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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. national phase application of PCT International Application No. PCT/EP2007/054552, filed May 11, 2007, which claims priority to German Patent Application No. DE 102006023342.5, filed May 17, 2006 and German Patent Application No. DE 102006035564.4, filed Jul. 27, 2006, the contents of such applications being incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a pulse-width-modulated current control circuit for driving inductive loads in motor vehicles and to its use.
[0004] 2. Background of the Invention
[0005] Electronic motor vehicle control units, such as controllers for ABS and/or ESP motor vehicle brake control units, comprise multiply redundant microprocessor systems and additional power circuits for driving loads such as, for example, the electromagnetic valve solenoids which are necessary for regulating pressure. Modern electronic brake control units for brakes now only comprise for this purpose a limited number of highly integrated components in which most of the discrete components of the controller are combined in two integrated modules, or even just one integrated module. An integration stage which is customary nowadays comprises two integrated circuits, with the microcomputer systems being combined in a first component and the power circuits being combined in a second, mixed analog/digital circuit. In the second integrated circuit there is also an analog/digital converter making available the analog value for the microcontroller as digital values. For reasons of cost it is advantageous to use a single A/D converter for a plurality of measurements.
[0006] In high-quality electronic ABS and ESP brake control systems, the valve solenoids are, at least partially, no longer switched but rather analogized driving is carried out by means of a pulse-width-modulated current controller (PWM) which permits virtually analog driving of the hydraulic valves. For this purpose, multi-channel PWM driver stages are provided which can be constructed, for example, by means of MOS transistors which are switched in antiphase. In order to permit an economic and space-saving solution, such a PWM stage is usually implemented as an integrated circuit, especially since up to eight of such stages have to be present for a complex ESP system as well as numerous additional circuit components. A pure analog amplifier for driving a valve solenoid is not practical because of an excessively high power loss.
[0007] The basic procedure when using a single A/D converter for measuring the actual current within a PWM controller for driving the abovementioned valve solenoids is already known from WO 02/058967 A2 (P 10057) and WO 03/039904 A2 (P 10253). According to the circuit examples described therein, a specific number of current-measuring channels are assigned to the A/D converter in accordance with a complex priority logic corresponding to a time slice principle so that its conversion capacity can be used in the best way possible.
[0008] The requirements which are made of the above electronic control units are continually increasing since additional functions are also performed by the brake control unit and the brake systems are intended to exhibit improved control quality. A number of relatively recent control functions, including motor vehicle longitudinal control (ACC) which maintains a constant distance from a vehicle traveling in front, require, above and beyond the pure possibility of setting an analog current, particularly precise current control since the smallest deviations from the desired current value bring about perceptible differences in the brake pressure which is set, with the result that precise ACC control with corresponding comfort is no longer possible. In addition, even small differences between the pressure which is set at the front axle and the rear axle during a relatively long period of ACC control can lead to a failure of the brake function of an axle. In particular, relatively low currents in the range from approximately 100 to 400 mA should have a high level of precision since these currents are required to set small pressure differences such as are typical for longitudinal control.
[0009] In the case of PWM stages which are embodied according to the previously mentioned patent applications WO 02/058967 A2 (P 10057) and WO 03/039904 A2 (P 10253) there is therefore need to improve the precision of PWM current control still further. In a PWM mentioned controller according to the prior art, considered in general terms an inductive load (for example valve solenoid) is actuated in the general application case of brake control. The inductive load has a specific inductance L and an ohmic resistance R. A time constant of the load L/R can be defined from the inductance L. Depending on this time constant and the pulse-width-modulation frequency which is aimed at a typical profile of the current I L due to the inductive load plotted against the time t is obtained as indicated in FIG. 1 . As a result of the use of an A/D converter which is used repeatedly for measuring current in different PWM channels, the current cannot be determined at a plurality of points of the current profile in FIG. 1 . The current is therefore measured at specific times (time-discrete measurements), as described in the documents cited above. The current value which is determined in this way deviates considerably, depending on the measuring time, from the mean value of the current which is to be actually determined for the PWM controller. This deviation from the mean value is also referred to below as form error. If, as illustrated in FIG. 2 , the current value is, for example, measured regularly in the center of the switch-on phase at the time t ON /2, the form error which is illustrated in FIG. 2 is produced as a difference between the measured value and the mean value.
[0010] However, the form error is not only influenced by the measuring time of the discrete measurement of current but also by other operating parameters of the PWM controller such as, for example, the high side voltage which is present on the load and by the temperature-dependent ohmic resistance of the load at the particular time. In particular, integrated analog circuits reach a high absolute precision level only at very high cost. Although, for example, differential circuit technologies known per se and trimming techniques which are known per se permit a certain degree of independence from technological variations and temperature effects, there are limits on these methods owing to the high degree of expenditure. Trimming the circuit by means of the temperature would take a very long time during fabrication and is therefore less advantageous in terms of fabrication with high production numbers.
[0011] In order to measure current, an arrangement composed of a sense FET in conjunction with a respectively assigned sense amplifier is used in the PWM stages according to the patent applications WO 02/058967 A2 (P 10057) and WO 03/039904 A2 (P 10253) which have already been mentioned. The sense FET which is used in this arrangement typically has a temperature-dependent switch-on resistance which already leads to an extremely high measurement error at least at currents in the mA range in conjunction with an offset error which is usually present in the sense amplifier.
[0012] The current measuring principle which is illustrated in FIG. 2 requires a minimum value for the switch-on period of the PWM signal for a current value to be able to be sensed under all peripheral conditions in every period. The consequence of this minimum value is that a minimum current, below which control is no longer possible, results depending on the ohmic resistance of the solenoid, the high side voltage at the inductance and the PWM frequency which is set. In the typical application case of an ACC controller for motor vehicles, it is therefore possible, for example, only to apply currents up to a minimum of 200 mA. However, ACC-optimized current/brake pressure characteristic curves of a valve solenoid usually require lower currents down to approximately 100 mA.
[0013] The resolution of a PWM current controller determines the precision levels with which currents can be set. This depends essentially on the maximum current which can be set and on the resolution of the A/D converter which is provided for measurement of the actual value of the current.
SUMMARY OF THE INVENTION
[0014] An object of the present invention is to specify a method and a circuit arrangement for PWM current control with which more precise and reliable setting of a current can be performed.
[0015] In the method according to aspects of the invention, the current within an integrated PWM control circuit is measured by means of at least one A/D converter which is, in particular, also integrated into the circuit. In this context, the A/D converter converts an electrical value which has preferably previously been determined with at least one current measuring element (for example resistor). Before the actual current of the PWM controller is acquired, said current being determined using the at least one A/D converter, the current is smoothed by means of a low pass filter. As a result of the current signal, or a voltage signal corresponding to a specific current, being smoothed, the time of an A/D conversion operation is largely independent of the current position within a PWM period. The smoothing of the current signal can either take place in the analog signal component or in the digital signal component of the current measuring path.
[0016] Preferably an analog low pass filter or a digital circuit which acts as a low pass filter can be used for the smoothing operation.
[0017] According to one preferred embodiment of the method, auto-calibration of the integrated circuit is carried out, during which auto-calibration correction values for the current are acquired and are used to correct the current. As a result, an absolute precision level of the current measured value—which precision level is limited owing to the usually in electronic components and in particular also in integrated analog components—can be increased even further. According to the method of auto-calibration, a continuous adjustment of the circuit is preferably carried out. This adjustment can be carried out in such a way that in addition to offset errors, which are long-term errors, short-term effects such as temperature fluctuations and voltage fluctuations are also compensated.
[0018] According to a first preferred embodiment of an auto-calibration method, the current is set using digital correction of the setpoint current demand.
[0019] The correction values preferably comprise offset values and gain factors.
[0020] The invention relates both to the method and to a circuit arrangement for measuring current.
[0021] In the circuit arrangement according to aspects of the invention, at least one low pass filter ( 11 ) for smoothing the current signal is provided in the signal path for measuring the current. In order to convert the current measured value, at least one A/D converter ( 19 ) and at least one current measuring element ( 30 , 30 ′) are provided. The low pass filter can be implemented either by means of an analog filter or a digital filter, in which case, depending on what kind of filter is used, the low pass filter is arranged either upstream or downstream of the A/D converter in the current-measuring signal path.
[0022] These and other aspects of the invention are illustrated in detail by way of the embodiments and are described with respect to the embodiments in the following, making reference to the Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention is best understood from the following detailed description when read in connection with the accompanying drawing. Included in the drawing are the following figures:
[0024] FIG. 1 shows the current profile in a PWM-controlled inductive load in a control circuit according to the prior art,
[0025] FIG. 2 shows just one PWM period of the current profile according to the prior art corresponding to FIG. 1 ,
[0026] FIG. 3 shows a schematic illustration of an output stage circuit with recirculation path according to the prior art,
[0027] FIG. 4 shows a circuit arrangement for measuring current in the driving path and recirculation path,
[0028] FIG. 5 shows a diagram for illustrating the smoothing of the current signal I L by means of low pass filtering,
[0029] FIG. 6 shows corresponding smoothing of the current signal I L through low pass filtering when the cutoff frequency of the filter is too low,
[0030] FIG. 7 shows corresponding smoothing of the current signal I L through low pass filtering with dynamic adaptation of the cutoff frequency of the filter,
[0031] FIG. 8 shows an exemplary embodiment of a circuit arrangement with an auto-calibration device, and
[0032] FIGS. 9 and 10 show a second exemplary embodiment of a circuit arrangement with an auto-calibration device and additional range adaptation means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The schematic illustration of an output stage circuit which is illustrated in FIG. 3 and has a low side driver 1 and a recirculation driver 2 serves to explain the illustrated currents during PWM driving of the inductive load L. The load L is connected to ground via the low side driver 1 , as a result of which the solenoid current rises exponentially when the maximum current has not yet been reached. In the switched-off state of the PWM driving means, the driver 2 is conductive, with the result that the decay current of the solenoid can flow through the recirculation path 3 . This causes the current to decay exponentially.
[0034] According to one exemplary embodiment of the invention, the current of the recirculation path 3 is also measured in order to measure the actual current of the current control means. This provides the advantage that current can be measured even with relatively short switch-on times of the PWM driving means.
[0035] In the circuit arrangement according to FIG. 4 , the current measuring signal 5 , 6 of the recirculation driver 2 and the current measuring signal 7 , 8 of the driver 1 are combined to form a common sum signal 9 and are directed via a low pass filter 11 . It is therefore possible to dispense with costly prioritization logic for A/D converters 10 , which logic defines the sequence during the evaluation of a plurality of PWM stages. The low pass filter 11 , 12 is embodied as a first order filter composed of a trimmable resistor 12 and a capacitor 35 , in which case the time constant of the low pass filter can be changed through the possibility of trimming the resistor 12 .
[0036] The currents in the respective power paths 1 and 2 are measured in a known fashion by means of sense FETs. Sense FETs make available a picture of the load current which is reduced by several orders of magnitude (for example a factor of 100-1000) and which flows through the power FETs. The measuring current 5 , 6 and 7 , 8 , respectively, is amplified by means of sense amplifiers OP 2 and OP 1 . The FSD-FET 13 illustrated in FIG. 4 is used to reduce the current more quickly (off-commutation), as is explained in patent application DE102004017239 (P 10676). By means of this reduction in the current which is known per se, the decay time of the solenoid current can be reduced from approximately 10 ms to approximately 1.5 ms.
[0037] The currents I LS and I HS are the currents of the low side path and of the recirculation path, respectively. The sum of the two currents I LS +I HS produces a voltage drop at the measuring resistor R meas which is amplified by means of the operational amplifier OP 3 . So that the currents I LS and I HS have the same direction, the current from the low side measuring circuit is fed via a current mirror 14 . The voltage which drops across the R meas is amplified by means of the operational amplifier OP 3 . Alternatively, the circuit can also be configured in such a way that the amplifier OP 3 acts as a voltage follower.
[0038] According to an alternative circuit example (not illustrated), the measured low side current and the recirculation current can also be combined directly by means of an NMOS current mirror. However, for this purpose, it is necessary for the amplifier OP 3 to be embodied as an inverting operational amplifier with the measuring resistor R meas in the feedback line, in which case the positive input is connected to a reference potential.
[0039] Since only either the current I LS or the current I HS ever flows during the operation of the circuit, an essentially continuous signal is available at the output of the amplifier OP 3 within one PWM period, both during the switch-on time and during the switch-off time.
[0040] In FIG. 5 , I L denotes the voltage signal present at the output end of amplifier OP 3 ( FIG. 4 ) in the time profile. Since each voltage value is assigned a specific current value, for reasons of simplicity the corresponding voltage values are denoted as currents. I avg denotes the signal which is present at the output of the low pass filter 11 , 12 . In FIG. 5 it is apparent that the signal I avg still has a small residual ripple. Owing to the inductance of the load, the current I L is subject to strong fluctuations. In the case of time-discrete measurements of the current, different current measured values are obtained, at least when the measurements take place at different times. The signal I L is smoothed by the low pass filter 11 , 12 whose cutoff frequency can be adapted. Time-discrete current measurements on which the smoothed signal I avg is based, can then be carried out with considerably greater precision than measurements using the unsmoothed signal I L .
[0041] FIG. 6 shows by way of example a load current I L which changes comparatively quickly and in which the smoothed current signal which is directed through the low pass filter 12 , 11 no longer follows quickly enough. In this case, in order to ensure a functioning PWM control process, the time constant of the low pass filter has to be reduced. However, a correspondingly low time constant then brings about incomplete smoothing of the signal and finally gives rise to a certain reduction in the precision of the current control. Although the cutoff frequency can be set on average in such a way that on the one hand signal smoothing occurs and on the other the current signal still reacts quickly enough to changes in current, the maximum possible current measuring precision is thus not yet achieved.
[0042] By using an adaptive low pass filter with a variable cutoff frequency it is possible, while continuing to use a circuit which is sparing in terms of components, at the same time to achieve satisfactory smoothing and improved dynamics. The change in the cutoff frequency can come about, for example, through driving a MOS transistor as a controllable resistor 12 which has a linear resistance range which is sufficient for the present purpose of use. Alternatively, instead of the transistor 12 , it is possible, for example, to use a switched capacitor circuit in which a variable resistance can be set by means of an auxiliary frequency which is used for driving purposes.
[0043] The adaptation of the cutoff frequency of the filter will be explained below using FIG. 7 . If a constant current I L is to be applied precisely in the time range 15 , the cutoff frequency f g of the low pass filter can be set to a comparatively low value. If the PWM controller is made to bring about a comparatively rapid change in current (see time range 16 ) through a new setpoint current demand, the cutoff frequency of the low pass filter is reduced to such an extent that sufficient dynamics are ensured. If the setpoint value and actual value of the current approach one another (see range 17 ), the cutoff frequency f g is then reduced successively again—which is preferred according to aspects of the invention—in order to achieve a high level of precision of control of the current.
[0044] The circuit illustrated in FIG. 8 constitutes an exemplary embodiment with an auto-calibration device and is based on the circuit example in FIG. 4 . In addition to the circuit in FIG. 4 , a digital, that is to say programmable, reference current source 22 is present, with which a reference current I ref can be generated. I ref is fed into the current path of the load via corresponding lines, in which case the current is also conducted via a measuring resistor R Ref — sense which is illustrated in FIG. 9 . Since particular precision of the reference current sources is not necessary, they can expediently easily be built up from elementary transistors, a suitable number of which are connected in parallel. In order to determine the current which is generated by the digital current source, an external measuring resistor (R ref — sense in FIG. 9 or R ref — redun in FIG. 10 ) is provided. “External” means here that the measuring resistor is, in contrast to the other circuit components, not a component of the integrated circuit. A voltage tap (also not illustrated) on said measuring resistor is routed to the A/D converter 10 . Furthermore, a digital compensation stage 18 is additionally provided. The compensation stage 18 comprises a digital input 23 with which a setpoint value (symbolized by box 19 ) which is predefined by the software can be corrected as a function of the digital input, for example by digitally adding or subtracting an offset value. The offset-compensated digital signal 20 is then fed into a digital PID controller 21 which serves to generate the duty cycle of the PWM (d.c.). The current sources I LS and I HS , respectively, symbolize the measured low side current and recirculation current, respectively. If the digital result which occurs at the output of the A/D converter does not correspond to what is expected, this deviation is a measure of the error made by the low side measuring path or recirculation measuring path.
[0045] In the circuit corresponding to FIG. 8 , a measuring current I ref is firstly fed into the low side path and subsequently into the recirculation path, and the actual current is respectively determined by means of the current measuring circuit. By comparing the actual current with the known measuring current I ref , a correction value is determined which is taken into account in the form of a digital correction in the compensation circuit 18 in order to correct the setpoint value 19 . If the comparison measurements are carried out differentially, it is also advantageously possible here for the A/D converter error to be taken into account. The compensation circuit leads to considerably more precise setting of the current during the PWM control process, in particular if each measuring path is evaluated separately in terms of its quality by correspondingly feeding in the measuring current I ref . This can be done particularly easily by virtue of the fact that the measuring current passes through the low side path and the recirculation path simultaneously. A further advantage of the compensation circuit which is described above is that less expensive, less precise analog ICs can be used.
[0046] The circuit illustrated in FIGS. 9 and 10 illustrates a second exemplary embodiment with an auto-calibration device, and for reasons of simplified illustration the circuit components for the low side path are illustrated in FIG. 9 , and the circuit components for the recirculation path are illustrated in FIG. 10 . The circuit is similar to the circuit in FIG. 8 and FIG. 4 so that only the existing differences will be explored below. In contrast to the current summation in FIG. 4 , in the concept according to FIGS. 9 and 10 the current measured value of the low side path and of the recirculation path are combined with one another by means of a voltage signal (node point 33 ). In principle, instead of the exemplary analog signal processing it is also possible to process digital data. In this case, the combination will expediently be implemented by means of a digital summing element. With the switch 24 ( 24 ′ in FIG. 10 ), the reference current I ref , which is fed in by the reference current source 22 ( 22 ′ in FIG. 10 ), can be directed via the measuring resistor R Ref — Sense (R Ref — redun in FIG. 10 ) or through the low side path 1 (recirculation path 2 in FIG. 10 ). Correspondingly, the input of the A/D converter 10 is connected either to R Ref — Sense or to the low side path 1 by means of the switches 25 and 26 ( 25 ′ and 26 ′ in FIG. 10 ). The arrangement of the power FET 27 ( 31 in FIG. 10 ) and sense FET 28 ( 32 in FIG. 10 ) in the low side path 1 comprises additional amplifier stages 27 ′ and 28 ′ which permit the measuring range to be adapted (see description further below). The offset can be compensated with the offset compensation stage 29 ( 29 ′ in FIG. 10 ), which is connected to the input of the operational amplifier OP 4 . In FIG. 10 , the output of the compensation stage 29 ′ is connected to similarly acting, further differential amplifier stages 34 , 36 which are explained in more detail below. An analog current signal for the recirculation path is available at the output 37 of the amplifier stage 36 , said recirculation path being connected to the terminal 38 in FIG. 9 .
[0047] A description is given below of how the individual measuring paths of the low side path and of the recirculation path can be adjusted by using trimmable current sources and resistances. To be more precise, this means that the reference current measurements have to respectively be carried out separately for the low side path and the recirculation path. First, a defined current is directed via R Ref — Sense ( FIG. 9 ). In this context, the switches 24 and 25 are in the position shown by unbroken lines in FIG. 9 . I Ref is read out by means of the A/D converter 10 . This defined current is then also applied to FET 27 ′. The switches 24 , 25 and 26 are then in the switched position illustrated by dashed lines. The current flowing through the sense FET 28 is read out by means of the A/D converter 10 . The above measurements are then repeated once more with a relatively low current. Corresponding to the measurements carried out with various reference currents, gain trimming is performed by means of a digital trimming resistor 30 ( 30 ′ in FIG. 10 ) in FIG. 4 . Furthermore, offset trimming is carried out with the circuit component 29 .
[0048] The calibration steps described above are preferably carried out iteratively both for the low side path ( FIG. 9 ) and for the recirculation path ( FIG. 10 ), in which case as the number of steps increases, the precision consisting of the offset and the gain factor increases incrementally. After a few iteration steps, the method can already generally be aborted since the precision of the iterative method then only increases to a small degree.
[0049] The above circuit examples each relate to a load driving channel of a multi-channel PWM output stage. Parts of the circuits, such as for example the external measuring resistor R Ref — Sense , are, however, only present once and are used by each channel of the stage. Correspondingly, the reference current measurements which relate to the external measuring resistor only have to be carried out once. All the other calibration measurements have to be carried out separately for each output stage channel.
[0050] The calibration method which is described above can also be repeated or continued at later times, even during the control process, on condition that the respective channel which is to be calibrated is not driven by the PWM driving means at this time.
[0051] The circuit examples in FIGS. 9 and 10 comprise, in addition to the FETs 27 , 28 , 31 and 32 , also additional circuit means 28 , 28 ′, 28 ″, 32 , 32 ′ and 32 ″ for increasing the resolution in the active current range. In the case of a 10 bit A/D converter, the resolution is limited over a range of 3 A to approximately 3 mA. A higher resolution can be achieved by limiting the measurable current range to a specific, required dynamic range. Therefore, for example with the circuit shown in FIG. 8 or FIG. 9 , switching over is possible between 1 A, 2 A and 3 A measurable maximum current through separately adding equally large sense FETs 28 ′ and 32 ′. Correspondingly, a possible resolution of 1 to 3 mA results in the respective range.
[0052] The selection of the current measuring range can be carried out by means of a logic unit, for example by taking into account the setpoint value of the current at that particular time.
[0053] The resolution of the A/D converter can also correspondingly be utilized better by firstly subtracting a suitable offset value and adding it again later, after the A/D conversion.
[0054] In addition it is possible, according to a further example of a circuit arrangement according to aspects of the invention, to extend said circuit arrangement with fail-safe structures 34 in such a way that a redundant current signal is available. It is particularly expedient here if the A/D converter 10 is provided, on the line 39 , with a measuring signal which is inverted compared to the other redundancy path (difference amplifier stage 36 composed of the voltage follower OP and downstream difference OP) or changed (see difference amplifier 34 ), as a result of which the A/D conversion can be checked.
[0055] While preferred embodiments of the invention have been described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. It is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.
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Method in which the current is measured inside an integrated PWM control circuit using at least one A/D converter which is likewise integrated in the circuit is described. The PWM controller is provided for the purpose of driving inductive loads and is arranged, in particular, in an electronic circuit of an electronic controller for a motor vehicle braking system. Before determining the actual current of the PWM controller, which is determined using the at least one A/D converter, the current is smoothed using a low-pass filter. A circuit arrangement for carrying out the above method and its use in electronic motor vehicle control systems is also described herein.
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BACKGROUND
This invention pertains generally to the cooling of a hermetic compressor pump used in cryogenic refrigeration. During operation, the pump compresses a mixture of oil and helium. The purpose of the oil is to absorb the heat produced in compressing helium and to provide lubrication to the pump. From the compressor, the mixture exits a feed line in which the oil is separated from the mixture. Conventional methods use an oil separator and then an oil adsorber to filter the oil out of the mixture. Once separated, the gas is then pumped to the cold head of a cryogenic refrigerator such as a Gifford-MacMahon cryogenic refrigerator disclosed in U.S. Pat. No. 3,218,815 to Chellis et al. After traveling through the refrigerator, the gas is returned to the compressor through a return line to start the process over again.
As a result of compressing helium, rather than freon which is used in other refrigeration systems, more heat is produced by the compressor pump. In order to maintain operating efficiency and prolong the life of the pump, this heat by-product must be removed.
DISCLOSURE OF THE INVENTION
In accordance with the invention, a hermetic refrigerant compressor pump which is used to compress helium is cooled by fins which are press fitted on to the compressor's housing. Preferably, each fin comprises a cylindrical blade surface and a flange bent away from the blade surface for engagement with the housing. By tapering the flange toward the axial center of the fin, heat conducted from the housing to the blade surface can be maximized.
The compressor is further cooled by an external heat exchanger which cools oil from an oil sump located within the compressor housing. Suction created by the compressor pump provides the mechanism for pumping oil from the sump, through the heat exchanger, before the oil is mixed with helium.
Preferably, there is a fan placed adjacent to the fins and the heat exchanger for directing a flow of air past the fins and the exchanger. Further, it is preferred that there is a means for separating oil from the compressed helium before it is used in a cryogenic refrigeration system.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 is an illustration of a partial cross section of a compressor pump.
FIG. 2 is a schematic illustration of a compressor system embodying the invention.
FIG. 3 is a cross section of a fin.
FIG. 4 is an illustration of a compressor pump having a plurality of fins press fitted to the compressor's housing.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a cryogenic refrigeration system which has a compressor pump cooled by a convection system. A partial cross section of a typical compressor pump 10 is shown in FIG. 1. The compressor pump 10 draws a helium gas and oil mixture through an inlet port 14 to a suction chamber 16 which is created as a rolling piston 18 rotates around a cylinder 20. The mixture is then compressed in a compression chamber 22 as the piston 18 makes a complete revolution around the cylinder 20. Simultaneously, more of the mixture is drawn into the suction chamber 16. A vane 24 which is biased to remain in contact with the rolling piston 18 defines the suction chamber 16 and the compression chamber 22. The compressed mixture is exhausted out an exhaust port 26.
The compressor pump 10 is located within a compressor housing 28, as shown in FIG. 2. As the compressed mixture is exhausted from the pump 10 into the housing 28, the bulk of the oil separates from the compressed gas and collects at an oil sump 30. The compressed gas is then fed into a feed line 32 for work in a cryogenic refrigerator 34 such as a Gifford-MacMahon cryogenic refrigerator. To further prepare the compressed gas for work it is preferred that the gas is cooled by a heat exchanger 36 and further filtered from oil by an oil seperator 38 and an absorber 40. The ordering of the filtering and cooling may be interchanged. Oil separated by the oil separator 38 may be returned to the pump 10 through a suction line 39.
Once the gas has performed work in the refrigerator 34, it is returned to the pump by a return line 42 connected to the inlet port 14. Preferrably, a check valve 43 has been placed along the return line 42 to prevent the flow of gas from back flowing to the refrigerator 34.
During operation of the refrigeration system, a considerable amount of heat is generated by the pump. In order to maintain operating efficiency and prolong the life of the pump, the compressor must be cooled. In accordance with the present invention, a series of fins 35 which serve as heat exchangers are press fitted to the housing of the hermetic compressor. Additionally, oil in the sump 30 is cooled by circulating it through an external heat exchanger 48.
As shown in FIG. 3, each fin 35 comprises a circular blade surface 52 and a center flange 54 bent away from the blade surface 52. Preferably, the fin 35 is made of a highly conductive material such as aluminum. To optimize the surface area in contact with the wall of the housing 28 and thereby maximize the amount of heat conducted to the fin, the flange 54 is inwardly tapered towards the axial center of the fin. When the fin is pressed onto the housing, the resiliance of the flange operates as a force to maximize the surface area in contact with the wall of the housing. The resiliance force also operates as a lock to prevent the fin from moving once it has been placed on the housing. Further, contact between the housing and the fins 35 can be increased by wedging the flange 54 between a curved portion 55 of another fin and the wall of the housing 28 as shown in FIG. 4. Wedging the flange in this manner also helps lock the fin in place along the housing.
Referring back to FIG. 2, the compressor is also cooled by pumping oil from the oil sump 30 through an external heat exchanger 48. Oil cooled by this heat exchanger 48 is then returned to the pump 10 through an orifice 49. Suction created by the pump 10 serves as the mechanism used to pump the oil through this heat exchanger 48 as well as from the separator 38 and to pump gas from the refrigerator 34.
Situated between the heat exchangers 36 and 48 and the fins 35 on the housing is a fan 50. During operation, the fan 50 directs a flow of air past the heat exchangers 36 and 48 and the fins 35 to increase the cooling rate of the overall compressor system.
While this invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention as defined in the appended claims. For example, gases other than helium may be used. Further, a pressure valve may be used between the feed line and the return line to regulate the presssure of the system.
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In accordance with the invention, a hermetic refrigerant compressor pump which is used to compress helium is cooled by fins which are press fitted to the compressor's housing. The compressor is further cooled by a heat exchanger which cools oil in an oil sump located within the compressor housing. Preferably, a fan is located between the fins and the heat exchanger to help cool the pump.
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TECHNICAL FIELD
[0001] The disclosure relates to the new energy vehicle power control design field and, in particular, relates to a hybrid power-train torque control method and a hybrid vehicle to which the method is applied.
BACKGROUND ART
[0002] Hybrid vehicles are largely different from conventional vehicles in their power-trains, the hybrid power-train featuring in multi-power sources, complex operation modes, and substantial engine-motor response characteristic distinction. Appropriately distributing power between the multi-power sources, i.e., how to couple and output torques of power source components, has a substantial effect on smooth performance and reliability of operation of the power-train.
SUMMARY
[0003] An object intended to be achieved in the disclosure is to provide a hybrid power-train torque control method for ensuring smoothness of output of the power-train and better response of the power-train and for optimizing drive ability of a hybrid vehicle.
[0004] The object is achieved by the following technical solution.
[0005] A hybrid power-train torque control method, power source components of the power-train including an engine and a motor, comprising steps of:
[0006] (1) interpreting driver's torque requirement, including:
(1a) calculating a maximum torque achievable from the power-train; (1b) calculating a power-train load rate according to driver's instruction; and (1c) calculating the torque requirement based on the maximum torque and the power-train load rate; and
[0010] (2) torque distributing and coordinating between the power sources, including:
(2a) distributing the torque requirement between the power sources, to obtain at least an engine pre-distributed torque for the engine and a motor pre-distributed torque for the motor; and (2b) acquiring an output torque of the engine in real time, calculating the difference between the output torque and the engine pre-distributed torque, and compensating the difference with the motor.
[0013] Two parts are included in the hybrid power-train torque control method to which the disclosure relates: 1. driver's torque requirement interpretation; and 2. torque distribution and coordination between the power sources. For the hybrid-powered electric vehicle, operation modes of its power-train should include at least one or two or even more power source torque coupling modes, including but not limited to, a parallel mode, a parallel mode, a pure electric drive mode, a serial mode, and any combination thereof, which are common for hybrid power-trains.
[0014] The driver's torque requirement interpretation includes several aspects as follows: 1. calculating a maximum torque ability of the hybrid power-train; 2. calculating a power-train load rate desired by the driver; 3. torque distributing and coordinating; and 4. torque requirement filtering. The maximum torque ability of the hybrid power-train is the maximum driving torque achievable in all operation modes in a current state of the power-train (the state of components, such as traction batteries, motors, and engine etc.), without limited by the current operation mode. The power-train load rate desired by the driver denotes a proportion of the power performance required by the driver to the total ability of the power-train, wherein the total ability of the power-train not only can refer to the optimal performance achievable by the system in the most optimized state, but also can refer to the maximum ability achievable from the power-train in the current state. As for the torque distributing and coordinating, driver's initial torque requirement is obtained based on the maximum torque ability of the hybrid power-train and the driver's desired load rate. The driver's initial torque requirement is arbitrated with other torque requirements (which may include, but not limited to, constant speed cruise torque requirement etc.) to obtain a first intermediate torque, and the first intermediate torque is limited depending on the operation mode of the hybrid power-train and arbitrated to obtain a second intermediate torque. The torque requirement filtering means limiting a change rate of the second intermediate torque obtained in the previous step with a filter, making it to follow the desired power performance for the driver while not causing shaking and vibrating of the power-train or the whole vehicle due to the rapidly change of the torque. The driver's torque requirement is finally obtained.
[0015] During the driver's torque requirement interpretation, an accelerator pedal Map profile, but not limited to the accelerator pedal Map profile, can be used in the driver's desired power-train load rate calculation. An input of the accelerator pedal Map profile may be accelerator pedal opening (depressed degree) and signals characterizing the power-train or the whole vehicle speed, including a vehicle speed, a rotating speed of an output shaft of a driving system, and a rotating speed of an input shaft of the driving system. The Map profile is embodied as a discrete storage manner of calibrated data, typically in the form of a one-dimensional or two-dimensional table. For the one-dimensional table, a variable is input as an input value for table look-up, and the difference value between two break points on the input shaft which are most closest is calculated out as an output value; and for the two-dimensional table, two variables are input as input values for table look-up, and the difference value between two break points on the input shaft which are most closest is calculated out as an output value.
[0016] The torque distributing and coordinating in the driver's torque requirement interpretation can be carried out by three, but not limited to three, methods, including: (1) multiplying the real-time maximum torque ability of the hybrid power-train by the driver's desired load rate to obtain the initial torque requirement; (2) multiplying the torque ability of the hybrid power-train in an optimal state by the driver's desired load rate to obtain the initial torque requirement; and (3) multiplying load rate requirement outputted in a basic part of the accelerator pedal Map profile by a constant reference torque, multiplying an assistant part of the accelerator pedal Map profile by the difference between the real-time maximum torque ability of the hybrid power-train and the constant reference torque, and adding the two multiplied results to obtain the initial torque requirement.
[0017] The torque requirement filtering in the driver's torque requirement interpretation can be carried out by the following methods, but not limited to these methods: (1) choosing torque slope control to the change rate based on the state of the hybrid power-train and other parameters; (2) choosing a first-order filtration control to a time constant based on the state of the hybrid power-train and other parameters; and (3) choosing a second-order filtration control to a time constant based on the state of the hybrid power-train and other parameters.
[0018] The torque distributing and coordinating between the multiple power sources means distributing the driver's torque requirement obtained by the interpretation to the power sources driving the vehicle in the current operation mode, fundamentally based on energy management strategy and efficiency optimization strategy of the hybrid power-train. The torque distributing and coordinating between the multiple power sources mainly includes several aspects as follows: 1. torque pre-distribution between the power sources; 2. filtration and change rate limitation; and 3. torque dynamical compensation. The torque pre-distribution between the power sources means determining preliminary torque requirements of the power sources, such as the engine and the motor, based on the energy management strategy, i.e. the desired power which is required for charging, discharging, or charging and discharging traction batteries; and based on the efficiency optimization strategy, i.e. the current engine load with which the optimal overall fuel efficiency is achieved. Filtering and change rate limiting means filtering and slope limiting the outputted torques, provided that the preliminary torque requirements for the power sources have been determined, and in consideration of torque response characteristic of the engine and of the motor. The torque dynamical compensation includes, in view of the fact that the engine has a slower torque response than the motor, measuring in real time the difference between the engine torque requirement and an actual engine output torque, and compensating the difference with the motor to ensure that the total torque output of the power sources conforms to the driver's torque requirement.
[0019] The disclosure also provides a hybrid vehicle, wherein the torque control method described as above is applied to a power-train of the hybrid vehicle. The same or even better drive ability can be achieved for the hybrid vehicle compared with conventional power vehicles.
[0020] The disclosure has beneficial effects which lie in that: (1) for a hybrid power-train having multiple operation modes, the drive ability control method can ensure a consistent driving feeling of the driver within a real-time power source torque ability, that is, whichever operation mode the hybrid power-train operates in, the same vehicle speed and the same accelerator pedal opening always leads to the same total torque requirement of the power-train, and (2) the method facilitates match calibration of the hybrid power-train, wherein the driver torque requirement interpretation is optimized firstly, total torque output loads of power sources and final results of the driver's torque requirement interpretation in all operation modes are ensured depending on different operation modes, and implementing and testing are facilitated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The disclosure will be better understood with reference to the drawings. It is easily understood for those skilled in the art that the drawing are given only for an illustration purpose and are not intended to limit the protecting scope of the disclosure.
[0022] FIGS. 1-7 are illustrative views of steps of a hybrid power-train torque control method that the disclosure relates to.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] Particular embodiments of the disclosure are now described in detail in connection with the drawings, in order for those skilled in the art to better understand the subject matter claimed by the disclosure.
[0024] The term “drive ability” cited in the disclosure includes two aspects: (1) match of a desired power output for a driver and an actual power output, wherein, as an example, in a condition of 10% depressed degree of an accelerator pedal and at a speed of 50 kph (kilometres per hour), an desired acceleration of the driver is generally 1 m/s 2 , and therefore a required power torque (Nm) can be estimated based on a drag force of a vehicle of a target type at the speed of 50 kph, the whole vehicle mass etc. and be considered as a primary result of torque explanation; and (2) ride comfort and response speed with reference to the power output, wherein high frequency components contained in the power torque required by the driver are eliminated and medium and low frequency components are selected after filtration to balance the response speed and the ride comfort.
[0025] An example of an embodiment of a drive ability control method for a hybrid power electrical vehicle is described in the following. This embodiment is directed to a full hybrid power-train with two motors (an integrated starter and generator ISG and a driving motor TM, wherein, hereinafter, a first motor refers to the integrated starter and generator ISG and a second motor refers to the driving motor TM). The hybrid power-train has operation modes including: a pure electric drive mode, a serial mode, and a parallel mode.
[0026] The driver torque requirement interpretation includes calculation of maximum torque ability of the hybrid power-train, calculation of driver's desired power-train load rate, torque arbitration and limitation, and torque requirement filtration.
[0027] Referring to FIG. 1 , the maximum torque ability of the hybrid power-train refers to the maximum torque achievable in the parallel mode in a current state of the power-train (the states of components of traction batteries, the motors, an engine etc.). In the parallel mode, the engine, the first motor and the second motor are all connected to a driving system, and the maximum torque of the power-train in the parallel mode is larger than in other modes, provided that the traction batteries have a normal dischargable power.
[0028] Referring to FIGS. 2-3 , the driver's desired power-train load rate includes two parts: a basic part and an assistant part. Each of the basic part and the assistant part has an accelerator pedal Map profile. Only the basic part is included in the driver's desired power-train load rate and the assistant part has a load rate of 0 in cases of medium and low accelerator pedal openings. In cases that the accelerator pedal opening is above the medium accelerator pedal opening, the basic part Map profile rises up to a 100% load rate output first, and then the load rate of the assistant part increases as the accelerator pedal opening increase, up to 100%. Driver's basic torque requirement is derived by multiplying the load rate outputted in the basic part Map profile by a fixed curve of torque-speed characteristic. The fixed curve of torque-speed characteristic is established based on holding torque ability of the engine and of the motors and is obtained through smooth transition. Driver's assistant torque requirement is derived by multiplying the load rate outputted in the assistant part Map profile by the difference between the maximum torque ability of the hybrid system and the fixed torque characteristic. In this way, driver's initial torque requirement is then obtained as the sum of the driver's basic torque requirement and the driver's assistant torque requirement.
[0029] Referring to FIGS. 3-4 , the driver's initial torque requirement is subjected to arbitration based on cruise control torque requirement, wherein the so called arbitration means choosing one from a plurality. A first intermediate torque is derived through the arbitration first, a second intermediate torque is derived then after the first intermediate torque being limited by the maximum torque of the driving system, and, finally, the second intermediate torque is subjected to the drive ability filtration to smoothly transition the torque requirement.
[0030] Operation mode torque limitation means setting an “upper limit” for the torque requirement according to the current actual operation mode, and the torque ability is adjusted to be matched with a corresponding mode only when the current actual operation mode is switched to the corresponding mode. Typical conditions, for example, from the serial mode to the parallel mode, the torque ability in the serial mode is typically lower than in the parallel mode.
[0031] When the driver's torque requirement in the serial mode increases and exceeds the maximum ability in the serial mode, limitation is carried out also based on the maximum torque in the serial mode, and at this time, switching from the serial mode to the parallel mode can be triggered and limitation is then carried out based on the maximum torque in the parallel mode after the switch. In this embodiment, the drive ability filtration is performed in a manner of torque change rate control, i.e., correcting the torque change rate based on the vehicle speed, the accelerator pedal opening, and the difference between the torques before and after filtration, in order to obtain a final torque requirement. The term filtration, as a relatively broard concept herein, can be interpreted as converting raw, non-uniform signals (in respect of the frequency domain, signals containing relatively more high frequency components) into uniform signals (in respect of the frequency domain, signals containing medium and low frequency components), and can be achieved by a variety of technical means, one of which is controlling the change rate of the second intermediate torque (others include: a first-order filtration, a second-order filtration etc.). The change rate is represented by Newton-meter per second (Nm/s) and refers to the level of the change rate of the torque in time domain. This ensures a driver's target torque to be achieved, the ride comfort is obtained, and there is no notable power lag for the driver.
[0032] Multi-power source torque distribution and coordination includes torque pre-distribution between the power sources, filtration and change rate limitation of the torques, and torque dynamical compensation.
[0033] Referring to FIGS. 5-7 , during the torque pre-distribution between the power sources, the torque requirement is pre-distributed preliminarily to the engine, the first motor, and the second motor depending on energy management strategy and efficiency optimization strategy, to obtain a first pre-distributed torque for the engine, a first pre-distributed torque for the first motor, and a first pre-distributed torque for the second motor. The requirement is subjected to filtration and change rate limitation and is converted into torque requirement for the engine, torque requirement for the first motor, and torque requirement for the second motor, which are a second pre-distributed torque for the engine, a second pre-distributed torque for the first motor, and a second pre-distributed torque for the second motor, respectively, in consideration of torque response characteristic of the engine and of the motors. During torque dynamical compensation, the difference between the engine torque requirement and an actual engine output torque is monitored in real time and is compensated with the first motor and/or the second motor, in order that the total torque output of the power sources is consistent with the driver's torque requirement.
[0034] By way of example, the torque pre-distribution between the power sources will be explained below. In a first step, in a condition that the driver's torque requirement is determined as 100 Nm with the speed of the power-train of 2000 rpm, it can be derived, through energy optimization algorithm (or an efficiency optimization Map profile obtained through offline optimization calculation), that the result of pre-distribution includes an engine output of 120 Nm and a total motor output of −20 Nm and the overall efficiency is optimal. Therefore, the pre-distribution plan is 100 Nm for the engine and −20 Nm for the motor. However, in an actual drive condition, it takes a long time for the engine torque to increase and the engine has a slower response than the motor, initiatively lowering the engine torque change rate facilitating emission and improving fuel economy. Therefore, in the above condition, the actual torque output of the engine may be 110 Nm. In order to ensure that the driver's torque requirement be met, further correction is needed to do to the motor torque so that an output of −10 Nm, instead of −20 Nm, is obtained. The exact desired distribution results, i.e. 120 Nm for the engine and −20 Nm for the motor, can only be obtained after a period of time when driving cycle characteristic becomes stable.
[0035] While some particular embodiments of the disclosure have been described and illustrated to show the principle of the disclosure, the disclosure can be implemented in other ways without departing from its principle.
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A hybrid system torque control method and hybrid automobile using same, the method comprising the following steps: (1) analyzing the torque required by a driver; (2) allocating and coordinating the multiple-source torque. The method ensures a consistent driving feel within the range of real-time power source torque capacity, and facilitates hybrid system matching.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a process for making acrylic coating resins and more specifically to superior solvent blends useful in the synthesis of acrylic high solids coating resins.
2. Description of the Prior Art
A large variety of acrylic coating compositions are known. Low solids coatings, i.e., those containing about 18 to 40 wt.% solids and the balance solvents, have heretofore been developed in which the resins themselves are characterized by high molecular weights, e.g., molecular weights in the range of 20,000 to 40,000. Such high solvent concentrations are required with these high molecular weight resins in order to supply flowability and other properties necessary for ease in applying a uniform coating. Due to strict air pollution regulations, pollution abatement of solvents is of paramount importance. To this end, the industry has expended much effort in attempting to develop high solids coatings, that is, coatings having low molecular weight resins (e.g., from about 1,000 to 6,000 molecular weight) in order to reduce the amount of solvents necessary in the blend for coating applications and, hence, the pollution difficulties associated with the solvents themselves. These high solids acrylic coatings are useful as exterior finish for automobiles, trucks, airplanes and as an appliance finish.
Illustrative of prior art, high solids acrylic resins are those disclosed in U.S. Pat. No. 4,276,212 and in European patent application Nos. 27,719; 29,339; 29,594 and 29,683.
The prior art has employed a variety of solvents in the preparation of their high solids coatings and it is desirable to employ the same solvent both as the polymerization solvent and as the coating solvent to avoid the need to remove a polymerization solvent before formulating the high solids coatings from a polymerized resin.
Solvents which are indicated to be typical in these references (e.g., those mentioned in European patent application No. 29,594) are: toluene, xylene, butyl acetate, acetone, methyl isobutyl ketone, methyl amyl ketone, methyl ethyl ketone, butyl alcohol and other aliphatic, cycloaliphatic and aromatic hydrocarbons, esters, ethers, ketones, and alcohols.
SUMMARY OF THE INVENTION
According to the present invention, an improved method for preparing acrylic copolymer resins is provided in which the polymerization solvent comprises a blend of methyl isobutyl ketone and certain alkyl-substituted benzene solvents. The monomers comprise hydroxy-substituted alkyl(meth)acrylates, and non-hydroxy substituted alkyl(meth)acrylates, and the process provides an improved method for forming low molecular weight acrylic resins useful as components in acrylic coatings. The polymerization solvent can remain in the resin to become the solvent employed in the higher solids coating containing the thus-formed acrylic resins and provide improved electrical resistivity, improved solvency and decreased surface tensions over prior art polymerization solvents.
In addition, the solvent blends of this invention provide the low-molecular weight acrylic resins at lower reflux temperatures which give significant process advantages, among them lower energy requirements and ease of pollution control. Surprisingly, the solvent blend of this invention produces low molecular weight acrylic copolymers which are characterized by superior molecular weight and viscosity properties, and are therefore especially suited for use in high solids coatings.
DETAILED DESCRIPTION OF THE INVENTION
According to the improved process of this invention, acrylic polymers are prepared by contacting under polymerizing conditions a hydroxy-substituted alkyl(meth)acrylate and a non-hydroxy substituted alkyl(meth)acrylate in the presence of a free radical polymerization catalyst and a polymerization solvent comprising from about 35 to 80 wt.% methyl isobutyl ketone and the balance an aromatic solvent containing as a majority component an alkyl-substituted benzene in which the alkyl substituent(s) comprise a total of at least 2 carbon atoms when the benzene ring is mono-alkyl substituted and of at least 3 carbon atoms when the benzene ring is substituted by two or more alkyl groups.
