in structure and method are possible. For example, it will also be apparent that cable attachment U bar 47 could be omitted and cable eye 45 applied directly about pivot bolt 35. However, it is preferred to employ a link such as U bar 47 for pivotally applying force to force dividing toggle 29, 31 at pivot 35.
Because many varying and different embodiments may be made within the scope of the inventive concept taught herein and because many modifications may be made in the embodiment herein detailed in accordance with the descriptive requirements of the law, it should be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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A torque indicating attachment for a pipe tong arm is disclosed. The attachment comprises support means releasably connected to the arm and a toggle pivotally connected to the support means. The toggle includes a second toggle link oriented radial to the center of the pipe gripping means of the pipe tong and a first toggle link oriented perpendicular to the line from the center of the pipe to the pivot point of the pivotal connection of the second toggle link to the support means. The first toggle link includes an electro-mechanical transducer connected to a visual and sonic readout galvonometer.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This non-provisional application claims benefit of provisional application U.S. Ser. No. 61/935,186 filed on Feb. 3, 2014.
BACKGROUND
[0002] Field of the invention
[0003] The present invention generally relates to the design of a mechanical connection assembly used in conjunction with jointed pipe., threaded pipe, coiled tubing, stick pipe and any threaded or non-threaded pipe section or tubular for down hole operations that involve and utilize in-line safety valves also known in the art as check valves, safety valves, flapper valves and ball valves or valves of similar nature that permit isolation of wellbore fluids from returning to surface via the tubular inside diameter. In particular aspects, the invention relates to a device used for connecting joints of pipe using a manual make up connection (Clutch) that requires no significant tools other than an Allen wrench or screw driver type hand tool to secure the connection. The system can also be used to make up a system known as a bottom hole assembly (BHA). A secondary aspect to the connection is the ability to prevent return of hydrocarbons or fluid and gas of any type to surface by use of a single or multi check valve arrangement integrated into the connection. This dual flapper cheek valve arrangement, depicted in the art work, provides for servicing of the flapper carrier assembly on the rig floor without the need to rig down surface equipment. The present invention also permits torque loading through the connector in both clockwise and anti clockwise direction without risk of backing off the assembly it is attached too.
[0004] The ability to eliminate threaded connections from many aspects of the oil and gas industry provides for superior joints in terms of a useable connection that cannot back off, eliminates specification requirements for makeup torque, prevents mistakes, vastly reduces the risk of accident and injury and reduces time and increase cost efficiencies across the operational spectrum, for example during drilling or coiled tubing deployed through tubing intervention or drilling
[0005] Description of the Related Art
[0006] Standard oil and gas practices use threaded pipe connection; a box thread on top of the pipe and a pin thread on the bottom. These threads permit connection to other pipe sections but also allows for connection to other assemblies and tools Is mown as a bottom hole assembly or BHA.
[0007] The current invention provides for a system that allows pipe, coil tubing, bottom hole assemblies and other devices, strings, components, tools and equipment to be connected using a is manual make up connection whereby no ‘iron roughneck’, tongs, wrenches or other significant mechanical, pneumatically or hydraulically actuated systems am needed to connect two pipe joints together.
[0008] Makeup of the pipe is achieved by pushing the connections together and rotating manually a threaded ring, that locks bob the male and female connections together making a joint suitable in strength and application to use in all environments currently used for jointed connections. Within the joint the cheek valve assembly, if needing servicing in the event the surface integrity test fails, can be manually retrieved from the connection and either serviced or replaced in-situ. Something current system do not offer.
SUMMARY OF THE INVENTION
[0009] The present invention offers significant improvements over that of today's thread pipe and bottom hole assembly systems. Whereas premium threads are required to ensure pressure integrity of the pipe connection, bottom hole assembly or tooling the Clutch connector accomplishes this by use of elastomeric seals containing pressure both tubing and annular. Detrimental to today's connections is the need for heavy makeup equipment. This makeup equipment can come in many forms but ultimately provide the same end result—a tight high torque sealing connection. Makeup equipment to secure the threads requires heavy equipment such as iron rough neck systems. These systems are both expensive, heavy,hydraulically actuated and require skill and training to use w efficiently and safely. Other tools such as manual rig tongs have been known to be extremely dangerous with many incidents recorded over the decades and many men losing fingers and other body parts. Wrenches and come-a longs, chains have been and are still employed to make up smaller pipe and coiled tubing assemblies. These are also very dangerous techniques to implement and offer the end user little margin for safety when in use. Other ways to secure threaded connections include throwing chains, strap wrenches and even bonding agents. hi many of these applications the actual torque force required to secure the pipe thread connection is rzut recorded during thread makeup and as such equipment is prone to back off and ultimately left down hole to be retrieved ‘fished’ at a later date.
[0010] The present invention eliminates the need for all of the above aforementioned systems, provides for an exceptionally strong connection, increase safety to personnel masking up the connection and eliminates unknown torque requirements for the connection because there are no torque specifications needed.
[0011] Also today's pipe connections offer no pressure integrity within the pipe body to prevent hydrocarbons or fluids to return to surface either at a single joint point or at multiple joint intervals. Normally a surface Kelly valve or ball valve/BoP system is installed to aid in the control and prevention of hydrocarbons to surface. The present invention incorporates a dual flapper check valve carrier that is ‘on the pipe’ serviceable and can he employed at one or multiple joints. The flapper check can also he replaced with a ball valve system to eliminate the need for the Kelly valve. Threaded pipe connections have only one way to transmit torque through the string and that is in the direction of the thread machined profile, generally clockwise. This means that in the event of back torque, stick slip of pipe or indeed anti-clockwise rotation, the risk of backing off the threaded connection is highly possible and happens regularly throughout the industry. The present invention eliminates the possibility of thread back off due to the implementation of multi-castellation on both the male and female connections. In the event pipe problems occur, stuck pipe, sticking in hole, debris issues, etc the Clutch connector can be manipulated both in the clockwise and anti clockwise directions to aid in freeing the pipe. This cannot be achieved with todays threaded technology due to risk of thread back-off and separation of the tubing, drill pipe, bottom hole assembly.
[0012] The present invention allows for makeup and breakout of connections in seconds rather than minutes and provides for a safer handling pipe joint, bottom hole assembly or tooling accessories.
BRIEF DESCRIPTION THE DRAWINGS
[0013] The advantages and other aspects of the invention will be readily appreciated by those of skill in the art and better understood with further reference to the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawings and wherein:
[0014] FIG. 1 illustrates an exemplary wellbore 3 which has been drilled through the earth 4 down to a hydrocarbon-bearing formation 5 from the surface 6 . Perforations 7 , a type known in the art, extend through the wellbore 3 and outwardly into the formation 5 to permit hydrocarbon production fluid to flow from the formation 5 to the interior of the wellbore 3 .
[0015] FIG. 2 is a cross sectional view of the fully assembled connector is the released position numerically detailed constructed in accordance with the present invention.
[0016] FIG. 3 is a cross sectional view of the fully assembled connector is the released position constructed in accordance with the present invention.
[0017] FIG. 4 is a cross sectional view of the fully assembled connector is the Locked position constructed in accordance with the present invention.
[0018] FIG. 5 is a cross sectional view of a pipe joint portraying the male and female connectors disconnected constructed in accordance with the present invention.
[0019] FIG. 6 is a cross sectional view of a pipe joint portraying the male and female connections connected constructed in accordance with the present invention.
[0020] FIG. 7 is across sectional view of a coiled tubing system portraying a connector system attached to the bottom of the coiled tubing string for make up bottom hole assembly constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] FIG. 1 illustrates an exemplary wellbore 3 which has been drilled through the earth 4 down to a hydrocarbon-bearing formation 5 from the surface 6 . Perforations 7 , of a type known in the art, extend through the wellbore 3 and outwardly into the formation 5 to permit hydrocarbon production fluid to flow from the formation 5 to the interior of the wellbore 3 .
[0022] The present invention FIG. 2 provides for a way to either cross-over onto existing pipe a ‘Clutch’ joint connection that allows for make-up to individual pipe joints collet tubing pipe joints, bottom hole assemblies, tools and equipment utilizing the male and female threaded portion of the connections # 13 & # 14 . The system can also be manufactured directly onto pipe, coiled tubing or bottom hole assemblies, tooling, etc without the need for iron rough necks, pipe wrenches, mechanical and hydraulic make-up tools, etc.
[0023] The connection # 1 & # 2 incorporate two sets of locking dogs # 6 & # 7 . Locking dogs # 6 are manufactured as part of the connector # 1 and # 2 . The locking dogs # 7 are manufactured as individual dogs. Locking dogs # 6 , allows for torque to be applied through the joint connection # 1 & # 2 in both clockwise and counterclockwise directions and allows for tensile and compression loading to permit both deployment and recovery the pipe, coil tubing bottom hole assembly, etc. The dogs # 6 & # 7 can be manufactured in multiples of two thereby permitting minimal rotation of the male # 2 and female # 1 pipe joints to align the connectors.
[0024] The second set of dogs # 7 are the primary locking dogs designed to interlock the male # 2 and female # 1 connections through a set of windows # 17 manufactured on the female connector. The second set of dogs # 7 engage within a recessed groove # 18 manufactured into the male section # 2 of the Clutch connector.
[0025] The outer locking sleeve # 5 is mounted upon a thread # 19 on the female connector Clutch. Rotation of this sleeve clockwise will engage the four dogs # 7 into the male mating groove # 18 thereby locking the male # 2 and female # 1 Clutch connectors together. Dogs # 6 will be locked to permit bi-directional torque loading during operations such as drilling. Rotation of the locking sleeve 5 engages an internal upset # 9 that forces the dogs # 7 into the male engagement groove # 18 .
[0026] Rotation of the locking sleeve # 5 in the anti-clockwise direction will permit unlocking of dogs # 7 thereby unlocking the music # 2 and female # 1 Clutch connectors for disassembly from the pipe, coiled tubing, bottom hole assembly or tools.
[0027] A spring release mechanism # 8 assembled into the locking dogs # 7 will apply a constant force outwardly on the locking dogs # 7 . When the Locking sleeve # 5 is released in the anti-clockwise position the spring release mechanism # 8 forces the locking dogs # 7 outward away from the male locking groove # 18 thereby enabling the male # 2 and female # 1 connectors to release.
[0028] In the event the male # 2 and female # 1 Clutch connectors become difficult to remove the looking sleeve # 5 can be used to ‘jack’ apart the male # 2 and female # 1 connectors. During normal operations the locking sleeve # 5 is design to stay engaged with the threads # 19 when in the release position at all times.
[0029] When the locking sleeve # 5 is in the locked position (clockwise), four set screws # 10 are installed to prevent the locking sleeve # 5 from backing off due to vibration or rotation. A separate anchor ring # 20 can be placed between the male # 2 and female # 1 Clutch connections to ensure the Locking ring # 5 cannot move in the anti-clockwise position during operations. This anchor ring # 20 can be secured with cap head or set screws.
[0030] A single anchor screw can be implemented that also prevents the locking ring from any anti-rotational movement and is placed in the # 6 dog section.
[0031] Elastomeric seals # 11 , 15 & 16 are contained on the male # 2 and female # 1 Clutch connectors to ensure tubing to annulus seal integrity. Wiper rings # 21 & 22 are installed a top and bottom of the seals # 11 , 13 & 16 and locking ring # 5 . These prevent ingress of debris that could result in the locking sleeve # 5 becoming inoperable.
[0032] When the male # 2 and female # 1 connectors are mated and the locking ring # 5 is rotated clockwise to the set position setting the locking dogs # 7 into the mating groove; 18 the system is ready to deploy into the wellbore.
[0033] Once the system is ready to perform the given operation and weight is set down on the connector the load is then transferred from the locking dogs # 7 to the load Shoulder # 12 . This design feature prevents excessive force being applied to both the locking dogs # 7 and the four windows # 17 . Only when load is applied to the connectors in the upward axis does the locking dogs # 7 required to have any load carrying capacity.
[0034] In coiled tubing and drilling operations to prevent the return of hydrocarbons to surface via the inside diameter of the connector assembly a dual flapper cheek valve assembly # 3 is installed within the connector sub # 1 . The dual flappers # 4 are hinged and spring loaded to return to a closed position in the event hydrocarbons travel upward within the connector system. Once the flappers # 4 have closed they will seal and prevent any fluid travel to surface.
[0035] The dual flapper arrangement # 4 is housed in a carrier body # 3 . This carrier body # 3 is a service item that can be removed readily by disconnecting the Clutch connection # 1 & # 2 by rotating the locking ring # 5 , releasing the locking dogs # 7 and pulling the connectors apart. The dual flapper assembly # 3 can now be manually retrieved from within the connector # 1 and either serviced or replaced with a new dual flapper carrier arrangement # 3 .
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A connection that provides for a means to manually make-up a pipe connection or assembly without the need for wrenches, tongs, hydraulic torque equipment, etc. A connection design that can be assembled and manufactured without threads and permits the same loading, torque and integrity requirements of threaded joint systems. A system that incorporates a locking mechanism that requires only manual effort to disengage.
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FIELD OF THE INVENTION
The present invention relates generally to physiological sensors. More specifically, the present invention relates to a fingertip sensor adapted to improve sensor stability in order to minimize the occurrence of motion-induced artifacts within a physiologic signal.
BACKGROUND OF THE INVENTION
Non-invasive physiological monitoring is a common means for testing, detecting, and treating a physiological condition. Typically, non-invasive monitoring techniques such as pulse oximetry, electrocardiography (ECG), electroencephalography (EEG), and ultrasonic imaging, to name a few, require that a sensor be placed in direct contact with a patient undergoing the procedure.
Pulse oximetry involves the non-invasive monitoring of oxygen saturation level in blood-profused tissue indicative of certain vascular conditions. In practice, light is passed through a portion of a patient's body which contains arterial blood flow. An optical sensor is used to detect light which has passed through the body, and variations in the detected light at various wavelengths are then used to determined arterial oxygen saturation and/or pulse rates. Oxygen saturation may be calculated using some form of the classical absorption equation know as Beer's law.
Accurate measurement of oxygen saturation levels are predicated upon optical sensing in the presence of arterial blood flow. A finger provides a convenient access to a body part through which light will readily pass. Local vascular flow in a finger is dependent on several factors which affect the supply of blood. Blood flow may be affected by centrally mediated vasoconstriction, which must be alleviated by managing the perceived central causes. Peripheral constriction via external compression, however, can be induced by local causes. One such cause of local vasococompression is the pressure exerted by the sensor on the finger. Many currently available pulse oximetry finger sensors have a hard shell which has a high profile and is maintained on the finger by the action of a spring. Since excess pressure on the finger can dampen or eliminate the pulsation in the blood supply to the finger, these springs are intentionally relatively weak. The result of this compromise is that the spring-held sensors readily fall off the finger. It is desirable for a finger sensor to be retained on the finger with only slight pressure, while at the same time being immune to easy dislocation.
Non-disposable finger sensors typically utilize a clamp design for retaining the sensor on the finger. Such devices generally consist of a small spring-loaded clip which attaches to the finger tip in a manner similar to a common clothespin.
Many known non-disposable sensors are relatively bulky. The prior art sensors with their high profile exhibit a relatively high inertia of the housing relative to the finger. This results in a susceptibility to relative motion between the sensor and the finger as the finger is moved. This relative motion manifests itself as motion artifacts in the detected signal. It would be desirable for a finger sensor to be as light as possible so as to minimized relative inertial motion between the sensor and the finger.
Motion artifacts caused by displacement of the lead wire are especially problematic for oximetric sensors. Common oximetric finger sensors often locate the lead wire from the sensor over a central portion of a patient's finger. When the patient flexes or curls his finger, it is common for the lead wire to pull against the sensor causing the light elements to be displaced.
Consequently, there is a need in the art for a sensor assembly which is capable of mechanically isolating a sensor holder without the need to tightly secure the sensor to the patient.
SUMMARY OF THE INVENTION
The present invention is directed to a sensor assembly which provides improved mechanical isolation between the sensor holder region and other regions of the sensor assembly. In one embodiment, the sensor assembly includes a collar, a fenestrated region, a sensor holder, and a sensor. The collar, the fenestrated region, and the sensor holder are preferably made of a flexible material, such as a polymer. The sensor can include any known sensors used for monitoring of physiological parameters.
In one embodiment of the invention, the collar defines an entrance into the sensor assembly. In one embodiment, a strain relief extends generally perpendicularly to the collar and is located near a lateral side of the sensor assembly. The strain relief cooperates with the collar to define a pathway for a lead wire which connects the sensor to a physiological monitor.
In one embodiment, the fenestrated region includes a plurality of bridges separated by windows. The fenestrated region may additionally be of a reduced thickness compared to other portions of the sensor assembly. In another embodiment of the invention, the fenestrated region can include one relatively large opening in the sensor assembly. The fenestrated region may respond to external forces transferred through the collar by substantial deformation, including stretching, twisting, buckling and bending. As a result, the fenestrated region contributes to mechanical isolation of the sensor holder from the collar. Consequently, when a force is applied to the collar, the relatively thin fenestrated region is able to stretch or distort without disrupting the sensor holder. The fenestrated region which can include one or more fenestrations or openings into the interior of the sensor assembly, promotes an increase in user comfortability and digit ventilation. The fenestrated region is optional and embodiments of the present invention may be device of one or more fenestrations.
In one embodiment, the sensor holder provides seats wherein portions of the sensor element is received. The seats are positioned such that the sensor element is optimally located with respect to the patient. A finger stop and guide may be provided within an interior of the finger assembly in order to facilitate the positioning of the finger relative to the sensor element.
In one embodiment, an elongated pleat extends across each lateral side of the sensor assembly. The pleats enable the sensor assembly to expand and accommodate a variety of finger sizes.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages 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 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. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS AND FIGURES
For purposes of facilitating and understanding the subject matter sought to be protected, there is illustrated in the accompanying drawings an embodiment thereof. From an inspection of the drawings, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated.
FIG. 1 is a perspective view of a first embodiment of a finger assembly according to the present invention.
FIG. 2 is a top plan view of the finger assembly of FIG. 1 .
FIG. 3 is another perspective view of the finger assembly of FIG. 1
FIG. 4 is a cross-sectional view of the finger assembly of FIG. 2 taken along lines B-B.
FIG. 5 is a cross-sectional view of the finger assembly of FIG. 2 taken along lines A-A.
FIG. 6 is a cross-sectional view of the finger assembly of FIG. 2 taken along lines C-C.
FIG. 7 is a perspective view of another embodiment of the present invention.
FIG. 8 is a perspective view of another embodiment of the present invention.
FIG. 9 is a perspective view of another embodiment of the present invention.
FIG. 10 a perspective view of another embodiment of the present invention.
FIG. 11 is a perspective view of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In one embodiment of the present invention, as shown in FIGS. 1-6 , a finger sensor assembly 10 is provided which mechanically isolates the sensor elements relative to other portions of the sensor assembly 10 in order to minimize inadvertent displacement of the sensor elements caused by external forces. For the purposes of explanation only, the present invention is disclosed utilizing an embodiment that is configured for the measurement of oxygen saturation through known oximetric transmittance techniques. As one skilled in the art can readily appreciate, the present invention is easily adaptable to accommodate a number of different physiological monitoring applications and configurations, including but not limited to, other optical sensors, reflective sensor, etc.
FIG. 1 illustrates an embodiment of the assembly 10 adapted as an electro-optical sensor for a fingertip. In the illustrated embodiments, sensor assembly 10 is utilized within a system including a monitoring unit (not shown) for oxygen saturation measurement. Sensor assembly 10 preferably includes a molded polymeric body defining a collar 12 , a fenestrated region 14 , and sensor holder 16 . As illustrated in FIG. 5 , sensor assembly 10 further includes an oximetric sensor having one or more LED's 18 and one or more photodetectors 20 and being connected to the monitoring unit via a lead wire 22 . The oximetric sensor can also or alternatively contain other known components utilized in the measurement of oxygen saturation.
As shown in FIGS. 1 and 3 , collar 12 defines an entrance into an interior of the sensor assembly 10 . The collar 12 defines internal surfaces 26 , 28 which are shaped to comfortably conform to the top and bottom surfaces of a human digit. The collar 12 is preferably substantially thicker than either the fenestrated region 14 or sensor holder 16 . The molded shape and thickness of collar 12 enable it to comfortably engage the human digit. As illustrated in FIG. 5 , collar 12 extends in a longitudinal direction and has a length L c . The sensor assembly has an overall length, L.
The illustrated embodiment of sensor assembly 10 includes a strain relief 30 extending away from collar 12 . The strain relief 30 defines an internal passageway 32 in communication with the interior of assembly 10 . The strain relief 30 and collar 12 together define a pathway for a lead wire 22 . In one preferred embodiment, the strain relief 30 is positioned near a lateral side of the collar 12 . As described in more detail hereinafter, by so positioning the lead wire 22 near a lateral side of collar 12 the deleterious effects of external forces applied to lead wire 22 may be minimized. In the illustrated embodiment, strain relief 30 is positioned between the longitudinal centerline and the lateral edge of the sensor assembly 10 . In other embodiments of the present invention, the strain relief 30 may be positioned further away from the centerline.
The fenestrated region 14 includes one or more fenestrations such as openings, windows, holes, perforations and/or slits. The fenestrations contribute to the mechanical isolation of the sensor holder 16 from the collar 12 by permitting the fenestrated region 14 to undergo substantial deformation or displacement relative to its relaxed state without displacing the sensor holder 16 . In one embodiment, the fenestrated region 14 is preferably thinner than both the collar 12 and the sensor holder 16 . As a result, the relatively thin fenestrated region 14 is able to deform in response to an external forces (transferred through collar 12 and/or sensor holder 16 ) while minimizing disturbances transferred to the sensor holder 16 .
In the embodiment of FIGS. 1-6 , the fenestrated region 14 includes a plurality of elongated bridges 40 which connect the collar 12 to the sensor holder 16 . Each bridge 40 includes a plurality of resilient, laterally extending folds 42 which facilitate buckling or expansion of the bridges 40 in response to external forces transferred through lead wire 22 . A plurality of openings 44 are defined between the bridges 40 . As illustrated in FIG. 5 , fenestrated region 14 extends in a longitudinal direction and has a length L fr . Openings 44 of the illustrated embodiment are generally unobstructed. In other embodiments of the present invention, openings 44 may include a screen, mesh or fabric structure. For example, the fenestrations of the embodiment of FIG. 8 are defined by a screen element 50 , and the embodiment of FIG. 7 includes a plurality of small holes 52 defining the fenestrations. FIG. 9 illustrates a finger sensor assembly 10 according to the present invention which lacks a fenestrated region. In place of the fenestrated region, an area of reduced thickness 58 is defined between the collar 12 and the sensor holder 16 . As another alternative, FIG. 10 illustrates a finger assembly 10 having a single relatively large opening or fenestration 44 on each side.
Referring particularly to FIG. 5 , preferably the length of the collar, L c , is between 5% to 35% of the overall length of sensor assembly 10 , L, and the length of the fenestrated region, L fr , is between 20% to 50% of sensor 10 length, L. In a preferred embodiment, the length of the fenestrated region, L fr , is approximately 35% of sensor length, L, and the collar length, L c , is approximately 20% of sensor 10 length, L.
The sensor assembly 10 defines an expandable interior for receiving the user's finger. In the illustrated embodiments, the sensor assembly 10 includes a finger seat 54 and finger stop 56 for engaging the finger and thereby locating the sensor elements relative to the nail region of the user. The sensor holder 16 is adapted to align the sensor elements 18 , 20 in position relative to a finger surface. Preferably, sensor holder 16 includes a finger seat 54 which functions to orient the sensor assembly 10 relative to a human digit so that sensor elements 18 , 20 are optimally positioned relative to a finger surface. One skilled in the art will readily appreciate that the sensor holder 16 is easily reconfigured so that the seat 54 and/or stop 56 may be positioned or shaped to accommodate the needs of a particular sensor.
In the illustrated embodiments of the present invention, a pleat structure 60 extends along each opposing lateral side of the sensor assembly 10 . The pleat structure 60 expands to allow the finger assembly 10 to accommodate a variety of differently sized fingers. Pleat structure 60 may include one or more folds of material. In other embodiments of the present invention (not shown), pleat structure 60 may be differently configured and/or limited to the collar 12 and/or sensor holder region 16 .
Lead wire 22 may include one or more conductive wires or may include a light conducting fiber (not shown). In a preferred embodiment, a portion of lead wire 22 is maintained within the interior of the sensor assembly 10 . That portion of the lead wire 22 within the sensor assembly 10 may be a conductive wire, a flexible conductive sheet, or another conductive element having a different configuration. Those of ordinary skill in the art will appreciate a variety of different ways to route portions of the lead wire 22 from the strain relief structure 30 to the sensor elements 18 , 20 of the sensor holder 16 .
Sensor assembly 10 may be comprised of thermoplastic materials, thermoelastic materials, silicone rubbers, etc. Sensor assembly 10 may be comprised of a plurality of different materials having different material properties. For example, collar 12 may be of a stiffer material than the material of fenestrated region 14 and/or sensor holder 16 . One of ordinary skill in the art would appreciate a wide variety of different materials that may be utilized to practice the present invention.
Referring to FIG. 11 , another embodiment of the sensor assembly 10 is illustrated. In this embodiment, collar 12 of sensor 10 is less massive than the embodiments of FIGS. 1 .- 10 . Collar 12 of FIG. 11 may be comprised of a different material than other elements of sensor 10 . For example, collar 12 may have a different durometer than other portions of sensor 10 , but may otherwise be of an identical or similar material. As a result, collar 12 of the present invention need not be thicker than other portions of sensor 10 . Collar 12 is defined as the structure proximate the digit opening of sensor 10 .
In application, the digit is inserted into sensor assembly 10 and the lead wire 22 extends from the sensor assembly 10 and is connected to a physiological monitor. The sensor assembly 10 is maintained in place by resilient forces created by the collar 12 , fenestrated region 14 and sensor holder 16 . The strain relief 30 and collar 12 cooperate to oppose lateral movement of lead wire 22 . Preferably, the fenestrated region 14 has a reduced capability to transfer forces applied at the collar to the sensor holder 16 . In one embodiment of the present invention, the fenestrated region would be minimally capable of transferring a compressive force from the collar 12 to sensor holder 16 , and would instead buckle or deform under such a compressive force. In a preferred embodiment, the strain relief 30 positions the lead wire 22 away from the center of the inserted finger. With this offset of lead wire 22 relative to the longitudinal axis of the sensor assembly 10 , the patient is able to curl his finger without tensioning the lead wire 22 and disturbing the sensor holder 16 .
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, device, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
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A flexible finger sensor having a finger entrance, a sensor holder at a distal end of the assembly, and a fenestrated region disposed between the finger entrance and the sensor holder. A displacement resistant finger sensor and method of use for reducing motion-related artifacts by mechanical isolation from external forces by providing a resilient sensor body having a digit entrance, a sensor holder, and a fenestrated region between the digit entrance and the sensor holder. The sensor holder maintains sensing elements relative to a user's finger, with said sensing elements being in communication with a monitoring device via a lead wire. The lead wire may extend at a lateral edge of the sensor body. A force to the lead wire may be applied so as to distort the fenestrated region without substantially disturbing the sensing elements relative to the finger surface.
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BACKGROUND OF THE INVENTION
This invention relates to an improved container. This invention will be shown and described as a container for holding, shipping and storing ice cream, however other products may be used with this invention.
Products, such as ice cream, are typically packed, shipped, and stored in cardboard containers. One problem with these containers is that they are not structurally sound. Ice cream must fill the entire container in order to give the cardboard container structural strength for stacking multiple layers of the ice cream containers.
Another problem with this type of container is that as the ice cream thaws and becomes more liquefied the container begins to soften and can fall apart. Thus, a more structurally sound ice cream container is desirable.
Another problem with traditional ice cream containers is that, as mentioned above, they are traditionally filled clear to the rim with ice cream, and then a lid is placed on top of the ice cream container. When shipments of ice cream in this type of container are shipped over high elevation areas, the air and ice cream in the containers begins to expand as they reach higher elevations. Thus, the lids tend to be either deformed, or pushed completely up off of the top of the container. As a result, ice cream containers may be opened and the contents not fit for consumption. Therefore, a container which accommodates for this problem of shipping ice cream or other frozen products over high elevation areas is desirable.
In view of the foregoing, it is a primary feature of advantage of the current invention to provide an improved container.
Another feature or advantage of the current invention is a container which is tamper resistant.
Another feature or advantage of the current invention is a container which indicates once the container has been opened after being factory sealed.
Another feature or advantage of the current invention is a container which structurally supports itself and is stackable.
Another feature or advantage of the current invention is a container which is useable for medium to low temperature applications.
Another feature of advantage of the current invention is a provision of a container which is efficient in operation, durable in use, and economical to manufacture.
A further feature or advantage of the current invention is a method of filling ice cream in a container to reduce overflow of ice cream when being shipped over high altitudes or low atmospheric pressures.
These and other features and advantages of the current invention will become apparent according to the claims and specification that follow.
BRIEF SUMMARY OF THE INVENTION
One aspect of the current invention is a container having a base and an integral sidewall extending upward from the base forming a continuous sidewall around the base with an integral upper seal rim at an upper portion of the sidewall for engaging a lid and a container skirt around an upper outside portion of the sidewall integrally connected between the sidewall and the upper seal rim. A tear tab is integrally and removably formed in the skirt and approximately parallel to the skirt. The tear tab is formed with a tear tab lever extending upward and outward from the tear tab allowing a user to pull downward and outward to separate the pull tab from the skirt.
Another aspect of the current invention is a container having an upper seal rib extending outward from and adjacent to the upper seal rim around the upper seal rim.
Another aspect of the current invention is a lid for sealing a container comprising a continuous inner wall with a lid skirt integrally formed around the inner wall forming a lid channel. A continuous pressure rib is formed inside the lid channel around the lid adjacent the inner wall and the lid channel. A continuous rim shoulder is formed inside the lid channel adjacent the lid channel and the lid skirt and a non-continuous seal rib is formed inside the lid channel around the periphery of the lid channel forming one or more vents.
Another aspect of the current invention is a lid having one or more lift tabs integrally formed with and extending outward from the lid skirt.
Another aspect of the current invention is a lid wherein the lid skirt extends greater than 0.1 inches below the inner wall.
Another aspect of the current invention is a combination of the lid and container wherein the inner wall of the lid is above a fill line within the container on the sidewall providing an air gap between the product within the container and the lid when the container is filled to about the fill line and the product and the lid is placed on the container to seal the product within the container.
Another aspect of the current invention is a method of filling a container with a frozen product and preventing the frozen product from expanding so much as to pop a lid off of the container when shipped at high altitudes, the method comprised of filling the container with the product to a fill line within the container, placing a sealable lid on the container so that there is an air gap between the product and the lid and providing one or more vents along a seal on the lid which allows air to escape the air gap to outside the container as the pressure inside the air gap increases due to increases in altitude, but the seals preventing air from re-entering the air gap.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the container and lid of the current invention.
FIG. 2 is a front view of the container and lid of FIG. 1 .
FIG. 3 is a top view of the container and lid of FIG. 1 .
FIG. 4 is a side view of the container and lid of FIG. 1 .
FIG. 5 is a sectional view of the container taken along lines 5 - 5 in FIG. 3 .
FIG. 6 is a partial enlarged view of the container in FIG. 5 .
FIG. 7 is a top view of one embodiment of the tear tab of the current invention.
FIG. 8 is a front view of one embodiment of the tear tab of the current invention.
FIG. 9 is a top perspective view of one embodiment of the lid of the current invention.
FIG. 10 is a bottom perspective view of the lid of FIG. 9 .
FIG. 11 is a side view of the lid of FIG. 9 .
FIG. 12 is a top view of the lid of FIG. 9 .
FIG. 13 is a side view of the lid of FIG. 9 .
FIG. 14 is a bottom view of the lid of FIG. 9 .
FIG. 15 is a sectional view taken along lines 15 - 15 of FIG. 12 .
FIG. 16 is a sectional view taken along lines 16 - 16 of FIG. 12 .
FIG. 17 is a partial enlarged view of FIG. 15 .
FIG. 18 is an enlarged partial sectional view taken along lines 18 - 18 of FIG. 12 .
FIG. 19 is an enlarged partial sectional view of FIG. 16 .
FIG. 20 is an enlarged partial view of FIG. 10 .
FIG. 21 is an enlarged sectional view taken along lines 21 - 21 of FIG. 3 with the container and lid assembled.
FIG. 22 is an enlarged partial sectional view taken along lines 22 - 22 of FIG. 3 with the container and lid assembled.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the container 10 and lid 100 which assemble together for this invention are shown in FIGS. 1-22 . Both the container 10 and lid 100 are preferred to be made of food grade polypropylene, but any other type of material can be used with this invention.
A sidewall 12 extends upward from the base 16 and around the base, thereby creating a product holding portion of the container 10 . The container 10 of this invention can be of any size or shape. However, it is preferred that a top view of the container 10 create an oval shape as shown in FIG. 3 . Additionally, the shape of the container 10 is preferred to be slightly sloped for ease of molding the container 10 and stacking or nesting the empty container 10 . This type of stacking or nesting lids also preferred for the lid 100 .
The top portion of the sidewall 12 has both an upper seal rim 24 and a container skirt 18 formed around the outside edge of the sidewall 12 . The upper seal rim 24 helps fit into a lid channel 112 of the lid 100 and forms a seal between the lid 100 and the container 10 . Therefore, the upper seal rim 24 should be properly sized in height and thickness depending on the lid channel 112 of the lid 100 which is to be used with the container 10 .
A container skirt 18 extends outward from the sidewalls 112 around the upper portion of the container 10 and adds structural strength to the container 10 having a portion of the skirt 18 horizontal and a portion of the skirt 18 relatively vertical. However, the relatively vertical portion of the skirt 18 should still allow for a draft for easy mold release. Additionally, the mold skirt 18 adds strength to the container 10 by the use of multiple skirt ribs 22 integrally formed between the skirt 18 and the sidewall 12 .
The container skirt 18 also has a tamper resistant rim 32 extending upward from the skirt 18 allowing a lid skirt 106 to remain between the upper seal rim 24 and the tamper resistant rim 32 when the container 10 is engaged by a lid 100 . This is best seen in FIG. 21 . This prevents a person from easily lifting up on the lid 100 and removing it from the container 10 in places other than the tear tab 14 , as shown in FIG. 22 .
The container skirt 18 also preferably has a container skirt indent 20 . The container skirt indent 20 allows for ease carrying a cold damp container 10 , however, is not necessary for the current invention.
The container skirt 18 also has a tear tab 14 , as shown in FIGS. 8 and 22 . The tear tab 14 is also integrally formed with container 10 , however, as shown in FIG. 22 , the tear tab 14 is very thin where it attaches to the skirt 18 and is therefore easily torn outward and downward from the container 10 to be removed. Once the tear tab 14 is removed from the container 10 , the user has access to the lid skirt 106 and possibly a lift tab 104 which is integrally formed with the lid skirt 106 to lift the lid 100 off of the container 10 .
Additionally, the container skirt 18 preferably has one or more skirt protrusions 21 , which is a portion of the skirt 18 which extends further out than the skirt 18 , as shown in FIG. 3 . The protrusions 21 allow the lid 100 to be made with multiple lift tabs 104 . In other words, the skirt protrusion 21 , as shown, is located axially opposite the tear tab 14 so that no matter how the lid 100 is oriented on the container 10 , the lift tab 104 will not interfere with the tamper resistant rim 32 . Thus, a proper fit of the lid 100 is assured. There should be at least as many protrusions 21 as there are lift tabs 104 . In addition, the lift tabs 104 should orient with the protrusions 21 .
To make removing the tear tab 14 (shown in FIGS. 8 and 22 ) easier, the tear tab 14 preferably has a tear tab lever 30 extending upward and outward from the tear tab 14 , as best seen in FIG. 22 . The tear tab lever 30 covers the lift tab 104 and the lid skirt 106 when the tear tab 14 is in place on the container 10 . Additionally, the tear tab lever 30 , by extending upward and outward from the tear tab 14 , allows easier access to grab a hold of the tear tab 14 for removing it. Furthermore, the tear tab lever 30 provides more leverage to aid in tearing out the tear tab 14 .
It is preferred, but not necessary to have an inner wall tear tab indent 28 , as best seen in FIG. 5 on the inside of the sidewall 12 opposite the tear tab 14 , shown in FIG. 3 . Additionally, the inner portion of the sidewall 12 preferably has a fill line 34 for use as an indicator when filling the container 10 to help prevent overfilling the container 10 , which in turn, reduces overflowing of frozen products, such as ice cream when taking them over high altitudes.
The upper seal rim 24 has an upper seal rim rib 26 around the outside upper portion of the upper seal rim 24 . This upper seal rim rib 26 allows for the container 10 to interfere with a seal rib 110 , preferably within the lid channel 112 of the lid 100 . Therefore, as a lid 100 engages the container 10 , a tight interference fit is formed between the upper seal rim rib and the seal rib 110 on the lid 100 thereby preventing easy removal of the lid 100 from the container 10 . Both the lid 100 and the container 10 are preferably constructed of a relatively flexible material which flexes enough to allow the upper seal rim rib 26 and the seal rib 110 deflects out of the way to pass one another when the lid 100 is being placed onto the container 10 . The frictional fit between the upper seal rim rib 26 and the seal rib 110 are best shown in FIGS. 21 and 22 .
The lid 100 also preferably has a pressure rib 102 and a rim shoulder 108 for both guiding the upper seal rim 24 into the lid channel 112 and helping add additional material to the lid 100 thereby creating a tighter fit of the lid 100 on the container 10 .
The lid 100 preferably has a lid inner wall 114 , which is a continuously formed surface within the lid skirt 106 . Once again, the lid channel 112 should extend around the outside portion of the lid 100 between the lid inner wall 114 and the lid skirt 106 . The lid channel 112 should be as deep and wide as necessary to create a good tight seal and fit with the upper seal rim 24 of the container 10 . Additionally, the lid channel 112 may contain one or more inner channel vertical ribs 120 to help give strength to the lid 100 and also help create a tighter fit between the lid 101 ) and the container 10 . Exemplary inner channel vertical ribs are best shown in FIGS. 14 , 16 and 19 . FIGS. 19 and 21 best illustrate how the inner channel vertical ribs 120 extend gradually outward into the lid channel 112 to press the upper seal rim 24 of the container 10 against the sealed rib 110 of the lid 100 .
As best shown in FIG. 20 , the seal rib 110 is not continuous around the periphery of the lid 100 thereby creating one or more vents 116 . The vents areas 116 seal between the lid 100 and the container 10 with the upper seal rim rib 26 . However, the seal at the vent 116 allows air within an air gap 118 between a product within the container 10 and the lid 100 , as shown in FIG. 22 , to escape the air gap 118 as air pressure within the air gap 118 increases by having the air proceed out of the air gap 118 into the lid channel 112 and up and over the upper seal rim 24 and the upper seal rim rib 26 and outside of the container 10 . Thus, when a container that is full of product to about the fill line 34 is transported to lower pressure areas, such as high altitudes, the pressure created within the air gap 118 can escape. This prevents either air or expanding product in low pressures from popping the lid 100 off of the container 10 at these low pressure areas. However, when going to high pressure areas, air cannot enter through the vent 116 because the pressure in the high pressure areas actually pushes the lid 100 tighter onto the container 10 preventing air from entering the air gap 118 .
As shown above, a method of filling a container to a fill line 34 and placing a lid 100 onto the container 10 and thereby creating an air gap 118 between the product within the container 10 and the lid inner wall 114 of the lid 100 allows for expansion of the product without forcing the lid 100 off the container 10 . Additionally, the container 10 and the lid 100 of this invention are structurally capable of stacking multiple units on top of one another, thereby not needing the structural support of a completely filled container such as cardboard ice cream containers.
Another advantage of the current invention is when the container is used with ice cream, the plastic container flexes a small amount when scoping ice cream out of the container from along the long axis of the container 10 thereby causing the container to widen and make it easier to scoop the product out of the container 10 .
Another advantage of the current invention is that this container 10 and lid 100 are easily labeled for product identification with in-mold labels (not shown for clarity of showing the container), which are generally known in the art. The in-mold labels tend to add a less-smooth textured surface around the outside of the sidewall 12 and the lid inner wall 114 . This textured surface caused by in-mold labeling creates an easier to grip container, especially when filled with ice cream which causes a slick wet outer surface of the container 10 .
The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives.
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A container, a lid, a combination of the two, and a method of using the same is disclosed. The container has a base and a sidewall extending upward from the base forming a continuous sidewall around the base. The upper portion of the sidewall has a rim and a skirt around the perimeter. The skirt has a removable tear tab to allow access to a lid for removing the lid from the container. The lid also has vents for air to exit the container, thereby preventing rising of the lid in low pressure areas. The vents further prevent entry of air into the container when the sealed container is taken to areas of higher pressure. A method of filling the container leaving an air gap between the product and the lid and utilizing the aforementioned vents is also provided.
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FIELD OF THE INVENTION
This invention relates to locking mechanisms for connectors and, more particularly, to a mechanism to prevent rotation of a connector during connect and disconnect operations.
BACKGROUND OF THE INVENTION
Many connectors, such as SMA or SMC connectors, attach to mating connectors by means of threads or other means that require application of rotational force during connection and disconnection. Unless prevented in some manner, a connector will rotate due to the rotational force exerted when connecting or disconnecting mating connectors.
A persistent problem in the telecommunications industry is base station connectors that rotate when mating connectors are disconnected. These base station connectors extend through a wall (or panel) of the base station enclosure and allow an external cable to be electrically connected to the base station's internal electronics. FIG. 1, discussed below, shows a typical example of a connector 100 extending through a panel 120 of a base station. Base station connectors mate with another connector (a mating connector) that usually is attached to a coaxial cable of some sort. The base station connectors often have a soldered electrical connection on the internal side of the base station enclosure. Even a few degrees of rotation can be enough to break solder joints so it is very important to prevent the base station connector from rotating.
FIG. 1 shows a prior art method of preventing a connector 100 from rotating during connection or disconnection of mating connectors. Connector 100 has threads at one end for screwing into a threaded hole in panel 120 and at the other end for attaching a nut 110 . Nut 110 is then screwed down tight against panel 120 to prevent connector 100 from rotating. This method is commonly used but does not prevent rotation very well.
FIG. 2 shows a prior art method of preventing a connector 200 from rotating during connection or disconnection of mating connectors. Connector 200 has a rectangular flange 210 with screw holes 230 in each corner. Connector 200 inserts into a hole in panel 120 . It is held in place by screws inserted in each of the screw holes 230 . This method works well but requires drilling and thread tapping of four additional holes. Therefore this method is expensive, difficult to manufacture, and requires extra steps to attach connector 200 to panel 120 .
FIG. 3 shows a prior art method of preventing a connector 300 from rotating during connection or disconnection of mating connectors. Connector 300 has a flange 310 . When connector 300 is screwed into a threaded hole in panel 120 , flange 310 compresses O-ring 330 against panel 120 . Under ideal conditions, O-ring 330 provides enough frictional resistance to rotation that mating connectors can be connected or disconnected without causing connector 300 to rotate. When exposed to the elements in the field, the connector oxidizes. The oxidation causes the connector to bind when joined with its mate, requiring application of greater rotational connect/disconnect force than the O-ring 330 can resist. Thus this method does not prevent rotation under commonly encountered field conditions.
Additional general background, which helps to show the knowledge of those skilled in the art regarding the system context, and of variations and options for implementations, may be found in Catalog Number 82074 version 5-98 from AMP Incorporated, all of which is hereby incorporated by reference.
SUMMARY OF THE INVENTION
A lock washer and method for preventing a connector from rotating when mating connectors are attached or detached. In the presently preferred embodiment, the disclosed connector locking mechanism incorporates an innovative lock washer that, in combination with a groove in a panel holding the connector, prevents rotation of the connector when a mating connector is twisted on or off.
In the presently preferred embodiment, a connector that is attached to a panel is prevented from rotating by the use of an innovative lock washer that fits in a groove in the panel. The lock washer has a keyhole-shaped cutout. Part of the cutout has approximately parallel edges. Another part of the cutout allows the lock washer to fit over the larger perimeter (meaning without flat regions) portion of connector. After the lock washer is on the connector, the lock washer slides so that the approximately parallel edges of the cutout are aligned over flat regions on the connector. Then a nut is screwed onto the connector, compressing the approximately parallel edges of the lock washer cutout against the flat regions on the connector. The groove in the panel prevents the lock washer (and thus the connector) from rotating during attachment/detachment of mating connectors.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosed inventions will be described with reference to the accompanying drawings, which show important sample embodiments of the invention and which are incorporated in the specification hereof by reference, wherein:
FIG. 1 depicts a prior art system for preventing connector rotation.
FIG. 2 depicts a prior art system for preventing connector rotation.
FIG. 3 depicts a prior art system for preventing connector rotation.
FIG. 4 depicts a top view of the presently preferred embodiment of the disclosed innovative connector system.
FIG. 5 depicts a cut-away side view of the presently preferred embodiment of the disclosed innovative connector system.
FIG. 6A depicts a top view of the presently preferred embodiment of the disclosed innovative lock washer.
FIG. 6B depicts a side view of the presently preferred embodiment of the closed innovative lock washer.
FIG. 7A depicts a side view of a connector having flat regions.
FIG. 7B depicts an end view of a connector having flat regions.
FIG. 7C depicts top view of a connector having flat regions.
FIG. 8A shows an alternate shape for the disclosed lock washer.
FIG. 8B shows an alternate shape for the disclosed lock washer.
FIG. 8C shows an alternate shape for the disclosed lock washer.
FIG. 8D shows an alternate shape for the disclosed lock washer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The numerous innovative teachings of the present application will be described with particular reference to the presently preferred embodiment. However, it should be understood that this class of embodiments provides only a few examples of the many advantageous uses of the innovative teachings herein. In general, statements made in the specification of the present application do not necessarily delimit any of the various claimed inventions. Moreover, some statements may apply to some inventive features but not to others.
FIGS. 4 and 5 show a top view and cut-away side view (taken along line AA), respectively, of the presently preferred embodiment of the disclosed innovations. A first end 490 of an SMA connector 440 extends perpendicularly from a panel 460 . A groove 470 is manufactured into panel 460 . A washer 400 fits over the end 490 of connector 440 and into groove 470 . Washer 400 has a keyhole-shaped cutout 420 with approximately parallel edges 430 . A portion 425 of cutout 420 is large enough to allow washer 400 to slip over end 490 of connector 440 . After washer 400 is placed on connector 440 , washer 400 slides so that the approximately parallel edges 430 of the keyhole-shaped cutout 420 are aligned with flat regions 530 on connector 440 . Note that FIG. 4 shows the “post-slide” alignment in which approximately parallel edges 430 align with flat regions 530 . After washer 400 is in place, a nut 450 screws onto connector 440 . As nut 450 presses against washer 400 , the approximately parallel edges 430 are forced closer together by the deformation of washer 400 . Thus approximately parallel edges 430 of cutout 420 are compressed tightly against flat regions 530 of connector 440 .
Threads 500 at end 540 hold connector 400 to panel 460 . A wire or cable (not shown) is connected at solder connection pin 510 . Washer 400 fits into groove 470 . Edges 480 of groove 470 restrict movement of washer 400 . As nut 450 is tightened onto connector 440 , the approximately parallel sides 430 of cutout 420 in washer 400 are compressed against the flat regions 530 of connector 440 and the outer perimeter of washer 400 is compressed against edges 480 of groove 470 . In the presently preferred embodiment, the concave shape of washer 400 helps push approximately parallel sides 430 of cutout 420 tight against flat regions 530 of connector 440 . The concave shape also helps push the outer perimeter of washer 400 against edges 480 of groove 470 . Thus the concave shape has advantages over a flat shape: the edges of the cutout can be tightened against the flat regions on the connector and the washer perimeter can be tightened against edges of the groove. These advantages lead to a further advantage: increased tolerance for dimensional variations in manufacturing. A flat washer must precisely match the dimensions of the connector and the groove because a solder connection has very small tolerance for rotation. This would require that a flat washer be custom manufactured to match a particular connector and groove, an economically unfeasible alternative. A concave washer avoids this problem due to its spring-like properties.
FIG. 6A shows a top view of the presently preferred embodiment of washer 400 . Approximately parallel flat edges 410 are on the outer perimeter of washer 400 . A keyhole shaped cutout 420 , having approximately parallel edges 430 , is disposed within the outer perimeter of washer 400 . Cutout 420 also a portion 425 that allows the washer to slip over end 490 of connector 440 .
FIG. 6B shows a side view of the presently preferred embodiment of washer 400 . Due to the concave surface, the distance between the approximately parallel edges 430 will decrease when the washer is compressed. Rotation is prevented because movement of outer perimeter edges 410 is restricted (by edges 480 of groove 470 as shown in FIG. 4 ).
For clarity, FIGS. 7 A-C show a side view, end view, and top view of connector 440 , respectively. Flat regions 530 can more easily be seen in FIGS. 7 A-C than in FIGS. 4 and 5. FIG. 7B shows an end view from end 490 .
FIG. 8A shows an alternative washer embodiment. Washer 800 is similar to washer 400 except that the outer perimeter 810 is circular and does not have flat edges. As in the presently preferred embodiment, a keyhole-shaped cutout 820 with approximately parallel edges 830 (and a portion 825 for slipping over an end of a connector) is disposed within the outer perimeter of washer 800 .
FIG. 8B shows an alternative washer embodiment. Washer 850 is similar to washer 400 except that it is octagonal. As in the presently preferred embodiment, a keyhole-shaped cutout 870 with approximately parallel edges 880 (and a portion 875 for slipping over an end of a connector) is disposed within the outer perimeter of washer 800 .
FIG. 8C shows an alternative washer embodiment. Washer 900 is rectangular in shape and is folded along the centerline. A keyhole-shaped cutout 920 has approximately parallel edges 910 and a portion 925 for slipping over an end of a connector. The keyhole-shaped cutout 920 is disposed along the centerline 940 . When concave washer 900 is compressed, edges 930 are forced against edges of a groove on a panel.
FIG. 8D shows an alternative washer embodiment. The outer perimeter of washer 950 has flat edges 980 similar to the presently preferred embodiment. A slot-shaped cutout 960 has approximately parallel edges 970 . Unlike the cutouts of the previously disclosed embodiments, the slot-shaped cutout 960 opens to the outside perimeter. This allows washer 950 to be placed onto flat regions (such as regions 530 shown in FIG. 7A) on a connector without having to fit over the end of the connector. When concave washer 950 is compressed, edges 980 are forced against edges of a groove on a panel.
As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a tremendous range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given.
For example, the washer cutout could be any suitable shape and is not limited to a keyhole shape.
As another example, the washer shown in FIG. 8B could have another polygonal shape with more or fewer flat edges on the outer perimeter.
As another example, the washer 400 does not have to be concave. It may be flat, although more precise machining is required when using a flat washer.
As another example, connector 440 could extend from panel 460 at any suitable angle, not just perpendicularly.
As another example, the groove in the panel could be any suitable structure for preventing the lock washer from rotating, including grooves with different geometries than those disclosed above. A suitable structure may include two smaller parallel grooves into which only the edges of the concave washer fit. Another suitable structure may be a groove that is approximately the same size as the washer, such that the approximately parallel edges of the cutout must be aligned with the flat regions of the connector before the washer fits into the groove. Another suitable structure may be raised ridges (instead of a groove) that prevent the lock washer from rotating.
As another example, the parallel edges of the cutout do not have to be parallel. Any suitable geometry that will grip a flat region of the connector can be used. A suitable geometry of cutout may have sawtooth-like edges. Another suitable geometry may only use one flat edge in the cutout to mate with a flat region on the connector.
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A product and method for preventing a connector from rotating when a mating connector is attached to, or detached from, the connector. When a nut on the connector is tightened, a washer is compressed in a groove in a panel to which the connector is attached. Edges on the outer perimeter of the washer press against the edges of the groove, thus preventing the washer from rotating in relation to the panel having the connector. A portion of the washer's cutout presses against flat regions on the connector and, in conjunction with the groove in the panel, prevent the connector from rotating when attaching or detaching cables.
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BACKGROUND OF THE INVENTION
This application is a continuation-in-part of my earlier co-pending application Ser. No. 604,346 filed on Aug. 13, 1975, now abandoned.
FIELD OF THE INVENTION
This invention relates generally to flush control mechanisms used in flush tank type toilets and more particularly, to a device for attachment to a conventional flush tank to allow manual selection of water volume used in a flush cycle.
DESCRIPTION OF THE PRIOR ART
In flush tank toilets a reservoir of water is retained in the flush tank. To flush the toilet the user pivots a handle on the flush tank which moves a lever connected to the handle. The end of the lever is mechanically linked to a ball stopper which is seated in the flush tank discharge outlet. Operating the flush handle pivots the lever upward, lifting the stopper ball from the discharge outlet. In a normal flush cycle the ball stopper is lifted far enough to remain buoyed on the water. The water in the flush tank then escapes out the discharge outlet through a number of orifices in the toilet bowl and the bowl contents are flushed into the sewage disposal system. When the water level in the flush tank drops low enough, the stopper ball falls and seats in the discharge outlet. The flush tank refills and is ready for the next flush cycle.
Allowing the ball stopper to buoy upward allows the flush cycle to proceed to completion even though the flush lever has been allowed to drop to its resetting position. A primary disadvantage of this system is that the entire content of the flush tank is used in every flush cycle whether or not the full amount of water is needed to provide adequate flushing of the toilet bowl contents.
SUMMARY OF THE INVENTION
The short flush device of this invention comprises a support member adapted to be mounted inside the flush tank. A rod engages the ball stopper lever and is vertically movable in a guide assembly supported on the support member. A float-operated cam is pivotally connected to the guide assembly and serves to act against the rod when lifted thereby preventing further upward movement of the lever and ball stopper. When the flush lever is pivoted, the ball stopper is lifted from the discharge outlet but not far enough to allow the stopper to buoy upward. The lever also lifts the rod member until positive stop means on the rod and guide assembly such as, for example, a notch in the rod is aligned with a matching detent on the guide assembly. Pressure from the float-operated cam forces the notch in the rod member to engage the detent, locking the rod in place and hence the flush lever and stopper in the limited raised position. After the flush tank water level has dropped below the cam float, force is no longer maintained on the rod by the cam. The notch disengages from the detent freeing the rod, allowing the flush lever to drop to its resting position and allowing the stopper to seat in the flush tank discharge outlet stopping the flushing operation. Means are provided to allow engagement and disengagement of the device of my invention. I provide a spring biased flush handle whereby the lever connected thereto may be displaced laterally. The flush lever is linked to the ball stopper in the conventional manner and due to the spring bias, normally engages a horizontally extending slot in the rod member. When a long flush is activated, pushing inward on the flush handle displaces the flush lever laterally and disengages it from a slot in the rod member. Then, when the flush handle is rotated, the flush lever moves upward and the flush cycle proceeds to completion in the conventional manner. When a short flush is desired, the flush handle is rotated without pushing it inward toward the tank wall. The flush lever remains engaged in the slot of the rod member. The amount of water discharged in the short flush is determined by the position of the flush control float on the arm that attaches to the cam. The higher the flush control float is positioned, the shorter the flush cycle.
It is, therefore, the primary object of my invention to provide a flush control device for conserving water which can be easily installed on existing tank type toilets.
Another object of my invention is to provide a flush control device for conserving water that is adjustable in the amount of water discharged in the short or long flush cycle.
Still another object of my invention is to provide a flush control device for conserving water which is operable with a non-floatable outlet stopper.
Other objects and advantages of this invention will become apparent by a careful study of the following detailed description when read with reference to the accompanying drawings which illustrate the preferred embodiment of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the flush control device of my invention connected to the toilet flush tank which is shown in fragment;
FIG. 2 is a rear view of the flush control device in the flush tank which is shown broken and in cross section;
FIG. 3 is a top view of the flush handle and bushing assembly shown in cross section along lines 3--3 of FIG. 2;
FIG. 4 is a detailed view of the float-operated cam of this invention;
FIG. 5 is a perspective view of the flush control device showing the component parts thereof in exploded relation;
FIG. 6 is a top view of the preferred flush control device of my invention shown broken in part;
FIG. 7 is a rear view of the flush control device of my invention looking from the rear of the flush tank which is shown broken and in cross section;
FIGS. 8 and 9 are perspective views of the preferred flush control device of my invention showing the component parts thereof in exploded relation;
FIG. 10 is a rear view of another preferred embodiment of the flush control device in the flush tank which is shown broken and in cross section;
FIG. 11 is a side view of the flush control device of FIG. 10 shown partly sectioned;
FIG. 12 is a rear view of the flush control device taken along lines 12--12 of FIG. 11;
FIG. 13 is a rear view of the flush control device taken along lines 13--13 of FIG. 11;
FIG. 14 is a top view of an outlet stopper; and
FIG. 15 is a front view of the outlet stopper of FIG. 14.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings particularly FIGS. 1 through 5, the flush control device of my invention is designated generally by the numeral 10. It comprises a support member 12 formed with a horizontally extending arm 14 and a vertically extending leg 16 depending therefrom. Leg 16 is provided with flange 18. Flange 18 is formed with a slotted aperture 20 and further provided with a T shaped lug 22. Arm 14 is formed with a hole 24 and provided with wedge block 26. Supported on support member 12 against flange 18 is rod guide assembly 28. Rod guide assembly 28 is preferably formed with back plate 30 having at the top thereof rod guide bracket 32 and a second rod guide bracket 34 spaced below bracket 32. Bracket 34 is formed with pivot lug 36 and connected to back plate 30 with stiffeners 37. Though it is not necessary to provide means for a positive stop because the rod may be supported in its elevated position solely by friction between the members if the side force exerted by the float-operated cam is great enough, detent or projection 38, as an example of a positive stop means, may be provided on back plate 30. Back plate 30 is further provided at the bottom thereof with slot 40. Back plate 30 and guide bracket 32 are provided with a threaded hole 42 for receiving therethrough thumb screw 44 by which means rod guide assembly 28 is connected against flange 18 of support member 12. In providing slot 20 in flange 18 through which thumb screw 44 passes for tightening in threaded hole 42, guide assembly 28 may be vertically adjusted on flange 18. T shaped lug 22 engages back plate member 30 through slot 40 therein whereby the bottom end of back plate 30 straddles the anchor stem of T lug 20 and is retained thereby when secured thereto by thumb screw 44 and allows easy removal therefrom, when desired.
Float 46 is connected to the distal end of float arm 48 by any convenient means such as screw block 50 provided with thumb screw 52 whereby float 46 may be radially and longitudinally positioned on arm 48 to control the level at which the flush device of my invention will cycle. The other end of arm 48 is provided with pivot yoke 54 having cam roll 56 at the end thereof. Float arm 48 is pivotally connected to pivot lug 36 on guide bracket 34.
Elongated rod member 58 is freely movable in guide brackets 32 and 34. I form rod member 58 with slotted aperture 60 and spaced therebelow I provide, if positive stop means is desired, a notch 62 in the side of rod member 58 facing back plate 30 for engagement with detent 38 thereon during the operation of my invention. The portion of rod 58 containing slotted aperture 60 is movable within guide bracket 32 and receives the extended shaft 64 of thumb screw 44 to limit the vertical movement of rod 58 within the longitudinal limits of slot aperture 60. Extending from the top of rod 58 is a resiliently flexible sheet member 66 which is formed with a horizontally extending slot 68, one side thereof as at 70 extends horizontally to provide a base against which the conventional ball stopper lever 72 rests. The upper edge of horizontal slot 68 terminates as at 74 and that part of member 66 extends upright to prevent lever 72 from accidentally pivoting over flexible member 66 thereby preventing lever 72 from returning to its support edge 70.
As shown in FIGS. 1 and 3, the conventional ball stopper lever 72 is connected to flush handle 76 through wall 78 of water tank 80. For the selective operation of the flush device 10 of my invention, I provide spring means 82 in the bushing assembly 84 through which lever 72 and flush handle 76 are connected to bias handle 76 away from water closet wall 78.
Lever 72 is normally seated in slot 68 in flexible member 66 because spring 82 normally biases handle 76 away from tank wall 78 and lever 72 is thereby contained in slot 68 preparatory for the short flush operation. When handle 76 is manually pushed against tank wall 78 against the bias of spring 82, lever 72 is laterally displaced on edge 70 of flexible member 66 clearing the top edge 74 of slot 68 and then upon rotation of handle 76 stopper 86 may be lifted from its seat in discharge outlet 90 for the conventional flush. Edge 74 of flexible member 66 extends upright a sufficient distance to prevent lever 72 from accidentally being displaced toward wall 78 of toilet tank 80 and thereby escaping the confines of edge 74 and slot 68.
In the operation of my invention, support member 12 is connected to water closet wall 78 at bushing assembly 84 axially supporting flush handle 76. This may conveniently be accomplished by inserting the threaded end of bushing 84 through hole 24 in horizontal arm 14 of support member 12 and connect support member 12 as well as handle 76 to water closet wall 78 by a single nut 88. My invention 10 assembled as herein described is normally ready for short flush operation since liquid waste is more frequently discharged than solid wastes. Accordingly, if the flush handle 76 is rotated, a short cycle flush is initiated. In such flushes, ball stopper lever 72 being normally positioned in slot 68 of flexible member 66, rotation of flush handle 76 and lever 72 connected thereto, operate to lift stopper 86 from its seat in discharge outlet 90. The pivotal movement of lever 72, being contained in slot 68 by the bias of spring 82, will lift rod 58 within the limits of slots 60 which will abut against shaft end 64 of thumb screw 44 as rod 58 is guided in its vertical movement by guide brackets 32 and 34. As rod 58 is lifted, flexible member 66 flexes as distal end 94 thereof moves along incline surface 92 of wedge block 26. Rod 58 is lifted by the pivot movement of lever 72 until notch 62 is aligned with detent 38 on back plate member 30 at which time detent 38 will engage notch 62 and rod 58 will thereby be prevented from dropping downward by the action of cam roll 56 bearing against the opposite side of rod member 58. Roll 56 bears against the side of rod 58 since float arm 48 is pivotally connected to lug 36 of guide bracket 34. The pressure exerted by roll 56 is a function of the weight of the water displaced by float 46 acting at a moment arm which is float arm 48. Ball stopper lever 72 is thus limited in its upward pivot movement thereby limiting the elevation of ball stopper 86 from its seat in discharge outlet 90 allowing the water to be discharged therethrough accomplishing the flushing operation with ball stopper 86 sufficiently in the way of the discharging wall so that upon release of the detent-notch engagement of rod 58, the outflowing water will pull stopper 86 to its seat in outlet 90 immediately stopping the flushing operation. Stopper 86 as mentioned will be released when the water level W in the water closet tank descends below float ball 46 of the device of my invention. The water level W thus receding, will allow float arm 48 to pivot clockwise as viewed in FIG. 2 thereby removing the pressure exerted by roll 56 against rod member 58 whereupon the flexed distal end 94 of flexible member 66 will cause the bottom end of rod 58 to spring away disengaging notch 62 from detent 38. This action removes the elevated support provided by edge 70 which prevented lever 72 and stopper 86 from descending to its seated position in discharge outlet 90 while the water level W was above float 46. As soon as the water level W descends below float 46, the locking action of detent 38 in notch 62 is released allowing the seating of stopper 86 terminating the flush with a substantial amount of water remaining in the water closet tank.
The conventional flushing operation is initiated by first pushing in handle 76 prior to the rotation movement. This action removes lever 72 from slot 68 thereby disengaging it from the flush device of my invention and allowing the action of a conventional flush. Since lever 72 will then pivot to raise ball stopper 86 to its maximum height so that it will float out of the way of the discharging water, the water contents of the tank will be completely discharged and stopper 86 will descend to its seat in the discharge outlet 90 as it floats on the water level.
It should be understood that the structure of the means by which rod member 58 is supported in its elevated position when the float cam means pivots against the rod member, may be any convenient structure. Friction alone between rod member 58 and guide members 32 and 34 will be sufficient if the lateral force provided by cam roller 56 against rod member 58 is sufficient to prevent rod member 58 from dropping while float ball 46 is buoyed up by the water level in the tank. For purposes of showing a positive stop, I illustrate a detent-notch engagement between rod member 58 and guide means 28. However, other structures may perform this function equally well such as, for example, the bottom of rod member 58 resting on a projection provided on back plate 30. It should also be understood that other types of spring means other than flexible member 66 may be used to free rod member 58 from its positive stop engagement, or for that matter no spring means at all will be necessary if upon removal on the side force on rod member 58 exerted by cam roller 56, rod member 58 will drop unaided. Though I show the resiliency of flexible member 66 reacting against wedge block 26 as aiding the disengagement of the positive stop means between guide means 28 and rod member 58, it should be understood that other type spring means can be located at any convenient position to bear against rod member 58 in order to disassociate the elements of the positive stop means.
The device 10 of my invention may also be used to control a fixed amount of water to be discharged in a flush. The flush cycle will not be determined by the user but will be pre-set by adjusting float 46 in combination with the height adjustment of rod guide assembly 28 on flange 18 as determined by the position of thumb screw 44 in slot 20. Spring 82 may be removed or made inoperable, or flush handle 76 may be conventional flush handle, so that it may not be pushed in an d stopper lever 72 will be in permanent engagement with flexible member 66. So adjusted, or if spring 82 is removed, or if device 10 is connected to a conventional flush handle, a controlled amount of water will be discharged for every flush operation regardless whether the waste flushed is liquid or solid. The amount of water flushed will be more than the short flush but less than the conventional flush. This modified use of the flush device 10 of my invention may be used in situations where it will be impractical to teach users the selective flushing feature of this invention such as when used in hotels and motels and other such places where there will be transient users.
It will be noted that I provide rod guide assembly 28 separable from support frame 12 and easily removable therefrom. This feature of my invention is particularly advantages since assembly 28 contains all the moving parts which could wear and may be economically and easily replaced without removing the entire device of my invention.
FIGS. 1 through 5 illustrate the flush control device of my invention disclosed in the original patent application. Through the flush control device 10 of my invention functions satisfactorily and accomplishes the stated objectives, several experimental models manufactured subsequent to the filling of the original application revealed that a second preferred embodiment of this invention can be made operating on the same general principle but simpler, more economical in structure and less likely to malfunction then my flush control device 10 illustrated in FIGS. 1 through 5.
Accordingly, this invention as illustrated in FIGS. 6 through 9 discloses an improved flush control device in that it is simpler in structure, more economical to manufacture in that it has less parts and is not subject to malfunction.
With reference to FIGS. 6 through 9, numeral 110 designates generally my now preferred flush control device. It comprises a support member 112 formed with a horizontally extended arm 114 and a vertically extended leg 116 depending therefrom. Leg 116 is provided with a flange 118. Flange 118 is provided with a projection 120 which extends toward rod lift member 122. Though it is not necessary to provide means for a positive stop because rod 122 may be supported in an elevated position solely by friction between rod 122 and flange 118 if the force exerted by float-operated cam end 124 is great enough, a detent 126, as an example of a positive stop means, is preferably provided on flange 118. Horizontally extended arm 114 has a hole 128 to allow mounting of the flush control device in water tank 80 in the same manner as flush control device 10 as shown in FIGS. 1 through 3.
Supported on support member 112 against flange 118 and leg 116 is guide bracket 130. Guide bracket 130 maintains rod-lift member 122 in the required position for longitudinal movement. Rod member 122 is formed with a tapered section as at 132 between the upper portion and thinned flexible lower portion 134. Notch 136 is formed in the end of lower portion 134 of rod member 122 to engage detent 126 thereby forming a means for positively locking rod member 122 in its elevated position.
Extending from the top of rod member 122 is lever engaging means 140 for engaging lever 72 connected to lift stopper 86 when flush control device 110 is installed in water tank 80 of FIGS. 1 and 2 in place of flush control device 10. Means 140 prevents further pivotal movement of lever 72 when rod 122 is arrested in its longitudinal movement. Means 140 which may be formed integral with or attached to rod member 122 has a horizontally disposed slot 146 for receiving lever 72 which is normally seated in slot 146. The upper edge of horizontal slot 146 terminates at 148 and that part of means 140 extends upright to form a notched side above slot 146 for cooperation with lever 72 when it is desired to use the full contents of water tank 80 shown in FIG. 2.
A float lever arm generally designated as 152 is pivotally connected to housing 154 mounted on flange 118. Housing 154 preferably has a flange 156 protruding from at least one side of housing 154 toward member 122 positioned therebetween. Flange 156 limits the pressure applied to end portion 134 of member 122 by cam end 124. Float lever arm 152 has an adjustable positioned float 158 connected to threaded distal end 160 of float arm 152 by any convenient means such as ratchet joint connection 162 and held in the desired position by any convenient means such as fastener 164 on distal end 160. The other end of arm 152 is provided with pins 168 for pivotal connection to housing 154 in holes 170. Housing 154 also serves as a lower guide means for member 122.
As shown in FIG. 3, the conventional ball stopper lever 72 is connected to flush handle 76 through wall 78 of water tank 80. For selective operation of flush device 110 of my invention, I provide spring means 82 in bushing assembly 84 through which lever 72 and flush handle 76 are connected to bias handle 76 away from water closet wall 78.
Similarly, lever 72 is normally seated in slot 146 in lever engaging means 140 because spring 82 normally biases handle 76 away from tank wall 78 and lever 72 is thereby contained in slot 146 preparatory for the short flush operation. When handle 76 is manually pushed against tank wall 78 against the bias of spring 82, lever 72 is laterally displaced from slot 146 and then upon rotation of handle 76, stopper 86 may be lifted from its seat in discharge outlet 90 for the conventional flush. Notched side 148 provided in lever engaging means 140 extending upright from slot 146 a sufficient distance to prevent lever 72 from accidentally being displaced toward wall 78 of toilet tank 80 and thereby escaping the confines of means 140.
In the operation of the preferred embodiment of my invention, support member 112 is connected to water closet wall 78 at bushing assembly 84 axially supporting flush handle 76. This may conveniently be accomplished by inserting the threaded end of bushing 84 through hole 128 in horizontal arm 114 of support member 112 and connect support member 112 as well as handle 76 to water closet wall 78 by a single nut 88 much in the same manner described above for flush control device 10. My invention 110 assembled as herein described is normally ready for short flush operation since liquid waste is more frequently discharged than solid wastes. Accordingly, if the flush handle 76 is rotated, a short cycle flush is initiated. In such flushes, ball stopper lever 72 being normally positioned in slot 146 of means 140 in my now preferred embodiment, rotation of flush handle 76 and lever 72 connected thereto, operate to lift stopper 86 from its seat in discharge outlet 90. The pivotal movement of lever 72, being contained in slot 146 by the bias of spring 82, will lift rod 122 until notch 136 is vertically aligned with detent 126, at which time detent 126 engages notch 136 and rod 122 will thereby be prevented from dropping downward by the action of cam end 124 bearing against the opposite side of rod member 122. Cam end 124 bears against the opposite side of rod 122 since float arm 152 is pivotally connected to housing 154. The pressure exerted by cam 124 is a function of the weight of the water displaced by float 158 acting at a moment arm which is float arm 152. Ball stopper lever 72 is thus limited in its upward pivot movement thereby limiting the elevation of ball stopper 86 from its seat in discharge outlet 90 allowing the water to be discharged therethrough accomplishing the flushing operation with ball stopper 86 sufficiently in the way of the discharging water so that upon release of the detent-notch 126, 136 engagement of rod 122, the outflowing water will pull ball stopper 86 to its seat in outlet 90 immediately stopping the flushing operation. Stopper 86 as mentioned will be released when the water level W in the water closet tank descends below float ball 158 of the device of my invention. The water level W thus receding, will allow float arm 152 to pivot clockwise as viewed in FIG. 7 thereby removing the pressure exerted by cam 124 against rod member 122 whereupon thin flexible portion 134 of rod 122 will spring away disengaging notch 136 from detent 126. As soon as the water level W descends below float 158, the locking action of detent 126 in notch 136 is released allowing the seating of stopper 86 thus terminating the flush with a substantial amount of water remaining in the water closet tank 80.
The conventional flushing operation is initiated by first pushing in handle 76 prior to the rotation movement. This action removes lever 72 from slot 146 thereby disengaging it from the flush device of my invention and allowing the action of a conventional flush. Since lever 72 will then pivot to raise ball stopper 86 to its maximum height so that it will float out of the way of the discharging water, the water contents of the tank will be completely discharged and stopper 86 will descend to its seat in the discharge outlet 90 as it floats on the water level.
It should be understood that the structure of the means by which rod member 122 is supported in its elevated position when the float cam means 124 pivots against rod member 122, may be any convenient structure. Friction alone between rod member 122 and flange 118 will be sufficient if the lateral force provided by cam end 124 against rod member 122 is sufficient to prevent rod member 122 from dropping while float ball 158 is buoyed up by water level W in the tank. For purposes of showing a positive stop, I illustrate a detent-notch engagement between rod member 122 and flange 118. However, other structures may perform this function equally well such as, for example, the bottom of rod member 122 resting on a projection provided on flange 118. It should also be understood that other types of spring means other than flexible member 134 may be used to free rod member 122 from its positive stop engagement, or for that matter no spring means at all will be necessary if upon removal of the side force on rod member 122 exerted by cam end 124, rod member 122 will drop unaided. Though I show the resiliency of flexible member 134 reacting on wedge block 120 as aiding the disengagement of the positive stop means between flange 118 and rod member 122, it should be understood that other type spring means can be located at any convenient position to bear against rod member 122 in order to disassociate the elements of the positive stop means.
Still, a third embodiment of my invention is illustrated in FIGS. 10 through 13 of the drawings. This embodiment of my invention which functions to control the long flush cycle, is designated generally by the numeral 210 and comprises a duplex version of the flush control device 110 illustrated in FIGS. 6 through 9. It will be noted from the comparison of FIGURES illustrating the devices 110 and 210 that the duplex flush control device 210 comprises a similar support member 212 formed with a horizontally extended arm 214 and a vertically extended leg 216 depending therefrom. Leg 216 is provided with flange 218 which is formed with lateral extensions on which are provided guide bracket 230, fulcrum projection 220 and detent 226 which perform the same functions as their counterparts of flush control device 110 of FIGS. 6 through 9. The structure a rod lift member 222 is similar to rod lift member 122 of device 110 of my invention above described having a tapered section 232, a flexible portion 234 and a notch 236 in the lower end of member 222 to engage detent 226 to lock rod member 222 in an elevated position.
Extending from the top of rod lift member 222 is lever engaging means 240 for engaging lever 72 which is connected to stopper lift link 288 when flush control device 210 is installed in water tank 280 of FIG. 10. Means 240 prevents further pivotal movement of lever 72 when rod 222 is arrested in its longitudinal movement. Means 240 which may be formed integral with or attached to rod member 222 has a horizontally disposed slot 246 for receiving lever 72 which is normally seated in slot 246 due to the bias of spring 82 (FIG. 3). Lever engaging means 240 unlike lever engaging means 140 and 66 of flush control devices 110 and 10 respectively, is formed with a straight edge 248 to which slot 246 opens.
A second rod member 223 is spaced laterally adjacent to rod member 222 and is similar in structure to rod member 222 differing only in the length thereof and the facing direction of lever engaging means 241 being reversed so that slot 247 formed therein is horizontally aligned with slot 246 of means 240 when both rod lift members are in non-flushing repose. The corresponding edge 249 of lever engaging means 241 mates with and is in contiguous sliding contact with the edge 248 of means 240 of rod member 222. Due to the extended length of rod lift member 223, flange 218, as shown in FIG. 12, is provided with a second housing 255 and detent 227 for guiding and engaging respectively the notch 237 provided in the lower portion 235 of rod member 223. Projection 221 is provided on flange 218 extending toward rod lift member 223 to serve as a flexing fulcrum therefor. The purpose of the duplex arrangement of rod members 222 and 223 is to provide control for both the short and long flush. This embodiment 210 of my invention is particularly applicable for an outlet stopper 286 which does not float. Outlet stopper 286 is connected to the base of the water overflow pipe 282 and is formed from flexible material to allow pivoting movement when lifted by link 288 so that upon release, stopper 286 will pivotedly fall to seat in outlet 290. Accordingly, the function of duplex rod lift member 223 is to retain lever 72 in the elevated position so that a long flush may be accomplished with outlet stopper 286 which does not float. This embodiment of my invention utilizes float operated cam 224 for locking rod member 222 in the elevated position until water level W recedes below float 258 at which point cam 224 releases rod member 222 allowing it, together with lever 72, to fall, dropping stopper 286 to seat in outlet 290 thereby accomplishing the short flush operation. When it is desired to perform the long flush whereby the entire or controlled amount of the water content of toilet tank 280 is discharged, flush handle 76 (FIG. 3) is pushed toward the tank against the bias of spring 82 laterally moving stopper lift lever 72 in horizonal slot 247 (FIG. 11) of lift means 241 of rod member 223 thereby lifting rod member 223 until its notch 237 in the lower end thereof engages detent 227 and retained in locking engagement by float operated cam 290 and maintaining stopper 286 in the raised position allowing the water to be discharged from tank until water level W in the tank recedes below float 259 at which time cam member 225 will release rod member 223 from the detent-notch engagement allowing the tapered end 235 of rod member 223 to disengage by springing away from the detent. This embodiment of my invention has the added advantage of not only controlling or regulating the amount of water to be used for the short flush, but also the amount of water to be used for along flush. This is accomplished by adjusting the ball floats 258 and 259 on their respective cam lever arms 252 and 253. Since the amount of water to be used in the respective flushes may be controlled very accurately by the use of my invention, particularly the embodiment of FIGS. 10 through 13, I provide in conjunction with my invention an outlet stopper 286 which is new and novel and operates to open and close outlet 290 quickly and firmly. FIGS. 14 and 15 show outlet stopper 286 of my invention which is to be used with the duplex embodiment of my flush control device. It comprises a stopper body having a shallow dished bottom 294 circumscribed by a circumferential rim 296 which projects rearwardly as a flexible flap 284 provided with a circular opening 295 for anchoring to the base of discharge pipe 282 by means which it is hingedly connected to outlet 290 for pivoting out of the outlet seat for the flushing operation. The top 300 of stopper 286 is domed to provide an interior hollow 298 having an opening 302 in the forward quadrant thereof adjacent the lift link 304 so that when pivotedly raised, the opening 302 in the domed part thereof is at the zenith position so that hollow 298 remains filled with water. The purpose of this construction is to provide the stopper 286 with sufficient weight to close stopper 286 in outlet 290 with sufficient force to effect a tight seal. This construction also allows the bottom 294 of the stopper to be narrowly dished so that upon lifting the stopper, the flush commences rapidly and forcefully.
While I have described my embodiments of my invention, it will be understood by those skilled in the art that various other alternatives and combinations of my invention can be practiced and I intend only to be bound by the scope of the appended claims.
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This invention relates to flush tank type toilets and is a device by which a long or short flush cycle may be selected by manipulation of the flush lever handle. The conventional flush uses the full contents of the flush tank and is selected when solid waste must be flushed through the toilet. The short flush uses a portion of the flush tank contents and is selected to conserve water when liquid waste is flushed. This device controls the lifting of the outlet stopper by providing float operated cam member (or members) acting on a rod link connected to the flush lever which lifts the stopper, holding the lever and stopper in the lifted position. When the water level in the tank drops below the float, the cam releases the rod link and the stopper will be force-seated into the discharge outlet of the tank by the water remaining in the tank.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2012-218252, filed on Sep. 28, 2012, the entire contents of which are incorporated herein by reference.
FIELD
[0002] The embodiments discussed herein are related to an electronic device that includes a slide lock mechanism.
BACKGROUND
[0003] In a portable electronic device, a battery is used as a driving power supply. The battery is mounted in a housing of the electronic device as a battery pack. The battery pack is replaceable. The battery pack is accommodated in a battery pack accommodating part in an opening provided to part of the housing of the electronic device. The opening of the housing is covered with a cover.
[0004] Related art is disclosed in Japanese Laid-open Patent Publication No. 2012-141803 or Japanese Laid-open Patent Publication No. 2000-22347.
SUMMARY
[0005] According to one aspect of the embodiments, an electronic device includes: a housing provided with an opening that accommodates a component; a cover member that covers the opening; a projecting part that projects from an inside face of the housing; a slide knob slidably provided to a surface of the housing; and an elastic slide lock member that fixes the cover member to the housing, wherein the elastic slide lock member includes: a movement part that is coupled to the slide knob, moves together with the slide knob, and is provided with a fixing projection; a fixing part that is rotatably supported by the projecting part of the housing; and a coupling part that couples the movement part and the fixing part and is elastically deformable.
[0006] The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
[0007] It is to be understood that both the foregoing general description and the following detailed description are examples and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF DRAWINGS
[0008] FIG. 1 illustrates an example of an electronic device;
[0009] FIG. 2 illustrates an example of an electronic device;
[0010] FIG. 3 illustrates an example of a tablet terminal;
[0011] FIG. 4 illustrates an example of a housing;
[0012] FIG. 5 illustrates an example of a spring-type slide lock mechanism;
[0013] FIG. 6 illustrates an example of a spring-type slide lock member;
[0014] FIG. 7 illustrates an example of a cross section of a housing;
[0015] FIG. 8 illustrates an example of a cross section of a housing;
[0016] FIGS. 9A to 9D illustrate an example of operations of a spring-type slide lock member;
[0017] FIG. 10 illustrates an example of a cross section of a housing;
[0018] FIG. 11 illustrates an example of a cross section of a housing;
[0019] FIG. 12 illustrates an example of a latch-type slide lock mechanism;
[0020] FIG. 13 illustrates an example of a latch-type slide lock mechanism; and
[0021] FIGS. 14A to 14D illustrate an example of latching operations.
DESCRIPTION OF EMBODIMENTS
[0022] A slide lock mechanism is used for fixing a cover to a housing. In the slide lock mechanism, the cover becomes fixed or unfixed by a user causing a slide knob provided to the housing to slide. The slide lock mechanism includes a latch-type slide lock mechanism and a spring-type slide lock mechanism.
[0023] When the slide knob is caused to slide in the latch-type slide lock mechanism, the slide knob is held or latched at a position to which the slide knob is caused to slide. For example, when the slide knob is caused to slide to a fixing position, the slide knob is maintained at the fixing position and a state in which the cover is fixed is maintained. When the slide knob is caused to slide to a fixing canceling position, the slide knob is maintained at the fixing canceling position and a state in which the cover is unfixed is maintained. In the spring-type slide lock mechanism, the slide knob is urged to the fixing position by a spring and maintained at the fixing position. When canceling the fixing, a user causes the slide knob to slide to the fixing canceling position. When the user releases the slide knob, the slide knob returns to the fixing position automatically by spring force and the cover is maintained in the fixed state.
[0024] With the miniaturization of an electronic device, a battery pack is also miniaturized. A cover that covers an opening of a battery pack accommodating part may also be miniaturized and a space around the battery pack and the cover may be decreased, and a slide lock mechanism for fixing the cover may be miniaturized as well.
[0025] FIG. 1 illustrates an example of an electronic device. The electronic device illustrated in FIG. 1 may be a small-sized tablet terminal, and a perspective view of a small-sized tablet terminal 10 is depicted. The front face side of the tablet terminal 10 is provided with a liquid crystal display (LCD) part 12 . A user causes the LCD part 12 to display various kinds of information or images, or inputs various kinds of information on a screen of the LCD part 12 . The tablet terminal 10 is a portable electronic apparatus and is provided with a battery pack as a power source.
[0026] FIG. 2 illustrates an example of an electronic device. The electronic device illustrated in FIG. 2 may be a small-sized tablet terminal and a perspective view viewed from the back side of the small-sized tablet terminal 10 is depicted. An accommodating part that accommodates the battery pack is provided in the tablet terminal 10 . The battery pack accommodating part is provided in an opening provided to the back side of a housing 14 , and when the battery pack is accommodated in the accommodating part, the opening is closed with a cover 16 . A portion that corresponds to the cover 16 may be integrally formed in the battery pack itself. When the cover 16 is fixed, the battery pack may also be fixed.
[0027] Two slide lock mechanisms are provided so as to fix the cover 16 to the housing 14 . A slide knob 20 of one of the slide lock mechanisms is provided to a portion along one of the shorter sides of the cover 16 that is approximately rectangular. A slide knob 22 of the other slide lock mechanism is provided to a portion along the other shorter side of the cover 16 .
[0028] The slide lock mechanism that includes the slide knob 20 is a spring-type slide lock mechanism 30 and the slide knob 20 is urged to the fixing position. The slide lock mechanism that includes the slide knob 22 , meanwhile, is a latch-type slide lock mechanism 40 and the slide knob 22 is held at the fixing position or the fixing canceling position.
[0029] Since the spring-type slide lock mechanism 30 and the latch-type slide lock mechanism 40 are provided at different positions on the periphery of a single cover, which is the cover 16 , unexpected separation of the cover 16 may be avoided. For example, some external force may act on the slide knobs 20 and 22 and both of the slide knobs 20 and 22 may slide to the fixing canceling position, and the cover 16 may separate from the housing 14 . When the cover 16 separates from the housing 14 , the battery pack accommodated in the accommodating part may be exposed and the battery pack may also separate from the accommodating part in the housing 14 . When the battery pack and the cover 16 are integrally formed, the cover 16 and the battery pack may separate.
[0030] In many cases, while external force is acting on the slide knobs 20 and 22 , force that presses the cover 16 against the housing 14 is acting, and in this state, the cover 16 may remain at the housing 14 . When the external force acting on the slide knob 22 is removed, the slide knob 22 of the latch-type slide lock mechanism 40 is held at the fixing canceling position. Accordingly, the cover 16 is not fixed by the latch-type slide lock mechanism 40 . When the external force acting on the slide knob 20 of the spring-type slide lock mechanism 30 is removed, the slide knob 20 automatically returns to the fixing position. Accordingly, the cover 16 is fixed by the spring-type slide lock mechanism 30 .
[0031] In the spring-type slide lock mechanism 30 of the two slide lock mechanisms, even when the slide knob 20 is unexpectedly caused to slide to the fixing canceling position, the slide knob 20 automatically slides to the fixing position and fixes the cover 16 on removal of the external force acting on the slide knob 20 . Thus, the separation of the cover 16 and the battery pack may be avoided.
[0032] The spring-type slide lock mechanism 30 and the latch-type slide lock mechanism 40 are miniaturized and simplified, and therefore may be included in a miniaturized electronic apparatus.
[0033] FIG. 3 illustrates an example of a tablet terminal. FIG. 3 depicts a perspective view of the tablet terminal 10 illustrated in FIG. 1 , from which the LCD part 12 is removed such that the inside of the tablet terminal 10 is visible. In FIG. 3 , the back side of a bottom plate 14 a of the rectangular accommodating part that accommodates the battery pack is depicted. The spring-type slide lock mechanism 30 that includes the slide knob 20 is arranged between one of the shorter sides of the accommodating part and one of the shorter sides of the housing 14 . In FIG. 3 , most of the spring-type slide lock mechanism 30 may be hidden under a board 16 B. The latch-type slide lock mechanism 40 is arranged in the vicinity of the other shorter side of the accommodating part. Most of the latch-type slide lock mechanism 40 may be covered with a board 16 A and in FIG. 3 , only part of the latch-type slide lock mechanism 40 may be depicted.
[0034] FIG. 4 illustrates an example of a housing. In FIG. 4 , a plan view viewed from the inside of the housing 14 is depicted. A state in which the spring-type slide lock mechanism 30 and the latch-type slide lock mechanism 40 are mounted is illustrated.
[0035] The spring-type slide lock mechanism 30 is short in size in the longitudinal direction and is miniaturized. Thus, the spring-type slide lock mechanism 30 is used as a fixing mechanism for fixing the cover 16 of the tablet terminal 10 , which is a small-sized electronic device.
[0036] FIG. 5 illustrates an example of a spring-type slide lock mechanism. In FIG. 5 , an enlarged view of a portion to which the spring-type slide lock mechanism 30 illustrated in FIG. 4 is provided is depicted. The spring-type slide lock mechanism 30 includes the slide knob 20 , a slide frame 32 to which the slide knob 22 is fixed, a spring part 34 that extends from the slide frame 32 and is shaped like an arch, and a fixing part 36 provided to the top end of the spring part 34 . The slide frame 32 , the spring part 34 , and the fixing part 36 may be a single member integrally formed of resin. The single member may be a spring-type slide lock member 38 . The slide frame 32 that moves together with the slide knob 20 may correspond to a movement part. The spring part 34 that couples the slide frame 32 , which may correspond to the movement part, and the fixing part 36 may correspond to a coupling part that is elastically deformable. The spring-type slide lock mechanism 30 may be an elastic slide lock mechanism, and the spring part 34 may be used as an elastic member. The spring part 34 may provide elasticity and may be an elastic body, such as a plate spring made of resin or metal, a rubber material, or a coil spring.
[0037] FIG. 6 illustrates an example of an elastic slide lock member. In FIG. 6 , a perspective view of the spring-type slide lock member 38 is depicted. The slide frame 32 corresponds to a frame-shaped portion that is approximately rectangular, and a lock projection 32 a projecting out is formed on the outside face of the slide frame 32 . The lock projection 32 a may engage with part of the cover 16 or part of the battery pack integrated with the cover 16 and correspond to a portion for fixing the cover 16 . The slide knob 22 is attached to the slide frame 32 , and when the slide knob 20 is caused to slide, the slide frame 32 moves together.
[0038] Each of FIGS. 7 and 8 illustrates an example of a cross section of the housing 14 . FIG. 7 is a sectional view along line VI-VI in FIG. 4 . FIG. 8 is a sectional view along line VII-VII in FIG. 4 . The slide knob 20 is provided outside the housing 14 and at a position that faces the slide frame 32 located inside the housing 14 . An engaging part 20 a extending from the slide knob 20 penetrates the housing 14 and engages with the inside of the slide frame 32 . Thus, the slide knob 20 is fixed to the slide frame 32 via the housing 14 . When the slide knob 20 slides, the slide frame 32 moves. When the slide frame 32 moves, the lock projection 32 a moves and the fixing or the fixing cancellation of the cover 16 is performed.
[0039] As illustrated in FIG. 5 , the fixing part 36 of the spring-type slide lock member 38 is rotatably fitted and fixed with respect to a boss 14 b formed so as to project from the housing 14 . The slide frame 32 of the spring-type slide lock member 38 is movable in a direction toward or away from the fixing part 36 . For example, when the slide knob 20 is caused to slide, the slide frame 32 moves in the direction toward or away from the fixing part 36 . When the slide knob 20 is at the fixing position, the slide frame 32 is at a position away from the fixing part 36 . When the slide knob 20 is at the fixing canceling position, the slide frame 32 is at a position close to the fixing part 36 .
[0040] FIGS. 9A to 9D illustrate an example of operations of a spring-type slide lock member. When the slide knob 20 is not operated, the slide frame 32 is at the position away from the fixing part 36 as illustrated in FIG. 9A . In the state illustrated in FIG. 9A , no force may be applied to the spring part 34 that connects the slide frame 32 and the fixing part 36 , and the spring part 34 may be neither elastically deformed nor bent.
[0041] When the slide knob 20 is caused to slide from the fixing position to the fixing canceling position, the slide frame 32 moves toward the fixing part 36 while elastically deforming the spring part 34 as illustrated in FIG. 9B . At this time, the fixing part 36 engages with the boss 14 b of the housing 14 to be fixed, and is rotatable about the boss 14 b. Thus, when the spring part 34 attempts to bend, a component of force that causes the fixing part 36 to rotate occurs and the fixing part 36 slightly rotates.
[0042] When the slide knob 20 slides further toward the fixing canceling position, as illustrated in FIG. 9C , the spring part 34 is elastically deformed further and the fixing part 36 also rotates further. When the slide knob 22 reaches the fixing canceling position, the spring part 34 is elastically deformed further and the fixing part 36 also rotates further as illustrated in FIG. 9D . This state may correspond to the state in which the fixing of the cover 16 is canceled.
[0043] Since the spring part 34 is elastically deformed or bent in the state illustrated in FIG. 9D , returning force caused by the elastic deformation acts on the slide knob 20 . For example, the slide knob 20 is pressed against the elastic force of the spring part 34 so as to maintain the state illustrated in FIG. 9D .
[0044] When the force being applied to the slide knob 20 is released, the slide frame 32 is urged in the direction away from the fixing part 36 by elastic reversion force caused by the spring part 34 attempting to retrieve an original shape, and returns to the state illustrated in FIG. 9A . Thus, the slide knob 20 is caused to slide to the fixing position. When the spring part 34 returns from the elastic deformation and the slide frame 32 moves away from the fixing part 36 , the fixing part 36 also rotates in the opposite direction and returns to the state illustrated in FIG. 9A .
[0045] In the spring-type slide lock member 38 , the fixing part 36 rotates about the boss 14 b as the spring part 34 is elastically deformed. When the fixing part 36 rotates, the elastic deformation of the spring part 34 is reduced. For example, the amount of the elastic deformation of the spring part 34 is decreased, compared to the case in which the fixing part 36 is fixed without rotating, and the slide knob 20 slides with smaller force. For example, when the amount of the elastic deformation of the spring part 34 is the same, the slide frame 32 may move by a longer distance with respect to the fixing part 36 because of the rotation of the fixing part 36 . Thus, in a small space, the distance by which the slide frame 32 moves may be increased and the spring-type slide lock mechanism 30 may be simplified and miniaturized.
[0046] The housing 14 may be molded by die casting using a magnesium alloy. Since the boss 14 b is integrally formed of the magnesium alloy, the boss 14 b is provided with a projection 14 b - 1 in view of the molding quality in performing the die casting. Thus, the fixing part 36 of the spring-type slide lock member 38 is provided with a hole that is partially cut away, and this hole fits the boss 14 b. When the boss 14 b is shaped like a cylinder that does not include the projection 14 b - 1 , the hole provided to the fixing part 36 of the spring-type slide lock member 38 may have no lacking portion and the cross section of the hole may be shaped like a complete circle. Since an end face of the lacking portion of the hole of the fixing part 36 comes into contact with the projection 14 b - 1 of the boss 14 b, the rotation of the fixing part 36 in the opposite direction may be avoided.
[0047] When the positions of the fixing part 36 and the slide frame 32 are close to each other because of the operations of the spring-type slide lock member 38 , the distance by which the slide frame 32 moves may be long. Thus, when the spring-type slide lock member 38 is placed in a small space and when, for example, the spring-type slide lock member 38 is small in size, the distance by which the slide frame 32 moves, such as a stroke, may be long. Since the distance by which the slide knob 20 slides is set to be sufficient, force for causing the slide knob 20 to slide may be reduced. Since the fixing part 36 is rotatable, the spring-type slide lock member 38 may be miniaturized while securing a sufficient slide distance. The spring-type slide lock mechanism 30 that is miniaturized and includes a simplified structure may be provided.
[0048] As illustrated in FIG. 4 , the latch-type slide lock mechanism 40 includes the slide knob 22 , a slide frame 42 , and a latch part 44 extending from the slide frame 42 . The latch part 44 includes a pair of arms 44 a and 44 b. The pair of arms 44 a and 44 b fixes the position of the slide frame 42 by sandwiching a boss 14 c that is formed so as to project from the housing 14 and engaging with the boss 14 c. Similar to the slide frame 32 of the spring-type slide lock member 38 , the slide frame 42 is provided with a lock projection 42 a. The lock projection 42 a may be a portion that engages with part of the cover 16 or part of the battery pack integrated with the cover 16 and fixes the cover 16 . The slide knob 22 is attached to the slide frame 42 and when the slide knob 22 is caused to slide, the slide frame 42 moves together. The slide frame 42 and the latch part 44 may be integrally formed of resin as a latch-type slide lock member 48 . The latch-type slide lock member 48 may be formed by fixing the latch part 44 to the slide frame 42 .
[0049] Each of FIGS. 10 and 11 illustrates an example of a cross section of a housing. FIG. 10 illustrates a sectional view along line IX-IX in FIG. 4 . FIG. 11 illustrates a sectional view along line X-X in FIG. 4 . The slide knob 22 is arranged outside the housing 14 and at a position that faces the slide frame 42 located inside the housing 14 . An engaging part 22 a extending from the slide knob 22 penetrates through the housing 14 and engages with the inside of the slide frame 42 . Thus, the slide knob 22 is fixed to the slide frame 42 via the housing 14 . When the slide knob 22 slides, the slide frame 42 moves. When the slide frame 42 moves, the lock projection 42 a moves and the fixing or the fixing cancellation of the cover 16 is performed.
[0050] Each of FIGS. 12 and 13 illustrates an example of an latch-type slide lock mechanism. FIG. 12 depicts a perspective view of the latch-type slide lock mechanism 40 , which is viewed when the slide knob 22 is at the fixing position. FIG. 13 depicts a perspective view of the latch-type slide lock mechanism 40 , which is viewed when the slide knob 22 is at the fixing canceling position.
[0051] When the slide knob 22 is at the fixing position, the slide frame 42 is at the fixing position as illustrated in FIG. 12 . At this time, the latch part 44 extending from the slide frame 42 latchingly engages with the boss 14 c of the housing 14 at a top end portion positioned farther from the slide frame 42 . When the slide knob 22 is caused to slide to the fixing canceling position, the slide frame 42 also moves to the fixing canceling position as illustrated in FIG. 13 . At this time, the latch part 44 extending from the slide frame 42 engages with the boss 14 c of the housing 14 at a portion closer to the slide frame 42 than to the top end portion of the slide frame 42 .
[0052] FIGS. 14A to 14C illustrate an example of latching operations. The latch part illustrated in FIGS. 14A to 14C may be the latch part 44 illustrated in FIGS. 12 and 13 .
[0053] The latch part 44 includes the pair of arms 44 a and 44 b , sandwiches the boss 14 c with the pair of arms 44 a and 44 b, and latchingly engages with the boss 14 c. Inside the arm 44 a, a first projection 44 a - 1 is formed on the top end side, and a second projection 44 a - 2 is formed on the side closer to the slide frame 42 than the first projection 44 a - 1 . Similarly, inside the arm 44 b, a first projection 44 b - 1 is formed on the top end side, and a second projection 44 b - 2 is formed on the side closer to the slide frame 42 than the first projection 44 b - 1 . The first projection 44 a - 1 and the first projection 44 b - 1 are arranged at the positions opposite to each other. The second projection 44 a - 2 and the second projection 44 b - 2 are also arranged at the positions opposite to each other.
[0054] When the slide frame 42 is at the fixing position, the arms 44 a and 44 b of the latch part 44 engage with the boss 14 c at a position on the top end side, which is closer to the top end than the first projection 44 a - 1 and the first projection 44 b - 1 as illustrated in FIG. 14A .
[0055] When the slide knob 22 slides from the fixing position toward the fixing canceling position, the slide frame 42 also moves and the latch part 44 moves as well. When the latch part 44 moves, the first projection 44 a - 1 of the arm 44 a and the first projection 44 b - 1 of the arm 44 b travel over the rim of the boss 14 c as illustrated in FIG. 14B . At this time, the arms 44 a and 44 b are elastically deformed so that the arms 44 a and 44 b bend outward.
[0056] When the slide frame 42 moves further, the first projection 44 a - 1 of the arm 44 a and the first projection 44 b - 1 of the arm 44 b travel over the rim of the boss 14 c as illustrated in FIG. 14C . Thus, the boss 14 c enters between the first projections 44 a - 1 and 44 b - 1 and the second projections 44 a - 2 and 44 b - 2 . At this time, returning force toward the inside acts on the arms 44 a and 44 b that are elastically deformed to bend outward and helps with the movement of the slide frame 42 .
[0057] When the slide frame 42 moves to the fixing canceling position, the boss 14 c is completely accommodated between the first projections 44 a - 1 and 44 b - 1 and the second projections 44 a - 2 and 44 b - 2 . In order to cause the slide frame 42 to move back in the opposite direction from this state, a certain amount of force may be applied to the slide frame 42 or, for example, to the slide knob 22 because the first projection 44 a - 1 of the arm 44 a and the first projection 44 b - 1 of the arm 44 b travel over the rim of the boss 14 c. Thus, the slide frame 42 remains at the fixing canceling position and the state in which the fixing of the cover 16 is canceled is maintained.
[0058] In the latch-type slide lock mechanism 40 , the boss 14 c is sandwiched between the pair of arms 44 a and 44 b. When the first projections 44 a - 1 and 44 b - 1 travel over the rim of the boss 14 c, the directions in which the arms 44 a and 44 b are deformed may be opposite to each other. Thus, force that may displace the slide frame 42 , which is connected to the base of the pair of arms 44 a and 44 b, in a direction perpendicular to the movement direction may be removed and no force may be applied to the slide frame 42 in the lateral direction. Accordingly, a guide for stopping the lateral displacement of the slide frame 42 or the like may be undesired and the structure of the latch-type slide lock mechanism 40 may be simplified.
[0059] In the latch-type slide lock mechanism 40 , the boss 14 c projecting from the housing 14 is used as a member for allowing the latch part 44 to engage and fix the position. In the spring-type slide lock mechanism 30 , the boss 14 b projecting from the housing 14 is used for rotatably supporting the fixing part 36 . When FIGS. 9A to 9D and FIGS. 14A to 14D are compared, the relation between the positions of the slide frame 32 and the boss 14 b in the spring-type slide lock mechanism 30 is substantially the same as or similar to the relation between the positions of the slide frame 42 and the boss 14 c in the latch-type slide lock mechanism 40 , and a common arrangement may be employed.
[0060] The cover 16 may be fixed using two independent lock mechanisms, which are the spring-type slide lock mechanism 30 and the latch-type slide lock mechanism 40 . It may be undesired to provide two lock mechanisms. For example, the spring-type slide lock mechanism 30 may be provided on one side of the cover 16 , and a fixing structure for merely inserting a projection into a hole formed on the side of the housing 14 may be provided on the other side of the cover 16 so that the cover 16 may be fixed to the housing 14 . The fixing of the cover 16 may be canceled by the operations of the slide knob 20 of the spring-type slide lock mechanism 30 .
[0061] All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although the embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
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An electronic device includes: a housing provided with an opening that accommodates a component; a cover member that covers the opening; a projecting part that projects from an inside face of the housing; a slide knob slidably provided to a surface of the housing; and an elastic slide lock member that fixes the cover member to the housing, wherein the elastic slide lock member includes: a movement part that is coupled to the slide knob, moves together with the slide knob, and is provided with a fixing projection; a fixing part that is rotatably supported by the projecting part of the housing; and a coupling part that couples the movement part and the fixing part and is elastically deformable.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a division of identically titled application Ser. No. 10/867,532, filed Jun. 14, 2004.
SEQUENCE LISTING
[0002] A printed Sequence Listing accompanies this application, and has also been submitted with identical contents in the form of a computer-readable ASCII file on a CD-Rom.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention is broadly concerned with novel, low cost vaccine preparations, methods of preparing such vaccines and uses thereof. More particularly, the invention is concerned with vaccines and methods wherein the vaccines comprise recombinantly modified and killed microorganisms including therein recombinant DNA encoding at least one protective protein (e.g., an antigenic protein) and which has been expressed by the microorganism prior to killing thereof. These killed recombinant microorganisms can be directly administered as effective vaccines without the necessity of separation of the expressed protective protein(s) from the microorganisms, which has heretofore been considered essential.