The hydroxy-substituted alkyl(meth)acrylates which can be employed comprise members selected from the group consisting of the following esters of acrylic or methacrylic acid and aliphatic glycols: 2-hydroxy ethyl acrylate; 3-chloro-2-hydroxypropyl acrylate; 2-hydroxy-1-methylethyl acrylate; 2-hydroxypropyl acrylate; 3-hydroxypropyl acrylate; 2,3-dihydroxypropyl acrylate; 2,3-dihydroxypropyl acrylate; 2-hydroxybutyl acrylate; 4-hydroxybutyl acrylate; diethyleneglycol acrylate; 5-hydroxypentyl acrylate; 6-hydroxyhexyl acrylate; triethyleneglycol acrylate; 7-hydroxyheptyl acrylate 2-hydroxy-1-methylethyl methacrylate; 2-hydroxypropyl methacrylate; 3-hydroxypropyl methacrylate; 2,3-dihydroxypropyl methacrylate; 2-hydroxybutyl methacrylate; 4-hydroxybutyl methacrylate; 3,4-dihydroxybutyl methacrylate; 5-hydroxypentyl methacrylate; 6-hydroxyhexyl methacrylate; 1,3-dimethyl-3-hydroxybutyl methacrylate; 5,6-dihydroxyhexyl methacrylate; and 7-hydroxyheptyl methacrylate. Although one of ordinary skill in the art will recognize that many different hydroxy-substituted alkyl(meth)acrylates including those listed above could be employed, the preferred hydroxy functional monomers for use in the resin of this invention are hydroxy-substituted (meth)acrylates, meaning alkyl acrylates and methacrylates having a total of 5 to 7 carbon atoms, i.e., esters of C 2 -C 3 dihydric alcohols and acrylic or methacrylic acids.
Most preferably, the hydroxy-substituted alkyl(meth)acrylate monomer comprises a compound of the formula (I): ##STR1## wherein R 1 is hydrogen or methyl and R 2 and R 3 are independently selected from the group consisting of hydrogen and alkyl of from 1 to 6 carbon atoms. Illustrative of these particularly suitable hydroxy-substituted alkyl(meth)acrylate monomers are 2-hydroxy ethyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, 2-hydroxybutyl acrylate and 2-hydroxy-1-methylhexyl acrylate.
Among the non-hydroxy substituted alkyl(meth)acrylate monomers which may be employed are (meth)acrylates (as before, meaning esters of either acrylic or methacrylic acids) as well as mixtures of acrylates and vinyl hydrocarbons. Preferred non-hydroxy unsaturated monomers are esters of C 1 -C 12 monohydric alcohols and acrylic or methacrylic acids, e.g., methylmethacrylate, ethylacrylate, butylacrylate, butyl-methacrylate, hexylacrylate, 2-ethylhexylacrylate, lauryl-methacrylate, glycidyl methacrylate, etc.
Particularly preferred non-hydroxy substituted monomers are compounds selected from the group consisting of monomers of the formula (II): ##STR2## wherein R 4 is alkyl of from 1 to 6 carbon atoms and R 5 is hydrogen or methyl. Particularly preferred are butyl acrylate, butyl methacrylate and methyl methacrylate.
The total monomer mixture passed to the polymerization process step will generally comprise from about 5 to 30 wt.%, and preferably from about 10 to 20 wt.%, of the hydroxy-substituted alkyl(meth)acrylate and from about 5 to 95 wt.%, preferably from about 70 to 90 wt.% of the non-hydroxy substituted alkyl(meth)acrylate monomer, in addition to any optional monomers (discussed below). The non-hydroxy substituted (meth)acrylate will typically comprise a mixture of methyl methacrylate or methyl acrylate, which will be present in an amount of from about 5 to 30 wt.%, more preferably from about 10 to 25 wt.%, of the total monomer mixture, and up to about 60 wt.%, more preferably from about 25 to 45 wt.%, of the total monomer mixture of butyl acrylate, butyl methacrylate, or mixtures thereof.
Additional optional monomers which can be employed in the polymerization are monovinyl aromatic hydrocarbons containing from 8 to 12 carbon atoms, including styrene, alpha-methyl styrene, vinyl toluene, t-butyl styrene, chlorostyrene and the like. Where employed, these optional monovinyl hydrocarbons will be generally present in an amount of from about 5 to 30 wt.%, preferably from about 10 to 20 wt.% of the total monomer mixture.
In addition, other modifying monomers such as vinyl chloride, acrylonitrile, methacrylonitrile, vinyl acetate and acrylic acid may also be present. In the case of acrylic acid, when employed, this monomer will generally be present in an amount from about 2 to 5 wt.% of the total monomer mixture. The remaining above-mentioned modifying monomers will generally be present in an amount of from 3 to 10 wt.% of the monomer mixture, where employed.
The polymerization solvent of this invention comprises a mixture of methyl isobutyl ketone (MIBK) and an aromatic solvent. The MIBK component of the solvent will be generally present in an amount of from about 35 to 80 wt.%, preferably from about 50 to 75 wt.%, of the solvent mixture, and the aromatic solvent component will be present in an amount of from about 65 to 20 wt.%, preferably from about 50 to 25 wt.%, of the solvent mixture. The aromatic solvent component comprises at least one aromatic hydrocarbon solvent containing as a majority component an alkyl-substituted benzene in which the alkyl substituent (as disclosed) comprise a total of at least 2 carbon atoms when the benzene ring is mono-alkyl substituted and of at least 3 carbon atoms when the benzene ring is substituted by two or more alkyl groups. More preferably, the aromatic solvent component comprises an alkyl-substituted benzene of the formula (III): ##STR3## wherein n is an integer of from 1 to 4, and X is in each instance in which it appears independently selected from the group consisting of straight and branched-chain alkyl of from 1 to 4 carbon atoms, with the proviso that when n is 1, X must contain at least 2 carbon atoms and with the further proviso that when n is 2 or greater, the X groups must contain a total of at least 3 carbon atoms, and mixtures of the foregoing aromatic compounds.
Illustrative of suitable alkyl-substituted benzene solvents for use in the solvent blends of this invention are ethyl benzene, isopropyl benzene, n-propyl benzene, 1-methyl-3-ethylbenzene, 1-methyl-4-ethylbenzene, 1,3,5-trimethylbenzene, 1-methyl-2-ethylbenzene, 1,2,4-trimethylbenzene, isobutylbenzene, sec-butylbenzene, 1-methyl-3-isopropylbenzene, 1-methyl-4-isopropylbenzene, 1,2,3-trimethylbenzene, 1-methyl-2-isopropylbenzene, 1,3-diethylbenzene, 1-methyl-3-n-propylbenzene, n-butylbenzene, 1,4-diethylbenzene, 1,3-dimethyl-5-ethylbenzene, 1,4-dimethyl-2-ethylbenzene, 1,3-dimethyl-4-ethylbenzene, 1,2-dimethyl-4-ethylbenzene, 1,2,4,5-tetramethylbenzene, 1,2,3,5-tetramethylbenzene and the like, and mixtures of the foregoing.
The aromatic solvent component can also contain up to about 50 wt.%, preferably less than about 40 wt.%, and more preferably up to about 25 wt.%, of other hydrocarbon solvents such as C 6 to C 14 aromatic solvents not satisfying the definition of formula III above, as well as C 6 to C 14 saturated aliphatic and cycloaliphatic hydrocarbons.
In preparing the polymers of this invention, the selected monomers, including the required hydroxy-substituted alkyl(meth)acrylate, and non-hydroxy substituted alkyl(meth)acrylate, together with any modifying or other monomers, may be mixed and reacted by conventional free radical initiated polymerization in such proportions as to obtain the copolymer desired, this reaction being effected in the presence of the solvent blend of this invention. A large number of free radical initiators are known to the art and are suitable for the purpose. These include: benzoyl peroxide; lauryl peroxide; t-butylhydroxy peroxide; acetylcyclohexylsulfonyl peroxide; diisobutyryl peroxide; di-(2-ethylhexyl)peroxydicarbonate; diisopropylperoxydicarbonate; t-butylperoxypivalate; decanoyl peroxide, azobis-(2-methylpropionitrile), 2-t-butylazo-2-cyanobutane, etc.
The total monomer mixture to be employed in preparing the polymers according to the process of this invention will generally comprise from about 40 to 80 wt.%, preferably from about 50 to 60 wt.%, of the total mass of monomers and solvent passed to the polymerization reaction vessel. Thus, the MIBK/alkyl-substituted benzene solvent blend of this invention will generally comprise from about 20 to 60 wt.%, preferably from about 40 to 50 wt.%, of the total mass of monomers and solvent passed to the polymerization vessel. The quantity of free radical initiators employed as catalyst in the reaction can also vary widely and will generally be present in an amount of from about 0.5 to 5 wt.% of the total monomer components charged to the reaction mixture.
The conditions of temperature and pressure for conducting the polymerization reaction can vary widely. Generally, the polymerization will be conducted at reflux temperature of the reaction mixture, which will generally range at from about 120° to 135° C. at atmospheric pressure. Pressures of from about 10 to 500 psig are entirely suitable, although higher or lower pressures can be employed. The polymerization reaction can be carried out in any of the conventional equipment employed by the industry for such reactions. Thus, the reaction vessel can comprise a stirred reactor in which an inert atmosphere (e.g., N 2 , Ar) is maintained during the polymerization to avoid reactions with gaseous oxygen which compete, or interfere, with the desired polymerization reaction.
The polymerization process can be carried out batchwise, semi-continuously, or continuously. The monomers and solvent can be premixed or passed separately to the polymerization vessel alone, or in combination with the free radical initiators and other components.
The time for which the polymerization reaction is allowed to proceed can also vary widely and will generally range from about 0.5 to 10 hours, preferably from about 1 to 6 hours.
The acrylic resins produced by the process of this invention are characterized by number average molecular weights of from about 1,000 to about 6,000, and preferably from about 2,500 to about 4,500. These acrylic resins can then be employed in the formulation of coatings with or without the addition of other solvents. The components of such coating compositions formulated using these acrylic resins can be any of the conventional catalysts, antioxidants, UV absorbers and stabilizers, surface modifiers, wetting agents as well as pigments. These materials are conventional and a more complete description thereof is not necessary for a full understanding of this invention. For example, illustrative conventional UV absorbers and stabilizers are illustrated by those discussed in European Patent Application No. 29,594.
The coatings prepared by use of the acrylic resins of this invention can be applied to substrates, such as automobiles and the like, using conventional methods known to the art, such as roller coating, spray coating, electrostatic spray coating, dipping or brushing. Of course, the particular application technique will depend on the particular substrate to be coated and the environment in which the coating operation is to take place. A particularly preferred technique for applying the high solids compositions, particularly when applying the same to automobiles as top coats, is spray coating through the nozzle of a spray gun.
The process and compositions of this invention can be further illustrated by reference to the following examples, wherein parts are by weight unless otherwise indicated.
In the Examples, the MIBK/alkyl-substituted benzene solvent blends of this invention were formulated using AROMATIC 100™ solvent (manufactured by Exxon Company USA) which comprised a narrow-cut aromatic solvent containing about 40 wt.% trimethyl benzenes, 35 wt.% methyl ethyl benzenes, 10 wt.% propyl and isopropyl benzenes, 3 wt.% ethyl dimethyl benzenes, 2 wt.% methyl (n- and iso-) propyl benzenes, 2 wt.% diethyl benzenes, <1 wt.% each of mono butyl benzenes and tetramethyl benzenes, 6 wt.% xylenes and minor amounts of ethyl benzene, C 10 and C 11 saturates and unknowns.
Solvent resistivities in the Examples were determined using a Beckman Conductivity Bridge Model RC-16C. Number average molecular weights (M n ) and weight average molecular weights (M w ) were found by gel permeation chromatography. Inherent viscosities (η inh ) were determined from the relation ##EQU1## where C=grams of polymer per 100 ml. of solution and η rel =[(viscosity of solution)÷(viscosity of solvent)]. (Solutions, for viscosity determinations, contained 1.5-1.7 grams of polymer per 100 ml. of solution.)
EXAMPLE 1
To a one liter flask equipped with a mechanical stirrer, two addition funnels and a reflux condenser was added 164 grams of methyl isobutyl ketone (MIBK) and 76 grams of AROMATIC 100™ solvent (Exxon Company USA). One of the addition funnels (500 ml. capacity) contained:
______________________________________ Grams Wt. %______________________________________Hydroxyethyl acrylate 60 20Methyl methacrylate 60 20Styrene 30 10Butyl methacrylate 150 50 300 100______________________________________
The second addition funnel of 50 ml capacity contained 15 grams of azobis(isobutyronitrile) dissolved in 25 ml. of acetone. The liquids in the two addition funnels and in the reaction flask were kept under a nitrogen blanket (1 atm. N 2 ). The solvent blend in the reaction flask was heated to reflux temperature (124°-128° C.) and the contents of the two funnels were added slowly, with stirring over a period of 2 hours. Periodically, acetone was allowed to evaporate through the top of the condenser and was removed to maintain the selected reflux temperature. After completion of the addition, stirring and heating was continued for an additional one-half hour. Then 2 more grams of azobis(isobutyronitrile) dissolved in 10 ml. of acetone were added in small portions and stirring and heating was continued for 2 hours to complete the polymerization. The polymer solution thus prepared had an inherent viscosity (η inh ) of 0.082 and a solids content of 51.8 wt.%. The number average molecular weight, M n =1660 and M w /M n =3.68. The solvent resistivity was 80 mega ohms.
COMPARATIVE EXAMPLE 1A
The procedure of Example 1 was repeated except that the solvent comprised methyl amyl ketone (240 grams). The reflux temperature in this run was about 146° C.
The resultant acrylic polymer had an inherent viscosity of 0.073, M n =1,240 and M w /M n =3.60. The solvent resistivity was 22 mega ohms.
EXAMPLE 2
Following the procedure of Example 1, the following mixture was charged to the first dropping funnel:
______________________________________ Wt. Wt. %______________________________________Hydroxyethyl acrylate 60 20.0Methyl methacrylate 60 20.0Styrene 30 10.0Butyl acrylate 142 47.3Acrylic acid 8 2.7 300 100.0______________________________________
The charge to the second addition funnel comprised 9 grams of azobis(isobutyronitrile) and 20 grams of acetone. The contents of these two funnels were then added dropwise with stirring over a period of 2 hours at refluxing conditions to the glass flask containing the selected solvent, which in this example comprised 164 grams of MIBK and 76 grams of AROMATIC 100™ solvent mixture. After addition of the contents of the two addition funnels, stirring was continued at reflux conditions for an additional one-half hour. Then, 2 grams of azobis(isobutyronitrile) in 10 ml. of acetone were added dropwise and reflux was continued for an additional 1.5 hours.
The acrylic resin thus produced was then recovered and analyzed, yielding the data set forth in Table I.
COMPARATIVE EXAMPLES 2A AND 2B
The procedure of Example 2 was repeated in a series of additional runs except that the solvent comprised 240 grams of methyl amyl ketone or 240 grams of methyl isobutyl ketone. The data thereby obtained are also set forth in Table I.
TABLE I__________________________________________________________________________ Solvent Reflux Acrylic CopolymerExampleSolvent Resistivity Temp. kin.No. System (mega ohms) (°C.) M.sub.n M.sub.w /M.sub.n η.sub.inh vis.*__________________________________________________________________________2 MIBK/Aromatic 80 128 2,244 3.87 0.102 ˜215100 Solvent2-A MAK 22 146 2,280 5.89 0.092 2092-B MIBK 28 124 2,818 8.84 0.110 --__________________________________________________________________________ *kinematic viscosity (cps)
EXAMPLE 3
The procedure of Example 2 was repeated except that the initiator was t-butylazo-2-cyanobutane (9 grams) dissolved in 25 ml. MIBK. The reaction flask contained 139 grams MIBK and 76 grams AROMATIC 100™ solvent. The addition was completed in 3 hours with continuous heating and stirring, having a reflux temperature of 124°-128° C. As in Example 2, an additional 2 grams of t-butylazo-2-cyanobutane was added in small portions and the heating and stirring was continued for 2 hours. The acrylic polymer thus obtained had an inherent viscosity of 0.093, M n =2,490 and M w /M n =5.52 (determined by GPC). The copolymer solution was also found to have a kinematic viscosity of about 215 cps.
EXAMPLE 4
Example 3 was repeated and the resultant polymer was found to have η inh =0.089, M n =2,299 and M w /M n =4.99. The kinematic viscosity of the polymer solution was 219 cps.
EXAMPLE 5
The procedure of Example 3 was repeated except that the initiator (15 grams of t-butylazo-2-cyanobutane) was mixed with the monomer blend in the addition funnel. The reaction flask contained 164 grams of MIBK and 76 grams of AROMATIC 100™ solvent. The final copolymer was found to have η inh =0.089, M n =2,195 and M w /M n =4.86.
COMPARATIVE EXAMPLE 6
The procedure of Example 2 was repeated except that the initiator, azobis(isobutyronitrile) was dissolved in 25 ml. of acetone and then mixed with the monomer blend to facilitate the addition of the initiator and except that the solvent charged to the reaction flask comprised 164 grams MIBK and 78 grams of toluene. A reflux temperature was maintained during the run of 120° C. The resultant polymer was found to have η inh =0.098, M n =3,519 and M w /M n =91.37. The very wide molecular weight distribution (very high M w /M n ) renders this copolymer product unsuitable for acrylic higher solids coatings.
COMPARATIVE EXAMPLE 7
The procedure of Example 2 was repeated except that 240 grams of xylene was charged to the reaction flask instead of the MIBK/AROMATIC 100™ solvent. The resultant acrylic copolymer solution was found to have an inherent viscosity of 0.084 and a kinematic viscosity of 692 cps, which makes the copolymer solution unacceptable for formulation of higher solids coatings.
COMPARATIVE EXAMPLE 8
The procedure of Example 7 was repeated except that 240 grams of toluene was employed as the polymerization solvent in the reaction flask. The polymer solution which was thus obtained was found to have an inherent viscosity of 0.104 and a kinematic viscosity of 690 cps which is unacceptable for the formulation of higher solids coatings.
EXAMPLE 9
Following the procedure of Example 1, the following acrylic monomers were charged in the large addition funnel, together with 15 grams t-butylazo-2-cyanobutane as initiator:
______________________________________ Grams Wt. %______________________________________Hydroxyethyl acrylate 60 20.0Methyl methacrylate 80 26.7Styrene 30 10.0Butyl methacrylate 30 10.0Butyl acrylate 100 33.3 300 100.0______________________________________
The monomer blend was added dropwise with constant stirring to the reaction flask containing 164 grams of MIBK and 76 grams of AROMATIC 100™ solvent, at reflux conditions. As before, the liquids were protected with an atmosphere of nitrogen. The addition was completed in 2 hours, and the stirring and heating was continued for an additional one-half hour. Then, 2 grams of t-butylazo-2-cyanobutane initiator were added in small portions, and stirring and heating was continued for another 2 hours. The resultant polymer had an inherent viscosity of 0.080. M n =2,240 and M w /M n =2.59. The kinematic viscosity of the polymer solution was in the range of 200-240 cps, as determined by visually observing the ease of flow of the polymer solution when poured. The flowability of the polymer solution was observed to be comparable to the polymer solution obtained in Example 4.
The MIBK/alkyl-substituted benzene polymerization-solvent systems of this invention have been found to produce acrylic polymer solutions, having kinematic viscosities of less than about 400 cps, and preferably less than about 300 cps, which are particularly suited for use in formulating high solids coatings.
It will be obvious that various changes and modifications may be made without departing from the invention and it is intended, therefore, that all matter contained in the foregoing description shall be interpreted as illustrative only and not limitative of the invention.
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According to the present invention, an improved method for providing acrylic copolymer resins is provided in which the polymerization solvent comprises a blend of methyl isobutyl ketone and certain alkyl-substituted benzene solvents. The monomers comprise hydroxy-substituted alkyl (meth)acrylate monomers and non-hydroxy substituted alkyl (meth)acrylate monomers, and the process provides an improved method for forming low molecular weight acrylic resins useful as components in acrylic coatings. The polymerization solvent can remain in the resin to become a solvent employed in the higher solids coating containing the thus-formed acrylic resins and provides improved electrical resistivity, improved solvency and decreased surface tensions over prior art polymerization solvents.
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This application is a continuation-in-part of U.S. patent application Ser. No. 08/953,119 filed Oct. 17, 1997 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a method of cleaning broken glass. More specifically to a method and plant for removing labels and debris from broken glass and preparing it for processing in a crusher/classifier where it is further crushed and sorted into smaller pieces or grades to be used in a variety of applications.
Typical recycling of glass has in the past, been a labor intensive industry as glass bottles of different colors are often sorted into separate areas prior to melting. When this glass is melted, labels, adhesives and other materials are generally burned away. The melted glass may then be processed and mixed with virgin glass as necessary.
A second type of glass recycling involves crushing glass into small particles. The processing of glass in this manner requires that the glass remain below a temperature of 600 degrees Fahrenheit, as the molecular structure of the glass begins to change above this temperature, rendering the glass unsuitable for crushing.
One of the primary uses for crushed glass is in abrasive blasting, which has replaced sand blasting in many areas. Sand blasting has commonly used silica sand as the abrasive element in the procedure. The use of silica sand has been banned or severely restricted in many areas. This is due to the silica dust contained in silica sand. Silica dust has been found to be one the most dangerous types of dust that a human can breath. Due to the toxicity of silica dust, it has been necessary to replace the sand in blasting with other abrasive media. It has been discovered that finely crushed or powdered glass has excellent qualities when used as an abrasive material. Current uses have included industrial blasting of steel equipment all the way to medical uses including abrasive blasting of dental fixtures such as dentures.
A second use for finely crushed or ground glass is as a filter media for potable public water supplies. Much research is currently being done using crushed glass as a filter media in place of sand which is typically used. Glass has been found to be superior to sand in filtering, and responds more favorably to back washing than sand filters. Still other uses include additives for paint and tiles, while larger pieces may be used for decorative applications such as gravel in fish tanks.
Recycled glass used for crushing has, in the past, been manually sorted, removing the bottles which have paper labels or adhesives. Typically, any glass which does not contain lead is suitable for use in the crushing process, regardless of color. During sorting and recycling many pieces are broken into quarter size pieces and smaller this type of glass, when of a uniform color, is referred to as cullet. If the crushed glass is not sorted as to color the resulting product is referred to as mixed cullet. Mixed cullet containing labels and label adhesives has, in the past, been unsuitable for crushing, as the labels could not easily be removed. Further, this glass is usually unsuitable for melting as it cannot easily be color sorted. Thus, this glass or mixed cullet has ended up as land fill material.
From this discussion it can be seen that it would be desirable to create a plant and method for cleaning dirty cullet containing labels so that it may be used for crushing and thus, recycled instead of ending up as land fill material. Further, it can be seen that it would be desirable to provide such a method that would remove labels and adhesives in a manner that would not change the molecular structure of the glass contained therein
The present invention addresses these problems by providing a large tumbling device into which broken pieces of labeled glass such as beverage bottles, or cullet, are fed. The glass is tumbled and passed through a flame which heats the cullet to a temperature well below 600 degrees Fahrenheit (the temperature at which the molecular structure of glass begins to change) but high enough to burn a large percentage of the labels from the glass. The tumbling process is repeated numerous times, ensuring that high percentage of the foreign material is removed, before the cullet passes through the entirety of the chamber and is cooled to be processed into the desired grades. The present invention also offers other advantages over the prior art and solves various problems associated therewith.
SUMMARY OF THE INVENTION
It is the primary objective of the present invention to provide a means by which the vast amount of labeled glass that is discarded today can be reused in an economical and efficient manner without regard for the original color of the glass being processed.
It is an additional objective of the present invention to provide a means of removing labels and other debris from the surface of this discarded glass which most typically consists of the glass bottles used in beverage production.
It is a still further objective of the present invention to provide a means of removing this debris in a manner that does not change the molecular structure of the glass that is being processed.
These objectives are accomplished through the use of a large tumbling device into which broken pieces of labeled glass, or cullet, are fed. After entering the interior chamber of the tumbler, the cullet is carried by a plurality of interior fins along the inside circumference of the tumbler to a point where they fall back to the low point of the tumbler. During this fall, the cullet passes through a flame generated in the interior cavity of said tumbler. The flame heats the cullet to a temperature of approximately 430 degrees Fahrenheit which is well above the flash point of the foreign labeling material on the cullet. Additionally, the temperature inside the chamber is well below 600 degrees Fahrenheit (the temperature at which the molecular structure of glass begins to change) therefore ensuring that the processed glass retains its original properties. This process is repeated numerous times, ensuring that a high percentage of the foreign material is removed, before the cullet passes through the entirety of the chamber and is cooled to be processed into the desired grades.
For a better understanding of the improvements provided by the present invention, reference should be made to the drawings in which there is illustrated and described preferred embodiments of the present invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of the broken glass cleaning plant showing its major components and the orientation of the other equipment used in conjunction with it during operation.
FIG. 2 is a front elevation view of the present invention showing the orientation of its forward major components and their relationship to the material bins and conveyor belts during operation.
FIG. 3 is a rear elevation view of the present invention showing the orientation of its rearward major components and their relationship to the material bins and conveyor belts during operation.
FIG. 4 is a front elevation view of the gas delivery system of the present invention detailing the manner in which gas is supplied to the burner and the method by which it is mixed with air prior to ignition.
FIG. 5 is a top elevation view of the gas delivery system of the present invention, again detailing the manner in which gas is supplied to the burner, and the method by which it is mixed with air prior to ignition.
FIG. 6 is a rear elevation view of the present invention showing the manner of construction of the rear glass tumbler cover and the orientation of the external exhaust and cooling air components of said invention.
FIG. 7 is a side elevation cut-away view of the combustion chamber of the present invention showing the manner of construction of the burner, the exhaust collection manifold and the glass collection fins located therein.
FIG. 8 is a side elevation cut-away view of the cooling chamber of the present invention showing the manner of construction of the exhaust and cooling components of said invention.
FIG. 9 is a front elevation cut-away view of the combustion chamber of the present invention showing the manner in which glass particles are collected by the internal fins and carried to a point at which they will fall through the gas flame generated by the burner.
FIG. 10 is a side elevation of the drive system of the present invention detailing the manner in which the drive tire engages the drive ring on the tumbler cylinder and the manner by which said tire is driven by the electric motor.
FIG. 11 is a top elevation view of the drive system of the present invention showing how it is attached to the frame of said invention and detailing the manner in which the two drive tires are driven by a single drive axle.
FIG. 12 is a side elevation view of an alternative embodiment of the present invention which employs a stepped tumbling chamber and an improved method of cooling the product prior to its exit from the chamber.
FIG. 13 is a side elevation of the cooling chamber component of the alternative embodiment of the present invention detailing the manner of construction of the cool air intake portion of the invention.
FIG. 14 is a side elevation cut-away view of the alternative embodiment of the present invention detailing the internal construction of the exhaust manifold.
FIG. 15 is a side elevation internal view of the alternative embodiment of the present invention detailing the manner of construction and operation of the chamber divider plate.
FIG. 16 is a side elevation cut-away view of the alternative embodiment of the present invention detailing the internal construction of the connection between the combustion and cooling chambers.
FIG. 17 is a sectional side elevation view of the connection point between the combustion chamber and the divider plate of the alternative embodiment of the present invention illustrating the manner in which a seal is obtained in the is connection.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more specifically to FIGS. 1, 2 and 3 , the broken glass cleaning plant 10 is made up of a large tumbler cylinder 12 which is mounted at a slight front to rear downward sloping angle on the tumbler frame 18 . The frame 18 is positioned and held in place by the use of the front support legs 20 and the rear support legs 22 which are mounted respectively to the front and rear portions of the frame 18 and are all individually adjustable to allow for the level deployment of the present invention on an uneven surface. This feature facilitates the even flow of glass through the present invention during operation.
The primary mechanism by which the tumbler cylinder is held in place is by the use of the rear drive wheels 26 and the front idler wheels 56 which respectively engage the front idler ring 14 and the rear drive ring 16 which, in turn, each extend slightly outward from and completely encircle the outside circumference of the tumbler cylinder 12 . The tumbler cylinder itself is constructed in a manner that allows its outside shell to rotate freely while the inside components remain in a stationary position. Therefore, as rotational force is supplied to the drive wheels 26 it is transferred to the tumbler cylinder 12 . Additionally, the drive wheels 26 work in conjunction with the idler wheels 56 to keep the tumbler cylinder 12 in the correct longitudinal position in relation to the other components of the present invention. Thus, the idler wheels 56 and the drive wheels 26 not only support the majority of the weight of the tumbler cylinder 12 , but also provide the rotational force and longitudinal stability necessary to facilitate the movement of glass through the present invention.
During operation, the present invention is typically used in conjunction with other equipment such as a raw material bin 36 , a clean material bin 38 , and a crusher/classifier 44 . The raw material bin 36 is positioned towards the front of the tumbler cylinder 12 and provides the storage capacity for the materials to be processed by the present invention. Broken glass is dumped into the open top of the raw material bin 36 and during operation is metered out the bottom onto the raw material conveyor 58 . The raw material conveyor 58 then moves the glass to the front of the tumbler cylinder 12 and dumps it into the raw material collector 80 where it then enters the interior of the present invention for processing.
Once the glass cleaning process is completed, the cleaned glass exits the rear of the tumbler cylinder 12 through the clean material chute 70 and drops into the clean material collector 54 where it is picked up by the clean material conveyor 42 and transferred to the open top of the clean material bin 38 . From here, the cleaned material is metered out the bottom and onto the crusher/classifier conveyor 43 , which transfers it to the crusher/classifier 44 which processes the raw material into the different grades desired. This entire operation is controlled by the control box 24 located on the frame 18 towards the front of the tumbler cylinder 12 .
These figures also illustrate the location of the major external components of the present invention. These include the gas feed line 46 , which supplies the gas to the gas manifold 62 (and therefore the gas used in the burning process) located on the forward end of the tumbler cylinder 12 . Also included in the gas supply system are the main gas vent 48 , which provides the OSHA required venting mechanism for the gas system, the pilot gas feed 66 , which provides a method for system ignition during plant start up, and the pilot gas vent 50 , which vents the pilot system to the outside air.
At the rear of the tumbler cylinder 12 there is located the rear tumbler cover 52 , which provides the rear seal for the tumbler cylinder 12 . The rear tumbler 52 cover also is the attachment point for the exhaust venting and cooling systems of the present invention. Exhaust produced by the plants combustion process exits through the exhaust trap 40 , which serves to trap any larger air borne particles in the exhaust, and into the exhaust stack 28 . This exhaust system is powered by the exhaust fan 30 , which is located at the furthest point on the exhaust stack 28 , and draws the exhaust gases from tumbler cylinder 12 .
The rear tumbler cover 52 is vented in its outward surface by the cool air intake ports 76 , which allows cool air to enter the rear of the tumbler cylinder 12 and helps to cool the cleaned material before it exits the plant. This process is enhanced by the use of the cooling stack 32 and the cooling fan 34 , which are connected to the tumbler cylinder 12 through the rear tumbler cover 52 . The cooling fan 34 , located at the furthest point on the cooling stack 32 , serves to draw cool air into the tumbler cylinder 12 through the cool air intake ports 76 .
The gas delivery and burning systems of the present invention are illustrated in FIGS. 2, 4 , 5 , and 7 . Gas for the burning process is supplied from an outside source through the gas feed line 46 and into the gas regulator 68 . From this point it travels through the manifold gas feed line 64 to the gas manifold 62 . Air is supplied to the manifold 62 by the air blower 60 which is fixed to the most forward end of the frame 18 below the tumbler cylinder 12 .
From the gas manifold 62 the gas/air mixture is forced, by the air pressure created by the air blower 60 , into the gas burner 84 which extends from the gas manifold 62 into the combustion chamber 102 of the tumbler cylinder 12 . The gas burner 84 is made up of the burner pressure side 86 and the burner back-pressure side 88 . These two components meet and join at the furthest extent of the burner 84 and thus, in conjunction with the gas manifold 62 , form a continuous ring of pressurized gas/air mixture to feed the burner 84 . The purpose of this design of the burner 84 is that if a straight burner tube was used, the flame screen 90 furthest from the gas manifold 62 would be supplied with less gas than the portion located closer to the gas manifold 62 and would, therefore, operate less efficiently. This configuration ensures that all of the flame screen 90 , of the present invention, is supplied with an equal amount of gas/air mixture and, therefore, operates at an equal level of efficiency.
The gas/air mixture leaving the manifold 62 and entering the burner 84 is ignited by the pilot 82 . The pilot is supplied with gas by means of the pilot gas feed 66 which, through the pilot gas regulator 78 , takes gas from the manifold gas feed line 64 . Both the main gas and pilot gas supply systems are vented to the outside, as required by law, by the use of the main gas vent 48 and pilot gas vent 50 .
The manner in which the glass particles 108 , or cullet, pass through, and are processed by the present invention, is detailed in FIGS. 6, 7 , 8 , and 9 . After entering the combustion chamber 102 of the tumbler cylinder 12 , the glass particles fall to the lowest point of the internal surface of the rotating tumbler cylinder 12 . At this point the glass particles are picked up by one of the plurality of glass collection flightings 94 which line and extend inwardly from the interior wall of the tumbler cylinder 12 . The glass particles are then carried by these flightings 94 to a point along the interior which corresponds to about 10 O'clock at which point, and continuing to about 11:30, they to fall back to the lowest point of the rotating tumbler cylinder 12 . As the glass particles fall, they pass through the burner flame 106 that extends from the burner 84 towards the nearer portion of the rotating tumbler cylinder 12 . The movement of the glass particles 108 is facilitated by the glass collection flighting 94 and the general front to back slope of the tumbler cylinder 12 . Therefore, the glass particles 108 , or cullet, repeatedly go through this process as they pass down the length of the combustion chamber 102 .
By the afore described process, the glass particles 108 in the combustion chamber 102 are heated to a temperature of between 410 and 450 degrees Fahrenheit. This temperature is sufficient to remove a vast majority of the paper and other substances used in labeling bottles. It is also important that this temperature is well below the temperature at which the molecular structure of the glass begins to alter, or about 600 degrees Fahrenheit. Therefore, the finished product obtained by this process retains all of the desirable properties of the raw material glass.
The tumbler cylinder 12 is internally divided by the chamber divider plate 96 which serves to separate the combustion chamber 102 , at the front end of the cylinder from the cooling chamber 104 , located at the rear. The chamber divider plate 96 is held in place by the divider plate support 98 which extends down the length of, and is attached to either end of, the tumbler cylinder 12 . This configuration allows for the separation of the internal area of the tumbler cylinder 12 , which provides for the partial cooling of the cleaner glass particles 108 , before they leave the present invention.
As the glass particles pass underneath the chamber divider plate 96 , and into the cooling chamber 104 , the falling action facilitated by the glass collection flighting 94 continues. This provides the maximum cooling of the glass particles 108 , as each has a high degree off contact with the unheated air of the cooling chamber 104 . This is optimized by the continuous introduction of outside air into the cooling chamber 104 by the use of the cool air stacks 100 , the cooling air stack 32 , and cooling air fan 34 . The outside air enters the cooling chamber 104 through the rear tumbler cover 52 , and the cool air intake ports 76 , and are introduced well inside of the cooling chamber 104 by the use of the cool air stacks 100 . Air movement in this system is provided by the cooling fan 34 which is located at the far end of the cooling stack 32 and connected to the upper end of the cooling chamber 104 . This process cools the glass particles before leaving the tumbler cylinder 12 .
The exhaust gases produced in the combustion chamber 102 are collected by the exhaust collection manifold 92 , which is a vented pipe extending from the exhaust stack 28 , into the combustion chamber 104 . The negative pressure necessary in moving the exhaust from the collection manifold 92 to the exhaust stack 28 , is provided by the exhaust fan 30 located at the far end of the exhaust stack 28 . As the exhaust passes from the collection manifold 92 to the exhaust stack 28 , it passes through the exhaust trap 40 where larger particles contained in the exhaust gases are trapped. It is at this point that the temperature and the pressure of the produced exhaust gases are monitored by the use of the exhaust pressure sensor 72 and the exhaust temperature sensor 74 .
The drive system that provides the rotational force necessary to rotate the tumbler cylinder is illustrated in FIGS. 10 and 11. The drive wheels 26 engage the drive ring 16 that entirely encircles the outside circumference of the tumbler cylinder 12 . The rotational force is supplied to the drive tires 26 by the electric motor 114 , which is mounted on the inside wall of the frame 18 . The electric motor 114 supplies rotational power to the drive gear box 116 through the drive belt 118 . The gear box 116 then rotates the drive axle 112 which in turn drives the wheel drive chains 110 and, therefore, the drive wheels 26 . The drive axle 112 is held in place by being attached at its front and rear ends to the two drive system cross-members 122 , which perpendicularly span the distance between the two parallel members of the frame 18 .
Perpendicularly attached across the drive system cross-members 122 are the drive wheel supports 120 , which provide the attachment points for the drive wheels 26 . In addition to the rotational force that this configuration provides, it also supplies most of the support to the tumbler cylinder 12 by bearing the weight of said cylinder between the two drive wheels 26 used.
An alternative embodiment of the present invention is illustrated in FIGS. 12, 13 , 14 , 15 , 16 , and 17 . The purpose of this embodiment of the invention is to provide a means by which the glass particles 108 leaving the combustion chamber 102 can be more effectively cooled before exiting the invention than in the previous embodiment. This is accomplished by the use of a stepped tumbler cylinder 124 which has a cooling chamber 104 that is significantly larger in diameter than the combustion chamber 102 . The primary benefit of this larger cooling chamber 104 is that it allows for the introduction of larger amounts of cool outside air into the chamber 104 where it contacts and cools the glass particles 108 and further moves a greater rotational distance.
The general exterior manner of construction of the stepped cooling chamber 104 and the orientation of the air intake and exhaust components are illustrated in FIG. 12 . This Figure clearly shows the step between the combustion and cooling chambers, 103 and 104 , and also illustrates that this embodiment of the invention still employs the front and rear idler rings, 14 and 16 , that are used in the previous embodiment to rotate the tumbler cylinder 124 during operation. The remaining components illustrated in this Figure depict additional components that, for the purposes of this discussion, are specific to this later embodiment but it must be made clear that any of these components could also be used with the previous or any other embodiment of the present invention.
The stepped tumbler cylinder 124 illustrated in FIG. 12 also has an additional air exhaust system that is designed to work with the larger cooling chamber 104 to lower the temperature of the glass particles 108 leaving the invention. The primary component of this exhaust system is the exhaust manifold 126 which fits around and encloses the portion of the stepped tumbler 124 at the point at which the combustion and cooling chambers, 102 and 104 , are joined together. This forms a chamber at this point which is connected through an air damper 130 and the cool air exhaust stack 128 to the bag house 136 . The bag house 136 is equipped with a powerful fan which serves to draw fresh air from the cooling chamber 104 , through the cool air exhaust stack 128 , and into the interior of the bag house 136 where impurities are removed prior to the release of the air. The flow of this air through these systems is controlled by the stack damper 130 located just above the exhaust manifold.
This system is also connected just above the exhaust stack damper 130 to the hot air exhaust stack 132 which serves to remove the heated air generated within the combustion chamber 102 during the operation of the invention. The flow of air in the hot air exhaust stack is generated by the fan in the bag house 136 through the connection above the exhaust stack damper 130 and is itself controlled by the use of the hot air damper 134 . These connected air exhaust systems allow for the removal and cleansing of all the air used by the present invention through one device which increases the overall operating efficiency of all the invention's components.
The manner in which the cooling air is introduced to the cooling chamber 104 and the manner in which it passes from the interior of the chamber 104 to the interior of the exhaust manifold are illustrated in FIGS. 13 and 14. The flow of air into the cooling chamber 104 is controlled by the cooling chamber air intake 138 which is essentially a cap that seals off the end of the cooling chamber 104 that is opposite the exhaust manifold 126 . The cooling chamber air intake 138 is made up of two cooling chamber doors 152 which can be opened outwards from the center to allow access to the interior of the cooling chamber for cleaning and other maintenance. The cooling chamber air intake 138 is also equipped with a plurality of air louvers 140 which are a series of longitudinal flaps that can be opened or closed to control the flow of air depending on the needs of the cooling chamber 104 .
The flow of air through the cooling chamber 104 and into the exhaust manifold 126 is also facilitated by the use of the air exhaust slots 142 which are located in the surface of the cooling chamber 104 within the portion that is enclosed by the exhaust manifold 126 . The air exhaust slots 142 are a plurality of holes that are cut into the exterior shell of the cooling chamber 104 and which allow for the passage of air from the interior of the chamber 104 to the exhaust manifold 126 . This design allows the fan that is contained within the bag house 136 to draw cool air into the cooling chamber 102 through the air louvers 140 and then into the exhaust manifold 126 and bag house 136 through the air exhaust slots 140 . This ensures that an adequate amount of cool air is always available to cool the glass particles 108 that are passing through the invention.
This embodiment of the present invention is also equipped with a specially designed chamber divider plate 96 which is further illustrated in FIGS. 15 and 16 and that effectively separates the combustion chamber 102 from the cooling chamber 104 . As in the previous embodiment of the invention, the divider plate 96 is held in place by the use of the divider plate support bar 98 which extends for the length of the tumbler cylinder 124 . However, the divider plate 96 in this embodiment is only open between the chambers in one small diagonally cut area called the divider plate dispersion slot 144 which is located at its lower most edge. This design allows the glass particles 108 to pass from the combustion chamber 102 to the cooling chamber 104 through this small opening while limiting the amount of heated air that gets into the cooling chamber 104 . This limited transfer of heat to the cooling chamber 104 occurs because of the relatively small size of the divider plate dispersion slot 144 and its location on the lowest possible area as the heat tends to rise within the combustion chamber 102 .
These Figures also illustrate the manner in which the glass particles 108 pass from the combustion chamber 102 to the cooling chamber 104 . At the portion of the combustion chamber 102 that is at the center of the tumbler cylinder 124 the glass particles 108 fall to the lowest part of the interior of the combustion chamber 102 . From this point, the glass particles 108 are forced through the dispersion slot 144 and the dispersion spout 154 at the bottom of the divider plate 96 and they fall onto the lowest part of the interior of the cooling chamber 104 at a point beyond the location of the air exhaust slots 142 where they are picked up by the movement initiators 146 which begins their transference to the rear of the cooling chamber 104 where they exit the invention in a cooled state.
Finally, the divider plate 96 of this embodiment of the present invention is also equipped with a mechanism which allows the combustion chamber 102 to be sealed off from the cooling chamber 104 . This design feature is detailed in FIG. 17 and is accomplished by the design of the outer edge of the divider plate 96 . The outer edge of the divider plate 96 is manufactured in a U-shaped lip 148 that extends over the outside edge of the combustion chamber 102 . This divider plate lip 148 at its most rearward edge extends slightly down towards the outer surface of the combustion chamber 102 . At this point, there is attached a high temperature rubber seal 150 (this attachment being made by a seal bolt 154 which passes through the seal 150 and the divider plate lip 148 ) which extends down to the point at which it contacts the surface of the combustion chamber 102 . This not only creates a seal between the combustion chamber and the cooling chamber 104 , but also creates a seal between the interior of the tumbler cylinder 124 and the outside air. This ensures that the exhaust forces supplied to the interior of the tumbler cylinder 124 by the bag house 136 work effectively and enhance the operation of the invention.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
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A large tumbling device into which broken pieces of labeled glass such as beverage bottles, or cullet, are fed. After entering the interior chamber of the tumbler, the cullet is carried by a plurality of interior fins along the inside circumference of the tumbler to a point where the glass falls back to the low point of the tumbler. During this fall, the cullet passes through a flame generated in the interior cavity of said tumbler. The glass is heated to a temperature well below 600 degrees Fahrenheit (the temperature at which the molecular structure of glass begins to change) therefore ensuring that the processed glass retains its original properties. This process is repeated numerous times, ensuring that all of the foreign material is removed, before the cullet passes through the entirety of the chamber and is cooled to be processed into the desired grades.
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FIELD OF INVENTION
[0001] The invention relates to the catalytic oxidation of alcohols to aldehydes, in particular the formation of benzaldehyde and diformylfuran, which are useful as intermediates for a multiplicity of purposes. The invention also relates to the polymerization and the decarbonylation of a dialdehyde.
BACKGROUND
[0002] 5-(Hydroxymethyl)furfural (HMF) is a versatile intermediate that can be obtained in high yield from biomass sources such as naturally occurring carbohydrates, including fructose, glucose, sucrose, and starch. Specifically, HMF is a conversion product of hexoses with 6 carbon atoms. It is known that HMF can be oxidized using a variety of reagents to form any of four different products, which can themselves be converted to one or more of the others:
[0003] The selective oxidation of an alcohol functionality in the presence of an aldehyde functionality on the same compound is difficult because of the high reactivity of the aldehyde group. Furthermore, if HMF is reacted with molecular oxygen (O 2 ), the aldehyde functionality would be expected to oxidize more rapidly than the alcohol and the expected product would be predominantly 5-(hydroxymethyl)furan-2-carboxylic acid (Sheldon, R. A. and Kochi, J. K. “Metal Catalyzed Oxidations of Organic Compounds”, Academic Press, New York, N.Y. 1981, p 19).
[0004] Diformylfuran (DFF) has been prepared from HMF using CrO 3 and K 2 Cr 2 O 7 (L. Cottier et al., Org Prep. Proced Int. (1995), 27(5), 564; JP 54009260) but these methods are expensive and results in large amounts of inorganic salts as waste. Heterogeneous catalysis using vanadium compounds has also been used, but the catalysts have shown low turnover numbers (DE 19615878, Moreau, C. et al., Stud. Surf Sci. Catal ( 1997), 108, 399-406). Catalytic oxidation has been demonstrated using hydrogen peroxide (M. P. J. Van Deurzen, Carbohydrate Chem. (1997), 16(3), 299) and dinitrogen tetraoxide (JP 55049368) which are expensive. The relatively inexpensive molecular oxygen (O 2 ) has been used with a Pt/C catalyst (U.S. Pat. No.4,977,283) to form both DFF and furan-2,5-dicarboxlic acid (FDA), but yielded low amounts of DFF. Good yields were found for FDA, but only as the disodium salt which resulted in wasteful salt formation during conversion to the acid form.
[0005] Metal bromide catalysts have been used to oxidize substituted alkylbenzenes to various products including the oxidation of alkyl to aldehydes, alkyl to alcohols, alkyl to acids, alcohol to acid, and aldehydes to acids (W. Partenheimer, Catalysis Today, 23(2), 69-158, (1995)). However, in such cases, the aldehyde product is either a minor component or is quickly oxidized further. FDA has also been prepared using a Co/Mn/Br catalyst from 5-methyfurfural with DFF seen as a minor byproduct (V. A. Slavinskaya, et al., React. Kinet. Catal. Lett. (1979), 11(3), 215-20).
[0006] DFF has been polymerized to form polypinacols and polyvinyls (Cooke, et al., Macromolecules 1991, 24, 1404). However, preparation of polyesters prepared from diformylfuran is not known in the literature.
[0007] DFF can also be used to produce unsubstituted furan. Unsubstituted furan is an important commodity in the chemical industry used in the production of tetahydrofuran. Supported metal catalysts have been used in the decarbonylation of the monoaldehyde furfural to furan, but a basic promoter is required, adding expense and complexity to the process (U.S. Pat. No.3,007,941, U.S. Pat. No. 4,780,552).