[0005] 2. Description of the Prior Art
[0006] A vast array of vaccines have been developed in the past to provide varying degrees of immunity against diseases. Generally speaking, prior vaccines have been in the form of preparations of dead or attenuated pathogenic microorganisms or antigenic substances extracted from them. In the case of bacterial vaccines, it has been known to genetically engineer bacteria to enhance their value as vaccines. Recombinant DNA techniques can also be used to generate attenuated strains, by deletion of pathogenesis-causing genes, or by engineering the protective epitope from a pathogen into a safe bacterium. It is also common to produce antigens or other protective proteins using conventional recombinant DNA techniques, wherein a plasmid or other appropriate vector is inserted into a bacterial host (e.g., E. coli ) which then expresses the desired protein. While such engineered proteins can be effective biopharmaceutical vaccines, it has heretofore been thought essential that the expressed proteins be fully separated from the host recombinant microorganism(s) as a part of vaccine production. However, it is sometimes difficult and time consuming to perform such protein separations, and this significantly increases vaccine costs.
[0007] Bordetella bronchiseptica is a respiratory tract pathogen of dogs, pigs, cats, laboratory animals and humans. B. bronchiseptica can cause canine respiratory disease in the absence of prior or concurrent viral respiratory tract infection. Clinically, dogs with bordetellosis (“kennel cough”) exhibit a soft, dry to severe paroxysmal cough and can develop extensive histopathological lesions including edema of the bronchial and retropharyngeal lymph nodes, marked polymorphonuclear infiltration of the respiratory tract mucosa and epithelial necrosis. Canine bordetellosis is remarkably similar to pertussis (whooping cough) caused by Bordetella pertussis infection of humans in terms of clinical disease, pathology and epidemiology. See, Keil, Canine Bordetellosis: Improving Vaccine Efficiency Using Genetic and Antigenic Characterization of Bordetella Bronchiseptica Isolates from Dogs (1999).
[0008] Kennel cough affects dogs of all ages, has a worldwide distribution, and can have an incidence as high as 50-90% in facilities housing large numbers of dogs. Outbreaks of kennel cough in vaccinated racing greyhounds and other dogs indicate that the disease continues to be a significant problem and that better vaccines are needed. Indeed, outbreaks in well-vaccinated dogs at racing tracks and kennels result in significant economic losses to the greyhound racing industry and at the very least are a periodic nuisance to dog owners, kennel managers and track administrators.
[0009] Current vaccines to prevent kennel cough include low-virulent live strains, whole-cell bacterins and undefined antigenic extracts, which are administered by various routes including parenterally and intranasally. Concerns about the efficacy and safety of current kennel cough vaccines have spurred the development of multivalent, acellular vaccines to prevent the disease. However, present-day vaccines do not provide sufficient disease control.
[0010] Filamentous hemagglutinin (FHA) is a secreted (but membrane associated) protein conserved within the genus Bordetella (Leininger et al. Inhibition of Bordetella pertussis Filamentous Hemagglutining-mediated Cell Adherence with Monoclonal Antibodies . FEMS Microbiology Letters 1993; 106:31-8.). The structural gene for the FHA of B. pertussis fhaB) has been cloned and sequenced (Relman et al., Filamentous hemagglutinin of Bordetella pertussis: nucleotide sequence and crucial role in adherence . Proc Natl Acad Sci USA 1989 Apr;86(8):2637-41). FHA is essential for bacterial adherence to eukaryotic cells (Relman et al., Filamentous hemagglutinin of Bordetella pertussis: nucleotide sequence and crucial role in adherence . Proc Natl Acad Sci USA 1989 Apr;86(8):2637-41). Additionally, the immunologic response against FHA is protective in animal models of infection with B. pertussis (Locht et at. The Filamentous Hemagglutining, a Multifaceted Adhesin Produced by Virulent Bordetella . Supplemental Molecular Microbiology 1993; 9:653-60.; Brennan M J, and Shahin S. Pertussis. Antigens That Abrogate Bacterial Adherence and Elicit Immunity . American Journal of Respiratory Critical Care Medicine 1996; 154: S145-S149.).
[0011] While the protective benefits of FHA have been recognized for some time, the immunodominant regions have only recently been identified. Using a panel of monoclonal antibodies, Leininger et al. found two immunodominant domains (type I domain located near the COON-terminus, type II domain located near the NH 2 -terminus) within the FHA protein (Leininger et at. Immunodominant Domain Present on the Bordetella pertussis Vaccine Component Filamentous Hemagglutining . Journal of Infectious Disease 1997; 175:1423-31.). Pepscan analysis, using monoclonal antibodies that recognized the type I immunodominant domain, indicated that the epitope for these antibodies was within the amino acid sequence RGHTLESAEGRKIFG (SEQ ID No. 1). Finally, convalescent whooping cough serum, as well as post vaccination serum, contained antibodies that specifically recognize the type I region of FHA.
[0012] In order to further characterize the antigenic makeup of the FHA of B. pertussis , Wilson et al. characterized polyclonal anti-FHA reactive clones identified in a phage display library (Wilson et al. Antigenic Analysis of Bordetella pertussis Filamentous Hemagglutinting with Phage Display Libraries and Rabbit Anti-filamentouts Hemagglutining Polyclonal Antibodies . Infectious Immunology 1998;66:4884-94.). They determined that the portion of FHA between residues 1929-2019 contained the most immunodominant linear epitope of FHA. They also concluded that because this region contains a factor X homologue (Sandros and Tuomanen. Attachment factors of Bordetella pertussis: mimicry of eukaryotic cell recognition molecules. Trends Microbiol, 1993 Aug;1(5):192-6.) and the type I domain peptide defined by Leininger et al. (RGHTLESAEGRKIFG) (SEQ ID No. 2) peptides derived from this region are strong candidates for future protection studies.
[0013] Pertactin is the other protein used by B. bronchiseptica to adhere to the respiratory tract. Pertactin gets its name from the fact that it is the only protein that is capable, by itself, of inducing protective immunity against disease. Variations in nucleotide sequence, predicted amino acid sequence, and size of the pertactin proteins expressed in canine B. bronchiseptica isolates have been identified and have been confirmed from researchers working with swine strains of B. bronchiseptica as well as with strains of B. pertussis isolated from whooping cough cases. It is clear that canine vaccine strains of B. bronchiseptica and field isolates from vaccinated dogs with kennel cough do not express the same types of pertactin protein.
SUMMARY OF THE INVENTION
[0014] The present invention provides relatively low cost yet effective vaccines for administration to living subjects (e.g., mammals and birds) which comprise a quantity of recombinantly modified and killed microorganisms including therein recombinant DNA encoding at least one protective protein which has been expressed by the microorganism prior to killing thereof. The protective protein(s) are operable to prevent or reduce the severity of a disease of the subject.
[0015] In one aspect, the invention is predicated upon the discovery that safe and effective vaccines can be produced by administration of such killed, recombinantly modified microorganisms without the need for costly separation of the proteins expressed by the microorganisms. It has heretofore been thought that administration of these whole microorganisms would elicit unwanted immune responses or toxic reactions in the subjects, i.e., E. coli and other gram-negative bacteria contain endotoxic cell membrane components and other toxic proteins which would deleteriously affect a living subject if administered.
[0000] Vectors and Host Cells The vaccines of the invention are usually in the form of cellular microorganisms containing therein a recombinant vector. A vector is a replicon, such as a plasmid, phage, or cosmid, into which another DNA segment maybe inserted so as to bring about the replication of the inserted segment. The vectors of the invention are expression vectors, i.e., a vector that includes one or more expression control sequences that controls and regulates the transcription and/or translation of another DNA sequence.
[0016] In the expression vectors of the invention, the nucleic acid is operably linked to one or more expression control sequences. As used herein, “operably linked” means incorporated into a genetic construct so that expression control sequences effectively control expression of a coding sequence of interest. Examples of expression control sequences include promoters, enhancers, and transcription terminating regions. A promoter is an expression control sequence composed of a region of a DNA molecule, typically within 100 nucleotides upstream of the point at which transcription starts (generally near the initiation site for RNA polymerase II). To bring a coding sequence under the control of a promoter, it is necessary to position the translation initiation site of the translational reading frame of the polypeptide between one and about fifty nucleotides downstream of the promoter. Enhancers provide expression specificity in terms of time, location, and level. Unlike promoters, enhancers can function when located at various distances from the transcription site. An enhancer also can be located downstream from the transcription initiation site. A coding sequence is “operably linked” and “under the control” of expression control sequences in a cell when RNA polymerase is able to transcribe the coding sequence into mRNA, which then can be translated into the protein encoded by the coding sequence.
[0017] Suitable expression vectors include, without limitation, plasmids and viral vectors derived from, for example, vacteriophage, vaculoviruses, tobacco mosaic virus, herpes viruses, cytomegalovirus, retroviruses, poxyviruses, adenoviruses, and adeno-associated viruses. Numerous vectors and expression systems are commercially available from such corporations as Novagen (Madison, Wis.), Clontech (Palo Alto, Calif.), Stratagene (La Jolla, Calif.), and Invitrogen/Life Technologies (Carlsbad, Calif.).
[0018] The invention also provides host cells containing vectors of the invention. The term “host cell” is intended to include prokaryotic and eukaryotic cells into which a recombinant expression vector can be introduced. Usually the host cells are themselves non-pathogenic, but this is not essential. As used herein, “transformed” and “transfected” encompass the introduction of a nucleic acid molecule (e.g., a vector) into a cell by one of a number of techniques. Although not limited to a particular technique, a number of these methods are well established within the art. Prokaryotic cells can be transformed with nucleic acids by, for example, electroporation or calcium chloride mediated transformation. Nucleic acids can be transfected into mammalian cells by techniques including, for example, calcium phosphate co-precipitation, DEAE-dextran-mediated transfection, lipofection, electroporation, or microinjection. Suitable methods for transforming and transfection host cells are found in Sambrook et al., Molecular Cloning: a Laboratory Manual (2nd edition), Cole Spring Harbor Laboratory, NY (1989), and reagents for transformation and/or transfection are commercially available (e.g., Lipofectin (Invitrogen/Life Technologies); Fugene (Roche, Indianapolis, Ind.); and SuperFect (Qiagen, Valencia, Calif.)).
[0019] In particularly preferred forms, the microorganisms of the invention are selected from the group consisting of bacteria and yeast, with bacteria such as E. coli being commonly employed. The vector of choice is normally an appropriate plasmid which expresses a fusion protein containing an antigenic protein or fragment. Vaccines in accordance with the invention may be monovalent or polyvalent as required. The vaccines may be administered to a variety of living subjects, especially those selected from the group consisting of mammals and birds, for example humans, livestock and domestic pets.
[0020] In the case of the preferred kennel cough vaccines of the invention, the vaccines include microorganisms which have recombinant DNA therein encoding protective proteins selected from the group consisting of pertactin and filamentous hemagglutinin proteins, fragments of such proteins, and mixtures thereof. Especially preferred kennel cough vaccines include killed E. coli having expression vectors therein which encode for fusion proteins having protein fragments selected from the group consisting of SEQ IDS Nos. 5, 6, 7, 8 and 9, and mixtures thereof.
Complete Vaccines
[0021] The vaccines of the invention can also include various pharmaceutically acceptable carriers, excipients and/or adjuvants. For example, complete vaccines can include buffers, stabilizers (e.g., albumin), diluents, preservatives, and solubilizers, and also can be formulated to facilitate sustained release. Diluents can include water, saline, dextrose, ethanol, glycerol, and the like. Additives for isotonicity can include sodium chloride, dextrose, mannitol, sorbitol, and lactose. Compositions can be formulated for particular routes of administration, including, for example, oral, intranasal, intramuscular, intra-lymph node, intradermal, intraperitoneal, or subcutaneous administration, or for a combination of routes.
[0022] In some embodiments, the vaccines can include an adjuvant. Suitable adjuvants can be selected based, for example, on route of administration and number of planned administrations. Non-limiting examples of adjuvants include mineral oil adjuvants such as Freund's complete and incomplete adjuvant, and Montanide incomplete seppic adjuvant (ISA, available from Seppie, Inc., Paris, France); oil-in-water emulsion adjuvants such as the Ribi adjuvant system (RAS); TiterMax®, and syntax adjuvant formulation containing muramyl dipeptide; or aluminum salt adjuvants.
Administration of Vaccines
[0023] The vaccines of the invention can be administered orally, transdermally, intravenously, subcutaneously, intramuscularly, intraocularly, intraperitoneally, intrarectally, intravaginally, intranasally, intragastrically, intratracheally, intrapulmonarily, or any combination thereof. The most preferred administration route is subcutaneous, especially for the kennel cough vaccines.
[0024] Suitable doses of the vaccine elicit an immune response in the subject but do not cause the subject to develop severe clinical signs of the particular viral infection. The dose required to elicit an immune response depends on the route of administration, the nature of the composition, the subject's size, weight, surface area, age, and sex, other drugs being administered, and the judgment of the attending practitioner. Wide variations in the needed dose are to be expected in view of the variety of compositions that can be produced, the variety of subjects to which the composition can be administered, and the differing efficiencies of various routes of administration. For example, oral administration would be expected to require higher doses than administration by intravenous injection. Variations in these dose levels can be adjusted using standard empirical routines for optimization, as is well understood in the art. Encapsulation of the composition in a suitable delivery vehicle (e.g., polymeric microparticles or implantable devices) may increase the efficiency of delivery, particularly for oral delivery.
[0025] To determine if an immune response was induced in the subject, a biological sample from the subject can be examined to determine if it contains detectable amounts of antibodies having specific binding affinity for one or more antigens of the particular organism the subject was vaccinated against. The biological sample can be blood (e.g., serum), a mucosal sample (e.g., saliva or gastric and bronchoalveolar lavages), or meat juice or meat exudate (i.e., the liquid that escapes from extra- and intracellular spaces when muscle tissues are frozen and thawed). Methods for detecting antibodies, including IgG, IgM, and IgA, are known, and can include, for example, indirect fluorescent antibody tests, serum virus neutralization tests, gel immunodiffusion tests, complement fixation tests, enzyme-linked immunosorbent assays (ELISA) or Western immunoblotting. In addition, in vivo skin tests can be performed on the subjects. Such assays test for antibodies specific for the organism of interest. If antibodies are detected the subject is considered to be seropositive.
[0026] Vaccinated subjects also can be tested for resistance to infection by the relevant organism. After immunization (as indicated above), the test subjects can be challenged with a single dose or various doses of the disease causing microorganism. The test subjects can be observed for pathologic symptoms familiar to those in the art, e.g., restlessness, dyspnea after exercise, neurological signs such as posterior weakness, paresis, ataxis, lameness, head pressing or hanging, aggressive behavior, morbidity, and/or mortality. Alternatively, they may be euthanized at various time points, and their tissues (e.g., lung, brain, spleen, kidney or intestine) may be assayed for relative levels of the virus using standard methods. The data obtained with the test subjects can be compared to those obtained with a control group of subjects. Increased resistance of the test subjects to infection relative to the control groups would indicate that the test vaccine is an effective vaccine. Thus, in some embodiments, a vaccinated subject is resistant to an infection upon challenge. That is, the subject does not develop severe clinical signs of the infection after being challenged with a virulent form of the disease causing microorganism. In other embodiments, a vaccinated subject exhibits an altered course of the infection. In still other embodiments, overall mortality from a particular microorganism in a group of subjects may be reduced.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The following examples set forth preferred procedures for the development of recombinant microorganisms useful in the context of the invention, and in the production of specific vaccines against kennel cough. It is to be understood, however, that these examples are provided for illustrative purposes only, and nothing therein should be considered as a limitation upon the overall scope of the invention.
Example I
Development Of Pertactin Clone (PRN2)
[0028] Step 1—Growth of Bordetella bronchiseptica and Isolation of Enomic DNA
[0029] In this procedure, a known strain of B. bronchiseptica is struck for isolation on a room temperature Bordet-gengou plate, which was then incubated for 48 hr at 37° C. The plate was inspected at 24 and 48 hr to assure that growth is pure and colonies are isolated. B. bronchiseptica should form small, glossy, white, isolated colonies and appear mucoid where growth is dense. If growth was very heavy or the plate contaminated, the plate was restreaked for isolation from an area of least growth.
[0030] Pure, isolated colonies were observed, a single colony was inoculated into a 2 ml aliquot of 2 ml sterile nutrient broth in a 15 ml centrifuge tube. The tube was then capped tightly and vortexed. Next, the tube was incubated for 48 hr at 37° C., with shaking at 200 rpm. Thereupon, the culture was transferred to a 2 ml microcentrifuge tube. As a further assurance of purity, a loopful of the culture was separately streaked onto a BG plate and incubated for 24 hr The microcentrifuge tube was harvested by centrifugation at 13,000 rpm for 10 minutes. The supernatant was discarded, leaving an easily visible cell pellet.
[0031] One microliter (1 ml) of sterile purified water was added to the pellet and the tube was capped tightly and vortexed thoroughly to resuspend the pellet. The resulting suspension was then heated in a boiling water bath for 10 minutes. The heated product was then centrifuged at 13,000 rpm for 10 minutes and the supernatant was collected for use as template DNA in PCR.
[0000] Step 2—PCR of Pertactin Gene from Genomic DNA
[0032] This procedure involves amplification of the pertactin gene (PR/V) from genomic DNA of B. bronchiseptica using the polymerase chain reaction (PCR). After analysis, the PCR product obtained is used for cloning.
[0033] The following cocktail was mixed in a microcentrifuge tube:
[0000]
10X PCR buffer (without MgCl 2 )
25
μL
MgCl 2 (25 mM)
5
μL
dNTPs (equal volume of all nucleotides)
2
μL
Forward PCR primer (10 μM)
6.25
μL
Reverse PCR primer (10 μM)
6.25
μL
Taq DNA polymerase
2.5
μL
Dimethyl sulfoxide (DMSO)
25
μL
Water
150
μL
[0034] The forward primer had the sequence 5′-CGCGGATCCCTCCCATCATCAA-GGCCGGCGAGC-3′ (SEQ ID No. 3), whereas the reverse primer had the sequence 5′-TGCTCTAGACTTTCGGCGTACCAGAGCGTCC-3′ (SEQ ID No.4, and are based upon GenBank X54815 B. bronchiseptica sequence).
[0035] 24 μL of the cocktail was aliquoted into each of 10 PCR tubes. 1.0 μL of water was added to the first tube, which served as a negative control. 1.0 μL of the genomic DNA from Step 1 was added to each of the remaining tubes. All tubes were then placed in a thermocycler. Amplification of PRN was carried out with the following thermocycler program: preheating at 95° C. for 3 minutes, followed by 30 amplification cycles of 20 seconds at 95° C., 30 seconds at 58° C. and 3 minutes at 72° C. The reaction was concluded with an extension cycle of 70° C. for 7 minutes.
Step 3—Analysis and Quantification of DNA by Agarose Gel Electrophoresis
[0036] In this protocol, the pertactin PCR product was analyzed using gel electrophoresis.
[0037] The casting gel was first prepared by pouring TBE into a large flask followed by addition of sufficient agarose needed to make a 1.2% gel (1.2 gm agarose per 100 mL of TBE). The suspension was then heated in a microwave oven until completely melted which generally involved microwaving the suspension for 20-30 seconds, followed by gentle swirling and further heating in 10-15 second bursts alternated with gentle swirling until the agarose melted When the product was cool to the touch (approximately 55° C.) 2 μL Ethidiun bromide stock solution was added followed by thorough swirling with the avoidance of bubble creation. Next, the mixture was slowly poured into a prepared casting stand, again without bubble creation. A comb was inserted into the agarose before it began to set, and the gel was allowed to solidify.
[0038] Following the instructions for the electrophoresis unit, the solidified gel was submerged in 1× TBE. Next a small aliquot (2-10 μL) of each sample, including markers, was prepared for electrophoresis by adding DNA loading dye in a ration of at least 1:6 dye to sample. The samples were then loaded into the wells, taking care not to overfill or allow bubble formation. This loading was done so as to ensure that the samples sank into the submerged wells. The unit was electrophoresed until the dye front moved two-thirds to three-fourths the length of the gel. Using a commercially available molecular weight marker (Lambda DNA digested with Eco RI and Hind III) the gel ran until the 1.904 Kb and 2.027 Kb bands separated. The gel was then gently separated from the casting tray and placed on a UW transilluminator and the size of the product was confirmed; at 1.7 Kb, (e.g. the pertactin PCR product was between the 1.904 Kb and 1.584 Kb marker bands.
[0039] Quantification of DNA was performed using a calibrated molecular weight marker in one of the agarose gel lanes. All-Purpose Hi-Lo DNA Marker was used. Conventional gel analysis software was employed to estimate the amount of DNA.
Step 4—Purification of PCR Products
[0040] In this step the PCR products were purified using a commercially available QIAquick Purification Kit.
[0041] First, the PCR products from Step 2 were pooled to obtain 100 μL of product. This was purified by following the kit manufacturer's instructions. In brief PB buffer was added to the combined PCR product and the mixture was loaded into a QIAquick spin-column. This column was centrifuged with flow-through being discarded. The spin-column was washed with buffer PE and the PCR product was eluded with 50 μL purified water. A vacuum-equipped centrifuge was then used to dry the sample and the dried sample was resuspended in 10 μL purified water. As set forth above, the product was quantitated by electrophoresing.
Step 5—Quantification of DNA by UV Spectrophotometry
[0042] The spectrophotometer was warmed up following the manufacturer's directions, and the DNA was diluted in water to the volume required for the cuvettes being used. The spectrophotometer was zeroed using water as a no DNA reference control and absorbance of the samples were taken at 200 nm. The OD values were then converted to concentration of nucleic acid.
Step 6—Growth and Isolation of Plasmid DNA
[0043] Initially, a culture of E. coil containing expression vector plasmid pProEX Htb was prepared. A vial of the vector was thawed on ice, and the vector was streaked on room temperature LB agar supplemented with 50 μg/ml ampicillin. The streaked agar was incubated at 37° C. for 24 hr. The plate was then visually inspected to ensure that growth was pure and that colonies were isolated. The colonies were large (1-2 mm diameter), white, and smooth. If the growth were very dense, the plate was restreaked for isolation from an area of least growth. If the culture were deemed contaminated, it was discarded and the process begun again with frozen stock.
[0044] Next, 2 ml of the LB medium supplemented with 50 μg/ml ampicillin were aliquoted into a sterile, disposable, 15 ml tube. The tube was then inoculated with a single pProEX Htb colony, capped tightly and vortexed. The tube was then inoculated for 24 hr at 37° C. with shaking at 200 rpm. The 24 hr culture was then transferred to a 2 ml microcentrifuge tube. The culture was turbid, indicating a dense growth of bacteria. In order to confirm culture purity, a loopful of the culture was streaked onto a BG plate for isolation, followed by incubation at 37° C. for 24 hr. The microcentrifuge tube was centrifuged at 13,000 rpm for 10 minutes, in order to harvest cells. The supernatant was then discarded, leaving an easily visible pellet of 4-5 mm in diameter.
[0045] Plasmid DNA was isolated using a commercially available kit (QIAprep Miniprep by Qiagen) following the manufacturer's instructions. Briefly, the harvested cell pellet was treated with buffer P1, followed by buffer P2 and buffer N3. The resulting solution was passed through a spin-column and the column was washed with PE buffer. The plasmid DNA was then eluted in 50 ML purified water. A vacuum-equipped centrifuge was employed to dry the sample and the sample was then resuspended in 10 μL purified water. The 1 ML of resuspended plasmid DNA was quantified by electrophoresing as described above. Because plasmid DNA can be found in three states (linearized, circularized, or convoluted) the agarose gel may show up to three bands in the plasmid lane. Linearized plasmid runs slowest, so the band is at full length (ex. 4.2 kb). Circularized plasmid runs at about half-length (ex. 2.1 kb). Convoluted plasmid runs at about quarter-length (ex. 1 kb). A very good plasmid preparation with few broken, linearized plasmids, will not exhibit a full length band, and thus only half-length or half and quarter-length bands may appear.
[0046] If the concentration is greater than 100 ng/μL, the volume is adjusted with purified water so that the final concentration is 100 ng/μL. If the concentration is between 20 ng/μL and 100 ng/μL, the sample is discarded and the isolation sequence is repeated.
Step 7—Restriction Digestion of DNA
[0047] This procedure involves preparation of PCR product and vector for ligation using restriction enzyme digestion. The work is done on ice with water baths of 37° C. and 65° C. The restriction digestion of the PCR product was performed prior to ligation, and therefore the digestion of the PCR product and plasmid DNA were performed simultaneously. Two replicates of the plasmid DNA digestion were prepared, one to receive the PCR product insert and one for reference.
[0048] In the first step, 500 ML microcentrifuge tubes were labeled and chilled. The following was placed into each tube: 2 μL 10× Multicore buffer and sterile purified water. The tubes were mixed by tapping or using a pipette tip, and then returned to ice. Restriction enzymes (0.5 μL each BamHI and XbaI) were added to each tube, with mixing and an immediate return to ice. DNA samples were then added to the appropriate tubes, with mixing and immediate return to ice. The tubes were sealed with paraffin and placed in a floating tube rack, followed by incubation for three hours in the 37° C. water bath. The restriction enzymes were then inactivated by transferring the tubes to the 65° C. water bath for 10 minutes. A vacuum-equipped centrifuge was then employed to dry the samples. The dehydrated samples were then resuspended in 10 μL purified water. The samples were then quantified by electrophoresing 1 μL of the resuspended digested DNA as described above. If the concentration is greater than 10 ng/μL, the volume is adjusted with purified water to give a final concentration of 10 ng/μL. If the concentration is between 2 ng/μL and 10 ng/μL the sample may be used without further dilution. If the concentration is less than 2 ng/μL, it is discarded.
Step 8—Ligation of Restriction Digested DNA
[0049] This procedure describes the ligation of PCR product into a vector. The resultant recombinant DNA molecule is then introduced into E. coli . All work was done on ice, and the digested samples are the products from Step 7. The total volume of the ligation reaction mixture is 10 μL. In order to maximize the chances of success, ligations in several stoichiometric ratios of plasmid DNA to PCR product in the range of 1:2 top 1:10. First, microcentrifuge tubes were labeled and chilled. Using a DNA ligation kit the ligation was performed following manufacturer's instructions. This involved addition of 1 μL of 10× ligation buffer, 1 μL 10 mM rATP, purified water, digested PCR product (50 ng), digested plasmid DNA and 0.5 μL T4 DNA ligase (4 U/μL). In a no insert control, no PCR product was added. The tubes were incubated overnight at 4° C.
[0000] Step 9—Transformation of Recombinant DNA into E. coli Host
[0050] This procedure describes the cloning of recombinant DNA molecules into E. coli. Work was done on ice and competent cells were stored at −80° C. and protected from temperature fluctuation. Vials of cells were taken from the −80° C. freezer and placed on dry ice unless they were to be rapidly thawed for use as described below.
[0051] One 1.5 μL microcentrifuge tube was labeled and chilled for each ligation mixture from Step 8. A vial of competent cells (Maximum Efficiency E. coli : DH5α F′ IQ) was removed from dry ice and thawed rapidly by rubbing between hands. 100 μL of cells were immediately dispensed into each chilled microcentrifuge tube. 5 μL of ligation mixture (from Step 8) were added to one tube, with mixing and immediately returned to ice. These steps were repeated with the ligation control mixture (self-ligation). The cell suspensions were maintained on ice for 10 minutes. The cells were then heat shocked by transferring the tubes to a 42° C. water bath for 2 minutes, whereupon the tubes were returned to ice. 1 mL LB broth (without ampicillin) was added to each tube, followed by incubation for 1 hr at 37° C., with shaking for each transformation reaction, an LB agar plate supplemented with 50 μg/mL ampicillin was labeled, and the plates were warmed to room temperature (if the agar surfaces were moist, they were placed in a hood with the lids opened for 5-10 minutes or until the agar surfaces appeared dry). After the 1 hr incubation 100 μL of each culture were transferred to the appropriate plate, using a sterile glass “L” or sterile disposable spreader to spread the cultures evenly over the agar surfaces. If the agar appeared wet, the lids were opened until the surfaces dried. The cultured plates were incubated for 12-16 hr at 37° C.
[0000] Step 10—Screening of E. coli Colonies for Recombinant DNA
[0052] In this step the E. coli colonies are screened for the presence of recombinant DNA molecules.
[0053] The cultured plates from Step 9 were counted, and the number of colonies on each plate was recorded. More colonies were apparent on the PCR-plasmid plates than on self-ligation plates. Colonies were selected for screening, and for each such colony a 15 mL sterile, disposable centrifuge tube was prepared and labeled. 2 mL of LB broth supplemented with 50 μg/μL ampicillin was added to each tube, and each tube was inoculated with a single isolated colony. The tubes were then capped and vortexed, followed by incubation overnight at 37° C., with shaking at 200 rpm. Each culture sample was aseptically transferred to an appropriately labeled 2 mL microcentrifuge tube, which is capped and stored at 4° C. until completion of screening. The tubes were centrifuged at 13,000 rpm for 10 minutes to harvest the cells. Plasmid DNA is isolated from each sample using the QIAprep Miniprep Kit following the manufacturer's instructions, as indicated in Step 6. Next, the DNA was quantified as described in Step 3. The isolated DNA samples were digested with Ba HI and XbaI following the procedure of Step 7. Agarose gels were prepared as described in Step 3. 5 μL of each digested sample was mixed with 5 μL DNA loading dye, and this mixture was loaded onto the gels as described in Step 3. Colonies that released 1.7 kb fragments upon BamHI-XbaI digestion were considered to be positive clones. The positive clones were retained whereas the remaining tubes were discarded. Samples of the positive clones were streaked onto LB agar plates supplemented with 50 mg/mL ampicillin, and the plates were incubated at 37° C. for 24 hr. The plates were checked for growth and stored at 4° C., until the clones were checked for protein expression.
[0054] The positive clones expressed a fusion protein containing a pertactin clone having a pertactin fragment partially characterized by SEQ ID No. 5, which is an immunoprotective region which corresponds with positions 281-408 of the GenBank sequence of B. bronchiseptica strain AY376325.
Buffers and Reagents
[0055] The following describe the preparation of various buffers and reagents used in the foregoing procedure:
[0056] Ampicillin stock (50 mg/ml):
Dissolve 0.5 g of ampicillin powder (sodium salt) in 9 ml water. Adjust the volume to 10 ml after the powder dissolves completely. Filter sterilize. Aliquot and store at −20° C.
[0061] DNA loading dye:
25 mg Bromophenol blue. 25 mg Xylene cyanol. 3 ml (v/v) Glycerol. Adjust volume to 10 ml with purified water. Mix thoroughly. Aliquot and store at 20° C.
[0068] Ethidium bromide:
Dissolve 1 g of Ethidium bromide in 10 ml purified water. Stir for several hours to ensure dye is dissolved. Aliquot. Store in dark at room temperature. Add 1 μl of to each 10 ml molten agarose.
[0074] Luria-Bertani (LB) Agar:
Dissolve 25 g of LB Broth powder in 950 ml purified H2O. Add 25 g Bacto-Agar. Mix thoroughly Adjust volume to 1 1. Aliquot into autoclavable containers. Autoclave LB agar at 121° C., 15 psi for 30 minutes. Pour plates immediately after agar has cooled to about 50° C. or store at room temperature in tightly closed bottles. To melt agar that has solidified, microwave (alternate 15-30 sec microwave “bursts” with swirling until agar is melted). Cool the medium to 50° C. and immediately pour into Petri plates.
[0083] Loria-Bertani (LB) agar supplemented with ampicillin:
Add ampicillin stock to 50° C. LB agar to a final concentration of 50 μg/ml. Ampicillin stock=50 mg/ml, thus, 100 μL of stock is added to 100 ml of agar. Alternatively, 25 μL of stock can be spread on the surface of an agar plate.
[0087] Luria-Bertani (LB) Broth:
Dissolve 25 g of LB Broth powder in 950 ml purified H2O. Adjust volume to 1 1. Autoclave LB Broth at 121° C., 15 psi for 30 minutes. Store at room temperature in tightly closed bottles.
[0092] Luria-Bertani (LB) Broth supplemented with ampicillin:
To sterile LB Broth, add ampicillin stock as needed just before inoculation.
[0094] Nutrient Broth:
Dissolve 8 gm of Nutrient Broth powder in 1 1 of purified water. Mix well. Aliquot into autoclavable bottles. Autoclave at 121° C., 15 psi for 15 minutes. Store at room temperature in tightly closed bottles.
[0100] 10× TBE:
Pre-measured TBE salts are purchased from Amresco. One package of 10× TBE salts is dissolved in 950 ml purified water. Adjust volume to 1 1 with purified water. Mix well. Aliquot into autoclavable bottles. Autoclave at 121° C., 15 psi for 15 minutes. Store at room temperature in tightly closed bottles.
[0108] 1× TBE:
1× TBE can be obtained by diluting 10× TBE 1:10 with purified water (10 ml of 10× TBE plus 90 ml of purified water to make 100 ml of 1× TBE). cl Example II
Development of Pertactin Clones (PRN 1, 3 and 4)
[0110] In this example, three other pertactin clones were generated using three different B. bronchiseptica strains. The procedures of Example I were followed, including the use of the forward and reverse PCR primers (SEQ IDS Nos. 3 and 4).
[0111] The positive clones were found to express fusion proteins having pertactin fragments with the sequences of SEQ ID Nos. 6 (PRN 1), 7 (PRN 3) and 8 (PRN 4), which are respectively sequences of immunoprotective regions which corresponds with positions 281-408, 281-408 and 281-418, respectively, of the GenBank sequence of B. bronchiseptica strain AY376325.
Example III
Development of Filamentous Hemagglutinin Truncated Protein (FHAt)
[0112] A truncated fusion protein (FHAt) was prepared which included a conserved domain homologous to the immunodominant region of FHA of B. pertussis . FHAt was shown to be safe and antigenic in rabbits and reduced the formation of antibodies that inhibited the hemagglutination associated with full length B. pertussis FHA. Briefly, polyclonal anti- B. pertussis FHA antiserum was used to identify an immunoreactive clone (PDK1) from the DNA library of a B. bronchiseptica field isolate. The insert of pDK1 was subcloned into a prokaryotic protein expression vector, to produce the FHAt fusion protein. The details of the procedure are set forth in the above-cited and incorporated by reference 1999 Keil thesis, Section V.
[0113] This fusion protein had the sequence of SEQ ID No. 9, which is an immunoprotective region which corresponds with positions 1620-2070 of Genebank sequence M60351.
Example IV
Vaccine Preparation
[0114] The positive E. coil clones produced pursuant to Examples I-III respectively bear plasmids which express protective B. bronchiseptica proteins, namely PRN2, PRN3 and FHAt.
[0115] Vaccine formulations were produced under standard commercial vaccine production conditions using the two pertactin clones (PRN2 and PRN3) and one filamentous hemagglutinin clone (FHAt). Briefly, the E. coli host cells bearing the PRN2, PRN3 and FHAt plasmids were grown in sterile culture media. Expression of the protective proteins was induced without extracellular secretion by the addition of IPTG. When the cultures reached log phase, growth was stopped by the addition of phenol to the media to kill the E. coli . After neutralization of the phenol, the cell suspensions were repeatedly washed with sterile saline, and the suspension(s)—either concentrated or diluted—to achieve a standard concentration. Three vaccine formulations were prepared, using equal volumes of the clones which were then combined with equal volumes of adjuvant (FHA) (proprietary light oil and water adjuvant).
[0116] The specific vaccine formulations were as follows:
[0117] Formulation 1=PRN2+FHAt
[0118] Formulation 2=PRN3+FHAt
[0119] Formulation 3=PRN2+PRN3+FHAt.
[0120] In order to assess the safety of the vaccines a 10× dose (10 ml) of Formulation 3 was injected into each of four dogs subcutaneously. Formulation 3 was used because it contained all of the components of the various formulations. The animals were observed for the onset of acute reactions every one to two hours over a period of four hours then with decreasing frequency. No systemic reactions occurred and all dogs remained normal in all regards. At 30 hr after injection, localized mild swelling was noted at the injection site of two animals. At one week, these two animals had developed sterile, localized, firm, non-painful swellings at the injection sites. These localized reactions were opened to allow for cleaning after which they healed rapidly.
[0121] In order to assess the immunogenicity of the vaccines, young Greyhounds were injected three times at approximately two week intervals with lx doses (1 ml) of a formulation. Ten dogs received three doses of Formulation 1; nine received three doses of Formulation 2; and ten received three doses of Formulation 3. As with the previous experiment, all dogs that were vaccinated remained healthy and exhibited no systemic reactions to the vaccine formulations. In a few dogs, localized, firm, non-painful swellings developed at the injection site which resolved spontaneously without intervention. The reactions were characteristic of a type-III hypersensitivity reaction commonly associated with the use of some adjuvant in dogs.
[0122] Serum was collected from each dog prior to the first injection, at the time of each subsequent injection, and ten days after the final injection. Immune responses to the vaccines were assessed by purified protein ELISA.
[0123] In brief, ELISAs were performed as follows: PRN and FHA clones were grown and induced as described above. When the cultures reached log phase, the cells were harvested by centrifuigation and lysed by ultrasonic exposure. PRN2, PRN3, and FHAt were separated from the cell lysates by nickel column chromatography. Wells of assay plates were coated with the purified proteins. Serum samples were diluted and applied in triplicate to the coated wells. Enzyme-linked secondary antibody was applied, followed by ABTS (calorimetric agent). Reactions as a measure of antibody concentration were evaluated by measuring the optical density of each well and averaging the triplicate wells.
[0124] The attached tables represent the results of the assays. The four serum samples from each Greyhound were tested against the antigens included in the vaccine the animal received. The results demonstrate that the animals' immune responses to the antigens increased after vaccination. Immune response to these antigens has-been shown to be protective against Bordetella bronchiseptica infection.
[0125] All of the references noted herein are specifically incorporated by reference.
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Improved, low cost vaccines for administration to living subjects such as mammals and birds are provided, which include killed recombinantly modified microorganisms (whole cell recombinant bacterin vaccine), the latter including recombinant DNA encoding at least one protective protein (e.g., an antigenic protein) which has been expressed by the microorganisms prior to killing thereof. The protective protein(s) are operable to prevent or reduce the severity of a disease of the subject. The vaccine preparations of the invention do not require separation of the protective protein(s) from the host recombinant microorganism(s), thereby materially decreasing the complexity and cost of the vaccine formulations. A preferred vaccine against kennel cough includes recombinantly modified microorganisms which express protective antigens containing pertactin and filamentous hemagglutinin protein products.
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[0001] This application is a continuation-in-part application to and claims priority to U.S. patent application Ser. No. 11/005,514, filed Dec. 6, 2004, which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] Doppler helmets, more particularly, Doppler helmets custom fit to the head with the further addition of securing pins for fastening and pins to positively locate the helmet adjacent the skull of the user and a method for using the same.
BACKGROUND OF THE INVENTION
[0003] When a patient suffers a subarachnoid hemorrhage (SAH), he is at risk of developing vasospasm in some of the major intracranial arteries at some time during the first two weeks after the bleed. When vasospasm occurs, the muscle wall of the artery contracts, narrowing the lumen, and restricting the blood flow. Prolonged vasospasm will cause a stroke in that part of the brain relying on this artery. The current management of vasospasm is somewhat risky, and is not initiated in the absence of true vasospasm, but should be initiated as soon as it is detected. Whereas current practice involves intermittent manual monitoring, the helmet ( 1 ) can be set up for automatic constant monitoring.
[0004] Monitoring of the intracranial blood flow as well as extracranial blow flow is essential. Those physiological factors that influence heart rate and blood flow generally affect both intracranial and a extra-cranial arteries similarly. Vasospasm from SAH does not affect the extra-cranial arteries. Because of this, the rise in the ratio of the flow rates, of intracranial to extra-cranial arteries, is the best indication of active vasospasm. Applicant's helmet ( 1 ) allows for monitoring both. The monitor can easily be programmed to constantly calculate the ratio and set off an alarm if the ratio exceeds a predetermined level.
[0005] It must be noted that current Doppler technology does not adequately penetrate an intact skull, except over the temporal bones, where the skull is thin. The device described here would necessitate making burr holes in the patient's skull along the flow vectors of the major intracranial arteries. The precise position for these burr holes can be determined at the time of the initial digital scan, and the scalp can be marked appropriate for later craniostomies.
[0006] The object of this invention is to provide a means to maintain a Doppler probe ( 2 ) in an exact position, with respect to a patient's intracranial arteries, to continuously monitor blood flow in those arteries.
BRIEF SUMMARY OF THE INVENTION
[0007] This application provides for a helmet that is custom-made for one person. This helmet is typically made of a rigid plastic material to specifications dictated by the data obtained from a digital scan of the person's head, such as a CAT scan or MRI scan. The helmet is designed to be secured to the user's skull by, typically, four skull pins threaded through the helmet, and seated on the user's skull. The helmet is constructed with a plurality of windows, through which Doppler monitoring probes will be fitted. When properly affixed to the user's head, the windows will be positioned such that the flow vectors of the major intracranial arteries of the user will be directed through the windows and thus at the Doppler monitoring probes. In order to fix the helmet to the head in the correct position, the helmet typically will be made with orientation lines scribed on the surface that will point to a plurality of easily recognized landmarks on the user's head, i.e., internal auditory canal and medial canthus of the eye. The data needed for placement of the windows and the orientation lines is provided by the initial digital scan.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] FIG. 1 is an elevational view of the front of the helmet ( 1 ) showing it fitted to the user with a Doppler monitor probe ( 2 ) mounted to an adapter ( 3 ), attached to the helmet over the left temporal bone, and a representation of the left internal carotid artery ( 4 ) with left middle cerebral ( 5 ) and left anterior cerebral branches ( 6 ) (ghosted in).
[0009] FIG. 1A illustrates the view of a window ( 20 ) with the Doppler probe in place.
[0010] FIG. 2 is an elevational view of the right side of the helmet ( 1 ) showing it fitted to the user with a Doppler monitor probe ( 2 ) mounted to an adapter ( 3 ), attached over the right temporal bone, and a representation of the right internal carotid artery ( 7 ) with the right middle cerebral ( 8 ) and right anterior cerebral ( 9 ) branches (ghosted in).
[0011] FIG. 3 is an elevational view of the front of the helmet ( 1 ) fitted to the user with a Doppler monitor probe ( 2 ) mounted to an adapter ( 3 ) attached over the apex and a representation of the basilar artery ( 10 ) and some of its branches ( 11 ) (ghosted in).
[0012] FIG. 4 is an elevational view of the right side of the helmet ( 1 ) fitted to the user with a Doppler monitor probe ( 2 ) mounted to an adapter ( 3 ) attached over the apex and a representation of the basilar artery ( 10 ) and some of its branches ( 11 ).
[0013] FIG. 5 is an elevational view of the right side of the helmet ( 1 ) fitted to the user with a Doppler monitor probe ( 2 ) mounted to an adapter ( 12 ) attached to the lower edge of the helmet ( 1 ) and with a representation of the extra-cranial portion of the internal carotid artery.
[0014] FIG. 6 is a view of the right side of the helmet ( 1 ) fitted to the user showing the orientation lines ( 14 ) inscribed on the helmet directed at anatomical landmarks.
[0015] FIG. 7 is a typical Doppler probe ( 2 ).
[0016] FIG. 8 is a Doppler probe ( 2 ) secured to an adapter ( 3 ) that attaches to the helmet ( 1 ) (not shown).
[0017] FIG. 9 is a Doppler probe ( 2 ) secured to the adapter ( 12 ) that attaches (with fasteners, not shown) to the helmet ( 1 ) over the extra-cranial portion of the internal carotid artery (see FIG. 5 ).
[0018] FIG. 10 is a view of the right side of the helmet ( 1 ) fitted to the user showing two skull pins ( 15 ) threaded through the helmet ( 1 ).
[0019] FIG. 11 is a view of the top of the helmet ( 1 ) fitted to the user showing four skull pins ( 15 ) threaded through the helmet ( 1 ).
[0020] FIG. 12 is a cross-section view of the helmet ( 1 ) showing a skull pin ( 15 ) threaded through the helmet ( 1 ).
[0021] FIG. 13 is a cross-section view of the skull ( 16 ) with a skull pin ( 15 ) seated on the skull ( 16 ).
[0022] FIG. 14 is a view of an adapter ( 17 ) affixed to a window in the helmet ( 1 ) and upon which the Doppler probe ( 2 ) will be mounted.
[0023] FIG. 15 is a view of an adapter to adjustable locate a Doppler probe.
[0024] FIG. 16 illustrates burr holes drilled in the skull aligned along the Doppler probe axis.
DETAILED DESCRIPTION OF THE INVENTION
[0025] With reference to FIGS. 1-16 , it is seen that the helmet ( 1 ) is made to fit on the head of one specific person, and that it is secured to that person's head with skull pins ( 15 ), and that the precise position of the helmet is dictated by the orientation lines ( 14 ) inscribed on the surface of the helmet ( 1 ).
[0026] It is further seen that the helmet ( 1 ) may typically be fitted with several types of adapters ( 3 ) ( 12 ) that hold Doppler probes ( 2 ) secured to predetermined windows ( 20 ) on the helmet ( 1 ). These adapters or brackets secure Doppler probes ( 2 ) to the helmet ( 1 ); and can fix a probe ( 2 ) anywhere within a few millimeters of the center of the window at an angle typically within a few degrees of the axis of the window; in order to precisely line up with the flow vector of the artery that the probe ( 2 ) is monitoring. Adapters or brackets may thread into the helmet ( FIG. 1A ) and hold the probe by friction fit or other ways. The adapters or brackets may be constructed as in FIG. 15 to adjustably mount the probes with respect to the helmet.
[0027] In current use is the machinery to produce accurate physical models of a patient's skull and intracranial arteries derived from the data obtained from medical imaging studies, i.e. a digital CAT scan or MRI scan. Once the raw data is obtained, specialized software is used to construct a virtual 3D model. This is fed to a prototyping machine that produces a final model of the helmet in physical form. The same technology and machinery can also be used to make a shell (helmet) to fit a patient's head. The virtual model will also identify the exact spatial relationship between the flow vectors of the major intracranial arteries and the surface of the helmet ( 1 ). The prototyping machine will make a helmet ( 1 ) with precut windows precisely in line with those flow vectors. The lab will typically provide the adaptors to attach the probes to the helmet at the window sites and will tap the holes for fasteners.
[0028] Windows are simply round holes cut through the helmet. The site of the window is accurately determined by the computer lab.
[0029] Separate from the windows, the lab can set threads in the helmet for skull pins 15 , typically four as seen in FIGS. 10-14 . Skull pin 15 may be a threaded fastener and would typically have a button tip 15 A attached thereto.
[0030] The same data can provide coordinates of several skull landmarks that are readily identifiable on a patient, i.e. external auditory canal, nasion, zygoma, mastoid process. When the virtual model of the helmet ( 1 ) is made the software can identify these landmarks with respect to an arbitrary point on the helmet surface. When the physical model is made it can be inscribed with surface lines oriented from the arbitrary point toward the landmarks. This will help ensure that the helmet is properly fitted to the patient.
[0031] The helmet ( 1 ) is then fitted with special mounting adapters ( 3 ), that have a tubular part that is inserted through the pre-cut window, and rests gently against the scalp of the user where it is fixed in place in the helmet ( 1 ). Each adapter is designed to secure to a window while holding a probe ( 2 ) aligned to a flow vector. The adapter ( 2 ) is further designed for fine adjustments of the probe ( 2 ), such that the probe ( 2 ) can be set anywhere within a few millimeters of the center of the window and angled a few degrees with respect to the axis of the window, and then secured in place for continuous monitoring.
[0032] Orientation lines 14 in FIG. 6 are inscribed in the helmet when it is made. These lines are directed at anatomical landmarks in order to mount the helmet onto the individual in the desired orientation. The computer identifies the location of the orientation lines 14 and makes a virtual image of the helmet surrounding the head and picks up an arbitrary point on the surface of the helmet (X,Y,Z). It then tilts and rotates the combined images of the head and helmet until it is an identifiable skull landmark and X,Y,Z in the same plane and then inscribes a line along this plane for the fabricating machine to reproduce when constructing the helmet. The computer prepares a few orientation lines having the same origin, thus positioning the helmet with respect to the head and thus being capable of positioning windows thereupon.
[0033] When the helmet is placed on the patient's head, it is held lightly in place with the skull pins adjacent the skull. This allows the surgeon a little leeway to move the helmet until he gets it situated where he wants it, using localizing lines to help with initial orientation of the helmet to the head. The Dopplers are then adjusted to obtain an adequate signal from each of the Dopplers and when they can be monitored properly through all windows, the pins are then finally positioned and secured to the patient's head (see FIGS. 11, 12 , and 13 ).
[0034] Because the original data typically identifies all the major intracranial arteries, and their flow vectors, the helmet ( 1 ) provides the opportunity to monitor several major arteries simultaneously with different probes ( 2 ). It is also seen, from FIG. 5 that the left or right extra-cranial portion of the internal carotid artery can also be monitored with a Doppler probe properly mounted and directed.
[0035] With further reference to FIG. 15 , it is illustrated how adaptors 3 may be adjustably mounted to aim Doppler probes. More specifically, FIG. 15 is seen to illustrate that adaptors 3 could consist of a tube 22 with outside threads that screw into the helmet at each window 20 . Since the helmet is typically about ⅛ to ¼ inch thick, the holes could be tapped and threaded when the helmet is made for lab.
[0036] When the DMP holder is screwed into the helmet at the desired depth (i.e., with the tube just touching the scalp), a locknut 24 is tightened against the helmet surface securing the tube in place. The probe is then inserted, for example, by a snug friction fit through a channel 28 A and a ball 28 , which is placed atop the tube and would typically sit atop the tube, but fit within the cap 26 . Before tightening the cap, the probe can be rotated and positioned with a few degrees of angulation as needed. The desired position is the one that receives the best signal from the artery being monitored. The arterial segment being mounted is about ½ inch long and the signal will travel 2 to 3 inches.
[0037] Typically, the helmet would be initially set up with the DMP monitoring five arteries—both middle cerebral arteries, the basilar artery, the anterior cerebral artery complex, and one extra-cranial internal carotid artery.
[0038] The same type of DMP may be used for all sites. The adaptor or adjustable bracket that holds the DMP aligned to the extra-cranial internal carotid artery may be different in that it holds the DMP below the ear and behind the angle of the jaw and points upward, almost tangentially to the skull (see FIG. 5 ). In an alternate embodiment, the helmet could extend down a bit further and a window may be used.
[0039] At the time of setup, the DMPs and the helmet itself will need careful adjustment to assure the DMPs are aligned properly and receiving signals. The helmet is then secured to the skull and the DMPs are locked in place.
[0040] FIG. 16 illustrates burr holes 30 , such as a burr hole drilled by a ⅝″ drill bit, in the patient's skull, which are provided for and in alignment with the DMPs along flow vectors of the major intra-cranial arteries. These burr holes may be necessitated because current Doppler technology may penetrate an intact skull. These burr holes may be located along the Doppler axis at the time of the initial digital scan and the scalp can be marked appropriate for later cranial ostomies.
[0041] Although the invention has been described in connection with the preferred embodiment, it is not intended to be limit to the inventor's particular form set forth, but on the contrary, it is intended to cover such alterations, modifications, and equivalences that may be included in the spirit and scope of the invention as defined by the appended claims.