[0008] Considering the aforementioned discussion, there is a need for an inexpensive, high yield process for the preparation of both DFP and FDA that does not produce large amounts of waste products and which lends itself to easy separation and purification. Additionally, there is a need for a high yielding. process to prepare unsubstituted furan from relatively inexpensive, renewable sources.
SUMMARY OF THE INVENTION
[0009] The invention is directed to a first process for the preparation of a dialdehyde comprising a) contacting a compound containing an alcohol functionality and an aldehyde functionality with an oxidant in the presence of a metal bromide catalyst; and b) optionally isolating the dialdehyde product. A preferred metal bromide catalyst comprises a source of bromine and at least one metal selected from the group consisting of Co and Mn, and optionally containing Zr. More preferably the metal bromide catalyst contains Co.
[0010] Preferably the dialdehyde is of the formula H(C═O)—R—(C═O)H and the compound is of the formula HOH 2 C—R—(C═O)H, wherein R is selected from the group consisting of an optionally substituted C 1 -C 20 alkyl or aryl group. The R groups can be linear or cyclic, or a heterocyclic group. More preferably, R is furan, and most preferably the dialdehyde is 2,5-di(formyl)furan. The process of the present invention can be run in a solvent mixture comprising at least one aliphatic C 2 -C 6 monocarboxylic acid compound, preferably acetic acid.
[0011] The invention is further directed to a second process for the preparation of a diacid of the formula HOOC—R′—COOH from an alcohol/aldehyde of the formula HOH 2 C—R′—(C═O)H, wherein R′ is an optionally substituted furan ring, comprising the steps:
[0012] (a) contacting the alcohol/aldehyde with an oxidant in the presence of a metal bromide catalyst forming an alcohol/acid having the formula HOH 2 C—R′—COOH, and optionally isolating the alcohol/acid;
[0013] (b) contacting the alcohol/acid with an oxidant in the presence of a metal bromide catalyst forming an acid/aldehyde having the formula HOOC—R′—(C═O)H, and optionally isolating the acid/aldehyde;
[0014] (c) contacting the acid/dialdehyde with an oxidant in the presence of a metal bromide catalyst forming the diacid, optionally isolating the diacid.
[0015] The invention is further directed to a third process for the preparation of a diacid of the formula HOOC—R′—COOH from an alcohol/aldehyde of the formula HOH 2 C—R′—(C═O)H, wherein R′ is an optionally substituted furan ring, comprising the steps:
[0016] (a′) contacting the alcohol/aldehyde with an oxidant in the presence of a metal bromide catalyst forming a dialdehyde having the formula H(C═O)—R′—(C═O)H, and optionally isolating the dialdehyde;
[0017] (b′) contacting the dialdehyde with an oxidant in the presence of a metal bromide catalyst forming an acid/aldehyde having the formula HOOC—R′—(C═O)H, and optionally isolating the acid/aldehyde; and
[0018] (c′) contacting the acid/dialdehyde with an oxidant in the presence of a metal bromide catalyst forming the diacid, and optionally isolating the diacid.
[0019] The process further comprises the steps of a′, b′, and c′ and wherein before step c′ the acid/aldehyde is converted to an acetate ester of the formula CH 3 (C═O)OCH 2 —R′—(C═O)H.
[0020] Preferably, in the above process the diacid is furan-2,5-dicarboxlic acid and the alcohol/aldehyde is 5-(hydroxymethyl)furfural.
[0021] The process can optionally be run in a solvent or solvent mixture comprising at least one aliphatic C 2 -C 6 monocarboxylic acid compound, preferably acetic acid.
[0022] The invention is also directed to a fourth process for the preparation of an aldehyde comprising a) contacting a compound of the formula AR—CH 2 —OH wherein AR is an optionally substituted aryl with an oxidant in the presence of a metal bromide catalyst; and b) optionally isolating the aldehyde product. Preferably, AR an optionally substituted phenyl group. Most preferably, AR is an unsubstituted phenyl group. A preferred metal bromide catalyst is comprised of a source of bromine and at least one metal selected from the group consisting of Co and Mn. More preferably the metal bromide catalyst contains Co.
[0023] The process can be run in a solvent or solvent mixture comprising at least one aliphatic C 2 -C 6 monocarboxylic acid compound, preferably acetic acid.
[0024] The invention is also directed to a fifth process to form a polyester polymer and the polyester polymer so produced from 2,5-diformylfuran comprising the repeat units A and B and C.
[0025] wherein said process comprises polymerization of di(formyl)furan. The process can be performed in the presence of a catalyst of the formula M +n (O-Q) n wherein M is a metal, n is the positive charge on the metal, and Q is an alkyl group of 1-4 carbons. Preferably, M is aluminum and n is three. Preferably the polyester polymer formed from the process is a homopolymer.
[0026] An embodiment of the invention is a polyester polymer comprising repeating units A, B and C. Preferably, the polyester polymer is a homopolymer.
[0027] Another aspect of the invention is a sixth process for the preparation of furan comprising converting 2,5-diformylfuran into furan and furfural via decarbonylation in the presence of a catalytic amount of a compound consisting essentially of a optionally supported metal selected from Periodic Group VIII. The furan and furfural product may further be converted via decarbonylation into unsubstituted furan in the presence of a catalytic amount of a compound consisting of an optionally supported metal selected from Periodic Group VIII.
[0028] Preferably the catalyst is supported on a catalyst support member, more preferably the metal is palladium and the catalyst support member is carbon.
[0029] Another aspect of the invention is to convert the dialdehyde prepared using the above processes, wherein the dialdehyde is 2,5-di(formyl)furan, into furan via decarbonylation in the presence of a catalytic amount of a compound consisting of a optionally supported metal selected from Periodic Group VIII.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention concerns a first process for the preparation of a dialdehyde comprising contacting a first compound containing an alcohol functionality and an aldehyde functionality with an oxidant in the presence of a metal bromide catalyst. More specifically, the alcohol can be HMF, the dialdehyde can be DFF, and the catalyst can be comprised of Co and/or Mn, and Br, and optionally Zr.
[0031] In addition to the alcohol and the aldehyde, other functional groups may be attached to the first compound as long as the other functional groups are substantially inert under reaction conditions. In a preferred process the first compound is of the formula HOH 2 C—R—(C═O)H, and the resulting dialdehyde product that is prepared is of the formula H(C═O)—R—(C═O)H. In the above formula for the first compound and the dialdehyde product of this invention, R is selected from the group consisting of an optionally substituted C 1 -C 20 alkyl and optionally substituted C 1 -C 20 aryl group. The R groups are either linear, cyclic, or heterocyclic. More preferred is where R is selected from the group consisting of an optionally substituted C 1 -C 20 alkyl group, linear or cyclic, and a heterocyclic group. Most preferred is where R is a furan. By optionally substituted herein is meant a group that may be substituted and may contain one or more substituent groups that do not cause the compound to be unstable or unsuitable for the use or reaction intended. Substituent groups which are generally useful include nitrile, ether, alkyl, ester, halo, amino (including primary, secondary and tertiary amino), hydroxy, silyl or substituted silyl, nitro, and thioether.
[0032] The term “aryl” refers to an aromatic carbo-cyclic group having a single ring (e.g., phenyl), multiple rings (e.g., biphenyl), or multiple condensed rings of which at least one is aromatic (e.g., 1,2,3,4-tetrahydronaphthyl, naphthyl, anthryl, or phenanthryl), and which is optionally mono-, di-, or tri- substituted with a functional group such as halogen, lower alkyl, lower alkoxy, lower alkylthio, trifluoromethyl, lower acyloxy, aryl, heteroaryl, and hydroxy. The term “aryl” also refers to heteroaryl groups where heteroaryl is defined as 5-, 6-, or 7-membered aromatic ring systems having at least one hetero-atom selected from the group consisting of nitrogen, oxygen and sulfur. Examples of heteroaryl groups are pyridyl, pyrimidinyl, pyrrolyl, pyrazolyl, pyrazinyl, pyridazinyl, oxazolyl, furanyl, quinolinyl, isoquinolinyl, thiazolyl, and thienyl, which can optionally be substituted with, e.g., halogen, lower alkyl, lower alkoxy, lower alkylthio, trifluoromethyl, lower acyloxy, aryl, heteroaryl, and hydroxy.
[0033] A particularly preferred process is where R is 2,5-disubstituted furan, i.e., where the first compound is HMF and the dialdehyde is DFF.
[0034] DFF may be further converted via loss of CO to furan, which can be hydrogenated to tetrahydrofuran using standard techniques familiar to those skilled in the art.
[0035] The second process concerns preparation of a diacid of the formula HOOC—R′—COOH from an alcohol/aldehyde of the formula HOH 2 C—R′—(C═O)H.
[0036] The third process concerns preparation of a diacid of the formula HOOC—R′—COOH from an alcohol/aldehyde of the formula HOH 2 C—R′—(C═O)H.
[0037] In the second and third processes, R′ is preferably an optionally substituted furan ring. More preferably, R′ is a 2,5-disubstituted furan ring. A preferred metal bromide catalyst is comprised of a source of bromine and at least one metal selected from the group consisting of Co and Mn, and optionally containing Zr. More preferably the metal bromide catalyst contains Co.
[0038] Any of the intermediates, the alcohol/acid, acid/aldehyde, or the dialdehyde, may be isolated at any step, or the reaction may proceed without any purification. It is contemplated that the processes of the invention in which DFF and/or FDA is prepared can be run using a biomass feedstock containing HMF, such that only the final product need be isolated and purified.
[0039] For the preparation of the dialdehyde, the preferred temperatures are about 20° to 200° C., most preferably about 40° to 130° C. The corresponding pressure is such to keep the solvent mostly in the liquid phase. The preferred time of the reaction is determined by the temperature, pressure, and catalyst concentration such that maximum yield of dialdehyde is obtained. For preparation of diacid, the preferred temperatures are about 50 ° to 250° C., most preferentially about 50° to 160° C. The corresponding pressure is such to keep the solvent mostly in the liquid phase. The preferred time of the reaction is determined by the temperature, pressure and catalyst concentration such that a maximum yield of diacid is obtained.
[0040] The fourth process concerns preparation of an aldehyde comprising contacting a compound of the formula AR—CH 2 —OH, wherein AR is an optionally substituted aryl group, with an oxidant in the presence of a metal bromide catalyst. Preferably, AR an optionally substituted phenyl group. Most preferably, AR is an unsubstituted phenyl group. In addition to the alcohol, other functional groups may be attached to the compound as long as the other functional groups are substantially inert under reaction conditions.
[0041] A preferred metal bromide catalyst is comprised of a source of bromine and at least one metal selected from the group consisting of Co and Mn, and optionally containing Zr. More preferably the metal bromide catalyst contains Co.
[0042] The process can be run in a solvent or solvent mixture comprising at least one aliphatic C 2 -C 6 monocarboxylic acid compound, preferably acetic acid.
[0043] Metal bromide catalysts employed in all of the processes of this invention comprise a soluble transition metal compound and soluble bromine-containing compound. One metal or a combination of two or more metals may be present. Many such combinations are known and may be used in the processes of the instant invention. These metal bromide catalysts are described further in W. Partenheimer, Catalysis Today, 23(2), 69-158, (1995), in particular pages 89-99, herein incorporated by reference. Preferably the metal is cobalt and/or manganese, optionally containing zirconium. More preferably, the catalyst is comprised of Co/MnZr/Br in the molar ratios of 1.0/1.0/0.1/2.0. The amount of catalyst in the reaction mixture can be 59/55/203/4 ppm to 5900/5500/20000/390 ppm Co/Mn/Zr/Br, preferably 150/140/510/10 ppm to 2400/2200/8100/160 ppm (g of metal/g of solvent). As used herein, the molar ratio is the ratio of moles of the metals alone, not the metals as in their compound forms.
[0044] Each of the metal components can be provided in any of their known ionic or combined forms. Preferably the metal or metals are in a form that is soluble in the reaction solvent. Examples of suitable forms include, but are not limited to, metal carbonate, metal acetate, metal acetate tetrahydrate, and metal bromide. Preferably metal acetate tetrahydrates are used.
[0045] The source of bromide can be any compound that produces bromide ions in the reaction mixture. These compounds include, but are not limited to, hydrogen bromide, hydrobromic acid, sodium bromide, elemental bromine, benzyl bromide, and tetrabromoethane. Preferred is sodium bromide or hydrobromic acid. As used herein, the amount of bromine means the amount measured as Br. Thus, the molar ratio of bromine to total of the metals used in the catalyst is the moles of Br divided by the sum of the moles of the metal.
[0046] As described in Partenheimer, ibid, pages 86-88, suitable solvents for use in the processes of the present invention, described above, must have at least one component that contains a monocarboxylic acid functional group. The solvent may also function as one of the reagents. The processes may be run in a solvent or solvent mixture that does not contain an acid group, provided that one of the reagents does contain such a group. Suitable solvents can also be aromatic acids such as benzoic acid and derivatives thereof. A preferred solvent is an aliphatic C 2 -C 6 monocarboxylic acid, such as but not limited to acetic acid, propionic acid, n-butyric acid, isobutyric acid, n-valeric acid, trimethylacetic acid, and caproic acid and mixtures thereof. Components of said mixtures can include benzene, acetonitrile, heptane, acetic anhydride, chlorobenzene, o-dichlorobenzene, and water. Most preferred as solvent is acetic acid. One advantage of using a solvent such as acetic acid is that furan-2,5-dicarboxylic acid is insoluble, facilitating purification of the insoluble product.
[0047] The oxidant in the processes of the present invention is preferably an oxygen-containing gas or gas mixture, such as, but not limited to air. Oxygen by itself is also a preferred oxidant.
[0048] The processes of the instant invention described above can be conducted in the batch, semi-continuous or continuous mode. Especially for the manufacture of FDA, operation in the batch mode with increasing temperature at specific times, increasing pressure at specific times, variation of the catalyst concentration at the beginning of the reaction, and variation of the catalyst composition during the reaction is desirable. For example, variation of the catalyst composition during reaction can be accomplished by addition of cobalt and/or manganese and/or zirconium, and/or bromide at specified times.
[0049] The fifth process concerns the polymerization of di(formyl)furan to form a novel polyester polymer comprising the repeat units A, B and C, as shown in the summary above. The catalysts employed in the polymerization of di(formyl)furan can be selected from any catalyst used for the esterification of a dialdehyde or two separate aldehydes. This esterification is commonly known as the “Tishchenko reaction”. A partial list of catalysts used for this reaction are those listed in Mascarenhas, et al., Org. Letters, 1999, Vol. 1, 9, pg. 1427; U.S. Pat. No. 3,852,335; and Reagents for Organic Synthesis, Fieser (ed.), 1969, Vol. 5, pg. 48, and are herein incorporated by reference. An alternate catalyst is the Shvo catalyst, [(Ph 4 C 5 OHOC 5 Ph 4 )Ru 2 (CO) 4 (μ-H)], as described in Menashe, et al., Organometallics 1991, 10, 3885. This discussion concerning the Shvo catalyst is also incorporated herein by reference. Preferred catalysts are metal alkoxides of the formula M +n (O-Q) n where M is a metal, n is the positive charge on the metal, and Q is an alkyl group of 1-4 carbons. Most preferred is where M is aluminum and n is three. The catalysts of the invention can be obtained already prepared from manufacturers, or they can be prepared from suitable starting materials using methods known in the art.
[0050] The repeat units A, B, and C can all be present in the polyester polymer product but are present in varying ratios, in any order in which an ester linkage is present and a polyester is formed. The term polymer is herein defined to include oligomers of 3 or more repeating units as well as higher polymers. This polymer would be useful as a molding resin or may be spun into a fiber.
[0051] The polyester polymer produced by the present process may include other repeat units in addition to those shown above. Other polyesters having the above repeat units include, but are not limited to, polyesteramides, polyesterimides, and polyesterethers. A preferred version of the polymer is a homopolymer.
[0052] A preferred embodiment of the present invention is the catalytic decarbonylation of DFF to form a mixture of unsubstituted furan and furfural.
[0053] in the presence of a catalytic amount of a metal selected from Periodic Group VIII, herein defined as Fe, Ru, Os, Co, Rh, Ir, Ni, Pd, and Pt. Preferably, the catalyst consists essentially of one or more of the Periodic Group VIII metals. A particularly preferred catalyst consists essentially of Pd.
[0054] The metals may be in any form including Raney catalysts as known to those skilled in the art. The catalysts are preferably supported on a catalyst solid support. The catalyst solid support, which includes but not limited to SiO 2 , Al 2 O 3, carbon, MgO, zirconia, or TiO 2 , can be amorphous or crystalline, or a mixture of amorphous and crystalline forms. Selection of an optimal average particle size for the catalyst supports will depend upon such process parameters as reactor residence time and desired reactor flow rates. The amount of metal on the support is preferably about 0.5-10% and most preferably 1-5%. The catalysts of the invention can be obtained already prepared from manufacturers, or they can be prepared from suitable starting materials using methods known in the art. One typical procedure is by impregnation of the support by incipient wetness using a soluble metal salt precursor, such as the chloride, acetate, nitrate salt, following by reduction under hydrogen gas.
[0055] A preferred embodiment of the fifth process is a liquid phase reaction in which the DFF is dissolved in a suitable, inert solvent. The catalysts are placed in the solvent in a pressure vessel, and pressured to about 200-1000 psi, (1.4-6.9 MPa), more preferably about 500 psi (3.4 MPa) with an inert gas, preferably nitrogen. The reaction temperature is about 150° C.-250° C., more preferably about 200° C. The reaction product containing furan and furfural can be recycled through the process one or more times, to eventually form a reaction product consisting essentially of furan.
[0056] The above process can also be combined with the process to prepare DFF described above, to create a single integrated process wherein DFF is prepared using the metal bromide catalysts described above, then decarbonylated to furan or furfural.
[0057] Materials and Methods
[0058] HMF was obtained from Lancaster Synthesis, Windham, N.H. Unless otherwise stated, all materials were used as received without further purification. All percentages are by mole percent unless otherwise specified.
EXAMPLES 1-6
Reaction of HMF to DFF at Ambient Air Pressure
[0059] In a cylindrical glass fitted with a stirrer and baffles, 0.165 g of cobalt(II) acetate tetrahydrate, 0.169 g of manganese(H) acetate tetrahydrate, 0.142 g of sodium bromide, 0.220 g biphenyl (GC internal standard), and 10.02 g of 5-hydroxymethyl(furfural) were admixed with 100 g of acetic. The solution was purged with nitrogen gas and the temperature raised to 75° C. using an external oil bath. The nitrogen was replaced with air at a flow rate of 100 ml/min at ambient atmospheric pressure. The vent oxygen was constantly monitored and occasionally liquid and vent gas samples for GC analysis were taken at the times shown in Table 2. After 30 hrs the reaction was terminated. The results from the liquid samples taken from the reactor during reaction of Example 1 are given in Table 1. The DFF yield increased with time to a maximum yield of 51% and then decreases thereafter. The mini-reactor data is summarized in Table 3. The rate of reaction, as given by the rate of disappearance of HUY, was dependent upon the concentration of the catalyst, see especially Examples 3, 4. The maximum yields and chemical species selectivities were also dependent on the concentration of the catalyst, see Examples 1, 3-6. The dependence of the selectivity on the concentration of catalyst is given in detail for Examples 3, 4, and 6 in Table 2. The formation of carbon dioxide and carbon monoxide are undesirable because they are caused by the decomposition of HMF and its products, as well as from the solvent, acetic acid. As can be seen in Table 2, increasing the catalyst concentration greatly decreases the, formation of these carbon oxides. Example 4 combines the best yield, shortest reaction time, and one of the lowest rates of carbon oxide formation.
[0060] 2,5-Diformylfuran was isolated from the reaction mass as follows. The liquid from the reaction mixture was allowed to evaporate. The residue after evaporation of the reaction mixture was (a) sublimed under vacuum, followed by recrystallization of the sublimate from toluene or cyclohexane; or (b) mixed with silica gel and extracted with hexanes or cyclohexane in a Soxhlet extractor; or (c) extracted with hot toluene, with subsequent filtration of the hot toluene solution through silica, evaporation of the filtrate, and recrystallization of the product from toluene or cyclohexane.
[0061] One specific example of isolation of DFF is as follows. The dark reaction mixture that was obtained from Example 5, was evaporated to dryness on a vacuum line. The resulting waxy green-tan material was transferred to a sublimation apparatus and sublimed under vacuum (10-50 millitorr) at 90° C. (oil bath) to produce 5.2 g (51 mol % based on initial HMF used) of DFF. The resulting DFF (95% pure; 1 H NMR and GC-MS analysis) contained 3-5% of 5-acetoxymethylfurfural. DFF that was pure to the limits of spectroscopic detection was obtained by recrystallization of the sublimate from cyclohexane or toluene/hexanes. 1H NMR (CDCl 3 , 25° C.), ppm: 7.4 (s; 2H; furane CH), 9.8 (s; 2H; CHO). 13 C NMR (CD 2 Cl 2 , 25° C.), ppm: 120.4 (s; CH), 154.8 (s; q C), 179.7 (s, CHO). m/z=124. Alternatively, crude DFF can be purified by filtration of its concentrated dichloromethane solution through a short silica plug, followed by precipitation from the filtrate with hexanes.
TABLE 1 Formation of Diformylfuran in Example 1 Time, min Conversion, % Selectivity, % Yield, molar, % 66 31.9 44.5 14.2 96 40.3 52.6 21.2 111 46.6 54.9 25.6 130 54.7 51.2 28.0 144 54.5 59.4 32.4 171 62.5 55.4 34.6 190 66.9 55.5 37.1 204 71.0 52.7 37.4 310 82.9 56.6 46.9 384 88.3 56.1 49.5 450 92.1 55.5 51.1 516 95.2 53.3 50.7 1368 100 35.1 35.1 1410 100 35.7 35.7 1728 100 19.8 19.8 1800 100 19.5 19.5
[0062] [0062] TABLE 2 Summary of Mini-reactor Oxygenations of Hydroxymethyl(furfural) Ex.1 Ex.2 Ex.3 Ex.4 Ex.5 Ex.6 Temp, ° C. 75 50 then 95 (5) 75 75 50 then 75 (6) 75 HMF, g 10.015 9.143 10.139 10.051 10.04 10.158 HOAc,g 100 100 100 100 100 100.1 Ca, M 0.066 0.026 0.066 0.135 0.268 0273 Mn, M 0.069 0.025 0.069 0.139 0.274 0.278 Br, M 0.137 0.050 0.137 0.279 0.557 0.580 Zr, M 0.005 0.000 0.005 0.005 0.005 0.005 HMF rate, s −1(1) 9.68E −05 9.28E −05 8.13E −05 1.64E −04 — 1.37E −04 HMF half-life 119 124 142 70 — 84 R2 0.998 0.878 0.972 0.999 — 0.994 DFFY,max (2) 51 41 50 57 51 52 Time,max 450 414 642 310 550 430 C,max 92 98 95 91 95 97 S,max 55 42 53 63 54 54 time,min (3) 1800 564 640 366 550 430 C, % 100 99 95 95 95 97 S, % 19 41 53 58 54 54 Y, % 19 40 50 55 51 52 HMF acet, % 0.4 8.4 7.5 6.1 4.5 5.7 CO x , ml 878 — 1022 257 219 318 HMF to CO x (4) 7.4 — 8.5 2.1 1.8 2.6
EXAMPLES 7-15
Reaction of HMF to DFF
[0063] Table 3 further illustrates that placing HMF with acetic acid and catalyst metals and then subjecting them to 1000 psi air pressure (7 MPa), can produce high yields of DFF. Molar yields up to 63% were obtained. The yield varied with temperature and type of catalyst used.
TABLE 3 Initial Conditions for the Oxidation of HMF in Shaker Tubes HMF, HMF, DFF yld, Ex. Catalyst HMF, g Co, ppm Mn, ppm HBr, ppm Zr, ppm Temp, ° C. Time, hr conv., % select. % % 7 Co/Mn/Br/Zr 0.2504 203 189 551 20 50 2 60.4 66.6 40.2 8 Co/Mn/Br/Zr 0.2481 406 378 1102 20 50 2 69.2 65.3 45.2 9 CofMn/Br 0.2519 203 189 551 0 50 2 60.6 38.4 23.3 10 Co/Mn/Br 0.252 406 378 1102 0 50 2 61.7 54.6 33.7 11 Co 0.2516 7000 0 0 0 50 2 48.3 22.8 11.0 12 Co/Mn/Br/Zr 0.25 203 189 551 20 75 2 82.5 73.2 60.4 13 Co/Mn/Br/Zr 0.2517 406 378 1102 20 75 2 99.7 61.6 61.4 14 Co/Mn/Br 0.2529 203 189 551 0 75 2 71 54.3 38.6 15 Co/Mn/Br 0.2514 406 378 1102 0 75 2 92.2 68.3 63.0
EXAMPLES 16-40
The Reaction of HMF to CFF and FDA
[0064] Placing HMF in reactors with acetic acid and catalyst metals and having them react with air at 1000 psi (7 MPa) gave good yields of FDA. A particular advantage of this method is that the majority of FDA precipitates from solution upon cooling to room temperature. The yields to CFF and FDA, reported on Table 4, are those which were obtained from the solids only. Table 4 illustrates that different catalysts such as those using cobalt, or a mixture such as Co/Mn/Br and Co/Mn/Zr/Br all produced good yields of FDA. It also illustrates that increasing catalyst concentrations at a given temperature and time, nearly always increased the FDA yield.
[0065] Examples 35 through 37 are to be compared to Examples 38 through 40. In the latter series the temperature was staged-initially it was held at 75° C. for 2 hrs and then raised to 150° C. for two hrs. This staging of the temperature gave higher yields.
TABLE 4 Reaction of HMF to CFF and FDA All reactions at 1000 psi air (7 MPa) HMF, Co, Mn, HBr, Zr, Temp, Time, CFF, FDA, Ex. Catalyst g ppm ppm Ppm ppm C. hr yld yld 16 Co/Mn/Br/Zr 0.2517 203 189 551 20 100 2 3.1 18.7 17 Co/Mn/Br/Zr 0.2533 406 378 1102 20 100 2 6.8 42.3 18 Co/Mn/Br 0.2522 203 189 551 0 100 2 4.1 29.7 19 Co/Mn/Br 0.2505 406 378 1102 0 100 2 3.3 44.8 20 Co 0.2589 7000 0 0 0 100 2 5.1 31.0 21 Co/Mn/Br/Zr 0.2483 203 189 551 20 125 2 2.1 36.5 22 Co/Mn/Br/Zr 0.249 406 378 1102 20 125 2 2.3 45.6 23 Co/Mn/Br 0.2503 203 189 551 0 125 2 1.8 35.2 24 Co/Mn/Br 0.2526 406 378 1102 0 125 2 2.2 44.7 25 Co 0.2616 7000 0 0 0 125 2 4.3 16.8 26 Co/Mn/Br/Zr 0.7535 406 378 1102 20 105 12 3.1 26.4 27 Co/Mn/Br/Zr 0.7568 812 756 2204 20 105 12 4.2 50.6 28 Co/Mn/Br/Zr 0.7498 1218 1134 3306 20 105 12 2.5 S8.8 29 Co/Mn/Br/Zr 0.5057 406 378 1102 20 105 12 2.4 24.1 30 Co/Mn/Br/Zr 0.501 812 756 2204 20 105 12 5.1 44.0 31 Co/Mn/Br/Zr 0.4994 1218 1134 3306 20 105 12 5.6 47.4 32 Co/Mn/Br/Zr 0.499 406 378 1102 20 105 8 3.3 32.9 33 Co/Mn/Br/Zr 0.5046 812 756 2204 20 105 8 4.8 41.0 34 Co/Mn/Br/Zr 0.5 1218 1134 3306 20 105 8 7.3 50.6 35 Co/Mn/Br/Zr 0.2498 406 378 1102 20 105 2 3.7 36.9 36 Co/Mn/Br/Zr 0.254 812 756 2204 20 105 2 4.8 40.9 37 Co/Mn/Br/Zr 0.4988 406 378 1102 20 105 2 1.7 14.0 38 Co/Mn/Br/Zr 0.2517 406 378 1102 20 75,150 2,2 5.2 51.4 39 Co/Mn/Br/Zr 0.5077 812 756 2204 20 75,150 2,2 6.2 52.9 40 Co/Mn/Br/Zr 0.5105 406 378 1102 20 75,150 2,2 6.5 54.6
EXAMPLES 41-59
Oxidation of Benzyl Alcohol
[0066] 0.247 g of cobalt(II) acetate tetrahydrate, 0.242 g of manganese(II) acetate tetrahydrate, 0.337 g of hydrogen bromide, 0.198 g biphenyl (GC internal standard), and 9.72 g of benzyl alcohol were placed in 95 g of acetic acid and 5% water in a cylindrical glass flask fitted with a stirrer and baffles. The solution was purged with nitrogen gas and the temperature raised to 95° C. using an external oil bath. The nitrogen was replaced with air at a flow rate of 100 ml/min at ambient atmospheric pressure. Samples were withdrawn from the reactor and analyzed giving the results in Table 5. A yield of 55 mol percent benzaldehyde is observed. (Values of benzaldehyde, benzyl acetate, benzoic acid in mol % based on benzyl alcohol charged).
TABLE 5 Oxidation of Benzyl Alcohol Benzyl Benzoic Benzaldehyde, acetate, acid, Ex. Time, hr. Conv., % mol % mol % mol % 41 0 10.4 0.36 10.9 0 42 0.1 15 1.8 11.3 0 43 0.2 21 5.5 12.9 0 44 0.33 28 10.4 15.1 0 45 0.5 35 15 16.8 0 46 0.6 41 19.2 18.2 0 47 0.67 44 21.1 18.9 0.27 48 0.75 48 24.3 19.6 0.35 49 0.87 52 27.3 20.4 0.45 50 1 57 31.5 21.5 0.61 51 1.17 62 34.1 22 0.8 52 1.3 67 37.8 22.8 1.02 53 1.4 69 39.7 23.1 1.21 54 1.53 73 42 23.5 1.55 55 1.75 78 45.4 24.1 1.75 56 1.92 81 47.6 24.3 2.45 57 2.1 83 49.3 24.5 2.69 58 2.33 88 52.4 24.6 3.43 59 2.83 93 54.6 24.2 6.23
EXAMPLE 60
Polymerization of DFF of 5-(hydroxymethyl)-furan-2-carboxylic Acid (‘Tishchenko Polymerization’)
[0067] The reaction was conducted under rigorously dry conditions. The products were isolated in air. To a mixture of DFF (0.265 g) and dry toluene (6 mL) was added aluminum isopropoxide (Aldrich; 45 mg), and the reaction mixture was vigorously stirred at 95° C. (oil bath) for 3 hours. The greenish-brown precipitate was filtered off, washed with toluene, and dried under vacuum to give 0.190 g of a tan powder that appeared to be amorphous (fraction A). The combined mother liquor and the washings were evaporated and dried under vacuum to yield 0.105 g of fraction B as a viscous yellowish oil. 1 H NMR spectra of both fractions A and B(CDCl 3 , 25° C.) revealed a number of singlets at 5.2-5.4 ppm (—CH 2 —O(O)C—), indicative of polyester formation. A sample of the solid product (0.7460 mg) was studied by TGA in the temperature range of 40-600° C. The onset of decomposition was observed around 100-120° C. The total weight loss measured was about 10% at 147° C., and about 34% at 294° C.
EXAMPLE 61
[0068] The reaction was carried out under nitrogen. The Shvo catalyst ([(Ph 4 C 5 OHOC 5 Ph 4 )Ru 2 (CO) 4 (μ-H)]; as described in Menashe, N.; Shvo, Y. Organometallics 1991, 10, 3885; 5 mg) was added to a mixture of DFF (200 mg), toluene (5 mL), and formic acid (cocatalyst; 5 μL). The clear solution was stirred at 100° C. (oil bath) for 3 hours. 1 H NMR analysis of the reaction mixture indicated 50% conversion to polymeric material. More Shvo catalyst (3 mg) was added and the mixture was stirred at 100° C. (oil bath) for 2 days, 90% conversion was reached ( 1 H NMR).
EXAMPLES 62-69
[0069] The catalysts were prepared by taking a carbon support (Englehard Corp., 12 Thompson Rd., E. Windsor, Conn.) and impregnating by incipient wetness a metal salt. The precursors used were NiCl 2 .6H 2 O (Alfa), Re 2 O 7 (Alfa), PdCl 2 (Alfa), RuCl 3 .×H 2 O (Aldrich), H 2 PtCl 6 (Johnson Matthey), CrCl 3 .6H 2 O (Baker), and 5% Rh using RhCl 3 .=H 2 O(Alfa). The samples were dried and reduced at 400° C. in H 2 for 2 hours. The decarbonylation reactions were performed by dissolving 50 mg of DFF in 1 ml of dioxane, and which was then placed with 50 mg of catalyst in a 5 ml pressure vessel. The vessel was charged to 500 psi with N 2 and heated to 200° C. for 2 hours. The sample was then cooled, vented and the product analyzed by GC-MS Results are shown in Table 6 below.
TABLE 6 Decarbonylation of DFF Selectivity (%) Ex. Catalyst Conv. (%) Furan THF Furfural Others 62 5% Re/carbon 15.6 2.8 0.0 2.1 95.1 63 5% Pt/carbon 46.1 2.2 0.0 42.7 55.0 64 5% Cr/carbon 27.3 1.3 0.0 0.0 98.7 65 5% Rh/carbon 33.8 1.7 0.0 29.7 68.6 66 5% Ni/carbon 10.3 5.1 0.0 1.7 93.2 67 5% Pd/carbon 98.6 49.8 1.0 48.1 1.1 68 5% Ru/carbon 25.0 3.5 0.0 62.9 33.6
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Alcohols are catalytically oxidized to aldehydes, in particular to benzaldehyde and diformylfuran, which are useful as intermediates for a multiplicity of purposes. The invention also relates to the polymerization of the dialdehyde and to the decarbonylation of the dialdehyde to furan.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a join-structure of high-density connector and interface module, particularly to a join-structure of high-density connector and interface module that can save connecting material, hold connection firmly, and facilitate easy mounting and dismounting of an interface module.
2. Description of the Prior Art
A conventional join-structure of high-density connector and interface module usually has two categories in its conductive terminals, including a cutting face lateral contact type (abbrev. as type A hereinafter) and a folded plate contact type (abbrev. as type B hereinafter). U.S. Pat. Nos. 5,071,371 and 5,425,658 are examples of type A, wherein two separated pairs (4 terminal pieces) overlap each other in most of their areas, and the employed terminal material is in relatively large amount that seemed to have been overdone. In another U.S. Pat. No. 5,024,609 of type B, a component separator is used to fix and align the conductive strips that increases manpower, production cost, and complexity.
A U.S. patent application Ser. No. 08/430952 applied on Apr. 28, 1995 (ROC patent No. 312859) is a conventional join-structure of connector and interface module, wherein terminals in upper and middle layers are installed in straight lines in a reception slot, and volume of the entire body and needed terminal material are enlarged because of mounting of terminals at two lateral ends. And moreover, terminals in middle layer is prone to contact with that in lower layer when plugging in or pulling out a daughter board, so that, its function as well as usage has been compressed.
With respect to prior skill of join-structure of high-density connector and interface module, please refer to U.S. Pat. No. 5,026,292, wherein terminal of type A and B both are used in a connector that may require complicated procedures in manufacturing and assembling.
Major embodiments in U.S. Pat. No. 5,051,099 employ the same conductive strips as of type A and B in the mentioned U.S. Pat. No. 5,026,292, wherein FIG. 8 indicates another embodiment using terminals arranged in an upper as well as a lower layer respectively, and the terminals are laminated and polished aside that cannot contact with conductive strips thoroughly.
Moreover, FIG. 9 in the aforesaid patent reveals a type B embodiment, wherein the flaglike contact realm of the lower layer terminals requires a larger activity space that results in an enlarged slot at upper portion for reception a daughter board. However, owing to lack of guiding and positioning function, the daughter board cannot be plugged in the slot easily that may deform or impair the terminals to no longer coincide with golden fingers of the daughter board in geometric progression interval alignment (abbrev. as GPIA hereinafter).
Design of a usual join-structure of connector and interface module has progressed in GPIA alignment as revealed in U.S. patent application Ser. No. 08/712868 (ROC patent No. 304284), wherein terminals of type A and B have been employed and arranged in an upper layer as well as a lower layer disposed in a single reception slot, however, in case a defect is found in manufacturing process or in the upper layer of a finished product, the intact lower layer has to be dismounted before removing or replacing the erroneous upper layer. This troublesome maintenance procedure will cost considerable manpower that has to be improved for sure.
Besides, a known retention mechanism, which can be applied to hold either a card type or a cartridge type interface module, is weak in dismounting procedure. A user has to use his hands to hold and pull an interface module out from the slot bit by bit and end by end. Such an inconvenient dismounting operation is also in need of improvement conspicuously.
In view of the aforesaid imperfections, and after years of constant efforts in research, this invention is taking the opportunity to propose a preferred structure, which is to be summarized below.
SUMMARY OF THE INVENTION
The main object of this invention is to provide a join-structure of high-density connector and interface module, wherein terminals of a lateral contact type, which is designed to save material, area, and volume, will be plugged in a reception slot and fixed firmly. Another object of this invention is to provide a join-structure of high-density connector and interface module, wherein terminals of a plate face contact type designed staggering in root ends can be torn up for material saving.
One more object of this invention is to provide a join-structure of high-density connector and interface module, wherein positioning pins are either plugged to anchor or pivoted to anchor for fixing the retention mechanism onto a motherboard.
Another more object of this invention is to provide a join-structure of high-density connector and interface module, wherein fixing pins are employed to fix and latch a heat sink to the daughter board for low cost and easy assembly purposes.
A further object of this invention is to provide a join-structure of high-density connector and interface module, wherein a movable frame on the retention mechanism is foldable inwards or exchangeable to retain a card type or a cartridge type interface module for multipurpose application.
A furthermore object of this invention is to provide a join-structure of high-density connector and interface module, wherein a flexible portion and a snap fastening portion of the retention mechanism cooperating with a movable piece can release simply and rapidly the fastened interface module from the retention mechanism.
With the above-described merits, the join-structure of high-density connector and interface module comprises a dielectric housing unit, a plurality of terminals, an interface card, a heat sink, a retention mechanism and a motherboard, wherein two kinds of structure of a conductive strip are available—a cutting face lateral contact and a folded plate contact; for the former, a material feeding band is punched to form simultaneously two different independent terminal sets in zigzag alignment at opposite sides that can be torn up easily; and for the latter, the alignment is the same as in the former, while the root portion includes two sections, and a enhancing protruded strip is provided at two turning points in a terminal; and the terminals are snap-fastened to the reception slot in the dielectric housing unit.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding to the present invention, together with further advantages or features thereof at least one preferred embodiment will be elucidated below with reference to the annexed drawings in which:
FIG. 1A is a three-dimensional exploded view showing a join-structure of a high-density connector and a cartridge type interface module of this invention;
FIG. 1B is a three-dimensional exploded view showing the join-structure of a high-density connector and a card type interface module of this invention;
FIG. 2 is a schematic three-dimensional partial view showing the join-structure of a cutting face contact type high-density connector and an interface module of this invention;
FIG. 3 is a three-dimensional cutaway view showing the join-structure of a cutting face contact type high-density connector and an interface module of this invention;
FIG. 4A is a schematic partial view showing the join-structure of a cutting face contact type high-density connector and an interface module of this invention;
FIG. 4B indicates a partial completed section of the join-structure of a cutting face contact type high-density connector and an interface module of this invention;
FIG. 5 is a schematic view showing a cutting face contact type terminal and a material feeding band of the join-structure of a high-density connector and an interface module of this invention;
FIG. 6 is another schematic view showing alignment of cutting face contact type terminals in a material feeding band of the join-structure of a high-density connector and an interface module of this invention;
FIG. 7 is another schematic view showing alignment of folded plate contact type terminals in a material feeding band of the join-structure of a high-density connector and an interface module of this invention;
FIG. 7A is a schematic amplified view showing a fixed root in FIG. 7;
FIG. 8A is a schematic view showing a folded plate contact type terminal in upper layer and a material feeding band of the join-structure of a high-density connector and an interface module of this invention;
FIG. 8B is a schematic view showing a folded plate contact type terminal in lower layer and a material feeding band of the join-structure of a high-density connector and an interface module of this invention;
FIG. 9A is a schematic right end lateral view showing a folded plate type dielectric housing unit of the join-structure of a high-density connector and an interface module of this invention;
FIG. 9B is a schematic partial cutaway sectional view showing a folded plate type dielectric housing unit of the join-structure of a high-density connector and an interface module of this invention;
FIG. 10 is a schematic partial cutaway sectional view showing folded plate type terminals of the join-structure of a high-density connector and an interface module of this invention;
FIG. 11 is a schematic three-dimensional exploded view showing a retention mechanism of the join-structure of a high-density connector and an interface module of this invention;
FIG. 11A is an amplified view of the circled portion in FIG. 11;
FIG. 12 shows another embodiment of the join-structure of a high-density connector and an interface module of this invention;
FIG. 12A is an amplified view of the circled portion in FIG. 12;
FIG. 13A is a schematic action view of the join-structure of a high-density connector and an interface module of this invention in FIG. 12;
FIG. 13B is another schematic action view of the join-structure of a high-density connector and an interface module of this invention in FIG. 13A;
FIG. 13C is an amplified view showing the snap-fastening portion in FIG. 13A;
FIG. 13D is an amplified view showing the snap-fastening portion in FIG. 13B;
FIG. 14 is an embodiment diagram showing a pivot type fixing device of the join-structure of a high-density connector and an interface module of this invention;
FIG. 15A is another schematic action view of the join-structure of a high-density connector and an interface module of this invention in FIG. 14;
FIG. 15B is another schematic action view of the join-structure of a high-density connector and an interface module of this invention in FIG. 15A;
FIG. 16 is an embodiment diagram showing connection of the fixing device to a motherboard of the join-structure of a high-density connector and an interface module of this invention;
FIG. 17 is another embodiment diagram showing a plugged-to-fix device of the join-structure of a high-density connector and an interface module of this invention;
FIG. 18A is another schematic action view of the join-structure of a high-density connector and an interface module of this invention in FIG. 16;
FIG. 18B is another schematic action view of the join-structure of a high-density connector and an interface module of this invention in FIG. 17 A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1A, FIG. 1B, FIG. 2, and FIG. 4 A and FIG. 4B, a join-structure of high-density connector and interface module of this invention comprises a dielectric housing unit 1 , a plurality of terminals (conductive strip) 2 , a card type interface module 7 or cartridge type interface module 3 , a retention mechanism 5 , a movable piece 582 , and a motherboard 4 . An insertion slot 10 is formed in a central portion of the dielectric housing unit 1 , wherein a plurality of reception grooves 11 partitioned by inner walls 12 is aligned along both sides of the insertion slot 10 , and a fixing recess 120 is formed near bottom of the inner walls 12 , and a long protrusion strip 13 is disposed at bottom of the dielectric housing unit 1 .
There are two kinds of structure of a conductive strip 2 —a cutting face contact type and a folded plate contact type. As shown in FIG. 2, FIG. 3, and FIG. 4B, two pairs (4 pieces) of terminals 2 are formed in copper feeding band (one terminal at lower layer 20 and another at upper layer 21 become one pair). In each pair of terminals 20 , 21 , a fixing root 200 , 210 is located at knee position and further extended downwards to form a soldering portion 201 , 211 , wherein a protrusion 205 , 213 is disposed on the fixing root 200 , 210 and on reverse side, another protrusion 206 , 214 , and a protruded fixing strip 202 , 212 is formed. A protruded sticker 208 , 218 is arranged at lateral side of the protruded fixing strip 202 , 212 , wherein the protruded fixing strip 202 of the lower layer terminal 20 is extended upwards to form a stuffing fixer 203 and a protruded dot 204 to offer enough space for join with the reception groove 11 and the fixing recess 120 . Two pairs of terminals 2 are staggered and fixed in the reception groove 11 of the dielectric housing unit 1 , wherein the lower layer terminals and that in the upper layer are partitioned equally placed to obtain a uniform interval alignment of terminals 20 , 21 ; and the soldering portion 201 , 211 are poking out of the dielectric housing unit 1 . An interface module 3 is plugged in insertion slot 10 of the dielectric housing unit 1 in uniform alignment intervals. Further, a plurality of circular holes 40 are disposed on the motherboard 4 for reception of the soldering portion 201 , 211 .
As shown in FIG. 3, FIG. 4A, FIG. 4B, FIG. 5, and FIG. 6, the fixing root 200 , 210 of the terminals 2 is extended downwards to meet a connection strip 22 and a material feeding band 23 , wherein the upper layer terminals 21 and the lower layer terminals 20 are staggered that can be cut to detach from each other. Two terminal rows may stand independently in the material feeding band by folding the connection strips 22 in opposite directions. Point A between two contact points 28 , 29 in a pair of upper and lower layer terminals 21 , 20 , and a decent portion in the fixing root 200 , 210 and in the connection strip 22 will be cut off to detach a pair of terminals 2 . Thus, every material feeding band 23 can produce terminals 2 in two rows to save material and manpower for assembling. With a specified length of material feeding band 23 , a usual method produces two pieces of terminal 2 in one row, which is assembled one row at one time accordingly, while this invention can double the yield that two rows may be assembled simultaneously in the reception grooves 11 of the dielectric housing unit 1 . When assembling, cut off at first two lateral sides of the protruded fixing strip 202 , 212 , and by favor of burr face 207 , 217 in acute angle and protruded sticker 208 , 218 that enables a terminal 2 to stick intimately to the fixing recess 120 , and meantime to lean against the protrusion 206 , 214 , as well as protrusion 205 , 213 on the reverse face to have the terminal 2 positioned uprightly in the reception groove 11 .
As shown in FIG. 7, FIG. 7A, FIG. 8A, and FIG. 8B, terminals of upper and lower layers 20 a, 21 a are cross-aligned on a material feeding band 23 , and it needs only one set of mold to punch and form terminals in two rows at a time for saving of material and manpower. The snaky terminals wriggling to the fixing root 200 a, 210 a, which consists of two sections 24 , 25 , can be torn apart to form individuals, wherein the first section of the fixing root 24 is slightly smaller than the second section 25 , and in two turning points of the soldering portion 22 a of the lower layer terminals 21 a, an enhancing protruded strip 26 is provided for strengthening purpose.