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A helmet manufactured for one specific person, made from rigid synthetic materials, to specifications determined by data obtained from a previously obtained MRI (magnetic resonance imaging) scan of that person's brain, intra-cranial arteries, and skull. The helmet and its attached adapters hold in place various Doppler probes directed at specific arteries, both intra-cranial and extra-cranial, to provide continuous readings of the velocity of the blood flow through those arteries.
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BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for establishing humidity gradients within a single-zone air conditioned space. More particularly, the present invention relates to a method and apparatus for modulating humidity across large single-zone air conditioned spaces such as those typically found in supermarkets.
Supermarkets are highly intensive energy operations. Energy cost represents a significant share of overall operating cost, often equaling a store's annual profit. The largest share of supermarket energy cost is for refrigeration. Display cases refrigerated 24 hours a day typically account for more than half the electricity used in the store. Excess humidity causes the refrigeration system to consume more energy. Optimum dehumidification can help the efficiency of the refrigeration system and reduce the associated energy cost. In most commercial HVAC applications, the primary function of an air conditioning system is temperature control. In supermarkets, however, the emphasis is on dehumidification, because reducing the amount of moisture in the air causes the refrigeration system to operate more efficiently.
Once a lower humidity level is achieved in the supermarket, a number of operational benefits are simultaneously achieved. First, the energy expended by the refrigeration cases in removing moisture from the air is reduced. Second, the buildup of frost on the refrigeration coils is reduced, thereby reducing the insulating effect of frost on the coils and allowing the coils to be defrosted less frequently. Third, the need for anti-sweat heating of display case doors and other surfaces is reduced. In addition to reduced energy use for the anti-sweat heaters themselves, the load on the refrigerating coil is also reduced because less heat is transferred from the anti-sweat heaters into the display case.
An air conditioning zone is a space enclosed or separated from other spaces or environments. Traditionally, air conditioned zones are bounded by fixed walls or other physical separations. Such zones may also be bounded by flexible membrane barriers or high velocity streams of air known as "air curtains". System designers have heretofore recognized that temperature gradients, caused by internal heat generating sources such as lights, electrical equipment or refrigeration devices, may develop within such zones. Typically, the refrigeration cases in a supermarket are located some distance from the fresh produce section of the sales area. The ambient temperature in the area immediately surrounding the refrigeration cases is usually lower than the temperature in the other areas of the store and is often below a customer's comfort level. In the remainder of the store, temperature levels are generally acceptable, with the exception of the checkout area. Temperatures rise in the checkout area because windows, entryways, and concentrations of customers and employees are typically located there. It is also generally recognized that temperature gradients may result from vertical stratification of warmer air. To counteract these gradients and achieve temperature uniformity, return ducts located near the heat generating source and air circulation equipment such as ceiling fans are typically employed.
In contrast to temperature gradients, it has generally been believed that significant humidity gradients do not and cannot exist within a single zone. This belief rests in part on the rate with which moisture diffusion is thought to occur within such zones. As a result of this belief, the space conditioning control strategy recommended in professional literature specifies that large single zones such as supermarkets should be treated as a single entity, wherein fixed set points for temperature and humidity are maintained throughout the space. These set points are almost uniformly specified as 75° F. dry bulb temperature and 55% relative humidity. The operating condition defined by these set points is so well accepted by design and operating personnel in the supermarket industry that all equipment designed for the conditioned space (sales area) is rated at that operating condition. In fact, capacity and power consumption values for refrigerated cases are not published for other operating conditions. Moreover, since conventional air conditioning systems are intended primarily for temperature control, they produce relative humidities approximating the 55% level typically employed in supermarket applications. Such systems are not designed to produce lower humidity levels.
Because of the increased cost of electric power and the concern for the availability of electric power in the future, system designers and engineers have investigated the advantages of other set points. In applications such as supermarkets, wherein refrigeration cases are located within the conditioned space, significant power savings can be realized from the operation of the refrigeration cases if the ambient humidity is lessened to 30%. As explained above, this power savings results from the fact that it takes a refrigeration case less energy to cool dryer air, the latent load of such air having been reduced by the lower ambient humidity. Unfortunately, in the supermarket application, a lower overall humidity level within the conditioned space is unacceptable, because lower humidity levels have an adverse effect on fresh produce. Where the humidity is too low, vegetables begin to wilt--requiring spraying, which acts to raise the humidity again. This condition forces system designers to opt for an overall ambient humidity level of 55%--which is not optimal for the operation of the refrigeration cases.
When conventional electric systems have been employed to control humidity in supermarkets, their performance bas been less than satisfactory. When the system is operated long enough to achieve the desired 55% relative humidity level, the air in some or all of the store often becomes too cool, thus requiring heating to achieve a comfortable ambient temperature level. Several technologies, including gas fired desiccant systems and high efficiency air conditioning systems, have been adapted and developed to help supermarket owners efficiently achieve the desired 55% relative humidity level.
Gas fired desiccant systems, which were originally developed for sensitive product shipping and warehousing applications, remove moisture from the air to achieve a lower humidity level. In recent years, this technology bas been combined with conventional electric air conditioning systems for use in supermarkets. In such systems, the desiccant system first acts to dehumidify return air from the zone. Since the desiccant system also works to warm air passing through, this added heat must next be removed by electric air conditioning before the air can be passed back into the zone. The heat added by the desiccant equipment represents an additional load for the electric air conditioning system in addition to the space cooling load.
High efficiency electric air conditioning technologies cool return air to lower temperatures--approximately 40° to 45° F.--in order to remove moisture. In these systems, only a percentage of the return is cooled. More particularly, enough of the return air is cooled to achieve the required low humidity level. The remainder of the return air is allowed to bypass the cooling coil, thereby minimizing overcooling and the need to re-heat the conditioned air for its return to the store.
Different air flow techniques have also been employed in connection with these new technologies to further improve system performance. In a supermarket, much of the air returning the air conditioning system from within the store may already be cool as well as low in humidity. For example, to avoid uncomfortably cold aisles, the cold, dry air escaping from refrigeration display cases is typically captured by returns under the cases and returned to the air conditioning unit. In comparison with outside air, air returned from elsewhere in the store is also relatively cool and dry. Although such air does not require significant processing, conventional air conditioning systems channel it through the cooling and dehumidification process just as if it were warm and humid air taken from outside the store. Modern airflow techniques address these inefficiencies by channeling return air so as to bypass the cooling and dehumidification units.
In one such channeling technique known as a single path system, the cooling unit can be sized for the smaller volume of air which will actually pass through the unit. After that air is cooled to the low temperature needed to reach the desired humidity, it is mixed with the bypassed air. This blend is typically cooler than the conditioned air normally delivered by conventional air conditioning systems, so less of it is needed to achieved the desired store temperature (750° F.) and humidity (55%).
An alternative air channeling technique is known as dual path channelling. In the dual path system, the air is processed in two separate streams, with the outdoor air directed to a primary coil and the relatively cool and dry return air being cooled by a secondary coil only when necessary. Both the single and dual path systems allow system designers to employ smaller cooling units and circulation fans, thereby effecting significant energy savings. Other system enhancements which have been added to improve performance in the supermarket industry include heat pipe exchange and ice storage systems.
All of the above techniques share the common goal of maintaining a uniform temperature (75° F.) and humidity (55%) throughout the air conditioned zone. Although significant energy savings could result if the ambient humidity in the area around the refrigeration cases was lowered to 45%, no system to date has successfully capitalized on this fact because an overall lower humidity level throughout the store is undesirable for certain goods such as fresh produce, and achieving such gradients has, in practice, proven difficult to achieve.
SUMMARY OF THE INVENTION
By creating a humidity gradient across a conditioned space, the present invention achieves varied humidity levels within a single conditioned zone. In the supermarket application, this gradient places less humid air in the area surrounding the refrigeration cases. The humidity level in the zone increases as one moves away from the refrigeration cases and toward the fresh produce or other sections. This operating condition results in significant power savings in the operation of the refrigeration cases--while maintaining a humidity level in the fresh produce section which is acceptable for the storing of such goods. In addition, the present invention works to optimize the overall level of air circulation within the zone, thereby reducing the power typically consumed by the air circulation fans while assuring that drier air reaches the points where it is most effective.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the layout of a supermarket of the prior art.
FIG. 2 shows the layout of a supermarket arranged according to the present invention.
FIG. 3 shows the layout of a supermarket arranged according to an alternate embodiment of the present invention.
FIG. 4 shows a further alternative supermarket layout arranged according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In applying the present invention to an existing supermarket, the existing air conditioning equipment can be retained, however, the supply and return ducts to the area of the refrigeration cases should be disconnected from the existing equipment. A desiccant dehumidification unit, such as that described in Munters, U.S. Pat. No. 3,125,157 should then be installed to supply the area of the refrigeration cases. The disclosure of Munters is incorporated herein by reference.
The desiccant unit supplies dry air to the area of the refrigeration cases, thereby improving the energy efficiency of the refrigeration cases. The dry air supplied by the desiccant unit is also warmer than the return air, thereby increasing the temperature and customer comfort level within the area of the refrigeration cases. When the desiccant system is used as described in the present invention, a temperature set point of 75° F. can be achieved in both the refrigerated and non-refrigerated areas of the conditioned zone. In addition, a humidity set point of approximately 30% relative humidity can be achieved in the refrigerated area, while a 55% relative humidity is maintained in other areas of the zone or store.
Referring now to the figures, FIG. 1 shows the layout and load distribution of a typical supermarket of the prior art. Produce is typically located in area 11 and refrigeration cases are typically found in area 12, so as to be positioned on opposite ends of zone 10. Checkout area 13 is located in the front of zone 10. The load of zone 10 is distributed between air conditioning units 14 and 15. Supply air is injected into the front of zone 10 (checkout area 13) through supply ducts 17 and 17a, and return air is withdrawn from the back of zone 10 by return ducts 18 and 18a, thereby creating an air flow directed from the front to the back of zone 10. Unit 14 is typically connected to ducts 17 and 18, and unit 15 to ducts 17a and 18a. Alternatively, units 14 and 15 may share common supply and return paths. In a 20,000 square-foot store, unit 14 and 15 would each typically be a 40 ton unit having the capacity to move 24,000 CFM of air.
FIG. 2 shows the layout and load distribution of a supermarket designed in accordance with the present invention. Produce area 21 and refrigeration area 22 are located on opposite ends of zone 20, and checkout area 13 is located in the front of zone 20. The layout of the zone 20 is divided into a refrigeration space 24 and a non-refrigeration space 25. The load of zone 20 is distributed between desiccant unit 26 and air conditioning unit 27. Desiccant unit 26 draws its return air from and injects its supply air into refrigeration space 24; air conditioning unit 27 draws its return air from and injects its supply air into non-refrigerated space 25. Units 26 and 27 are connected to their respective spaces through conventional return and supply ducts located within the respective zones. More specifically, desiccant unit 26 draws return air from ducts 26a, and injects supply air through ducts 26b. Similarly, air conditioning unit 27 draws return air from ducts 27a, and injects supply air through ducts 27b.
Supply ducts 26b can descend from the ceiling in the center of a shopping aisle and, in aisles containing open (or coffin) refrigeration cases, these ducts will preferably direct the supply air parallel to the direction of the shopping aisle. In aisles containing closed door refrigeration cases, the supply air is preferably directed at the cases (or perpendicular to the direction of the aisle). Desiccant unit 26 is controlled by thermostat 26c and humidistat 26d, while air conditioning unit 27 is controlled by thermostat 27c and humidistat 27d. Both thermostats will typically be set at 75° F., humidistat 26d can then be set to achieve a 45% relative humidity (or lower) in refrigeration space 24, and humidistat 27d can be set to achieve a 55% relative humidity in non-refrigerated space 25. A Honeywell model T42 thermostat, or any other suitable model, can be used for thermostats 26c and 27c, and a Honeywell model H609A dew-point controller, or any other suitable model, can be used for humidistats 26d and 27d.
When the arrangement shown in FIG. 2 was applied to a supermarket with a sales area of approximately 45,000 square feet, wherein desiccant unit 26 was rated at 150 lbs/hour having the capacity to move 8,000 CFM of air, and air conditioning unit 27 was a 40 ton unit having the capacity to move 24,000 CFM of air, a 75° F. temperature level was generally created throughout the zone and a humidity gradient ranging from 45% to 55% relative humidity was targeted and achieved across zone 20. Dew points as low as -20° F. were also achieved in air supplied by desiccant unit 26. In addition, the energy needed for air circulation within the zone was substantially reduced.
Because the system of the present invention is capable of delivering supply air with dew points of from 40° F. to -20° F. and below, the system may be controlled to optimize the cost-efficiency of operation. Typically, heat used in regeneration of a desiccant wheel is derived from one or more of three sources: air conditioning condenser strip heat, desiccant wheel waste heat (transferred through a counter-flowing heat exchange medium such as a heat exchanger wheel), and supplementary heat derived from gas combustion or electrical resistance. The marginal energy cost of supplying air having less moisture content is the sum of all of the energy used over and above the available heat derived from normal operation of the HVAC systems.
The system of the present invention may be optimally controlled by calculating the marginal energy cost required to achieve a preselected level of dehumidification, and comparing that marginal cost against the calculated savings to be derived from lowering the moisture content of the supply air. For example, it is known that for every 1° F. reduction in dew point, a 1% reduction in energy consumption of refrigeration equipment (air conditioners, freezer cases, refrigerated cases, and the like) is achieved. This relationship bolds true down to dew points near the refrigerant temperature of a given piece of refrigeration equipment.
Similarly, glass-front refrigerated cases typically use resistive heaters in their doors to prevent condensation. Such heaters (anti-sweat beaters) are activated when the surrounding air is above approximately 40° F. dew point, and each door heater typically consumes 250 W of electrical energy. In addition, each heater reflects approximately 200 W of additional load into the refrigerated case, for a total load of approximately 0.5 KW per door. The energy savings which may be realized by deactivation of the door beaters stands in addition to the linear energy savings (1° F. reduction in dew point=1% reduction in energy consumption) which holds for refrigeration equipment described above.
Other points of criticality may be factored into the dew point optimization calculation. For example, when the ambient dew point passes below the surface temperature of goods stored in open refrigerated cases, elimination of surface condensation on the goods is achieved, thereby reducing the latent (and therefore overall) load on the refrigeration system.
Typically, supermarkets have separate open refrigeration cases for both medium temperature and frozen goods. In the 75° F. environment of most supermarkets, condensation is eliminated in the medium temperature cases when the dew point passes below 36° F., and in the frozen cases when the dew point passes below 5° F.
In addition, as the dew point is reduced toward the surface temperature of the cooling coils in the refrigeration cases, icing on the coils is reduced thereby reducing the frequency with which defrost cycles must be undertaken. In fact, in medium temperature cases the need for defrosting is totally eliminated when the dew point passes below 20° F., and the need for defrosting in frozen cases is eliminated below a dew point of -20° F. Since defrost cycling consumes energy, significant energy savings can be achieved by eliminating or reducing the need for defrosting. Moreover, since defrost cycles typically have a negative effect on many refrigerated goods, (e.g., water contained in ice cream typically crystallizes as a result of defrost cycling,) a lower ambient dew point may have the corollary benefit of improving shelf life.
As discussed above, while some of the energy savings available are threshold events (such as deactivation of door heaters), others are both threshold and proportional (such as lengthening the interval between defrost cycles, and the complete elimination of the need for such cycles), and others are strictly proportional (such as the increase in cooling efficiency of air conditioners with decreasing moisture content of the air to be cooled). Thus, for any predetermined adjustment in ambient air dew point, the cost to achieve the target dew point must be measured against the savings from the sum of these effects.
FIG. 3 shows the layout of a supermarket arranged according to an alternate embodiment of the present invention. In this arrangement, checkout area 13 is located in the front of the zone, however, it does not extend into the refrigeration space 24. In this alternate embodiment, cool air from other parts of non-refrigeration space 25 is redistributed within that space to checkout area 13. This redistribution may be accomplished through conventional duct work or other known means. In the embodiment shown, this redistribution is accomplished by redistribution fan 31, which acts to withdraw cool air through duct 32 and inject it back into non-refrigerated space 25 through duct 33. This embodiment is designed to counteract the higher temperature levels which typically occur within the checkout area.
Referring now to FIG. 4, there is shown a further alternative supermarket layout arranged according to the present invention. In this embodiment, refrigeration space 41 is located within the center of zone 40, with non-refrigeration space 42 surrounding refrigeration space 41. Non-refrigeration space 42 is subdivided into non-refrigerated regions 42a, 42b, 42c, 42d, 42e, 42f, 42g, 42h and 42i. In a typical supermarket, subregions 42a and 42b might contain produce, subregions 42c, 42d, 42e, 42f and 42g might represent the checkout and vestibule areas, and subregions 42h and 42i might contain general merchandise. Refrigeration space 41 is serviced by desiccant unit 43. Non-refrigeration space 42 is serviced by individual air conditioning units 44a, 44b, 44c, 44d, 44e, 44f, 44g, 44h and 44i, located within corresponding subregions 42a, 42b, 42c, 42d, 42e, 42f, 42 g, 42h and 42i. Desiccant unit 43 and air conditioning units 44a-i are each controlled by a conventional thermostat and humidistat. Each of the air conditioning units have return and supply ducts (not shown) which connect the intake and output of each air conditioning unit to its respective zone.
When the arrangement shown in FIG. 4 is applied to a supermarket with a sales area of approximately 45,000 square feet, wherein desiccant unit 43 is rated at 150 lbs/hour having the capacity to move 8,000 CFM of air, and air conditioning units 44a-i are each 4 ton units having the capacity to move 1,600 CFM of air, a 75° F. temperature level may generally be expected to be created throughout the zone. Moreover, a relative humidity of 45% is expected in refrigeration space 41, while non-refrigerated space 42 remains generally at a 55% relative humidity. In this embodiment, the energy needed for air circulation within the zone is again substantially reduced. Moreover a relative humidity of 45% is achieved in refrigeration space 41, while non-refrigeration space 42 remains generally at a 55% relative humidity. Moreover, given the smaller decentralized air conditioning units employed in non-refrigeration space 42, substantially less duct work is required for this system, thereby reducing its up-front cost.
In order to take maximum advantage of the humidity gradients created by the present invention, it is imperative that the dry air supplied to the conditioned space be directed into the space in a predetermined manner to ensure that it penetrates to floor level. Such distribution of air is dependent on ceiling height, supply air temperature, and the distance between supply registers. For instance, a correlation among these factors in a typical supermarket, having supply air at 85° F., 15%RH, with registers on 24 foot centers is as follows:
TABLE 1______________________________________Ceiling Height Terminal Velocity Deflection Angle(Feet) (FPM) (Degrees)______________________________________12 1,000 3014 1,400 1516 1,600 5______________________________________
Warm air is more difficult that cold air to drive to the proper levels because cold air is denser, and thus sinks to the floor more easily. Conventional direct expansion air conditioners supply air from 55° F. in summer cooling mode, to 110° F. in winter heating. Thus, registers which are appropriate for winter use create perceptible drafts during the summer. The desiccant system of the present invention supplies air within a narrower range of temperatures (85° F. summer to 110° F. winter for a supermarket, or 65° F. to 110° F. in a movie house).
Using registers which deflect 2/3 of the air volume outward at an angle of 45°, and 1/3 of the air volume directly downward, spaced on 24 foot centers, and measuring the air conditions directly under the register and at the center between two registers, the following results are achieved:
TABLE 2______________________________________ Under Register Between RegistersHeight Dry Bulb Grains Dry Bulb Grains______________________________________Supply Air 85 30 -- --7 ft. 73 47.8 71 46.95 ft. 72 45.3 71 46.93 ft. 70 44.4 70.5 45.61 ft. 67 41.3 69 46______________________________________
Air density differences are also pronounced, when typical air conditioning systems are compared with the present invention. Because air density effects the settling of conditioned air withing the conditioned zone (and thus the homogeneity of the air in the conditioned zone), it is desireable to achieve a close match between ambient air in the zone and conditioned supply air. Table 3 depicts the relationship between various supply air conditions and a typical zone condition.
TABLE 3______________________________________Humidity Density.sup.-1 Percent Deviation(DB/WB/Gr) (CF/Lb) to Zone______________________________________55/54 (60) 13.1 -4.1%65/54 (44) 13.4 -2.5%ZONE 75/64 (71) 13.7 0.085/57 (25) 13.8 0.7%110/67 (30) 14.5 5.5%______________________________________
As depicted above, the 55° F. supply air from a conventional air conditioner is approximately 1.6 times denser than the 65° F. drier supply which is typical of the present invention.
In addition, the air flow pattern should be matched in shape to the aisles defined by display shelves and refrigerated cases. In a typical supoermarket installation, the diffusers used should direct air flow along the aisles, and not wider than the aisles so as to invade vertical refrigerated cases. Thus selection and tuning of diffusers should allow for throw of air into the aisles, but not to the top surfaces of the shelves and refrigerated cases. One important exception to this principle, however, is the glass-door refrigerated case, where a dry air flow across the doors may be desired.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes of the invention. Accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
STATEMENT OF INDUSTRIAL UTILITY
The method and system of the present invention may be useful for reducing energy consumption of refrigeration systems in commercial spaces such as supermarkets and the like.
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A method and apparatus for modulating humidity across large single-zone air conditioned spaces such as those typically found in supermarkets wherein conventional air conditioning means and a desiccant unit are combined to supply varying levels of humidity to different regions within the single-zone space.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a mixing and conveying device for discontinuous mixing interrupted by feeding processes, and subsequent conveying of semifluid materials.
[0003] 2. The Prior Art
[0004] These devices are employed in the construction industry for mixing and conveying semifluid materials, in particular semifluid materials with low water content, for example mortar and flooring concrete. In this process, the components of the semifluid material are typically sand, a binding agent and water. These substances are first loaded into a mixing vessel through a filling opening and subsequently mixed by the agitator gear. The cover of the mixing vessel is closed and compressed air is admitted into the mixing vessel. The semifluid material contains lumps and bubbles of compressed air, and the material pressed through a conveying conduit that is connected to a short outlet pipe located in the lower zone of the mixing vessel. The air bubbles are formed because the blades of the agitator gear, which continue to run, periodically sweep the outlet opening leading into the conveying conduit. To convey the material, additional compressed air is blown in through another conduit feeding into a short outlet pipe. Such mixing and conveying devices are designed with an integrated or a separate compressor.
[0005] There are known devices that contain an integrated compressor. Oil-injected rotating compressors are used in such mixing and conveying equipment in most cases. An electric motor or an internal combustion engine drives the compressor element in the rotating compressors either directly or via a belt or toothed gear drive. No switching couplings are employed between the drive motor and the compressor element for cost reasons and because of other engineering drawbacks, i.e. the compressor element is always jointly driven when the drive motor is in operation.
[0006] The agitator gear is driven either via a switchable belt drive and a cardan shaft arranged between the drive motor and the agitator gear, or via a hydraulic motor mounted on the agitator gear, and a hydraulic pump attached to the drive motor.
[0007] It is cost effective to employ the power output of the drive motor as efficiently as possible, i.e. to achieve the shortest possible mixing and conveying time periods for a defined quantity of the viscous material.
[0008] Since the known devices do not contain a switching coupling device between the drive motor and the compressor element, the compressor is driven during the course of the mixing phase. At this stage, no compressed air is required for conveying any material. Therefore, the compressor is running idle, and consumes a notable proportion of the power output of the drive motor that is consequently not available for the mixing process.
[0009] The driving torque required for the agitator gear has the highest value at the start of the mixing phase and then drops quickly when the charged material is thoroughly mixed into a pasty compound. Furthermore, the driving torque required for the agitator gear is highly dependent upon the rotational speed of the agitator gear. Reducing the rotational speed of the agitator gear at the start of the mixing phase would reduce the required driving torque and the required driving power output. However, the known mixing and conveying devices do not provide for efficiently reducing the rotational speed of the agitator gear. completely utilized for the mixing process in the course of the mixing phase.
[0010] In the conveying phase, a rotational speed that is reduced from the mixing phase would be desirable, i.e. a rotational speed that would be sufficient for thorough mixing and for supporting the formation of lumps. However, in the known mixing and conveying equipment, the agitator gear operates during the conveying phase with an unnecessarily high rotational speed and with an unnecessarily high driving power output, especially if the rotational speed of the drive motor is increased in the course of the conveying phase to generate as much compressed air as possible for the conveying process. The unnecessarily high power requirement of the agitator gear is not available for the generation of compressed air, i.e. for conveying the viscous material.
[0011] A further disadvantage of the known mixing and conveying devices equipped with hydraulic pumps and hydraulic motors is the high costs incurred for the additional hydraulic circulation. German Patent DE 42 11 139 A1 discloses the combination of the oil circuit of the rotational compressor and the hydraulic circuit. This system has not been widely accepted until now, presumably because the high air component contained in the compressor oil causes substantial problems in the hydraulic system.
[0012] A further disadvantage associated with the known mixing and conveying devices having belt transmissions and cardan shafts are the harmful rotational oscillations of the power or drive train and vibrations resulting therefrom that lead to substantial noise development. Such mixing and conveying devices are described in German Patent DE 42 10 430 A1. This type of drive causes engineering restrictions that have higher manufacturing costs. Furthermore, the switchable belt drive contains a tensioning roller, actuation levers, a cardan shaft, reduction gear used for reducing the number of revolutions, a plurality of bearings, and systems for lubricating the bearings, these components substantially contribute to the high manufacturing costs. Moreover, the high maintenance requirements of the switchable belt drive gear represent another disadvantageous factor.
[0013] Known mixing and conveying devices with separate compressors are supplied with compressed air by mobile or transportable compressors set up at the construction site. Typically, an electric motor is employed for driving the agitator gear. The drawback in this case is that these devices are dependent on an additional power connection that is not always available at construction sites.
SUMMARY OF THE INVENTION
[0014] Therefore, it is an object of the present invention to improve the known mixing and conveying devices by increasing the output capacity of the drive motor during both the mixing chase and the conveying phase. In addition, the engineering expenditures, the manufacturing costs, and the maintenance for the device of the present invention are reduced. furthermore, the operating reliability of this a device is increased and its useful life is prolonged.
[0015] These and other objects are accomplished by providing the motor drive of the agitator gear with at least one compressed air motor. These motors are supplied with a proportion, preferably with 20% to 100%, of the compressed air generated by the compressor, and have a rotational speed that can be adapted to the various operating phases of the mixing and conveying process to influence the feed of compressed air to the compressed air motors and the discharge of exhaust air from the compressed air motors. A multi-component agitator gear is provided having individual components driven separately by a compressed air motor. Alternatively, several compressed air motors operating on a common shaft or coupled by a suitable transmission may drive a single-part agitator gear.
[0016] The compressed air motors contain several inlets for the compressed air and several outlets for the exhaust air. These compressed air motors are preferably connected with different, separate operating chambers or with different sections of the housing of the same operating chambers. The rotational speed can be changed by switching the feed of compressed air or the discharge of exhaust air in the inlets and outlets.
[0017] Compressed air motors are especially suited for this application purpose because of their rotational speed. Furthermore, these motors are also capable of delivering driving torques that are above their rated torque values, whereby the number of revolutions drops as the driving torque increases.
[0018] Therefore, the compressed air motors provide high driving torque to the agitator gear at the start of the mixing phase. Then, as the rate of revolutions decreases, the which compressed air can be tapped from or fed into the compression chambers in the compressor element already sealed off from the intake zone at a pressure that is substantially constant in terms of time, and which is in the range between the intake pressure and the operating pressure. The selection of the position of these connections is determined by the amount of the intermediate pressure.
[0019] By connecting these connections in an alternating manner with the inlets and outlets of the compressed air motors, it is possible to change the pressure difference between the inlets and outlets of the compressed air motors in a controlled manner. In addition, the pressure difference between the inlet and the outlet of the compressed air motors can be influenced by a variable bypass. With these measures it is possible to adapt the rotational speed of the compressed air motors to the operating phases.
[0020] According to a preferred embodiment of the invention, the compressed air is fed to the compressed air motors at a pressure substantially corresponding with the operating pressure of the compressor.
[0021] Furthermore, it is preferred that the compressed air is supplied to the compressed air motors at a temperature substantially corresponding with the final compression temperature of the compressor. In oil-injected rotational compressors, the temperature is between 70° C. and 100° C. The compressed air is tapped for this purpose in a location where no notable cooling has taken place as yet. It is possible to reduce a relatively high inlet temperature, so that the outlet temperature of the compressed air exiting from the compressed air motors will be safely above the ambient temperature for thermodynamic reasons, and no damaging condensation can occur. Furthermore, a maximum operating volume is obtained.
[0022] It is advantageous if the compressed air is heated in a heat exchanger before it is fed to the compressed air motors, to a temperature value above the compression temperature of the compressor. This will further increase the effective capacity of the compressed air during the expansion occurring in the compressed air motors. In mixing and conveying devices operating with an internal combustion engine as the driving motor, the compressed air can be heated, for example by a heat exchanger with the cooling fluid or the stream of exhaust gases from the internal combustion engine.
[0023] Furthermore, the compressed air can be fed to the compressed air motors with an oil content of preferably 0.5 to 50 mg oil per kilogram of air. As opposed to a dry operation, such lubrication of the compressed air motors increases their degree of efficiency and their operating reliability.
[0024] If oil-injected compressors are employed, the preferred oil content in the compressed air for the compressed air motors is achieved by tapping the compressed air in a suitable location situated upstream of the separation of the oil in the compressor. For example upstream of the coalescence filter located in the oil separation container.
[0025] Compressed air can also be fed to the compressed air motors at a pressure in the range between the intake pressure and the operating pressure. Therefore, the compressed air can be withdrawn in a suitable site in the compressor element. Furthermore, the feed of compressed air to the compressed air motor can take place via valves being opened between various tapping points.
[0026] The air exiting from the compressed air motors is preferably recycled into the circuit of the compressor. This offers the advantage that the oil for lubricating the compressed air motors will not escape into the environment, but is rather recycled into the compressor circuit. One possibility for accomplishing such recycling, is to return the oil into the inlets of the rotational compressor.
[0027] The air can also be recycled into the compressor element, specifically in a location where a pressure prevails that is in the range between the intake pressure and the operating pressure. This intermediate pressure is superimposed by minor pressure variations whose amplitude approximately corresponds with the pressure difference between two neighboring compression chambers located within the zone of the recycling site. Under operating conditions in which no recycling takes place, varying flow processes may ensue between the compression chambers and the volume in the recycling conduit, and cause capacity losses. To avoid this, it is advantageous if the exhaust air is recycled into the compressor element via a check valve. A volume is enclosed in the compressor element between the check valve and the compression chambers that is smaller than the volume of the compression chamber at the connection of the recycling conduit, and preferably less than 2%.
[0028] The exhaust air can also be discharged from the compressed air motor by connecting the outlet of the compressed air motor during the conveying process to the compressed air feed of the mixing vessel. Recycling or discharging of the exhaust air can be carried out via valves opened between different recycling points. A great number of possibilities are available for influencing, in a controlled manner, the pressure difference in the compressed air motors between the inlets and the outlets.
[0029] In a preferred embodiment of the invention, the compressed air is fed to a compressed air motor at the operating pressure of the compressor. The exhaust air of the compressor is recycled within the intake zone, or alternatively, into the compressor element at a location where the pressure is in the range between the intake pressure and the operating pressure. Switching between the two alternative recycling possibilities takes place by use of a valve. During the mixing phase, the return line on the outlet of the compressed air motor is connected with the intake zone of the compressor, so that the maximal pressure difference is available to the compressed air motor between the inlet and the outlet. During the conveying phase, the return line on the outlet of the compressed air motor is connected with a connection located on the housing of the compressor element. At this point, an intermediate pressure is preferably a pressure of about 2% to 60% of the operating pressure. This recycling reduces the pressure difference between the inlet and the outlet of the compressed air motor and its rotational speed drops to the value desired during the conveying phase.
[0030] Returning the exhaust air into the compression chambers in the compression element that are already closed, is advantageous because the compressed air motor is supplied within an inner circuit, so that substantially the entire volume of the intake flow of the compressor element is available as compressed air for conveying the viscous material. The compressor element can be dimensioned in a substantially smaller way as opposed to the case in which the exhaust air of the compressed air motor is returned into the environment or into the intake zone of the compressor element.
[0031] In another preferred embodiment of the invention, the compressed air is supplied to a compressed air motor at the operating pressure of the compressor, whereas its exhaust air is passed into the intake zone of the compressor or discharged into the environment, or alternatively fed into the mixing vessel. Reversing between the two alternatives is accomplished by at least one valve. During the mixing phase, the exhaust air of the compressed air motor is passed into the intake zone of the compressor, or discharged into the environment, so that the maximal pressure difference is available to the compressed air motor between the inlet and the outlet. If the exhaust air of the compressed air motor is Recycled into the intake zone of the compressor, an internal circulation is formed, so that the ambient air does not need to be purified through the inlet filter. This leads to a prolonged useful life of the filter. If the exhaust air is discharged into the environment, for example via a blow-off sound absorber, the return conduit can be dispensed with.
[0032] During the conveying phase, the exhaust air of the compressor is passed into the mixing vessel, where the prevailing pressure is in the range between the intake pressure and the operating pressure of the compressor.
[0033] Substantially the entire compressed air generated by the compressor is then first passed through the compressed air motor and then into the mixing vessel for conveying the mixed material.
[0034] The operating pressure of the compressor adjusts itself with respect to the overall compressed air consumption, and divides itself by self-adaptation to the given conveying process; a pressure difference between the inlet and the outlet of the compressed air motor, and a difference between the mixing vessel and the environment.
[0035] If the exhaust air of the compressed air motor contains oil, it is passed through a oil-separating element before it exits into the environment or enters the mixing vessel. The Separated oil is recycled into the circuit of the compressor.
[0036] Foreign matter may cause blocking of the agitator gear. this blockage can be eliminated by briefly reversing the direction of rotation. Therefore, in another embodiment of the invention, provision is made for the use of a compressed air motor with a reversible direction of rotation.
[0037] Furthermore, a method for controlling and operating a mixing and conveying device is provided. In this case, the compressed air generated by the compressor is employed during the mixing phase only for supplying the compressed air motors and driving the agitator gear. The compressed air is used for both conveying the viscous material and for supplying the compressed air motors driving the agitator gear.
[0038] In a preferred method, compressed air motors are employed for driving the agitator gear, whereby all of these motors are supplied with compressed air during the conveying phase, but not during the mixing phase.
[0039] According to a preferred implementation of the method, the pressure difference between the inlet and the outlet is influenced by the compressed air motor in such a way that the rotational speed of the agitator gear is higher during the mixing than in the course of the conveying phase. For this purpose, the pressure difference existing between the inlet and the outlet of the compressed air motors is set higher during the mixing than in the course of the conveying phase.
[0040] The pressure difference between the inlet and the outlet of the compressed air motors is changed by throttling, in a controlled manner, by reversing the feed of the compressed air, or the discharge of the exhaust air between different recycling points in the compressor. At this point, the prevailing pressure is substantially the intake pressure, the operating pressure or an intermediate pressure.
[0041] According to yet another variation of the method, the pressure difference between the inlet and the outlet of the compressed air motors can be influenced by feeding the exhaust air of the compressed air motors into the mixing vessel in the course of the conveying phase. A pressure is built up in the mixing vessel whose amount influences the pressure difference and thus the rotational speed of the compressed air motors.
[0042] Furthermore, release of both the supply of conveying air and the reduction of the rotational speed of the agitator can occur by use of a manually or automatically actuated Switching device after the mixing vessel has been closed.
[0043] Moreover, it may be useful to design the control of the mixing and conveying device in such a way that any possible blockage of the agitator is detected automatically and a temporary automatic reversal of the direction of rotation is triggered in that way. This is accomplished, because the consumption of compressed air of the compressed air motor practically drops to zero during a shutdown.
[0044] In addition, it is possible through the use of a compressed air motor to reduce the cost of construction elements and the manufacturing costs of other known devices.
[0045] As opposed to a variable belt drive with a connected cardan shaft, the present invention allows greater engineering freedom because only one air feed and one exhaust conduit needs to be installed between the compressor and the mixing vessel. If the exhaust air of the compressed air motor is passed into the mixing vessel during the conveying phase, end discharged into the environment during the mixing phase, only one compressed air conduit is needed between the compressor and the mixing unit. This means that a conventional or an only slightly modified construction site-type compressor can be employed. This results in only minor restrictions to the arrangement of the compressor and the mixing vessel. Furthermore, the maintenance costs are reduced and the operational reliability is increased. Furthermore, vibrations and noise from a variable belt drive with a cardan shaft are avoided.
[0046] Most of these advantages apply to devices with a separate compressor as well. In addition, when compressed air motors are employed for driving the agitator gear, no additional electrical power connection is required as opposed to the usual drive with electric motors. A construction site compressor with an internal combustion engine is available for supplying the mixing and conveying device with compressed air, and such a compressor can supply the compressed air for the compressed air motor for driving the agitator as well. Drives for other devices installed on mixing and conveying equipment (such as devices for feeding the mixing materials, loading shovels etc.) can be driven by means of compressed air motors as well, so that no electric power supply is required at all.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.
[0048] In the drawings, wherein similar reference characters denote similar elements throughout the several views:
[0049] [0049]FIG. 1 shows a control diagram of the mixing and conveying device in the mixing phase, as defined by the present invention;
[0050] [0050]FIG. 2 shows a control diagram of the mixing and conveying device in the conveying phase;
[0051] [0051]FIG. 3 shows a control diagram of a mixing and conveying device comprising an alternative valve arrangement in the idle run condition;
[0052] [0052]FIG. 4 shows the rotational speed characteristic of a typical compressed air motor and a typical agitator gear at the start and at the end of the mixing phase;
[0053] [0053]FIG. 5 shows a control diagram of the mixing and conveying comprising a connection variation of the components in the idle run; and
[0054] [0054]FIG. 6 shows a control diagram of another embodiment of the mixing and conveying device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0055] Referring now in detail to the drawings and, in particular, FIG. 1, an internal combustion engine 1 drives the compressor element 3 via a coupling 2 . Compressor element 3 aspirates ambient air via the inlet valve 4 and compresses the air while oil is being injected, such oil being fed via the injection conduit 5 , and conveys the compressed air/oil mixture via the pressurized conduit 6 into the oil separation container 7 . The major part of the oil is separated from the stream of air in container 7 and collects in the lower zone of the oil separation container 7 . From there, the oil is forced by the operating pressure through cooler 8 , and back into injection conduit 5 . The final temperature of the oil or the final compression temperature is controlled in this connection by a bypass 9 with a thermovalve 10 .
[0056] Compressed air is passed via a pressurized conduit 11 at operating pressure to compressed air motor 12 , which drives agitator gear 13 installed in mixing vessel 14 . Provision is made in pressurized conduit 11 for a 2/2-way valve 15 , by which the compressed air supply of compressed air motor 12 can be released and interrupted. The exhaust air of the compressed air motor is passed via an exhaust air conduit 16 to a 3/2-way valve 17 .
[0057] When 3/2-way valve 17 is in one switching position, the exhaust air is passed via conduit 18 into the inlet valve 4 ; when it is in the other switching position, the exhaust air is passed into a recycling connection 19 on the housing of the compressor element 3 . Recycling connection 19 is connected to an opening in the housing of compressor element 3 . During operation, an intermediate pressure of about 50% of the operating pressure prevails in the compression chambers in the housing.
[0058] Mixing vessel 14 can be charged with the material to be mixed and conveyed via an opening 20 , sealed by a cover 21 , and pressurized when it has been sealed with cover 21 .
[0059] Further details of the control system for the compressor and the mixing and conveying device are not shown here for the sake of simplification.
[0060] Cover 21 is opened in the mixing phase and 2/2-way valve 15 for the conveying air is closed. The compressor essentially generates compressed air for supplying compressed air motor 12 . The 2/2-way valve 15 is opened and releases the compressed air to the compressed air motor 12 . The 3/2-way valve 17 connects the outlet of the compressed air motor 12 with the inlet valve 4 of the compressor. The compressed air motor is supplied with the maximal pressure difference, so that it operates with a relatively high rotational speed and a relatively high driving power output. Cover 21 has to be closed before switching over to the conveying phase.
[0061] As shown in FIG. 2, during the conveying phase, compressed air flows from the oil separation container 7 through a coalescence filter 23 , an opened 2/2-way valve 22 and pressurized conduits 24 and 25 , and into mixing vessel 14 and a conveying conduit 26 . The 3/2-way valve is set in the ether switching position and permits the exhaust air of the compressed air motor to now flow into the recycling connection 19 of the compressor element, where an intermediate pressure is prevailing, so that a lower pressure difference is applied to the compressed air motor than during the mixing phase. This causes the consumption of compressed air of the compressed air motor, as well as also its rotational speed and its torque and its driving power to decrease.
[0062] Since the compressed air for supplying the compressed air motor is circulated in the conveying phase in an internal circuit comprising compressor element 3 , pressurized conduit 11 , exhaust air conduit 16 , 3/2-way valve 17 and return conduit connection 19 located on the compressor element 3 , substantially the entire stream of the intake volume of the compressor element is available for conveying the semifluid material.
[0063] [0063]FIG. 3 shows an alternative control diagram, in which a 3/3-way valve 27 is employed for controlling compressed air motor 12 instead of using the 3/2-way valve 17 . Furthermore, an additional adjustable throttling point 28 located in the conduit leading to the return conduit connection 19 is shown, by means of which further adaptation of the rotational speed, the torque, or of the driving power of the compressed air motor is possible in the course of the conveying phase. The valves 22 and 27 are shown in the switching positions for idle run and, respectively, shutdown of the mixing and conveying device.
[0064] A check valve 29 is arranged within return conduit connection 19 . In the mixing phase, i.e. when the return conduit is closed by valve 27 and no exhaust air of compressed air motor 12 flows into the compressor element via the return conduit connection 19 , check valve 29 prevents pulsating flows from occurring between the compression chambers and the return conduit.
[0065] As shown in FIG. 4, at the start of the mixing phase, in which the mixed material still puts up relatively high resistance to the agitator gear, the compressed air motor operates at a lower rotational speed and a higher torque than at the end of the mixing phase. This adaptation automatically Ensues from the curve of the rotational speed characteristic and was found to be advantageous versus known drives substantially operating during the mixing process with a constant number of revolutions.
[0066] The designations of the individual curves have the following meaning:
[0067] a: Rotational speed/torque characteristic of the compressed air motor;
[0068] b: Required torque of the agitator at the start of the mixing phase;
[0069] c: Required torque of the agitator at the end of the mixing phase;
[0070] d: Operating point of the agitator and the compressed air motor at the start of the mixing phase;
[0071] e: Operating point of the agitator and the compressed air motor at the end of the mixing phase.
[0072] Ne: Rotational speed of the agitator gear and the compressed air motor at the start of the mixing phase.
[0073] Ne: Rotational speed of the agitator and the compressed air motor at the end of the mixing phase.
[0074] Me: Rotational speed of the agitator and the compressed air motor at the start of the mixing phase.
[0075] Me: Rotational speed of the agitator and the compressed air motor at the end of the mixing phase.
[0076] [0076]FIG. 5 shows an alternative embodiment, in which the compressed air is directly passed from compressor element 3 to compressed air motor 12 both during the mixing and conveying phases. The outlet of compressed air motor 12 is connected to a 3/3-way valve. This valve permits the positions “standstill A”, “mixing B” and “conveying C”. In the position “A”, exhaust air conduit 16 is blocked and compressed air motor 12 is shut down. In the mixing phase (position “B”), the exhaust air of compressed air motor 12 is passed through exhaust air conduit 16 and into inlet valve 4 . This causes the maximally possible pressure difference to be adjusted via compressed air motor 12 , so that it operates with a relatively high rotational speed, a relatively high torque and a relatively high driving power. Furthermore, a closed circulation ensues in this position for supplying compressed air motor 12 with compressed air. In the valve position “C”, exhaust air conduit 16 is connected to the compressed air supply 30 of mixing vessel 14 . An oil separation element 31 is located in compressed air feed line 30 to separate the oil from the compressed air and to recycle such oil into compressor element 3 by way of a recycling conduit 32 .
[0077] Moreover, provision is made between the inlet and the outlet of compressed air motor 12 for a bypass conduit with a throttle valve 35 . In the bypass conduit, the pressure difference can be limited via compressed air motor 12 . Throttle valve 35 may be, for example a minimum-pressure valve that opens when a defined pressure difference is exceeded, and limits it to a defined value.
[0078] [0078]FIG. 6 shows another embodiment for interconnecting the components. In the present case, exhaust air conduit 16 of compressed air motor 12 is connected similarly to FIG. 5 with a 3/3-way valve 17 having the same switching capabilities. The difference is that in the course of the mixing process (valve position “B”), the compressed air is directly discharged into the environment via exhaust air conduit 16 and a blow-off sound absorber 33 . If oil-containing compressed air is required for lubricating the compressed air motor, an oil-separating element 31 can be integrated in exhaust air conduit 16 instead of using coalescence filter element 23 in oil-separating container 7 .
[0079] Accordingly, while only a few embodiments of the present invention have been shown and described, it is obvious that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.
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The invention relates to a mixing and conveying device for mixing and subsequently conveying semifluid materials, in particular mortar and concrete. The device comprises a compressor for generating compressed air, and a mixing vessel connected to a conveying conduit and an agitator gear. The mixing vessel is charged with the material to be mixed and conveyed, and compressed air is admitted into the mixing vessel for discharging the semifluid materials through the conveying conduit. The agitator gear is driven by at least one compressed air motor that is supplied with a proportion of the compressed air generated by the compressor.
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BACKGROUND OF THE NEW VARIETY
The present invention relates to a new and distinct variety of nectarine tree which is hereinafter denominated varietarily as "Crystal Belle" and more particularly to such a nectarine tree which bears an attractively colored semi-freestone fruit which has a firm, white colored flesh, and which is mature for harvesting and shipment in early June. The present variety of nectarine tree is somewhat similar in its date of harvesting with that of the Arctic Glo nectarine tree [U.S. Pat. No. 7,884], which is ripe for harvesting and shipment approximately June 9 under the ecological conditions prevailing in the San Joaquin Valley of Central California, but which is distinguishable therefrom by being ripe for harvesting and shipment as early as June 1 under the same ecological conditions.
ORIGIN AND ASEXUAL REPRODUCTION OF THE NEW VARIETY
It has long been recognized that an important factor contributing to the success of any variety of nectarine tree bearing fruit for delivery to the fresh market is the propensity for the fruit produced by these trees to be attractive in appearance. Another important factor is that the variety bear fruit at a time when other fruit of the same desirable qualities is not normally available for commercial purchase.
As noted earlier, the present variety of nectarine tree produces semi-freestone fruit in contrast to the fruit produced by the Arctic Glo nectarine tree which produces fruit which are clingstone by nature. Further, in relative comparison to the fruit produced by the Arctic Glo nectarine tree, the flavor of the fruit produced by the Crystal Belle nectarine tree is moderately acidic and sweet and further has a good balance, as opposed to the flavor of the fruit of the Arctic Glo nectarine tree which is considered to be subacid and mild.
The new and distinct variety of nectarine tree hereof is a hybrid nectarine tree resulting from the cross pollination of one of the inventor's stock nectarine trees, which is identified by the alpha-numeric designator 1S 2/4 and which is of unknown parentage. This stock tree was cross pollinated with the Snow-Queen nectarine tree.
Cross pollination of the trees, identified above, took place at the inventor's farm which is located near St. Vite, France. A selection from this cross pollination was germinated and several buds were removed from the original offspring and grafted into commercial rootstock which was then growing within the cultivated area of this same farm. Over the last several years, the fruit and grafted trees were compared and contrasted with that of the original cross pollinated offspring and it has been subsequently determined that this asexual propagation resulted in a nectarine tree being produced which possesses the same distinctive characteristics as the originally selected offspring resulting from the aforementioned cross pollination. As compared with the original parents, the present variety of nectarine tree produces fruit which are larger in size and more highly colored than those of the original parents.
SUMMARY OF THE NEW VARIETY
The new variety of nectarine tree described herein is characterized principally as to novelty by being ripe for harvesting and shipment on or about June 1 under the ecological conditions prevailing in the San Joaquin Valley of Central California. The variety is further distinguished from other known varieties by producing fruit which have a substantially ovate form in its lateral aspect and an oval form in its apical aspect. Additionally, the highly colored exterior appearance of the variety distinguishes it from that of the Arctic Glo nectarine tree which is less highly colored and which is ripe for harvesting and shipment some seven days later. Lastly, the present variety of nectarine tree produces semi-clingstone fruit as compared to the Arctic Glo nectarine tree which produces a clingstone fruit.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing is a color photograph of five mature fruit, one of which has been divided in the axial plane to show the flesh, and stone characteristics, together with a twig bearing typical leaves which display the coloration of the top and bottom surfaces thereof, along with a representative stone, all of the subject variety.
DETAILED DESCRIPTION
Referring more specifically to the pomological details of this new and distinct variety of nectarine trees, the following has been observed under the ecological conditions prevailing at the applicant's licensee's orchard which is located near Traver, Calif. All major color code designations are made by a reference to the "Dictionary of Color" by Maerz & Paul, First Edition, 1930. Common color names are also employed occasionally.
Tree:
Size.--Generally -- Medium. Test trees of the present variety were propagated by dormant budding in 1990 on seedling peach rootstock. In July of 1994, these same test trees had attained a height of approximately 11.5 to 12.5 feet, including 3.5 to 4.5 feet of new growth. The subject test trees were trained in a two leader palmette system which had a spread of approximately 9 feet by 6 feet in its two respective dimensions.
Form.--Generally -- The tree form is considered upright to upright spreading. The final form of the tree will be determined by pruning practices. As noted above, the test trees are trained in a two-leader palmette system with a spread of approximately 9 feet by 6 feet in its two respective dimensions.
Productivity.--Productive.
Vigor.--Vigorous, and hardy under typical central San Joaquin Valley climatic conditions.
Regularitive bearing.--Regular.
Trunk:
Size.--Generally -- Average in view of the age of the tree.
Trunk diameter.--Approximately 76 to 89 millimeters when measured at a point immediately above the rootstock union.
Surface texture.--Considered moderately rough with light scarfskin being evident.
Lenticels.--Numbers -- Numerous medium sized bark lenticels are present throughout the bark surface.
Lenticel shape.--Oval, and having dimensions of approximately 3 to 7 millimeters in width, and approximately 1 to 2 millimeters in height.
Bark color.--Brown -- Grey [6-A-10].
Branches:
Size.--Generally -- average in thickness.
Surface texture.--Variable, from relatively smooth to moderately rough.
Color.--Mature shoots -- Shoots that are at least two years old are considered medium brown [7-A-11].
Color of current season shoots.--Pale green, [17-J-6]. Further, portions of the new shoots which are exposed to direct sunlight have a rose-red blush [4-J-3].
Internode length.--Current season fruiting wood -- Approximately 27 to 39 millimeters.
Shoot tip color.--Bright green-yellow [19-L-5].
Leaves:
Size.--Generally. Medium to large.
Average length.--All leaves were measured from vigorous, upright, current season's growth. These leaves have a length of about 19.6 centimeters to about 21.6 centimeters including the leaf petiole.
Average width.--Approximately 4.9 centimeters to about 6.5 centimeters.
Leaf thickness.--This characteristic appears slightly thicker than average.
Leaf form.--Generally -- Lanceolate.
Leaf apices.--Generally -- Acuminate. The leaf tip often appears slightly curled, and twisted sideways.
Surface texture.--Upper surface -- Glabrous.
Marginal form.--Crenate. The leaves have rather large, low and regular crenations. As a general matter, the leaf margins are moderately to substantially undulate.
Leaf petiole.--Size -- Medium to large, as compared with other known varieties.
Length.--Approximately 10 to 15 millimeters.
Thickness.--Approximately 2 to 3 millimeters.
Color.--Pale green [19-J-5]. A darker green color appears within the petiolar groove [21-K-6].
Leaf color.--Top surface -- dark green [23-L-4].
Lower leaf surface.--A lighter, grey-green [22-K-4].
Color -- mid vein.--On the lower leaf surface, this color is a pale green-yellow [17-I-4].
Leaf glands.--Size -- Variable from quite large to quite small.
Gland form.--Predominantly reniform. Occasionally stalked glands may be found and these may be globose in form.
Gland number.--Variable, from two to as many as seven may be found. As a general matter, two to four glands normally appear on the petiole and one pair is positioned in close proximity to the base of the leaf margin. Still further, the petiole glands are strongly reniform unless they appear in the stalked form, in which case, the stalked form of the glands can have a reniform or globose shape. Additonally, one or two small, reniform shaped glands can be located along the base of the leaf margin.
Gland position.--Most frequently alternate.
Gland color.--Bright Green, [20-L-3] and becoming darker with advancing senescence.
Leaf stipule size.--Small.
Leaf stipule length.--Approximately 8 to 11 millimeters.
Leaf stipule form.--Linear lanceolate.
Leaf stipule marginal form.--Serrate.
Leaf stipule color.--Bright and shiny green when young, [20-I-4], and becoming darker with advancing senescence. The leaf stipules are considered to be early deciduous.
Flowers:
Blooming time.--Generally -- Average in comparison to other common commercial nectarine varieties which are grown in the San Joaquin Valley of Central California. In 1994, the date of full bloom was Mar. 3, 1994, at the test plot which is located near Traver, Calif.
Floral buds.--Size -- Medium.
Shape.--Conic. The floral buds are borne relatively free from the bearing stem. The flower buds are considered hardy under normal Central San Joaquin Valley climatic conditions.
Bud scale color.--Brown -- grey [15-A-8].
Bud scale surface texture.--Very Pubescent. The pubescence is a dense, dark grey. This color is not distinctive, however.
Flower size.--Generally -- Large and considered of the showy type.
Flower diameter.--The flower, when fully opened, is variable, from 46 to 56 millimeters.
Bloom quantity.--Abundant.
Flowers produced per node.--Variable, from one to two, most often, two.
Petal size.--Generally -- Large.
Petal length.--Approximately 23 to 27 millimeters.
Petal width.--Approximately 22 to 26 millimeters.
Petal form.--Broadly Ovate.
Petal number.--Five.
Petal color.--Light pink, [1-D-1].
Color -- mature petals.--Dark Pink [1-F-1]. The base of the petal and petal claw becomes a dark rose color [1-I-4] with advancing senescence.
Petal claw -- form.--Generally -- Considered tapering and truncate. Further, the claw appears relatively broad.
Petal claw width.--Approximately, 1.5 to 2 millimeters.
Petal claw length.--Approximately 1 millimeter.
Petal claw surface texture.--Moderately veined.
Petal margins -- form.--Undulate and often cupped in an inward direction.
Petal apex -- shape.--Domed.
Flower pedicle -- length.--Approximately 2.5 to 3 millimeters.
Pedicle thickness.--Approximately 1.5 to 2 millimeters.
Pedicle color.--Bright green [17-L-7].
Pedicle surface texture.--Glabrous.
Floral nectaries.--Color -- Greenish -- yellow [19-J-1]. This color darkens with advancing senescence.
Calyx -- surface texture.--The surface texture is glabrous and rugose.
Calyx color.--As a general matter, it is normally maroon [7-H-3] and further has some green tones which appear basally [17-L-7].
Sepal -- surface texture.--Pubescent. The pubescence appears along the margin and is usually of medium length, and is greyish-white in color.
Sepal size.--Moderately large and having a broadly ovate form.
Sepal color.--Maroon [7-J-7].
Anthers -- size.--Moderately large.
Anther color.--Normally deep red, dorsally [5-L-10]; and a buff color, ventrally, [11-H-3]. Further, the anthers may have a marginal edge which has a red color [5-L-10].
Pollen production.--Abundant.
Pollen color.--Yellow [9-L-3].
Stamens -- length.--Variable, with the longest stamens having a length dimension of approximately 12 to 18 millimeters. The stamens are normally longer than the pistil.
Filament color.--White, [1-A-1] and occasionally light pink [1-B-1]. The filament color darkens with advancing senescence and will appear rose colored [2-I-4].
Pistil -- length.--Approximately 17 to 19 millimeters including the ovary.
Pistil surface texture.--Glabrous.
Pistil color.--Pale green -- yellow [17-K-2]. With advancing senescence the pistil becomes reddish colored near the stigma end. This color is not particularly distinctive, however.
Fruit:
Maturity when described.--Ripe for commercial harvesting and shipment approximate 1 June through 11 June under the ecological conditions prevailing in the San Joaquin Valley of Central California.
Fruit size.--Generally -- Average in view of the early season of maturity.
Cheek diameter.--Approximately 54 to 62 millimeters.
Suture diameter.--Approximately 54 to 60 millimeters.
Axial diameter.--Approximately 57 to 65 millimeters.
Uniformity.--Uniform.
Fruit form.--Generally -- Variable in its lateral aspect. However, it appears most often ovate. Further, the fruit in its apical aspect is also somewhat variable although it normally appears oval and further has a slightly protruding suture. The fruit shape is considered asymmetrical.
Fruit suture.--Generally -- The suture appears as a relatively thin line which extends from the base to the apex.
Fruit suture width.--Approximately 1 to 2.5 millimeters.
Fruit suture coloration.--Variable. At times, the suture has a dark garnet-red color [8-L-6], although occasionally it may appear a lighter red color [6-L-4]. These colors normally blend in with the surrounding blush coloration. At other times, the suture may appear as a lighter color than the surrounding blush color. This color may appear as a medium red [3-L-9], to a pink-red color [2-G-9], with many shade variations therebetween. As a general matter, a moderate amount of red streaking is present in the vicinity of the suture area. In this regard, the streaking ranges in color from dark red [7-J-6], to a lighter red [5-K-9].
Ventral surface -- shape.--Somewhat uneven and at times appears slightly protruding. The ventral surface is moderately lipped on one side.
Stem cavity -- size.--Medium.
Stem cavity width.--Approximately 21 to 26 millimeters.
Stem cavity length.--Approximately 25 to 27 millimeters.
Stem cavity shape.--Oval.
Stem cavity depth.--Approximately 9 to 11 millimeters.
Stem well -- color.--Cream -- Green [18-D-2].
Fruit base -- form.--Slightly truncate.
Base angle.--Variable, but normally it appears at right angles to the fruit axis.
Fruit apex shape.--Slightly domed and having a small dentate pistil point.
Pistil point -- shape.--Variable with both apical and oblique forms appearing.
Fruit stem -- length.--Approximately 7 to 9 millimeters.
Fruit stem thickness.--Approximately 3 to about 4.5 millimeters.
Fruit stem color.--Olive green [13-J-1] and occasionally brown-green [13-I-3].
Skin color.--Generally -- Variable. Approximately 85% to 95% of the surface color of the skin has a red blush. This blush color appears in a washed pattern with occasional striping. This occurs most commonly basally. As a general matter, the darkest areas of the fruit surface possess a deep garnet-red color [7-J-6]. The lightest blush areas have a pink-red color [5-F-9] with many shade variations therebetween. Considerable russetting may be evident. This russetting can be dense, and may include light colored speckling. This is normally most prevalent over the apical end of the fruit and occasionally laterally.
Ground color.--This color is variable and ranges from approximately 5% to about 15% of the fruit surface. Normally, the ground color appears basally or where foliage has covered the fruit surface. The ground color is considered to be cream [9-D-1] and occasionally cream -- green [17-H-2].
Flesh color.--Generally -- White throughout [1-A-1]. This color appears from the skin surface to the area immediately next to the stone.
Color -- stone cavity.--Cream colored [17-F-1]. Occasionally, some red flecking may occur in the flesh. The color of the red flecking is most closely similar to the color 1-K-7. If red flecking is evident, it is normally located along the ventral suture area and is further more likely to occur during a later stages of maturity.
Flesh texture.--Generally -- Firm and fine textured.
Ripening.--Generally -- The fruit appears to ripen first at the apex and then along the ventral surface.
Flavor.--Generally -- Moderately acidic and sweet. Overall the fruit is considered well-balanced and has a rich flavor.
Aroma.--Moderate and very pleasant.
Eating quality.--Considered very good in view of the early season of maturity.
Stone:
Generally.--Semi-freestone and occasionally freestone at commercial maturity. As a general matter, the stone is held tightly in the stone cavity with no air space being evident between the stone and surrounding flesh. The stone will normally break free cleanly from the flesh at the more advanced stages of maturity.
Stone size.--Generally -- Small.
Stone length.--Approximately 32 to 36 millimeters.
Stone width.--Approximately 21 to 24 millimeters.
Stone thickness.--Approximately 16 to 18 millimeters.
Fibers -- numbers.--Moderate, and short. These fibers are attached to the stone, and are normally located basally and on the basal surfaces of the ventral suture.
Stone form.--Variable, from oval to occasionally ovate.
Stone base -- shape.--Variable, from rounded to occasionally truncate.
Base angle.--Variable. Normally oblique but occasionally at right angles to the stone axis.
Hilum -- size.--Medium.
Hilum -- form.--Oval, and it additionally appears heavily eroded.
Stone apex -- shape.--Acute and having a narrow, sharp tip.
Stone sides.--Variable, and normally unequal, but occasionally at times nearly so.
Stone surface -- texture.--Rough, and coarsely grooved and pitted. As a general matter, the stone surface is most heavily grooved over the apical shoulders and laterally. Further, large oval to round pits are evident and are normally most concentrated in the area from mid-stone to the base, laterally.
Ventral edge -- shape.--Moderately prominent and having several coalesced wings. The wings are approximately 4 to 6 millimeters in width, and appear at mid-suture. Further, a strong keel may be located at the base of the ventral suture. The keel may protrude a distance of approximately 3 millimeters to approximately 5 millimeters from the body of the stone.
Dorsal edge.--Generally -- A deep groove normally appears on the dorsal suture and extends from the base to a distance equal to about 75% of the length of the suture edge. The suture groove narrows to a point where it appears as a line which extends over the apical edge. Further, the apical shoulder is normally substantially eroded. Still further, ridges may appear on each side of the suture groove and are usually deeply cross cut with numerous cross grooves.
Stone color -- dry.--Light tan [11-I-5].
Tendency to split.--Not observed. Occasionally, internal splits were evident.
Use: Fresh market for both local and long distance shipping.
Keeping quality: Good.
Shipping quality: Unknown, although the firm and crisp flesh displayed at commercial maturity indicates that the variety should have noteworthy shipping characteristics.
Resistance to disease: No particular susceptibilities were noted.
Although the new variety of nectarine tree possesses the described characteristics as a result of the growing conditions prevailing at the applicant's licensee's ranch which is located near Traver, Calif., in the central part of the San Joaquin Valley of Central California, it is understood that variations of usual magnitude and characteristics incident to changes in growing conditions, fertilization, pruning and pest control are to be expected.
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A new and distinct variety of nectarine tree which has a harvesting date which is earlier than that of the Arctic Glo nectarine tree [U.S. Plant Pat. No. 7,884], which matures in the same season, but which is distinguished therefrom and characterized principally as to novelty by producing fruit which have a semi-freestone nature, firm flesh texture, and an attractive skin color at commercial maturity.
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CROSS-REFERENCE TO RELATED APPLICATION
This non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 2015-189154 filed in Japan on Sep. 28, 2015, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
This invention relates to organosilicon compounds having diphenylethyl and methoxysilyl groups which are useful as surface treating agents, paint additives, and polymer modifiers, and a method for preparing the same.
BACKGROUND ART
It is well known in the art that organosilicon compounds containing a diphenylethyl group are useful as surface treating agents, paint additives, polymer modifiers and the like. Specifically, when the diphenylethyl-containing organosilicon compound is added to a certain material, the material may be provided with a high refractive index.
Known diphenylethyl-containing organosilicon compounds include, for example, 2,2-diphenylethyl-containing chlorosilane compounds (Non-Patent Document 1 and Patent Document 1) and 2,2-diphenylethyl-containing ethoxysilane compounds (Patent Document 2, Example 7).
CITATION LIST
Patent Document 1: WO 2005/000856
Patent Document 2: PL 169330
Non-patent Document 1: Journal of general chemistry of the U.S.S.R. in English translation (1974), 44(8), 1730-1732
DISCLOSURE OF INVENTION
The diphenylethyl-containing chlorosilane compound is readily hydrolyzable, but generates highly corrosive hydrogen chloride upon reaction with active hydrogen-containing compounds such as water and silanol. For disposal, the hydrogen chloride is reacted with a basic compound, but the reaction forms a hydrochloride salt to be discarded. On the other hand, the diphenylethyl-containing ethoxysilane compound has a low polarity and a low affinity for active hydrogen-containing compounds, and it does not undergo quick hydrolysis and requires a long time for treatment.
There is a desire to have a diphenylethyl-containing organosilicon compound which is readily hydrolyzable and does not generate corrosive hydrogen chloride or the like on use.
An object of the invention is to provide an organosilicon compound having diphenylethyl and methoxysilyl groups, which is readily hydrolyzable and does not generate corrosive hydrogen chloride or the like on use. Another object is to provide a method for preparing the same.
In one aspect, the invention provides an organosilicon compound having a diphenylethyl group and a methoxysilyl group, represented by the general formula (1):
wherein R 1 is a substituted or unsubstituted, C 1 -C 12 monovalent hydrocarbon group and n is an integer of 0 to 2.
In another aspect, the invention provides a method for preparing the organosilicon compound of formula (1), comprising the steps of effecting hydrosilylation of 1,1-diphenylethylene having the formula (2):
with a hydrogenhalosilane compound having the general formula (3):
HSiR 1 n X 3−n (3)
wherein R 1 is a substituted or unsubstituted, C 1 -C 12 monovalent hydrocarbon group, X is a halogen atom, and n is an integer of 0 to 2, to form a diphenylethylhalosilane compound having the general formula (4):
wherein R 1 , X, and n are as defined above, and subjecting the diphenylethylhalosilane compound to methyl esterification.
The hydrosilylation is preferably performed at a temperature of 60 to 90° C.
Advantageous Effects of Invention
The organosilicon compound having diphenylethyl and methoxysilyl groups is more readily hydrolyzable than ethoxysilyl-containing organosilicon compounds and generates no hydrogen chloride on use. The organosilicon compound, when added to a certain material, imparts a high refractive index to the material.
BRIEF DESCRIPTION OF DRAWING
FIG. 1 is a diagram showing a 1 H-NMR spectrum in deuterated chloroform of the compound in Example 1.
FIG. 2 is a diagram showing an IR spectrum of the compound in Example 1.
FIG. 3 is a diagram showing a 1 H-NMR spectrum in deuterated chloroform of the compound in Example 2.
FIG. 4 is a diagram showing an IR spectrum of the compound in Example 2.
FIG. 5 is a diagram showing a 1 H-NMR spectrum in deuterated chloroform of the compound in Example 3.
FIG. 6 is a diagram showing an IR spectrum of the compound in Example 3.
DESCRIPTION OF PREFERRED EMBODIMENT
The notation (Cn-Cm) means a group containing from n to m carbon atoms per group.
The invention provides an organosilicon compound having a diphenylethyl group and a methoxysilyl group, represented by the general formula (1).
Herein R 1 is a substituted or unsubstituted, C 1 -C 12 monovalent hydrocarbon group and n is an integer of 0 to 2.
In formula (1), R 1 is a substituted or unsubstituted monovalent hydrocarbon group of 1 to 12 carbon atoms, preferably 1 to 6 carbon atoms, examples of which include straight, branched or cyclic alkyl, alkenyl, and aryl groups. Illustrative examples include straight alkyl groups such as methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, n-decyl, n-undecyl and n-dodecyl, branched alkyl groups such as isopropyl, isobutyl, sec-butyl, tert-butyl, isopentyl, neopentyl, isohexyl, isoheptyl, isooctyl, tert-octyl, isononyl, isodecyl, isoundecyl and isododecyl, cyclic alkyl groups such as cyclopentyl and cyclohexyl, aryl groups such as phenyl, tolyl and xylyl, and aralkyl groups such as benzyl. Some or all hydrogen atoms on the hydrocarbon group may be substituted by substituents. Suitable substituents include alkoxy groups such as methoxy, ethoxy and (iso)propoxy, groups containing halogen such as fluorine, chlorine, bromine and iodine, cyano, amino, aromatic hydrocarbon, ester, alkyl separated by oxygen, acyl, sulfide, alkylsilyl, alkoxysilyl groups, and mixtures thereof. Neither the site of substitution nor the number of substituents is limited. Inter alia, methyl and ethyl are preferred for R 1 .
Examples of the compound having formula (1) include (2,2-diphenylethyl)trimethoxysilane, (2,2-diphenylethyl)methyldimethoxysilane, (2,2-diphenylethyl)dimethylmethoxysilane, (2,2-diphenylethyl)ethyldimethoxysilane, (2,2-diphenylethyl)diethylmethoxysilane, (2,2-diphenylethyl)phenyldimethoxysilane, and (2,2-diphenylethyl)diphenylmethoxysilane.
The organosilicon compound having a diphenylethyl group and a methoxysilyl group, represented by formula (1) is prepared by effecting hydrosilylation of 1,1-diphenylethylene having the formula (2):
with a hydrogenhalosilane compound having the general formula (3):
HSiR 1 n X 3−n (3)
wherein R 1 is a substituted or unsubstituted, C 1 -C 12 monovalent hydrocarbon group, X is a halogen atom, and n is an integer of 0 to 2, to form a diphenylethylhalosilane compound having the general formula (4):
wherein R 1 , X, and n are as defined above, and subjecting the diphenylethylhalosilane compound to methyl esterification. Alternatively, the organosilicon compound having formula (1) may be prepared by effecting hydrosilylation of 1,1-diphenylethylene having formula (2):
with a hydrogenorganoxysilane compound having the general formula (5):
HSiR 1 n (OCH 3 ) 3−n (5)
wherein R 1 is a substituted or unsubstituted, C 1 -C 12 monovalent hydrocarbon group and n is an integer of 0 to 2.
Examples of R 1 in formulae (3), (4) and (5) are as exemplified above for R 1 in formula (1).
In formula (3), X is specifically fluorine, chlorine, bromine or iodine, with chlorine being preferred for availability.
Examples of the compound having formula (3) include trichlorosilane, methyldichlorosilane, dimethylchlorosilane, ethyldichlorosilane, diethylchlorosilane, phenyldichlorosilane, diphenylchlorosilane, trifluorosilane, methyldifluorosilane, dimethylfluorosilane, ethyldifluorosilane, diethylfluorosilane, phenyldifluorosilane, and diphenylfluorosilane.
Examples of the compound having formula (4) include (2,2-diphenylethyl)trichlorosilane, (2,2-diphenylethyl)methyldichlorosilane, (2,2-diphenylethyl)dimethylchlorosilane, (2,2-diphenylethyl)ethyldichlorosilane, (2,2-diphenylethyl)diethylchlorosilane, (2,2-diphenylethyl)phenyldichlorosilane, (2,2-diphenylethyl)diphenylchlorosilane, (2,2-diphenylethyl)trifluorosilane, (2,2-diphenylethyl)methyldifluorosilane, (2,2-diphenylethyl)dimethylfluorosilane, (2,2-diphenylethyl)ethyldifluorosilane, (2,2-diphenylethyl)diethylfluorosilane, (2,2-diphenylethyl)phenyldifluorosilane, and (2,2-diphenylethyl)diphenylfluorosilane.
Examples of the compound having formula (5) include trimethoxysilane, methyldimethoxysilane, dimethylmethoxysilane, ethyldimethoxysilane, diethylmethoxysilane, phenyldimethoxysilane, and diphenylmethoxysilane.
For hydrosilylation reaction between 1,1-diphenylethylene and a hydrogensilane compound of formula (3) or (5), conventional hydrosilylation catalysts can be used, which include platinum, rhodium, palladium, and iridium compounds, for example. From the aspects of activity, selectivity and stability, platinum compounds are preferred. Suitable platinum compounds include chloroplatinic acid, an alcohol solution of chloroplatinic acid, a toluene or xylene solution of platinum-1,3-divinyl-1,1,3,3-tetramethyldisiloxane complex, dichlorobisacetonitrile platinum, dichlorobisbenzonitrile platinum, and dichlorocyclooctadiene platinum. Platinum black on supports such as alumina, silica and carbon may also be used.
The amount of the catalyst used is not particularly limited. From the aspects of reactivity and productivity, it is preferably 0.000001 to 0.01 mole, more preferably 0.00001 to 0.001 mole per mole of 1,1-diphenylethylene. Less than 0.000001 mole of the catalyst may fail to exert a sufficient catalytic effect. If the amount of the catalyst exceeds 0.01 mole, a reaction promoting effect commensurate with that catalyst amount may not be obtained.
The reaction temperature is not particularly limited and typically in a range of 50° C. to 200° C., preferably 60° C. to 150° C. A temperature in the range of 60° C. to 90° C. is more preferred because 1,1-diphenylethylene preferentially undergoes hydrosilylation reaction rather than dimerization, and hydrosilylation reactivity is high. The reaction time is typically 1 to 100 hours, preferably 1 to 40 hours from the economic aspect, but not limited thereto.
Although the hydrosilylation reaction may take place in a solventless system, a solvent may be used. Suitable solvents include hydrocarbon solvents such as pentane, hexane, cyclohexane, heptane, isooctane, benzene, toluene and xylene, alcohol solvents such as methanol and ethanol, ether solvents such as diethyl ether, tetrahydrofuran and dioxane, ester solvents such as ethyl acetate and butyl acetate, aprotic polar solvents such as acetonitrile and N,N-dimethylformamide, and chlorinated hydrocarbon solvents such as dichloromethane and chloroform. These solvents may be used alone or in admixture of two or more.
Methyl esterification of a diphenylethylhalosilane compound having formula (4) can be performed by any well-known techniques, for example, by techniques using methanol; both methanol and a hydrochloride scavenger such as a tertiary amine or urea; a metal alkoxide such as sodium methoxide; or a trimethyl orthocarboxylate such as trimethyl orthoformate or trimethyl orthoacetate. The conditions of methyl esterification are not particularly limited and may be selected from well-known conditions.
The organosilicon compound of the invention may be used as such, but preferably diluted with a suitable solvent prior to use for ease of handling. Suitable solvents include water, alcohol solvents such as methanol and ethanol, hydrocarbon solvents such as pentane, hexane, cyclohexane, heptane, isooctane, benzene, toluene and xylene, ketone solvents such as acetone and methyl isobutyl ketone, ether solvents such as diethyl ether, tetrahydrofuran and dioxane, ester solvents such as ethyl acetate and butyl acetate, aprotic polar solvents such as acetonitrile and N,N-dimethylformamide, and chlorinated hydrocarbon solvents such as dichloromethane and chloroform, with water and alcohols being preferred. The solvent is preferably used in such amounts as to dilute the organosilicon compound in a concentration of 0.001 to 50% by weight.
One or more additives selected from pigments, defoamers, lubricants, antiseptics, pH control agents, film formers, antistatic agents, anti-fungus agents, surfactants, dyes and the like may be added to the organosilicon compound as long as the benefits of the invention are not impaired.
The organosilicon compound may be used in any desired applications. Typical applications include, but are not limited to, surface treatment of inorganic fillers, liquid sealants, treatment of casting molds, surface modification of resins, polymer modifiers, and paint additives.
EXAMPLE
Examples of the invention are given below by way of illustration and not by way of limitation. In Examples, the refractive index is measured at 25° C.
Example 1
Preparation of (2,2-diphenylethyl)trimethoxysilane
A flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 180 g (1.0 mol) of 1,1-diphenylethylene and an amount (1.0×10 −4 mol of platinum per mol of 1,1-diphenylethylene) of a 2-ethylhexanol solution of chloroplatinic acid. To the flask, 136 g (1.0 mol) of trichlorosilane was added dropwise at an internal temperature of 80-90° C. over 8 hours. Stirring was continued for 1 hour at the temperature.
To the flask, 77 g (2.4 mol) of methanol was added dropwise at an internal temperature of 60-70° C. over 5 hours. The contents were stirred for 1 hour at the temperature, after which 86 g (0.85 mol) of triethylamine was added. Then 42 g (1.3 mol) of methanol was added dropwise at an internal temperature of 60-70° C. over 1 hour. Stirring was continued for 2 hours at the temperature, after which the reaction solution was filtrated to remove salts. To the filtrate, a methanol solution of sodium methoxide was added. The solution was distilled, collecting 256 g of a colorless clear fraction at 165-167° C./0.3 kPa.
This fraction was analyzed by mass, 1 H-NMR and IR spectroscopy.
Mass spectrum: m/z 302, 270, 238, 167, 121
1 H-NMR spectrum (in deuterated chloroform): FIG. 1
IR spectrum: FIG. 2
From these data, the fraction was identified to be (2,2-diphenylethyl)trimethoxysilane. It had a refractive index of 1.528 at 25° C.
Example 2
Preparation of (2,2-diphenylethyl)methyldimethoxysilane
A flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 90 g (0.5 mol) of 1,1-diphenylethylene and an amount (1.0×10 −4 mol of platinum per mol of 1,1-diphenylethylene) of a 2-ethylhexanol solution of chloroplatinic acid. To the flask, 58 g (0.5 mol) of methyldichlorosilane was added dropwise at an internal temperature of 60-70° C. over 8 hours. Stirring was continued for 1 hour at the temperature.
To the flask, 19 g (0.6 mol) of methanol was added dropwise at an internal temperature of 60-70° C. over 2 hours. The contents were stirred for 1 hour at the temperature, after which 56 g (0.55 mol) of triethylamine was added. Then 21 g (0.7 mol) of methanol was added dropwise at an internal temperature of 60-70° C. over 1 hour. Stirring was continued for 2 hours at the temperature, after which the reaction solution was filtrated to remove salts. To the filtrate, a methanol solution of sodium methoxide was added. The solution was distilled, collecting 109 g of a colorless clear fraction at 155-156° C./0.3 kPa.
This fraction was analyzed by mass, 1 H-NMR and IR spectroscopy.
Mass spectrum: m/z 286, 254, 222, 167, 105
1 H-NMR spectrum (in deuterated chloroform): FIG. 3
IR spectrum: FIG. 4
From these data, the fraction was identified to be (2,2-diphenylethyl)methyldimethoxysilane.
Example 3
Preparation of (2,2-diphenylethyl)dimethylmethoxysilane
A flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 90 g (0.5 mol) of 1,1-diphenylethylene and an amount (1.0×10 −4 mol of platinum per mol of 1,1-diphenylethylene) of a 2-ethylhexanol solution of chloroplatinic acid. To the flask, 57 g (0.6 mol) of dimethylchlorosilane was added dropwise at an internal temperature of 80-90° C. over 12 hours. Stirring was continued for 1 hour at the temperature.
To the flask, 4 g (0.1 mol) of methanol was added dropwise at an internal temperature of 60-70° C. over 0.5 hours. The contents were stirred for 1 hour at the temperature, after which 71 g (0.7 mol) of triethylamine was added. Then 21 g (0.7 mol) of methanol was added dropwise at an internal temperature of 60-70° C. over 1 hour. Stirring was continued for 2 hours at the temperature, after which the reaction solution was filtrated to remove salts. To the filtrate, a methanol solution of sodium methoxide was added. The solution was distilled, collecting 96 g of a colorless clear fraction at 135-136° C./0.1 kPa.
This fraction was analyzed by mass, 1 H-NMR and IR spectroscopy.
Mass spectrum: m/z 270, 238, 222, 151, 89
1 H-NMR spectrum (in deuterated chloroform): FIG. 5
IR spectrum: FIG. 6
From these data, the fraction was identified to be (2,2-diphenylethyl)dimethylmethoxysilane.
Reference Example 1
Preparation of (2,2-diphenylethyl)trichlorosilane
A flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 36 g (0.2 mol) of 1,1-diphenylethylene and an amount (1.0×10 −4 mol of platinum per mol of 1,1-diphenylethylene) of a 2-ethylhexanol solution of chloroplatinic acid. To the flask, 27 g (0.2 mol) of trichlorosilane was added dropwise at an internal temperature of 50-60° C. over 8 hours. Stirring was continued for 1 hour at the temperature. At least 30% of the 1,1-diphenylethylene formed a dimer (i.e., 1,1,3,3-tetraphenyl cyclobutane).
Synthesis Example 1
Preparation of (2,2-diphenylethyl)triethoxysilane
The same procedure as in Example 1 was repeated aside from using ethanol instead of methanol, and sodium ethoxide instead of sodium methoxide, yielding (2,2-diphenylethyl)-triethoxysilane at 158-160° C./0.1 kPa.
Example 4 and Comparative Example 1
Hydrolysis Sensitivity Test
In Example 4, (2,2-diphenylethyl)trimethoxysilane synthesized in Example 1 was evaluated for hydrolysis. In Comparative Example 1, (2,2-diphenylethyl)triethoxysilane synthesized in Synthesis Example 1 was evaluated for hydrolysis. The test was performed by adding 1 wt % of the silane to a solution of 1% acetic acid aqueous solution/methanol=70/30, stirring the solution at room temperature, and observing the state at predetermined intervals. The results are shown in Table 1.
TABLE 1
After 2 hr
After 4 hr
After 6 hr
After 8 hr
After 12 hr
Example 4
partially
completely
homogeneous
homogeneous
homogeneous
hydrolyzed,
hydrolyzed,
solution
solution
solution
inhomogeneous
homogeneous
solution
solution
Comparative
partially
partially
partially
partially
partially
Example 1
hydrolyzed,
hydrolyzed,
hydrolyzed,
hydrolyzed,
hydrolyzed,
inhomogeneous
inhomogeneous
inhomogeneous
inhomogeneous
inhomogeneous
solution
solution
solution
solution
solution
In Example 4, (2,2-diphenylethyl)trimethoxysilane was completely hydrolyzed after 4 hours, forming a homogeneous solution. The solution remained homogeneous even after 12 hours. In Comparative Example 1, (2,2-diphenylethyl)-triethoxysilane was not completely hydrolyzed even after 12 hours and remained separate.
Japanese Patent Application No. 2015-189154 is incorporated herein by reference.
Although some preferred embodiments have been described, many modifications and variations may be made thereto in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described without departing from the scope of the appended claims.
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An organosilicon compound having diphenylethyl and methoxysilyl groups is more readily hydrolyzable than ethoxysilyl-containing organosilicon compounds and generates no hydrogen chloride on use.
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FIELD OF THE INVENTION
This invention relates to liquid dispensers for birds, and more particularly to inverted ceramic dispensers.
DISCUSSION OF THE PRIOR ART
Heretofore liquid dispensers have been fabricated primarily out of glass and plastic. The thinness of the plastic and the insulative properties of the glass contributed to spoilage of the dispensed liquid. Sunlight causes honey and sugar mixtures to ferment and become sufficiently toxic to kill hummingbirds (Horticulture, February 1975, page 18). To avoid this problem zoological gardens feed their hummingbirds in the evening to avoid spoilage under the hot sun ("Hummingbirds", by W. Scheithauer, page 147, Thomas and Crouell Co.). In addition, the daily temperature cycle caused unnecessary loss of liquid through thermal expansion and contraction of the liquid.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide:
A ceramic liquid dispenser for birds with properties favorable for minimizing spoilage and loss through heating and exposure;
An integral ceramic liquid dispenser for birds which forms an improved seal around a resilient stopper; and
A ceramic liquid dispenser for birds which minimizes loss of the liquid through dripping.
These an other objects are accomplished by providing a hollow opaque ceramic body with a downwardly extending neck terminating in an aperture. A resilient stopper engages the aperture with a hollow feeder tube extending through the stopper and laterally away from the body. Liquid within the hollow body flows into the feeder tube to the external tip thereof where flying creatures may obtain the liquid in small portions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
These and other advantages of the ceramic dispenser and the meritorious features of the ceramic material will become apparent from the following detailed description and drawing showing a ceramic dispenser in section.
Referring to the drawing, there is shown a liquid dispenser 10 formed by a hollow ceramic body 12, with an aperture or mouth 14, a resilient stopper 16 inserted in mouth 14, and an obtuse feeder tube 18 extending through stopper 16. Ceramic body 12 is suspended by a thong 20 in an inverted position with mouth 14 and stopper 16 downward. Thong 20 engages a support 22 integrally formed in body 12. Body 12 preferably has an esthetic outside glaze 26 which facilitates cleaning body 12, and an inside glaze 28 to permit rinsing of a cavity 30 formed by the hollow interior of body 12. The glazes 26 and 28 extend over the entire surface of body 12, outside and inside, except proximate mouth 12. Preferably colored outside glaze 26 does not cover an annular end face 32 and a small vertical margin 34 adjacent to face 32 around the outside surface of body 12; and preferably inside glaze 28 does not cover the neck portion 36 of cavity 30 where stopper 16 engages the inside surface of body 12.
In operation, cavity 30 holds a liquid 38 to be dispenses. Liquid 38 may be a sugar-water syrup or other liquid nutrient (Hummingbirds, Water Scheithauer, pages 145-7) and is preferably bright in color. It is believed that color contrast of the liquid seen in tube 18 and the container itself attracts to drink from dispenser 10. Liquid 38 occupies the lower portion of cavity 30 and feeder tube 18 leaving an air pocket 40 in the upper end of cavity 30. A liquid bulge 42 or partial droplet forms at the exposed end of tube 18 delicately maintained in place by the surface tension of liquid 38. Flying creatures such as hummingbirds approach tube 18 and disturb bulge 42 with their beaks causing the release of a drop of liquid 38. As bulge 42 forms a completed drop, or is otherwise removed from tube 18, a small quantity of air enters tube 18 and bubbles up toward body 12. These bubbles accumulate in air pocket 40 displacing a corresponding volume of liquid 38 which enters tube 18 to replace the consumed or lost liquid. The ability of liquid 38 to bubble and the formation of bulge 42 are a function of the surface tension and viscosity of liquid 38 and the extent to which air pressure in pocket 40 exceeds the fluid head created by the depth of liquid 38.
In the preferred embodiment:
Ceramic body 12 is formed of commercial stoneware clay approximately one quarter inch thick;
resilient stopper 16 is a rubber cork size three;
feeder tube is 1/4 inch glass tube, about 4 inches long with a bend of about 45°;
outside glaze 26 is about 20 mils in thickness and inside glaze 28 is about 20 mils in thickness;
neck portion 36 has an end face 32 about three-sixteenth inches across, and vertical margin 34 is about one-fourth inch high;
unglazed neck 36 extends about 1.5 inches into cavity 30; and
liquid 38 is four parts water and one part sugar supplemented with vitamins and protein during the winter months.
Body 12 may be fabricated by conventional clay throwing techniques on a potter's wheel or by conventional molding techniques. If desired, porcelain or earthenware clays must be used. Preferably inside glaze 28 is a non-toxic, lead-free glaze, imprevious to acids to avoid contaminating long standing liquids. Also it is preferred that inside glaze 28 be a vitreous, porcelain type to facilitate cleaning cavity 30 of any spoiled liquid 38. Outside glaze 26 is preferably handsomely colored to provide a unique esthetic appearance.
Ceramic dispensers have many advantageous characteristics over the prior art glass or plastic material which uniquely cooperate with the liquid dispenser function. The following superior properties of the ceramic hummingbird feeder are particularly noted.
Ceramic dispensers offer greater thermal insulation than commercial glasses which minimizes solar heating effects. Bird feeders of this type are commonly hung outside near a patio or garden and typically receive direct sunlight for at least a portion of each day which causes the liquid therein to increase in temperature. For each 10° increase in temperature chemical reactions in liquid 38, such as spoilage or fermentation, increase by a factor of two. A 20° temperature increase quadruples the fermentation rate. Further, as body 12 and liquid 38 get warmer, the air in pocket 40 expands a proportional amount displacing a column of liquid 38 out through tube 18. In addition, liquid 38 has a lower vapor pressure as its temperature increases causing evaporation into cavity 30 to increase contributing to the increasing volume of cavity 40. The day-night thermal cycle causes a daily loss of liquid 38. Both the lost volume and the spoilage are a function of solar heating of dispesner 10. Reduction in solar heating reduces both causes of lost volume directly, and retards spoilage exponentially. The greater insulative properties of ceramic body 12 reduces internal heat flow from the heated surface to liquid 38 inside. Less of the sun's energy passes into liquid 38. The thick sides and base of ceramic body 12 permits absorbtion of more heat with less change in temperature.
The thermal insulative property of ceramic body 12 aids in preventing waste of liquid 36. In addition, the smooth highly pigmented surface of outside glaze 26 reflects incident light reducing the solar heat intake. Prior art glass materials do not have high surface pigmentation to prevent penetration of light energy. The pigmentation in glass, if any, is generally distributed internally permitting the light to partially penetrate the glass. In addition, ceramic dispensers thrown on a potter's wheel typically have a thick base 24 which enhances these insulative properties. Thick base 24 forms the top of dispenser 10 and receives the brunt of the sun's energy. The bulk of base 24 adds to the heat flow retardation, and forms a reservoir of material slow to change in temperature. Molded dispensers may be designed to include a generous base portion.
In addition, ceramic body 12 is opaque and shields liquid 38 from solar ultraviolet radiation which otherwise would oxidize the scarlet pigment in liquid 38. Nutrient solutions contained in transparent prior art glass dispensers fade when exposed to direct sunlight. It is commonly understood that hummingbirds are attracted by colors that stand out from the background, in which case the opaque and colorful characteristics of ceramic body 12 is beneficial. Only the small portion of liquid 38 in tube 18 is exposed to sunlight. The greater portion of liquid 38 remains in protected cavity 30 and retains its original color.
Unglazed tapered neck of ceramic body 12 cooperates with stopper 16 to form a more tenacious engagement and a superior seal. Ceramic material after firing has a rough or granular surface similar to the ground glass engaging surfaces of reagent bottles. The tiny irregularities on neck surface 36 bite into the surface of stopper 16 a minute amount. The collective effect these engagements produce is a substantial resistance to lateral movement between neck surface 36 and stopper 16. The prior art glass dispensers were smooth and relied solely on the radial expansive force of the stopper compressed into the mouth of the dispenser to maintain the stopper in position. The rough surface of ceramic neck 36 provides an additional retaining factor to supplement this conventional expansion force.
The expansive engagement force deteriorates proportionaly as stopper 18 is slowly and incrementally advanced out of mouth 14 through blows delivered by feeding birds, banging from the wind, the day-night thermal cycle, and other minor but repetitious disturbances which cause stopper 16 to creep down neck 36. The downward displacement of stopper 16 is slightly but perpetually encouraged by the fluid head of liquid 38. The expansive force gradually decreases because stopper 18 expands, or decompresses as it moves downward to fill the widening diameter of mouth 14.
The bite resistance to movement not only opposes the above downward creep, but also is not subject to the same deterioration as stopper 16 regains its original dimensions. Rough neck surface 26 retains its full bite as long as stopper 16 has sufficient expansion left to push the stopper surface into the rough ceramic surface. Alternatively stated, the expansive engagement diminishes proportionately to the decompression of stopper 16, but the bite resistance to movement forces remain fully effective until the expansive forces are no longer sufficient to urge the stopper into a biting relationship. The bite effect is similar to a lockwasher -- it opposes motion and the bite maintains a constant anti-motion force even if the opposed motion occurs. The motion-opposing force continues until the lockwasher is no longer in compression. The bite and lockwasher effects are particularly effective against seal deterioration due to impact to maintain the seal between stopper 16 and unglazed neck region 36. This seal must be maintained air-tight and waterproof or air will leak in and liquid 38 will be slowly lost through leakage.
The presence of unglzed vertical margin 34 and unglazed end face 32 also prevents loss of liquid 38. Each morning dew collects on the exterior surface of dispenser 10 which has cooled during the preceding night. The dew gathers in drops and runs down outside glaze 26. Glaze 26 is by nature very smooth and provides an excellent wetting surface with very little opposition to motion. The dew accumulates along the upper boundary of unglazed margin 34 as shown at 50. Margin 34 is rough, non-wetting surface. The surface tension of collected dew 50 prevents the dew from entering rough unglazed margin 34. Hopefully the dew is not excessive and evaporates without crossing margin 34. If body 12 were glazed across margin 34 and face 32, the dew would freely run downward past stopper 16 and out to the tip of feeder tube 18 where it would interfere with the delicate surface tension forces which maintain liquid bulge 42 at the tip of feeder tube 18. If the dew were permitted to accumulate at the tip of feeder 18, it would wet the glass proximate bulge 42 causing the liquid in tube 18 to rapidly drip out. The liquid would then be wasted on the patio floor where it forms sticky spot marks attracting flies and ants.
Heavy dew or rain collecting along the upper boundary of vertical margin 34 may overrun the margin barrier before being diminished by evaporation. The accumulated water is periodically released at the moment the weight of the water overcomes the retaining surface tension, causing the water to surge down margin 34 and drip off the lower edge thereof to the ground below. The rapidly moving water surge fails to negotiate the sharp angle between vertical margin 34 and horizontal end face 32. The angle is made even more acute by the outward flare of margin 34 caused by tapered neck 36. Unglazed margin 34 and face 32 prevent external wetting of the tip of tube 18 and priming of bulge 42.
Unfired ceramic material is in a plastic state which facilitates forming integral support 22. Support 22 may be fused to exterior surface of body 12 at room temperature by pushing the two plastic surfaces together. A ceramic fillet may easily be formed along the handle-body interface for improving both its strength and appearance. Prior art glass and plastic substances require an elevated temperature or special chemicals for such fusion to take place. Mechanical connecting devices such as bolts or screws are unsuitable because they require a hole through one or both of the members to be joined. Any hole through body 12 offers a potential air leak into air pocket 40 which must be maintained at a partial vacuum to hold up liquid 38. Further, prior art springbands which retain the dispenser body may slowly creep upwards and eventually lose the dispenser altogether. The fusion of prefired body 12 to support 22 forming an integral-permanent support may be done at room temperature, without additional chemicals, and without injury to the hermetic seal of body 12 around pocket 40 and liquid 38.
It will be apparent to those skilled in the art that the objects of the ceramic dispenser have been accomplished through the favorable thermal, physical, and surface texture properties of ceramic body 12. Various changes may be made in the hereinbefore described dispenser without departing from the scope of the invention. For example, body 12 may be mounted on the side of a structure by an extending device such as a nail. Body 12 may be provided with a flat surface portion which engages a corresponding flat surface of a wall. Heat flow across the flat surfaces reduces the daily thermal circle of body 12.
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An inverted ceramic container dispenses nutritional liquids through a short glass tube to hovering hummingbirds. The tube extends into the interior of the dispenser through a resilient stopper which engages a refill aperture in the dispenser. Various insulative properties of the ceramic dispenser protect the liquids from heat and light damage and loss. The rough unglazed inside surface of the dispenser neck establishes a tenacious seal with the resilient stopper. The unglazed exterior surface of the neck prevents dew and rain moisture from flowing down the outside surface of the dispenser to the tip of the glass tube. This surface moisture is objectionable because it wets the tip of the glass tube causing the nutritional liquid to drip out. The plastic nature of moist unfired clay readily permits the formation support loop integral with the ceramic body.
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BACKGROUND OF THE INVENTION
This invention relates to manufacturing of sodium hydroxide. More particularly, the invention relates to manufacturing of sodium hydroxide and ammonium sulfate by electrolyzing sodium sulfate.
Demonstrated worldwide demand for some sodium-based chemicals, particularly for sodium hydroxide (caustic soda), has been on the rise in recent years. This strong demand, which is forecast to continue, keeps this chemical in tight supply position, thereby holding the price at a high level. This trend is not the same with respect to all sodium-based chemicals. In particular, the demand for sodium sulfate and, as a consequence, the price of this chemical is declining at the same time as the demand for caustic soda is rising.
This declining trend in the demand for and prices of sodium sulfate combined with the strong demand for and relatively high prices of other sodium-based chemicals, in particular of caustic soda, created a need for a simple and economical process for producing sodium hydroxide from sodium sulfate as feedstock. This need is even more strongly perceived in countries endowed with vast natural resources of sodium sulfate. This is, for example, the case in Canada, which has large deposits of natural sodium sulfate located in Southern Saskatchewan.
The most direct process for producing sodium hydroxide from sodium sulfate is the electrolytic conversion of an aqueous solution of sodium sulfate into aqueous solutions of sulfuric acid and caustic soda. Numerous implementations of this process are known in the prior art. Most of them make use of electrolytic cells employing diaphragms or ion permeable membranes to separate the product solutions from the feed solution, thus avoiding contamination of the products by the feedstock material.
U.S. Pat. No. 2,829,095 discloses a process for the production of acidic and alkaline solutions by electrolysis of a salt solution in a multi-compartment electrolytic cell partitioned by a plurality of anion and cation exchange membranes. The patent also discloses the use of the process for direct production of sodium hydroxide and sulfuric acid from Glauber's salt (sodium sulfate decahydrate).
U.S. Pat. Nos. 3,135,673 and 3,222,267 claim a method and apparatus for converting aqueous electrolytic salt solutions to their corresponding acid and base solutions. A three or four compartment electrolytic cell separated by a cation exchange membrane and one or two porous, non-selective diaphragms is used for this purpose. When a solution of sodium sulfate is used as the salt solution, solutions of sodium hydroxide and sulfuric acid or sodium bisulfate are produced.
U.S. Pat. No. 3,398,069 claims a process for the electrolysis of an aqueous saline electrolyte in a multicellular device having cells separated by gas permeable electrodes and further partitioned by microporous fluid-permeable diaphragms or ion-permselective membranes. When applied to a solution of sodium sulfate, the process produces solutions of sodium hydroxide and sulfuric acid.
U.S. Pat. No. 3,907,654 discloses an electrolytic cell particularly useful in electrolysis of sodium sulfate to form sulfuric acid and sodium hydroxide. The cell, which does not employ any ion permeable membranes, comprises a housing having a parent solution chamber and two electrode compartments located on the lower side of the housing and separated from each other but in communication with the parent solution chamber and positioned vertically beneath or above. Mounted within the electrode compartments are an anode and a cathode, each of which is porous to permit passage of a product solution therethrough. The product solutions of sodium hydroxide and sulfuric acid separated by gravity forces are withdrawn through the porous electrodes.
U.S. Pat. No. 4,561,945 claims a process for producing sulfuric acid and caustic soda by electrolysis of an alkali metal sulfate in a three compartment membrane cell having a hydrogen depolarized anode. Hydrogen gas in the anode chamber is oxidized to produce hydrogen cations which migrate to the central (buffer) chamber through a membrane and combine with the sulfate anions from the alkali metal sulfate solution to produce sulfuric acid. Alkali metal ions are transported across another membrane to the cathode chamber to produce caustic and gaseous hydrogen. Both membranes used in the cell are cation selective membranes.
A similar process for increasing concentration of sulfuric acid in solutions containing an alkali metal sulfate, sulfuric acid and alkaline earth metal ions is disclosed in U.S. Pat. No. 4,613,416. Also in this case the anode compartment and the cathode compartment of a three compartment cell are each bounded by cation exchange membranes.
SUMMARY OF THE INVENTION
The development of ion selective membranes has promoted use of three compartment electrochemical cells partitioned by both cation and anion selective membranes. The use of such a cell for electrolysis of sodium sulfate has been disclosed, for example, by J. P. Millington ("An electrochemical unit for the recovery of sodium hydroxide and sulfuric acid from waste streams", in: Ion-Exchange Membranes, D. S. Flett, Ed., Ellis Harwood Ltd. Publishers, Chichester, 1983, p. 195). The cell consists of a central (feed) compartment, through which a solution of sodium sulfate is circulated, an anode compartment and a cathode compartment through which an anolyte and a catholyte, respectively, are circulated. The anode compartment is separated from the central compartment by an anion selective membrane and the cathode compartment by a cation selective membrane. When current is passed between the electrodes situated in the anode and cathode compartments, sodium ions and sulfate ions migrate across ion selective membranes into the cathode and anion compartments, respectively, where they combine with hydroxy and hydrogen ions generated by electrolysis of water. As the process proceeds, the concentrations of sodium hydroxide and sulfuric acid in the catholyte and anolyte increase, whereas the concentration of sodium sulfate in the central compartment decreases by an equivalent amount.
However, as the concentration of sulfuric acid in the anolyte increases, so does the rate of migration of protons back into the central compartment. This lowers the current efficiency for the production of sulfuric acid, as measured in the anolyte only. It leads eventually to competition between protons and sodium ions for the transport of charge across the cation exchange membrane and into the catholyte, thus lowering the current efficiency for the production of sodium hydroxide, as measured in the catholyte only. This problem can be partly eliminated by using membranes having low back-diffusion rates. However, the use of such membranes usually results in an increase of the total cell voltage, thus increasing the power consumption and lowering the overall process efficiency.
It is accordingly an object of the invention to provide a new process for producing sodium hydroxide by electrolysing an aqueous solution of sodium sulfate in an electrochemical cell partitioned by both cation and anion selective membranes, which process substantially reduces back migration of protons from the anolyte into the feed compartment.
It is another object of the invention to provide a process for producing sodium hydroxide by electrolysing an aqueous solution of sodium sulfate, which process also produces ammonium sulfate with high current efficiency.
It has now been found that the problem of the back migration of protons from the anolyte into the feed compartment in a three compartment cell of the type described above can be overcome or substantially reduced by adding ammonia to the anolyte to convert sulfuric acid to ammonium sulfate or ammonium hydrogen sulfate, thus avoiding the build-up of the acid in the anolyte compartment and subsequent back migration of protons across the anion selective membrane.
Thus, the invention provides a process for producing sodium hydroxide, which process comprises electrolysing an aqueous solution of sodium sulfate in an electrolytic cell having at least one anode compartment and at least one cathode compartment, said anode compartment containing an anolyte and having an anode located therein, said cathode compartment containing a catholyte and having a cathode located therein, said anode compartment and said cathode compartment being separated from the sodium sulfate solution by an anion selective ion exchange membrane and a cation selective ion exchange membrane, respectively, wherein during the process ammonia is added to the anolyte to at least partially neutralize sulfuric acid produced in the anode compartment.
Beside the advantages mentioned above, the present invention has also the considerable advantage that, in addition to producing the desired sodium hydroxide, it also produces ammonium sulfate, which is of higher commercial value than sulfuric acid. Moreover, ammonium sulfate produced by the process of the invention is of a purity such that it can immediately be used as fertilizer. Because of the substantially reduced back migration of protons from the anolyte into the feed compartment, the efficiency of the production of ammonium sulfate is substantially higher than efficiencies achievable when sulfuric acid is produced. While the current efficiency of the production of ammonium sulfate according to the invention is usually higher than 95%, the current efficiency of the production of sulfuric acid under comparable process conditions is normally lower than 70%. Also final concentrations of ammonium sulfate which may be achieved without adversely affecting the current efficiency of the process are substantially higher than concentrations of sulfuric acid (up to about 37% for ammonium sulfate versus about 15% for sulfuric acid). Higher concentrations of ammonium sulfate, up to the solubility limits, are possible.
To carry out the process according to the invention, any electrolytic flow cell using a three compartment configuration can be used in either continuous or batch mode of operation.
In the process, the anolyte, the catholyte and the feed solution are circulated through the respective compartments of the cell at a flow rate depending on the cell used, typically of from about 0.1L/min to about 20L/min. The current density is limited by the efficiency considerations (current efficiency of the process decreases with growing current density) and by the stability of the membranes used. Typical current densities are in a range of from about 1 mA/cm 2 to about 500 mA/cm 2 .