As shown in FIG. 9A, FIG. 9B, and FIG. 10, the fixing recess 120 corresponding to the two-layer terminals 2 is constructed in a two-section type, that is the first section 120 a and the second section 120 b; the former is to receive the first section fixing root 24 , and the latter for the second fixing root 25 . In virtue of the enhancing protruded strip 26 and thick inner walls, the lower layer terminals 21 a can be buried in the fixing recess 120 in a firm construction. As shown in FIG. 1A, FIG. 1B, FIG. 11, and FIG. 11A, a retention mechanism 5 comprises a base 50 and a frame 51 , wherein a pair of bases 50 are installed in opposite positions independently or linked with a bridge 53 on a motherboard. A through hole 52 is provided at corresponding positions in the base 50 , wherein a guide flute 521 and a positioning recess 522 are disposed for receiving a fixing device 8 , and a flange 84 near bottom thereof is used to fix the base 50 onto the motherboard 4 . On lateral face 54 of the base 50 , a positioning hole 55 is offered at each of two corresponding positions respectively. A recess 57 is formed at each of two lateral walls, and two windows are opened at upper portion of the back wall for fixing a fastening portion 62 in a cartridge type interface module 3 . At bottom sides of the frame 51 , a fixing pin 56 is provided, wherein a positioning pin 560 is offered to join the positioning hole 55 to enable the frame 51 to pivot within a limited angle. Moreover, a sliding groove is prepared on each of two corresponding inner walls of the frame 51 , and in back wall thereof, an elastic leaf 58 locates right under the windows 570 , a snap fastener 580 and a clamping tongue 581 are arranged below the elastic leaf 58 , and the clamping tongue 581 can move in a limited range according to movement of a movable piece 582 that can slide up and down on the frame 51 .
As shown in FIG. 12 and FIG. 12A, a circular hole 70 locates at each of four corners at an interface card 7 , and attached thereto a heat sink 6 with fins 61 is provided with holes 60 at positions corresponding to that in card 1 . At two lateral ends of the heat sink 6 , a fastening portion 62 and a retaining recess 63 are formed respectively. A snap fastening portion 880 is arranged at rear end in a three-sectional fixing pin 9 , which is to be inserted through the circular hole 70 and fastened on the heat sink 6 . As shown in FIG. 13A, 13 B, 13 C, and 13 D, when the movable piece 582 is pushed down wards to a preset point, the elastic leaf 58 is shoved outwards to lessen friction between two lateral ends of the fastening portion 62 and the elastic leaf 58 or the fastener 580 . Then, push again the movable piece 582 upward to another preset point, the elastic leaf 58 will bounce back and let the fastener 580 be snap-fastened at the retaining recess 63 of the fastening portion 62 ; and reverse the above simple procedure to release the interface card 7 .
As shown in FIG. 14, and FIG. 15A, the fixing device 8 can be of a pivot type comprising a fixing device body 80 , and a plug 81 , wherein a plug-in hole 83 is formed in central portion of the fixing device body 80 ; a rim flange 84 is provided to its bottom portion; a dissection groove 85 is molded in each of two opposite lateral faces, and a protruding piece 86 is preserved on each of the rest two faces. The middle section of the plug 81 is a plug post 87 , and its bottom end is a rectangular packing slat 88 , and a slat 89 is formed at its top portion. When plugging the fixing device body 80 in the through hole 52 of the base 50 , as shown in FIG. 16, the protruding piece 86 enters the guide flute 521 and turn to match the positioning recess 522 for a primary positioning purpose. Then, let the plug 81 enter the plugging hole 83 , there the packing slat 88 will stay at a resting portion 851 . The next step is to press the fixing device body 80 to penetrate a fixing hole 41 in the motherboard 4 , and force the rim flange 84 to be snap-fastened at reverse face of the same board, now, a user may insert a driver or coin to the slot 89 and drive the plug 81 to turn 90°, so that the packing slat 88 will prop a bearing portion 852 to complete installation of the base 50 of the retention mechanism 5 . On the contrary, when dismounting the fixing device is desired, all a user has to do is drive the plug 81 to turn another 90° to release the packing slat 88 from the bearing portion 852 to restore elasticity of the rim flange 84 for an easy detachment.
As shown in FIG. 17, FIG. 18A, and FIG. 18B, the fixing device 8 can be of a plug-in type comprising a fixing device body 80 and a plug 81 , wherein a plug-in hole 82 is formed in central portion of the fixing device body 80 ; a rim flange 84 is provided to bottom portion; a dissection groove 85 is molded in each of two opposite lateral faces, a guide slope 853 is offered thereunder, and a positioning portion 854 is arranged at middle section, which is extended to form a positioning groove 850 ; and the protruding piece 86 is preserved on each of the rest two lateral faces. A plug post 87 is provided to the plug 81 , and a positioning protrusion 870 is formed at opposite positions on the plug post 87 near its bottom. When plugging the fixing device body 80 in the through hole 52 of the base 50 , the protruding piece 86 enters the guide flute 521 and turns to match the positioning recess 522 for a primary positioning purpose. Owing to design of the dissection groove 85 , the fixing device body 80 possesses elasticity to some extent. Plug the rim flange 84 in the fixing hole 41 of the motherboard 4 , there the plug 81 seems to be loose-jointed because of elasticity. When a user is to insert the plug 81 in the fixing device 80 , the positioning protrusion 870 must aim at the dissection groove 85 , so that it will be guided by the guide slope 853 to turn an angle automatically and rest at bottom of the positioning groove 850 , and when more pressure is exerted, the rim flange 84 will be tightly snap-fastened and becoming stiff in the fixing hole 41 of the motherboard 4 . For dismounting, just pull the plug 81 upwards, and the positioning protrusion 870 will be stopped at the positioning portion 854 , the entire plug 81 will not be pulled out thoroughly, so that it will fly nowhere without troubling to find and put it back to the plug-in hole 82 accordingly.
In short, when comparing with the above-cited prior skills, the join-structure of high-density connector and interface module is advantageous in:
1. The lateral contact type terminals that can save material, area, and volume;
2. The cross alignment of plate contact type terminals that can save material;
3. The Join-structure of fixing device and plug of plug-in or pivot type that facilitates an easy mounting or dismounting of the retention mechanism;
4. The three-sectional fixing pin used to combine an interface card and a heat sink that can attain an efficacy of low cost and easy mounting/dismounting;
5. A Fastener and its clamping tongue of the elastic leaf in the retention mechanism that can fasten either a card type or a cartridge type interface module;
6. The movable piece of the retention mechanism that provides an easy operation of mounting/dismounting an interface module.
In the above described, at least one preferred embodiment has been elucidated with reference to relating drawings annexed, it is apparent that numerous variations or modifications may be made without departing from the true spirit and scope thereof, as set forth in the following claims.
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This invention relates to a join-structure of high-density connector and interface module comprising a dielectric housing unit, a plurality of terminals, an interface card, a retention mechanism, and a motherboard, wherein the join-structure includes a lateral contact and a plate contact type. In the lateral contact type, terminals in upper layer and lower layer are punched and aligned in a single material feeding band in staggered arrangement, and the terminals in the material feeding band can be folded at connection strips to stand in two rows. As to plate contact type, two-layer terminals are cross-inserted to fixing roots, which are designed in two-section manner and supported at two turning points with enhancing protruded strips. The terminals are plugged and fixed in reception grooves of the dielectric housing unit. A retention mechanism cooperating with a movable piece facilitates an easy dismounting of an interface module, wherein a fixing device is employed to fix the retention mechanism onto a motherboard, and an interface card may join a heat sink with fixing pins for a convenient assembly and a rapid disassembly.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrodeposited metal plate peeling off machine, which functions to sense any contingent failure of peeling-off of the electrodeposited metal plate attached to both sides of a cathode plate and discharge the sensed cathode plate with unpeeled metal plate and also functions to fill a vacancy arising from said discharge with a spare base plate separated from the electrodeposited metal plate.
2. Description of the Prior Art
Nowadays, the electrodeposited metal plate peeling off process in the nonferrous metal refinery has been mechanized and the electrodeposited metal plate can be automatically peeled off a cathode plate. However, the condition of cohesion of the electrodeposited metal plate to the base plate is not uniform: it varies with, for instance, the composition of electrolyte, the temperature of electrolyte, the current density, the condition of the surface of base plate, etc., and there often comes out the so-called base plate with unpeeled metal plate or base plate with tightly stuck metal plate. Therefore, according to the prior art, the working personnel usually keep an eye on the peeling off apparatus, and whenever a cathode plate that failed to have its electrodeposited metal plate peeled off the base plate by means of the peeling off apparatus (hereinafter called `base plate with unpeeled metal plate`) comes out, the working personnel would take the trouble of stopping the peeling off apparatus and removing said base plate with unpeeled metal plate. Accordingly, the operation has hitherto been very troublesome.
SUMMARY OF THE INVENTION
In view of the foregoing defects in the prior art, one object of the present invention is to provide an electrodeposited metal plate peeling off machine which will overcome varieties of defects as above.
Another object of the present invention is to provide an electrodeposited metal plate peeling off machine, which comprises a hammering apparatus, a peeling off apparatus and a transfer means, with the addition of an apparatus for discharging base plates with unpeeled metal plate to the outside of the machine and further a sensing means attached to the peeling off apparatus for the purpose of sensing success or failure of peeling-off work when the operation of said peeling off apparatus is over, whereby any base plate with unpeeled metal plate -- or cathode plate of which the peeling-off of metal plate has not been sensed by said sensing means -- is remembered, and whenever a base plate with unpeeled metal plate arrives at said discharging apparatus by means of said transfer means, the discharging apparatus is actuated under instructions from the sensing means to discharge said base plate with unpeeled metal plate to the outside of the transfer means, thereby rendering it possible to automatically perform the removal of base plate with unpeeled metal plate which has hitherto been carried out manually, entailing enhancement of the operation efficiency and economy in personnel expenses.
A further object of the present invention is to provide an electrodeposited metal plate peeling off machine, which comprises an apparatus for supplying spare base plates in addition to the discharging apparatus for base plate with unpeeled metal plate as disposed parallel to said discharging apparatus, whereby a vacancy in the transfer means corresponding to the capacity occupied by the base plate with unpeeled metal plate discharged by the discharging apparatus is filled up with a spare base plate thereby rendering it possible to perform the succeeding process of returning the base plate to an electrolytic cell smoothly and accurately.
BRIEF DESCRIPTION OF THE DRAWING
In the appended drawings:
FIG. 1 is a block diagram illustrative of one embodiment of the present invention;
FIG. 2 is a front view of an electrodeposited metal plate peeling off apparatus according to the present invention;
FIG. 3 is a cross-sectional view of the essential part of the apparatus in FIG. 2 as taken along the line III--III;
FIG. 4 is a front view -- on an enlarged scale -- of the essential part of the apparatus in FIG. 2;
FIG. 5 is a side view of the discharging apparatus for the base plate with unpeeled metal plate;
FIG. 6 is a side view of the spare base plate supplying apparatus; and
FIG. 7 is illustrative of sequences of operations, wherein (A) is the sequence of operations of the electrodeposited metal plate peeling off apparatus, (B) is the sequence of operations of the discharging apparatus, and (C) is the sequence of operations of the supplying apparatus.
DETAILED DESCRIPTION OF THE INVENTION
Details of the present invention will be explained hereunder with reference to an embodiment shown in the appended drawings. In the drawings, the reference numeral 1 denotes a crossfeed conveyer for cathode plate P, and along this crossfeed conveyer 1 are installed at specified intervals the hammering apparatus 2, the electrodeposited metal plate peeling off apparatus 3, the discharging apparatus 4 for discharging base plate with unpeeled metal plate P to the outside of the system and the supplying apparatus 5 for supplying spare base plates having their electrodeposited metal plates peeled off from the outside of the system after discharging the base plate with unpeeled metal plate, in order.
As to said hammering apparatus 2, though particulars thereof are not illustrated in the drawings, it is so devised as to apply impact on both sides of a cathode plate P conveyed sideways while having its lower end put on the crossfeed conveyer 1 and it upper end guided by guide plates thereby to form a fine gap between the cathode's base plate P and the electrodeposited metal plates P' adhering thereto.
The peeling off apparatus 3 for the electrodeposited metal plate P' is as illustrated in FIGS. 2-4. That is, it is equipped with the clamps 6 which are disposed along two sides of the cathode plate P to front on the region of movement of the upper part thereof and supposed to hold said cathode plate P between, the air nozzle pipes 7 for jetting air in between the base plate P and the electrodeposited metal plate P' and the wedges 8 to be driven in between the base plate P and the electrodeposited metal plate P', with the addition of the roller conveyers 9 which are disposed along two sides of the cathode plate P to front on the region of movement thereof for the purpose of receiving the electrodeposited metal plate P' after peeling off and the conveyers 10 disposed below said roller conveyers 9 for the purpose of transferring the base plate P.
The clamps 6 are equipped with a clamp plate 11 respectively and capable of reciprocation toward two sides of the upper part of the cathode plate P by means of the cylinder 12 connected to the rear end thereof. The air nozzle pipe 7 is installed on the side of each clamp 6 and reciprocates together with the clamp 6. The wedges 8 are respectively connected to the cylinder 13 and also pivotally fitted on the rod 15 with the aid of the spring 16, said rod 15 being provided on the arm 14 incorporated with clamp 6. This wedge 8 is not only capable of reciprocation toward two sides of the upper part of the cathode plate P by means of the clamp 6, but also capable of vertical movement along the side of the cathode plate P.
The roller conveyers 9 are, as illustrated in FIGS. 2 and 3, inclined outward respectively, and one side of each conveyeer is pivotally supported on the frame with the aid of the shaft 17 so that both conveyers can be turned by the cylinder 18 to open together downward, whereby the electrodeposited metal plate P' received thereon can be piled up on the conveyer 10 disposed thereunder.
The discharging apparatus 4 for the base plate with unpeeled metal plate is, as illustrated in FIG. 5, constructed such that, a conveyer 19 to suspend to base plate P with unpeeled metal plate with the aid of a head bar H is installed in the upper part of the frame and a shifting means 20 is installed on one end -- which confronts the region of movement of said base plate P with unpeeled metal plate -- of said conveyer 19. In FIG. 5, references 21, 22 denote links constituting said shifting means 20, said link 21 having its one end fixed on a shaft 23 which is pivotally supported on the same shaft as that of a chain wheel of the conveyer 19 while said link 22 having its one end fixed on a shaft 24 which is pivotally supported on the frame below it. A link 25 is pivotally connected to both other ends of these links 21, 22 by means of a shaft 26 respectively. And, on the upper end of this link 25 is provided a groove 27 for the purpose of transferring the base plate P with unpeeled metal plate put on the crossfeed conveyer 1 onto the conveyer 19 with the aid of the head bar H.
Reference 28 denotes a guide frame for the purpose of guiding the upper edge of the base plate P with unpeeled metal plate at a portion confronting the discharging apparatus 4 as a substitute for a guide plate: this guide frame is devised to be capable of ascending and descending by means of a cylinder 32. Reference 29 denotes a ratchet mechanism, and 30 denotes a cylinder which is supposed to drive the conveyer 19 intermittently at regular intervals. Reference 31 denotes a motor.
The supplying apparatus 5 FIG. 6 for supplying a spare base plate separated from electrodeposited metal plate in place of a base plate with unpeeled metal plate is substantially the same in construction as the foregoing discharging apparatus 4 for base plate with unpeeled metal plate, excepting that the shifting means 20' has its upper part inclined backward in contrast with the shifting means 20 of said discharging apparatus 4, the direction of movement of the shifting means 20' is reversed and it engages with the base plate P put on the conveyer 19' thereby to transfer it onto the crossfeed conveyer 1, and the direction of driving of the conveyer 19' is inverse. Therefore, for the sake of simplification, the members of the supplying apparatus 5 which correspond to that of the foregoing discharging apparatus 4 are represented by the same reference numeral save for attachment of the mark('), and description thereof is dispensed with.
OPERATION
Next, the mode of operation of the present embodiment will be explained by reference to the sequences in FIG. 7. In this context, in the sequence (A), inasmuch as the symmetrical wedges 8 disposed along two sides of the cathode plate P and so forth are of the same behavior, a portion of the sequence is herein omitted and accordingly explanation relevant thereto is also omitted in part.
When a cathode plate P put on the crossfeed conveyer 1 and conveyed sideways along the guide plate arrives at a position confronting the hammering apparatus 2, a sensor not shown in the drawings senses this and stops the crossfeed conveyer 1, the air hammer is actuated to apply impact intermittently upon the electrodeposited metal plates attached to both the surface and the back of the upper part of the cathode plate thereby to form a fine gap in between the cathode's base plate P and the electrodeposited metal plate P', and after a prescribed time the air hammer stops working and retreats. Then, the crossfeed conveyer 1 is driven again to shift the cathode plate P which has undergone the impact process by a distance equivalent to one pitch transversely, and when the cathode plate P arrives at a position confronting the peeling off apparatus 3, a sensor not shown in the drawings senses this thereby to stop the crossfeed conveyer 1. When the stop of the crossfeed conveyer 1 is confirmed, the contacts A2, AX3 close accordingly, the electromagnetic valve SOL-B1 is opened by means of the relay B2, the cylinder 12 is actuated to advance the clamp 6 toward the cathode plate P, the air nozzle pipes 7 and the wedges 8 also advance in concert with the clamp 6, and at the time when the clamp plates 11 of the clamps 6 have held the cathode plate P therebetween, the clamps 6 reach to the terminum of advance. At this, the limit switches LB1R, LB1L sense this, the contact BX1 closes by means of the relay BX1 and the electromagnetic valve S0L-A opens, whereby air is jetted from the nozzle pipe 7 toward the gap between the base plate P and the electrodeposited metal plate P' to widen said gap. At the point in time when the clamp 6 arrived at the terminum of advance, by the closure of the contact BX1, the timer BT1 is set, and when the contact BT1 closes after a prescribed interval of time and the contact B3 closes by means of the relay B3, inasmuch as the contact B2 is already closed, the contact B4R is closed by the relay B4R, whereby the electromagnetic valve S0l-B2R opens and the cylinder 13 is actuated to make the wedge 8 descend. And, at the same time, the contact B5R is closed by the relay B5R and also the timer BT2R is set. When the wedge 8 is sensed by the limit switches LB2R, LB2L upon descending by a prescribed distance, the electromagnetic valve S0L-A is closed by the relay BX2 to discontinue the jetting of air from the nozzle pipe 7, but the wedge 8 is let cut in between the base plate P and the electrodeposited metal plate P' to descend and peel off said metal plate P'. When the wedge 8 reaches to the terminum of descent, the limit switches LB4R, LB4L senses this. At this, the normally closed contact BX4R is opened by the relay BX4R, and the relay B4R is cut to close the electromagnetic valve S0L-B2R, whereby the cylinder 13 is actuated reversely to make the wedge 8 ascend. And, at the same time, the contact BX4R is closed, the contact B6R is closed by the relay B6R, and also the timer BT3R is set. The wedge 8 stops upon arrival at the terminum of ascent. When the limit switches LB3R, LB3L sense this, each contact BX3R is closed by the relay BX3R. Even during this operation, the timers BT2R, BT3R remember the fall of metal plate P' and the relay B2 is cut, and this state of being set is held intact until the clamp 6 retreats and the contact B2 opens.
Meanwhile, the metal plate P' peeled off the base plate P falls down on the roller conveyer 9 to slip down along the slope thereof. When the limit switches LB5R, LB5L sense this, the contact B9R is closed by the relay B9R and remembers the peeling-off. As to the roller conveyer 9, when the wedge 8 reaches the terminum of ascent and the contacts BX3R, BX3L close, by virtue of the memory of the contact B9R, the electromagnetic valves S0L-B3R, S0L-B3L open and the roller conveyer 9 turns downward centering around the respective shaft 17 by means of the cylinder 18, whereby the metal plate P' is let fall on the conveyer 10 disposed below the roller conveyer 9 to be piled up thereon. When the roller conveyer 9 reaches the terminum of descent, it is sensed by the limit switches LB6R, LB6L, the relays B9R, B9L are cut, the contacts B9R, B9L open, the electromagnetic valves S0L-B3R, S0L-B3L close and the cylinder 18 is actuated reversely, whereby the roller conveyer 9 is restored to its initial position.
When the electrodeposited metal plate P' on the roller conveyer 9 is sensed by the limit switches LB5R, LB5L and the peeling-off of said metal plate P' is confirmed, the normally closed contacts B10R, B10L open, and the relay B2 is cut to open the contact B2, whereby the setting of the timers BT2R, BT2L BT3R and BT3L is cancelled.
Further, when the electromagnetic valve S0L-B1 closes, the cylinder 12 is actuated reversely, the clamp 6, nozzle pipe 7 and wedge 8 retreat and reach the terminum of retreat, and the limit switches LB7R, LB7L sense this, the crossfeed conveyer 1 is driven to advance the base plate P deprived of the electrodeposited metal plate P' by a prescribed distance while accepting a new cathode plate P.
In the case where the cathode plate P confronting the peeling off apparatus 3 is the so-called tightly electrodeposited cathode plate and fails to have its electrodeposited metal plate P' peeled off, this is sensed in the following way:
There are two instances where the electrodeposited metal plate P' fails to be peeled off: one is the case where no gap is formed between the electrodeposited metal plate P' and the cathode's base plate P even through subjected to the impact process, or even if any gap can be formed, said gap cannot be widened by jetting air from the air nozzle pipe and accordingly the wedge 8 fails to cut in between the electrodeposited metal plate P' and the base plate P but it slides down along the outer surface of the metal plate P'; the other is the case where the wedge 8 manages to cut in between the electrodeposited metal plate P' and the base plate P, but because of the cohesion of both plates being too strong, the wedge 8 is stopped in the course of descent.
1. In the case where the wedge 8 slides down along the outer surface of the electrodeposited metal plate P':
When the wedge 8 reaches the terminum of descent, it is sensed by the limit switch LB4R as described in the foregoing, the contact BX4R closes, the contact B6R is closed by the relay B6R, and the timer BT3R is set. Upon arrival at the terminum of descent, the wedge 8 ascends directly to return to its initial position, but as the electrodeposited metal plate P' is left unpeeled, even after the lapse of a prescribed time, the limit switches LB5R, LB5L cannot sense any peeled off metal plate P', and accordingly, the timer BT3R is not released but is left working continuously and after the lapse of a prescribed time closes the contact BT3R, and the contact B7R is closed by the relay B7R. And, as the contact BX3R is being closed at the time when the wedge 8 has reached the terminum of ascent, the clamp 6 is made to retreat by the relay B8R at the same time, the occurrence of the base plate with unpeeled metal plate is remembered by the relay B11 which gives a signal to the discharging apparatus 4 for discharging the base plate with unpeeled metal plate.
2. In the case where the wedge 8 becomes incapable of peeling off in the course of descent:
After the lapse of a prescribed time subsequent to finishing the clamping motion of the clamp 6 on the cathode plate P, the contact B3 is closed by the relay B3, the wedge 8 starts descending, and at the same time, the contact B4R is closed by the relay B4R, whereby the timer BT2R is set.
However, as the wedge 8 is stopped in the course of descent, the electrodeposited metal plate P' will never be peeled off. Therefore, a prescribed time passes while the limit switch LB5R on the roller conveyer 9 is still unable to sense the metal plate P', so the contact BT2R is closed by the actuation of the timer BT2R, the failure in peeling-off is sensed by the relay B7R, the contact B7R is closed, the occurrence of a cathode plate P with unpeeled metal plate is sensed by the relay B11, a signal is given to the discharging apparatus 4 and, at the same time, the normally closed contact B7R is opened to cut the relay B4R, the contact B4R is opened to close the electromagnetic valves S0L-B2R, and the cylinder 13 is actuated reversely, whereby the wedge 8 is pulled up. When the limit switches LB3R, LB3L sense the return of the wedge 8 to the terminum of ascent, the contact BX3R is closed by the relay BX3R, the normally closed contact B8R is opened by the relay B8R, and the relay B2 is cut to make the clamp 6 retreat. When the limit switches LB7R, LB7L sense the clamp 6 at the terminum of its retreat, the crossfeed conveyer 1 is actuated to shift the base plate P with unpeeled metal plate transversely by a distance equivalent to one pitch thereby to make it confront the discharging apparatus 4.
Next, the mode of operation of the discharging apparatus 4 for the base plate with unpeeled metal plate will be explained in the following.
It is to be ascertained first that the cathode plate has been conveyed along the crossfeed conveyer 1 and arrived at a position confronting the discharging apparatus 4 with the closure of the contacts A4, AX5. In the case where the cathode plate P arrived at said position is a normal base plate after having the electrodeposited metal plate P' peeled off, the contact B11 does not close and accordingly the discharging apparatus 4 is not actuated, but in the case where said plate is a base plate with unpeeled metal plate, the contact B11 is closed by the relay B11, and accordingly the contact C1 is closed by the relay C1, the contact C2 is closed by the relay C2, and the electromagnetic valve S0L-C1 opens to actuate the cylinder 32, whereby the guide frame 28 ascends. While the guide frame 28 is in the course of ascending to the terminum of ascent, the limit switch LC1 senses this, the contact C3 is closed by the relay C3, the contact C4 is closed by the relay C4, the motor MSC (or 31) is driven to rotate the shifting means 20, and the head bar H of the base plate with unpeeled metal plate is engaged with the groove 27 of said shifting means 20, whereby said base plate P with unpeeled metal plate is lifted from the crossfeed conveyer 1 and transferred onto the conveyer 19. In the course of this transfer, said base plate P with unpeeled metal plate is sensed by the relay C5, the relay C2 is cut to close the electromagnetic valve S0L-C1, the cylinder 32 is actuated reversely, the guide frame 28 is made to descend thereby to return to its initial position, the shifting means 20 is further turned thereby to suspend the base plate P with unpeeled metal plate from a chain above the conveyer 19, and when the shifting means 20 turning downward finishes one revolution, the limit switch LC2 senses this and cuts the relay C4 to stop the motor MSC(31), whereby one cycle is finished. Meanwhile, when a base plate P with unpeeled metal plate has been transferred onto the conveyer 19 and a sensor not shown in the drawings senses this, said conveyer 19 is driven to advance by the actuation of the cylinder 30 and the ratchet mechanism 29 thereby to advance said base plate P with unpeeled metal plate by a prescribed distance, and stops thereupon.
Next, the mode of operation of the supplying apparatus 5 for the purpose of filling a vacancy arising from the discharge of a base plate with unpeeled metal plate on the crossfeed conveyer 1 with a spare base plate P will be explained in the following.
In the case of a normal cathode plate P from which the electrodeposited metal plate P' has been peeled, the relay B11 for sensing the occurrence of a base plate with unpeeled metal plate and the relay C2 for guiding a base plate with unpeeled metal plate to the discharging position do not work thereon, and accordingly the contacts B11, C2 are left open, the keep relay DK is not actuated, and the spare base plate supplying apparatus is not actuated either. But, in the case of occurence of any base plate with unpeeled metal plate, the contacts B11, C2 close, the keep relay DK is set to remember it, the crossfeed conveyer 1 advances by a distance equivalent to one pitch to actuate the relay D1, the conveyer stopping relay A9 is actuated to bring the crossfeed conveyer 1 to a halt, and the relay D2 is actuated to close the contact D2. When the contact D2 closes, the contact D3 closes, the electromagnetic valve S0L-D1 opens, the guide frame 28' is elevated by the cylinder 32', said guide frame 28' is sensed by the limit switch LD1 while being thus elevated, the contact D4 is closed by the relay D4, and next the arrival of the base plate P to be supplied onto the conveyer 19' is sensed by the limit switch LD. Also, the contact D5 is closed by the relay D5, the motor MSD (31') is driven to actuate the shifting means 20', the head bar H of the base plate P on the conveyer 19' is engaged with the groove 27' whereby said base plate P is hung up, and said shifting means 20' thus hanging the base plate P rotates and deposits it on the crossfeed conveyer 1. At this point in time, the limit switch LD3 senses the base plate P, the normally closed contact D6 is opened by the relay D6, the relay D3 is cut to open the contact D3, the electromagnetic valve S0L-D1 is closed, the guide frame 28' is made to descend by the cylinder 32' and its guide groove is fitted on the upper part of the base plate P thereby to hold it. The shifting means 20' is further rotated, and at the point in time when the shifting means 20' finishes one revolution, the limit switch LD2 senses this, the relay D5 is cut, the contact D5 opens, the motor (31) is stopped, and the rotation of the shifting means 20' is discontinued, whereby one cycle is finished. Meanwhile, when one base plate P has been taken away from the conveyer 19' and the limit switch LD4 senses this, the cylinder 30' and the ratchet mechanism 29' are actuated to drive the conveyer 19' to progress by a prescribed distance, the remaining spare base plates P are advanced accordingly to be ready for the next supply of a base plate P.
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The electrodeposited metal plate peeling off machine comprises a hammering apparatus, a peeling off apparatus, and a transfer means installed throughout the foregoing apparatuses for the purpose of intermittently transferring a cathode plate between different working stations. A discharging apparatus is disposed in the rear of the peeling off apparatus and devised to receive a cathode plate sent out from the peeling off apparatus without having its electrodeposited metal plate peeled off successfully by the peeling off apparatus. The discharge apparatus is activated by a means for sensing success or failure of the peeling-off of the metal plate when the operation of the peeling off apparatus is over. An apparatus for supplying spare cathode plates is disposed parallel to the discharging apparatus, whereby every time a cathode plate with unpeeled metal plate sensed by said sensing means arrives at said discharging apparatus, said cathode plate with unpeeled metal plate is discharged to the outside of the machine and a spare base plate is supplied by said supplying apparatus to fill the resulting vacancy.
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PRIORITY CLAIM
This application claims priority to U.S. Provisional Patent Application No. 61/020,126 entitled “THE USE OF A ZEOLITE MATERIAL WITHIN THE FLOW CHANNEL OF A GAS PUMP BASED ON THERMAL TRANSPIRATION”, which was filed on Jan. 9, 2008 by Yogesh B. Gianchandani, the contents of which are expressly incorporated by reference herein.
BACKGROUND
Pumps are devices used to move fluids, such as gases or liquids. Displacement of fluid is achieved by physical or mechanical means. Pumps may be used to evacuate gas from a confined space, thereby creating a vacuum. Conversely, pumps may also be used to draw in gas from one environment to another. In another example, pumps may be used to pressurize a sealed volume or to generate a pressure gradient along a restricted flow path.
Most pumps are not suitable for miniaturization as they possess mechanical parts or require a low backing pressure that makes it necessary to use a backing pump. Miniaturized pumps, such as micropumps and mesoscale pumps, can suffer from poor performance and reliability, or introduce undesired vibrations into a system.
Thermal transpiration pumps work by maintaining a temperature difference across an orifice under rarefied conditions. However, there is room for improvement in throughput, range of pressure under operating conditions, operating voltage, energy efficiency, and other aspects affecting cost, manufacturability and performance.
The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent upon a reading of the specification and a study of the drawings.
SUMMARY
The following examples and aspects thereof are described and illustrated in conjunction with systems, tools, and methods that are meant to be exemplary and illustrative, not limiting in scope. In various examples, one or more of the above-described problems have been reduced or eliminated, while other examples are directed to other improvements.
A technique provides a system and method for constraining gas molecules to the free molecular or transitional flow regime using nanoporous ceramic materials in gas pumps based on the principle of thermal transpiration.
A system based on the technique may comprise a single nanoporous ceramic element or may comprise multiple layers of one or more types of nanoporous ceramic materials. A temperature difference may be achieved across the nanoporous ceramic element by the use of one or more heaters, thereby creating a flow of gas molecules through the nanoporous ceramic element.
A method based on the technique may provide differential molecular pumping speeds for different gas molecules of varying sizes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an exploded view of a thermal transpiration driven gas pump with a nanoporous ceramic element.
FIG. 2 depicts an alternative embodiment of a thermal transpiration driven gas pump using nanoporous ceramic elements.
FIG. 3 depicts an example of a nanoporous ceramic element including multiple layers of one or more types of ceramic materials.
FIG. 4 depicts an alternative embodiment for the encapsulation shown in FIG. 1 .
FIG. 5 depicts an example of a thermal transpiration driven gas pump that provides different flow rates for different gas molecules.
FIG. 6 depicts an example of an arrangement comprising various types of ceramic elements arranged in series or parallel along a flow path.
FIGS. 7A and 7B depict an example of a sequence of steps required to estimate some of the potential performance parameters for a transpiration driven Knudsen pump.
FIG. 8 depicts the modeled pressure in the hot chamber.
FIG. 9 depicts the idealized theoretical mass flow rate of air across a zeolite element subject to a given temperature drop across its thickness.
DETAILED DESCRIPTION
In the following description, several specific details are presented to provide a thorough understanding. One skilled in the relevant art will recognize, however, that the concepts and techniques disclosed herein can be practiced without one or more of the specific details, or in combination with other components, etc. In other instances, well-known implementations or operations are not shown or described in detail to avoid obscuring aspects of various examples disclosed herein.
A technique provides gas pumping by thermal transpiration using nanoporous ceramic materials to constrain the gas molecules to free molecular or transitional flow regime at pressures up to around atmospheric pressure. A method and system based on the technique may provide differential pumping rates for different gas molecules. The degree of differential pumping is determined primarily by the size of the gas molecules and their rates of interaction with the matrix of the nanoporous ceramic element.
In a non-limiting example, the nanoporous ceramic element may be zeolite. Zeolites are hydrated alumino-silicate minerals with an “open” structure with a large surface area to volume ratio. They are characterized by an interconnected network of nanopores, which are typically in the range of 0.3 nm to 10 nm. Zeolites can be naturally occurring or may be synthesized.
The Knudsen number (Kn), which is used as a parameter to characterize various gas flow regimes, is defined as the ratio of the mean free path of gas molecules (i.e. the average distance traveled by a molecule between two successive collisions) to the hydraulic diameter of the channel (i.e. the equivalent diameter to circular ducts). These flow regimes, which include free molecular, transitional, slip and viscous, correspond to Kn>10, 0.1<Kn<10, 0.01<Kn<0.1 and Kn<0.01, respectively. For the free molecular or transitional flow conditions to be satisfied at pressures near atmospheric pressure, the gas flow channels must have a hydraulic diameter (d h ) on the order of 100 nm or less.
A thermal transpiration driven vacuum pump, also known as Knudsen pump, works by the principle of thermal transpiration as manifest in the equilibrium pressures of two chambers that are maintained at different temperatures, while connected by a channel that permits gas flow in the free molecular or transitional flow regimes, but not in the viscous regime. By equating the molecular flux between these chambers, it can be shown that the idealized ratio of the pressures is related to the ratio of their absolute temperatures by:
P
2
P
1
=
(
T
2
T
1
)
1
2
A Knudsen pump has high structural efficiency because of the lack of moving parts. Thermal transpiration, the mechanism for a Knudsen pump, has its observable effects on the gas molecules flowing across the channels with Knudsen number (Kn) greater than 0.1.
FIG. 1 depicts a diagram 100 of an exploded view of a thermal transpiration driven gas pump with a nanoporous ceramic element. FIG. 1 includes a first part of an encapsulation 101 , a second part of an encapsulation 105 , heaters 102 , passive thermal elements 103 , nanoporous ceramic element 104 , sensors 106 , feedback control 107 , coolers 108 , provisions for sensors 109 , and ports 110 .
In the example of FIG. 1 , the nanoporous ceramic element 104 may be disposed within an encapsulation. In a non-limiting example, the encapsulation may include a first encapsulation 101 and a second encapsulation 105 , which are configured to provide a seal around the nanoporous ceramic element 104 (with the exception of the inlet/outlet ports 110 ). The encapsulation may be bonded to the nanoporous ceramic element 104 , thereby restricting gas molecules passing through the device to flow through the nanoporous ceramic element 104 . Encapsulations 101 and 105 may be made of a thermally insulating material, such as polyvinyl chloride (PVC), to minimize the parasitic losses of heat from the device.
In the example of FIG. 1 , the heaters 102 may be resistive heaters. The heaters can be operated in such a way as to create a temperature difference between two sides of the nanoporous ceramic element 104 . A single heater may also be employed instead of two heaters as illustrated in FIG. 1 . Alternatively, other mechanisms may be employed to provide the temperature difference, such as cooling the gas on one side of the nanoporous ceramic element 104 (for example, using coolers 108 ), using heat from a source outside of the device (such as scavenging waste heat from an independent system), or any other means of cooling or heating. The temperature difference may be created using at least one of the coolers 108 with at least one of the heaters 102 in conjunction or combination.
Coolers 108 may be finned conductors providing passive cooling or heat sinks with liquid pumped through for active cooling. Heaters 102 and coolers 108 may be selectively turned on to control the temperature difference across the nanoporous ceramic element 104 , and to control the gas flow rate and/or direction of flow.
In the example of FIG. 1 , passive thermal elements 103 are disposed on either side of the nanoporous ceramic element 104 within the encapsulation 101 and 105 . The passive thermal elements 103 may be made of a material with high thermal conductivity, such as, in a non-limiting example, aluminum or silicon, and may have an array of holes through which a gas can flow. The size of the holes should be such that gas molecules within the passive thermal elements 103 are in the viscous flow regime. The high thermal conductivity of the passive thermal elements 103 and their proximity to heaters 102 means that the thermal elements 103 will reach a temperature close to that of the heaters 102 . In another embodiment, a heater may be directly fabricated onto the passive thermal element 103 , or the passive thermal element 103 may act as a heater and/or cooler itself.
The nanoporous ceramic element 104 has a plurality of interconnected molecular sized pores throughout the volume. In a non-limiting example, the nanoporous ceramic element 104 may consist of zeolite or a combination of zeolite and other materials. The zeolite may be naturally occurring or synthesized.
Sensors 106 may be disposed within provisions 109 to measure temperature, pressure, and/or flow rate across the nanoporous ceramic element 104 . The pressure, temperature and flow rate data may be analyzed and used by the feedback control 107 to reversibly control the temperature difference and hence the gas flow rate across the nanoporous ceramic element 104 .
In operation, a temperature difference may be maintained between two sides of a nanoporous ceramic element 104 . The size of the pores of the ceramic element 104 constrains a gas to the free molecular or transitional flow regime within the matrix of the ceramic element 104 , even if the gas is at atmospheric pressure. The temperature difference generates a flow across the nanoporous ceramic element 104 due to thermal transpiration. Heat transfer between the hot side and the cold side of the nanoporous ceramic element 104 is reduced due to the low thermal conductivity of the ceramic element 104 , thus allowing for greater and more efficient temperature differences. Gas flowing through the device will enter the device through one of the ports 110 . The passive thermal element 103 allows the gas to achieve a desired temperature before the gas reaches the nanoporous ceramic element 104 .
FIG. 2 depicts an alternative embodiment of a thermal transpiration driven gas pump using nanoporous ceramic elements. FIG. 2 includes encapsulation 202 , first nanoporous ceramic element 204 , second nanoporous ceramic element 206 , first passive thermal element 208 , second passive thermal element 210 , third passive thermal element 212 , fourth passive thermal element 214 , heater 216 , inlet ports 218 , and outlet port 220 .
The elements are similar to those as described with reference to FIG. 1 . In the example of FIG. 2 , the first nanoporous ceramic element 204 is disposed between the first passive thermal element 208 and the second passive thermal element 210 . The second nanoporous ceramic element 204 is disposed between the third passive thermal element 212 and the fourth passive thermal element 214 . Heater 216 is in thermal contact with both the second passive thermal element 210 and the third passive thermal element 212 . These elements are sealed within encapsulation 202 . The nanoporous ceramic elements 204 and 206 and heaters provide a molecular (or transitional) flow regime and temperature gradient, respectively, such that a gas flow is created between the inlet ports 218 and the outlet port 220 due to thermal transpiration.
FIG. 3 depicts a diagram 300 of a nanoporous ceramic element including multiple layers of one or more types of ceramic materials. FIG. 3 includes first nanoporous ceramic layer 301 , second nanoporous ceramic layer 302 , third nanoporous ceramic layer 303 , fourth nanoporous ceramic layer 304 .
In the example of FIG. 3 , the nanoporous ceramic element includes multiply stacked layers of one or more types of nanoporous ceramic materials. Stacking layers of nanoporous ceramic materials may act in favor of thermal efficiency of the device by disrupting the path of phonons moving across the thickness of the nanoporous ceramic element. In another embodiment, passive thermal elements, heaters, and/or coolers may be disposed between the stacked layers.
FIG. 4 depicts an alternative embodiment for the encapsulation shown in FIG. 1 . The encapsulation 400 is hollowed to accommodate a thermally conductive base 405 , which provides greater uniformity in temperature across the facet of the ceramic element 104 . It may also serve as a heat sink that maintains the cold end of the ceramic element 104 close to room temperature. FIG. 4 includes port provisions 401 and 406 , sensor provision 402 , and thermally conductive base 405 .
In the example of FIG. 4 , port provisions 401 and 406 may be used for inlet or outlet of gas flow. Sensor provisions 402 may accommodate various sensing elements to measure, for example, the gas flow rate through the nanoporous ceramic element, the temperature, or other variables.
The thermally conductive base 405 may be used to create a temperature gradient across the nanoporous ceramic element 104 . In a non-limiting example, the thermally conductive base 405 may absorb all the necessary heat from an outside source and may therefore not require a heater as described in FIG. 1 . In one embodiment, thermally conductive base 405 may be connected to a cooler 108 . In another embodiment, the thermally conductive base 405 may be used in combination or conjunction with a heater and/or cooler, as described with reference to FIG. 1 . Thermally conductive base 405 may be made of copper, and may be used for thermal coupling of the transpiration driven gas pump with heat from an external system.
FIG. 5 depicts a diagram 500 of a thermal transpiration driven gas pump that provides different flow rates for different gas molecules. FIG. 5 includes nanoporous ceramic element 501 , seal 502 , encapsulations 503 and 505 , sensors 504 , passive thermal elements 506 , heaters 507 , sensor provisions 508 , port provisions 509 , and feedback control system 5 10 .
The transpiration driven flow speeds may depend on the mass of the gas molecules and their rates of interaction with the matrix of the nanoporous ceramic element 501 . This may lead to different flow characteristics for different gases. The interaction between the gas molecules and the ceramic element 501 may further be controlled by coating the surface of the matrix of the ceramic element 501 . The coating may comprise of one or more types of layers of polymer that may be treated chemically.
In the example of FIG. 5 , encapsulations 503 and 505 , sensors 504 , passive thermal elements 506 , heaters 507 , sensor provisions 508 , port provisions 509 , and feedback control system 510 are similar to those as described in reference to FIG. 1 .
In the example of FIG. 5 , the nanoporous ceramic element 501 is configured to provide a flow path that is long compared to the mean free path of the gas molecules. The nanoporous ceramic element 501 may be shaped in lithographically fabricated flow channels and may be sealed, as indicated by seal 502 , to prevent the gas molecules from escaping through the edges of the nanoporous ceramic element 501 .
The lithographically fabricated flow channels may include a micromachined recess on the surface of a glass wafer. Ends of the nanoporous ceramic element 501 may have encapsulations 503 and 505 , which have provisions for inlet/outlet 509 . The device encapsulations 500 may further comprise passive thermal elements 506 and heaters 507 required to reversibly control the differential pumping of the gas. Encapsulations 503 and 505 may have provisions 508 for sensors 504 that can sample temperature, pressure and flow rate of the gas sample entering and leaving the nanoporous ceramic element 501 . The pressure, temperature and flow rate data may be used to provide feedback to the control system 510 , which regulates the gas flow rate across the nanoporous ceramic element 501 .
FIG. 6 depicts an example 600 of an arrangement comprising various types of ceramic elements arranged in series or parallel along a flow path. FIG. 6 includes nanoporous ceramic sub-elements 602 - 610 .
In the example of FIG. 6 , the nanoporous ceramic element, as described with reference to FIGS. 1 and 5 , is divided into sub-elements 602 - 610 , which may be of varying sizes, shapes and materials. Sub-elements 602 - 610 may or may not have independent heaters associated with them. The sub-elements 602 - 610 may be arranged in series along the flow path such that the gas molecules must sequentially pass through each one, or they may be arranged in parallel, such that each gas molecule may pass through only one. This arrangement may further provide a means for physically separating the flow path of certain types of molecules.
FIGS. 7A and 7B (herein referred to as FIG. 7 collectively) depict an example of a flowchart for estimating performance parameters for a transpiration driven pump. These parameters may include the percent porosity of the nanoporous ceramic element, effective leakage aperture of a defect, correction for thermal contact resistance, correction for the delay in heating of the air trapped in the hot chamber and so on.
In the example of FIG. 7 , the flowchart starts at module 702 with choosing a time step (Δt) and calculating interpolated temperature in the hot chamber (Th_int) and in the cold chamber (Tc_int).
In the example of FIG. 7 , the flowchart continues to module 704 with estimating the initial number of molecules entrapped in the hot chamber. The initial number of molecules relates to the dead volume (V) of the entrapped gas, its temperature (T) and pressure (P) by the correlation
PV k B T ,
where k B is the Boltzmann constant.
In the example of FIG. 7 , the flowchart continues to module 706 with selecting the percent porosity (Por) of the nanoporous ceramic element, selecting the effective aperture diameter for gas leakage through macrocracks for the duration the heater is on (D_ap_on), and selecting the effective aperture diameter for gas leakage through macrocracks for the duration the heater is off (D_ap_off). Por D_ap_on and D_ap_off may be selected such that it minimizes the least squared error between the modeled pressure in the hot chamber (Ph_mod) and the interpolated value (Ph_int) of the experimentally measured pressure (Ph_exp) in the hot chamber. Ph_int may be a cubic interpolation of Ph_exp of the form e.t 3 +f.t 2 +g.t+h=Ph_int, where the coefficients e, f, g and h may depend on Ph_exp.
In the example of FIG. 7 , the flowchart continues to module 708 with calculating the final pressure for the current time step. The final pressure may depend on the temperature rise over the duration Δt.
In the example of FIG. 7 , the flowchart continues to module 710 with calculating the average temperature and pressure over the time step. The average temperature and pressure may be assumed to be the average temperature and pressure over current time period for the purpose of subsequent calculation over this time step.
In the example of FIG. 7 , the flowchart continues to module 712 with calculating the number of molecules (N_pos) leaking out of the hot chamber through the aperture by virtue of Poiseuille's law over the time Δt, and calculating the number of molecules (N_tt) pumped into the hot chamber due to thermal transpiration flow across the nanopores of the ceramic element over the time Δt. This accounts for the transpiration flow due to temperature gradient and back flow due to the pressure gradient. The calculation of N_pos and N_tt may use average temperature and pressure over the current time step.
In the example of FIG. 7 , the flowchart continues to module 714 with estimating the final number of molecules in the hot chamber at the end of Δt. The final number of molecules after time step Δt may be given by the algebraic sum of N_pos, N_tt and the initial number of molecules in the hot chamber.