The feed solution of sodium sulfate may have a concentration of from about 0.1M to the solubility limit. The concentration of from about 1M to about 3.5M is preferred. The concentration of from about 2M to about 3M is particularly preferred. For concentrated feed solutions, it may be necessary to heat the solution prior to circulating it through the cell, to prevent the crystallization of the salt.
The feed solution should be as free as possible of heavy metal contaminants that are usually present in the naturally occurring Glauber's salt. If this salt is used as a starting material, the bulk of heavy metal ions can be precipitated, for example, by addition of sodium carbonate and/or sodium hydroxide to a solution of the salt. The remaining amounts of polyvalent cations, in particular of calcium and magnesium ions, can be removed by treating the resulting solution with an ion exchange resin, e.g. by passing the solution through an ion exchange column packed with a suitable ion exchange material, for example Duolite* C-467 from Rohm and Haas, or an equivalent material. After such a treatment the heavy metal ion concentration normally will not exceed about 20 ppb.
The catholyte and the anolyte can both be water, but it is preferred that they are solutions of sodium hydroxide and ammonium sulfate, respectively, as this gives improved conductivity. In the case of sodium hydroxide solution, the starting concentration should be in the range of from about 0.01M to about 9M. In the case of ammonium sulfate solution the starting concentrations should be in the range of from about 0.01M to about 3.5M. A concentration of about 3M is preferred. The choice of the starting concentrations of the anolyte and the catholyte may be also affected by the mode of operation of the electrolytic cell. For example, for the continuous mode of operation, starting concentrations closer to the upper limits of the above ranges are preferred.
To avoid an excessive accumulation of hydrogen ions in the anolyte, ammonia in either the liquid or the gaseous form is introduced into the anolyte at such a rate as to keep the pH of the solution at a predetermined level. The choice of suitable pH of the anolyte may be affected by several other factors, in particular by the ion exchange membranes and anode materials used. Generally, the pH of the anolyte may be maintained at any level in *Trade-Mark the range of from about 0.5 to about 12. A pH of from about 0.5 to about 7 is preferred and pH of from about 0.5 to about 3.5 is particularly preferred. It appears that under these acidic conditions there is little or no anode corrosion as well as no or very little formation of nitrogen and ammonium nitrate due to electrooxidation of ammonia.
The materials for electrodes, beside providing good current conduction, must be corrosion resistant under the operating conditions of the cell. Suitable cathodes are low hydrogen over potential cathodes, for example gold, platinum, nickel or stainless steel. Because of the lower cost, nickel and stainless steel are preferred.
The choice of the anode material is mostly restricted by the presence of ammonia in the anolyte solution. Under alkaline conditions (pH 9 to 12) anodes made of some materials, such as nickel, graphite and stainless steel may corrode quickly. In this range of pH anodes made of platinum, platinized titanium, magnetite or anodes of low oxygen over potential such as DSA* type electrodes (iridium or platinum oxides on a titanium substrate) are preferred. Under acidic conditions (pH 0.5 to 2) DSA-O 2 anodes are preferred. However, less expensive materials, such as lead dioxide on titanium or Ebonex* (material comprising Ti 4 O 7 ) may be used. Lead dioxide on lead would be even less expensive anode material, but there exists a possibility that this material might liberate lead into the anolyte, thus making ammonium sulfate unacceptable for use as a fertilizer.
The ion-selective membranes used to separate the anode and cathode compartments from the central compartment are essentially *Trade-Mark insoluble, synthetic, polymeric organic ion-exchange resins in sheet form. Those selective to cations usually have sulfonate and/or carboxylate groups bound to the polymers; those selective to anions usually have amino functionality bound to the polymer. These ion exchange membranes are commercially available under various trade names, for example Nafion* or Flemion* (cation exchange membranes) or Neosepta* (anion exchange membranes). Cation selective membranes made of stable perfluorinated cation exchange resins are preferred.
Even though, in principle, any cation or anion exchange membrane may be used in the process according to the invention, their choice may be in practice limited to those showing sufficiently good stability under operating conditions of the electrolytic cell. For example, the choice of the anion selective membrane maybe limited by both the concentration of sulfate ion and/or ammonia in the anolyte and the presence of hydroxyl ions in the feed solution, due to the back migration of hydroxyl ions from the catholyte. Of the membranes showing good stability, membranes having high ionic selectivity and low electrical resistance are preferred. A person skilled in the art will be able to choose suitable membranes without difficulty.
An example of the anion exchange membrane preferred for carrying out the process of the invention is Neosepta AMH membrane, which shows good stability at the anolyte pH in a range of 1-12. Examples of preferred cation exchange membranes are perfluorinated membranes such as Nafion and Flemion membranes, which show good stability for NaOH concentration up to 50%. *Trade-Mark
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents schematically the set-up of a three-compartment electrolytic cell used for conducting flow cell electrolyses and
FIG. 2 represents schematically the configuration of a three-compartment electrolytic cell for conducting the process according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the Figures, a three-compartment electrolytic cell 1 is divided into a cathode compartment 2, a central (feed) compartment 3 and an anode compartment 4 by a cation exchange membrane 5 and an anion exchange membrane 6. A cathode 7 and an anode 8 are situated in the cathode compartment 2 and the anode compartment 4, respectively.
To operate the cell, storage reservoirs 9, 10 and 11 are charged with a catholyte solution, a feed solution and an anolyte solution, respectively. These solutions are circulated through respective compartments of the cell by pumps 12, 13 and 14 at a flow rate measured by flow meters 15, 16 and 17. As a direct current is passed from a source (not shown in the drawings) between the cathode 7 and the anode 8, sodium ions from the feed solution are transported through the cation exchange membrane 5 into the catholyte, whereas sulfate ions are transported through the anion exchange membrane into the anolyte, as shown in FIG. 2. At the same time hydroxide ions and protons are produced in the cathode compartment 2 and the anode compartment 4, respectively, due to the following electrode reactions:
anode: 2H 2 O=4H + +O 2
cathode: 2H 2 O→20H - +H 2
Hydrogen and oxygen produced in these reactions are vented through outlets 18 and 19, respectively.
The combined result of the above processes is a build-up of sodium hydroxide in the catholyte and sulfuric acid in the anolyte. The build-up of sulfuric acid in the anolyte can be prevented by introducing ammonia into the anolyte, as shown schematically in FIG. 2.
EXAMPLE 1
Glass Cell Electrolyses
Glass cell electrolyses were conducted in H-type cells to check the stability of various anode materials to ammonia solution. The anolyte was 1M ammonium sulfate maintained at pH 9-12 by periodic additions of concentrated NH 4 OH. A Nafion 417 cation exchange membrane was used to separate the anolyte from the catholyte, which was 1M NaOH with a graphite rod as the cathode. A constant current of 1A (200 mA/cm 2 ) was supplied by an ESC Model 420 power supply in conjunction with a Model 410 potentiostat in the galvanostatic mode. Anodes were 5 cm 2 flags. Nickel, graphite, 316 stainless steel, magnetite (Fe 3 O 4 ), platinized titanium, and DSA-O 2 materials were tested. PbO 2 /Ti and Ebonex (Ti x O 4 ) anodes were also tested at a lower anolyte pH of 1-2. The anodes and anolyte were observed for changes in appearance and in some cases anode weight loss was measured. Electrolyses were performed for 4-24 hours depending on the extent of anode corrosion.
Table 1 shows the results of corrosion tests carried out in glass cells. The first three anode materials tested (nickel, graphite, and 316 stainless steel) quickly corroded in ammonium sulfate+ammonium hydroxide as evidenced by anolyte color changes within 4 hours of electrolysis. The next three materials tested (magnetite, platinized titanium, and DSA-O 2 ) showed no visible evidence of corrosion after 24 hours of electrolysis. Slight weight losses were seen at platinized titanium and magnetite, but not at DSA-O 2 , indicating that it was the best anode for use in ammonia solutions.
TABLE 1______________________________________Stability of Anode Materials to Ammonia Solutions Weight Loss,Anode Material Solution mg/1000 coul Corrosion______________________________________Nickel Lavender -- ModerateGraphite Brown -- Severe316 SS Yellow -- SevereMagnetite No Change 11.7 SlightPt/Ti No Change 3.3 SlightDSA-O.sub.2 No Change 0 NonePbO.sub.2 /Ti No Change -- NoneEbonex No Change -- Slight______________________________________
In acid ammonium sulfate, PbO 2 /Ti showed no signs of corrosion, while Ebonex was slightly pitted. Thus lead dioxide on titanium may be an alternative anode material to DSA-O 2 under acidic conditions. However, in the manufacture of such electrodes the titanium is first platinized to avoid peeling of the PbO 2 layer, and consequently such electrodes are as expensive as DSA-O 2 . Lead dioxide on lead would be a less expensive material but may corrode lead into the anolyte making it unacceptable for use as a fertilizer.
EXAMPLE 2
Purification of Glauber's Salt
Raw Glauber's salt was dissolved in hot water to give a solution with a concentration greater than 2M. Suspended impurities were flocculated with an anionic flocculating agent (Percol* 156, Allied Colloids) and the resulting suspension filtered. The calcium and magnesium contents of the solution at this stage were 442 ppm and 224 ppm, respectively. Sodium carbonate was then added to the resulting solution and the pH was raised to 12 with sodium hydroxide to precipitate out the calcium and magnesium ions. The resulting fine precipitate was flocculated and removed by filtration. This gave a solution that contained 61.6 ppm Ca and less than 0.1 ppm Mg. The solution was then passed through an ion exchange column (Ionac SR-5, Sybron Chemicals) to remove any last traces of polyvalent cations from the solution. Analysis of this solution showed that the heavy metal ion concentrations had been reduced to below the limits of detection, that is below 0.5 ppm Ca and 0.1 ppm Mg. The purified solution was then diluted with water to the required concentration of 2M before being used for flow cell experiments.
EXAMPLE 3
Electrolytic Production of Sodium Hydroxide and Ammonium Sulfate
Flow cell electrolyses of Glauber's salt purified described in Example 2 above were performed in a MP Cell* (ElectroCell AB, Sweden) using a three compartment configuration as shown in FIG. *Trade-Mark 1. Initially, ammonia was introduced to the anolyte from a dropping funnel containing 100% liquid NH 3 to maintain an excess of ammonia in solution giving a pH of 9-11. Later experiments (#176-91 to 200-14) utilized gaseous NH 3 addition from an ammonia cylinder through a glass sparger tube into the anolyte. The compartments were charged with the following solutions for flow cell experiments:
______________________________________Catholyte: 1L 1M (or 2.5M) NaOHFeed: 2L 1.75M Na.sub.2 SO.sub.4Anolyte: 1L 1M (NH.sub.4).sub.2 SO.sub.4______________________________________
The solutions were circulated through the respective compartments of the cell by March* MX-MT3 pumps at a flow rate of 0.4 gal/min. A Sorenson* DCR 60-45B power supply provided a constant current of 20 amps (200 mA/cm 2 ) to the cell and the charge was followed by using a coulometer (ESC Model 640) in the circuit. Anolyte pH was measured by a Corning* combination probe mounted in line and connected to a Cole-Parmer* 5997-20 pH meter. Membranes used were Neosepta* ACM or AMH anion exchange membranes (Tokuyama Soda Co.), Nafion* 324, 901, or 9O2 cation exchange membranes (DuPont), or Flemion* FCA cation exchange membrane. The cathode was 316 stainless steel or nickel, and the anode was either nickel, platinized titanium, shiny platinum, or DSA-O 2 . Anolyte and catholyte samples (10 ml) were periodically taken and analyzed for ammonium sulfate (gravimetrically by evaporating and weighing) and sodium hydroxide (by titration vs. standardized HCl). Feed samples were also taken to determine caustic content by titration. The volumes of each compartment were measured at the end of the *Trade-Mark run to allow the calculation of the number of moles of ammonium sulfate and sodium hydroxide formed. Cell voltage and temperature were measured throughout the run and reported when steady state values had been reached towards the end of the run.
At the end of the runs, anolyte samples were analyzed by HPLC for nitrate (NO 3 - ) content from NH 3 oxidation. A Waters* 600 HPLC equipped with a micro-Bondapak* C-18 column and UV detector (214 nm) was employed for the analysis. The mobile phase was 0.05M KH 2 PO 4 with 0.025M PIC-A reagent (Waters), running at a flow rate of 2.5 ml/min. By comparing the sample nitrate peak area to that of a known standard, the anolyte nitrate concentration could be determined.
In flow cell runs where gaseous NH 3 addition was employed, the anolyte chamber was sealed so as to be gas tight and the off gases were scrubbed through a sealed trap containing dilute sulfuric acid to remove NH 3 , and then sampled and analyzed for nitrogen. The concern was that nitrogen could be produced from the oxidation of ammonia, resulting in an excess amount of NH 3 required to form ammonium sulfate. Oxygen and nitrogen were separated and quantified on a molecular sieve 5A column mounted in a Perkin-Elmer* 8500 gas chromatograph equipped with a thermal conductivity detector. Helium was used as the carrier gas at a flow rate of 60 ml/minute and the injector and detector temperatures were set at 120° C. while the oven temperature was 70° C.
Table 2 summarizes the results of initial flow cell runs. The experiments were run to about 40% of complete theoretical conversion (300,000 coulombs) of sodium sulfate to ammonium *Trade-Mark sulfate and sodium hydroxide. Current efficiencies and concentrations are reported at the end of the runs. Because of overall volume losses of 50 to 100 ml seen in all flow cell runs, the current efficiencies reported show some variance.
The first experiment (#176-59) utilized a nickel anode which corroded into solution giving a purple color to the anolyte. When dimethyl glyoxime was added to anolyte samples, a red precipitate indicative of the presence of nickel was observed. The Neosepta ACM membrane was deeply discoloured in areas where it contacted the anolyte and feed solutions which contained ammonia.
The next experiment (#176-63) used a platinized titanium anode. This run was terminated when a rapidly rising cell voltage was observed after the passage of 380,000 coulombs. When the cell was inspected a number of holes were found in the ACM membrane indicating that it was not stable to alkaline solutions. The Pt/Ti anode had a thin coating of brown solids on it, indicating that it had corroded to a small extent.
A shiny platinum anode was used in the next experiment (#176-75) along with Neosepta AMH and Nafion 901 membranes. The AMH allowed a high current efficiency (99.4%) for (NH 4 ) 2 SO 4 formation and showed no evidence of deterioration. The 901 membrane allows very high current efficiencies for caustic formation because it is a bilayer membrane which resists hydroxide back migration from the catholyte. However, it was not known if the membrane would be stable in the presence of high sulfate concentrations.
TABLE 2__________________________________________________________________________STABILITY OF ANODE MATERIALS FOR ELECTRODIALYSISOF SODIUM SULFATE IN MP FLOW CELLExperiment # 176-59(a) 176-63(a) 176-75(b) 176-79(b)__________________________________________________________________________Coul. Passed ×1000 333 384 283 428Electrodes, Ni/316SS Pt-Ti/316SS Pr/Ni DSA-02/NiAnode/CathodeMembranes, ACM/324 ACM/324 AMH/901 AMH/901Anion/CationConcentration, g/lAmm. Sulfate 249.3 260.7 250.4 300.9NaOH 129.0 140.3 165.3 192.0% Current EfficiencyAmm. Sulfate 100.8 107.4 99.4 98.5NaOH 93.5 90.9 87.9 86.1Cell Voltage 9.5 14 9.5Temperature, °C. 48 44 43 45Anolyte Wt. % 2.8 4.4 3.5 3.6Amm. NitrateFeed Conc. NaOH.sub.1 g/l -- -- 5.6 8.8Δ Volume, ml/1000 CAnolyte +1.34 +1.49 +0.92 +0.91Catholyte +0.78 +0.80 +0.71 +0.69Feed -1.64 -2.66 -1.88 -1.80Δ Volume, overall ml +168 -179 -68 -85Anolyte pH 10-12 8-10 8-10 8-10Anode Corrosion Severe Slight Slight NoneMembrane Stability ACM discolored ACM failed OK OK__________________________________________________________________________ (a)Starting Conditions: Amm. Sulfate 132.14 g/l, NaOH 40 g/l, Sodium Sulfate 249 g/l, 200 mA/sq. cm. (b)Starting Conditions: Amm. Sulfate 132.14 g/l, NaOH 100 g/l, Sodium Sulfate 249 g/l, 200 mA/sq. cm.
Actual current efficiency for caustic formation (87.9%) is lower than expected, possibly due to caustic mist being entrained in the hydrogen off gas from the catholyte. A film of brown solids on the Pt anode indicated slight corrosion.
Glass cell tests indicated that DSA-O 2 was the most stable anode material. When used in flow cell run #176-79, no corrosion of the DSA-O 2 anode was seen. Again, high current efficiency for ammonium sulfate formation and relatively low current efficiency for sodium hydroxide formation were seen. At this point DSA-O 2 /Ni and AMH were selected as the best electrode pair and anion exchange membrane for the process. Further flow cell tests focused on the stability of these materials as well as the optimal cation exchange membrane material.
Table 3 gives the results of flow cell tests designed to check the stability of the DSA-O 2 anode, AMH membrane, and various cation exchange membranes in repeated experiments. Previous experiment #176-79 had shown no corrosion of these materials. However, when this experiment was repeated (#176-84), a very thin film of brown solids was seen on the anode indicating slight corrosion, and the 901 membrane blistered, delaminating the two layers of this membrane. Good current efficiencies for product formation were observed. It was thought that reducing the free ammonia concentration in the anolyte would alleviate the corrosion of the DSA-O 2 anode, and thus further experiments were conducted at lower anolyte pH (less NH 3 added).
The next two experiments (#176-91 & 95) were performed at a neutral anolyte pH. Also, a higher current density (250 mA/cm 2 ) was employed in these experiments to more rigorously test the membranes. Under these conditions, slight anode corrosion was still observed and the cation exchange membrane failed, allowing caustic to leak into the feed compartment in the second experiment, thus lowering current efficiency for caustic formation. No damage to the AMH membrane was observed.
The 901 membrane was tried one more time in experiment #200-1 under less taxing conditions. Even with a lower initial caustic concentration and a lower current density, the membrane still blistered. The anolyte pH was lowered further to a range of 1-2. At this pH, some ammonium bisulfate may form and thus it was necessary to add extra ammonia to anolyte samples to ensure that only the sulfate form was present for analysis. No corrosion of the DSA-O 2 anode was observed. Also, much less ammonium nitrate was formed from the oxidation of ammonia than at higher pH values where an excess of ammonia was present (0.04% of the ammonium sulfate formed was ammonium nitrate vs. 4.0% in experiment #176-84). No nitrogen could be detected in anolyte off gases, indicating that ammonia was not being oxidized to nitrogen. Thus operation at a low anolyte pH seemed desirable and was tested further.
Two other cation exchange membranes were tested in the next three experiments (#200-6, 10, 14). Nafion 902 is another bilayer membrane similar to Nafion 901 but thinner. Damage to bilayer membranes by sulfate is known to be reduced as the membrane thickness decreases. Flemion FCA membrane is a monolayer perfluorinated carboxylic acid membrane which may not be damaged
TABLE 3__________________________________________________________________________STABILITY OF MEMBRANES AND DSA-02 ANODE FORELECTRODIALYSIS OF SODIUM SULFATE IN MP CELLExperiment # 176-84(a) 176-91(b) 176-95(b) 200-1(c) 200-6(c) 200-10(c) 200-14(c)__________________________________________________________________________Coul. Passed ×1000 322 360 625 382 275 297 362Electrodes, DSA-02/Ni DSA-02/Ni DSA-02/Ni DSA-02/Ni DSA-02/Ni DSA-02/Ni DSA-02/NiAnode/CathodeMembranes, AMH/901 AMH/901 AMH/901 AMH/901 AMH/902 AMH/ AMH/902Anion/Cation Flemion FCAConcentration, g/lAmm. Sulfate 286.9 280.6 326.5 270.7 258.0 254.6NaOH 173.2 187.2 230.2 139.4 123.6 127.8 148.2% Current EfficiencyAmm. Sulfate 97.9 93.9 83.8 91.8 93.1 100NaOH 95.0 95.8 70.3 94.9 92.6 87.4 86.2Cell Voltage 8.6 9.7 10.2 9.5 8.7 9.0 8.7Temperature, °C. 44 50 51 48 46 46 46Anolyte Wt. % 4.0 0.3 0.4 0.04 0.02 0.02Amm. NitrateFeed Conc. NaOH, g/l 0 2.0 30.8 5.1 0.9 4.8 4.0Δ Volume, ml/1000 CAnolyte +0.59 +0.85 +0.82 +0.99 +0.67 +1.35 +0.60Catholyte +0.91 +0.94 +0.35 +0.30 +0.60 +0.55 +0.45Feed -1.64 -1.86 -1.34 -1.44 -2.35 -2.21 -2.39Δ Volume, overall ml -45 -26 -108 -58 -116 -92 -166Anolyte pH 9-10 6-8 7-10 1-2 1-2 1-2 1-2Anode Corrosion Slight Slight Slight None None None NoneCation Exchange Blistered Blistered Blistered Blistered OK OK OKMembrane Stability slightly heavily heavily heavily__________________________________________________________________________ (a)Starting Conditions: Amm. Sulfate 132.14 g/l, NaOH 100 g/l, Sodium Sulfate 249 g/l, 200 mA/sq. cm. (b)Starting Conditions: Amm. Sulfate 132.14 g/l, NaOH 100 g/l, Sodium Sulfate 249 g/l, 250 mA/sq. cm. (c)Starting Conditions: Amm. Sulfate 132.14 g/l, NaOH 40 g/l, Sodium Sulfate 249 g/l, 200 mA/sq. cm. by sulfate. The experiments were performed at a current density of 200 mA/cm.sup.2 and at the lower initial NaOH concentration of 40 g/l. The Nafion 902 membrane was undamaged after two experiments (#200-6 & 200-14). The current efficiencies for caustic formation are surprisingly low (92.6% and 86.2% for the two experiments) but large volume losses were seen in both experiments and thus current efficiencies may be suspect. Flemion FCA membrane (#200-10) was likewise undamaged after the run and gave a current efficiency for caustic formation similar to that seen for Nafion 902. At an anolyte pH of 1-2, no anode corrosion, no N.sub.2 formation, and very little NH.sub.4 NO.sub.3 formation was seen in these three experiments.
COMPARATIVE EXAMPLE
Electrolytic Production of Sodium Hydroxide and Sulfuric Acid.
Flow cell electrolyses of Glauber's salt purified as described in Example 2 were performed in an MP Cell (Electrocell, Sweden) using a three compartment configuration shown in FIG. 1. A stainless steel cathode and an DSA-O 2 anode were used for all the experiments.
In a typical experiment the compartments were charged with the following solutions:
______________________________________Catholyte 1L, NaOH (0.11M)Center compartment 2L, Na.sub.2 SO.sub.4 (2M)Anolyte 1L, H.sub.2 SO.sub.4 (0.09M)______________________________________
The solutions were circulated through the cell at a flow rate of 0.4 gal/min. A constant current of 20 amps (200 mAcm -2 ) was passed through the cell and the charge followed using a coulometer (Electrosynthesis Company) in the circuit. Samples (2 ml) were removed from the catholyte and the anolyte reservoirs at intervals and the concentration determined by titration against standardized acid and base. The temperature and cell voltages were recorded once they had reached a constant value, towards the end of the reaction. The volumes of the electrolytes were measured at the end of the reaction to allow the calculation of the number of moles of sodium hydroxide and sulfuric acid formed.
Membranes used include AM-1 and ACM membrane (Neosepta, Tokuyama Soda), ARA membrane (Morgane, France) and Nafion 324 and 901 membranes (DuPont).
The current efficiency for the formation of both sodium hydroxide and sulfuric acid was determined over a range of operating conditions. The results are summarized in Table 4.
As can be seen from a comparison of runs 3 and 5, the current efficiency is affected only slightly by increasing the current density. However, increasing the current density does increase the cell voltage, approximately one volt for a 100 mAcM -2 increase. The flow rate also seems to have only a minor effect on the current efficiency. If the flow rate is too low, however, it could lead to trapped gas bubbles on the electrode or the membrane, which will increase the cell voltage.
In experiments 1 to 5, when an AM-1 anion exchange membrane was used, there was a significant migration of protons into the center compartment. This lowers the current efficiency for the production of sulfuric acid (measured in the anolyte only). It also, eventually, leads to competition between protons
TABLE 4__________________________________________________________________________Summary of Results Experiment Number 1.sup.A 2.sup.A 3.sup.A 4.sup.A 5.sup.A 6.sup.A 7.sup.B 8.sup.B 9.sup.B,C 14.sup.A__________________________________________________________________________MembranesCation 324 324 324 324 324 324 324 324 901 324Anion AM-1 AM-1 AM-1 AM-1 AM-1 ACM ACM ARA ACM ACMCurrent 100 200 200 200 350 200 300 250 250 200density/mA cm.sup.-2Flow Rate/ 0.4 0.4 0.4 0.1 0.4 0.4 0.4 0.4 0.4 0.4gal min.sup.-1Charge passed/ 289 302 580 288 617 388 605 642 600 381Coulombs × 1000Wt PercentageNaOH 9.4 9.2 13.1 9.1 13.8 11.4 13.6 14.1 28.sup.D 16N.sub.2 SO.sub.4 9.4 9.4 13.1 9.7 15.7 16.2 19.9 18.3 18.1 16.6Wt Percentage H.sub.2 SO.sub.4 5.2 4.1 5.8 2.3 4.6 1.8 2.2 5.3 3.0 3.3in center compartmentCell Voltage 5.2 6.2 6.5 6.5 7.5 7.4 9.2 7.7 5.5 7.6Temperature/°C. 35 42 43 45 54 42 47 43 45 48Current Efficiencyafter250,000 CoulombsNaOH 93 90 89 92 84 90 99 94 90 95H.sub.2 SO.sub.4 61 51 60 55 66 84 83 66 75 73500,000 CoulombsNaOH -- -- 79 -- 78 -- 86 86 85 --H.sub.2 SO.sub.4 -- -- 50 -- 56 -- 72 61 65 --Final solutionVolumes/mlCatholyte 1178 1238 1376 1211 1444 1295 1514 1526 961 1287Anolyte 988 938 1100 969 1134 1100 1124 1116 1046 1074Center compartment 1800 1700 1440 1750 1400 1590 1310 1390 1626 1512loss/gain ml -36 -124 -84 -70 -22 -15 -52 +32 -117 -127Proton balance +0.15 -0.33 +0.17 -0.4 -0.11 +0.43 -0.11 +0.12 -0.443 -0.02moles H.sup.+ -moles OH.sup.-(moles formed)__________________________________________________________________________ Notes: .sup.A Reagent grade sodium sulfate 2M, 2 l; .sup.B Purified Glauber salt. 2M, 2 L; .sup.C NaOH starting concentration 5M, 750 ml; .sup.D Starting Wt percentages NaOH 19%
Two other anion exchange membranes were therefore investigated in an to attempt to minimize the proton migration. The membranes tested were ACM (Neosepta) and ARA (Morgane). The ARA gave current efficiencies very similar to that observed for the AM-1 membrane, thereby showing no significant advantage over the previous results. The ACM membrane, however, gave a 20% increase in the current efficiency for the production of sulfuric acid and approximately halved the proton migration into the center compartment. The use of this membrane, however, leads to an increase of approximately one volt in the total cell voltage, compared to the AM-1 membrane.
When sodium ions are transported across the cation exchange membrane, water is also transported across the membrane, which leads to a diluting effect on the concentration of sodium hydroxide formed. This limits the concentration of sodium hydroxide which can be attained. The concentration of sodium hydroxide which can be achieved is also limited by the back migration of hydroxide ions, across the cation exchange membrane. The Nafion 324 cation exchange membrane limits the maximum concentration of sodium hydroxide which can be produced, to about 15-20%. The maximum concentration which may be produced can, in theory, be improved by using a Nafion 901 membrane. This membrane limits the back migration of hydroxide ions by using a bilayer structure in the membrane. This membrane is, however, more sensitive than the 324 membrane to the presence of heavy metal ion hydroxides. It is also sensitive to the pH of the center compartment. This phenomenon was discovered during some of the later experiments performed, by observation of the membrane itself. Too low a pH causes the membrane to blister and thereby damaging it beyond repair. According to manufacturer's data the membrane should not be run at pH less than 2 even on the anolyte side of the membrane.
Experiment 14 was run with the optimum cell configuration, i.e. a Nafion 324 cation exchange membrane and a Neosepta ACM anion exchange membrane. The current efficiency for NaOH and H 2 SO 4 at 16% by weight concentration is 95% and 73% respectively. The water transport across these membranes has been estimated at three molecules of water accompanying every sodium ion transported across the Nafion membrane and two molecules of water with every sulfate ion transported across the ACM membrane.
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A process for producing sodium hydroxide and ammonium sulfate by electrolysing an aqueous solution of sodium sulfate is disclosed. The process is carried out in a three-compartment electrolytic cell having a central compartment separated from an anode and a cathode compartment by, respectively, anion selective and cation selective ion exchange membrane. The solution of sodium sulfate is circulated through the central compartment, while solutions of sodium hydroxide and ammonium sulfate are circulated, respectively, through the cathode and the anode compartment. During the process, ammonia is added to the anolyte to at least partially neutralize sulfuric acid produced in the anode compartment and reduce the back migration of protons from the anolyte into the central compartment. As a result, high purity ammonium sulfate of commercial value higher than that of sulfuric acid is produced with high current efficiency and in concentrations higher than those achievable for sulfuric acid.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a combined hull and steering mechanism for marine vessels and particularly for a special purpose marine vessel that is commonly used to move work barges and other similar craft required for the construction of piers, docks and other marine structures, this craft being referred to in the maritime trade as a “pushboat”.
2. Description of the Related Art
Pushboats are essential vessels required in the construction of piers, docks and the like. A pushboat must be highly maneuverable and must be able to move other large marine vessels, such as barges, in the typically tight surroundings of a construction project. Pushboats are relatively small and manned by a single operator.
Pushboats have been used on the aforementioned types of jobs for many years. The name pushboat is derived from a large flat vertical plate that extends across the bow, which can make stable contact with the flat side hull of a barge, floating dock or the like, to provide a broader area of contact, and therefore stability during the maneuvering operation. The distinctive feature of the pushboat is its flat bow surface or prow, which distinguishes it from a tug boat and other work boats that have a more traditional hydrodynamically tapered or pointed bow that is more efficient for forward movement.
One problem with pushboats, however, is the fact that the flat bow plate limits maneuverability of the boat through water as there is a significant amount of lateral resistance encountered when such a vessel is turned. Typically, additional rudders known as flanking rudders, are required to aide in the steering of pushboats to compensate for this lack of maneuverability. They are positioned outboard and forward of the propeller
One object of the present invention is to provide a marine vessel which is less resistant to lateral forces of the water when turning and thus has much greater maneuverability and is faster than other marine vessels of similar shape and size.
Another object of the present invention is to provide a marine vessel having a hull that is configured to allow the vessel to turn in a tighter pattern and to move more efficiently than other marine vessels of similar size and function.
Still another object of the present invention is to provide a marine vessel which is capable of coming about 180 degrees, and even of turning 360 degrees, in its own length.
SUMMARY OF THE INVENTION
These and other objects and advantages are achieved by the novel pushboat hull of the invention that is comprised of an upper and a lower portion whose shapes differ markedly from each other. The upper portion of the hull which is sometimes referred to as the upper hull, is generally rectangular in shape and overhangs a lower, dual-tapered hull. As used herein, the term “dual-tapered hull” means a hull having side walls that meet by tapering inwardly and are joined at the longitudinal center line, or the line defined by the keel of the boat. The hull rises towards the bow at an angle from a flat bottom, beginning at a transverse line about one-third of the length of the longitudinal axis from the bow of lower hull. The forward end of the lower dual-tapered hull is configured as a flat, triangular surface, which results in lift and less resistance when the vessel is moving forward.
The novel hull configuration of the invention significantly minimizes the lateral resistance encountered by prior art boats such as those disclosed in U.S. Pat. No. 3,822,661 issued Jul. 9, 1974, U.S. Pat. No. 6,112,687 issued Sep. 5, 2000 and U.S. Pat. No. 6,834,605 issued Dec. 28, 2004. Boats of the prior art generally disclose the concept of implementing a ship hull having two main hull portions that take the form of a relatively flat upper hull mounted above a lower portion formed of a smaller, rounded or cylindrical section attached to the underside of the upper hull.
However, the combined hull and steering configuration of the present invention is significantly superior to any of the claimed configurations of the prior art. One difference is that the lower portion of the hull is dual-tapered, that is, its oblong shape tapers from its outermost widest section, with the sides intersecting at a generally vertical line at the forward and aft ends. Tapering the aft or rear end of the lower dual-tapered hull permits a significantly better flow of water to the propeller and steering mechanism by drawing water toward the propeller as opposed to away from it as with conventional hull designs that are either generally flat and not tapered at all or are tapered only in the bow or forward end of the hull. This eliminates the need for additional rudders to steer the vessel as are generally used in the prior art. The aft end of the dual-tapered hull also eliminates the need for external supports for the propeller shaft housing, as depicted, for example, in U.S. Pat. No. 3,822,661. This configuration results in improved hydrodynamic flow, decreased lateral resistance and improved maneuverability.
The dual-tapered configuration is of particular importance when the combination of the partially enclosed directional thrust steering mechanism of the invention is employed to shorten the turning radius and the space required to maneuver the pushboat. A particular advantage of the hull design of the invention is realized when the propeller of the pushboat is reversed, since the tapered aft section allows the forces of the thrust from the propeller to flow either up both sides of the lower hull or to be applied away from, or along either of the side walls of the lower hull portion. This efficiency of operation is not possible where the lower hull transom is flat and extends a significant distance across the width of the aft portion of the hull as is typically found in vessels of the prior art.
The enclosed directional thrust steering mechanism is adapted for use in combination with a conventional screw propeller. The steering mechanism is comprised of two parallel fin-type blades, one on each side and outboard of a screw propeller. The blades are both connected to a single steering mechanism post. The distance between the blades is sufficient to allow turning of the steering mechanism without contacting the propeller.
The steering mechanism post or shaft is rotatable about a vertical axis, which is directly above, and perpendicular to the horizontal axis of the screw propeller. A significant portion of the rudder blades extends forward of the vertical axis of the steering mechanism post. Such positioning allows for the thrust of the propeller to be directed more efficiently when said propeller is rotated in the reverse direction.
In a particularly preferred embodiment, the vertical projection of the axis of rotation of the steering post and attached mechanism passes through plane of rotation of the propeller. The geometry and dimensions of the steering assembly can readily be determined based upon the size of the propeller and its extension from the aft end of the lower hull. The transverse width of the steering assembly must be sufficient to avoid contact with the rotating propeller when the assembly is in the maximum port or starboard position.
While the submerged dual-tapered hull is designed to minimize lateral resistance, the twin fin directional thrust steering mechanism maximizes the lateral forces needed to turn the vessel in the desired direction.
It has been found that enclosing the propeller in a tube or other confining structure can result in undesirable cavitation when the propeller rotational speed exceeds a specified rpm value. Cavitation produces vibration and results in a loss of efficiency. Since the type of work performed by pushboats often requires maximum power and corresponding maximum rpm output of the engine, caviation is to be avoided.
In a preferred embodiment, the area between the lower edges of the twin rudder fins and beneath the propeller is open- to avoid cavitation. This preferred open configuration can be utilized when the pushboat will be working or moored in water whose depth is expected to preclude grounding. If grounding is a possibility during low tide conditions or where the depth is variable or unknown and it is desired to protect the propeller in the event of grounding, a plate can be attached below the propeller and the directional steering assembly. The protective plate is configured to minimize the restriction of water flow and thereby to avoid cavitation. In a preferred embodiment, the plate is detachably installed using releasable fasteners, such as bolts secured to threaded studs or rods that are suspended from one or both of the hulls. Removal of the plate permits easy access to the propeller, its driveshaft and bearing in the event that repairs are required.
As will be understood from the above, a pushboat or any other marine vessel having a directional thrust steering mechanism as described for a single fixed screw propeller that extends from a dual-tapered lower hull, effectively permits the pushboat to turn 180 degrees, or even 360 degrees, in its own length, a maneuver that is not possible in any known watercraft of the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are further described with reference to the drawings, in which:
FIG. 1 is a side elevational view of a vessel having a hull and steering mechanism configured in accordance with the present invention;
FIG. 2 is a bottom view of said vessel;
FIG. 3 is a front elevational view of said vessel;
FIG. 4 is a rear elevational view of said vessel;
FIG. 5 is a side elevational view of a preferred embodiment of the directional thrust steering mechanism;
FIG. 6 is a rear elevational view of the steering mechanism;
FIG. 7 is a top plan view of said directional thrust steering mechanism, the top and bottom being similar;
FIG. 8 is a top plan view, partly in phantom, showing the aft end of the dual-tapered hull with the steering mechanism turned hard to port;
FIG. 9 is a bottom view of a second embodiment of the invention; and
FIG. 10 is a rear elevation view of the boat of FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
The invention is further described with specific reference directed to a combined hull and steering mechanism configured for the special purpose marine vessel referred to as a pushboat. Referring to FIG. 1 , there is illustrated a pushboat 1 provided with an upper hull portion 10 , which overhangs the lower dual-tapered hull portion 12 . An enclosed directional thrust steering mechanism 14 is positioned between the aft end 18 of the lower dual-tapered hull and the aft end of upper hull portion.
The upper hull 10 has a forward and aft section, and a top, bottom and sidewalls, it is generally flat on the bottom, but may also be rounded in an alternative embodiment (not shown). The forward section 11 of the upper hull rises above the waterline to meet the bow surface 10 A at the outside corners 29 of the upper hull, which eliminates the generally wide, flat submerged bow employed by the prior art. This configuration allows the water to pass under the vessel with a minimum of resistance, eliminating the resulting bow wave and loss of performance characteristics and efficiency when moving in the forward direction that is associated with craft of the prior art. This configuration also reduces lateral resistance while turning and improves maneuverability.
For the purposes of this description, a vessel having a nominal length L of about 25 feet, a beam W of 10 feet and a draft D of 3 feet is described. The lower hull can be 30 inches deep and the upper hull is submerged about 6 inches. A 210-horsepower diesel engine mounted in the lower hull will provide adequate power for a steel vessel of this configuration.
As can be readily seen in FIG. 2 , the lower dual-tapered hull 12 is displaced aft of bow surface 10 A a distance of about four feet or about 15% of the overall length of the vessel. The lower hull is attached to upper hull 10 , as by welding. This reduction in the overall length of the lower hull also greatly reduces lateral resistance encountered when turning the vessel. The forward bottom section 16 of the dual-tapered hull is angled upwardly along a transverse line 17 that is displaced a distance of about one-third of the lower hull's length from the bow, or about 5.5 feet, to form a substantially triangular section that produces lift when moving in the forward direction and that also serves to substantially reduce lateral resistance when turning as compared to prior art pushboat configurations. The forward bottom section of the dual-tapered hull is best seen in FIG. 3 and illustrates how it would cut through the water thereby reducing lateral resistance when turning.
The hydrodynamic shape of the dual-tapered hull 12 allows the water to flow freely past the aft tapered end 18 to the propeller 13 and to enter the area of the steering mechanism, or rudder assembly, 14 as the vessel moves forward.
FIGS. 4 and 5 depict the positioning of the steering mechanism 14 behind the aft tapered end 18 of the lower hull 12 . The propeller drive shaft 20 extends through a waterproof bearing seal 40 mounted in the lower hull. The propeller is displaced aft of the lower hull a distance that is sufficient to permit rotation of the steering assembly to direct the water from the propeller past the side of the hull in reverse.
In the pushboat of this example, the rudder blades 15 are about 3.5 feet long and 2.5 feet high. A vertically disposed support strut or post 21 , as shown in FIGS. 5 and 6 , secures the dual fin steering mechanism 14 in position aft of the dual-tapered lower hull. In the preferred embodiment illustrated, a second supporting cup bearing 23 is positioned below the steering mechanism and is attached to a strut 50 extending from and attached to the lower hull by mechanical fasteners 52 with vibrational dampers 54 , or by welding (not shown).
As the pushboat 1 is driven through the water by the propeller 13 , the directional thrust steering mechanism 14 becomes effective in two respects. First, as can be seen in FIGS. 6 and 7 , by having the two fin-like blades 15 positioned parallel on each side of propeller 13 , the thrust from the propeller is concentrated and there is a substantial increase in efficiency and performance. By connecting the parallel blades 15 with relatively thin, flat structural members 22 , the top and bottom portions of the steering mechanism 14 are not adversely affected by restricted water flow between the blades as may be the case in enclosed steering mechanisms of the prior art that employ round or tubular sections. The relatively thin, fiat structural members 22 include a pair of linking members 14 (C), 14 (D) joined to, and extending transversely between the fore and aft portions of the upper and lower edges of the rudder blades 15 and a longitudinal linking member 29 extending longitudinally between each of the transverse linking members 14 (C), 14 (D) to form an open framework, and, thereby maintain the rudder blades 15 in a parallel configuration. Second, as the pushboat 1 is turned to maneuver, one blade, provides directional thrust by diverting the water displaced by the propeller 13 in the desired direction and the other blade, provides lateral resistance which aids in the turning of the vessel. The combination provides exceptional maneuverability not possible with constructions of the prior art and permits the craft of the invention to complete a 180° turn, or even a 360° turn, on its own length.
Referring to FIG. 8 , when the propeller 13 is rotating in the reverse direction, it is significant to note that the steering mechanism 14 can be turned so that the thrust is directed completely to either side of the dual-tapered hull 12 at the aft tapered end 18 . The effect of the dual rudder elements and the directional thrust, when combined with the dual-tapered hull 12 produces a greater degree of maneuverability for the vessel of the invention than has been obtainable with the vessels of the prior art.
Referring again to FIGS. 9 and 10 , the optional protective plate 80 is shown positioned below the propeller and attached to the bottom of the lower hull 12 by fastener 82 and to a pair of struts 84 depending from the bottom of upper hull 10 by fasteners 86 . As best seen in FIG. 9 , the plate 80 is generally triangular and is of sufficient thickness to resist bending upwardly to interfere with the free turning of the twin fins in the event of an impact. In order to further minimize unnecessary structural members extending from the hulls, the struts 84 and fastener 82 can be removably installed when the pushboat is to be operated without the protective plate.
The hulls of the invention can be constructed of common structural steel plate using techniques and equipment well known and available in boatyards. Fabrication can be accomplished easily and inexpensively, using basic welding procedures and equipment. As will be apparent to one of ordinary skill in the art, no special bending or machining is required. The propulsion engine can be installed in a simple, straightforward manner. The configuration of the hull portions provides for easy access to conventional packing glands and bearings for maintenance or repair. Tankage for fuel and other necessary lubricants can also be positioned for easy access and enables the vessel to be balanced and seaworthy under a variety of sea conditions. Fresh water keel cooling pipes can be mounted under the upper hull portion making them more efficient and less vulnerable to damage in collisions with underwater objects.
The flat bottom of the dual-tapered hull adds to the stability and seaworthiness of the craft, while also providing a stable platform that keeps the vessel upright when grounded intentionally, or removed to a dry dock or boatyard where it can be placed directly on its bottom surface without special supports or framing. This hull configuration also facilitates easier handling during transport over land by flatbed truck or trailer.
The invention results in improved fuel economy, better speed, more maneuverability and overall performance, less maintenance, reduced repair costs and a consequent dollar savings in time and labor costs.
While the configuration described herein is specifically directed to a hull and steering mechanism configuration for a pushboat, nothing disclosed herein should be construed as a limitation to applying the invention to other types of marine vessels.
While the preferred embodiment of the present invention has been shown and described, it will be understood that this embodiment is provided by way of example only. Numerous variations, changes and substitutions will occur to those of ordinary skill in the art without departing from the spirit and scope of this disclosure of the invention. Accordingly, it is intended that the invention be limited only by the appropriate interpretation of the claims that follow.
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A combined hull and steering mechanism for a marine vessel has a substantially rectangularly-shaped upper hull joined to a lower hull that is dual-tapered from its sidewalls to both its forward and aft portions. A directional thrust steering mechanism having a pair of vertical rudder blades positioned on either side of a conventional propeller extending from the centerline of the lower hull directs the water from the propeller, thus enabling the vessel to move more efficiently and with greater maneuverability in both forward and reverse directions. The dual-tapered hull permits a significantly better flow of water to and from the propeller and steering mechanism of the vessel, particularly when operating in reverse, thereby allowing the vessel to turn 360° in its own length.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to motor vehicle passenger restraint systems and more particularly to a seamless trim panel for a motor vehicle airbag support assembly and a method of making the same.
[0002] The incorporation of airbags into motor vehicles has resulted in many design challenges for vehicle designers. It is desirable to incorporate an airbag into a motor vehicle trim panel, such as the instrument panel in the front passenger compartment of the vehicle. When incorporating an airbag into the trim panel, it is necessary to provide an airbag cover that will reliably and safely tear during a collision. To this end, a tear seam has generally been provided in the trim panel cover to insure that the airbag safely deploys.
[0003] Vehicle designers prefer to have a continuous surface on the front face of the trim panel whenever possible, so the designers would prefer to avoid having a tear seam in the trim panel that is visible to the vehicle passengers. Thus, recently there has been an effort to achieve a “seamless” design, wherein there is no visible indication on the front face of the trim panel that an airbag is located behind the trim panel. To achieve this design, tear seams provided in the trim panel are only provided on the under face, and not on the front face, of the trim panel.
[0004] A major design challenge with such “seamless” designs has been to provide a cover for the trim panel that has a tear seam that is not visible on its front face. A conventional cover has a relatively soft skin with a tear seam on its under face. The presence of the tear seam is often visible in the form of a protrusion on a front face of the soft skin due to its soft, pliable nature. A harder skin may be employed, however, providing a tear seam in a harder skin has proven to be difficult because harder skins interfere with the deployment of the airbag.
[0005] It is desirable to create a cover for the trim panel that has a skin that is sufficiently hard to prevent a visible sign of a tear seam on its front surface while not interfering with the deployment of the airbag. Preferably, such a cover would have a greater tensile strength, a greater tear strength, and greater elongation than covers currently used. Such a cover also would be easier and more cost effective to produce.
SUMMARY OF THE INVENTION
[0006] In a disclosed embodiment of this invention, an airbag support assembly includes a trim panel cover that includes a spray aromatic urethane skin having a tear seam in its under face, wherein the tear seam is formed with an ultrasonic knife. The invention is also directed to a method for producing a trim panel for an airbag support assembly comprising the steps of forming a spray aromatic skin and scoring the skin with an ultrasonic knife.
[0007] These and other features and advantages of this invention will become more apparent to those skilled in the art from the following detailed description of the presently preferred embodiment. The drawings that accompany the detailed description can be described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a front view of an instrument panel having an airbag assembly designed according to the present invention.
[0009] [0009]FIG. 2 is a cross-sectional view along line 2 - 2 of FIG. 1.
[0010] [0010]FIG. 3 is a perspective view of the skin on a fixture and a mechanical arm supporting an ultrasonic knife for scoring the skin to make a tear seam therein.
[0011] [0011]FIG. 4 is an enlarged cross-sectional view of a skin with a tear seam therein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] An embodiment of a vehicle instrument panel according to the present invention is shown generally at 20 in FIG. 1. The vehicle instrument panel 20 has a skin or shell 24 . Shown in phantom line is an airbag support assembly 28 located behind the skin 24 . Although the airbag support assembly 28 in the illustrated embodiment is located behind the skin 24 of the instrument panel 20 , it can be located behind any other trim panel that is positioned in the passenger compartment of the vehicle.
[0013] As illustrated in FIG. 2, the instrument panel 20 preferably includes a substrate or support 22 , which may be in the form of a structural plastic material, such as acrylonitrile-butadiene styrene (ABS)/polycarbonate, thermoplastic poly-olefin (TPO), polypropylene, polyphylene oxide (PPO)/high-impact polystyrene (HIPS), or styrene malaeic anhydrid (SMA). The substrate 22 has an opening formed therein through which an airbag may be deployed. The opening is closed by a door flap 32 . The door flap 32 is preferably in the form of plastic, aluminum, or other suitable lightweight material. An outer surface of the substrate 22 and the door flap 32 are preferably bonded to a layer of a suitable energy absorbing elastomeric foam, such as urethane foam, that forms a cushion 50 in an underlying relationship to the skin 24 . The skin 24 forms an outer decorative surface for the instrument panel 20 .
[0014] The door flap 32 has a plurality of outer edges and the opening has a plurality of sides. A flexible hinge member 36 connects one of the outer edges of the door flap 32 to one of the sides of the opening. The hinge member 36 is contiguous along substantially the entire length of one of the outer edges of the door flap 32 . As should be appreciated by one of ordinary skill in the art, the hinge member 36 can be in the form of multiple hinges spaced along an outer edge of the door flap 32 . Alternatively, the hinge member 36 can be in the form of a single hinge that extends along an outer edge of the door flap 32 . The hinge member 36 may be any suitable shape or configuration.
[0015] In the illustrated embodiment, the outer edges of the door flap 32 are spaced inwardly from the sides of the opening, although such is not necessary. This spacing creates a gap 35 between the sides of the opening and the outer edges of the door flap 32 . The gap 35 or the edge of the door closely overlies the tear seam 38 on an under surface of the skin 24 .
[0016] The airbag support assembly 28 in the illustrated embodiment is supported beneath the door flap 32 by a welded joint between an outer rim 30 of the airbag support assembly 28 and an under face of the substrate 22 . A support structure 52 extends rearward from the outer rim 30 . The support structure 52 includes a pair of L-shaped brackets 54 . An airbag module 56 includes a pair of channels 62 . The channels 62 are shaped to slidably mate with a portion of the L-shaped brackets 54 .
[0017] The airbag module 56 contains the airbag 60 and an airbag inflator 58 for inflating the airbag 60 . The airbag module 56 , the airbag 60 , and the airbag inflator 58 are all located behind the door flap 32 . The airbag module 56 , the airbag 60 , and the airbag inflator 58 are shown schematically for illustration purposes since such modules are well known in the art and their construction forms no part of this invention. It should be appreciated by one of ordinary skill in the art that the shape of the airbag module 56 , the airbag 60 , and the airbag inflator 58 may vary from that shown.
[0018] During a collision, when the airbag 60 deploys, it will initially be forced against an underside of the door flap 32 . The airbag 60 then ruptures the skin 24 along the tear seam 38 so that the portion of the skin 24 within the outlines of the tear seam 38 separates from the rest of the skin 24 and moves with the door flap 32 . The flexible hinge member 36 permits the door flap 32 to rotate outwardly (in the direction of arrow A when viewing FIG. 2) so that the airbag 60 can be released into the passenger compartment. During and after deployment of the airbag 60 , the weld joint maintains contact between the under face of the substrate 22 and the outer rim 30 of the airbag support assembly 28 . In the illustrated embodiment, the outer rim 30 surrounds the door flap 32 and the tear seam 38 . Thus, the outer rim 30 is supported around the entire opening in the substrate 22 , around the tear seam 38 , and around the door flap 32 .
[0019] In accordance with the present invention, the skin 24 is a spray aromatic urethane skin. The skin 24 is formed from two-components, which, when mixed together, produce a chemical reaction. The mixture is forced through a tube (not shown) and further through a nozzle (not shown) at the end of the tube to produce various spray patterns. The mixture is deposited on a heated tool where it solidifies after a brief period of time (e.g., 45 seconds) to form the skin 24 . The skin 24 according to the present invention has a greater tensile strength, a greater tear strength, and a greater elongation than skins currently in use. The skin 24 according to the invention is also harder and thus does not permit visible signs of the tear seam 38 to appear on the front face thereof. Moreover, the skin 24 is easier and more cost effective to produce.
[0020] As illustrated in FIG. 3, the skin 24 is placed on a fixture 64 with the front face of the skin 24 tightly against the fixture 64 . This can be accomplished in any suitable manner. A mechanical or robotic arm 66 is located next to the fixture 64 . The mechanical arm 66 supports an ultrasonic knife 68 . Mechanical arms and ultrasonic knives are well known in the art and their construction forms no part of this invention. The ultrasonic knife 68 is guided by the mechanical arm 66 along the skin 24 to score the skin 24 to form the tear seam 38 . This weakens the skin 24 in a localized area.
[0021] The ultrasonic knife 68 preferably modulates or vibrates at about 20 , 000 cycles per second to about 100 , 000 cycles per second. The ultrasonic knife 68 makes a very clean V-shaped tear seam, as illustrated at 38 in FIG. 4. The tear seam 38 may be a continuous tear seam, or a discontinuous tear seam. The mechanical arm 66 precisely controls the distance between the surface of the fixture 64 and the tip of the blade of the ultrasonic knife 68 so that the material of the skin 24 remaining between the tear seam 38 and the front face of the skin 24 remains substantially constant. This is important because the thickness of the skin 24 may vary. Consequently, the depth of the tear seam 38 varies according to variations in the depth of the skin 24 . In a preferred embodiment of the invention, the skin 24 is about 0 . 8 mm to about 1 . 3 mm and the material remaining between the tear seam 38 and the front face of the skin 24 is in a range of about 0.1 mm and about 0.9 mm. In such case, the skin 24 is sufficiently hard and thick to conceal the tear seam 38 on the front face of the skin 24 but the tear seam 38 sufficiently weakens the skin 24 to allow the airbag 60 to be deployed without interference.
[0022] The foregoing description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and do come within the scope of this invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims.
[0023] In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.
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A method for producing a trim panel for an airbag support assembly comprising the steps of forming a spray aromatic urethane skin and forming a tear seam in the skin by scoring the skin with an ultrasonic knife.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
This application claims priority under 35 U.S.C. §119(e) of the U.S. Provisional Patent Application Ser. No. 61/776,734, filed Mar. 11, 2013 and titled, “NOVEL ENGINE USING COMPRESSED GAS OF A FUEL AND AN INTERNAL COMBUSTION ENGINE,” which is also hereby incorporated by reference in its entirety for all purposes.
FIELD OF THE INVENTION
The present invention relates to engines. More specifically, the present invention relates to engines that use the physical property and chemical property of a fuel to power a vehicle or a machine.
BACKGROUND OF THE INVENTION
Since the early 1900s, most cars and trucks in the United States have been propelled using gasoline or diesel powered engines. In recent years, hybrid electric and pure electric powered vehicles have entered the fleet. There are two types of hybrids. One couples the power from the internal combustion engine to an alternator to charge the batteries and also to the drive train via mechanical ways. The batteries drive an electric motor which then also mechanically couples its power to the drive train. The alternative hybrid mechanism uses what is called the “locomotive” method. As in diesel locomotive engines, the fuel is used to generate electricity which then drives electric motors for powering the drive wheels.
Brazil has led the way in the use of neat ethanol powered vehicles. In France it is common to see gas stations offering liquefied petroleum gas (LPG) in addition to normal petroleum gasoline. The LPG is cryogenically stored at the delivery point and in the vehicle and the driver selects the traditional gasoline or the LPG. Countries from Turkey east to South Korea also use gasoline and liquefied natural gas (LNG) to power many of their vehicles.
In France, the vehicle has two tanks for the two different fuels. A user can merely turn a knob or switch to go from one fuel to the other. For both fuels, they are burned in a traditional internal combustion (IC) engine without the hybrid mechanism gaining momentum in North America.
There are research groups working on an approach using a compressed and non-combustible liquid/gas, such as liquid nitrogen, LN 2 . The expanded pressurized non-combustible gas is then used to drive a motor which is coupled to the drive wheels. One of the problems is frosting and icing due to energy required to compensate for the latent heat of vaporization. FIG. 1 shows a typical engine 100 powered by a compressed non-combustible liquid/gas. The engine 100 contains a fuel storage 102 . A compressed and non-combustible liquid/gas 104 is stored within the fuel storage 102 . By expanding the non-combustible liquid/gas 104 at a turbo expander or heat exchanger 106 , a high pressure gas 110 is produced at the chamber 108 . The high pressure gas 110 is used to propel a motor 112 .
In all of the above instances, energy is extracted only once from the fuel, either by fuel combustion or the compressed inert gas.
SUMMARY OF THE INVENTION
Methods of and devices for twice extracting energy from a fuel are disclosed. The methods and devices comprise turning a turbine or an expansion cylinder by using an expanded gas/liquid from a compressed, liquified, or solidified gas and then combusting/burning the gas/liquid in an internal/external combustion engine. The methods and devices disclosed herein are able to be used to provide power to a land, water or air vehicle. The dual power sources are able to drive an alternator/generator for producing electricity and/or storing it in a battery array, and driving the vehicle.
The methods and devices disclosed herein are able to be used as a propulsion and/or auxiliary power on land transportation vehicles (such as, a car, pick-up, SUV, hybrid vehicle), public transport vehicles (such as shuttles, buses, light rail, underground systems (e.g, subways)), land transportations for transporting gases, liquids and solids (such as the commonly named truck, “18 wheeler”) on streets, roads, highways, and interstate highways, land transportation of people and goods (such as, vehicles on rails and a train propelled by a locomotive), transportation of people and/or goods on or under water (such as, a boat, ferry, hydrofoil, catamaran or submarine), and transportation of goods and/or people above the ground in the air (such as, an airplane or jet aircraft). In the following some aspects of the invention are disclosed.
In an aspect, a vehicle comprises a fuel storage, a fluid driven generator fluidically coupling with the fuel storage, and a chemical energy converter fluidically coupling with the fluid driven generator. In some embodiments, the fluid driven generator comprises one or more turbines. In other embodiments, the fluid driven generator generates electricity when receiving a fluid flow. In some other embodiments, the fluid flow comprises a gas. In some embodiments, the fluid flow is driven by a pressure difference. In other embodiments, the fluid driven generator, the chemical energy converter, or a combination thereof provides an energy sufficient to move the vehicle. In some other embodiments, the chemical energy converter comprises a combustion engine. In some embodiments, the combustion engine makes a moving motion of the vehicle by combusting a fuel. In other embodiments, the vehicle comprises a land transportation vehicle. In some other embodiments, the land transportation vehicle comprises a sedan, a pick-up, a SUV, or a hybrid vehicle. In some embodiments, the land transportation vehicle comprises a truck or a train. In other embodiments, the vehicle comprises a public transportation vehicle. In some other embodiments, the public transportation vehicle comprises a shuttle, a bus, or a light rail train. In some embodiments, the public transportation vehicle comprises an underground system. In other embodiments, the underground system comprises a subway. In some other embodiments, the vehicle comprises a vehicle on water or under water. In some embodiments, the vehicle on water or under water comprises a boat, a ferry, a hydrofoil, a catamaran, or a submarine. In other embodiments, the vehicle is above the ground. In some other embodiments, the vehicle above the ground comprises an airplane or a jet craft.
In another aspect, a vehicle comprises a physical energy conversion unit and a chemical energy conversion unit fluidically coupling with the physical energy conversion unit. In some embodiments, the physical energy conversion unit generates electricity when a fuel passing through the physical energy conversion unit. In other embodiments, the chemical energy conversion unit receives the fuel from the physical energy conversion unit. In some other embodiments, the chemical energy conversion unit comprises a combustion engine.
In another aspect, a method of powering a vehicle comprises generating a first amount of power by passing a fuel through a turbine generator and generating a second amount of power by combusting the fuel. In some embodiments, the method further comprises controlling a pressure of the fuel to drive the turbine generator. In other embodiments, the method further comprises controlling a temperature of the fuel to drive the turbine generator. In some other embodiments, the fuel is combusted in a combustion engine. In other embodiments, the fuel generates the first amount of energy by a physical state conversion and the second amount of energy by a chemical energy conversion. In some other embodiments, the vehicle comprises a land transportation vehicle, a water transportation vehicle, an air transportation vehicle, or a combination thereof.
Other features and advantages of the present invention will become apparent after reviewing the detailed description of the embodiments set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will now be described by way of examples, with reference to the accompanying drawings which are meant to be exemplary and not limiting. For all figures mentioned herein, like numbered elements refer to like elements throughout.
FIG. 1 shows a typical engine powered by a compressed and non-combustible liquid/gas.
FIG. 2 illustrates a dual powering system in accordance with some embodiments of the present invention.
FIG. 3 illustrates a vehicle using the dual powering system in accordance with some embodiments of the present invention.
FIG. 4 is a flow chart illustrating a dual powering method in accordance with some embodiments of the present invention.
FIG. 5 is a flow chart illustrating an energy using method in accordance with some embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings. While the invention is described in conjunction with the embodiments below, it is understood that they are not intended to limit the invention to these embodiments and examples. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which can be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of the present invention, numerous specific details are set forth in order to more fully illustrate the present invention. However, it is apparent to one of ordinary skill in the prior art having the benefit of this disclosure that the present invention can be practiced without these specific details. In other instances, well-known methods and procedures, components and processes have not been described in detail so as not to unnecessarily obscure aspects of the present invention. It is, of course, appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application and business related constraints, and that these specific goals vary from one implementation to another and from one developer to another. Moreover, it is appreciated that such a development effort can be complex and time-consuming, but is nevertheless a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure. More details of the methods of and devices for using the physical property and chemical property of a fuel to power a vehicle or machine are disclosed in the following.
FIG. 2 illustrates a dual powering system 200 in accordance with some embodiments of the present invention. The system 200 is able to be used as the power generating part, such as an engine, of a motor. The motor is able to be used on a vehicle, such as a locomotive, car, truck, and any vehicle that can be operated with a power source. In some embodiments, the system 200 comprises a storage tank 204 , a boiler 208 , a turbine generator 210 , a combustion engine 212 , an energy storage 214 , a throttle 216 , a regenerative braking system 222 , and an electric motor generator 218 .
A fuel 202 , such as natural gas, is added or pumped to and stored at the storage tank 204 . In some embodiments, the storage tank is able to be a cryogenic tank. The term “fuel” used herein is able to refer to any materials that are capable of generating energy by lowering its internal energy in any physical states, such as liquid, solid, gas, supercritical fluid, or a combination thereof. In some embodiments, a liquefied fuel, such as a liquefied natural gas, is stored in the storage tank 204 at an ambient temperature and/or a pressure equal to the pressure at the boiler 208 . A liquefied fuel is advantageous in a way that it has maximum energy density and fluidity in terms of usage convenience.
In some embodiments, the boiler is configured and controlled to have a pressure of the fuel in the range of 300-600 psi (pounds per square inch) with a use of the valve 206 , which is referred as a bottoming cycle. In other embodiments, the pressure at the boiler 208 is controlled to be greater than 500 psi. A person of ordinary skill in the art appreciates that the pressures at the boiler 208 and at the storage tank 204 are able to be in any ranges so long as the pressure is able to be used to drive a turbine 210 A to move and not greater than the safety pressure of the boiler 208 and the storage tank 204 . In some embodiments, the boiler is heated by waste heat from the combustion engine 212 or turbine 210 A via the heat exchanger 220 . The use of the waste heat is able to avoid frosting and icing due to the loss of latent heat of vaporization of the fluid to gas transition.
The high pressure gas at the boiler 208 is transferred to the turbine generator 210 driving an alternator or generator (such as, the turbine 210 A) to generate a controlled amount of electricity, which is able to be determined by a computerized system 224 having computer executable instructions to automatically control the needed electricity, such as a speed of a vehicle or a voltage needed at a predetermined time point or duration. In some embodiments, the electricity generated at the turbine generator 210 is used to drive/power a portion of the system 200 or the entire system 200 directly without prior storage through a power control and transmission system (such as the computerized system 224 ). In other embodiments, the electricity generated at the turbine generator 210 is stored at the energy storage 214 , such as a battery array, before being used to drive/power a portion of or the entire system 200 , including the electric motor generator 218 . In some embodiments, the high pressure gas includes the fuel in a supercritical fluid state. In some embodiments, the pressure of the gas after running through one or more turbines in series or in parallel is able to be 125 psi. Using the high pressure gas to drive a turbine to generate electricity is able to be a process of a physical energy conversion, wherein a force is generated by passing a gas from a higher pressure state/location to a lower pressure state/location.
Next, the fuel at the turbine 210 at a reduced pressure is transferred to the combustion engine 212 , which is able to be an internal or external combustion engine. The fuel in the combustion engine 212 generates electricity by converting its internal energy/combusting by driving an alternator or generator, which constitutes a chemical energy conversion. The electricity from the turbine generator 210 and the combustion engine 212 are able to be sent to the electric motor generator 218 to propel the vehicle and/or the batteries for a load leveling. In some embodiments, the regenerative braking 222 is an additional source of electricity to charge the batteries.
FIG. 3 illustrates a vehicle 300 using the dual powering system in accordance with some embodiments of the present invention. The liquefied fuel is able to be added/pumped through the opening 302 . The fuel is able to be stored at the tank 304 . The liquified fuel is expanded to be in a gas state to be passed through the one or more turbines 306 , such that electricity is able to be generated. Next, the gas is passed to the combustion chamber 308 to chemically convert the chemical energy to electricity by a process of combustion. The energy generated at the turbine 306 and/or at the combustion chamber 308 is able to be stored at the battery set 314 , to be used at the control panel 312 , or to be used to drive the motor 316 for the movement of the vehicle 300 .
FIG. 4 is a flow chart illustrating a dual powering method 400 in accordance with some embodiments of the present invention. The method is able to begin at a step 402 . At the step 404 , a condition in the fuel tank is measured, such as temperature and pressure, such that the physical state (e.g., liquid or gas) of the fuel is able to be controlled and maintained. For example, a predetermined temperature (e.g., below 25° C.) and/or pressure (e.g., a greater than needed liquefying pressure at a current temperature) is able to be controlled and maintained. At the step 406 , a predetermined amount of fuel is transferred to a boiler. The amount of fuel is able to be determined by the amount of fuel needed to reach a predetermined condition, such as a speed of a vehicle, average or peak energy needed. At the step 408 , the temperature and pressure of the boiler are determined and controlled. The fuel in the boiler is controlled to have a pressure capable of driving a power generating turbine, such as greater than 500 psi. At the step 410 , the fuel gas is passed through a turbine generator to generate an amount of power or electricity. The power or electricity is able to be used as a power source to propel a vehicle or stored in a form as an electricity to power an electrical component or electric motor. At the step 412 , the fuel is transferred to be combusted at a combustion chamber/engine to generate electricity or power, which can be used as a source of electricity or power. The method is able to stop at a step 414 .
FIG. 5 is a flow chart illustrating an energy using method 500 in accordance with some embodiments of the present invention. The method 500 is able to begin at a step 502 . At the step 504 , a first amount of energy is generated from a physical transformation of a fuel. The physical transformation includes phase transformations (such as vaporization, sublimation, melting, condensation, freezing, and deposition) and pressure changes (such as, pressure change while remaining in purely gas phase or with an expanded liquid). A person of ordinary skill in the art appreciates that the physical transformation is able to include all the changes of the physical properties, such as change of strength, change of durability, changes to crystal form, textural change, shape, size, color, volume and density or a combination thereof. At the step 506 , a second amount of energy is generated from a chemical transformation of the fuel. The chemical transformation includes change of internal energy, change of chemical bonds (such as, bond formation, bond dissociation, and ionization), change of potential energy, or a combination thereof. At the step 508 , the first and/or second amount of the energy generated are stored and/or used. The above is an example of the energy generation by dual transformation. Other sequences or combinations are within the scope of the present invention. For example, a chemical transformation of the energy is able to be performed before the physical transformation of the energy. More than twice conversions of the fuel are within the scope of the present invention, such as a first physical energy conversion, a second physical energy conversion, and followed by a first and a second chemical energy conversion.
To utilize the dual powering system, a fuel's physical and chemical properties are both changed to generate an amount of force or electricity, such that the fuel is able to be used at least twice to generate energy needed. The systems and methods are advantageous in many aspects including that the system and method are able to generate more energy for each unit amount of the fuel comparing to the typical engines. The present invention is able to be used at a Stationary Engine working on liquid nature gas, which can be a fuel for Peakers (Peaking Power Plant).
In operation, a fuel is adjusted to have a predetermined pressure, passed through a power generation turbine, and transported to a combustion chamber to further generate more energy. The energy is able to be stored or used to power a movement of a motor vehicle.
The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto. It is readily apparent to one skilled in the art that other various modifications are able to be made in the embodiment chosen for illustration without departing from the spirit and scope of the invention as defined by the claims.
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An engine for propelling vehicles on land, in the air and on the water. The engine is able to extract energy from a same fuel twice, including extracting a first amount of energy with a gas turbine and a second amount of energy by burning the fuel in a combustion engine.
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BACKGROUND OF THE INVENTION
At present there is no effective method that can be used to quickly and efficiently construct defensive perimeters under battle conditions. The current method of digging protective foxholes requires the individual combat soldier to use a pick and shovel or a shovel only. This method is painfully slow and although extremely difficult when digging in normal density soils, it is almost impossible to accomplish with any measure of safety, when an attempt is made to dig in hardpan. The Mobile Foxhole Excavator has been designed to efficiently and speedily establish defensive combat perimeters. This equipment maintains the same mobility as the vehicle on which it is mounted and in addition to the tremendous advantage of speed in performing its excavating job, it releases highly trained specialists to perform their vital assignments. This invention will significantly reduce battle casualties by adding the explosion containment shaft, materially improving the normal foxhole protection.
SUMMARY OF THE INVENTION
This invention is a mobile foxhole excavator for use in battle defense construction and is also a general purpose earth boring apparatus. It is consists of a mast structure containing an earth boring auger and various positioning and adjusting means. It is designed to be installed on an all-terrain transporting and positioning vehicle that is standard armed forces equipment, such as an all-wheel drive or tracked vehicle. It can easily bore foxholes in virtually any soil including hardpan surfaces, subsoil containing rocks and gravel, loose dirt, and sand. It produces uniform foxholes for perimeter defense at a rate infinitely faster than personnel using hand tools.
It can also bore holes as needed for material storage, garbage dumps, latrines, tank traps, mines, explosive charges, footings for bunkers, planting posts and poles, etc., using special augers, the Excavator can bore holes in asphalt, concrete, rock and wood for purposes of construction, demolition, repair or any other purpose.
The positioning and adjusting actuators make the auger mast into an extremely versatile boring arm, capable of reaching outward from its supporting vehicle and boring holes at any angle from vertically downward up to the horizontal and at any overhead angle up to the near-vertical. It can also reach across barriers of moderate height and bore holes on the side opposite that on which the vehicle is located.
These characteristics give the MFE the capability of boring holes in difficult locations and hard-to-reach spaces, as may be required, given a particular set of circumstances. In addition they render the machine capable of shrinking its size to permit passage through narrow or restricted areas.
In operation, a driver positions the transport vehicle in a convenient position at the desired location of the hole to be bored. The operator sits at a control console to position and adjust the auger mast for drilling; the mast is set at the required angle and ground contact position and the hole is bored to the desired depth. The auger mast is then retracted for ground clearance and the driver moves the transport vehicle to the desired position for the next hole. In the new position, the operator makes any required adjustments in the auger mast position and angle, and the new hole is bored.
The principal object of this invention is to provide an efficient and time saving apparatus for excavating foxholes mechanically rather than by hand under combat conditions and to reduce reduce casualties. This is accomplished by means of several inter-related and connected mechanical and hydraulic devices embodied in a machine which bores foxholes to establish defense perimeters in a very timely manner. It also frees personnel from manual digging operations to do other expedient and necessary tasks such as scouting patrols, manning observation posts and securing their positions.
Another object is to provide an apparatus which permits boring holes at any angle from vertical to horizontal.
Another object is to provide an apparatus which permits boring holes at any and all overhead angles between the horizontal and the near-vertical upward direction.
Still another object is to provide a machine that can adjust its boring mast from the travel position, inclined at about 30 degrees above the horizontal, to the horizontal position in order to compact its bulk and permit movement through low clearance areas.
Another object is to provide an apparatus which can adjust its boring mast to an acceptable angle of elevation and extend it to a suitable length such that it can reach the tops of certain kinds of defensive barricades.
Another object is to provide an apparatus which has a staircase incorporated into its mast in its extended condition, over which fully equipped combat troops can run with hands free during offensive actions.
A further object of the invention is to provide a machine which can bore holes in uneven ground or on very steep slopes.
An even further object is to provide an apparatus which is capable of vertically lifting its support frame so as to permit motion up or down a slope and of boring holes at any elevation on the slope and at any desired angle into the slope.
Another object of the invention is to provide a machine to bore an explosion containment shaft into the bottom of the foxhole.
Still another object of the invention is to provide an apparatus which cuts a foxhole floor with a stepped slope leading to that shaft.
Yet another object of the invention is to provide an apparatus which bores an improved foxhole with an explosion containment shaft centered in its bottom, and a stepped slope leading to that shaft, in a one-step operation.
Another object of this invention is to provide a machine for constructing traps of various military applications such as tank and personnel traps.
BRIEF DESCRIPTION OF THE DRAWINGS
NOTE: Drawings are referenced to the operator's viewpoint and position.
FIG. 1 is a right side elevation view of a typical mobile foxhole excavator fabricated according to the current invention and mounted on a military transport and positioning vehicle.
FIG. 2 is a front elevation view of the auger mast portion of the apparatus in FIG. 1.
FIG. 3 is a left side elevation view of the base plate assembly of the apparatus in FIG. 1.
FIG. 4 is a top plan view of the pivot support for the base plate of the apparatus in FIG. 1.
FIG. 5 is a top plan view of the base plate assembly of the apparatus in FIG. 1.
FIG. 6 is a left side elevation view of the stair step mechanism in the auger mast of the FIG. 1 apparatus.
FIG. 7 is a right side elevation view of the auger mast support and positioning frame of the apparatus in FIG. 1.
FIG. 8 is a rear elevation view of the FIG. 1 apparatus mounted on a typical military vehicle for transport and positioning.
FIG. 9 is a block diagram of a typical control console and hydraulic system utilized on the apparatus of FIG. 1.
FIG. 10 is a right side elevation view of a staircase built into the auger mast of the FIG. 1 apparatus per the present invention and set up for scaling a barrier.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a representative mobile foxhole excavator (FIGS. 2 and 7) fabricated per the present invention, is disclosed in compact horizontal position to accommodate restricted passage. It is illustrated mounted on a typical military vehicle 77 (FIG. 1) for transport and positioning purposes. Auger mast 16, with augers 71 and 72, lateral tilt cylinder 34, mounting bracket 27, and mast crown 23, extends over top of vehicle. Hydraulic motor 8, cylinder mounting bracket 40, vertical positioning cylinder 33, frame elevation cylinder 36, and pivot arm 15, are shown. The locations of internal combustion engine 20, hydraulic pump 19, frame alignment cylinder 37, control console 21, and crank assembly 42, are indicated.
As shown in FIG. 2, the apparatus consists of an auger mast 16, containing a drive shaft 60, mast crown 23, sprocket assembly 26, roller chain anchors 52, roller chains 78, roller chain anchors 79, vertical mast positioning arms 15, base plate pivot support assembly 14, hydraulic motor mounting plate assembly 1 with integral stress distribution support members 2, 3, 4, 5, 6 and 7, cylinder mounting brackets 18, auger mast pivot support frame 11, base plate 10, transmission 9, sprocket assembly 17, auger actuating cylinder 35, translating roller chain and sprocket crosshead assembly 24, translating drive shaft pressurizing crosshead assembly 25, cylinder mounting bracket 27, lateral tilt adjusting cylinder 34, and cylinder mounting bracket 28.
In FIG. 3, the base plate assembly is illustrated. The hydraulic motor 8 is attached to mounting plate 1, supported by stress distribution members 2, 3, 4, 5, 6, and 7; transmission 9 is held by transmission pivot support assembly 13; auger mast 16 is held by the auger mast pivot support frame 11; base plate 10 and transmission assembly is supported by the base plate pivot support assembly 14; auger mast 16 is raised and lowered for required positioning by auger mast vertical positioning arms 15.
A top plan view of FIG. 3, except for base plate, is shown as FIG. 4. Pivot support assembly 14, transmission pivot support assembly 13, hydraulic motor mounting plate 1, stress distribution support members 2, 3, 6 and 7, and auger mast pivot support frame 11 are shown on this drawing.
FIG. 5 illustrates the base plate 10, showing auger mast 16, sprocket assembly 17, and auger actuating cylinder mount 18.
FIG. 6 shows stair step actuating assembly, with mast crown 23, auger mast 16, staircase 76, stair step 31, stair step mounting pivot 32, stair step actuating rod 30, stair step actuating cylinder 12, and cylinder mount 46.
FIG. 7 reveals the following details: the auger mast support and positioning frame 74, sliding frame extension 49, connected to 74 by frame extension cylinder 59, frame alignment cylinder 37, floor mount 45 for cylinder 37, pivot link 39, pivot guide plate 29, rotation links 38 and 44, rotation arcs 48, 50 and 51, crank assembly 42, elbow 43, frame elevation cylinder 36, cylinder mounting bracket 40, frame support pivot 41, frame support buttress 54, mounting floor plate 55, vehicle to floor plate mounts 56 and 57, frame cross support 53, and frame extension cylinder mount 58.
In FIG. 8, a rear elevation view is given of the apparatus of the present invention mounted on a typical military all-wheel drive vehicle 77 for transport, positioning, and earth boring operations. Auger drive shaft 60, transmission 9, auger mast pivot support frame 11, sliding frame extension 49, cylinder mounting bracket 40, frame elevation cylinder 36, frame support pivot 41, hydraulic outrigger support 69, operator seat 22, and crank assembly 42 are shown.
FIG. 9 is a schematic drawing of a typical control system for the present invention. Control 70 starts internal combustion engine power source 20 which drive hydraulic pump 19, supplying pressurized fluid to hydraulic reservoir 80; other controls are frame stair step control 81, left outrigger control 61, right outrigger control 62, auger control 63, hydraulic motor control 64, auger mast vertical control 65, auger mast tilt control 66, frame alignment control 67, frame extension control 68, mast stair step control 73, and frame elevation control 75.
FIG. 10 depicts a typical MFE construction of the present invention mounted on a typical military vehicle 77, set up with staircase 76 deployed for barrier scaling. Mast crown 23, auger mast 16, cylinder mounting bracket 27, lateral tilt adjusting cylinder 34, auger mast vertical positioning arm 15, hydraulic motor 8, sliding frame extension 49, auger mast support and positioning frame 74, and frame elevation cylinder 36, are shown; and locations of internal combustion engine power source 20, hydraulic pump 19, and crank assembly 42, are indicated, all in correct relation.
OPERATING THE MOBILE FOXHOLE EXCAVATOR (MFE)
1. Boring A Vertical Downward Hole: The transport vehicle 77 (FIG. 1) positions the Mobile Foxhole Excavator on the predetermined defense perimeter layout for foxholes, or for other required hole positions, located as needed. The operator engages control 70 (FIG. 9) to start the internal combustion engine power source 20 and the hydraulic pump 19 (FIG. 1), which is direct-driven by the engine output shaft; engages the outrigger support controls 61 and 62 on control console 21 (FIG. 9), moving outrigger supports 69 (FIG. 8) into position to stabilize the transport vehicle and MFE: moves control 65 (FIG. 9) for the vertical positioning cylinders 33 (FIG. 1), engaging positioning arms 15 (FIGS. 1 and 3) for base plate pivot support assembly (FIG. 4), bringing auger mast 16 (FIGS. 1, 3, and 5) into the vertical position: engages control 63 on control panel 21 (FIG. 9) for auger actuating cylinder 35 (FIG. 2), bringing continuous downward pressure to bear on the auger drive shaft 60 (FIGS. 2 and 8) making ground contact with auger 72 (FIG. 1): engages control 64 (FIG. 9), activating hydraulic motor 8 (FIG. 1), empowering auger drive shaft 60 (FIG. 8) through transmission 9 (FIG. 2) to rotate auger 72 (FIG. 1) and bore hole to desired depth. Control 63 (FIG. 9) is reversed to retract the auger 72 (FIG. 1) from the hole to its rest position: increasing pressure on control 64 (FIG. 9) spins auger 72 (FIG. 1) at a high rotational speed and disperses the material removed from the hole in a uniform berm about the periphery of the hole. The auger is clear of the ground in its rest position and the driver moves the transport vehicle to the location of the next hole.
2. Boring An Improved Foxhole On Generally Level Ground: The transport vehicle driver positions the MFE in the predetermined defense perimeter location. The operator engages control 70 (FIG. 9) to start the internal combustion engine power source 20 (FIG. 9) which uses its output shaft to continuously drive the hydraulic pump 19 (FIG. 1). The operator next engages controls 61 and 62 on control console 21 (FIG. 9), moving outrigger supports 69 (FIG. 8) into position to stabilize the transport vehicle and MFE: operator moves control 65 (FIG. 9) for the vertical positioning cylinders 33 (FIG. 1): engaging positioning arms 15 (FIGS. 1 and 3) on base plate pivot support assembly (FIG. 4) and bringing auger mast 16 (FIGS. 1, 3, and 5) into the vertical position: activates control 67 (FIG. 9) energizing frame alignment cylinders 37 (FIGS. 1 and 7) connected to pivot 39, raising link 44 (FIG. 7) and lowering link 38 (FIG. 7) through circular arc 48 (FIG. 7). This action locks elbow 43 in the upright position and aligns the auger mast 16 (FIG. 7) with the axis of the transport vehicle 77, which on level ground is horizontal. Operator engages control 75 (FIG. 9), operating frame elevation cylinder 36, (FIG. 7), lifting frame 74 (FIG. 7) to the extent necessary for ground clearance of the two-stage auger 71 and 72 (FIG. 1): engages control 65 (FIG. 9), activating mast vertical positioning cylinders 33 (FIG. 7), bringing mast into vertical position: engages control 63 on control panel 21 (FIG. 9) for auger actuating cylinder 35 (FIG. 2), bringing continuous downward pressure to bear on augers 71 and 72 (FIG. 1) and making ground contact with auger 71: engages control 64 (FIG. 9), activating hydraulic motor 8 (FIG. 1), empowering auger drive shaft 60 (FIGS. 2 and 8) through transmission 9 (FIG. 2), rotating augers 71 and 72 (FIG. 1), thus boring an improved foxhole, which includes a centrally located explosion containment shaft (ECS), to the desired depth.
3. Boring An Improved Foxhole On A Stepped Elevation Or A Sloping Surface: The procedure for this operation is identical to that of Operation 2, above, with the following exceptions: with the transport vehicle 77 (FIG. 1) in proper location and with outriggers 69 (FIG. 8) deployed for stability of the vehicle and MFE, operator activates control 67 (FIG. 9), energizing frame alignment cylinders 37 (FIG. 7) and bringing auger mast 16 (FIG. 1) into the horizontal position: activates control 68 (FIG. 9) energizing frame extension cylinder 59 (FIG. 7), moving frame extension 49 (FIG. 7) outward to position auger mast 16 over desired position on surface. Boring operation proceeds as in operation 2, above.
4. Boring A Hole At Any Angle Between The Vertical Downward And The Horizontal: Driver positions the transport vehicle 77 (FIG. 1) in the desired location. Operator engages control 70 (FIG. 9) to start the internal combustion engine power source 20 and hydraulic pump 19 (FIG. 1): deploys outriggers 69 (FIG. 8), stabilizing vehicle and MFE: engages control 65 (FIG. 9), for vertical positioning cylinders 33 (FIG. 1): engaging vertical positioning arms 15 (FIGS. 1 and 3) on base plate support assembly (FIG. 4), bringing auger mast 16 (FIGS. 1, 3 and 5) into the vertical position: activates control 67 (FIG. 9), energizing frame alignment cylinder 37 (FIGS. 1 and 7) connected to pivot 39 (FIG. 7), rotating links 38 and 44 (FIG. 7), through part of circular arc 48, stopping auger mast 16 at the desired angle for boring. If necessary, operator engages control 68 (FIG. 9), actuating frame extension cylinder 59 (FIG. 7) and sliding frame extension 49 (FIG. 7) to place auger mast 16 precisely over the desired hole location. Then operator engages control 65 (FIG. 9), empowering auger cylinder 35 (FIGS. 2 and 8), translating auger 72, or augers 71 and 72, to the ground and exerting continuous pressure on them: engages control 64, energizing hydraulic motor 8, which turns auger power shaft 60 through transmission 9, rotating auger 72, or auger 71 and 72, and boring to the desired depth and at the desired angle.
5. Boring a Hole At Any Angle Between The Horizontal and the Near-Vertical Upward Direction: Driver positions transport vehicle 77 (FIG. 1) in the desired location. Operator engages control 70 (FIG. 9) to start the internal combustion engine power source 20 and hydraulic pump 19 (FIG. 1): deploys outriggers 69, stabilizing vehicle and MFE: engages control 67 (FIG. 9) for frame alignment cylinders 37 (FIG. 7): engaging pivot 39, rotating links 38 and 44 through circular arc 48 (FIG. 7), locking elbow 43 and bringing auger mast into axial alignment with transport vehicle: control 67 (FIG. 9), actuating frame alignment cylinder 37 (FIG. 7) and control 75 (FIG. 9), actuating frame elevation cylinder 36 (FIG. 7) are employed as required to place auger mast support and positioning frame 74 (FIG. 7) at desired angle of elevation for positioning auger mast. Operator actuates control 68 (FIG. 9), energizing frame extension cylinder 59, to side frame extension 49 (FIG. 7) to necessary length to place auger mast in desired position: engages control 65 (FIG. 9), activating vertical positioning cylinders 33 (FIG. 1), and lifting auger mast 16 (FIG. 1) to desired elevation angle. Operator now makes any minute adjustments with controls as described above to exactly position auger mast 16 at the angular orientation and physical location of hole to be bored. Then operator engages control 63 (FIG. 9), energizing auger actuating cylinder 35 (FIG. 8), extending auger 72, or augers 71 and 72 (FIG. 1), making contact with surface and maintaining continuous pressure on auger: engages control 64 actuating hydraulic motor 8 and bore hole as in operations 1, 2 and 3.
6. Boring Holes Across Obstacles: The driver positions the transport vehicle as near to the obstacle as is practical. The MFE operator, with the power source in operation, activates control 67 (FIG. 9), energizing frame alignment cylinders 37, (FIG. 7), engaging pivot 39, rotating links 38 and 44, through circular arc 48 (FIG. 7): activates control 65 (FIG. 9), energizing vertical positioning cylinders 33 (FIG. 1), to lift auger 72 (FIG. 1); and engages control 75 (FIG. 9), energizing the frame elevation cylinders 36 (FIG. 7), as required, to get elevation clearance of obstacle. Operator engages control 68 (FIG. 9), energizing frame extension cylinder 59 (FIG. 7), sliding frame extension 49 (FIG. 7), and extending auger mast 16 across obstacle. If necessary, the driver carefully moves the vehicle closer to the obstacle. When the auger mast is across the obstacle, operator actuates controls 61 and 62, deploying hydraulic outrigger supports 69, stabilizing vehicle and MFE: activates control 65, energizing vertical positioning cylinders 33, rotating auger mast 16 to the desired angle for boring: engages control 63, energizing auger actuating cylinder 35, extending the auger to contact ground and maintain continuous pressure on it: engages control 64 energizing hydraulic motor 8 and boring holes as in operations 1, 2, 3 and 4, above.
7. Deploying Barrier Scaling Staircase: With auger mast 16 in the travel position, approximately 30 degrees above horizontal, and with the auger removed from the mast, the driver places the transport vehicle at a convenient location near the barrier, with the MFE facing the barrier and perpendicular to it. With power source 20 in operation, the operator engages controls 61 and 62 (FIG. 9), to energize hydraulic outrigger supports 69 (FIGS. 8 and 10)), positioning them as required to stabilize the vehicle: engages control 75 (FIG. 9), energizing frame elevation cylinder 36, raising auger mast support and positioning frame 74 (FIG. 7) to desired angle of elevation: engages control 65 (FIG. 9), activating vertical positioning cylinders 33 to raise auger mast 16 (FIG. 1), and align it with frame 74. Operator activates control 68 (FIG. 9), energizing frame extension cylinder 59, and sliding frame extension 49, moving auger mast crown 23 into supportive contact with breastwork of barrier. Operator now engages frame stair step control 81, activating stair step cylinders 12, moving stair step actuating rod 30, and adjusting stair steps 31 on frame to proper angle for use: engages mast stair step control 73, activating stair step cylinder 12, moving actuating rod 30, and adjusting stair steps 31 on mast to proper angle for use. Scaling staircase 76 (FIG. 10) is now deployed and ready for use.
8. Adjusting the MFE to Compact Form For Travel Through Restricted Clearance Areas: With the auger mast 16 in travel position, approximately 30 degrees above horizontal, and with power source 20 running, operator engages control 67, energizing frame alignment cylinders, and lowering auger mast 16 to the horizontal position over the top of the transport vehicle 77. This is the smallest cross-sectional area configuration of the MFE and permits passage through tight areas.
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A mobile foxhole excavator (MFE) is mounted on a standard military vehicle for transport and positioning. The excavator is powered by a self-contained internal combustion engine, which powers a hydraulic system for positioning an auger mast in three mutually perpendicular planes (horizontal, vertical and lateral) to permit the auger to bore holes at any desired angle between vertical, downward, and horizontal, as well as boring at various overhead angles between horizontal and near vertical. A single hydraulic motor is used to operate the boring auger, as well as various hydraulic cylinders to effect the desired positioning of the auger mast.
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BACKGROUND OF THE INVENTION
[0001] In-vehicle telematics systems provide an increasingly broad spectrum of services to users, such as entertainment, emergency notification, and so on. However, one of the most popular services provided by such systems is still navigational assistance. In this role, the telematics unit receives or generates a route starting point and a route ending point, and then generates a series of directions for taking the user from the starting point to the ending point. Since the user is most often in a road vehicle, the directions often take the form of directions to take certain roads for certain distances or until certain turning points. These are sometimes referred to as turn-by-turn directions.
[0002] For such directions to be optimally effective, however, it is important for the telematics device to have an awareness of current roads and their availability. For example, when a new roadway has been added to the road system, this may provide a better route for a given trip, and should be available for routing in that case. Similarly, when a road has been removed or moved, this information is also important in providing correct and efficient navigational assistance to a user.
[0003] While road moving/removal and road addition changes have been traditionally accounted for by way of map update packages, one class of road changes remains difficult to account for. In particular, temporary road closures are of too immediate an effect and too short a duration to be included in map update packages. Moreover, real-time road closure information is rarely publicly and widely disseminated. At the same time, an unknown temporary road closure can have a significant negative impact on a user's navigation experience.
[0004] Moreover, when a road is known to have been closed, the subsequent reopening of that road may allow more efficient routing of telematics users. However, as with road closure information, road reopening information is also not routinely widely available for consideration by telematics units in calculating turn-by-turn directions. Thus, a system and method are needed for enabling a vehicle telematics device to become aware of temporary road closures and subsequent reopenings.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention provides a system and apparatus for enabling a vehicle telematics device to detect and account for temporary road closures and reopenings. The invention operates to the benefit of users who would use the road if it were known to have been reopened. The described process operates without direct observation of the road condition, since road condition information is difficult to obtain by direct means, i.e., checking schedules of road crews or events, engaging in physical observation of the road itself, soliciting informal reports of road conditions by users, etc.
[0006] In an aspect, the described principles allow the system and method to automatically detect when a closed road has reopened while minimizing inconvenience to the population of route guidance users that would use that road if it were open. An analysis of the characteristics of alternate routes and the route with the closed road is used in one implementation of the invention to minimize the inconvenience to potential users of that road.
[0007] In one implementation, an optimal route between the geographic origination location and the geographic destination location is identified, along with a replacement route and a recovery route. While the optimal route assumes that the potentially closed road is open, the replacement route assumes that the potentially closed road is closed. The recovery route matches the optimal route between the geographic origination location and the potentially closed road, and then differs from the optimal route thereafter to avoid the potentially closed road. This implementation tests the status of the potentially closed road by sending a predetermined fraction of users along the optimal route, and sending users other than the predetermined fraction on the replacement route. If a reroute request is received from a user on the optimal route, the potentially closed road is assumed to be closed still, and the user is rerouted to the recovery route.
[0008] Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] FIG. 1 is a schematic diagram of an operating environment for a mobile vehicle communication system within which the described principles may be implemented;
[0010] FIG. 2 is a schematic illustration of an example turn-by-turn route;
[0011] FIG. 3 is a schematic illustration of an example turn-by-turn route showing a road closure within the route, with respect to which the present rerouting system may be applied;
[0012] FIG. 4 is a schematic illustration of an example turn-by-turn route showing a road closure within the route and a recovery route;
[0013] FIG. 5 is a schematic illustration of an example turn-by-turn route showing a road closure within the route and a replacement route; and
[0014] FIG. 6 is flow chart illustrating a process of detecting and remedying a road closure condition such as that illustrated by FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0015] Before discussing the details of the invention and the environment wherein the invention may be used, a brief overview is given to guide the reader. In general terms, not intended to limit the claims, the invention is directed to a system for automatically detecting and remedying a road closure through turn-by-turn routing requests and reroute requests. The system also allows the detection of a road reopening when a closed road has reopened while minimizing inconvenience to the population of route guidance users that would use that road if it were open. An analysis of the characteristics of alternate routes and the route with the closed road allows the system to minimize the inconvenience to potential users of that road while still allowing timely detection of road closure and opening status.
[0016] Given this overview, an exemplary environment in which the invention may operate is described hereinafter. It will be appreciated that the described environment is an example, and does not imply any limitation regarding the use of other environments to practice the invention. With reference to FIG. 1 there is shown an example of a communication system 100 that may be used with the present method and generally includes a vehicle 102 , a wireless carrier system 104 , a land network 106 and a call center 108 . It should be appreciated that the overall architecture, setup and operation, as well as the individual components of a system such as that shown here are generally known in the art. Thus, the following paragraphs simply provide a brief overview of one such exemplary information system 100 ; however, other systems not shown here could employ the present method as well.
[0017] Vehicle 102 is preferably a mobile vehicle such as a motorcycle, car, truck, recreational vehicle (RV), boat, plane, etc., and is equipped with suitable hardware and software that enables it to communicate over system 100 . Some of the vehicle hardware 110 is shown generally in FIG. 1 including a telematics unit 114 , a microphone 116 , a speaker 118 and buttons and/or controls 120 connected to the telematics unit 114 . Operatively coupled to the telematics unit 114 is a network connection or vehicle bus 122 . Examples of suitable network connections include a controller area network (CAN), a media oriented system transfer (MOST), a local interconnection network (LIN), an Ethernet, and other appropriate connections such as those that conform with known ISO, SAE, and IEEE standards and specifications, to name a few.
[0018] The telematics unit 114 is an onboard device that provides a variety of services through its communication with the call center 108 , and generally includes an electronic processing device 128 one or more types of electronic memory 130 , a cellular chipset/component 124 , a wireless modem 126 , a dual antenna 160 and a navigation unit containing a GPS chipset/component 132 . In one example, the wireless modem 126 is comprised of a computer program and/or set of software routines executing within processing device 128 . The cellular chipset/component 124 and the wireless modem 126 may be called the network access device (NAD) 180 of the telematics unit 114 .
[0019] The telematics unit 114 provides too many services to list them all, but several examples include: turn-by-turn directions and other navigation-related services provided in conjunction with the GPS based chipset/component 132 ; airbag deployment notification and other emergency or roadside assistance-related services provided in connection with various crash and or collision sensor interface modules 156 and sensors 158 located throughout the vehicle. Infotainment-related services where music, Web pages, movies, television programs, video games and/or other content is downloaded by an infotainment center 136 operatively connected to the telematics unit 114 via vehicle bus 122 and audio bus 112 . In one example, downloaded content is stored for current or later playback.
[0020] Again, the above-listed services are by no means an exhaustive list of all the capabilities of telematics unit 114 , as should be appreciated by those skilled in the art, but are simply an illustration of some of the services that the telematics unit 114 is capable of offering. It is anticipated that telematics unit 114 include a number of known components in addition to those listed above.
[0021] Vehicle communications preferably use radio transmissions to establish a voice channel with wireless carrier system 104 so that both voice and data transmissions can be sent and received over the voice channel. Vehicle communications are enabled via the cellular chipset/component 124 for voice communications and a wireless modem 126 for data transmission. In order to enable successful data transmission over the voice channel, wireless modem 126 applies some type of encoding or modulation to convert the digital data so that it can communicate through a vocoder or speech codec incorporated in the cellular chipset/component 124 . Any suitable encoding or modulation technique that provides an acceptable data rate and bit error can be used with the present method. Dual mode antenna 160 services the GPS chipset/component and the cellular chipset/component.
[0022] Microphone 116 provides the driver or other vehicle occupant with a means for inputting verbal or other auditory commands, and can be equipped with an embedded voice processing unit utilizing a human/machine interface (HMI) technology known in the art. Conversely, speaker 118 provides verbal output to the vehicle occupants and can be either a stand-alone speaker specifically dedicated for use with the telematics unit 114 or can be part of a vehicle audio component 154 . In either event, microphone 116 and speaker 118 enable vehicle hardware 110 and call center 108 to communicate with the occupants through audible speech. The vehicle hardware also includes one or more buttons or controls 120 for enabling a vehicle occupant to activate or engage one or more of the vehicle hardware components 110 . For example, one of the buttons 120 can be an electronic push button used to initiate voice communication with call center 108 (whether it be a live advisor 148 or an automated call response system). In another example, one of the buttons 120 can be used to initiate emergency services.
[0023] The audio component 154 is operatively connected to the vehicle bus 122 and the audio bus 112 . The audio component 154 receives analog information, rendering it as sound, via the audio bus 112 . Digital information is received via the vehicle bus 122 . The audio component 154 provides AM and FM radio, CD, DVD, and multimedia functionality independent of the infotainment center 136 . Audio component 154 may contain a speaker system, or may utilize speaker 118 via arbitration on vehicle bus 122 and/or audio bus 112 .
[0024] The vehicle crash and/or collision detection sensor interface 156 are operatively connected to the vehicle bus 122 . The crash sensors 158 provide information to the telematics unit 114 via the crash and/or collision detection sensor interface 156 regarding the severity of a vehicle collision, such as the angle of impact and the amount of force sustained.
[0025] Vehicle sensors 162 , connected to various sensor interface modules 134 are operatively connected to the vehicle bus 122 . Example vehicle sensors include but are not limited to gyroscopes, accelerometers, magnetometers, emission detection and/or control sensors, and the like. Example sensor interface modules 134 include power train control, climate control, and body control, to name but a few.
[0026] Wireless carrier system 104 is preferably a cellular telephone system or any other suitable wireless system that transmits signals between the vehicle hardware 110 and land network 106 . According to an example, wireless carrier system 104 includes one or more cell towers 138 , base stations and/or mobile switching centers (MSCs) 140 , as well as any other networking components required to connect the wireless system 104 with land network 106 . A component in the mobile switching center may include a remote data server 180 . As appreciated by those skilled in the art, various cell tower/base station/MSC arrangements are possible and could be used with wireless system 104 . For example, a base station and a cell tower could be co-located at the same site or they could be remotely located, and a single base station could be coupled to various cell towers or various base stations could be coupled with a single MSC, to but a few of the possible arrangements. Preferably, a speech codec or vocoder is incorporated in one or more of the base stations, but depending on the particular architecture of the wireless network, it could be incorporated within a Mobile Switching Center or some other network components as well.
[0027] Land network 106 can be a conventional land-based telecommunications network that is connected to one or more landline telephones and connects wireless carrier network 104 to call center 108 . For example, land network 106 can include a public switched telephone network (PSTN) and/or an Internet protocol (IP) network, as is appreciated by those skilled in the art. Of course, one or more segments of the land network 106 can be implemented in the form of a standard wired network, a fiber or other optical network, a cable network, other wireless networks such as wireless local networks (WLANs) or networks providing broadband wireless access (BWA), or any combination thereof.
[0028] Call Center (OCC) 108 is designed to provide the vehicle hardware 110 with a number of different system back-end functions and, according to the example shown here, generally includes one or more switches 142 , servers 144 , databases 146 , live advisors 148 , as well as a variety of other telecommunication and computer equipment 150 that is known to those skilled in the art. These various call center components are preferably coupled to one another via a network connection or bus 152 , such as the one previously described in connection with the vehicle hardware 110 . Switch 142 , which can be a private branch exchange (PBX) switch, routes incoming signals so that voice transmissions are usually sent to either the live advisor 148 or an automated response system, and data transmissions are passed on to a modem or other piece of equipment 150 for demodulation and further signal processing.
[0029] The modem 150 preferably includes an encoder, as previously explained, and can be connected to various devices such as a server 144 and database 146 . For example, database 146 could be designed to store subscriber profile records, subscriber behavioral patterns, or any other pertinent subscriber information. Although the illustrated example has been described as it would be used in conjunction with a manned call center 108 , it will be appreciated that the call center 108 can be any central or remote facility, manned or unmanned, mobile or fixed, to or from which it is desirable to exchange voice and data.
[0030] Turning to the details of an exemplary system operating within the described environment, FIG. 2 is a schematic illustration of a simple example turn-by-turn navigation route 200 to travel from an origination point 201 to a destination point 203 . The route 200 is made up of travel segments 205 - 217 . Each segment 205 - 217 represents a section of road way, also referred to herein as a road. Thus, references to road closure are referring to closure of section of the roadway in a way that that section cannot be traveled in at least the direction that the user would need to travel to complete the route 200 .
[0031] FIG. 3 shows the turn-by-turn navigation route 300 , which is the same as route 200 , but with a certain road 311 ( 211 ) closed. Thus, the user cannot complete the illustrated route 300 because they cannot travel on or past road 311 ( 211 ). In this case, the guidance provided by the route 300 ( 200 ) is inaccurate and is not useful to the user of the system.
[0032] Depending upon where a user is when the road closure condition is discovered, the system may provide either a recovery route or a replacement route. The recovery route is used when the user has traversed the original route for a substantial portion, e.g., up to the point of closure, and then requests a new route from that intermediate point to the destination. The replacement route is an alternative route between the origination point and the destination point, and is used if the road closure condition is known before routing instructions are calculated for the user.
[0033] Referring now to FIG. 4 , the original route 300 ( 200 ) is still shown visible, but a recovery route including a recovery portion 419 is also shown. The recovery portion 419 extends from the point 421 where the original route is blocked by the road closure, and extends by way of several segments to the destination point 403 . In the illustrated example, the recovery route, including the portion of the original route prior to the point 421 and the recovery portion 419 after the point 421 , is less preferred due to length of travel. Indeed, the recovery route will generally be less preferable than the original route based on travel time and/or speed. However, in some cases, the recovery route will be no less preferred than the original route. As noted above, the recovery route is utilized when the user has traversed the original route for a substantial portion and then requests a new route from some intermediate point, prior to the closed road, to the destination.
[0034] As also noted, when the road closure condition is known before routing instructions are calculated for the user, the user can be given a replacement route rather than a recovery route. The replacement route can be optimized from the origination point to the destination point, rather than for just part of the route as in FIG. 4 .