In the example of FIG. 7 , the flowchart continues to module 716 with calculating the modeled pressure in the hot chamber (Ph_mod). P_mod at a particular time-step may depend on the number of molecules remaining the chamber, temperature and pressure.
In the example of FIG. 7 , the flowchart continues to module 718 with determining:
ɛ = [ 1 n Σ Ph_int - Ph_mod 2 ] 1 2 ≤ err 1 ,
where ε is the root mean square deviation of Ph_mod with respect to Ph_int, n is the total number of interpolation points, and err1 is the tolerance limit on the root mean square deviation.
If the decision at module 718 is yes, then the flowchart continues to module 720 with choosing the rate of increase of temperature difference (RITD_on) between Tc_mod and Tc_exp for the duration when heater is on, choosing the rate of decrease of temperature difference (RDTD_off) between Tc_mod and Tc_exp for the duration when heater is off, and calculating Tc_mod. Due to thermal contact resistance Tc_mod is expected be higher than Tc_exp at all times. RITD_on and RDTD_off represent the loss in the performance due to the thermal contact resistance.
In the example of FIG. 7 , the flowchart continues to module 722 with calculating the modeled pressure in the hot chamber (Ph_mod). Ph_mod at this step accounts for the loss in performance due to the thermal contact resistance.
In the example of FIG. 7 , the flowchart continues to module 724 with determining:
ɛ = [ 1 n Σ Ph_int - Ph_mod 2 ] 1 2 ≤ err 2 ,
where ε is the root mean square difference between Ph_mod and Ph_int, and err2 is the tolerance limit on the root mean square deviation.
If the decision at module 724 is yes, then the flowchart continues to module 726 with choosing the factor (TCF_on) by which the time constant of heating of air is higher than Th_exp for the duration when heater is on, choosing the factor (TCF_off) by which the time constant of heating of air is higher than Th_exp for the duration when heater is off, and calculating the modeled temperature of air in the hot chamber (Th_air). TCF_on and TCF_off account for the delay in heating and cooling of air molecules, entrapped in the hot chamber, with respect to the heater itself.
In the example of FIG. 7 , the flowchart continues to module 728 with calculating the modeled pressure in the hot chamber (Ph_mod). Ph_mod at this step accounts for the delay in the heating of the air in the hot chamber.
In the example of FIG. 7 , the flowchart continues to module 730 with determining:
ɛ = [ 1 n Σ Ph_int - Ph_mod 2 ] 1 2 ≤ err 3 ,
where ε is the root mean square difference between Ph_mod and Ph_int, and err3 is the tolerance limit on the root mean square deviation. These deviations are representative numbers for variation of between Ph_mod as compared to Ph_int in these steps.
If the decision at module 730 is yes, then the flowchart terminates. If the decision at module 718 , 724 , or 730 is no, then the flowchart continues to module 706 .
FIG. 8 depicts the modeled pressure in the hot chamber (Ph_mod) as determined by a method as described with reference to FIG. 7 . Ph_mod takes into account some of the performance parameters, such as defects in the ceramic matrix, effect of delay in the heating of the air entrapped in hot chamber (Th_air), elevated temperature at the cold end of the ceramic element due to the thermal contact resistance (Tc_mod) and so on.
FIG. 9 depicts the idealized theoretical mass flow rate of air across a zeolite element (48 mm in diameter and 2.3 mm thick) subject to a given temperature drop across its thickness. The predictions are based on a semi-analytical model for gas flow in the free molecular and transitional flow regimes.
According to a known model, the average mass flow rate across a narrow channel, by the virtue of thermal transpiration, is given by:
M . avg = ( Q T T h - T c T avg - Q P P h - P c P avg ) π a 3 P avg l ( m 2 k B T avg ) 1 2 ( 2 )
where T h and P h are the temperature and pressure on the hot end of the nanoporous channel, T c and P c are the temperature and pressure on the cold end of the nanoporous channel, T avg and P avg are the average temperature and pressure in the nanoporous channel, m is mass of a gas molecule, k B is the Boltzmann constant, a is the hydraulic radius of the narrow tube, and l is the length of the nanoporous channel. Q P and Q T are the pressure and temperature coefficients that depend on rarefaction parameter δ avg given by
δ avg = ( π 3 2 ) 1 2 aD 2 P avg k B T avg ( 3 )
where D is the collision diameter of the gas molecules under consideration.
The analytical model described above, coupled with various performance parameters, may be used to describe a representative simulation model for thermal transpiration pumping through the nanoporous ceramic element.
The simulation model also serves as a platform for benchmarking various material properties and design features that may affect the performance of a transpiration driven gas pump. These include, for example:
The percentage porosity of the ceramic element Por and the effective diameter of the leak aperture D_ap_on or D_ap_off are two of the most important parameters that may affect the steady state pressure attained by the device. Loss in performance due to the thermal contact resistance may play a major role in the deterioration of transpiration based gas pumping in continuous operation. The time constants of heating and cooling of the air entrapped in the hot chamber of the device may cause an initial pressure spike that occurs before the pressure down to a steady state value.
A single stage transpiration driven gas pump, with 48 mm diameter and 2.3 mm thick zeolite element, subjected to a temperature gradient of 15.7 K/mm may produce a flow rate of approximately 0.1-10 ml/min against a back pressure of about 50 Pa offered by a typical measurement set-up. The matrix of the zeolite element, which is assumed to have pore diameter 0.45 nm and porosity (Por) of 34%, may have structural defects or leakage through the seals that would be accounted for by the effective leakage aperture (D_ap_on and D_ap_off).
While operating with sealed outlet, a typical variation of pressure in the hot chamber (Ph_mod) may appear as in FIG. 8 . This transient pressure profile, which is primarily dependent on thermal transpiration flow across the zeolite element, corresponds to the variation of temperature in the hot and the cold chambers. The temperature in the cold chamber is assumed to regulate the temperature at the cold end of the zeolite (Tc_mod). This temperature rise over time is due to the thermal contact resistance at the interface of various thermal elements. The temperature at the hot end of the zeolite is assumed to be regulated by the bulk air temperature (Th_air) entrapped in the hot chamber. The matrix of the zeolite element is assumed to have pore diameter 0.45 nm and porosity (Por) of 34%. Further, the zeolite matrix is assumed to have effective leak aperture diameters (D_ap_on and D_ap_off) of about 20 μm, which may be due to structural defects in the matrix of the zeolite element or due to the leakage through the seals.
During the intial phases of the device operation, thermal expansion of the gas entrapped in the hot chamber may be more prominent, which would result in a sharp rise in the pressure in the hot chamber ( FIG. 8 ). The pressure rise due to the thermal expansion of gas would be subsequently neutralized by the Poiseuille flow that may be responsible for the backflow of gas molecules from hot chamber to the cold chamber. Finally, while operating in steady state, thermal transpiration would be the dominant phenomenon and it would result in a higher steady state pressure. As soon as the heater is turned off the transpiration driven flow would cease and hence the Poiseuille flow may play a dominant role in equilibrating the pressure between the hot chamber and the ambient.
The pressure profile (Ph_mod), as predicted by the simulation model (based on the algorithm presented in FIG. 8 ), takes into account the design and material choices and assumptions listed above, and may be representative of a typical experimentally observed pressure (Ph_exp), such that the root mean square deviation (err1, err2 and err3) between the two is on the order of 1 kPa. The root mean square deviations err1, err2 and err3 serve as the convergence criteria for various simulation steps.
A semi-analytical model for the gas flow in free molecular and transitional flow regime may be used to estimate the idealized pumping efficiency of the transpiration driven gas pump. FIG. 9 suggests that under idealized conditions a 2.3 mm thick zeolite element with 48 mm diameter may generate a flow rate of about 0.1 sccm for a temperature drop of about 38 K. The idealized model assumes: (a) perfect structure of zeolite, which has no macro cracks, (b) perfect thermal contact at all interfaces, (c) uniform in-plane temperature, (d) negligible flow resistance offered by all other elements, except the zeolite element.
The model may be further used to estimate the idealized differential pumping capabilities of a Knudsen pump. The model predicts that for a temperature gradient of about 15.7 K/mm across the zeolite element, the hydrogen gas molecules, which are two and a half times smaller than nitrogen molecules, are pumped about four times faster. Moreover, Poiseuille flow may also provide a mechanism for differential pumping within the zeolite element. Under idealized conditions, for pressure driven flow of 21 kPa/mm across the zeolite element, with zero temperature gradient, hydrogen molecules are expected to move four times faster than nitrogen molecules.
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A system and method for using an element made of porous ceramic materials such as zeolite to constrain the flow of gas molecules to the free molecular or transitional flow regime. A preferred embodiment of the gas pump may include the zeolite element, a heater, a cooler, passive thermal elements, and encapsulation. The zeolite element may be further comprised of multiple types of porous matrix sub-elements, which may be coated with other materials and may be connected in series or in parallel. The gas pump may further include sensors and a control mechanism that is responsive to the output of the sensors. The control mechanism may further provide the ability to turn on and off certain heaters in order to reverse the flow in the gas pump. In one embodiment, the pump may operate by utilizing waste heat from an external system to induce transpiration driven flow across the zeolite. In another embodiment, the pump may selectively drive and direct gas molecules depending on the molecular size and the interaction between the gas molecule and the zeolite element.
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RELATED APPLICATIONS
This application is a continuation of application Ser. No. 08/665,607, filed Jun. 18, 1996 now U.S. Pat. No. 5,664,144 which is a divisional of U.S. patent application Ser. No. 08/052,039 filed Apr. 23, 1993, entitled REMOTE DATA MIRRORING (U.S. Pat. No. 5,544,347 issued Aug. 6, 1996), which is a continuation-in-part of U.S. patent application Ser. Nos. 07/586,796 filed Sep. 24, 1990 entitled SYSTEM AND METHOD FOR DISK MAPPING AND DATA RETRIEVAL (U.S. Pat. No. 5,206,939 issued Apr. 27, 1993); which is a continuation-in-part of Ser. No. 07/587,247 filed Sep. 24, 1990 entitled DYNAMICALLY RECONFIGURABLE DATA STORAGE SYSTEM WITH STORAGE SYSTEM CONTROLLERS SELECTIVELY OPERABLE AS CHANNEL ADAPTERS OR STORAGE DEVICE ADAPTERS (U.S. Pat. Nos. 5,269,011 issued Dec. 7, 1993) and 07/587,253 filed Sep. 24, 1990 entitled RECONFIGURABLE MULTI-FUNCTION DISK CONTROLLER SELECTIVELY OPERABLE AS AN INPUT CHANNEL ADAPTER AND A DATA STORAGE UNIT ADAPTER (U.S. Pat. No. 5,335,352 issued Aug. 2, 1994).
The following disclosure in this application is the disclosure in U.S. patent application Ser. No. 07/586,796 as filed on Sep. 24, 1990 and entitled SYSTEM AND METHOD FOR DISK MAPPING AND DATA RETRIEVAL (U.S. Pat. No. 5,206,939 issued Apr. 27, 1993), which is fully incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to data storage on disk drives and more particularly, to a method and apparatus for retrieving data records stored on a storage medium utilizing a data record locator index stored in memory.
BACKGROUND OF THE INVENTION
Large disk storage systems like the 3380 and 3390 direct access storage devices (DASD) systems employed with many IBM mainframe computer systems are implemented utilizing many disk drives. These disk drives are specially made to implement a count, key, and data (CKD) record format on the disk drives. Disk drives utilizing the CKD format have a special "address mark" on each track signifying the beginning of a record on the track. After the address mark comes the three part record beginning with the "COUNT" which serves as the record ID and also indicates the lengths of both the optional key and the data portions of the record, followed by the optional "KEY" portion, which in turn is followed by the "DATA" portion of the record.
Although this format gives the system and user some flexibility and freedom in the usage of the disk drive, this flexibility forces the user to use more complicated computer programs for handling and searching data on the disk. Since the disk drive track has no physical position indicator, the disk drive controller has no idea of the data which is positioned under the read/write head at any given instant in time. Thus, before data can be read from or written to the disk drive, a search for the record must be performed by sequentially reading all the record ID's contained in the count field of all the records on a track until a match is found. In such a search, each record is sequentially searched until a matching ID is found. Even if cache memory is used, all the records to be searched must first be read into the cache before being searched. Since searching for the record takes much longer than actual data transfer, the disk storage system spends a tremendous amount of time searching for data which drastically reduces system performance.
Disk drives employing what is known as a Fixed Block Architecture (FBA) are widely available in small, high capacity packages. These drives, by virtue of their architecture, tend to be of higher performance than drives employing a CKD format. Such FBA drives are available, for example, from Fujitsu as 5.25" drives with 1 gigabyte or greater capacity.
The distinct advantage of utilizing many small disk drives is the ability to form a disk array. Thus a large storage capacity can be provided in a reduced amount of space, and storage redundancy can be provided in a cost effective manner. A serious problem arises, however, when trying to do a "simple" conversion of data from CKD formatted disks to FBA disks. Two schemes for such a conversion have been considered which do not provide an acceptable solution to the conversion problem. The first of such schemes involves placing every field i.e. Count, Key and Data, of the CKD formatted record into a separate block on the FBA disk drive. Although this scheme does not waste valuable disk space when CKD formatted records contain large amounts of data, the "Count" field which is very short (8 bytes) occupies an entire block which is typically at least 512 bytes. For example, a CKD formatted record containing 47 K bytes of data could be converted to 95 blocks of FBA disk, 512 bytes in length. In such a conversion, one block would be used to store the count of the record while 94 blocks (47 K bytes length of data divided 512 bytes of FBA disk block) would be used to store data, for a total of 95 blocks. However, search time for finding the desired record is still a problem since all the records must be sequentially searched.
For records having very short data lengths such as eight bytes, however, one full track, or 94 CKD formatted data records would need 188 blocks on the FBA disk: 94 blocks for the count portion of the records and 94 blocks for the data portion of the records, even though each data record may only occupy 8 bytes of a 512 byte FBA block. Such a scheme may thus waste nearly 50% of the disk space on an FBA disk drive.
The second scheme for converting data from CKD to FBA drives involves starting each CKD record in a separate block and then writing the complete record in sequential blocks. Utilizing such a scheme, the first FBA block will contain the "count" portion of the record as well as the optional key portion and the start of the data portion of the record. This scheme, however, produces serious system performance degradation when data must be written to the disk, since before writing data to the disk, the entire record must first be read into memory, modified, and subsequently written back to the disk drive. Such a loss in system performance is generally unacceptable.
SUMMARY OF THE INVENTION
This invention features an apparatus and method for retrieving one or more requested data records stored on a storage medium by searching for a data record identifier and associated data record locator index stored in high speed semiconductor memory. The apparatus receives one or more data records, each of the data records including at least a record identification portion and a data portion. The apparatus transfers and stores the data records to one or more data storage mediums. As the records are transferred to the data storage medium, the apparatus of the present invention generates a plurality of record locator indices, each of the record locator indices corresponding to one of the plurality of data records, for uniquely identifying the location of each of the data records stored on the storage medium.
The apparatus further includes high speed semiconductor memory for storing at least the plurality of record locator indices and the associated plurality of record identification portions. Upon receiving a request for one or more data records stored on the storage mediums, the apparatus of the present invention searches the high speed semiconductor memory utilizing the data record identification portion and locates the corresponding record locator index associated with the requested data record. The apparatus then directly retrieves the data record from the storage medium using the record locator index located during the search of semiconductor memory.
In the preferred embodiment, the data records are received in CKD format and stored on an FBA formatted disk drive. The record identification portions and associated record locator indices are combined to form one record locator table stored in one or more blocks of the FBA formatted disk drive and also copied in the high speed semiconductor memory.
A method for retrieving one or more requested data records stored on a storage medium is disclosed utilizing a data record locator index stored in memory and includes the steps of receiving a plurality of data records, each record including at least a record identification portion and the data portion, and transferring and storing the data records to one or more storage mediums. The method also includes generating a plurality of record locator indices, each of which are associated with one of the plurality of data records and uniquely identify the location of the each of the plurality of data records stored on the storage medium. Also included are the steps of storing at least a plurality of record locator indices and the associated plurality of record identification portions in memory. In response to a request for access to one or more of the plurality of data records, the method includes searching the memory, locating one or more data record identification portions and associated record locator indices corresponding to the one or more requested data records, and directly retrieving from the storage medium the requested data records as directed by the record locator indices.
In one embodiment, the method of the present invention includes transforming and encoding CKD formatted data records onto one or more FBA disk drives. Also in the preferred embodiment, the step of storing the data record to one or more storage mediums includes storing the data to one or more directly addressable storage mediums, the step of storing further including the steps of transforming and encoding at least the record identification portion of each of the data records, generating a plurality of record locator indices, and combining the transformed and encoded record locator indices and record identification portions, for forming a record locator table stored in a high speed semiconductor memory.
BRIEF DESCRIPTION OF THE DRAWINGS
These, and other features and advantages of the present invention are described below in the following detailed description and accompanying drawings, in which:
FIG. 1 is a block diagram of a system for disk mapping and data retrieval according to the present invention;
FIG. 2 is a schematic representation of a CKD formatted data record;
FIG. 3 is a schematic representation of several blocks from a fixed block disk drive in which has been inserted the CKD formatted data transformed according to the method of the present invention;
FIG. 4 is a detailed schematic representation of a portion of the data identification and locator table of FIG. 3;
FIG. 5 is a detailed schematic representation of a portion of the data identification and locator table of FIG. 4;
FIG. 6 is a flowchart of the method for transforming CKD formatted data into fixed block data including a method for preparing a record identification and locator table; and
FIG. 7 is a flowchart illustrating the method for compressing the length of the record identification and locator table according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, the disk storage system 10, FIG. 1, for disk mapping and data retrieval includes one or more means for receiving write commands and data such as channel adapter boards 12a-12d. The channel adapter boards are adapted to receive disk read/write commands and data over a plurality of communication channels such as channels 14 from one or more host computers (not shown) over channels identified respectively as 1-8 in FIG. 1.
The channel adapter boards 12a-12d are connected to temporary or cache semiconductor memory storage unit 16 by means of bus 18. Bus 18 is also connected to one or more disk adapter boards 20 which read and write data to one or more disk drive units 22.
Each of the disk drive units 22 may include one or more disk drives, depending upon the user's requirements. Also included in the system is one or more uninterruptable power supply (UPS) 24.
In operation, one or more channel adapter boards 12a-12d receive write commands along with the accompanying data over one or more channels 14 from one or more host computers. In the preferred embodiment, the data is received in CKD format. In order to improve system performance, the disk storage system of the present invention does not wait for disk adapters 20 to locate and update the data on the appropriate disk drives but rather, the channel adapter boards store the data in CKD format in temporary semiconductor memory storage unit or cache 16.
In addition to storing the data that must be written to one or more disk drives 22, channel adapter boards 12a-12d store in the memory, an indication associated with each data record that must be written to disk, indicating to the disk adapters 20 that the associated data record stored in cache must be written to the disk drives. A more detailed description of a disk storage system with write preservation utilizing a write pending indicator is described in U.S application Ser. No. 07/586,254 filed concurrently with the present application and incorporated herein by reference. U.S. application Ser. No. 07/586,254 was continued in U.S. application Ser. No. 156,394 filed Nov. 22, 1993, which issued on Aug. 23, 1994 as U.S. Pat. No. 5,341,493.
In one embodiment, the system and method for disk mapping and data retrieval includes mapping CKD formatted data onto fixed block disk drives. To facilitate understanding of the CKD to FBA data transformation a CKD record 30, FIG. 2 is shown and described below.
In order for a CKD disk drive to locate the first record on any given track, the disk drive read/write head must search the entire track until it encounters a position indicator called an address mark 32. Following a short gap 34 in the track, the first record 30 begins. The CKD record is divided into three fields or portions: the record identification portion, called the count, 36 followed by another gap, 37; the optional key portion 38; and the data portion 40.
The count portion of the data record uniquely identifies this record. The count is the portion of the record that a host system requesting access to a given record presents to the disk drive in order to enable the disk drive to search for and locate the record.
The count is comprised of 8 bytes of information. Bytes 0 and 1, as shown at 42, are used to designate the length of the data, while the third byte, 44, designates the length of the optional key field. The fourth byte 46, designates the record number on the track. The fifth and sixth bytes 48, and the seventh and eighth bytes, designate the head and cylinder numbers respectively, at which the record is located on the device. The second record 52, is located immediately following the end of the data portion 40 of the first record 30.
Thus, in accordance with the present invention, a portion of an FBA disk having CKD formatted data stored thereon is shown in FIG. 3 and includes record identification and locator table 58 including the 5 blocks labeled 60a-60e, for the tracks of the previous cylinder which is organized as described below.
The first data record 61 of the next CKD cylinder being emulated and located on the FBA drive begins in block, 62. If the data portion of the record is longer than the length of the second block 62, the data portion of the first record will be continued in the next block 64, and subsequent blocks as necessary to store the data portion of the first record. If the length of the first record 61 is equal to or smaller than block 62, any remaining unused portion of block 62 will not be used and instead, the data portion of record 2, 63, will begin in FBA disk drive block 64. This process will repeat itself until all of the blocks of a given cylinder being emulated have been copied. Thus, because the data portion of every record begins at the beginning of a block, (i.e. there is never more than one data record per block), once the system computes the address or block in which a requested data record resides, immediate access is possible with little or no disk drive search time. Utilizing the record identification and locator table of the present invention, the system is able to compute the number of fixed length blocks that must be read to retrieve all the data of a given record, as illustrated herein below. Each record identification and locator table is subsequently loaded into the system memory to facilitate and greatly reduce data record searching and data retrieval time.
Shown in greater detail in FIG. 4, is a data record and identification table 70 according to the present invention for one device such as one disk drive including multiple cylinders. Each cylinder being emulated includes such a table on the drive itself, as well as a corresponding copy in the semiconductor cache memory.
Each device record identification and locator table includes a header portion 72 followed by one or more cylinder portions 74-78. In turn, each cylinder portion is comprised of a plurality of track portions 80.
Device header portion 72 of the record locator and identification table includes such information as shown in Table 1 below, including the length of the header, line 1; the starting address of the device scratch memory address, line 2; and the length of the device header including the scratch area, line 3. The header also includes one or more bytes for device flags, line 4.
TABLE 1__________________________________________________________________________DEVICE ID TABLE HEADER BUFFER AND FLAG OFFSETS__________________________________________________________________________1. DV HEADER SIZE $1000 LENGTH OF DV HEADER AT THE ID TABLE2. DV SCRATCH OFFSET DV HEADER DV SCRATCH START ADDRESS3. DV HEADER LENGTH SIZE $10000 LENGTH OF DV HEADER AT THE ID TABLE INCLUDING THE SCRATCH AREADV HEADER BUFFERS OFFSETS4. DV FLAGS OFFSET 0 DV TABLE FLAGS5. DV STATISTICS OFFSET 4 STATISTICS/RESERVED BYTES6. DV READ TASK OFFSET $40 READ TASK (ONLY ONE)7. DV SENSE INFO OFFSET $60 SENSE INFO FOR THIS DV8. DV TABLE SELECT BUFFER OFFSET $80 $40 BYTES SELECTION BUFFER FOR THE DEVICE9. RW COUNT BUFFER OFFSET $C0 8 BYTES R/W COUNT COMMAND DATA BUFFER10. DV WR PEND FLAGS OFFSET $100 $140 BYTES WR PENDING BIT PER CYLINDER11. DV WR PEND GROUPS OFFSET $240 $20 BYTES WR PENDING BIT FOR 8 CYLINDERS12. DV FLAGS SELECT BUFFER OFFSET $280 $40 BYTES SELECTION BUFFER FOR UPDATES13. DV FMT CHANGED FLAGS OFFSET $300 $140 BYTES FMT CHANGED BIT FOR CYLINDER14. DV FMT CHANGED GROUPS OFFSET $440 $20 BYTES FMT CHANGED BIT FOR 8 CYLINDERS15. DV TEMP BLK OFFSET $400 $200 BYTES TEMP BLK FOR RECOVERY16. TEMP CYL ID SLOT OFFSET $600 $A00 BYTES TEMP ID FOR RECOVERY__________________________________________________________________________
Such flags include a write pending flag which is set if one or more records on the device are temporarily stored in cache memory awaiting writing and storing to the disk drive, as well as an in-cache bit indicating that at least one record on the device is located in cache memory to speed up access to the record, line 4. Other bytes of the device header provide various informational, operational, or statistical data to the system.
For example, the write pending group flags shown at line 11 include one bit indicating a write pending on any one record on any of the 64 preselected consecutive cylinders comprising a cylinder group. Similarly, each cylinder has a write pending flag bit in the device header as shown at line 10. The various write pending flags form a "pyramid" or hierarchy of write pending flags which the system may search when no access to records stored on disks is requested for handling write pending requests. Such a hierarchy structure allows the system to inquire level by level within the structure whether any records on the device; any records within a group of cylinders; any records on a given cylinder; any records on a track; and record by record, whether any write pending flags are set or whether any records are located in cache memory. Such information is useful when processing data such as writing data to disk after a power failure as more fully described in U.S. application Ser. No. 07/586,254 filed concurrently herewith and incorporated herein by reference. U.S. application Ser. No. 07/586,254 was continued in U.S. application Ser. No. 156,394 filed Nov. 22, 1993, which issued on Aug. 23, 1994 as U.S. Pat. No. 5,341,493. The "last track" header is a header of a fictitious or non-existent track and serves to indicate that the record locator table was itself modified and must also be written to disk.
A more detailed description of the cylinder header portions 82a-82c of the device record identification and locator table 70 of FIG. 4 is shown in Table 2 wherein any given cylinder header includes such information as the length of the cylinder header, line 1; cylinder write pending flags, line 4; the physical address of the cylinder line 6; and the CRC error check byte of the cylinder, line 7.
TABLE 2______________________________________CYLINDER ID TABLE HEADER BUFFERS AND FLAGS OFFSETS______________________________________1. CYL.sub.-- HEADER.sub.-- LENGTH SIZE $AO LENGTH OF CYL HEADER AT ID TABLE2. CYL.sub.-- FLAG OFFSET 0 CYL FLAGS3. CYL.sub.-- FLAG.sub.-- AUX OFFSET 1 ADD ON TO THE ABOVE4. CYL.sub.-- WR.sub.-- PEND.sub.-- FLAGS OFFSET 2 WR PENDING BIT PER TRACK5. CYL.sub.-- STATISTICS OFFSET 4 STATISTICS/RE- SERVED BYTES6. CYL.sub.-- PH.sub.-- ADD OFFSET 16 PH ADD OF CYL7. CYL.sub.-- SLOT.sub.-- CRC OFFSET 23 CRC OF CYL______________________________________
Each track entry in the record identification and locator table is shown in greater detail in FIG. 5 and comprises a track header portion 84 and a track body portion 86. The track header portion 84 includes information as shown in Table 3 below, including a track flag byte, line 1; record-count bytes, line 2,; the track CRC check byte, line 3; track compress patterns line 4; and cache address pointer, line 5.
The body 86, FIG. 5 of the track portion of the record identification and locator table includes a plurality of record flags 83, (line 6, Table 3,) beginning at byte 20 and record modifiers 85 (line 7, Table 3) beginning at byte 159 and extending sequentially backward as necessary or until a collision with the record flags 83 occurs.
TABLE 3__________________________________________________________________________ID TABLE TRACK HEADER AND BODY OFFSETS__________________________________________________________________________1. TRACK.sub.-- FLAG OFFSET 0 TRACK FLAGS2. RECORD.sub.-- COUNT OFFSET 1 NUMBER OF RECORDS AT THIS TRACK3. TRACK.sub.-- CRC OFFSET 5 CRC BYTE FOR TRACK4. COMPRESS.sub.-- PATTERNS OFFSET 6 TRACK COMPRESS PATTERNS5. CACHE.sub.-- TRACK.sub.-- POINTER OFFSET 14 POINTER TO CACHE6. RECORD.sub.-- FLAGS OFFSET 20 → 159 COMMON FLAG POINTER7. TRACK.sub.-- TABLE.sub.-- BODY OFFSET 159 → 20 TRACK BODY (MODIFIER)TRACK COMMON FLAG BITS8. DEFECTIVE BIT 7 DEFECTIVE TRACK9. ALT BIT 6 ALTERNATE TRACK10. EX.sub.-- TRACK.sub.-- TABLE BIT 5 EXTENDED TRACK TABLE SLOT WRT.sub.-- PEND BIT 4 WRITE PENDING IN TRACK DIAG.sub.-- CYL BIT 3 DIAGNOSTICS CYL (`CE`, `SA`) NOT.sub.-- USED BIT 2 NOT USED INVALID.sub.-- ID BIT 1 ID SLOT DEFECTIVE AND INVALID IN.sub.-- CACHE BIT 0 TRACK IN CACHE FLAGRECORD FLAGS BITS COMPRESS.sub.-- CODE BITS 0 → 3 COMPRESS ALGO` FOR THIS RECORD KEY.sub.-- IN.sub.-- CACHE BIT 4 KEY FTELD IN CACHE DATA.sub.-- IN.sub.-- CACHE BIT 5 DATA FIELD IN CACHE KEY.sub.-- W.sub.-- PEND BIT 6 KEY FIELD WRITE PENDING20. DATA.sub.-- W.sub.-- PEND BIT 7 DATA FIELD WRITE PENDING__________________________________________________________________________
The track flags shown on line 1 in table 3 are described in detail on lines 8-15 and include such bits indicating a defective track bit, line 8; a write pending bit, line 11; and track in cache bit, line 15. Similarly, the record flag bits of line 6 are shown in greater detail in lines 16-20 including bits comprising the compression algorithm for this record, line 16; key and data fields in cache, lines 17 and 18; and key field and data field write pending bits, lines 19 and 20.
The channel adapters 12a-12d, FIG. 1, receive data and read/write commands from one or more hosts over its respective channels. The data records are provided by the host in CKD format and are stored in cache memory 16 in CKD format. All records stored in cache whether temporarily while awaiting writing to disk, or records which have been read from the disk to be stored in cache for quicker access, are stored in CKD format. When the record is to be written to the disk drive, one of disk adapters 20 reads the data from cache memory over bus 18 and converts the CKD formatted data to the format of the present invention including a record identifier and locator table all of which can be stored in a plurality of fixed blocks before outputting the data over the disk adapters' SCSI interface to one or more of disk drives 22.
The present method for mapping CKD formatted data into fixed block disk drives is, in part, based on the recognition that under usual conditions, a sequence of CKD formatted records will include the URN portion of the count identifying the record number from among a number of sequentially numbered data records of the same length. Further, the records are generally stored on the same device cylinder and accessed by the same device head. Additionally, the key length will generally be zero or some predetermined generally constant number. Thus, the method for disk mapping 100, FIG. 6 of the present invention includes establishing the profile of an expected record, step 110. In the preferred embodiment, the expected record is established with the count CCHH code as the physical cylinder and head identification, as well as the key length (K 1 )=0, data length (D 1 )=8 and the "R" byte of the count assigned as record number (n)=0. Further, the record flags are set to 00.
During step 112, the system employing the method of the present invention obtains the first CKD formatted record and compares the CKD record with the previously established expected record at step 114. At step 116, a determination is made as to whether or not the CKD formatted record including the "count" and record flags match those of the expected data record. If the CKD formatted record and the expected record match, the method proceeds to step 118 wherein the body of the track portion of the record identification and locator table previously discussed in conjunction with FIG. 5 and table 3 is built. Since the CKD formatted record matched the previously established expected data record, the record flag is set to 00 and no entry is made in the record modifier portion of the track ID cable. Subsequently, the "R" byte for the record number of the next expected data record is incremented by one, step 120, before returning to the step of obtaining the next CKD formatted data record at step 112.
If the results of the comparison at step 116 indicate that the CKD formatted record does not match the expected data record, the method proceeds to step 122 wherein a change format code (see Table 5) and record modifier, as required, are prepared. Next, the record format code and, if required, record modifier are inserted into the track identification table, step 124. If the track ID table is not full as determined at step 126, processing continues to step 128 wherein the current CKD count becomes the next expected count. Processing then returns to step 120 where the "R" byte is incremented by one before getting the next CKD record at step 112.
If, as indicated at step 126, the track identification table is full, meaning that the record flag portion of the ID table has collided with the record modifier portion of the ID table, the method of the instant invention will attempt to compress or shrink the body of the track ID table as shown in flowchart 130, FIG. 7. During the compression process of the instant invention, the system and method of the present invention attempt to define from one to eight data lengths which are repeated within this track. Such repeating data lengths are then classified as "patterns" and are thereafter referred to by a pattern "code" in the track header as shown on line 4 of Table 3, thus saving up to 2 bytes in the modifier portion of the track ID table for each repeated data length.
The method of the present invention first reads the ID table, step 132, searching for ID's with format code 03 for repeating values of data lengths, step 134. From those repeating values, the system and method of the present invention build a data length pattern table beginning with the data length that is most frequently repeated, and continuing on to find the seven most repeated data lengths and replaces the old 8 byte pattern with the new 8 byte pattern, step 136.
The method then proceeds to compare the data lengths of all the CKD records of the current track which have previously been read to determine whether or not any of the data lengths match the data patterns loaded in the pattern table, step 138. If any data lengths match the data patterns in the pattern table, the method proceeds to insert the data pattern code for the data length in a temporary ID table. Thus, the replaced record modifiers which previously contained the changed or modified data lengths are now unnecessary and eliminated, thus compressing or shrinking the size of the record identification and locator table and therefore allowing more room for the system to complete reading the CKD records for a given track. The system verifies at step 140, that the ID table was in fact compressed. If no ID table compression was achieved, the system reports an error, step 142. If ID table compression was achieved, the method replaces the old ID table with the temporary ID table with compressed counts, step 144, before returning to step 120, FIG. 6.
Although this count compression routine somewhat reduces system performance, the time to compute repeating data patterns and thus, to compress the "count" information in a record identification and locator table is minimal when compared to the tremendous savings of time which results from the ability to search the record locator table containing the count information in semiconductor memory instead of searching the disk drives for the requested record given the respective access times.
An example of a record identification and locator table for track 0 of a representative disk drive along with decoded information of each record is reproduced below as Table 4. This track identification and record locator table forms part of the device record identification and locator table as discussed previously in conjunction with FIG. 4. Line 2 of Table 4 corresponds to the track header portion 84, FIG. 5 of the track identification table also previously discussed in conjunction with table 3. The second byte of the header, the number "5" indicates that there are five records on this track.
TABLE 4__________________________________________________________________________1. TRACK NUMBER 02. FLAGS/COUNT/H/W/R/S/PAT/CACHE PTR: 00 5 00 00 00 00 0000000000000000000000003. FLAGS 00 01 03 03 014. BODY: 0000000000000000 0000000000000000 0000000000000000 00000000000000005. 0000000000000000 0000000000000000 0000000000000000 00000000000000006. 0000000000000000 0000000000000000 0000000000000000 00000000000000007. 0000000000000000 0000000000000000 0000000000000000 000000000000000F8. B0E050900418A0RECORD FLAGSREC ID KEY DATA WR IN NON PHYSICAL ADDRESS # CCHHR LENGTH LENGTH PEND CACHE STD BLOCK TRACK CACHE ADD__________________________________________________________________________ 00 0000000000 00 0008 -- -- 00 00000000 02E010. 01 0000000001 04 0018 -- -- 01 00000001 04E0 02 0000000002 04 0090 -- -- 03 00000002 0800 03 0000000003 04 0050 -- -- 03 00000003 0B80 04 0000000004 00 0FB0 -- -- 01 00000004 0EC0__________________________________________________________________________
Line 3 begins the record flag portion of the track identification table and is comprised of five record flags namely, flags: 00; 01; 03; 03; and 01. Each of the record flags is associated with a corresponding record, in ascending order. Thus record flag 00 is associated with data record 0; record flag 01 is associated with data record 1; and record flag 03 is associated with data record 2 and so forth.
A representation of a record modifier portion of the track identification and locator table is shown at lines 4-8 of Table 4. As discussed in conjunction with FIG. 5, the record modifier portion of the track identification and record locator table is read backwards beginning with the byte, "A0" of line 8.
The track identification and record locator table of Table 4 may be further understood in conjunction with lines 9-13. As shown on line 9, which identifies record 0 of this track, the second, third and fourth columns comprise the original "count" information of the CKD record. It should be noted that this record matches the description of the "expected" record utilized in the example associated with the method of FIG. 6 since the first record on the track is record 0, the key length is 0, and the data length is 8 bytes. Thus, the record locator flag associated with that record, "00" is the first record flag byte encountered on line 3.
Proceeding to line 10, record number 1 on the track has a key length of 04 and a data length of 18 and thus, deviates from the previously established "expected" data record and thus is assigned a record flag of 01.
Various codes which comprise the record flags are reproduced in Table 5 below wherein as shown in line 1, the code 00 means no change to the previously established "expected" record. As shown in line 2 of the table, record flag format 01 indicates that the first byte of the record modifier is the change flag byte, indicating that every bit flagged with a "1" points to the byte in the record identifier that should be replaced by the following bytes in the record modifier. The order of the record identifier is shown in line 7 of table 5 and begins with the key length, followed by data length (high), data length (low) and the first byte of the cylinder.
TABLE 5__________________________________________________________________________RECORD FORMAT CHANGE CODES ID FLAG FORMAT CODE 0: NO CHANGE ID FLAG FORMAT CODE 1: 1ST BYTE 0F MODIFIER IS THE CHANGE FLAG BYTE3. EVERY BIT FLAGGED POINTS TO BYTE IN THE4. ID THAT SHOULD BE REPLACED BY THE NEXT INFO BYTES.5. NUMBER OF EXTRA INFO BYTES IS THE NUMBER OF `1`S6. IN THE 1ST BYTE. THIS CODE IS USED IF WE CAN'T USE ANY OTHER CODE.7. K.sub.L D.sub.LH D.sub.LL CHHR ID FLAG FORMAT CODE 2: ONE BYTE INFO TO DL L + DL H = 2 ID FLAG FORMAT CODE 3: ONE BYTE INFO TO DL L + DL H = 010. ID FLAG FORMAT CODE 4: ONE BYTE INFO TO DL L DL H UNCHANGED ID FLAG FORMAT CODE 5: TWO BYTES INFO TO DL ID FLAG FORMAT CODE 6: ONE BYTE INFOR TO DL L + DL H = 1 ID FLAG FORMAT CODE 7: ONE BYTE INFO TO DL L + DL H = PATT FROM ID TABLE HEADER ID FLAG FORMAT CODE 8: DL L = PATT #0 FROM ID TABLE HEADER + DL H = 0 ID FLAG FORMAT CODE 9: DL L = PATT #1 FROM ID TABLE HEADER + DL H = 0 ID FLAG FORMAT CODE A: DL L = PATT #2 FROM ID TABLE HEADER + DL H = 0 ID FLAG FORMAT CODE B: DL L = PATT #3 FROM ID TABLE HEADER + DL H = 0 ID FLAG FORMAT CODE C: DL L = PATT #4 FROM ID TABLE HEADER + DL H = 0 ID FLAG FORMAT CODE D: DL L = PATT #5 FROM ID TABLE HEADER + DL H = 020. ID FLAG FORMAT CODE E: DL L = PATT #6 FROM ID TABLE HEADER + DL H = 0 ID FLAG FORMAT CODE F: DL L = PATT #7 FROM ID TABLE HEADER + DL H__________________________________________________________________________ = 0
Thus, returning now to line 10 of table 4, the flag code 01 indicates that the first byte of the modifier namely, "A0" indicates the bits that are to be changed in the record identifier. Reading change byte A0 in conjunction with line 7 of Table 5 discloses that the successive bytes in the record modifier will modify the key length and data length (low) of the data record. The record modifier bytes in the track identification table modify the record identifier in reverse order as that shown in line 7 of Table 5 that is, from record number to key length. Thus, the second byte, "18" of the record modifier at line 8 of table 4 indicates that the previously expected data length is to be replaced with a data length (low) of "18", while the next byte of the record modifier, "04" is to replace the previously expected key length. It is in this manner that the system "reconstructs" the count portion of a CKD record from the "encoded" record identification and locator table.
Record number 2, line 11 of Table 4 also has a key length of "04" but the data length changes to "90". Thus, a flag of 03 is entered. The record flag of 03, as shown at line 9, Table 5, indicates that the next sequential byte of information in the record modifier is to be used as the data length (low) and the data length (high) will equal 0. Thus, the next consecutive entry of "90" in the record modifier portion of the track identification table body is accounted for.
Similarly, the next byte of the modifier portion of the track identification table is "50" which is the changed data length of record 3 read in conjunction with a record flag of "03" at line 12 of Table 4.
The final record flag "01" in the record flag portion of this track indicates that the next sequential byte namely, "E0" in the record modifier portion of the table is the changed flag byte pointing to the bytes in the record identifier that are to be changed or modified by the subsequent bytes in the record modifier portion of the table. Code E0 indicates that the key length, data length (high) and data length (low) are to be changed by the three bytes which follow as indicated by line 7, table 5. Thus, byte "B0" of the record modifier is used as the data length (low); byte "0F" is used as the data length (high) byte, and byte 00 modifies the former key length entry.
The building of a record identification and locator table in accordance with the present invention greatly reduces the amount of fixed block disk space required to store the "count" portion of a CKD formatted data record.
An additional example of a track level record identification and locator table is reproduced in table 6 below and is useful in showing an entry in the data pattern table previously described in conjunction with FIG. 7. Table 6 is a representation of a track identification table for an exemplary track number "D00" and is used for illustrative purposes only.
TABLE 6__________________________________________________________________________1. TRACK NUMBER D002. FLAGS/COUNT/H/W/R/S/PAT/CACHE PTR: 11 81 00 00 00 C7 3E14181500FB902403FDE0003. FLAGS00A320 28 202020XX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX4. XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX5. XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XX6. BODY:XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX7. XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXX28RECORD FLAGSREC ID KEY DATA WR IN FORMAT PHYSICAL ADDRESS # CCHHR LENGTH LENGTH PEND CACHE CODE BLOCK TRACK CACHE ADD__________________________________________________________________________ 00 00D0000000 00 0008 -- -- 0 00047DB0 02E0 01 00D0000001 00 0028 D. D. 3 00047DB1 04E0 03FDE11810. 02 00D0000002 00 0028 -- D. 0 00047DB2 0700 03FDE150 03 00D0000003 00 003E -- D. 8 00047DB3 0920 03FDE188 04 00D0000004 00 003E -- D. 0 00047DB4 0B60 03FDE1D0 05 00D0000005 00 003E -- D. 0 00047DB5 0DA0 03FDE218 .25 06 00D0000006 00 003E -- D. 0 00047DB6 0FE0 03FDE260__________________________________________________________________________
On line 2 of table 6, the track "header" information is presented including the first byte "11" indicating that on this track, there is at least one record which is in cache; and at least one record which has a write pending, as previously explained in conjunction with Table 3. The second byte of the track header, "81" indicates there are 81 records in this track, while byte 5, "C7" is the CRC byte for this track The next byte of the header, "3E" is the first byte of the data pattern table which extends for 8 bytes ending with "24". In this example, bytes 1-7 of the pattern table are not used, but are merely shown for illustrative purposes only. The last four bytes of the track header, "03 FD E0 00" is the cache beginning memory address at which any records from this track which are stored in cache are located.
Of particular interest in Table 6 is record 03 located at line 11. Since the data length, "3E" of record 3 is a deviation from the previously established data length "28", a record flag of other than 00 is expected, and thus the record flag "08" is entered As can be compared from line 14 of the record flag codes in Table 5, record flag code "08" indicates that the data length (low) of this record identifier is to be loaded with pattern 0, the first pattern from the identification table header and thus, the "3E" pattern from line 2 of Table 6 is used as the data length for record number 3 when the system reconstructs the data record. The record flag, "28" which is shown and underlined on line 3 of table 6 also indicates that the data of this record is stored in cache. The cache address is ascertained by adding up the cache memory starting address (line 2) contained in the header of the track identification table along with the length of any intervening data or key information stored in cache.
Modifications and substitutions of the present invention by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the claims which follow.
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An apparatus and method for disk mapping and data retrieval includes a data storage medium on which has been stored a plurality of data records. Each record includes at least a record identification portion, for uniquely identifying each record from among the plurality of data records. The apparatus builds a record locator table in high speed semiconductor memory which comprises the unique record identifiers for the records on the storage medium as well as a record locator index generated by the apparatus, which indicates the address of the data record on the storage medium. Data retrieval is facilitated by first searching the record locator table in high speed semiconductor memory for a requested data record. Utilizing the record locator index associated with the reqested data record, the system directly accesses the requested data record on the storage medium thereby minimizing storage medium search time. Also disclosed is an apparatus and method for converting CKD formatted data records to FBA formatted disk drives and for building and compressing the "count" portion of the CKD data formatted record into a record locator table.
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PRIORITY INFORMATION
[0001] The present application is a continuation of U.S. patent application Ser. No. 10/192,212, filed Jul. 10, 2002, the content of which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to multimedia content delivery in pervasive computing environments. Specifically, a method and apparatus are defined to customize delivery and minimize duplication of information for users in the environments.
BACKGROUND OF THE INVENTION
[0003] A pervasive computing environment contains a high density of mobile and non-mobile information devices. IT provides easy access to information at any time, from any place, on any device. These devices span a wide range of complexity. They include set top boxes, stereos, radios, televisions, and other applications that are familiar to consumers. They also include handheld and wearable devices that are embedded in clothing and jewelry. These devices can adapt their behavior to their user and surroundings.
[0004] There are many research and prototyping activities in this field. The article “Pervasive Computing: Vision ad Challenges” by Satyanarayanan in IEEE Personal Communications, August 2001 is an excellent overview of these efforts. It is incorporated by reference. Other relevant articles include “Mobile Information Access” by Satyanarayanan in IEEE Personal Communications, February 1996 and “Uniform Web presence Architecture for People, Places, and Things” by Debaty and Caswell in IEEE Personal Communications, August 2001.
[0005] Personal area networks (PANS) allow devices in the same environment to establish wireless connections, discover resources, and share information. The article “Wireless Networked Digital Devices: A New Paradigm for Computing and Communication” by Zimmerman in IBM Systems Journal, Volume 38, Number 4, 1999 provides an excellent overview of these technologies. Bluetooth, IrDA, and HomeRF are examples of wireless technologies. Specifications are available at http://www.bluetooth.org, http://www.irda.org, and http://www.homerf.org, respectively. Users in pervasive computing environments receive information from many sources. Radio and television stations transmit news programs containing reports about local, national, and international events. Streaming and non-streaming multimedia content is available from the Internet.
[0006] These sources often duplicate information. Competing television stations discuss the same events. Each broadcaster duplicates reports on their local and national programs. Information from popular Web portals duplicates that which is available from radio and television stations. For example, a consumer may visit a Web portal and learn about important news developments of the day. The information may be repeated on a radio program during a commute home. Finally, a television program delivered by a set top box may also report the same information.
[0007] Consumers need an efficient way to assimilate this information. Duplication should be minimized unless a user specifically requests additional details or perspectives on an event or topic. Maximum benefit must be obtained from the time spent viewing news and other information.
SUMMARY
[0008] Limitations of the prior art are overcome and technical advance is made by the present invention. It minimizes duplication of information and, therefore, enables a user to efficiently assimilate information from many different content providers (e.g. radio, television, and Web) in pervasive computing environments.
[0009] Content providers generate and transmit metadata for their information. This metadata provides additional detail about the content (e.g. content provider, date/time of delivery, topic, duration).
[0010] Mobile and non-mobile devices (e.g. personal computers, personal digital assistants, radios, set top boxes, televisions) are enhanced to contain short-range wireless transceivers. The devices use these transceivers to communicate with each other and select content that is most valuable for a consumer and do not duplicate information that has already been received by that individual.
[0011] In an embodiment of this invention, mobile devices maintain a user profile and viewing history. The user profile specifies the topics in which the user has an interest. A priority may be assigned to each topic. Preferences for different content providers may also be indicated. The viewing history stores metadata for information that has already been received by that individual.
[0012] A typical usage scenario is: (1) A mobile device establishes wireless communication with a non-mobile device in an environment. (2) The mobile device transmits a user profile and viewing history to the non-mobile device. (3) The non-mobile device uses this data to select and sequence content for that user. (4) As the non-mobile device presents content, it transmits metadata associated with that content. (5) The mobile device receives this metadata and updates its viewing history.
[0013] A mobile device can establish transient wireless communication with a sequence of non-mobile devices in one or more pervasive computing environments. Communication is established when the mobile and non-mobile device are in proximity to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above-summarized invention will be more fully understood upon consideration of the following detailed description and the attached drawings wherein:
[0015] FIG. 1 shows the system architecture for the first embodiment of the present invention;
[0016] FIG. 2 shows additional detail for a non-mobile and mobile device.
[0017] FIG. 3 shows the message sequence for the first embodiment of the present invention.
[0018] FIG. 4 shows a block diagram of a representative non-mobile device (viz. cable television set top box).
[0019] FIG. 5 shows a block diagram of a representative non-mobile device (viz. personal computer with Web browser).
[0020] FIG. 6 shows a block diagram of a representative mobile device (viz. personal digital assistant).
[0021] FIG. 7 shows a graphical user interface for examining and modifying the user profile that is stored on a mobile device.
[0022] FIG. 8 shows a graphical user interface for examining the viewing history that is stored on a mobile device.
[0023] FIGS. 9-10 are flowcharts for a non-mobile device.
[0024] FIG. 11 is a flowchart for a mobile device.
[0025] FIG. 12 shows the message sequence for the second embodiment of the present invention.
[0026] FIG. 13 shows a flowchart for a non-mobile device.
[0027] FIG. 14 shows a sample schema for content metadata.
[0028] FIG. 15 shows sample metadata for radio content.
[0029] FIG. 16 shows sample metadata for television content.
[0030] FIG. 17 shows sample metadata for web content.
DETAILED DESCRIPTION
[0031] FIG. 1 shows the system architecture for the first embodiment of the present invention. Content providers 102 generate multimedia content and metadata that is stored in a server 104 (e.g. streaming and non-streaming Internet content, television programs, or radio programs). This information is accessible via backbone network 106 . Backbone network 106 can use wide area network technologies in the current art (e.g. circuit switching, packet switching). Multiple access networks 110 connect to the backbone network 106 . Access network 110 can use a variety of technologies in the current art (e.g. hybrid fiber coax, digital subscriber loop, wireless).
[0032] The current art provides techniques by which content providers may generate, store, and transmit metadata for their information. For example, the MPEG-2 video format enables metadata to be transmitted as a component of a digital video stream. The book “Digital Video: An Introduction to MPEG-2 (Digital Multimedia Standards Series)” by Haskell et al., Chapman and Hall, 1996 provides details.
[0033] Multiple pervasive computing environment 112 may contain non-mobile devices 114 - 120 and mobile devices 122 - 124 . Mobile devices 122 - 124 enter and exit these environments. Transient short-range wireless connections 126 - 128 are automatically established between a mobile device and a non-mobile device via techniques in the current art.
[0034] As a mobile device 122 moves within an environment 112 (or moves among environments), connections are dynamically established and dropped to devices. Data is exchanged that enables the devices to adjust their behavior for the user of the mobile device and minimize repetitive presentation of information.
[0035] A statistics server 108 can accumulate statistics on the content that is selected for presentation. It can also accumulate statistics about advertising that is inserted into the presentation. Reports can be generated for all of these activities. This data can be shared with content providers for a fee.
[0036] FIG. 2 shows additional detail for an exemplary non-mobile device 114 and an exemplary mobile device 122 in an environment 112 . The non-mobile device 114 contains a software controller 202 , a server having stored multimedia content and metadata 204 , and a short-range wireless transceiver 206 . Components of the software controller may be dynamically downloaded to the device by using Java software technology. See http://www.javasoft.com for additional details. The mobile device 122 contains a software controller 208 , short-range wireless transceiver 210 , user profile 212 and viewing history 214 . The user profile is generated based on data gathered by the mobile device 122 and preferences inputted by the user. Such preferences can include the type of content that is of interest to the user, the subject matter of interest, dates of interest, etc. The viewing history is compiled by the mobile device 122 based on the data gathered from the short-range wireless transceiver 210 . As the user travels from one environment to another, the content that the user is exposed to is captured by the short-range wireless transceiver 210 . This data is used to help filter out desired content stored on the non-mobile device. This user profile and viewing history 214 are transmitted to a non-mobile device 114 so it can customize its behavior for the owner of the mobile device.
[0037] FIG. 3 shows how a mobile device 122 interacts with two non-mobile devices 114 - 116 and a statistics server 106 . The mobile device 122 and non-mobile device 114 establish a connection via messages 301 according to techniques in the current art. Message 302 is then transmitted to the non-mobile device. This message contains the user profile and viewing history. The non-mobile device uses this data to select and sequence stored multimedia content. As content is presented, the metadata for the content is transmitted to the mobile device 122 . This done by messages 303 - 305 . This metadata is stored in the viewing history 214 on the mobile device 114 . This is shown as 306 on the diagram.
[0038] The mobile device 122 and non-mobile device 116 establish a connection via messages 307 according to techniques in the current art. Message 308 is then transmitted to the non-mobile device. This message contains the user profile and viewing history. The non-mobile device 116 uses this data to select and sequence stored multimedia content. As content is presented, the metadata for that content is transmitted to the mobile device 122 . This is done by messages 309 - 311 . This metadata is stored in the viewing history 214 on the mobile device. The mobile device 122 then drops its connection to non-mobile device 116 . This is shown as 312 on the diagram.
[0039] The mobile device 122 may periodically transmit statistics to the statistics server 108 . This data may indicate the specific multimedia content that was received by the mobile device. The statistics server can use this information to generate reports that can be distributed to content providers. Mobile devices may also be billed for this service.
[0040] FIG. 4 shows a block diagram of a representative non-mobile device 114 (e.g. cable television set top box). The set top box connects to the access network 110 (e.g. hybrid fiber coax network) and receives television signals. These signals are supplied to one or more audio/video RF CATV demodulators 402 . Output from the demodulators is supplied to one or more MPEG-2 decoders 404 . Output from the decoders is stored in the multimedia content and metadata storage server 204 .
[0041] The software controller 202 receives requests from a mobile device 122 via the short-range wireless transceiver 206 . In response to these requests, the software controller 202 examines the metadata in server 204 and selects a subset of the content for that user. The content is retrieved from server 204 and output via digital/analog converter 406 and audio/video RF CATV modulator 408 to a television 410 . The content can be viewed immediately or scheduled for viewing at a later date and/or time.
[0042] Several products in the current art can be enhanced for the present invention. For example, digital video recorders are available from TiVO, Replay TV, and Microsoft. These products can be programmed to receive and store digital television content. Additional details can be found at http://www.tivo.com, http://www.replaytv.com, http://www.microsoft.com.
[0043] FIG. 5 shows a block diagram of another representative non-mobile device 116 (e.g. personal computer). This device contains a Web browser 502 . The software controller 202 receives requests from a mobile device 124 via the short-range wireless transceiver 206 . In response to these requests, the software controller 202 examines the metadata in server 204 and selects a subset of the content for that user. The content is retrieved from server 204 and output via the Web browser 502 .
[0044] FIG. 6 shows a block diagram of a representative mobile device 122 (e.g. cell phone, personal digital assistant). The software controller 208 coordinates execution of the various system components. Long-range wireless transceiver 604 is used for communication with a mobile switching center (MSC) in the current art. Short-range wireless transceiver 210 is used for communication with other devices in the local environment. The audio 608 , data 610 , and video 612 subsystems are used to input and output those specific media types. A Web browser 614 enables streaming and non-streaming multimedia content from the content providers 102 to be retrieved and displayed. A Web server 616 receives and processes requests for Web pages 618 . These Web pages enable the user profile 212 to be examined and modified. They also enable the viewing history 214 to be examined.
[0045] FIG. 7 shows an exemplary Web page 618 for examining and modifying the user profile 212 that is stored on the mobile device 122 . A user profile may specify a prioritized list of information sources 704 . The information sources 704 may represent a number of different media such as broadcast, cable, web pages, audio downloads, etc. The sample data shows that the sources CNN, NBC, ABC, CBS, Yahoo and RealAudio are to be used. A user profile may also specify a prioritized list of topics 706 . The sample data shows that the topics AT&T, economy, terrorism, severe weather, and New York City are to be used. The duration of an information summary 708 can also be defined. The sample data shows that the user wishes to view a composite information summary for thirty minutes. These thirty minutes will be filled with multimedia content that is retrieved from the content internally stored on the non-mobile device. A check box 7110 enables the user to request that duplication of information be minimized. A submit button 712 and cancel button 714 submit and cancel form submission.
[0046] FIG. 8 shows a Web page 618 for examining the viewing history 208 that is stored on the mobile device 122 . The page contains hyperlinks to all of the content that has recently been viewed by the consumer. The hyperlinks are presented in the same sequence as the corresponding content was viewed. Previous 812 and next 814 buttons provide access to additional pages of hyperlinks. Each hyperlink allows the consumer to revisit the particular content described by the hyperlink.
[0047] FIG. 9 is a flowchart for a non-mobile device 114 . It shows the execution of a thread that receives multimedia content and metadata from content providers and decides if that information will be saved in storage 202 . Execution begins at step 902 . Multimedia content and metadata is received from content providers at step 904 . A decision is made at step 906 if this information should be saved. If not, execution continues at step 904 . Otherwise, it is determined if older information must be deleted to obtain sufficient storage for this new information at step 908 . If no, execution continues at step 912 . Otherwise, execution continues at step 910 and the older information is deleted. The new content and metadata is saved in storage 202 at step 912 . The routine is then repeated beginning at step 904 .
[0048] FIG. 10 is a flowchart for a non-mobile device 114 . It shows the execution of a thread that waits for a connection from a mobile device 122 and communicates with the device. Execution begins at step 1002 . Execution blocks at step 1004 until a short-range wireless connection 126 is established with mobile device 122 . The user profile 206 and viewing history 208 are received from that mobile device at step 1006 . Based on this information, multimedia content is selected from storage 202 at step 1008 . The sequence in which this content will be displayed is also determined. The multimedia content is displayed at step 1010 . The metadata for that content is transmitted to mobile device 122 at step 1012 . A check is done at step 1014 to determine if the connection to the mobile device has dropped. If yes, execution continues at step 1004 . Otherwise, execution continues at step 1008 .
[0049] FIG. 11 is a flowchart for a mobile device 122 . Execution starts at step 1102 . Execution blocks at step 1104 until a short range wireless connection 126 is established with a non-mobile device 114 . The user profile 212 and viewing history 214 are transmitted to the non-mobile device at step 1106 . The non-mobile device uses that data as outlined in FIG. 10 . Execution blocks at step 1108 until metadata is received from the non-mobile device. This metadata is stored in a viewing history 214 at step 1110 A check is done at step 1112 to determine if the connection to the non-mobile device was dropped. If yes, execution continues at step 1104 . Otherwise, execution continues at step 1108 .
[0050] FIG. 12 shows how a mobile device 122 interacts with two non-mobile devices 114 - 116 and a statistics server 108 . The mobile device 122 and non-mobile device 114 establish a connection via messages 1201 according to techniques in the current art. Message 1202 is then transmitted to the non-mobile device. This message contains the user profile and viewing history. The non-mobile device uses this data to select stored multimedia content. Metadata for the selected content is returned to the mobile device as message 1203 . The mobile device examines this metadata and selects and sequences the content for the user. The selection is transmitted to the non-mobile device 114 as message 1204 . As content is presented, the metadata for that content is transmitted to the mobile device 122 . This is done by messages 1205 - 1206 . This metadata is stored in the viewing history 214 on the mobile device. The mobile device 122 then drops its connection to the non-mobile device 114 . This is shown as 1207 on the diagram.
[0051] The mobile device 122 and non-mobile device 116 establish a connection via messages 1208 according to techniques in the current art. Message 1209 is then transmitted to the non-mobile device. This message contains the user profile and viewing history. The non-mobile device uses this data to select stored multimedia content. Metadata for the selected content is returned to the mobile device as message 1210 . The mobile device examines this metadata and selects and sequences the content for the user. The selection is transmitted to the non-mobile device 116 as message 1211 . As content is presented, the metadata for that content is transmitted to the mobile device 122 . This is done by message 1212 . This metadata is stored in the viewing history 214 on the mobile device. The mobile device 122 then drops its connection to non-mobile device 116 . This is shown as 1213 on the diagram.
[0052] The mobile device 122 may periodically transmit statistics to the statistics server 108 . This data may indicate the specific multimedia content that was received by the mobile device. The statistics server can use this information to generate reports that can be distributed to content providers. Mobile devices may also be billed for this service.
[0053] FIG. 13 is a flow chart for non-mobile device 114 . It shows the execution of a thread with mobile device 122 to determine what metadata should be communicated to mobile device 122 . Execution begins at step 1302 . Non-mobile device 114 waits for connection to mobile device 122 at step 1304 . The non-mobile device 114 receives a user profile and viewing history from mobile device 122 at step 1306 . Metadata is transmitted from non-mobile device 114 to mobile 122 that describes all of the content stored by non-mobile device 114 at step 1308 . The mobile device 122 selects content based on the metadata and transmits its content selection and the sequencing for that content at step 1310 . The selection multimedia content is displayed by non-mobile device 114 at step 1312 . The metadata for the selected content is transmitted to the mobile device at step 1314 . A determination is made as to whether the connection to the mobile device has been dropped at step 1316 . If the connection has been dropped, the non-mobile device waits for connection to the same or another mobile device and execution returns to step 1304 . If the connection has not been dropped, the non-mobile device retransmits a list of all stored content to the mobile device and execution continues at step 1308 .
[0054] FIG. 14 shows a sample generic schema for content media that is transmitted to a mobile device. The schema comprises a plurality of elements that are used to identify multimedia content stored by a non-mobile device and available to the user. Included in these elements is an element 1402 that describes the content type. Types of content include, but are not limited to, radio, television, web pages, etc. Elements 1404 , 1406 and 1408 illustrate specific elements for particular types of media. Element 1404 lists the metadata for radio content and includes data such as title, source, date, time, duration of content and keywords associated with the content. Element 1406 lists the metadata for television content and includes data such as title, source, date, time, duration and keywords. Element 1408 lists the metadata for web-based content and includes title, source and keywords. Each data piece of the metadata description is then elaborated in elements 1410 - 1422 .
[0055] FIG. 15 shows a more specific example of sample metadata for radio content. Associated with each of the data factors listed above (e.g., title, source, etc.) more detailed information is provided. In the current example, the multimedia content is a report on stem cell research. The source of the report (e.g., ABC news) is provided along with the data and time of the report and its duration. Any and all of the metadata can be searched to determine if the associated multimedia content is of interest to the user. The metadata is also used to reduce duplicity of content presented to the user.
[0056] FIG. 16 shows a more specific example of sample metadata for television content. Associated with each of the data factors listed above (e.g., title, source, etc.) more detailed information is provided. In the current example, the multimedia content is a report on genetic engineering. The source of the report (e.g., CBS news) is provided along with the data and time of the report and its duration. Whether the uses wishes to view this content may depend on a number of factors. Some considerations may be what content the user has already been exposed to as identified by the mobile device, historical data regarding the user's preferences (e.g., a preference for particular media, media sources, or reporters). Depending upon the amount of content that meets a user's preferences, the amount of content may need to be pared down. Such reduction may occur based on these factors.
[0057] FIG. 17 shows a more specific example of sample metadata for Web content. In the current example, the multimedia content is a report on genetic engineering. The source of the report (e.g., http://www.pbs.org/science/gene-therapy.ra) is provided along with the data and time of the report and its duration. Once all of the metadata is received by the mobile device, it is presented to the user. The user can then select any of the associated multimedia content for viewing and/or listening.
[0058] While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention that is defined in the following claims.
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A method and apparatus for delivering selected multimedia content to a user of a mobile device in a pervasive computing environment is disclosed. Communications with a mobile device in the environment is established. A user profile and viewing history is received from the mobile device. Multimedia content is selected and sequenced for viewing by the user. The selection of multimedia content is based on search logic that includes the user profile and viewing history. Metadata is transmitted to the mobile device that is associated with the selected multimedia content.
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BACKGROUND OF THE INVENTION
This invention relates generally to direct-digital synthesizers.
As is known in the art, direct-digital synthesizers (DDS) are used extensively for generation of digital sinusoidal signals; both real and complex (quadrature). One capability of DDS is the generation of signals with extremely high frequency resolution. Synthesizers of this type can be used for the generation of precision analog signals when accompanied by a digital to analog converter (DAC). In addition, they can be used as local oscillators for digital up or down-conversion functions. These operations are commonly used in implementations of digital radios and digital modems.
A block diagram of a typical DDS 10 is shown in FIG. 1A for generating sine and/or cosine waveforms. The DDS 10 includes a phase accumulator 12 fed by a phase increment, or frequency control, digital word, X, where (0<X<2 N ). The accumulator drives the address input of a read only memory (ROM) 14 . The ROM 14 stores digital samples of the sine and/or cosine waveform to be synthesized. The phase output of the accumulator 12 increases linearly with time at a rate proportional to the input frequency control word X and such phase wraps around whenever it exceeds the size of the register 16 in the accumulator 12 loop. The register 16 and a modulo 2 N adder 18 in the accumulator 12 loop operate under modulo 2 N arithmetic, where N is the wordlength of the phase accumulator governing the frequency resolution of the synthesizer 10 output signal. The phase signal, Y, produced by the accumulator 16 is converted to a sine and/or cosine waveform using the ROM 14 as a look-up table or by using some other means of generating trigonometric functions such as a trigonometric engine, or the CORDIC algorithm. The output frequency, Fout, of the sine and/or cosine waveform generated by the DDS 10 is equal to the rate at which the phase increases per second divided by 2π, that is
Fout=(X/2 N )Fclock (1)
where Fclock is the master clock rate fed to the register 16 of the DDS 10 . In most applications, not all N bits of the phase output, Y, are used to address the ROM 14 or trigonometric engine. Rather, only the M most significant bits (MSBs) of the phase output, Y, are used to address the ROM 14 and the N-M least significant bits (LSBs) of the phase output Y are truncated. As a consequence of this truncation, phase noise is introduced. In a practical design, the value of M is chosen to meet certain noise and spurious free dynamic range requirements.
The number of output bits L used in the DDS 10 determines the noise due to amplitude quantization and the complexity of any subsequent digital signal processing (DSP) or digital to analog converter (DAC), not shown, used in conjunction (i.e., the output of the ROM 14 is typically followed by a digital to analog converter or DSP. It is generally desirable to keep L and M as low as possible to minimize circuit complexity and power. The noise floor (power spectral density, PSD) due to amplitude quantization may be represented by:
S Q (f)=6.02L+1.8+10log(Fclock/2)dbc/Hz (2)
assuming a full scale signal, i.e., X is N bits. Similarly, the spurious free dynamic range (SFDR) due to the phase truncation to M bits may be represented by:
SFDR=6.02M−4(db) (3)
The nature of phase truncation is to introduce a periodic error signal made up of a fundamental and several harmonic components. Since this signal is not “white”, M must be suitably chosen to accommodate the largest spurious tone. Typically, the number of bits M of the phase signal, Y, is larger than the number of bits L of the output of ROM 14 in order to keep the SFDR close to the noise floor dictated by the amplitude quantization.
Another direct-digital synthesizer is described in an article entitled: “A Direct-Digital Synthesizer with Improved Spectral Performance”, by Paul O'Leary and Franco Maloberti, published in the IEEE Transactions on Communications, Vol. 39, No. Jul. 7, 1991, pages 1046-1048. Referring to FIG. 4 in such article, here shown in somewhat different form in FIG. 1B, a first-order truncation noise-shaped modulator is in cascade with a conventional phase accumulator. While such system may be useful in some application, the system will not suppress phase noise around the synthesized frequency which suppression is required in other applications. That is, with the system described in the article, the synthesized frequency will contain the sum of phase noise at T sh (0) and T sh (2ω o ), where T sh is the phase noise shaped transfer function and ω o is the carrier frequency; however, the phase noise at T sh (2ω o ) is not notched out. Thus, the system is only effective at low frequency ω o where T sh (2ω o ) is still notched out somewhat.
The system described in the above-referenced article was extended to a second-order of noise shaping in an article entitled “A Direct Digital Synthesizer with a Tunable Feedback Structure”, by John Vankka, published in the IEEE Transactions on Communications, Vol. 45, No. 4, pages 416-420.
SUMMARY OF THE INVENTION
In accordance with the invention, a direct-digital synthesizer is provided for generating a signal having a frequency selected by an input digital word. The synthesizer has a feedback loop to attenuate phase noise of the synthesizer in the neighborhood of the selected frequency of the signal being generated. The synthesizer includes a digital accumulator fed by a phase increment word and responsive to a series clock pulses for successively adding the phase word in response to the clock pulses producing a series of bit phase words. A trigonometric generator is provided for producing sine and cosine digital signals related to the M most significant bits of the phase word. A feedback loop is fed by truncation error words comprising at least a of N-M least significant bits of the N bit phase words producing truncation error words. A complex digital filter is fed by the trigonometric generator for producing real or complex output signals with significantly reduced phase noise artifacts.
In accordance with another embodiment of the invention, a direct-digital synthesizer is provided for generating a waveform. The synthesizer includes a digital accumulator fed by a phase increment word and responsive to a series of clock pulses for successively adding the phase increment word in response to the clock pulses producing a series of N bit phase words. A feedback loop producing N bit truncation error compensated phase words is fed by truncation error words comprising at least a portion of the N-M least significant bits of the truncation error compensated phase words produced therein. A trigonometric generator is provided for producing sine and cosine digital signals related to the M most significant bits of the truncation error compensated phase words. A complex digital filter is fed by the trigonometric generator for producing real or complex output signals with significantly reduced phase noise artifacts.
With such an arrangement, spurious tones are reduced and a lower noise floor is produced. The synthesizer also allows fewer bits of precision to be used to represent the phase output that directly maps to trigonometric values thereby reducing complexity and lowering power.
In accordance with another feature of the invention, the feedback loop includes a digital filter.
In accordance with another feature of the invention, the feedback loop including the digital filter provides a low pass truncation error response to the truncation error having at least one zero in the transfer function thereof at DC.
In accordance with still another feature of the invention, the truncation error response has a transfer function comprising the term (1−az −1 ) where: z is the discrete time frequency variable, and a is a unity or non-unity weighting factor.
In accordance with yet another feature of the invention, the filter includes an adder fed by the truncation error words and a storage device fed by the clock pulses and by the truncation error words for producing at an output thereof the truncation error words delayed by each one of the clock pulses fed thereto. The adder is fed by the output of the storage device to produce an algebraic sum of the truncation error words fed to the adder and the delayed truncation error words produced by the storage device. The output of the adder provides the truncation error compensation words fed to the accumulator along with the phase increment word.
In accordance with still another feature of the invention, a multiplier is included. The multiplier is fed by the truncation error words and by a weighting coefficient to weight the truncation error words by the weighting coefficient prior to feeding such truncation error words to either the adder or the delay device.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the invention will become more readily apparent with reference to the following description taken together with the accompanying drawings, in which:
FIGS. 1A and 1B are block diagrams of direct-digital synthesizers according to the prior art;
FIG. 2A block diagram of a direct-digital synthesizer according of the invention;
FIG. 2B is a block diagram of a direct-digital synthesizer, having cascaded-noise shaping, according of the invention;
FIG. 3A is a model useful in analyzing the direct-digital synthesizer of FIG. 2A;
FIG. 3B is a model useful in analyzing the direct-digital synthesizer of FIG. 2B;
FIG. 4A is a block diagram of the direct-digital synthesizer of FIG. 2A showing a digital filter used therein in greater detail;
FIG. 4B is a block diagrams of a high-order noise shaping filter with F.I.R response, such filter being adapted for use in the synthesizers in FIGS. 2A and 2B;
FIGS. 5A-5D are simulated results showing power spectral densities of various direct-digital synthesizers, FIG. 5A for a direct-digital synthesizer according to the prior art and FIGS. 5B-5D being for direct-digital synthesizers according to the invention;
FIG. 6A is a block diagram of a complex filter having 4 real filters adapted for use in the synthesizers in FIGS. 2A and 2B;
FIG. 6B is a block diagram of a half complex filter having 2 real filters adapted for use in the synthesizers in FIGS. 2A and 2B;
FIG. 7 is a diagram showing the frequency response magnitude of a complex filter which attenuates negative frequencies, such of complex filter being adapted for use in the synthesizers in FIGS. 2A and 2B; and
FIG. 8 is the impulse response of the filter in FIG. 7 .
DETAILED DESCRIPTION
Referring now to FIG. 2A, a direct-digital synthesizer 20 is shown for generating sine and/or cosine waveforms. The DDS 20 includes a phase accumulator 22 fed by a phase increment, or frequency control, digital word, X, where (0<X<2 N ). The accumulator 22 drives the address input of a table 24 . Such table 24 may be a trigonometric engine, or waveform generator, for example. Here the table 24 is a read only memory (ROM) 24 . The ROM 24 stores digital samples of the sine and/or cosine waveform. The phase output of the accumulator 22 , Y, increases linearly with time at a rate proportional to the input frequency control word X and such phase wraps around whenever it exceeds the size of a register 26 in the accumulator 22 loop. The register 26 and a modulo 2 N adder 28 in the accumulator 22 loop operate under modulo 2 N arithmetic, where N is the wordlength of the phase accumulator governing the frequency resolution of the synthesizer 20 output signal. The phase signal, Y, produced by the accumulator 26 is converted to a sine and/or cosine waveform using the ROM 14 as a look-up table or by using some other means of generating trigonometric functions such as a trigonometric engine. The output frequency, Fout, of the sine and/or cosine waveform generated by the DDS 20 is equal to the rate at which the phase increases per second divided by 2π, that is
Fout=(X/2 N )Fclock (1)
where Fclock is the master clock (CK) rate fed to the register 26 of the DDS 20 . Here, not all N bits of the phase output, Y, are used to address the ROM 24 or trigonometric engine. Only the M most significant bits (MSBs) of the phase output, Y, are used to address the ROM 24 and the N-M least significant bits (LSBs) of the phase Y are truncated.
The DDS 20 includes a feedback loop 30 used to attenuate phase noise of the synthesizer 20 in the neighborhood of the selected frequency of the signal being generated at output Q. More particularly, the feedback loop is fed by truncation error words T(z) comprising at least a portion of N-M least significant bits of the N bit phase words produced by the accumulator 22 (here R bits) for producing truncation error compensation words on R bit bus 32 . The produced truncation error words are fed to the accumulator 22 (i.e., to an input of adder 28 ), after passing through a digital filter 34 , along with the phase increment word, X.
Thus, the synthesizer 20 includes a digital accumulator 22 fed by an N bit phase increment word, X, and a series of clock pulses, CK, for successively adding the phase increment word, X, to produce a series of N bit phase words, Y. A memory, here ROM 24 , stores a relationship between M most significant bits of the phase words, Y, produced by the accumulator 22 and corresponding sample values of the waveform to be produced at output Q. A portion of, here R least significant bits) of the phase words, Y, are fed back to the accumulator 22 through the digital filter 34 . The transfer function of the digital filter 34 is here represented as:
V(z),
where z is the discrete frequency variable.
Referring to FIG. 3A, a model useful in analyzing the DDS 20 of FIG. 2A is shown. The truncation error (i.e., the R least significant bits of the phase words, Y) is represented by T(z). Thus, setting X(z)=0,
Y(z)=T(z)[1−{z −1 /(1−z −1 )}V(z)].
Thus, the noise transfer function H(z)=Y(z)/T(z) is given by:
[1−z −1 −z −1 V(z)]/(1−z −1 ).
If H(z) is required to be equal to 1−z −1 , for example, then,
V(z)=1−z −1 .
Thus, in accordance with the DDS 20 , the phase truncation error, T(z), is fed back to the phase accumulator 22 so as to cancel truncation error over a range of frequencies. In the prior art, the truncation error is completely additive to the ideal output phase signal. By feeding back the phase error signal, T(z), as in DDS 20 (FIGS. 2 A and 3 A), a specific transfer function, H(z), can be applied to the noise signal (i.e. to the truncation error, T(z)). If the noise transfer function H(z) is considered as a low-pass signal, a zero (or a multiple of zeros) at DC in the error signal can attenuate the phase noise in the vicinity of DC. This means that the phase noise in a frequency band centered around the frequency of the output signal being synthesized is significantly attenuated.
It should be noted that with the DDS 20 , FIG. 2A, only R≦N−M bits of the N-M most significant bits in the truncation error T(z) are fed back to the accumulator 22 via the filter 34 . For N=32, typical values of R range from 2 to M. This significantly reduces the complexity in the feedback path 30 .
Let us now consider an embodiment of the invention that provides first-order shaping of the phase noise, (i.e., the transfer function, V(z), of filter 34 and hence H(z) has a single zero associated with phase noise signal, T(z)). An extension to higher-order shaping is discussed later. The transfer function between the input X(z) and the phase output Y(z) shown in FIG. 2A can, as discussed above, be characterized by:
Y(z)=z −1 X(z)/(1−z −1 )−H(z)T(z) (4)
where T(z) and X(z) are the z transforms of the phase error signal (i.e., the truncation error) and the input signal, respectively, and H(z)=(1−z −1 ) is the transfer function associated with the phase error signal) in this first-order embodiment. In this case the transfer function of the feedback network (i.e., filter 34 ), V(z)=(1−z −1 ) and, consequently, the zero at DC of H(z) significantly suppresses the low frequency phase noise. This translates to suppression of the phase noise in the vicinity of the carrier frequency produced by the DDS 10 (i.e., the frequency of the waveform produced at output Q).
For a complex exponential signal, a Taylor series expansion can be used to derive the relationship between the output signal, Y, and the phase noise in both time and frequency domains. Normally the shaped truncation signal, t sh (n)<<1, (where T sh (ω)=−H(ω)T(ω)) and consequently, the expansion can be limited to the first two terms. Therefore,
y(n)=e j[ω o n+t sh (n)] {tilde over (=)}e jω o n +je ω o n t sh (n) (5)
Y(ω){tilde over (=)}Σ2π[δ(ω−ω o +2πk)+jT sh (ω−ω o +2πk)] (6)
This shows that the spectrum of the shape phase error, given by T sh (ω), is modulated to the frequency of synthesized exponential signal ω o . This results in the suppression of the noise spectrum in the band surrounding the desired signal, a desirable phenomenon. If this technique is applied directly to a real signal instead of a complex exponential, then we get a less satisfactory result as shown below.
y(n)=cos[ω o n+t sh (n)]{tilde over (=)}cos(ω o n)−sin(ω o n)t sh (n) (7)
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As can be noted from the above equation, the phase error is modulated to both plus and minus ω o . Since T sh (ω) is a real signal that is zero at ω=0 and nonzero elsewhere, the expression T sh (ω−ω o )−T sh (ω+ω o ) is nonzero at the frequencies plus and minus ω o . The resulting noise, at the carrier frequency ω o , corresponds to the level of the noise of T sh (2ω o ) which is not suppressed by the zero at DC.
The spectrum of the real signal, however, is still significantly better than that obtained from a conventional DDS 10 , shown in FIG. 1 A. In applications where it is desired to suppress the noise in the vicinity of the carrier signal, we present four different methods to effect this.
METHOD 1
A complex filter 40 (FIG. 2A) which suppresses the signals that will image at ω=ω o can be used in conjunction with the output of the DDS 20 , as shown in FIG. 2 A. To cover a large range of frequencies, this filter 40 should be a complex band-pass filter that attenuates, say, negative frequencies and passes most of positive frequencies. A simple technique to obtain this band-pass filter 40 is to first design a real half-band filter and then complex modulate the impulse responses by e jnπ/2 . Such a filter 40 would suppress all the negative frequencies and pass most of the positive frequencies depending upon the characteristics of the half-band filter. After filtering, a real signal having the band-pass noise shaping characteristic is obtained. The frequency response of a complex filter obtained in this manner is shown in FIG. 7 and the corresponding impulse responses are shown in FIG. 8 . The block diagram of a complex filter comprised of four real filters is shown in FIG. 6A; however, to produce just a real output, a half-complex filter shown in FIG. 6B that only requires 2 real filters can be used.
METHOD 2
In this method, a narrowband complex band-pass filter 40 is designed that passes only the carrier frequency. Such a filter must have a stop band that includes the frequency ω=−ω o , where ω o is the direct digital synthesizer carrier frequency.
METHOD 3
The image at ω=−ω o can be suppressed by a complex filter 40 that has a zero (or a multiple of zeros) at this frequency. The transfer function of such a filter 40 cascaded with the transfer function of the accumulator 22 is of the form H(z)=(1−e −jωo z −1 ) P , where P is the order of the zero at ω o .
In all the above methods, (i.e., Methods 1-3) the sine and cosine outputs, Q, from the ROM 24 (or the trigonometric engine) having L bits of precision are convolved with the complex coefficients of the filter 40 . These coefficients, however, could be represented in canonic signed digit (CSD) format thereby reducing the convolution operation to a set of shifts and add/sub operations.
METHOD 4
As mentioned above, for a real signal, the resulting noise at the carrier frequency ω o corresponds to the level of noise at 2ω o . Evidently, a zero at this frequency (besides the zero at DC) in the transfer function associated with the phase noise error would suppress the noise around this frequency. Accordingly, a transfer function of the form H(z)=(1−z −1 )(1+bz −1 +z −2 ) can be used for filter 40 cascades with the accumulator 22 , where b=−2 cos(2ω o ) and consequently H(z)=(1−z −1 )(1−2 cos(2ω o )z −1 +z −2 )=1−(1+2 cos(2ω o )z −1 +(1+2 cos(2ω o )z −2 −z −3 .
Extension to Higher-Order Noise Shaping Filter 34
In all the methods described above, higher-order noise shaping can be accommodated to offer further reduction in phase noise. For methods 1-3, the class of transfer functions given by H(z)=(1−z −1 ) j , for example, where J is an integer greater than or equal to one, can be used to provide j zeros at DC to yield better noise-shaping characteristics. For Method 4, the transfer function of the form:
H(z)=(1−z −1 ) J (1+bz −1 +z −2 ) K (9)
where j is an integer greater or equal to one and K is an integer greater than, or equal to, one. The transfer function in Eq. (9) can provide multiple zeros at DC as well as K zeros at ω=2ω o . It can easily be shown that the transfer function of the feedback network, i.e, the transfer function for filter 34 , V(z), for all methods, is characterized by
V(z)=z(1−z −1 )[1−H(z)] (10)
Referring now to FIG. 4A, DDS 20 is shown with the filter 34 thereof being shown in more detail. Thus, the filter 34 is a Jth order filter having multipliers M O -M J , as shown. Fed to each of the multipliers M O -M J is the phase truncation error signal T(z), made up of R less than (N-M) of the least significant bits of the phase words, Y, produced by the accumulator 22 . The multipliers M O -M J are fed by weighting coefficients a O -a J , respectively, as shown. The filter 34 includes adders A O -A J , fed by the outputs of multipliers M O -M J−1 , respectively, as shown. One clock pulse delays, here registers D 1 -D J−1 are coupled between pairs of adders A O , A 1 ; A 1 , A 2 ; . . . ; and, A J−2 , A J−1 , respectively, as shown. A one clock pulse delay, here a register D J is coupled between multiplier M J and adder A J−1 , as shown. The registers D 1 -D J , are fed clock pulses, CK, as indicated.
In Methods 1-3, for a second-order noise shaping (J=2), the coefficients for the structure shown in FIG. 4A are: a0=2, a1=−3 and a2=1. Similarly, for a third-order noise shaping (J=3), the coefficients are: a0=3, a1 32 −6, a2=4 and a3=−1. Except for a0, all the other coefficients can readily be obtained from a binomial expansion. These coefficients can be effected by simple shifts and add/subtract operations. Also since the number of bits R that are fed back is small, these operations can be accomplished easily with significantly low complexity. This is important since DDS are often used at very high clock rates in order to generate high frequency signals.
In Method 4, for a first-order noise function (J=1, K=1), the coefficients for the structure shown in FIG. 4A are: a0=2(b−1), a2=(2−b) and a3=−1. These coefficients can be approximated by CSD numbers, where b=−2 cos(2ω o ). Consequently, these again, can be effected by simple shifts and add/subtract operations. It is straightforward to obtain the coefficients for other values of J and K by expanding Eq. (9) and substituting Eq. (10). In order to provide the same amount of attenuation at ω=0 and ω=2ω o , J must be equal to K. However, this is not a requirement in the design.
In FIG. 4A, the feedback filter 34 is a nonrecursive network which is a transpose of the direct form. However, the invention clearly allows for the incorporation of other nonrecursive and recursive structures.
Simulation Results
FIGS. 5A-5D present power spectral densities (PSDs) finite precision simulations. FIG. 5A is the PSD for a simulated conventional DDS, such as DDS 10 (FIG. 1 A). FIG. 5B is the PSD for a simulated DDS 20 (FIG. 2A) having a complex noised shaped filter 34 . FIG. 5C is the PSD for a simulated DDS 20 (FIG. 2A) having a first order filter 34 . FIG. 5D is the PSD for a simulated DDS 20 (FIG. 2A) having a third order filter 34 . In all these simulations, N=32 and M=6. Amplitude quantization is not shown here since the phase noise effects are dominant. FIG. 5A shows the spectrum of a complex exponential signal from a conventional DDS. As can be seen from FIG. 5A, the SFDR is approximately 36 dB, as predicted in Eq. 3. FIG. 5B shows the spectrum of a complex exponential signal having a first-order noise shaping at DC with R=6. The noise-shaped DDS clearly shows the suppression of the phase noise at the frequency of the synthesized carrier signal, and also has no appreciable spurious tones. FIG. 5C shows the spectrum of a real signal using method M3 with R=6. As can be seen from FIG. 5C, the spectrum is similar to that of FIG. 5 B. Finally, FIG. 5D shows the spectrum of a real signal using Method 4 for R=2. Here, only two bits are fed back and if the coefficients of V(z) are represented in CSD format, the shifts and add/sub operations become trivial.
Other embodiments are within the spirit and scope of the appended claims. For example, the invention is applicable to DDS frequency synthesizers, digital upconverters and downconverters, phase-locked loops and modems, for example. Further, the invention increases the SFDR of a DDS for a given M and provides base-reject phase noise shaping around the synthesized frequency. This can be used in conjunction with a ROM look-up table or an efficient trigonometric engine to generate sine and cosine values.
Further, the invention described above in connection with methods 1-4 are applicable to the systems the cascaded noise-shaped phase accumulator and the extended noise shaped phase accumulator described in the O'Leary et al. and Vankka articles referred to above. A small-signal model for the truncation noise-shaped modulator is shown in FIG. 3 B and the extension to higher orders of noise shaping is shown in FIG. 4 B.
Still further, another embodiment of the invention is shown in FIG. 2B where the DDS 20 ′ includes the phase accumulator 22 , the ROM or trigonometric engine 14 , and the complex filter 40 , as described above in connection with FIG. 2 A. Here however, a noise-shaped modulator 34 ′ is coupled between the accumulator 22 and the ROM or trigonometric engine 24 , as shown. One such noise-shaped modulator 34 ′ is described in connection with FIG. 4A of the above-referenced article by Paul O'Leary and Franco Maloberti, the entire subject matter thereof being incorporated herein by reference.
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A direct-digital synthesizer for generating a waveform includes a digital accumulator fed by a phase increment word and a series of clock pulses for successively adding the phase increment word to produce a series of N bit phase words. A table or trigonometric engine produces sine and cosine digital signals related to the M most significant bits of the phase word produced by the accumulator. A feedback loop is fed by truncation error words comprising at least a portion of N-M least significant bits of the N bit phase words producing truncation error compensation words. The feedback loop includes a digital filter. The feedback loop includes a digital filter. The feedback loop including the digital filter provides a low pass truncation error response to the truncation error having at least one zero in the transfer function thereof at DC. The truncation error response has a transfer function comprising the term (1−az −1 ) where: z is the discrete time frequency variable and a is a unity or non-unity weighting n factor. One such filter includes an adder fed by the truncation error words and a storage device fed by the clock pulses and by the truncation error words for producing at an output thereof the truncation error words delayed by each one of the clock pulses fed thereto. The adder is fed by the output of the storage device to produce an algebraic sum of the truncation error words fed to the adder and the delayed truncation.
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BACKGROUND OF THE INVENTION
The present invention relates generally to an implement supported on caster wheels, and more specifically to a device for controlling caster wheel motion.
Caster wheels are commonly used on agricultural equipment to prevent skidding of a wheel or wheels when the implement is turned. These wheels can cause a problem when transporting the machine at higher than field-operating speeds by wobbling or attempting to rotate about their caster frame vertical spindle. This action can cause such problems as tire wear, structural damage or loss of control of the machine. In some previously available implements with caster wheels, the caster wheels have been rigidly pinned to prevent oscillation, but such an arrangement causes the wheel to skid and results in high stresses in the structural members when the implement is turned.
Other previously available devices, such as the caster wheel assembly shown in U.S. Pat. No. 2,761,692 include a friction disk fixed to the spindle and engaging a friction plate interlocked with the framework and spring-urged downwardly. Such a device is relatively expensive, since it requires special castings or the like. Swivel wheel dampers for the caster wheels of aircraft 20 have also been available for some time, but these devices are also relatively complicated and expensive to manufacture. Examples of such aircraft devices are shown in U.S. Pat. Nos. 2,367,993; 2,482,961; 2,508,057; 2,693,003 and 2,770,832. U.S. Pat. No. 2,388,874 shows a caster wheel with an arm that is spring-loaded to restore the wheel to its operating position from any castered position. At transport speeds, wobbling would still be present with such a device.
In certain applications, such as when a seeder is towed behind a grain cart, and the grain cart, in turn, is towed behind a tractor or the like, the cart is supported on four caster wheels spaced fore-and-aft in pairs. In some situations it is desirable that all the wheels be able to caster freely, while in other situations it is necessary to limit the castering of a front or rear pair of wheels while permitting the remaining wheels to caster freely. Heretofore, devices for selectively locking the caster wheel in position or alternately adjustably braking the caster action have been relatively expensive or ineffective and often have been difficult to adjust for the proper caster wheel action.
BRIEF SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an improved caster wheel assembly for an implement.
It is a further object of the invention to provide an improved caster wheel assembly for an implement for preventing wobble from starting when the vehicle is towed at higher than field-operating speeds. It is another object to provide such an assembly which is relatively inexpensive and easy to adjust.
It is a further object of the invention to provide an improved damping device for a caster wheel which allows the caster wheel to pivot freely 180 degrees when turning or backing, but prevents wobble or oscillation of the caster wheel at transport speeds. It is a further object to provide such an assembly wherein the resistance to swiveling of the caster wheel is easily adjusted.
It is still another object of the invention to provide a caster wheel assembly with an elongate member which reciprocates in response to castering of the wheel and which has a braking device which adjustably resists the reciprocating motion of the member.
It is yet another object of the invention to provide a cart or similar implement with a plurality of supporting caster wheels which includes a plurality of caster wheel control devices which may be quickly and easily adjusted to resist or prevent castering of preselected combinations of the wheels.
In accordance with the above objects, a control arm is rigidly connected to the caster wheel frame vertical spindle. An elongated tubular member or brake tube is pivotally connected to the end of the control arm and reciprocates as the caster wheel casters about its vertical axis. The break tube slides between a pair of brake pads mounted in a support carried by the cart frame. A threaded handle in the support allows adjustment of the pressure exerted by the brakes against the brake tube. With proper adjustment of the brake pads, the caster wheel is free to pivot 180 degrees when turning or backing the machine, but the resistance provided by the brake prevents wobble or oscillation of the caster wheel at transport speeds. One or more of the caster wheels can be locked in position by inserting pins in the brake tube to prevent relative reciprocation between the tube and the support. The device is relatively simple and inexpensive to manufacture and provides for easy adjustment of the resistance to castering of the caster wheels. The braking action prevents tire wear and structural damage during transporting of the machine by preventing wobbling of the caster wheel. With proper adjustment of the braking device, the wheel can still caster during turns to prevent skidding action of the wheel and eliminate high stresses in the structural members.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an implement utilizing the device of the present invention.
FIG. 2 is a perspective view of one of the rear caster wheel assemblies utilized with the implement of FIG. 1 with the wheel in position for forward movement.
FIG. 3 is an exploded view of a portion of the assembly shown in FIG. 2.
FIG. 4 is a detailed view of the brake support assembly shown in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, therein is shown an implement 10 supported for forward movement over the ground by a plurality of caster wheels 12. The implement 10 is shown as a grain drill cart for an air seeder, but it is to be understood that the present invention may be utilized with other implements. Each caster wheel 12 is rotatably mounted on a horizontal axle 14 of a caster wheel frame assembly 16 having a vertical spindle 18 offset in the forward direction from the axle 14. The vertical or upright spindle 18 is journalled in a bearing member 20 carried by a fore-and-aft extending beam 22 of cart frame assembly 24. As seen in FIG. 1, the cart frame assembly includes a pair of transversely spaced and generally parallel fore-and-aft beams 22, and each beam supports a pair of caster wheel assemblies at its opposite ends.