[0035] In FIG. 5 the original route 300 ( 200 ) is still visible, but a replacement route 500 is also shown. The replacement route 500 extends from the origination point 501 to the destination point 505 . As can be seen, the replacement route 500 entails a greater driving distance than the original route. However, it bypasses the closed road 511 and is generally also at least as preferable as, and generally more preferable than, the recovery route.
[0036] Thus, a telematics device will be able to provide more accurate and efficient directions if it can acquire information regarding the availability of known roads, i.e., where there is a temporary road closures or a subsequent reopening after such a closure, prior to generating a turn-by-turn route. In one aspect of the described principles, a call center associated with the telematics unit deduces the identity of a closed road and an approximate starting time of closure by making certain computations relative to reroute requests in the area.
[0037] In particular, when turn-by-turn directions are provided prior to knowledge of the road closure condition, the user will follow the given directions until reaching the closed road. At that point, the user will generally ask for a reroute around the closed road, causing the telematics unit, via the call center, to generate a recovery route as noted above. While isolated reroute requests are not necessarily indicative of a road problem, a cluster of such requests may be used to indicate that at least the leg of the journey immediately following the location where the reroute request is made is closed.
[0038] With this in mind, the details of the innovative method and system are further elucidated with reference to FIG. 6 , which illustrates a flowchart of a process 600 for making route decisions in the presence of a possible road closure occurrence. The process 600 begins at stage 601 , wherein the call center 108 monitors reroute requests to detect any closed roads based on such requests. If a reroute request from a closed road is not detected at stage 603 , the process reverts to stage 601 and continues to monitor.
[0039] If instead a reroute request is detected at stage 603 , the process 600 moves forward to stage 605 , wherein the call center 108 determines whether the route request indicates a closed road. In an embodiment of the system, a reroute request is considered to indicate a closed road if it meets all of a set of predetermined criteria. For example, a reroute request may be indicative of a road closure if the request is (a) new relative to the present requester, (b) not in a tunnel, (c) on a road in the right direction, i.e. that is part of the designated route, and (d) a large percentage, i.e., 95-100% of routes with that segment generate a reroute request.
[0040] If the analysis of the reroute request against the predetermined criteria at stage 605 does not indicate a road closure, then the process flows to stage 607 to serve the request normally and returns to stage 601 . If instead the analysis of the reroute request against the predetermined criteria at stage 605 indicates a road closure, then the process flows forward to stage 609 , wherein the affected road segment is designated at the call center 108 as closed for the present reroute request and potentially closed with respect to future reroute requests. Note that the route will not be closed for all other requests, but may be impeded, i.e., used for only a limited number of requests, as will be discussed below.
[0041] At this point, the call center 108 will still serve the request, but will do so in a way that most efficiently accommodates the apparent road closure. Recall from above that there are three possible routes to consider for the origination point/destination point pair. The first is, of course, the old route, i.e., the route that attempted to go through the closed segment. The second route to consider is the new route or replacement route, which is another route between the origination point/destination point pair that may or may not include portion of the old route, but which represents the next best route with the closed segment blocked. The third route to consider is the recovery route, i.e., the route that is used to recover only after the driver has been routed to the closed segment. In some cases, the new route may be the same as the recovery route.
[0042] In general terms, certain facts may be deduced regarding the various routes. For example, the old route, when open, is better than the other routes. Also, the old route is apparently blocked, and there is no indication as to when it will again be available, but it may at some point reopen. The terms better, worse, longer, and shorter are used herein to indicate relative preference between routes. The preference measure may be speed, time length, complexity, or other measure. Typically the measure used is time length, taking into account any user-specific preferences such as toll avoidance etc. Other measures may include dynamic traffic loading or road impedance which characterizes the flow of traffic along a road.
[0043] Continuing with the available deductions, the new route is worse than the old route, and may indeed be much worse in some cases. The recovery route is worse than the old route—perhaps much worse—and it is also equal to or worse than the new route. For purposes of the following stages of the process 600 , a convention of labeling the route quality will be as follows: A label of 0 indicates that the route in question is approximately the same length as the old route, e.g., within a predetermined tolerance such as 5%. A label of 1 is used to indicate that the route in question is longer than the old route. Finally, a label of 2 indicates that the route in question is much longer than the old route, e.g., greater by more than some predetermined tolerance such as 40% by way of example only.
[0044] Thus, at stage 611 , the process 600 calculates the replacement route and a recovery route, and assigns a preference value (e.g., 0, 1, or 2) to each of the old route, replacement route, and the recovery route. Once the routes are known and labeled, the process 600 determines which route to provide based on a set of criteria at stage 613 , keeping in mind that the goal in an implementation is to provide the best route on average for the most users while preserving the ability to detect road reopening. Thus, the route labels are used at stage 613 to select a routing strategy. In particular, different route label triples (Old Route Label/Replacement Route Label/Recovery Route Label) will lead to different strategies.
[0045] Thus, if at stage 613 it is determined that the labels provide a route label triple of (0/0-1-2/0), the process flows to stage 615 , wherein the process 600 follows a strategy of generally providing the recovery route, while occasionally (e.g., a predetermined portion or percentage of the time) providing the old route to test it for reopening by awaiting a reroute request if any. The percentage of use for the old route in this strategy is not critical, but a percentage of about 10% allows an occasional test while avoiding excess user inconvenience. This strategy generally minimizes the inconvenience to users while still allowing some determination as to when the route is no longer blocked.
[0046] Similarly, if at stage 613 it is determined that the labels provide a route label triple of (0/1-2/1) or (0/2/2), the process flows to stage 615 . In the case of a (0/1-2/1) triple, the user inconvenience of rerouting is no greater than if the new route were used from the outset. In the case of a (0/2/2) triple, the new route and recovery route are similarly alike in value. Moreover, in this case, the old route is significantly more beneficial than either of the other routes, making an occasional test worth the user inconvenience even if the route is still blocked.
[0047] If at stage 613 it is determined that the labels provide a route label triple of (0/0/1-2), the process flows to stage 617 , wherein the process 600 follows a strategy of providing the replacement route. Since the replacement route and the old route are essentially equivalent, this strategy avoids inconvenience to users and does not check for the reestablished availability of the old route.
[0048] Similarly, if at stage 613 it is determined that the labels provide a route label triple of (0/1/2), the process flows to stage 617 . In this particular case, this is the only triple that indicates a significant detriment to sending the user on the old route and forcing a reroute if the road is still blocked. This is because the recovery route is both worse than the old route and significantly worse than the new route.
[0049] Once a routing strategy is selected and executed based on the determined route triples, the process returns to stage 601 , wherein the call center 108 continues to monitor reroute requests to detect any closed roads based on such requests.
[0050] Although the process 600 provides some indication as to when the closed road again becomes passable, there are other techniques that are additionally or optionally used to determine this information in one aspect of the described principles. For example, the process 600 may also monitor for the presence of any user vehicle on the link that is thought to be closed, and may designate the link as no longer closed when this occurs. There are number of ways that the presence of a user vehicle on the link may be monitored including checking communications between vehicles and servers, checking for emergency button activation, noting TBT downloads including reroutes, and observing any airbag deployment calls.
[0051] It will be appreciated that the disclosed system and method provide a road closure detection and remediation mechanism, and also allow for timely notice of road reopening, in a way that works especially well with respect to closures that impact large numbers of users and closures with the largest consequences. The process is also scalable and easily implemented via automation, allowing human operators to specifically focus on closures that impact large number of users, have large consequences, and/or have existed for an extended period of time.
[0052] It will also be appreciated, however, that the foregoing methods and implementations are merely examples of the inventive principles, and that these illustrate only preferred techniques. It is contemplated that other implementations of the invention may differ in detail from foregoing examples. As such, all references to the invention are intended to reference the particular example of the invention being discussed at that point in the description and are not intended to imply any limitation as to the scope of the invention more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the invention entirely unless otherwise indicated.
[0053] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0054] Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
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The described principles provide a method and system for identifying a potentially closed road based on reroute requests, and of accommodating the potential road closure while continuing to test the road status periodically via routing decisions and rerouting requests. While the optimal route assumes that the potentially closed road is open, a replacement route is defined assuming that the potentially closed road is closed. A fraction of users are sent along the optimal route, and if a reroute request is received, the potentially closed road is assumed to be closed still. The affected user is rerouted to a recovery route that matches the optimal route up to the potentially closed road, and then differs from the optimal route thereafter to avoid the potentially closed road.
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FIELD OF INVENTION
The present invention is directed to dock structures.
BACKGROUND TO THE INVENTION
Dock structures, particularly floating or standing docks for pleasure craft, conventionally are formed of wood and include a plurality of transversely-extending slats joined to depending parallel side rails and possibly one or more intermediate rails, depending on the width of the dock. The depending side rails are joined to one or more floats, in the case of a floating dock, or to pillars or uprights anchored on the river or lake bed in the case of a standing dock. End rails extending between the side rails also may be provided.
Wooden structures suffer from many disadvantages. In regions where the water body in which the dock is located freezes during the winter months, the dock must be removed from the water to prevent ice damage. Wooden structures are heavy, especially when waterlogged, making removal from the water a difficult operation, especially since the structure must be removed as a single unit.
Wooden structures also degrade rapidly under the exposure to weather and traffic and require replacement from time to time. Broken slats are difficult to replace effectively and to dispose of.
SUMMARY OF INVENTION
In accordance with the present invention, there is provided a dock structure which does not suffer the drawbacks of the prior art structures. The dock structure of this invention has the main structural parts formed of aluminum. The deck members are releasably connected to parallel elongate side rails connected to aluminum end rails, and an aluminum bumper rail having a bumper bar is releasably connected to the side rails. The structure is lightweight, virtually indestructible and may be readily assembled and readily disassembled for removal and storage.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of the end part of a dock structure in accordance with one embodiment of the invention provided in floating dock form;
FIG. 2 is a perspective view, with parts cut away and exploded, showing details of the assembly of the dock of FIG. 1;
FIG. 3 is a detail perspective view of one deck member and connector therefor;
FIGS. 4 and 5 are end views of the connection of a deck member to a side rail;
FIG. 6 is a sectional view taken on line 6--6 of FIG. 1;
FIG. 7 is a sectional view of an alternative bumper rail structure;
FIG. 8 is a plan view of the dock frame structure of the dock structure of FIG. 1;
FIG. 9 is a perspective view of the interconnection of frame structure members in the structure of FIG. 8; and
FIG. 10 is an alternative dock frame structure for use in a dock structure.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, a dock structure 10 comprises a plurality of generally parallel deck members 12 constructed of aluminum releasably connected to a pair of parallel aluminum side rail members 14 extending generally perpendicularly to the deck members 12. Aluminum end rail members 16 extend between and generally perpendicular to the ends of the side rail members 14 and are connected thereto.
The dock frame 17 is completed by an aluminum rail member 18 extending between and connected to the side rail members 14 at the approximate midpoint along their length. In the frame structure of FIG. 8, additional aluminum rails 20 extend parallel to the side rails 14 and are connected between one end rail 16 and the center rail 18 to provide strength and rigidity to the frame 17. In dock frames 17 of lesser width, as shown in FIG. 10, the additional rails 20 may be omitted.
The dock frame 17 comprised of the rail members is rigid and is attached to one or more floats 22. The floats may be of any convenient form, for example, hollow plastic floats. If the dock 10 is a standing structure, the frame 17 is connected to pillars or ground anchors. The invention will be described particularly with reference to a floating dock structure.
Each side rail member 14 has a generally E-shaped cross-section opening outwardly of the dock frame 17 and each end rail member 16 is of generally flat-based C-shaped cross-section opening inwardly of the dock frame 17. Adjacent ends of the side rail members and the end rails 16 are rigidly joined by angle plates 24 which are bolted to both the side rail 14 and the end rail 16 by bolts 26.
The center rail 18 and the additional rails 20, if any, are also of flat-based C-shaped cross-section, but the upper and lower projections of the additional rails 20 are cut away adjacent their ends to allow for entry into the C-shaped cross-section of the end rails 16 and center rail 18.
The center rail 18 is connected at its ends to the side rails 14 by angle plates 26' which are bolted to both the side rail 14 and the center rail 18. The additional rails 20 are connected to the end rails 16 by angle plates 28 which are bolted to both the rails 16 and 20 and to center rail 18 by angle plates 30 which are bolted to both the rails 18 and 20.
Only one of the additional rails 20 need have the upper and lower projections cut away at both ends, while the other need have the projections cut away at the end connected to the end rail 16, since this rail 20 does not project into the opening of the center rail 18. However, for ease of manufacture and assembly, it is preferred to have both additional rails 20 identically constructed, as illustrated.
The aluminum rail members 14, 16, 18 and 20 may be conveniently formed by extrusion, although any desired manufacturing technique may be adopted.
Each end rail 16 has a bumper bar 32 connected thereto in any convenient manner. Usually the bumper bar 32 is of rectangular of square cross-section and constructed of wood, but any other convenient constructional material may be used.
Each side rail member 14 has a vertically-extending web 34 and three integrally-formed projections 36, 38 and 40 therefrom. The projection 36 extends horizontally from the lower end of the web 34 and engages the upper surface of the float 22.
The projection 38 is L-shaped and forms an upwardly-opening channel 42 with the web 34. The projection 40 includes a horizontally-extending portion 44 and an upwardly-opening channel-defining portion 46 at the end of the portion 44 remote from the web 34. The purpose of the channels 42 and 46 will become apparent hereinafter.
The horizontally-extending portion 44 has a plurality of upwardly-extending integrally-formed laterally-thin and longitudinally-extending protrusions 48 equally spaced along the length of each side rail member 14 and equal in number to the number of the deck members 12.
Each of the protrusions 48 is undercut at its ends to define therein shoulders 50 and 52 respectively and undercuts 54 and 56 respectively. While the structure is illustrated with one protrusion 48 at each end for each deck member 12, a plurality of such protrusions 48 may be provided for each deck member 12, for greater strength or rigidity.
Each deck member 12 has a continuous planar surface 58, preferably provided with a non-slip outer surface, which cooperates with other like surfaces to form a planar deck surface to the dock 10. Integral skirt portions 60 and 62 depend from adjacent the lateral sides of the planar surface 58 generally perpendicularly thereto.
At the lower end of each skirt portion 60 and 62 is a shoulder-engaging member 64 and 66 respectively. Each shoulder-engaging member includes a portion projecting inwardly of the skirt 60 or 62 towards the other and a shoulder face-engaging portion. Generally, the shoulder-engaging member 64 projects inwardly a greater distance than the shoulder-engaging member 66 and a distance substantially equal to the depth of the undercut 54.
While the undercuts 54 and 56 have the dimensions and depth approximately equal to the extremity of the shoulder-engaging member 64, this arrangement is for convenience in assembly of the dock 10, allowing the longer shoulder-engaging member 64 to be inserted in either undercut 54 and 56 to engage both the shoulder and end wall of the undercut, so that the arrangement shown in FIGS. 4 and 5 with respect to the relative positions of the shoulder-engaging members 64 and 66, may be attained.
However, if desired, the undercuts 54 and 56 may be dimensioned such that the undercut 54 has a depth at least equal to the maximum distance of extension of the shoulder-engaging member 64 and the undercut 56 has a lesser depth at least equal to the maximum distance of extension of the shoulder-engaging member 66.
Each shoulder 50 and 52 has a sloping outer surface 68 while the surface of the shoulder-engaging member 66 intended to engage the sloping surfaces 58 during assembly, as described below, is bevelled at 70.
The deck members 12 also include a pair of webs 72 depending from the planar surface 58 parallel to the skirt portions 60 and 62 for engagement with the horizontally-extending portion 44. A single such web 72 may be used, if desired, although it is preferred to provide the pair of such webs for strength and stability. Greater numbers of such webs 72 may be used, if desired.
Slots 74 are provided in each of the webs 72 for receiving the protrusion 48 therein. The interaction of the protrusion 48 with the slots 74 constitutes stop means and prevent longitudinal displacement of the deck members 12 relative to the side rails 14 in an assembled dock. In this way, a stable assembly is achieved.
Each deck member 12 has a thickness and size allowing limited flexibility when bent along along its longitudinal center line. This flexibility, the dimensioning of the deck members 12, the dimensioning and shape of the protrusions 48 and the dimensioning of the shoulder-engaging members 64 and 66 combine to provide snap-fit means, readily releasably interlocking the deck members 12 to the side rails 14. The interlocking and releasing of the deck members 12 and side rails 14 is achievable without the use of special tools or skills.
As seen particularly in FIGS. 3 to 5, the deck members 12 are assembled with the side rails 14 at each intersection thereof by inserting the longer shoulder-engaging member 64 into the undercut 54 and pushing the shorter shoulder-engaging member 66 against the upper and outer surface of the shoulder 52, causing the deck member 12 to flex slightly about its center line, thereby moving the shoulder-engaging members 64 and 66 a greater distance apart, so that the bevelled surface 70 of the shoulder-engaging member 66 rides on and round the surface 68 of shoulder 52 and snap fits into the undercut 56 in engagement with the underside of the shoulder 52. At the same time, the protrusions 18 extend into the slots 74.
Disassembly of the interlock is readily achieved by flexing the member 12 about its center line until the shoulder-engaging members 64 and 66 are spaced apart a distance sufficient to remove the shoulder-engaging member 66 from the undercut 56.
The disassembly of the deck members 12 and side rails 14 is not prevented by the stop means constituted by the interaction of the protrusion 48 with slots 74.
If desired, the additional rails 20 may be provided with one or more protrusions 48 with the webs 72 being provided with appropriate slots 74 for releasable interconnection of the deck members 12 to the additional rails 20 at their intersections to increase the rigidity and strength of the overall structure.
Additionally, while the protrusions 48 are shown as a single integral member, the protrusions may be formed in discontinuous manner, typically having three separate parts, one at each end having the undercuts therein and a central tab for projection into the slot 74.
The dock 10 also is provided with a pair of side bumper rails 76 releasably connected one to each side rail 14. Each bumper rail 76 comprises an elongate aluminum member 78, which generally is formed by extrusion having a generally E-shaped cross-section opening towards the side rail 14 and a generally flat-based C-shaped cross-section opening away from the side rail 14. A bumper bar 80 of any convenient material, such as wood, plastic or rubber, having a suitable cross-section, such as the generally rectangular or square cross-section illustrated or a part-circular cross-section, is received in the U-shaped cross-section opening of the elongate member 78 and secured therein, such as, by securing screws 82.
The elongate member 78 includes a vertically-extending web 84 and integrally-formed projections 86, 88 and 90. The projection 86 extends horizontally on both sides of the web 84 perpendicularly thereto. The projection 88 extends horizontally on both sides of the web 84 perpendicularly thereto and also includes a depending skirt portion 92 at the end of the projection 88 remote from the web 84 and closest to the side rail 14. The projection 90 is L-shaped and forms a downwardly-opening channel 94 with the web 84.
In the assembled dock 10, the downwardly-opening channel 94 of the bumper rail 76 interengages with the upwardly-opening channel 46 of the side rail member 14 and the downwardly-depending skirt member 92 of the bumper rail 76 projects into the upwardly-opening channel 42, resulting in releasable assembly of the bumper rail 76 with the side rail 14. Temporary securement of the bumper rail 76 to the side rail 14 to prevent accidential dislodgement of the bumper rail 76 may be achieved using self-tapping screws 96, or any other convenient fixing means.
The portion of the projection 86 extending towards the side rail 14 overlaps the ends of the deck members 12, as shown in FIG. 6, to provide an aesthetic assembly. As seen in FIG. 1, the bumper bar 32 attached to the end rails 16 extends beyond the ends of the end rails 16 to overlap the ends of the bumper bar 80.
The dock structure 10 of the present invention, suitable for assembly with floats 22 to form a floating dock, is comprised of a rigid aluminum frame 17, deck members 12 and aluminum bumper rails. The only wooden parts of the structure are the bumper bars 32 and 80 which are only a minor portion of the overall structure, and may be replaced by other materials, such as, vinyl or rubber, if desired.
The dock structure 10 possesses many advantages over conventional wooden dock structures. Thus, the structure may be assembled without special tools and skills and may be disassembled readily for removal from water bodies during freeze up, in contrast to wooden structures.
The aluminum is not readily corrodible or damaged by exposure to the elements and hence does not need replacement for many years in contrast to the wooden structures, does not absorb water and hence remains light in weight, easing removal from the water body, is inflammable and very durable. Any worn or broken parts have scrap value as aluminum and hence are 100% recyclable, in contrast to the difficulties of disposal of broken wooden parts. Repairs can be readily effected, owing to ease of disassembly of the parts.
SUMMARY
The present invention, therefore, provides a dock structure which has considerable advantages over the prior art wooden structures. Modifications are possible within the scope of the invention.
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A readily assemblable and collapsible floating or standing dock is constructed of a plurality of transversely-extending elongate aluminum deck forming members releasably connected, through a simple interlocking fastening arrangement, to parallel elongate aluminum side rail members provided at each longitudinal side of the dock. Aluminum end rails are releasably interconnected between the side rail members to provide a rigid frame structure. An aluminum bumper rail extends along each longitudinal side of the dock with portions overlying the ends of the deck-forming members and portions releasably connected to the elongate aluminum side rail members.
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TECHNICAL FIELD
This invention relates to friction stir welding and riveting, more particularly, to methods of joining multiple workpieces using a precessing stir rivet to create a mechanical bond, an interweld, and a diffusion bond.
BACKGROUND OF THE INVENTION
Friction stir welding (FSW) is a method used to join metal workpieces. The method generally uses a cylindrical, shouldered tool with a profiled pin that is rotated at the joint line between two workpieces while being traversed along the joint line. The rotary motion of the tool generates frictional heat which serves to soften and plasticize the workpieces. This softened material, contributed by both workpieces, intermingles and is consolidated by the pin shoulder. As the pin moves laterally the frictional heating is reduced and the softened material hardens, creating a bond between the two workpieces. The best current understanding of the process is that no melting occurs and the weld is left in a fine-grained, hot worked condition with no entrapped oxides or gas porosity.
A common design of FSW stir rods is that the stirring element is substantially symmetrical with some irregularity to induce a stirring motion. Frequently the stir rod has a threaded appearance similar to a bolt. However, to promote intermingling and to retain the plasticized material in the weld zone for as long as possible the direction of rotation of the rod is such that the threads carry the plasticized material downward to create as turbulent a flow and as efficient an intermingling as possible. Particularly for metal workpieces the high thermal conductivity strongly localizes the region, which is plastic enough to be deformed by the stirring action. Thus, the width of the stirred region is substantially equal to the width of the stirring rod.
SUMMARY OF THE INVENTION
This invention is based on a newly developed method which we call friction stir riveting. This method improves friction stir welding by using a stir rod as a rivet. The stir rivet is rotated and advanced into multiple workpieces to plasticize material around the rivet for stir welding the workpieces together. The rivet is then left in place to form a weld between the rivet and the hardened or solidified material.
The present invention provides a modified stir rivet which includes an angled body that is asymmetrical about a rotational axis. The body preferably lies on a centerline that extends outward and downward from the rotational axis so that the body centerline processes as it rotates on the rotational axis.
The rivet has an upper and lower portion. The upper portion of the rivet includes a cap which serves as the head of the rivet and includes an upper side, an underside, and an outer face. A recessed socket is centrally located along the rotational axis of the upper side of the cap. The underside of the cap is inwardly recessed and joins with an elongated body.
The lower portion of the rivet includes the elongated body having sidewalls and a lower end surface. The body has a cross-section that increases smoothly along the length of the elongated body from the cap down to the lower end, causing the body of the rivet to have re-entrant features. The lower end of the body is bulbous, having a pear like shape. Alternative shapes for the body of the rivet include conical, cylindrical, and spherical shapes. A portion of the sidewall angles inward toward the rotational axis of the rivet, which creates a re-entrant portion along at least one side of the elongated body. The lower portion of the rivet has helical flutes which run the length of the elongated body to redirect displaced material to the lower surface of the rivet.
The cap acts as a retaining element to prevent plasticized material from displacing out of the cavity. Specifically, when the cap comes in contact with the first workpiece the inwardly recessed underside of the cap forces displaced material back into the cavity. As the material re-enters the cavity, helical flutes located on the elongated section of the rivet push material down to the lower surface of the rivet to pack material around the lower end of the rivet.
To rotate the rivet, a rotational apparatus is inserted into the recessed socket of the rivet. The recessed socket is centrally located on the upper surface of the cap and is aligned with the rotational axis of the rivet. The lower portion of the rivet is aligned along the precession axis which runs at an angle to the rotation axis. Offsetting the alignment of the lower portion of the rivet relative to the axis of rotation causes the lower portion of the rivet to move in a precessing motion when rotated.
The precessing motion of the rivet creates more contact around the sidewalls of the rivet and increases stir radius around the rivet. The extra contact between the sidewall and the workpieces to be welded promotes the stir welding process by stirring up a greater area around the rivet. As a result, more plasticized material is intermingled and inter melted. Also, the extra friction created by the precession motion of the rivet creates extra heat to further aid the process.
Scrubbing the sidewalls of the rivet removes oxidation from the rivet which allows a better bond to form between the rivet and the stirred material. If the oxidation is not removed from the sidewalls of the rivet the bond that forms between the rivet and stirred material will be adversely affected by the oxidation layer around the rivet.
Weld strength is further increased by the re-entrant section of the rivet. The elongated body of the rivet creates a re-entrant section along the angled sidewalls of the rivet. The re-entrant section extends from the lower portion of the rivet up to the underside of the cap. This design allows plasticized material to fill in between the cap and the lower surface of the rivet, thereby, increasing the volume of mechanical retention around the re-entrant section of rivet.
The rivet should be formed of a relatively high melting point metal or refractory metal so that the rivet has a higher melting point than the workpieces to be joined. Preferably, the rivet should have a melting point that is at least 100° Fahrenheit higher and more preferably at least 200° Fahrenheit higher than workpieces, such as aluminum. Further, the rivet should be formed of a metal of substantially greater hardness than the metal workpieces to be joined. Exemplary metals include high carbon steel, titanium (e.g. titanium 6-4) and the like. Preferably, the rivet should be formed of a metal that is capable of forming a diffusion bond with the metal workpieces to be joined.
A suitable rotational device is used to rotate and press the rivet into the metal workpieces to be joined. The rivet penetrates best when it is rotated at speeds between 4,500 and 27,000 revolutions per minute. The amount of pressure needed to allow the rivet to penetrate the metal workpiece depends upon the speed of rotation. The rate of penetration is increased when the amount of pressure applied is increased, or when the revolutions per minute are increased. Under good conditions, the friction stir rivet can penetrate aluminum at up to 27 millimeters per minute.
These and other features and advantages of the invention will be more fully understood from the following description of certain specific embodiments of the invention taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side view of an exemplary embodiment of a friction stir rivet according to the invention;
FIG. 2 is a side view of the friction stir rivet of FIG. 1 rotated 90°; and
FIG. 3 is a cross-sectional view showing the friction stir rivet of FIG. 1 at the conclusion of rotation during stir riveting of two workpieces together.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIGS. 1 and 2 of the drawings in detail, numeral 10 generally indicates a friction stir rivet. Rivet 10 includes an elongated stirring body 12 and a cap 14 . Elongated body 12 includes a sidewall 16 and a lower end 18 . The cross-section of the body 12 increases smoothly from the cap 14 down to the lower end 18 , which optionally has a hemispherical shape. Sidewall 16 has an angled portion 20 that slopes inward toward the rotational axis 22 of rivet 10 to create a re-entrant section 24 . The elongated body 12 has helical flutes 26 .
Cap 14 acts as the head of rivet 10 and includes an upper side 28 , an underside 30 , and an outer face 32 . A recessed socket 34 is centrally located along rotational axis 22 of the upper side 28 of the cap 14 . A rotational apparatus engages recessed socket 34 to rotate and drive rivet 10 . The underside 30 of the cap 14 has an inwardly recessed portion 36 which joins with the elongated body 12 . The body 12 Us offset relative to the rotational axis 22 of the rivet and aligned along precession axis 38 that forms an angle with the rotational axis 22 .
Referring to FIG. 3 , the rivet 10 is shown in use for stir riveting a first workpiece 40 , such as a fusible aluminum sheet or plate, to a second workpiece 42 , such as a fusible aluminum frame or other substrate. In operation, the rivet 10 is rotated around its rotational axis 22 while the elongated body 12 , extending along the precession axis 38 , rotates with the axis 38 in a precession like motion.
During rotation, downward force is applied to the rivet 10 causing the lower end 18 to frictionally contact an exposed surface 44 of the first workpiece 40 . The downward force and rotation of the rivet 10 cause a portion of the first workpiece 40 to plasticize, allowing the rivet 10 to penetrate and create a cavity 46 partially or completely filled with plasticized material 52 . As the rivet 10 is driven through an unexposed surface 48 of the first workpiece 40 , rivet 10 frictionally contacts an unexposed surface 50 of the second workpiece 42 . The downward force and rotation of rivet 10 cause a portion of the second workpiece 42 to plasticize, allowing rivet 10 to continue penetrating cavity 46 . As the rivet 10 is driven through the first workpiece 40 into the second workpiece 42 , the plasticized material 52 is intermixed.
As rivet 10 is further driven into workpieces 40 , 42 the underside 30 of cap 14 contacts exposed surface 44 , causing the cap 14 to act as a retaining element restricting plasticized material 52 from escaping during the friction stir riveting process. Specifically, the inwardly recessed portion 36 of underside 30 forces plasticized material 52 into the helical flutes 26 . As the rivet is rotated in a clockwise direction as shown by direction arrow 54 , the flutes 26 push plasticized material 52 down the length of rivet 10 to the lower end 18 , which packs material around the lower end 18 of the rivet 10 .
The precession motion of body 12 increases contact between the sidewall 16 of the rivet 10 and the cavity 46 . The extra contact created by the sidewall 16 of the rivet 10 promotes the welding process by stirring up a greater area around the rivet 10 , causing more plasticized material 52 to be intermingled.
The extra contact between the sidewall 16 and the cavity 46 abrades oxidation from sidewall 16 . Removing oxidation around the rivet allows a better bond to form between rivet 10 and the plasticized material 52 . If the oxidation is not removed from the sidewall 16 of rivet 10 , the oxidation layer will interfere with chemical bonding between rivet 10 and the plasticized material 52 .
Preferably, rivet 10 is driven though the first workpiece 40 and partially into the second workpiece 42 until the cap 14 of the rivet 10 is partially recessed into the exposed surface 44 of the first workpiece 40 . Thereafter, the rotary motion of rivet 10 is stopped, allowing locally plasticized material 52 to solidify and form several welds. Rivet 10 forms a mechanical bond between the first workpiece 40 and the second workpiece 42 . Plasticized material 52 preferably forms a diffusion bond between the rivet 10 and the first and the second workpieces 40 , 42 . Furthermore, the plasticized material 52 forms an interweld between the first workpiece 40 and the second workpiece 42 .
The weld strength is further increased by the re-entrant sections of rivet 10 . The elongated body 12 of the rivet 10 creates re-entrant sections around the sidewalls 16 , 20 of the rivet 10 . Re-entrant section 24 extends from the lower portion 18 of the rivet up to the underside 30 of the cap 14 . This design allows plasticized material 52 to fill in between the cap 14 and the lower surface 18 of the rivet 10 , thereby, increasing the strength of mechanical retention around the sidewalls 16 , 20 of the rivet 10 .
The foregoing description is directed, as an example, to joining aluminum metal workpieces with a stir rivet made of metal with a higher temperature melting point. However, it should be understood that other fusible materials may be joined using the same process with a proper selection of compatible materials. Thus, other metals and thermoplastics may also be successfully joined with a stirring rivet and process within the guidelines above described.
While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the disclosed embodiments, but that it have the full scope permitted by the language of the following claims.
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A friction stir rivet is rotated in a precessing motion and driven through a first fusible workpiece into an engaged second fusible workpiece, causing local portions of the first and second workpieces to plasticize. When the rivet is driven through the first workpiece and into the second workpiece, rotation is stopped and the plasticized material solidifies around the rivet creating an enlarged weld joining the metal workpiece and encompassing the rivet, which provides additional mechanical strength.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/482,124, filed Jun. 23, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to devices for holding umbrellas, and in particular, to a portable device which can be mounted to a support shaft, e.g., a chair leg, and is adapted for receiving and supporting an umbrella.
[0004] 2. Description of the Related Art
[0005] It is often desirable to have an umbrella close at hand for relief from rain as well as from direct sunlight. This is especially true when watching an outdoor sporting event, e.g., a soccer or baseball game, or a motorcar race. At such times, it also is desirable to be able to mount or plant such an umbrella in an upright, unfolded position to or in a suitably stable object such that a user of the umbrella need not fatigue his or her arms and hands by holding and maintaining the umbrella in the desired position. To that end, a conventional beach umbrella or sun shade umbrella typically has a pointed pole that can be driven into the sand at a beach to immobilize the umbrella However, in locations where the ground is not as soft, e.g., dirt fields or pavement, it is usually impractical or impossible to attempt to anchor the umbrella in the ground. In these locations, an alternative mounting option is desirable. Thus, there is a need for a portable, light-weight umbrella mounting device that can be easily and quickly installed and removed from a support shaft, e.g., a portable chair leg.
[0006] Various devices are disclosed in the literature for mounting an umbrella to a free-standing structure, thereby eliminating the need for anchoring the umbrella to the ground. However, the prior art devices are often cumbersome, heavy, or large, or require time and/or tools to install and remove such a prior art umbrella mounting device. For example, U.S. Pat. No. 6,474,097 issued on Nov. 5, 2002, to Treppedi et al. shows a mobile cooler having a cylindrical umbrella shaft retainer with a retaining knob that holds an umbrella either in a raised position above the ground during transport or in place when the umbrella shaft is embedded in the ground. However, Treppedi et al. does not show an umbrella mounting device that is detachably mounted to a support shaft, that can be re-positioned along a support shaft, or that maintains the umbrella shaft above the ground surface at all times.
[0007] Turning now specifically to umbrella mounting devices used in conjunction with chairs, U.S. Pat. No. 3,637,046 issued on Jan. 25, 1972, to Emmons discloses the use of a U-bolt clamp to secure an umbrella shaft to a chair. The Emmons device requires a hole to be bored in the chair seat to maintain the umbrella in an upright position, as well as holes and/or a permanently attached U-bolt clamp on the seat to anchor the umbrella shaft.
[0008] U.S. Pat. No. 3,904,161 issued on Sep. 9, 1965, to Scott discloses a clamp for attaching an umbrella to a lawn chair. The Scott device must be attached to a horizontal portion of the chair frame, preferably the uppermost horizontal portion of the chair back, and its jaws clamp a relatively small portion of the handle of an umbrella with no further stabilization of the umbrella shaft at any other point along the umbrella shaft.
[0009] U.S. Pat. No. 4,871,141 issued on Oct. 3, 1989, to Chen discloses an adjustable umbrella support that clamps on the side of a chair. An umbrella shaft is simply deposited into a hole bored through most of the length of the device. No further means of more securely attaching the umbrella shaft to the device are shown.
[0010] U.S. Pat. No. 5,100,198 issued on Mar. 31, 1992, to Baltzell discloses a seat cooler apparatus that has a support cylinder mounted upon a rear portion of the cooler located under the seat. As in the above-mentioned Chen device, an umbrella shaft is simply deposited into the cylinder and no further means of more securely attaching the umbrella shaft to the device are shown. This device also is not described as being detachable and/or adjustable.
[0011] U.S. Pat. No. 5,255,954 issued on Oct. 26,1993, to Rogers discloses a sun shade umbrella mount for a chair back. An umbrella shaft is supported by a sleeve secured to a frame that hooks to a mounting plate. The mounting plate must be permanently attached to the chair back using bolts, screws, or the like.
[0012] U.S. Pat. No. 5,478,041 issued on Dec. 26, 1995, to Mayne, as well as U.S. Pat. No. 5,836,327 issued on Nov. 17, 1998, to Davis, disclose clamping and holding devices suitable for mounting umbrellas to chairs. On both devices, a first clamping arm and a second opposing clamping arm provide a single area of attachment where the device clamps the chair, rather than providing two or more areas of attachment for added stability.
[0013] U.S. Pat. No. 5,518,218 issued on May 21, 1996, to Leonard discloses an umbrella-holding tube that can be bound to a chair using bungee cords. An umbrella is bound to the device using a bungee cord as well, and no rigid or non-stretchable fastening means are used for such bindings.
[0014] U.S. Pat. No. 5,641,197 issued on June 24,1997, to Springmann discloses a collapsible sports chair that includes a permanently attached umbrella support mechanism having five apertures with bushings that hold an umbrella at a single area of contact with a fixed diameter.
[0015] U.S. Pat. No. 6,439,659 issued on Aug. 27, 2002, to Neubauer, Jr. discloses an collapsible portable chair having an opening in a vertical portion of the chair frame such that an umbrella shaft may be deposited therein. The umbrella holder is an integral part of the chair and is thus not removable or repositionable.
[0016] U.S. Pat. No. 6,536,733 issued on March 25, 2003 to Sharp discloses a cooler having a permanently fixed and integrated umbrella stand attached to one side. The umbrella stand is simply two rings secured to the cooler such that an umbrella shaft slides through both rings and holds the umbrella in an upright position.
[0017] European Pat. Application Publication No. EP 0 860 113 A1 discloses a folding chair having an attached tube for holding an umbrella The device is designed to be attached to and used only with the folding chair described, as opposed to being usable with any chair.
[0018] Therefore, each of the prior art umbrella mounting devices is either too cumbersome, requires extended time to install and remove the device, or is incapable of working with an existing folding chair and a conventional umbrella such that the device securely holds the umbrella over the folding chair. There is a need for a portable, light-weight umbrella mounting device that can be easily and quickly installed and removed from a support shaft, e.g., a portable chair leg, wherein the umbrella mounting device securely holds a conventional umbrella in a desired position over a user.
SUMMARY OF THE INVENTION
[0019] The present invention is an accessory device that allows for the ready attachment and detachment of an umbrella, preferably a portable beach umbrella, to a conventional foldable outdoor chair as is used at the beach, when camping, or at picnics. As such, the present invention provides a convenient, portable, and inexpensive mounting option for an individual using an umbrella. The present invention therefore enables a user to temporarily immobilize an umbrella for convenient, hands-free use, even in areas having hard surfaces, such as patios or decks.
[0020] The present invention is an umbrella mount having a tube with a top end and a bottom end, a top binder, a bottom binder, a support member, and a securing member. The top binder attaches the tube near its top end to a support shaft, e.g., a leg of a portable, folding chair, whereas the bottom binder attaches the tube near its bottom end to the support shaft. The binders are preferably Velcro-type hook and loop straps that detachably bind the tube to the support shaft. Also, a non-slip collar is positioned on the tube under each binder such that both the top binder and the bottom bind pass over a collar. The collar provides the means for preventing slippage of the straps and preventing slippage of the tube against the support shaft. The support member prevents the umbrella shaft from slipping out the bottom end of the tube. The securing member adjusts the diameter of the cylindrical cavity of the tube to secure the umbrella shaft within the tube.
[0021] There are several advantages of the umbrella mount over conventional devices. First, the umbrella mount is easily and quickly installed on and removed from any support shaft. Second, the use of a support member that does not close off the bottom end of the tube allows water and dirt to pass through the tube and not collect within the cylindrical cavity. Third, the umbrella mount is extremely light weight and portable. Fourth, the umbrella mount can be used with any existing foldable chair or support shaft so long as the top and bottom binders are long enough to encompass the support shaft and tube. The present invention does not require any modification to a support shaft nor the use of extra tools in the installation and removal of the umbrella mount.
BRIEF DESCRIPTION OF THE FIGURES
[0022] The present invention is described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements. Additionally, the left-most digit of a reference number identifies the drawing in which the reference number first appears.
[0023] FIG. 1 is a perspective view of a preferred embodiment of an umbrella mount of the present invention bound to a chair and holding an umbrella;
[0024] FIG. 2 is a perspective view of a preferred embodiment of the umbrella mount of the present invention;
[0025] FIG. 3 is a planar side view of a preferred embodiment of the umbrella mount of the present invention bound to a chair and holding an umbrella;
[0026] FIG. 4 is a cross-sectional view of the device of FIG. 3 at line 4 - 4 ;
[0027] FIG. 5 is a cross-sectional view of the device of FIG. 3 at line 5 - 5 ;
[0028] FIG. 6 is a top end view of a tube and top collar of the present invention; and
[0029] FIG. 7 is a perspective view of an alternative embodiment of a bottom end of a tube of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] As shown in FIG. 1 , the umbrella mount 100 of the present invention is adapted to detachably mount on a support shaft, such as a back leg 104 of a folding chair 102 , and to securely hold in place an umbrella shaft 106 of an umbrella 108 . However, the depiction of the umbrella mount 100 used in conjunction with the back leg 104 of a folding chair 102 is for convenience purposes only. The umbrella mount 100 works equally as well mounted on any chair leg, table leg, post, or other generally vertical shaft (collectively, “support shaft”), so long as the length of the support shaft 104 is at least about as long as the umbrella mount 100 and the umbrella shaft 106 rises above the support shaft 104 .
[0031] As shown in FIGS. 2-6 , a preferred embodiment of the umbrella mount 100 comprises a tube 202 , a top cinch strap 204 , a bottom cinch strap 206 , a machine screw or roll pin 208 , and a thumb screw 210 . The tube 202 comprises atop end 212 , an outer surface 214 , an inner surface 216 , and a bottom end 218 . The tube 202 is defined by a length running from the top end 212 to the bottom end 218 , as well as by an inner diameter and an outer diameter, such that the tube defines a cylindrical cavity 220 . The tube 202 is preferably made of a plastic or polyvinyl chloride (PVC) tube or pipe, but other materials having comparably similar strength and durability characteristics may alternatively be used, such as metal, wood, rubber, or a composite material. The tube 202 preferably has a length of between about twelve inches and thirteen inches, with an inner diameter of about one inch. PVC pipe is readily commercially available and is well-know to those skilled in the art. The cylindrical cavity 220 of the tube 202 acts as a receptacle into which the umbrella shaft 106 is deposited. The length and size of the tube 202 is described in these terms for convenience only. It would be readily apparent to one of ordinary skill in the relevant art to use a different length and diameter tube 202 depending on the size of the umbrella shaft 106 intended to be used with the umbrella mount 100 .
[0032] Attached in proximity to or near the top end 212 of the tube 202 is the top cinch strap 204 , and attached in proximity to or near bottom end 218 of the tube 202 is the bottom cinch strap 206 . Top cinch strap 204 and bottom cinch strap 206 detachably bind umbrella mount 100 to the support shaft 104 . Top cinch strap 204 and bottom cinch strap 206 are both preferably conventional Velcro-type straps having hook and loop fasteners about one inch wide and having a length that enables the straps to encompass both the support shaft 104 and the tube 202 . Optionally, the top cinch strap 204 and bottom cinch strap 206 have a buckle on one end (as shown in FIG. 2 ) such that the other end of each strap is inserted through its buckle and folded over the length of the strap, thereby securing the strap in place. Comparable means of binding the umbrella mount 100 to the support shaft 104 may alternatively be used such as bungee cords, straps, snaps, hooks, clamps, clips, fasteners, clasps, securing means, adhesives, pins, pegs, or any combination thereof (collectively, “top binder” and “bottom binder”). Such means of binding should preferably bind at least the top end 212 as well as the bottom end 218 of the tube 202 to the support shaft 104 such that any torsional forces, such as excessive wind, applied to the umbrella 108 do not wrench the umbrella mount 100 away from the support shaft 104 . Any number of additional means of binding the umbrella mount 100 to the support shaft 104 , as a supplement or supplements at any point or points along the tube 202 between the top binder and the bottom binder may also be used.
[0033] Top binder and bottom binder each also preferably operate in conjunction with a non-slip covering, such as a circular collar 222 , 224 made of foam, sponge or rubber. The use of a collar 222 , 224 is preferred because they can be easily put onto a tube 102 by sliding an end of the tube 102 through each collar 222 , 224 . See FIG. 6 . Each non-slip covering or collar 222 , 224 is located on the outer surface 214 of tube 202 near the top end 216 and bottom end 218 , respectively, and is preferably, at least in part, between the outer surface 214 of the tube 202 and the top cinch strap 204 and the bottom cinch strap 206 , respectively, and between the outer surface 214 of the tube 102 and the support shaft 104 . Each non-slip covering or collar 222 , 224 absorbs some of the pressure from top cinch strap 204 and bottom cinch strap 206 when they are tightened against a support shaft 104 , and also provides additional friction to prevent slippage between the tube 202 and the support shaft 104 . Each non-slip covering or collar 222 , 224 may be removable from the tube 202 , or may be permanently affixed to the outer surface 214 of the tube 202 with an adhesive, glue, two-sided tape, one or more fasteners, or other comparable means of attachment. The collars 222 , 224 are preferably wider than the top and bottom cinch straps 204 , 206 , e.g., are about one and one-half inches wide. Also, the top cinch strap 204 and bottom cinch strap 206 are preferably riveted, or otherwise permanently affixed, to the collars 222 , 224 , respectively, to prevent them from moving out of position off of the collars 222 , 224 and to prevent them from being separated from the tube 202 . However, the collars 222 , 224 may have alternative sizes and may be connected to the top cinch strap 204 and bottom cinch strap 206 , respectively, using alternative attachment means.
[0034] In alternative embodiments of the present invention, the use of collars 222 , 224 is optional so long as slippage between the tube 202 and the support shaft 104 is prevented in some manner. For example, in an alternative embodiment, the top cinch strap 204 and the bottom cinch strap 206 , and/or the outer surface 214 of the top end 216 and the bottom end 218 of tube 202 may have a non-slip or textured surface, or may be coated or wrapped with a non-slip or sticky material or surface, e.g., a coating containing grit, sand, or a sticky substance.
[0035] Also in the preferred embodiment, as shown in FIG. 2 , a machine screw or roll pin 208 is threaded through a hole 226 preferably near the bottom end 218 of the tube 202 . However, the machine screw/roll pin 208 and associated hole 226 may alternatively be placed at another point along the length of the tube 202 . The machine screw/roll pin 208 substantially traverses the inner diameter of the tube 202 such that the cylindrical cavity 220 is obstructed to a sufficient extent to retain the umbrella shaft 106 within the tube 202 without slipping out the bottom end 218 of the tube 202 . That is, the machine screw/roll pin 208 may protrude through the opposite side of the tube 202 (such that the hole 226 extends through both sides of the tube 202 ), may extend the length of the entire cylindrical cavity 220 , or may extend a portion of the length of the cylindrical cavity 220 . The machine screw/roll pin 208 acts as a support member for the umbrella shaft 106 . In addition, as shown in FIG. 5 , the machine screw/roll pin 208 may be secured to the inner surface 216 of the tube 202 by conventional means, thereby eliminating the need for a hole 226 .
[0036] As noted above, the machine screw/roll pin 208 may be located at another point along the length of the tube 202 . Thus, the machine screw/roll pin 208 would work equally as well (that is, be of such a distance from the bottom end 218 of the tube 202 as to provide the needed support to prevent the umbrella shaft 106 from flipping out of the tube 202 ) if located within the bottom one-fourth length of the tube 202 .
[0037] The use of a machine screw/roll pin 208 is for convenience, and any alternative support members or means for supporting the umbrella shaft 106 within the tube 202 would work equally as well. For example, as shown in FIG. 7 , one or more flanges or protrusions 704 within the cylindrical cavity 220 of the tube 202 may be used as support members. Alternatively, a cap 702 may be placed on the bottom end 218 of the tube 202 to act as a support member. The cap 702 may be pressure fit onto the bottom end 218 of the tube 202 or may be secured in place by an adhesive, fastener, or the like. Although a cap 702 would work for the intended purpose, it is important to note that the preferred embodiment employs a machine screw/roll pin 208 or similar means for supporting the umbrella shaft 106 that does not fully enclose the bottom end 218 of the tube 202 in order to allow water, dirt, grass, and other debris to pass freely through the tube 202 .
[0038] Also in the preferred embodiment, a thumb screw 210 is threaded through a hole 228 preferably near the top binder or top cinch strap 204 . As shown in FIG. 4 , the thumb screw 210 adjustably obstructs the cylindrical cavity 220 in order to hold the umbrella shaft 106 in place within the tube 202 . Specifically, the thumb screw 210 can be loosened such that the umbrella shaft 106 may easily be placed within the tube 202 . Then the thumb screw 210 can be tightened such that the end of the thumb screw 210 contacts and presses against the umbrella shaft 106 , thereby forcing the umbrella shaft 106 against the opposing inner surface 216 of the tube 202 . The umbrella shaft 106 is thus held securely in place within the tube 202 .
[0039] The use of the thumb screw 210 provides the means for the umbrella mount 100 to accommodate an umbrella shaft 106 of any diameter, so long as the umbrella shaft 106 has a smaller outer diameter than the inner diameter of the tube 202 . The thumb screw 210 and associated hole 228 may alternatively be located at another point along the length of tube 202 , so long as the thumb screw 210 is closer to the top end 216 of the tube 202 than is the machine screw/roll pin 208 . In general, however, the thumb screw 210 is preferably located closer to the top end 216 as opposed to the bottom end 218 . The use of thumb screw 210 is for convenience, and any alternative securing member or means for securing the umbrella shaft 106 within the tube 202 would work equally as well. For example, one or more clamps, adjustable pegs, or other adjustable obstructive members or projections may be used as securing members.
[0040] In operation, the umbrella mount 100 is bound to a support shaft 104 by first placing the umbrella mount 100 against the support shaft 104 in the desired location such that the tube 202 is aligned with the support shaft 104 . The top cinch strap 204 or top binder as well as the bottom cinch strap 206 or bottom binder are then strapped or bound to the support shaft 104 . The umbrella shaft 106 is then deposited into the top end 216 of the tube 202 such that the umbrella shaft 106 slides down into the tube 202 and comes to a rest on top of the machine screw/roll pin 208 or support member. The thumb screw 210 or securing member is then adjusted or tightened such that the umbrella shaft 106 is held securely in place within the tube 202 . The umbrella 108 may be opened either before depositing the umbrella shaft 106 within the tube 202 or after the securing member is tightened.
[0041] The umbrella mount 100 may subsequently be removed from the support shaft 104 by first loosening the thumb screw 210 or securing member, then removing the umbrella shaft 106 from the tube 202 by pulling it upward. The top cinch strap 204 or top binder as well as the bottom cinch strap 206 or bottom binder are then unstrapped or unbound from the support shaft 104 , and the umbrella mount 100 at that point is no longer attached to the support shaft 104 .
[0042] One important advantage of the present invention is that the tube 202 may be rotated in relation to the support shaft 104 to which it is mounted. Thus, a user may rotate the tube 202 prior to securing it to the support shaft 202 in order to make the thumb screw 210 easily accessible or to facilitate the positioning of the umbrella 108 over the chair 102 .
[0043] The umbrella mount 100 is described in these terms, these dimensions, and using these components for convenience purpose only. It would be readily apparent to one of ordinary skill in the art to manufacture and use a comparable umbrella mount using different dimensions, and/or comparable components.
CONCLUSION
[0044] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined in the appended claims. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
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An umbrella mount adapted to hold an umbrella shaft and to be detachably mounted to a support shaft such as a rear leg of a folding chair, lawn chair, or beach chair. The umbrella mount comprises a tube, a top binder, a bottom binder, a support member, and a securing member. The top binder detachably attaches the tube near its top end to the support shaft, whereas the bottom binder detachably attaches the tube near its bottom end to the support shaft. The binders are preferably hook and loop straps with non-slip collars. The bottom of the umbrella shaft is deposited into the tube. The support member prevents the umbrella shaft from slipping out the bottom end of the tube. The securing member adjusts to secure the umbrella shaft within the tube.
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