The vertical spindle 18 of each caster wheel assembly extends upwardly through its associated bearing member 20 and terminates in an upper end located above the beam 22. A control arm member 30 which is part of a caster wheel control assembly is rigidly attached to the upper end by a set screw 28 and rotates with the spindle 18 as the caster wheel swivels. In the preferred embodiment, the control arm 30 is fixed such that its axis is substantially parallel to the axis of the caster wheel 12 so that as the wheel pivots 90 degrees in either direction from the forward direction, the arm member approaches a position generally parallel to the beam 22. A guide member or bracket 34 is welded to the beam 22 at a position offset from the axis of the vertical spindle 18. The bracket 34 is located outside of the arc that the end of the control arm 30 traverses as the caster wheel swivels.
The bracket 34 includes a generally U-shaped outer portion having upright sidelegs 36 welded to the beam 22 and a transverse bight portion 38 extending between the sidelegs. A lower support plate 40 is welded to the sidelegs 36 and extends parallel to the bight portion 38.
A brake support assembly 44 having a generally open-ended box structure is pivotally supported inside the bracket 34. The assembly 44 includes parallel and substantially horizontal top and bottom plates 46 and 48, respectively, with central pivot-receiving apertures 50 and 52. Side plates 54 and 56 are welded to and space the plates 46 and 48. The plates 54 and 56 include centrally located apertures 58 and 60, respectively. A nut 62 is welded to the plate 54 in alignment with the aperture 58. The aperture 50 in the plate 46 is aligned with a hole 64 in the bight 38 of the bracket 34, and a vertical pivot assembly 66 is inserted through the aperture and hole. Likewise, a pivot assembly 67 is inserted through the aperture 52 and a corresponding axially aligned hole 69. The pivot assemblies 66 and 67 maintain the brake support assembly 44 within the bracket 34 while allowing the assembly 44 to pivot about an upright axis.
A pair of U-shaped brake pad members 70 are supported in the assembly 44 with leg portions 72 extending outwardly beyond the sides of the plates 54 and 56. Brake pads 74 are supported generally parallel to the plates 54 and 56. A pin 76 is inserted through a pair of opposed thrust washers 78 and through the hole 60 in the side of plate 56 to urge the corresponding brake pad member 70 inwardly from the sidewall 56. A threaded handle member 80 is screwed into the nut 62 to urge the opposite brake pad member 70 inwardly in the direction of the first mentioned pad member.
An elongated rod member or brake tube 82 having a rectangular cross section is connected at one end by a pivot pin assembly 84 to the outer end of the control arm member 30. The brake tube 82 extends through the support member 34 between the opposed brake pads 74 and between the upper and lower plates 46 and 48. The handle 80 is screwed inwardly to increase the pressure of the pads 74 against the sides of the brake tube 82 and, thereby, adjust the pressure applied by the brake pads 74 to the opposite sides of the brake tube 82.
As the caster wheel 12 swivels back and forth, the control arm member 30 pivots with the spindle 18 to recriprocate the brake tube 82 within the bracket 34. The recriprocating motion of the brake tube 82 is resisted by the brake pad members 70 with the amount of resistance provided depending upon the adjustment of the handle 80. As the angle of the brake tube 82 changes with the position of the control arm 30, the brake support assembly 44 pivots within the bracket 34 about the upright axis so that the brake pads 74 are maintained flatly against the sides of the tube 82. Apertures 90 are provided in the top and bottom surfaces of the tube 82 which, when the caster wheel is positioned for forward movement over the ground, (FIG. 2) are located on opposite sides of the bracket 34. To lock the caster wheel in this position, pins 92 are inserted in the holes to prevent the tube from recriprocating within the bracket.
When the cart 10 is operating in the field behind a towing vehicle and forwardly of a towed implement such as a grain drill or a seeder 100 (FIG. 1), the brake pads 74 are adjusted away from the brake tube 82 by turning the handle 80 so that all four caster wheels 12 can freely caster in any direction. When the cart 10 is pulled at transport speeds with the rear implement attached, the brake pads 74 are tightened against the brake tube 82 so that there is sufficient resistance or drag to prevent the caster wheel from oscillating. This adjustment is accomplished by turning the handle 80 until the brake pads 74 contact the sides of the brake tube 82 and, thereafter, turning the handle an additional fraction of a turn. All four caster wheel brakes are adjusted in the same manner. However, when the cart 10 is being towed by the tractor without an implement attached behind the cart, it is desirable that the front wheels be able to pivot while the rear wheels are held firmly in a straight line for forward movement. In this situation, the pins 92 are inserted through each rear wheel brake tube 82 on each side of the corresponding brackets 34 when the rear wheels are in position for forward movement (FIG. 2). The front wheel brake pads 74 are adjusted as described above so there is sufficient drag on the associated brake tubes 82 to prevent the wheels from oscillating while traveling at transport speeds. Therefore, the caster wheel control assemblies can be utilized to switch between a first situation where the cart is towing an implement and a crabbing action is required to a second situation where the cart is pulled like a trailer and only the front wheels 12 need to caster. The braking action of each caster wheel control assembly can be easily adjusted to prevent oscillations or wobble from starting while permitting the desired wheels to caster during turns.
As best seen in FIG. 2, maximum resistance to swivel occurs when the wheel is positioned for movement in the forward direction because of the angle of the control arm 30. Once the wheel begins to swivel, the effective moment arm acting to resist swivel decreases. Therefore, when the cart 10 is being towed at transport speeds with the brake pads 70 tightened against the brake tube 82, any tendancy of the wheel to begin to wobble is resisted with maximum force. However, resistance decreases as the caster wheel swivels from the forward direction to reduce side loading on the assembly during turns.
Having described the preferred embodiment, it will be apparent that modifications can be made without departing from the scope of the invention as defined in the accompanying claims.
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For an implement, a caster wheel assembly including a tubular member connected to reciprocate as the caster wheel swivels. An adjustable brake assembly resists movement of the tubular member to eliminate caster wheel wobble as the implement is transported. A plurality of caster wheel assemblies permit the implement to crab between the towing vehicle and a trailing implement. The brake assemblies provide convenient locking and control of selective wheels for the desired swivel action in numerous operating situations.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of pocket knives and more particularly to a novel knife of this type which includes a snap shackle for releasably carrying the knife from the belt or belt loop of the user and which further is provided with implements or tools for ancillary use with respect to a folding blade.
2. Brief Description of the Prior Art
In the past, it has been the conventional practice to either store knives in the pocket of the user, in a sheath or holder carrier on the belt or by means of a clip suspending the knife from the edge of a pocket. Although these prior attempts to provide a means for carrying a personal knife in a convenient manner have been somewhat successful, problems and difficulties have been encountered when the design of the knife includes other tools or implements that may be used in place of or in connection with the knife blade itself. Furthermore, the ultimate use of the knife is paramount in determining how the knife should be carried. For example, in instances where a knife or other implements are intended to be carrier by underwater divers, such as scuba divers, the knife should be able to be readily attached to or removed from the body of the diver in a convenient manner and when the diver is wearing gloves. Also, it is of great convenience for the diver when he can open the blade with one hand while his other hand is carrying additional equipment such as a speargun, light or probe.
Under such circumstances, it is of a necessity that whatever attachment is used for releasably securing the knife to the clothing or equipment of the diver, such connector, coupling or the like must not interfere with the use of the knife blade when it is in its extended position. A folding blade is of great convenience since it may be stored within the handle of the knife when not in use and can be extended to its operative position when in use. Therefore, the user does not run the risk of being cut or otherwise injured by an open blade either at its point or edge when the knife is being carried.
Therefore, a long standing need has existed to provide a utility knife which may be readily carried by a releasable fastener on the equipment or wearing apparel of the user wherein the attachment means is not obstructive to the use of a folding blade when the blade is in its unfolded and operative position. Also, the utility knife must have provision for a variety of implements or tools that may be used to perform a variety of functions when the knife blade is in its folded position.
SUMMARY OF THE INVENTION
Accordingly, the above problems and difficulties are obviated by the present invention which provides a novel utility knife having an elongated housing for carrying a pivotal blade at one end adjacent to an integral releasable, resilient fastening means suitable for detachable connecting relationship with a belt or belt loop of the user. The blade is characterized as having an enlarged portion with a finger depression such as a hole formed therein readily grasped by the thumb and finger of the user so as to provide for single-handed unfolding of the knife blade. A feature resides in the provision that the fastening means be conformal in shape with the shape of the enlarged portion of the blade so that when the blade is in its extended position, the fastening means forms a useful portion of the handle permitting the user to more readily use the sharpened edge of the blade.
Furthermore, the blade is characterized as having a channel formed along the back of the blade terminating in a cutting edge so that a line cutter results, adding to the usefulness of the knife. The end of the knife housing or body from its end carrying the pivoting blade and fastening means may be provided with an elongated tapered member comprising a pry bar which provides additional utility for the utility knife. A releasable lock mechanism is operably carried on the body for retaining the blade in its open position adjacent to the fastening means.
Therefore, it is among the primary objects of the present invention to provide a novel utility knife which may be readily carried from a loop or belt by means of a snap shackle or fastener which may be readily operated by a gloved hand.
Another object of the present invention is to provide a novel utility knife having a folding blade adapted to be opened by the fingers of one hand and wherein the blade incorporates not only a sharpened edge but a channel cutter as well.
Still another object of the present invention is to provide a novel utility knife having a variety of implements or tools carried on the body which may take the form of a folding cutting edge, a channel cutter, a pry bar or the like.
Yet another object of the present invention is to provide a novel sports knife that may be used in active situations, such as scuba diving, skin diving, sky diving or the like, which incorporates an enlarged latch release opening so that a gloved finger may be used to operate the latch for holding a blade in its open position preparatory for release.
Still a further object of the present invention is to provide a novel utility knife which not only includes a fixed shackle at one end, but permits the shackle to be rotated into the body for storage purposes and which further includes openings into the body for drainage purposes and drying purposes when the utility knife has been subjected to moisture or water environments.
Another object of the present invention is to provide a novel utility knife which may include a snap shackle at one end of its housing or body that may be fixed or movable into the body or housing for storage purposes and which further includes a tool or implement at its opposite end useful in connection with a particular sports activity.
Another object resides in the utility knife's having a line cutter on the back side of an extendable blade and which further includes attachment means for releasably securing the knife to the clothing or equipment of the user and which further includes added implements, tools or the like integrally formed with the housing or body that may be used by the user in addition to the knife blade and line cutter.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may best be understood with reference to the following description, taken in connection with the accompanying drawings in which:
FIG. 1 is a side elevational view of the novel utility knife incorporating the present invention and illustrated with the blade in its open or operative position;
FIG. 2 is a longitudinal cross-sectional view of the utility knife shown in FIG. 1, exposing the snap shackle for carrying or transportation purposes;
FIG. 3 is a transverse cross-sectional view of the utility knife as taken in the direction of arrows 3--3 of FIG. 2;
FIG. 4 is a side elevational view of the utility knife taken on the opposite side from the view shown in FIG. 2, illustrating a display area for carrying indicia;
FIG. 5 is a top plan view of the knife shown in FIGS. 1-4 inclusive; and
FIG. 6 is a side elevational view of another version of utility knife incorporating a tool or implement integrally formed on the housing or body.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, the novel utility knife of the present invention is illustrated in the general direction of arrow 10 which includes a body or housing illustrated in general by numeral 11. The body or housing is intended to be the handle of the knife when a blade 12 has been extended from its closed position as shown in FIG. 2 to its open position as shown in FIG. 1. The blade 12 is confined in a cavity in its closed position between a pair of elongated side portions 13 and 14 which are separated by a spacer 15, which takes the form of projections integrally formed on the side portions 13 and 14 and which will be described later. The side portions 13 and 14 are held together by means of a plurality of rivets, fasteners or the like, such as is illustrated by numeral 16. Also, the side portions 13 and 14 include semicircular cutouts indicated by numeral 17 which are coaxially related with respect to each other so as to expose a portion of a locking or retaining mechanism 18. The mechanism 18 is employed for holding the blade in an open or operative position. It is to be particularly noted that the cutouts 17 are oversized so as to permit entrance of a gloved finger into the cutouts during the release of the mechanism 18 when it is desired to close the knife by pivoting the blade into the storage position shown in FIG. 2.
Referring now in detail to FIG. 2, it can be seen that the blade 12 is pivotally carried with respect to the body 11 by means of a pivot pin 23. A leaf spring 24 is arranged so that one end is attached to the spacer portion of the side portion by an interference fit in a corresponding slot so that the spring cantilevers outwardly into the cavity so that its opposite end bears against the underside of the lock mechanism 18. The leaf spring 24 is substantially arcuate in cross-section so as to provide a normal bias against the underside of the lever for the mechanism 18, urging its opposite end, illustrated by numeral 25, into engagement with a flat surface 26 on the underside of the knife blade 12. In this fashion, the blade is yieldably held in the closed position by the bias of the leaf spring 24. Referring in detail to FIG. 1, when it is desired to actuate the knife blade 12 from its closed position in FIG. 2 to its open position in FIG. 1, the blade is rotated against the bias of spring 24 so that the latch of the mechanism 18 assumes the position in broken lines. Once the blade has been extended to its forward open and operative position, the cam surface, indicated by numeral 27, causes the latch of the lever mechanism 18 to drop into a corresponding notch, indicated by numeral 28. The bias of the spring 24 now urges the lever of the mechanism to rotate about its central pivot 30 so that the latch 25 is retained within the notch 28. With the knife blade 12 in its operative position, it is noted that cutting edge 32 is exposed for use. The cutting edge 32 is elongated and substantially extends across the full length of the blade on the underside or edge thereof while its topside or edge is provided with a slotted or grooved line cutter, indicated by numeral 31. The bottom of the groove or notch 31 is sharpened, as indicated by numeral 29, in order to provide a cutting edge for severing a line, cord or the like.
Also, it is noted that the top edge marginal region of the blade includes an enlarged portion 33 which is provided with a depression or opening 34. The enlarged portion 33 in the depression or opening 34 is useful to the user in opening the blade from its closed position, using the fingers of one hand. Preferably, the thumb of one hand engages with the depression or opening 34 while the back of the knife adjacent to the separator or spacer 15 fits against the palm of the hand. By forcibly urging the thumb outwardly, the blade 12 will follow the movement and open past the spring bias of spring 24. Once the resistance of the spring has been overcome, the blade 12 may readily be carried to its full operative position until stopped by insertion of the latch 25 into the notch 28.
FIGS. 1 and 2 further show that the housing or body 11 is provided with elongated slots for opening, as indicated by numeral 40, with respect to side piece 13. The oversized semicircular openings 17, as well as the lateral slots or openings 40, serve as drainage means when the utility knife is subjected to moist or wet environmental conditions. Also, the openings serve as vents for drying the interior of the housing in order to eliminate or substantially reduce oxidation, rust or collection of moisture.
A major feature of the present invention resides in the provision of a snap shackle, indicated by numeral 41, which is integrally carried on one end of the body by being formed with section 14 of the body. The snap shackle outwardly projects in a cantilevered manner from the end of the body pivotally carrying the blade 12. The shackle includes a loop portion 42 which forms a hook and in combination with a resilient member 43, such as a spring, closes the opening to form the shackle. The end of spring 43 bears against a flanged shoulder 49 carried on the end of the hook of the shackle whereby the interior of the shackle is closed. In this manner, the shackle is used to hook onto the belt of the user, a belt loop or any other suitable eyelet or provision on the user's clothing or equipment. A special feature resides in the formation of the shackle with a sloping or slightly curved backside 44, which is conformal in shape to the backside 45 of the knife blade 12. Thus, when the knife is in the operative position, as shown in FIG. 1, the contour of the blade at 45 in adjacent to and conformal with the sloping or curved backside 44 of the shackle 41. This permits the user's thumb to be pressed against the backside of the blade for additional support when pressure is placed onto the blade. Also, the user's hand may readily be gripped further forward than is possible on conventional knives with the user's hand bearing against the combined and cooperating back surfaces 44 and 45. Thus, the snap shackle 41 is not obstructing the use of the cutting edge of the blade or in the use of the line cutter 31. The single hand opening depression 34 is substantially coaxially disposed with respect to the opening of the shackle 41, as illustrated in FIG. 1.
If desired, a lanyard or other attachment means may be provided in combination with an opening or hole 46. Other support, holding, or attachment means can be used for supporting the knife from the equipment or person of the user besides the snap shackle when the opening and lanyard 46 are employed.
Referring now in detail to FIG. 4, it can be seen that a substantial surface on the body piece, such as side piece 14, can be used for display purposes. In the present illustration, a scale shown in the direction of arrow 47 may be carried and is useful to the user for the taking of measurement purposes. In other applications, other indicia, alpha-numeric characters or the like can be carried on the display area which would be suitable for the active sport engaged by the user.
Referring now in detail to FIG. 5, it can be seen that the snap shackle 41 resides adjacent to the blade 12 when the blade is in its operative position. No interference is provided and the leaf spring 43 is held in position by means of a riveted or screwed plate 48. The plate 48 may also be used for holding the pivot pin in position. Removal of plate 48 permits service and maintenance as well as repair for the leaf spring 43 and the pivot pin.
Referring now in detail to FIG. 6, another embodiment of the invention is shown wherein the body or housing of the utility knife is indicated by numeral 50 and a pry bar 51 is included on the end of the body opposite to its end carrying a snap shackle 52. The knife includes a blade similar to the one illustrated in the earlier version and is indicated by numeral 53. Therefore, it can be seen that the body or housing can include tools or implements which are integrally formed with the body and are operative from the end of the body or housing opposite to its end carrying the snap shackle and the pivot connection for the blade.
Therefore, it can be seen that the knife construction of the present invention provides not only a knife blade but a line cutter and other implements of utility. The snap shackle arrangement permits the knife to be carried outside of the pocket of the user in a ready position, either on the apparel of the user or his equipment. Not only may the snap shackle be operated by the fingers of one hand of the user, but the blade may also be extended from its storage position to its operative position by the single-handed use of the user. The enlarged openings for operating the release mechanism 18 are of great advantage to persons having gloved fingers and the enlarged openings, as well as the drying slots 40, are useful in drainage and drying purposes.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of this invention.
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A utility knife is disclosed herein having an elongated body pivotally housing a knife blade adapted to be moved between a folded position within a storage cavity and an operative position extended from one end of the body. A cutting edge is provided along one side of the blade and a finger grasping protrusion is integrally carried on its opposite side for moving the blade between its two positions. A snap shackle is carried on the end of the body adjacent to the pivot connection of the blade so that the shackle substantially fits the contour of the blade protrusion when the blade is extended into its operative position and so that the shackle is exposed when the blade is in its storage position. One side of the body displays a measuring scale and as an option, a pry bar may be integrally carried on the body end opposite from its end pivotally carrying the folding blade.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/656,702, filed Jun. 7, 2012, the contents of which are herein incorporated by reference in their entirety.
BACKGROUND
[0002] Devices such as hypodermic needles, syringes, and other similar devices are generally designed in a manner that can create unnecessary pain, fear and anxiety. The pain is typically derived from the stimulus of the insertion of a sharp needle into the patient's skin, while the anxiety typically stems from the expectation of this pain. The pain and anxiety can lead to reactions such as jerks or tremors by the patient, which in turn can result in a suboptimal use of the device for the patient and technician using the device. Furthermore, the pain and anxiety resulting from this use can be traumatic for the patient leading to a phobic response. A way of diminishing the pain and/or anxiety related to hypodermic devices is therefore needed.
SUMMARY
[0003] According to at least one exemplary embodiment, an injection device may be disclosed. The injection device may use a plurality of projections which may be placed against the skin to alleviate or distract from the anticipation, fear or pain of a shot. A vibration motor may be included within the device so that when desired the device and or the plurality of projections may vibrate. The vibration motor may be manual or electric and may be toggled or dialed across a gradient of vibration intensities. Decorative indicia may be provided on the exterior of the device. The exterior indicia may be removable and/or replaceable so as to enable a variety of designs. The injection device may further include noise making systems such as mp3 players, radios, bells, chimes, and rattles. The device may also include a chamber for syringes or needles which may allow the point of the needle to selectively extend or retract with respect to the plurality of projections.
[0004] According to at least one other exemplary embodiment, an injection device may be disclosed. The device can include a needle, which may be surrounded by a plurality of projections. The needle can further be adjustable between a first position and a second position. A vibration motor disposed within the device can impart vibration to the device. Decorative indicia may be provided on the exterior of the device. The device can facilitate reducing patient anxiety and pain by providing additional sensory stimuli to distract from the pain and the anticipation of an injection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Advantages of embodiments of the present invention will be apparent from the following detailed description of the exemplary embodiments. The following detailed description should be considered in conjunction with the accompanying figures in which:
[0006] FIG. 1 is a side view of an exemplary embodiment of an injection device.
[0007] FIG. 2 is a front view of an exemplary embodiment of an injection device.
[0008] FIG. 3 shows a schematic of an exemplary embodiment of an injection device.
DETAILED DESCRIPTION
[0009] Aspects of the present invention are disclosed in the following description and related figures directed to specific embodiments of the invention. Those skilled in the art will recognize that alternate embodiments may be devised without departing from the spirit or the scope of the claims. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.
[0010] As used herein, the word “exemplary” means “serving as an example, instance or illustration.” The embodiments described herein are not limiting, but rather are exemplary only. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the terms “embodiments of the invention”, “embodiments” or “invention” do not require that all embodiments of the invention include the discussed feature, advantage or mode of operation.
[0011] Generally referring to FIGS. 1-3 , an injection device 100 may be disclosed. Device 100 may have any desired shape that allows it to function as described herein, for example a cylindrical shape. Additionally, device 100 may include a reservoir 102 disposed therein. Reservoir 102 may be hollow and may be adapted to contain a liquid, for example a medical solution. A first end 104 of device 100 may include at least one needle 106 . A second end 108 of device 100 can include a user-operable mechanism 110 which may cooperate with reservoir 102 to facilitate administering the withdrawal or delivery of fluids to the patient via needle 106 . For example, mechanism 110 may be a plunger, a push-button, or any other mechanism known in the art that enables device 100 to function as described herein. Other exemplary embodiments may have a specially designed cavity that may accommodate the use of any commercially available syringe or specific sizes of commercially available syringes.
[0012] Needle 106 can extend outwardly from first end 104 , for example, substantially parallel to the longitudinal axis of device 100 . Needle 106 can further extend substantially co-linearly with the longitudinal axis of device 100 . First end 104 may further include a plurality of protrusions 112 extending outwardly therefrom. Protrusions 112 may have, for example, blunt or rounded distal ends but may have other ends. The length of protrusions 112 can be such that the protrusions contact the patient's skin while allowing needle 106 to extend under the patients skin so as to administer the desired hypodermic injection. The length of needle 106 may be adaptable for the particular type of hypodermic injection desired, e.g. a subcutaneous, intravenous, intramuscular, or other injection. Furthermore, for exemplary embodiments with a built in reservoir 102 , the needle 106 may be removably coupled to device 100 so as to allow a variety of needles of different lengths to be used with device 100 . Needle 106 may also be adapted to have a duller or sharper point than needles commonly used in the art, so as to reduce or minimize the pain stimulus.
[0013] In some exemplary embodiments, needle 106 may be movable between a first position wherein needle 106 is at least partially recessed within device 100 , and a second position wherein needle 106 is at least partially extended away from device 100 . In one exemplary embodiment, when needle 106 is in the first position, protrusions 112 may extend further than needle 106 , which may allow protrusions 112 to contact the patient's skin. When needle 106 is moved to the second position, the needle 106 may extend beyond protrusions 112 , thereby allowing the user to administer the injection. The position of needle 106 may be adjustable, for example, by mechanism 110 . For example, when depressed, mechanism 110 may be adapted to extend needle 106 and deliver the fluid within reservoir 102 in a single action. In other exemplary embodiments, needle extensions, syringe extensions and fluid delivery may be provided by several actions of mechanism 110 , or by separate mechanisms.
[0014] Device 100 may further be capable of vibration. The vibration may be generated by a vibrational motor 114 . Motor 114 may be, for example, an eccentric mass motor or any other vibrational motor that allows device 100 to function as described herein. Power to the motor may be provided by a battery 116 . The battery 116 may be removable and replaceable and may be disposed within the housing of device 100 . Alternatively, battery 116 may be rechargeable, and device 100 may include structures adapted to charge battery 116 , for example external contact points, induction coils, or a socket for a power adapter plug. In other exemplary embodiments, the vibration of device 100 may be manually facilitated or operated. For example, an eccentric mass disposed within the body of device 100 may be coupled to a user-operable member. Alternatively, any structure for manually vibrating the device 100 may be contemplated and provided as desired.
[0015] Motor 114 may be operable via a switch or dial 118 which may be provided on the exterior of device 100 . In an exemplary embodiment, switch 118 may be provided as a ring rotatably and concentrically coupled to device 100 , which the user may rotate to switch motor 114 on or off. In alternative embodiments, motor 114 may be toggled between an on or off position by any manner desired as would be understood by a person of ordinary skill in the art.
[0016] The device may further include indicia 120 which may aid in the relief of anxiety and fear that a patient could feel when experiencing or anticipating an injection. For example, for children, such indicia 120 can include, but are not limited to, visual representations of cartoon characters, combinations of color, cars, and sports or the like. In some exemplary embodiments, the device may also have the capability of producing audio as a means to alleviate a patient's anxiety and fear. In other exemplary embodiments, indicia 120 may be directed towards any age group or demographic, for example, adult or elderly patients.
[0017] Indicia 120 may further be detachably coupled to device 100 , so as to allow the user to vary or customize the types of indicia 120 . For example, a first indicia may be replaced with at least one second indicia depending on a patient's preference or reaction. The indicia 120 may be removably coupled via any desired fastening means known in the art, for example by clips, snaps, adhesive material, cling material and so forth.
[0018] In operation, a user may fill reservoir 102 with a desired liquid. In alternative embodiments, user may leave reservoir 102 empty, for example, if drawing fluids from a patient. User 102 may then attach any desired size needle 106 to device 100 . Subsequently, the user may switch motor 114 on so as to impart vibration to device 100 . The user may then contact the patient's skin with protrusions 112 , and may activate mechanism 110 so as to extend the needle 106 beyond protrusions 112 and administer or draw the desired liquid.
[0019] The plurality of protrusions 112 can provide multiple contact points between device 100 and the patient's skin. This may provide additional sensory stimuli to the patient, thereby distracting the patient from the pain stimulus of the needle 106 . The vibration provided by motor 114 may add yet more sensory stimuli, and further distract the patient from the pain stimulus. In the retracted position, needle 106 may not be as visible to the patient as in a typical hypodermic device, which may further lessen anxiety prior to injection. Indicia 120 may provide additional diversion for the patient, which may further lessen the patient's anxiety.
[0020] The foregoing description and accompanying figures illustrate the principles, preferred embodiments and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art.
[0021] Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims.
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A injection device may be disclosed. The device may include an outer casing, a needle, and a plurality of projections surrounding the needle. The needle may be adjustable between a first position and a second position. A vibration motor may be disposed within the device to impart vibration to the device. Decorative indicia may be provided on the exterior of the device. In use, the injection device may provide sensory stimuli to distract from the pain and the anticipation thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application cross references a previous provisional patent application filed on Jul. 30, 2005. The USPTO number is 60/703790. The number 113264 is also listed on the return postcard.
[0002] This patent addresses the need to pair or match two or more subunits of medication by using a vector to hold them together for the following reasons. First, this would allow a combination of medication that could be more tailored to a patient's need. This combination could be novel. Additionally, this patent would cover a situation where there are two or more subunits of medication that contain identical or readily identifiable doses. Thus the patient could remove the vector and get accurate partial doses. The subunits could also be readily identifiable so that they could be taken separately. Novel pairing/matching of medication could also occur as prescribed by a physician. In addition, this patent expands competition with combination medications. By definition, combination medications have components which can't be separated. Since this patent has subcomponents that can be separated, it is unique but competes for the same marketplace. Thus, this would drive down prices of combination medications. Also, this would help non-profitable combinations that are still useful make it to the market. There are other uses too. For example, it would also enable pharmacies to stock only the subunits of the medication and combine them as needed. This is especially useful when narcotics of varying doses are combined with acetaminophen of various doses.
BACKGROUND
[0003] A review of the patent literature does not show any instances where subunit medications are paired or matched so that one or more medications can be taken together without a patient having to worry about the matching processes themselves or if 2 closes of a single medication are matched, the patient wouldn't have to worry about dividing a medication to get accurate dosing. Matching medications would have several advantages. There are pre-existing patents with a goal of making an easy or accurately divisible tablet; these patents have to do with making capsules or tablets that are easy to split, introducing error, or difficulties in production of medication. Error is introduced because there is no guarantee that the tablets or pills will split 100% evenly. Thus with matched pre-divided tablets, one could simply remove the vector holding together the tablets and thus have pre-divided accurate doses. In addition, using a vector to hold together pre-divided medication would give the ability to match a variety of different medications giving the physician, patient or pharmacist the ability to give novel pharmaceutical products that do not exist on the market place. This could be done by machine or by hand. The patient would be ingesting fewer vectors than the comparative number of tablets or capsules, thus increasing patient compliance. Also, pharmaceutical companies are known to introduce combination medications in order to prolong competitive advantages. However, in most cases they are simply combining generic products in a way that gouge the public forcing patients to buy 2 or more generics and then to take them together. A matched, pre-divided tablet would circumvent this abuse since a combination medication patent by definition is not separable into individual components whereas a matched pre-divided tablet is separable into individual components so that one could simply pair two or more generics together to get the equivalent of a proprietary combination medication. This would save elderly, indigent, as well as society in general a good deal of money and eliminate the need for them to buy different generics and take them together as this would be a more simplified process. Also, a pharmacist or patient would be able to easily separate components so that different medication can be separated as needed or the dose can be reduced so that a patient wouldn't have to cut pills, etc. This would have production advantages as the producing company could produce fewer dosages of tablets knowing that they can be accurately divided or paired and thus gaining a competitive advantage. Patients could be issued a device to separate the vector from the pill. This would be a device analogous to a pill cutter.
BRIEF SUMMARY OF THE INVENTION
[0004] As stated above, this invention pairs/matches two or more medication subunits which are held together by a vector. The vector may also function as a medication subunit. Placebo is considered a medication subunit. The medications could be generic or proprietary. The benefits of this invention are listed throughout this patent application. If one were to define a caplet as a tablet shaped like a capsule, then an example would be to combine two half-caplets of medication and encase it in a capsule which would function as a vector.
DETAILED DESCRIPTION OF THE INVENTION
[0005] The following description is one interpretation of the patent claims. Assuming that a caplet is a tablet in the shape of a capsule, if it was halved down the middle, one would have 2 half-caplets. This invention would be in this case a pairing of two medication subunits in the shape of half-caplets that would be encased in a capsule. The capsule is thus the vector and the end creation would be similar in appearance to a normal capsule.
[0006] In the case of a capsule, in one possibility, it could be filled with components chat appear to be either quarter caplets so that up to four different medication subunits can be matched.
[0007] The medication subunit may be generic or proprietary. Because there are so many possible medications on the market it is assumed that there are many aspect of these medications that would be obvious when used in this patent. Such obvious aspects include:
1. Any medication component or the vector itself may function or have an enteric coating. 2. Any medication components may be chewable. 3. Vector or components or both can be designed to survive acidic environments such as the stomach and release medication after that environment has passed. 4. Vector or components or both can liberate one or more medications at different rates. 5. Specific components may be designed to release medication or other substances only if they are crushed, thus going through the digestive system unreleased if not crushed. 6. Medication components may be divisible. 7. The packaging may contain specific information about what matched medications have been issued and any relevant product information about the vector, components or effects of matching the components. 8. Components may be medications that have been used in the past, present or yet to be used in the future. 9. Any medication component of the vector itself may be immediate release. short/long acting, extended release, delayed release, quickly dissolving or have any other pertinent attribute of medications on the market. 10. A flavoring, coloring or any other secondary use may be added as a component or may be present in the vector itself. 11. Flavoring or flavoring components may be added for patient satisfaction, especially with regards to compliance in children. This can be added to the components, vectors or both. 12. Each component can have individual labeling on the component with regards to any information related to the medication including, but not limited to dose, medication name, maximum dose, side effects, contraindications, and other information. This labeling may also be on the vector itself or both the component and the vector.
In Practice, examples may be as follows:
EXAMPLE
[0020] 1. A pharmacist or patient has an 80 mg paired medication with 2 halves composed of identical medication. To obtain a 40 mg dose, the vector simply has to be removed and then one has two 40 mg doses per tablet. The vector could be easily removed by using a device that grabs each end of the vector, pulls it apart and then the vector is ejected from the device.
[0021] 2. There is a need to match two medications, say anti-hypertensives, and there is no combination medication. The two components could be matched using this technology.
[0022] 3. Medications are taken by a patient once per day. These medications can be matched into one vector, thus increasing compliance and making it simpler for the patient to remember to take one medication than to go over many bottles.
[0023] 4. An example of a matched medication is two subcomponents that are produced as pills that essentially are half of pills. Thus these two would be combined in a capsule that could be easily removed.
[0024] 5. Examples of a matched medication of more than 2 subcomponents are pills produced as discs, or small tablets that essentially would fit in a capsule as a vector. Thus these components would be combined in a capsule that could be easily removed.
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This patent pairs/matches medication components. This may help with more accurate dosing when the need arises to split tablets. Also there may be increased patient compliance with patients taking many medications. Additionally, this patent would function competition to combination patents, thus driving down the cost for consumers.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-in-Part of Application Ser. No. 09/522,784 filed Mar. 10, 2000.
BACKGROUND OF THE INVENTION
[0002] Electrostatic coating processes rely on a charge differential between an article to be coated and what is used to coat that article. In such processes, the article is typically grounded whereas the coating to be applied is endowed with a charge. When the article and coating are then brought into contact with one another, the result is that the coating adheres to the article. It is estimated that more than 10,000 facilities for accomplishing this exist in the US alone.
[0003] Most such coating procedures and facilities employ a variety of steps, i.e., a cleaning step, a drying step, a coating step, and a heating step wherein the adhered coating is cured to afford a more desirable and permanent coat. These steps usually take place sequentially using batch operations commonly employed in the art, or else in specialized stations connected by a continuous conveyor line.
[0004] Conveyor lines can be of varying length depending on the facility. Articles to be coated are hung from these lines via spaced electroconductive racks or hangers that serve to ground articles attached thereto. Racks and hangers are popular that have the capacity to hang multiple articles. This is accomplished by multiple hooks, usually spot welded at set distances from one another on the same rack. Such rack and hook configurations vary widely in shape, size, and configuration to support different types and sizes of articles.
[0005] Once attached, the hangers or racks bearing grounded articles are conveyed through a coating station followed by a curing station. Once coating and curing are finished, the coated objects are removed and the process begins anew.
[0006] The hangers and racks of such systems, being expensive, are typically re-used. After passing through the painting station a number of times, that portion or portions of the hanger which contact the article gradually becomes fouled by coating. The net effect is interference with grounding capacity, with consequent poor transfer efficiency and an eventual possibility for spark or fire. This necessitates periodic replacing or cleaning, which is both time-consuming and expensive.
[0007] In the case of recycling, conventional cleaning methods include chemical stripping, molten bath stripping, burning, and mechanical stripping, i.e., sandblasting, hammering, and filing. These processes reduce the useful life and capacity of racks by compromising their structural integrity over time. For example, it is the Applicants' experience that hooks break off fairly regularly, thereby lessening the capacity and desirability of continuing with that rack.
[0008] The art has thus far failed to provide a cost-effective alternative.
SUMMARY OF THE INVENTION
[0009] The invention provides a surprisingly efficient solution to the long-felt need described above.
[0010] It is an object of the invention to provide an electrically conductive intermediate at an interface or contact point between the hanger and article to be coated. This intermediate may be conveniently replaced or recycled at a comparatively small cost relative to existing procedures and implements.
[0011] In a first aspect, the invention features a system for extending the operating life of hangers or racks associated with electrostatic coating. This is accomplished by use of a relatively cheap, electrically conductive, and preferably pliable, intermediate that is suitable for grounding an article to be coated. The intermediate is interposed at a contact junction of the article and electroconductive hanger.
[0012] In exemplary embodiments, the intermediate slideably engages, wraps, or clamps to the hanger and may even adapt in shape or be engineered to accommodate the particular shape of a hook. In most preferred embodiments the article, via an orifice or recess, envelops at least a portion of the hook and intermediate attached thereto.
[0013] Various embodiments contemplate different conductive materials and configurations, including shape, of the intermediate. By way of materials, rubber, plastic, tape, and metalic foils all exist that are conductive and suitable, depending on the precise application. The intermediate may be a silicone sleeve or cap having a hollow interior for receiving a hook portion of a hanger. The article to be coated then fits over or engages this enveloped portion of the hook, usually via an orifice of sufficient dimension.
[0014] Concentric “layers” of pliable sleeves are also envisioned for some coating applications wherein one sleeve is positioned over another for rapid exposure of fresh contact surfaces as appropriate. A spent layer is simply peeled away or cut off thereby exposing a fresh one. One such embodiment contemplates a tape. Other embodiments contemplate a plurality of hollow tubes, one over the top of the next. These may be slit lengthwise and deposited one over the top of the next, or else constructed in multiplied layers which are then curled and fixed in form to wrap or clamp to a hanger of interest. Of course, the diameter differential associated with this technique must accordingly be accommodated by the article.
[0015] In other embodiments, at least a portion of the hanger itself comprises a nonmetallic material such as a conductive silicone rubber or plastic. This new material can be conductively and integrally fixed during manufacture, e.g., by injection molding. Preferably, the material is pliable or bendable with the hands or other gentle means to quickly release or free unwanted deposits of coating that hinder contact and hence grounding ability. In such embodiments, the sleeve or intermediate is recyclable.
[0016] In still other embodiments, the sleeve intermediate is disposable. Of course, everything including hangers are disposable at a cost, but what distinguishes the present invention is the relatively low cost of the intermediate relative to the cost of replacing or recycling a hanger or rack. In embodiments where the intermediate is integrally a part of the hanger, the novelty resides in the hanger being easily cleaned relative to conventional hangers, e.g., metal ones, and more durable or receptive to cleanings.
[0017] In exemplary embodiments, the intermediate bridges a hanger and an article to be coated. This bridge may occur in a variety of configurations as one of skill will appreciate. It may occur as described above, or else it may occur by a more comprehensive envelopment, not only of the hanger but also of the entire juncture, including a portion of the article itself. U.S. Pat. No. 5,897,709 issued to Torefors describes one such example. However, instead of a conductive bridge, Torefors specifies a non-conductive (“dielectric”) cover. The present invention, by contrast, serves a dual function in further providing a conductive bridge to facilitate grounding and suitable coating, while simultaneously preserving the operative part of the hanger or hook for future use.
[0018] In another exemplary embodiment of the invention, an intermediate member is designed for fitting over a horizontal cross-bar type of workpiece hanger which suspends large size panels or the like for electrostatic coating, and comprises a longitudinal, hollow sleeve of pliable, electrically conductive material having a longitudinal slit extending along its length so that the sleeve can be engaged transversely over a cross bar extending between two vertical hangers via the slit. An article to be coated, such as a large flat panel, can then be suspended from the cross bar via conductive hooks which engage over the sleeve.
[0019] The elongate sleeve may be of any suitable cross-sectional shape, such as circular, square, rectangular, or octagonal. The slit may form a longitudinal gap or slot in the sleeve, or may be a simple linear cut along the length of the sleeve. Alternatively, the sleeve may have opposite longitudinal edges which are overlapped along the length of the sleeve, so that there is no opening in the sleeve after it has been engaged over the cross bar. In another alternative, the sleeve may have no slit, for engagement over hook like hanger.
[0020] In an alternative embodiment, the intermediate may be a sheet or strip of pliable, electrically conductive material which is secured on top of a hanger by an electrically conductive adhesive, such that an article to be coated engages the strip or layer. The pliable strip may have any suitable cross-sectional and peripheral shape, such as square, rectangular, circular, triangular, and the like, and may be solid or may have a through bore. The adhesive may cover all or only part of an inner face of the strip.
[0021] The intermediate may suitably be made of a conductive material, preferably rubber, plastic, tape, foil, or grease that can be conveniently removed, disposed of, replaced, or recycled. The intermediate may have resistance of less than 6 megaohms, or one or less megaohms, or 0.5 megaohms, and in one example has a resistance of about 0.1 megaohms or less.
[0022] In exemplary embodiments, such intermediates are also heat resistant to temperatures up to 600° F., and may be heat resistant in ranges of between about 250° F. and 450° F.
[0023] At present, the favorite known material for the intermediate is conductive silicone, which may be fashioned by mixing different conductive and nonconductive commercially available grades in certain proportions testable by one of skill in the art, using routine experimentation to arrive at a final suitable product. Alternatively, fully conductive commercially available conductive silicone alone can be used that, while more expensive, still represents an improvement in the art.
[0024] The material used, e.g., silicone, may be molded to fit the myriad different sizes and shapes of hooks available, or else a universal piece may be used that fits a variety of hook shapes and sizes by conforming pliably in shape. Preferably, these sleeves or caps pull on and off conveniently with minor effort, but are not too loose as to permit undue amounts of coating to seep inside. Looseness is not known to otherwise disadvantage the system, provided there is some contact through which a ground may be established.
[0025] A second aspect of the invention features methods for electrostatic coating that make use of the above embodiments, either singularly or, where appropriate, combined. One method of providing an electrostatic pliable coating layer on one or more hanger members comprises dipping at least part of at least one hanger member in a bath of liquid electroconductive material, such as conductive silicone, so that the dipped surface is coated with a layer of electroconductive material, and then lifting the hanger member out of the bath and allowing the coating layer to cure in order to form a pliable, electroconductive coating layer. Some or all of the hanger member may be dipped, and entire hanger racks for use in electrostatically coating many parts at once may be dipped and coated with the pliable electroconductive intermediate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The present invention will be better understood from the following detailed description of some exemplary embodiments of the invention, taken in conjunction with the accompanying drawings, in which like reference numerals refer to like parts, and in which:
[0027] [0027]FIG. 1 is a perspective view of a rack with conductive sleeves according to a first embodiment of the invention;
[0028] [0028]FIG. 2 is an enlarged sectional view taken on line 2 - 2 of FIG. 1;
[0029] [0029]FIG. 3 is a perspective view of a sleeve with rectangular configuration, according to another embodiment of the invention;
[0030] [0030]FIG. 4 is a perspective view of an alternative, cylindrical sleeve;
[0031] [0031]FIG. 5 is a perspective view of a sleeve with a flange for ease of fastening and removal from a hook;
[0032] [0032]FIG. 6 is a side view of the flanged sleeve mounted on a hook;
[0033] [0033]FIG. 7 is a perspective view of a different type of hanger rack and an attached conductive sleeve according to another embodiment of the invention;
[0034] [0034]FIG. 8 is a cross-section on the lines 8 - 8 of FIG. 7;
[0035] [0035]FIG. 9 is a section similar to FIG. 8 illustrating a modified sleeve for use with the rack of FIG. 7;
[0036] [0036]FIG. 10 illustrates another modified sleeve;
[0037] [0037]FIG. 11 is a section similar to FIGS. 8 to 10 illustrating another modified sleeve;
[0038] [0038]FIG. 12 is a view similar to FIGS. 8 to 10 illustrating a modified sleeve shape;
[0039] [0039]FIG. 13 illustrates a sleeve according to another embodiment; and
[0040] [0040]FIG. 14 is a cross-sectional view similar to FIGS. 8 to 13 illustrating yet another modified sleeve.
[0041] [0041]FIG. 15 is a cross-section similar to FIG. 2 illustrating a hanger with an intermediate strip or layer according to another embodiment of the invention;
[0042] [0042]FIG. 16 is a cross-section on the lines 16 - 16 of FIG. 15;
[0043] [0043]FIG. 17 is a cross-section similar to FIG. 16 illustrating an alternative shape for the strip;
[0044] [0044]FIG. 18 is a cross-section similar to FIGS. 16 and 17 illustrating another alternative shape;
[0045] [0045]FIG. 19 is a cross-section similar to FIGS. 16 to 18 illustrating an intermediate strip engaged over a cross bar of the hanger rack of FIG. 7;
[0046] [0046]FIG. 20 is a perspective view of the inner face of an alternative version of an intermediate strip for adhering over a hanger member;
[0047] [0047]FIG. 21 is a cross-section illustrating the stip of FIG. 20 adhered to a hanger with an article suspended over the strip;
[0048] [0048]FIG. 22 is a rear plan view of a intermediate strip illustrating an alternative shape for the strip;
[0049] [0049]FIG. 23 is a rear plan view of a strip similar to that of FIG. 22 but with a different adhesive arrangement;
[0050] [0050]FIG. 24 is a plan view similar to FIGS. 22 and 23 illustrating an alternative shape;
[0051] [0051]FIG. 25 is a plan view similar to FIGS. 22 to 24 illustrating another alternative shape for the strip;
[0052] [0052]FIG. 26 is a perspective rear view of an alternative arcuate strip;
[0053] [0053]FIG. 27 is a schematic side elevational view illustrating a method for coating part or all of a hanger member with a pliable electroconductive cover layer;
[0054] [0054]FIG. 27A illustrates the hanger end of a hanger member coated according to the method of FIG. 27;
[0055] [0055]FIG. 27B illustrates a hanger member fully coated according to the method of FIG. 27;
[0056] [0056]FIG. 28 illustrates an entire hanger rack coated with a pliable electroconductive coating layer according to the method of FIG. 27;
[0057] [0057]FIG. 29 illustrates another type of hanger member partially coated with an electroconductive cover layer according to the method of FIG. 27;
[0058] [0058]FIG. 30 is a cross-section on the lines 30 - 30 of FIG. 29;
[0059] [0059]FIG. 31 is a perspective view of an end cap of pliable electroconductive material according to another embodiment of the invention;
[0060] [0060]FIG. 32 illustrates the end cap of FIG. 31 in use during an electrostatic coating process for an automobile hood or the like;
[0061] [0061]FIG. 33 illustrates a modified, open-ended cap; and
[0062] [0062]FIG. 34 is a perspective view illustrating a pliable electroconductive intermediate according to another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0063] The invention makes use of novel intermediate components for use in electrostatic coating processes. The intermediate is conductive and relatively inexpensive in cost and practice, allowing for ready cleaning and/or replacement with a concomitant more efficient operation afforded to the overall system. The object is the preservation of proper grounding and the protection and preservation of more expensive implements used in the process, e.g., hangers, hooks, and racks.
[0064] As used herein, and in the claims, the following terms have the following meanings:
[0065] A “system” includes, but is not limited to, traditional apparatuses used in electrostatic coating processes.
[0066] The term “electrostatic coating” embraces any powder, paint, or electroplating procedure wherein a charge differential is established to facilitate coating of an object to be coated. This includes but is not limited to the use of thermoplastics and teflon-type additions. Those of skill in the art know the broad latitude of the term, which can apply to different charging techniques and systems.
[0067] By “intermediate” refers to an object which interfaces in some fashion with both an article to be coated and an electrically conductive hanger. The shape is not to be construed as limited by the drawings or discussion herein, so long as one or more objects of the invention are otherwise met. The intermediate is typically hollow or capable of being made so, e.g., in the case of foil by wrapping it around a hook to be used in an electrostatic coating process of the invention. In tubular embodiments, this can be a uniform, hollow piece of varying internal and external dimensions, additionally including in some embodiments one or more flanges or grips that allow easy placement and replacement, in addition to providing leverage or mechanical manipulation and recycling. The intermediate can be a sleeve or cap, with the difference being that a sleeve has opposing free ends while a cap does not.
[0068] The terms “suitable for grounding”, “grounding” and “conductive” are to be understood jointly. “Conductive” means capable of passing a charge, e.g., a stream of electrons, and can mean any substance having suitable resistance and capable of fulfilling one or more objectives of the invention. Preferably, the material should have between about 0 and 6 megaohms of resistance, more preferably less than 1 megaohm of resistance, still more preferably less than 0.5 megaohm of resistance, and most preferably having about 0.1 megaohm or lower resistance. The more preferred parameters respect, although are not limited by, National Fire Protection Agency (NFPA) standards and rationale: “To minimize the possibility of ignition by static electric sparks, powder transportation, application, recovery equipment, work pieces and all other conductive objects shall be grounded with a resistance . . . not exceeding one megaohm.” NFPA Bulletin No. 33, Ch. 13, paragraph 13-4c.
[0069] “Ground” or “grounding” is a phenomenon that describes an equilibration of charge approximating that of the earth's surface. It is a reference standard by which more or less charge is gauged. For purposes of the invention, however, ground can also embrace situations where the hanger possesses a charge opposite to that of the coating material such that electrostatic bonding is achieved and promotes good transferability and coating.
[0070] The term “hanger” is not meant to be geometrically or materially limiting and may embrace a variety of structures and compositions known in the art, including but not limited to conventional metal hangers, racks, hooks, combinations of racks and hooks, and any other instrument useful in securing or supporting an article to be electrostatically coated. Of course, the piece must also be electroconductive and otherwise suitable for electrostatic coating processes. Magnetic systems and applications are also envisioned.
[0071] The terms “slideably engages”, “wraps”, and “clamps” are each broad terms descriptive of many potential, not necessarily mutually exclusive embodiments. Besides what are shown in the instant drawings, another non-limiting example of a clamp, for instance, includes that disclosed in U.S. Pat. 5,897,709, herein incorporated by reference. Although the clamp described there is nonconductive, the geometry and-other functions can be recruited for purposes of the instant invention.
[0072] The terms “silicone”, “plastic”, “tape”, and “foil” similarly have many acceptable permutations that are envisioned to be suitable for the invention, and which are either known in the art, or can be readily determined and implemented without undue experimentation by one of ordinary skill. These are discussed in greater detail below.
[0073] The term “integral with said hanger during manufacture” denotes either the conjoining of multiple individual components during manufacture of the hanger itself, or else embodiments where the hanger itself is made entirely of a homogeneous material, e.g., conductive silicone, which presents durability and cleaning advantages over previous compositions, systems, and methods.
[0074] The terms “disposable” and “recyclable” are meant to demonstrate alternative, not necessarily mutually exclusive, embodiments. Thus, at the discretion of the end-user a disposed of intermediate may also be suitably recycled. In other embodiments, there can be mutual exclusivity, e.g., where the sleeve, cap, etc., is engineered to fulfill its grounding and protective function only once, and then degrades, e.g., during the heating/curing step.
Other Features of the Intermediates
[0075] The conductive intermediates of the invention preferably withstand a temperature in the range of temperatures 200° F. to 600° F., most preferably 450° F., and over course of time about ten (10) or more minutes. Conforming intermediates are preferably pliable adapt in shape to envelop at least that portion of the hanger or rack to which the article to be coated is fastened or hangs. The point of this contact may represent substantially the whole of the exterior surface area of the intermediate, or else may represent any subfraction or portion thereof.
[0076] The intermediate may assume the shape of a prophylactic cap or sleeve, e.g., tubular or hollow, that has one or more exposed hanger or rack portions flanking its point of engagement with the hanger. Also, the shape of the intermediate may appear much different in appearance when affixed to the hanger relative to when not affixed. This owes to the intermediate's pliability and/or ready ability to conform in shape to the shape of the hook or subportion thereof to which the intermediate attaches. However, as noted, in certain embodiments the fit can be engineered to be more or less precise, so that pliability is not as great a consideration.
[0077] A further aspect is that the intermediate may be readily engaged and detached with minimal effort, e.g., peeled, unwrapped, scraped, or slideably disengaged as needed, and conveniently replaced or recycled so as to economically promote proper grounding and coating efficiency. This is, at least in part, because the cost of the intermediate is typically a fraction of the cost of the other system hardware, e.g., the racks, hooks, and hangers.
[0078] The ease with which recycling (where appropriate) is accomplished depends on the physical characteristics of the intermediate. In most preferred embodiments, the intermediate is a conductive silicone having suitable thermal stability. The intermediate is ideally elastomeric or pliable, easily engageable with the hanger, e.g., by sliding over, wrapping, or impaling a surface thereof, and readily disengageable as well.
[0079] A further embodiment, as mentioned, is the layered intermediates, wherein a plurality of intermediates overlaying one another are positioned on the rack and peeled off as needed to expose fresh contact area for new objects to be coated or recoated. This layered effect may result either from tape or from layers deposited one atop another. In tubular formats, multiple tubes may be stretched substantially over one another while the bottom most tube directly contacts the hanger/hook/rack and the subsequent added layers indirectly contact it via electrical conductance across the layers. Assumed is that the means for attachment of the article to the intermediate can accommodate a range of thicknesses supplied by the additional layers, and that sufficient contact and hence conductance between the layers can be maintained.
[0080] Characteristic of preferred recycling embodiments is that by using minimal or mild perturbation the intermediate can be easily regenerated, i.e., freed of unwanted coating deposits. This is especially so for silicone sleeve embodiments, but not advised for metalic foil embodiments. In the latter case, disposal, or recycling by burning or chemical stripping is preferred. Recycling and nonrecyling embodiments, as stated, are not necessarily mutually exclusive and may be at the discretion of the operator using the system. Such intermediate may therefore be suitable for either process.
[0081] It is also anticipated that the inherent benefits of the invention will find additional merit in automation. This will be more or less practicable depending on the specific embodiment used. At present, conductive silicone sleeves or caps are envisioned to best perform the task. They are easily mounted via sliding, clamping, or adhering, and similarly disengageable.
[0082] In summary, prior to the invention racks and hangers in the art required frequent replacement or cleaning which entailed considerable cost and labor. Down-time associated with these processes was unacceptable and/or, in the case of recycling, exacted a heavy toll on one or more of the following factors: structure and usable life of the racks and hangers, labor allocation, environmental impact, and energy consumption. With the teachings of the invention, these concerns are overcome, simplifying the overall coating and manufacturing process. The net result is increased efficiency and profit, which may in turn be passed on to the consumer.
EXAMPLE 1
Determining Suitable Ground and Resistance
[0083] A common device used to measure continuity to ground, and which may be used to further optimize parameters and configurations suitable for the invention, is an ohm meter having a megaohm scale. This can be a volt/ohm meter (VOM) or a Megger. A VOM is adequate for checking electrical circuits, but its low voltage power source makes it less suited for checking the proper grounding of a coating system. The best device is the Megger which has a power source of 500 volts or higher. This higher voltage provides the current required to accurately measure the resistance to ground.
[0084] An exemplary technique for measuring resistance is to start at the end of the process and work backward. The meter is connected between a known building ground and the uncoated part to be tested using a long test lead. This procedure is used to determine that the part is correctly ground through the entire spray booth. The amount of resistance to ground can be read on the meter, as one of skill aware.
[0085] Because the meter is attached to a known ground and to a clean part on the conveyor in the booth, all the devices in between (hanger, conveyor, swivels, etc.) are in the circuit and the resistance to proper ground can be measured. If the reading is less than one megaohm, the grounding is ideal.
[0086] If the resistance reading is greater than one megaohm, one can verify by hooking the lead to the contact point on the hanger and read it again. Then, by repeating the procedure and working back through the system (swivel or conveyor hook, conveyor) until the resistance reads in the proper range. By this method it can be determined which device needs corrective action.
[0087] A similar technique can be used to check for proper grounding of other objects and equipment in the coating area and system.
EXAMPLE 2
Silicone Sleeve or Cap
[0088] A prototype intermediate was designed and built as follows: Three quarter parts conductive silicone rubber compound (Shin-Etsu Chemical Co., Japan; part KE3611U) combined with one quarter part nonconductive silicone paste (Shin-Etsu; part KE961U) was mixed, compression molded, and cured in the form of tubing having a wall thickness of about 0.1 cm and an overall tubing diameter of about 1 cm. With reference to FIG. 2 or 6 , the resulting tubing was then cut to approximately 5 cm in length and the resulting sleeve intermediate 1 slideably coaxed over and along the shaft of a metal conductive hook 2 via a free end 3 of said sleeve intermediate 1 . This was done until the sleeve 1 substantially covered the hook 2 , or at least that portion fated to engage and contact a workpiece or article to be coated.
[0089] The overall concept, e.g., for a multi-hooked rack, is illustrated in FIG. 1, which depicts one configuration of sleeve mounted onto a plurality of hooks of a single rack. Each work-piece hook in FIG. 1 is analogized to the individual configurations demonstrated in FIGS. 2 and 6. With reference to FIG. 1, the article or articles to be coated 4 engage the hooks 1 by virtue of one or more orifices or recesses 6 in said article(s) 4 having suitable dimensions for receiving the intermediate sleeve/hook combination 7 . At the vertically highest point in the figure is another hook 8 to which the overall rack of the Figure is typically grounded. The hanger diameter for this prototype measured approximately 0.6 cm, although the particular dimensions are not limiting and merely illustrative of one workable embodiment. For this particular prototype, the depth of curve of said portion of the hanger measured 6 cm, and the vertical length of the hanger, not including curve, measured about 55 cm. Analogy may be had with reference to FIG. 1 for other rack and hook configurations.
[0090] Coating and curing then proceed as standard in the art. Upon coating, the coated article is removed, an uncoated article added, and the process repeated. Between coatings, typically every 3-5 rounds, the sleeve/fitting is examined for paint build-up and manipulated gently to peel away or relieve unwanted coating build-up on the intermediate, thereby re-establishing a suitable ground for the electrostatic process. If desired, the recycling can take place in situ, or else can first entail removal of the rack or hanger from the conveyor. The latter is preferred so that new racks can be added as the intermediates on the old racks are serviced, thereby promoting a more continuous operation. “Used” sleeves may be replaced with unused ones, followed by a resumption of coating operations, or else the individual sleeves can be removed, gently manipulated to recycle them, and replaced.
[0091] For purposes of the prototype, the Applicants formulated the 75:25 mix to decrease costs. Higher ratios of conductive silicone, e.g., 76-100% will also work and still be more economical than previously described art methods, and the Applicants further believe that lower ratios can also be determined without undue experimentation, and using routine procedures.
[0092] As one of skill in the art is aware, however, conductive silicones exist that vary in constituents. This may have a bearing on the relative success of the precise functional ratios used. Moreover, as one of skill is also aware, there can be lot-to-lot variations in silicone performance. However, as stated, one of skill may easily determine suitability using minimal, routine experimentation. Indications of some of the variations that exist and methods for preparation of the same may be found, e.g., in U.S. Pat. Nos. 6,010,646, 6,013,201, 5,217,651, 5,164,443, 5,135,980, 5,082,596, 4,957,839, 4,898,689, 4,672,016, 4,571,371, 4,552,688, pertinent disclosures of which are herein incorporated by reference.
[0093] Besides Shin-Etsu, other current commercial vendors of conductive and nonconductive silicones include Dow Corning (Indianapolis, Ind.) and Toshiba (JP). No doubt other vendors also exist and improvements in silicone structures and characteristics are anticipated.
EXAMPLE 3
Flanged Prototype
[0094] Electrostatic coating is performed as per Example 2, except that instead of a uniformly dimensioned sleeve or cap, the sleeve or cap possesses a flange or rib for gripping or otherwise facilitating the process. This is demonstrated by the prototype exhibited in FIG. 5. The dimensions shown (mm) are designed to fit over a wire hook 2.35 mm in diameter. The internal diameter of the tubing is 2.75 mm, the length is 75.00 mm, the diameter of the flange is 13.00 mm, the flange thickness 1.6 mm, and the tube wall thickness 0.8 mm. This particular embodiment demonstrates a cap format wherein a flange exists on an end opposing the capped (closed) end . When positioned onto the wire hook, this flanged cap or sleeve resembles the format shown in FIG. 6.
EXAMPLE 4
Foil Intermediates
[0095] Electrostatic coating is performed as per Example 2, except that instead of using the silicone sleeve fitting, conductive metalic foil, e.g., tin or aluminum, is substituted and wrapped around the bare or otherwise conductive hook to provide an equivalent effect.
EXAMPLE 5
Hybrid Hanger Comprising Conductive Silicone
[0096] In this embodiment, hangers are produced via compression molding that are comprised, at least in part, of conductive rubber, e.g., silicone, as described above. The silicone portion, if a minority, is preferably localized to that portion of the hanger as described for Examples 2 and 3. Thus, sleeve fittings as described above are either eliminated or else rendered redundant to the process, with the latter embodiment also anticipated to have independent advantage.
[0097] [0097]FIGS. 7 and 8 illustrate an intermediate sleeve 40 of electrically conductive, pliable material according to another embodiment of the invention. The sleeve 40 is an elongate, cylindrical, tubular member which is open at both ends and which has a longitudinal slit 42 extending between its opposite ends. It is designed for fitting over a different type of rack 44 for suspending workpieces such as large, flat panels 45 to be electrostatically coated, as illustrated in FIG. 7. The rack 44 has a pair of vertical posts 46 having grounding hooks 48 for attachment to a conveyor or grounding system, and a cross bar 50 extending between the posts and from which the workpiece 45 is suspended via conductive hooks 52 . The elongate conductive sleeve 40 can be fitted over the cross bar 50 via the slit 42 , as indicated in FIGS. 6 and 7. In this example, the slit 42 is defined between opposite longitudinal side edges 54 which are spaced apart to form a gap.
[0098] [0098]FIG. 9 illustrates a modified cylindrical sleeve 56 in which a simple longitudinal slit 58 is cut, with no gap between opposing side edges of the cut. FIG. 10 illustrates another alternative sleeve configuration 60 in which opposite longitudinal side edges 62 of the sleeve are overlapped. Due to the pliable nature of the sleeve material, opposite side edges of the sleeve can be urged apart in both of the embodiments of FIGS. 9 and 10 while the sleeve is inserted transversely over cross bar 50 , and then released to close the slit as in FIGS. 9 and 10, for added security. FIG. 11 illustrates a modified cylindrical sleeve 64 similar to that of FIG. 8 but with a thicker wall.
[0099] FIGS. 12 to 14 illustrate some alternative cross-sectional shapes for the elongate tubular sleeve 40 of FIG. 7. In FIG. 12, the elongate tubular sleeve 66 for fitting over a cross bar 50 is of square, rather than circular, cross-section, and has a longitudinal slit 68 extending along one side of the sleeve. In the embodiment of FIG. 13, the sleeve 70 is of triangular cross-section and has a slit 72 at one apex of the triangle. Finally, in FIG. 14, the sleeve 74 is of octagonal cross-section and has a slit 75 . In each of these cases, the slit may define a gap as in FIG. 8, or no gap as in FIG. 9, or have overlapping side edges as in FIG. 10. Many other alternative cross-sectional shapes may be used if desired.
[0100] Each of the sleeves of FIGS. 8 and 11 to 13 may be provided without any longitudinal slit, for use on racks with hangers having free ends over which the sleeve can be engaged. The sleeve may be closed at one end, as in the embodiments of FIGS. 2 to 6 , or may be open ended.
[0101] [0101]FIGS. 15 and 16 illustrate another alternative embodiment, in which the intermediate comprises a strip or piece 80 of calendared, pliable conductive silicone adhered to an upper surface of a hanger 5 or cross bar 50 of a rack by a backing layer 82 of conductive adhesive. The strip 80 may be secured over only that region of the hanger or support bar which is engaged by the part, or by a hanger or hook 15 or 52 for the part.
[0102] Strip 80 may be of rectangular cross-section, as indicated in FIG. 16. However, any cross-sectional shape may be used, such as a strip 84 of circular cross-section, as in FIG. 17, or a strip 85 of triangular cross-section, as in FIG. 18, or any other shape. FIG. 19 illustrates a pliable strip 86 adhered over the upper face of the cylindrical cross bar 50 of the rack in FIG. 7, in place of sleeve 40 .
[0103] [0103]FIGS. 20 and 21 illustrate a rectangular or square shape strip 90 of pliable electroconductive material such as conductive silicone in which, instead of a backing layer of conductive adhesive extending over the entire inner face of the strip, stripes 92 of adhesive material are provided along the opposite side edges 93 of the strip, each stripe 92 being covered with a peel-off cover layer 94 of paper or the like to protect the adhesive stripe until the strip is to be applied to a hanger member. The strip 90 may be provided in a continuous length for cutting to a desired size by an end user. As illustrated in FIG. 21, after removing the cover layers 94 , the strip 90 may be adhered to a hanger member 5 using the side stripes 92 of adhesive. An article to be coated can then be suspended from the hanger member, with a portion 95 of the article engaging over the center of the strip 90 so as to press the central portion directly against the hanger member, as indicated in FIG. 21. Thus, the conductive silicone strip 90 forms a direct junction between the article 95 and the electroconductive hanger member, with no intervening adhesive. In this case, the adhesive need not be electroconductive.
[0104] The adhesive-backed pliable electroconductive member may have one or more adhesive coating layers covering all or part of its inner surface, and may be of any desired peripheral shape. Some alternative shapes are illustrated in FIGS. 23 to 26 . In FIGS. 23 and 24, an electroconductive member 96 of circular shape is provided. The member 96 has a central stripe 97 of adhesive in FIG. 23, and a peripheral layer 98 of adhesive extends around an annular portion of the periphery of member 96 in FIG. 24. Alternatively, the inner face may be completely coated with an adhesive layer.
[0105] [0105]FIG. 24 illustrates an electroconductive member 100 of alternative, trapezoidal shape with side stripes 102 of adhesive material. In FIG. 25, the electroconductive pliable member is a flat, generally diamond shaped panel 104 coated with an inner layer 105 of adhesive. In each case, the panel or electroconductive member may have an adhesive layer completely or partially coating its inner surface, with the adhesive provided in any desired region or regions. FIG. 26 illustrates an alternative electroconductive strip member 106 which is of rectangular shape but generally arcuate cross-section, for conforming to the outer surface shape of a round bar or rod like hanger. Member 106 is provided with strips 108 of adhesive along its opposite side edges, in a similar manner to the embodiment of FIG. 20, although the adhesive may completely coat the inner surface of member 106 in alternative examples.
[0106] In each of the embodiments of FIGS. 15 to 26 , the adhesive material may be any suitable electroconductive adhesive, such as a silicone base adhesive available from Kirkhill Rubber of Los Angeles, Calif., or a high temperature acrylic adhesive. The alternatives which have only side strips of adhesive may not require the adhesive to be conductive, which will increase the choice of possible high temperature adhesives for use in these embodiments.
[0107] [0107]FIG. 27 illustrates an alternative method of providing an electroconductive pliable intermediate at a junction between an electrically conductive, rigid hanger and an article to be coated. In this method, instead of engaging a pre-formed sleeve, tube or adhesive backed strip on the hanger, part or all of a hanger member 110 is dipped into a bath 112 containing a liquid form 114 of the electroconductive, pliable material. The surface of the hanger member which is submerged in the liquid will be coated with the material, and the hanger member is then removed from the bath into a drying station at a suitable temperature for curing the coating layer of electroconductive pliable material. Where the material is electroconductive silicone, the curing temperature will be at or around room temperature. FIG. 27A illustrates one alternative where the hanger member has been partially dipped in bath 112 , to form a coating layer 116 of pliable electroconductive material on the hanger end of the member only. FIG. 27B illustrates a second alternative where the entire hanger member 110 is submerged in the bath to form a coating layer 118 extending over its entire length.
[0108] Instead of dipping an individual hanger 110 in bath 112 and subsequently hanging the hanger from a-coating rack, an entire rack 120 as illustrated in FIG. 28 may be dipped in the bath 112 so that it is completely covered with a layer of the conductive silicone material 114 . Rack 120 comprises a framework of side rails 122 and cross rails 124 , with a plurality of spaced hangers 125 secured on each cross rail. After the rack is dipped and coated, and the coating layer is allowed to cure, an intermediate, pliable coating will cover the entire surface of the rack, forming a conductive bridge between any article hung from the rack and the rigid conductive material of the rack. Because the coating layer is soft and pliable, it can be pinched and kneaded in order to remove any powder build up as a result of the electrostatic coating process. It will be understood that the same procedure may be used for coating racks and hangers of any shape or size.
[0109] [0109]FIGS. 29 and 30 illustrate an alternative, loop-type hanger 126 which has been coated with an outer layer 128 of a pliable electroconductive material such as conductive silicone. As illustrated in FIG. 29, a series of spaced, loop hangers 126 are welded or otherwise secured to a conductive cross bar 130 of a rack or the like. The hangers 126 may be dipped in a bath 112 of liquid electroconductive material in the manner illustrated in FIG. 27, so that each loop 126 becomes coated with a layer of the material, which is subsequently allowed to cure at room temperature to form an electroconductive, pliable coating layer 128 or intermediate.
[0110] [0110]FIGS. 31 and 32 illustrate an electroconductive, pliable cap or sleeve 130 according to another embodiment of the invention. Cap 130 is similar to the embodiment of FIGS. 5 and 6, except that it is of shorter length and of round, rather than rectangular, cross-section. It basically comprises a short tubular portion with one closed end 132 and an annular flange 134 at the opposite end for ease of handling and placement. The cap is formed of an electroconductive pliable material such as conductive silicone. Cap 130 may be placed over the end of a metal conductive hook 135 , as indicated in FIG. 32, with a series of such hooks with caps being used to support a large item 136 to be coated, such as a car hood or body. It has been found that, without such a protective cover, the paintwork of the hood or body may be scratched when it is lifted off the hooks, by the metal ends of the hooks. With this arrangement, the pliable caps 130 will protect the paint from such scratches. FIG. 33 illustrates a modified cap 138 which has a through bore open at both ends and an annular flange 139 at one end. The caps 130 and 138 may be made in various different lengths and diameters, depending upon the application.
[0111] Finally, FIG. 34 illustrates an alternative electroconductive sleeve or tubular member 140 according to another embodiment of the invention. Unlike the sleeves of FIGS. 2 to 6 , sleeve 140 is not of uniform thickness along its length. Instead, the sleeve 140 has a through bore 142 of uniform diameter, but has a stepped outer diameter, with a first end portion 144 of a first diameter and a second end portion 145 of a second, larger diameter, with an annular flange 146 at the end of the larger diameter portion 145 . The sleeve may be closed at its smaller diameter end. The sleeve is of a suitable electroconductive pliable material, for example electroconductive silicone. This version may be used in cases where a stepped diameter hanger or support for electrostatic coating is required. Rather than making the metal hanger or rod of stepped diameter, the pliable cover sleeve is stepped, so that a simple, uniform diameter hanger rod may be used, which will be less expensive.
[0112] Although exemplary embodiments of the invention have been described above by way of example only, it will be understood by those skilled in the field that other embodiments are also possible and that significant modifications may be made to the disclosed embodiments without departing from the scope of the invention.
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The invention relates to an intermediate component for protecting hangers associated with electrostatic coating processes. The component is an electrically conductive, pliable, tubular member, and inexpensive relative to the hanger which it serves to protect. The component lessens the cost associated with traditional hanger cleaning and preserves hanger life and integrity. The tubular member may have a longitudinal slit for installing the member over a cross bar of a hanger.
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CROSS REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/573,964 filed on May 24, 2004.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to a controller integrated within a computer memory which is used for memory testing during wafer testing and for performing additional useful functions when installed in a User's system. For the purposes of this application the terms Controller and Processor will mean the same thing and the Test CPU (TCPU) is a Processor. The term User includes the end user of the memory such as when the memory is installed in a Personal Computer or other device.
2. Background of the Invention
Typically, in addition to hard errors such as stuck nodes, memories are subject to errors caused by a sensitivity to the pattern of data stored in the memory. It is not feasible to test every combination of data bits in a large memory because it would simply take too long. Therefore, patterns are selected that are either predicted or known to cause errors. Pattern sensitivities can change as processes are changed; thus it may be necessary to change the test suite as wafers are processed. It is also possible that new pattern sensitivities may be discovered after a part is installed in a User's system. When this new pattern is added to the test suite the yield goes down. To bring the yield back up the process is tweaked and/or the part is redesigned.
In the manufacturing process, after a wafer is fabricated the common practice is to test each IC by positioning a test head containing probes over each IC one at a time to contact the IC's pads, exercise the IC to determine whether it is good, and mark the bad ones. After all the ICs on the wafer are tested they are cut from the wafer and the good ones are packaged. These are then tested again. By testing the ICs before they are cut from the wafer the bad ones can be discarded before they are packaged, thus saving money. However, as ICs become more complex, the time needed to test them increases. This is especially true with memories because of the need to test for memory sensitivity to data patterns. ICs are also commonly tested at different speeds because memories that fail at the highest rated speed may perform properly at lower speeds. Good memories are then sorted by speed so the lower speed devices can be sold instead of thrown away. Another problem faced by memory manufacturers is that as ICs become faster it becomes more difficult to test them at their rated speed due to the limitations imposed by using a test head.
Another common practice (called burn-in) is to subject the wafer to elevated temperatures. Premature IC failure tends to occur early in an IC's expected operating life. Subjecting the wafer to elevated temperatures accelerates the early-failure rate of the ICs.
Burn-in is more effective if the ICs on the wafer are powered during the test. One method to accomplish this is taught in U.S. Pat. No. 5,461,328 Fixture for burn-in testing of semiconductor wafers issued Oct. 24, 1995, to Devereaux, et al. Another method is taught in U.S. Pat. No. 5,766,979 Wafer level contact sheet and method of assembly issued Jun. 16, 1998, to Budnaitis. A further method is taught in U.S. Pat. No. 6,020,750 Wafer test and burn-in platform using ceramic tile supports issued Feb. 1, 2000, to Berger, et al.
However, these methods only apply power to the ICs on the wafer. They do not allow the ICs to be tested during burn-in. Some ICs may work perfectly well at room temperature and after burn-in but fail to work properly at the elevated temperature experienced during burn-in. Other ICs may work at room temperature, after burn-in, and at the elevated temperature, but fail to work at temperatures between room temperature and the elevated temperature. Since ICs are also rated to operate at a minimum temperature the same problem exists when testing these ICs at this low temperature. Some ICs may work at room temperature and low temperature but fail to work properly at intermediate temperatures.
Therefore a need exists to be able to continuously test ICs at the wafer level during testing, whether at elevated temperatures, low temperatures, or temperatures in-between, and keep a record of the results so that only good devices are packaged and sold to customers.
U.S. Pat. No. 4,757,503 Self-testing dynamic ram issued Jul. 12, 1988 to Hayes, et al. contains a built-in testing circuit using hard-wired logic. Changing the test suite requires redesigning the IC.
U.S. Pat. No. 6,154,861 Method and apparatus for built-in self-test of smart memories issued Nov. 28, 2000, to Harward contains a Test Controller ( FIG. 4 ), the details of which are not disclosed. There is no suggestion that the Test Controller can be reprogrammed after the IC is fabricated. Likewise, there is no suggestion that the Test Controller can be used for other than memory testing.
Accordingly, one of the objects and advantages of the present invention is to provide a programmable processor integrated into the memory for efficiently testing memories during both wafer testing and after packaging. An additional object and advantage is to provide a programmable processor integrated into the memory that can be used for functions such as graphics primitives and data matching. Further objects and advantages of my invention will become apparent from a consideration of the drawings and ensuing description.
SUMMARY OF THE INVENTION
An internal programmable processor is added to a computer memory by adding a small processor, a small amount of processor RAM memory, a small amount of non-volatile memory, and some logic. During wafer testing and after the memory is packaged this internal processor can be used for memory testing. A programmable clock allows the memory to be tested at different speeds. After the memory is installed in a User's system, the programmable processor can also be used to perform useful functions such as data pattern matching, moving data, and graphics primitives such as clearing and setting memory and for drawing lines. Additional functions, such as data encryption and decryption can be implemented. When used in dynamic memory the processor can be used to perform self-refresh. These additional functions can be used to justify the slightly added complexity of the memory.
The present invention is to be distinguished from a standard microcontroller. A standard microcontroller is generally intended for use as a standalone system, contains a limited amount of internal memory, and does not provide direct access to its internal memory by a host system. The present invention is primarily a memory to be used with a host processor, such as for main system memory. The internal programmable processor is intended to facilitate memory testing during and after wafer fabrication and to provide additional functionality in a User's system.
During wafer testing the internal processor allows the memory to be tested at full speed and substantially simultaneously with the testing of other memories on the wafer. During wafer testing, the test head loads the test program into the processor RAM and starts the test program. It then moves on to the next memory on the wafer. After thus starting all the memories on the wafer it goes back to the first memory, and if necessary, waits for the test to finish.
If the memory fails the test it is marked as bad and the tester goes to the next memory. If the memory passes the test, the tester writes information into the non-volatile memory such as:
1. Manufacturer's identification code; 2. Part Number; 3. Part Serial Number; 4. Memory Algorithm number; 5. Maximum clock speed for proper performance.
The results from the remaining memories are then available in the order that the memories were loaded with the test program and the program started.
After a memory is packaged, the non-volatile memory cannot be written to, only read. This is to prevent unscrupulous vendors from remarking bad parts as good or improperly increasing the speed rating.
At any stage after packaging, the part can be tested by having the host processor read the non-volatile memory, determine what test program to use, load it into the processor RAM memory, and start the self-test processor. The internal Self-Test allows the memory to be tested at full speed and in parallel with other host system operations, such as the testing of other main memory.
Since the test program is RAM-based it can be changed without changing a mask, such as would be necessary if it were in masked ROM. This is advantageous because, other than hard errors such as permanently stuck bits, the main problem with large memories is pattern sensitivity. It is not feasible to test every combination of data bits in a large memory because it would simply take too long. Therefore, patterns are selected that are either predicted or known to cause errors. Pattern sensitivities can change as processes are changed; thus it may be necessary to change the test suite as wafers are processed. It is also possible that new pattern sensitivities may be discovered after a part is shipped to the user. By having a RAM-based test program the manufacturer is able to distribute new test programs for the life of the part.
An additional advantage is that since the information in the non-volatile memory contains a unique serial number that can be read by the host processor in any system using this part, by keeping track of serial numbers the parts that are identified as having been stolen can readily be identified.
If desired, manufacturers can publish the serial numbers of parts known to have been stolen and make this information available through a public network like the Internet. The appropriate software can then automatically determine if a user's memory is on this list.
Since all memory serial numbers are unique, the serial number will also uniquely identify all boards and systems that incorporate it.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the integrated processor system with a programmable clock in a memory with non-multiplexed address inputs.
FIG. 2 shows the integrated processor system with a programmable clock in a memory with multiplexed address inputs.
FIG. 3 shows the integrated processor system with a programmable clock in a memory with a serial interface.
FIG. 4 shows the integrated processor system without a programmable clock in a memory with non-multiplexed address inputs.
FIG. 5 shows the integrated processor system without a programmable clock in a memory with multiplexed address inputs.
FIG. 6 shows the integrated processor system without a programmable clock in a memory with a serial interface.
DETAILED DESCRIPTION
In the following description, numerous specific details are set forth to provide a thorough understanding of the invention. However, it is understood that the invention may be practiced without these specific details. In other instances, well-known circuits, structures and techniques have not been shown in detail in order not to obscure the invention.
In the following discussion it should be noted that while conventional Dynamic RAMs (DRAMs) generally use a multiplexed address bus and conventional Static RAMs (SRAMs) generally use a non-multiplexed address bus, these are design choices made for various reasons (including tradition) that are not dictated by the technology itself. A DRAM can be made using a non-multiplexed address bus and an SRAM can be made using a multiplexed address bus. Memories which provide a serial interface for access by the User's system may also be practiced with the present invention.
Referring to FIG. 1 , Memory Array 106 may take several forms. It may be a conventional read/write memory comprising row and address decoders, a memory cell array, and sense amplifiers. The memory cell array may be dynamic or static. Memory Array 106 may also contain a shift register, making it particularly suitable for shifting data out of the array to be displayed on a video monitor. An example of this type of memory, commonly called a Video RAM (VRAM) is taught in U.S. Pat. No. 4,498,155 Semiconductor Integrated circuit memory device with both serial and random access arrays issued Feb. 5, 1985, to Mohan Rao. A further example of a memory optimized for video operations is U.S. Pat. No. 5,553,229 Row addressable graphics memory with flash fill issued Sep. 3, 1996, to the present inventor. However, Memory Array 106 may also be Read-Only (ROM), Write Once, or Read-Mostly (such as Flash Memory). The design of the preceding memory arrays are well known to those skilled in the art of memory design.
Again referring to FIG. 1 , the invention's internal programmable processing system is made up of processor TCPU 103 , TCPU RAM Memory 104 , Non-Volatile Memory 105 , and Programmable Clock 102 .
TCPU 103 (Test CPU) may use a Reduced Instruction Set (RISC) or a Complex Instruction Set (CISC), and may use a standard von Neumann architecture, a Harvard Architecture, a Very Long Instruction Word (VLIW) architecture, or a variation of architectures. The instruction set and architecture may be optimized for the tasks it is designed to perform.
TCPU RAM Memory 104 is used by TCPU 103 for storing instructions and data. It may have a single partition such as that required by a von Neumann architecture or it may be partitioned for use in a Harvard Architecture or the like. TCPU RAM Memory 104 may be static memory or dynamic memory but, due to its ease of use, static memory is preferred.
Non-Volatile Memory 105 is a non-volatile memory used for storing information such as: Manufacturer's identification code, Part Number, Part Serial Number, Memory Algorithm number, and Maximum clock speed for proper performance.
Programmable Clock 102 allows TCPU 103 to test the memory at different speeds as part of the manufacturing test protocol. Programmable Clock 102 may use a number of techniques to accomplish this, such as a Phase-Locked-Loop (PLL), a programmable divider, or Direct Digital Synthesis (DDS). Programmable Clock 102 normally powers-up at its minimum speed. Programmable Clock 102 may use the CLOCK input to MUX 101 as a reference or may contain an on-chip oscillator.
The bus comprising the TCPU Interface connects TCPU 103 , TCPU RAM Memory 104 , Non-Volatile Memory 105 , and MUX 101 and contains data, address, and control signals.
Multiplexor MUX 101 controls and arbitrates access between the internal programmable processor, Memory Array 106 , and the User's system. It allows TCPU 103 to access Memory Array 106 . It also allows Memory Array 106 to be accessed by external buses such as when the invention is used as main memory in a User's system. In addition, through the use of the RS input on MUX 101 , MUX 101 allows the User's system to control TCPU 103 , access TCPU RAM Memory 104 in order to load the program to be run by TCPU 103 , and access Non-Volatile Memory 105 . The BUSY output on MUX 101 tells the User's system that Memory Array 106 is being used by TCPU 103 and to wait. The TCPU Interface contains a similar signal to tell TCPU 103 that Memory Array 106 is being used by the User's system and to wait. The preferred memory arbitration scheme is to give the User's system priority to Memory Array 106 . If TCPU 103 is accessing Memory Array 106 at the beginning of a User system access, the User system waits until the next memory cycle at which point TCPU 103 is stalled and the User system gets access to Memory Array 106 . The CLOCK input to MUX 101 is used by TCPU 103 when the invention is used by a User's system in order to avoid the potential for conflicts caused by metastable instability of an arbitration logic circuit that would exist if TCPU 103 used a clock having a frequency not synchronized to the clock used by the User's system. During Wafer testing, the CLOCK input to MUX 101 may be used as a reference by Programmable Clock 102 . In FIG. 1 , MUX 101 provides external access to Memory Array 106 through a non-multiplexed address bus.
FIG. 2 shows an embodiment that is identical to that shown in FIG. 1 except that MUX 201 provides external access to Memory Array 106 through a multiplexed address bus. TCPU 103 accesses Memory Array 106 before the addresses are multiplexed, thus avoiding the speed penalty incurred by multiplexing the address bus.
FIG. 3 shows an embodiment that is identical to that shown in FIG. 1 except that MUX 301 provides external access to Memory Array 106 through a serial interface. TCPU 103 accesses Memory Array 106 before the serial interface, thus avoiding the speed penalty incurred by the serial interface.
FIG. 4 shows an embodiment that is identical to that shown in FIG. 1 except Programmable Clock 102 is omitted. This is for memories which are tested at only one speed during wafer testing. MUX 401 is similar to MUX 101 shown in FIG. 1 and provides external access to Memory Array 106 through a non-multiplexed address bus. TCPU 403 performs the same function as TCPU 103 but does not control a programmable clock.
FIG. 5 shows an embodiment that is identical to that shown in FIG. 4 except that MUX 501 provides external access to Memory Array 106 through a multiplexed address bus. TCPU 403 accesses Memory Array 106 before the addresses are multiplexed, thus avoiding the speed penalty incurred by multiplexing the address bus.
FIG. 6 shows an embodiment that is identical to that shown in FIG. 4 except that MUX 601 provides external access to Memory Array 106 through a serial interface. TCPU 403 accesses Memory Array 106 before the serial interface, thus avoiding the speed penalty incurred by the serial interface.
An example of a test suite for testing pattern sensitivity is show in Table 1(a) through Table 1(k). They are intended to be performed in sequence. When testing Main Memory in systems using Cache Memory care must be taken to turn off the Cache Memory so that Main Memory is tested and not Cache Memory.
TABLE 1(a)
Set all memory locations to ‘0’
Start with address 0
Check that the data = $00
Turn on each bit (d0-d7); Check the byte for correct data
Increment the address and repeat for all memory addresses
The data pattern for each memory address is:
(d7 d6 d5 d4 d3 d2 d1 d0)
00000000
00000001
00000011
00000111
00001111
00011111
00111111
01111111
11111111
At the end of this test, all memory locations are set to ‘1’.
TABLE 1(b)
Start with address 0
Check that the data = $FF
Turn off each bit (d0-d7); Check the byte for correct data
Increment the address and repeat for all memory addresses
The data pattern for each memory address is:
11111111
11111110
11111100
11111000
11110000
11100000
11000000
10000000
00000000
At the end of this test, all memory locations are set to ‘0’.
TABLE 1(c)
Start with highest memory address
Check that the data = $00
Turn on each bit (d7-d0); Check the byte for correct data
Decrement the address and repeat for all memory addresses
The data pattern for each memory address is:
00000000
10000000
11000000
11100000
11110000
11111000
11111100
11111110
11111111
At the end of this test, all memory locations are set to ‘1’.
TABLE 1(d)
Start with highest memory address
Check that the data = $FF
Turn off each bit (d7-d0); Check the byte for correct data
Decrement the address and repeat for all memory addresses
The data pattern for each memory address is:
11111111
01111111
00111111
00011111
00001111
00000111
00000011
00000001
00000000
At the end of this test, all memory locations are set to ‘0’.
TABLE 1(e)
Start with address 0
Check that the data = $00
Turn each bit (d7-d0) on, then off; Check the byte for correct data
Increment the address and repeat for all memory addresses
The data pattern for each memory address is:
00000000
10000000
00000000
01000000
00000000
00100000
00000000
00010000
00000000
00001000
00000000
00000100
00000000
00000010
00000000
00000001
00000000
At the end of this test, all memory locations are set to ‘0’.
TABLE 1(f)
Start with highest address
Check that the data = $00
Turn each bit (d0-d7) on, then off; Check the byte for correct data
Decrement the address and repeat for all memory addresses
The data pattern for each memory address is:
00000000
00000001
00000000
00000010
00000000
00000100
00000000
00001000
00000000
00010000
00000000
00100000
00000000
01000000
00000000
10000000
00000000
At the end of this test, all memory locations are set to ‘0’.
TABLE 1(g)
Set all memory locations to ‘1’
Start with highest memory address
Check that the data = $FF
Turn each bit (d7-d0) off, then on; Check the byte for correct data
Increment the address and repeat for all memory addresses
The data pattern for each memory address is:
11111111
01111111
11111111
10111111
11111111
11011111
11111111
11101111
11111111
11110111
11111111
11111011
11111111
11111101
11111111
11111110
11111111
At the end of this test, all memory locations are set to ‘1’.
TABLE 1(h)
Start with highest memory address
Check that the data = $FF
Turn each bit (d0-d7) off, then on; Check the byte for correct data
Decrement the address and repeat for all memory addresses
The data pattern for each memory address is:
11111111
11111110
11111111
11111101
11111111
11111011
11111111
11110111
11111111
11101111
11111111
11011111
11111111
10111111
11111111
01111111
11111111
At the end of this test, all memory locations are set to ‘1’.
TABLE 1(i)
Fill all memory addresses with $55
Start with address 0
Check that the data = $55
Write $AA to the address; Check the byte for correct data
Increment the address and repeat for all memory addresses
The data pattern for each memory address is:
01010101
10101010
At the end of this test, all memory addresses are set to $AA.
TABLE 1(j)
Start with address 0
Check that the data = $AA
Write $55 to the address; Check the byte for correct data
Increment the address and repeat for all memory addresses
The data pattern for each memory address is:
10101010
01010101
At the end of this test, all memory addresses are set to $55
TABLE 1(k)
Start with address 0
Use the Least Significant 8 bits of the address as data
Write the data to the memory address
Increment the address and repeat for all memory addresses
Start with address 0
Use the Least Significant 8 bits of the address as data
Check the data at the memory address
Increment the address and repeat for all memory addresses
The data pattern for the first 8 addresses is:
00000000
00000001
00000010
00000011
00000100
00000101
00000110
00000111
While preferred embodiments of the present invention have been shown, it is to be expressly understood that modifications and changes may be made thereto and that the present invention is set forth in the following claims.
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An internal processing capability is added to a computer memory by adding a small processor, a small amount of processor RAM memory, a small amount of non-volatile memory, and some logic. During wafer testing the internal processor system allows the memory to be tested at full speed and substantially simultaneously with the testing of other memories on the wafer. At any stage after packaging, the part can be tested by having the host processor read the non-volatile memory, determine what test program to use, load it into the RAM memory, and run the Self-Test program. The internal processor system also allows additional functions such as data searching, data moving, and graphics primitives to be performed entirely within the memory.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field.
[0002] This invention relates to electronic imaging devices and, in particular, to imagers having FET reset switches.
[0003] 2. Related Art.
[0004] Conventionally, CMOS imagers contain a number of photodiodes that are continuously queried and reset. The resetting of the photodiodes attempts to place each of the photodiodes into a known state (i.e. an expected voltage or charge level) and is commonly controlled by a N-channel Metal Oxide Semiconductor (NMOS) Field Effect Transistor (FET) acting as a reset switch. The NMOS FET has a drain implant that is in direct contact with a lighter doped P-well and protrudes into the material under the gate region of the NMOS FET.
[0005] The utilization of NMOS FETs acting as reset switches in CMOS imagers results in an additional source of noise, commonly known as reset noise (known as kTC noise). The typical construction of a NMOS FET allows charge to flow back to the drain and contributes to the reset noise in a CMOS imager. The length of time between resets and temperature changes affects the rate at which charge in a NMOS FET flows back to the drain and increases the reset noise when voltage is removed from the gate. The problem created by reset noise in a CMOS imager is that it causes uncertainty about the voltage values at the photodiodes after a reset. Attempts to compensate for reset noise in a NMOS FET have been generally unsuccessful due to charge redistribution that depends on the localized substrate noise (i.e. correlated double sampling measurements of the reset noise during a read operation). In addition, for signal readout circuits configured to integrate the photogenerated signal on the total sense capacitance, such as the source follower arrangement of Fry, et al., (IEEE JSSC, Vol. SC-5, No. 5, October 1970), is affected by the increased capacitance. The increased capacitance of a conventional reset FET decreases the electrical gain of the signal readout circuits. The decreased electrical gain results from the sense capacitance being the aggregate of the detector capacitance and various stray capacitances in compact pixel designs. The stray capacitances include, for example, the gate capacitance of the transistor gate driven by the photodiode cathode and the associated capacitance of the reset transistor. Therefore, the increased capacitance of a conventional NMOS FET reset switch results in optical degraded sensitivity for the CMOS imager due to both higher reset noise and lower electro-optical sensitivity. Thus, the use of known types of compensation for reset noise still results in a loss of sensitivity in the CMOS imager.
[0006] Additional reset noise problems occur due to the single chip construction of a conventional NMOS FET utilized as a reset switch in a CMOS imager. Construction of conventional NMOS FET utilize fabrication methods using sub-micron technology. As a result, the NMOS FET is susceptible to junction leakage. It is not uncommon for high leakage to occur from the increased electric field associated with a shallow junction, Arsenic implant damage, gate induced drain leakage, or a combination of all of the previous. The junction leakage of a conventional NMOS FET results in poor optimization and continuous soft resets during low light operation of a CMOS imager. Soft resets generate image lag because the charge that is not fully cleared from the photo-detector is subsequently added to the signal in the next integration period. The poor optimization and continuous soft resets significantly contributes to the reset noise and loss of sensitivity at low light level problems in a CMOS imager. Therefore, there is a need for a device and method to increase sensitivity at low light level while reducing the reset noise in CMOS imagers regardless of temperature and periods between resets of photodiodes while reducing junction leakage of the NMOS FET.
SUMMARY
[0007] The tapered threshold reset FET for a CMOS imager has a sensor having a transistor with a gate located partially over a source and partially over a drain having material between the source and drain beneath the gate of a predetermined length. The sensor also has a detection device that may be coupled to the drain by a signal path, where the material allows the detection device to be reset to a predetermined state.
[0008] Broadly conceptualized, the sensor may be formed with a reset transistor that reduces the capacitance of the photodiode. This may be accomplished by moving the p-type well, that isolates the source from the drain such that the p-type well partially dopes the channel of the transistor. The transistor may also be constructed to reduce reset noise through the use of the tapered reset operation. The tapered reset operation may include a reset transistor of relatively high impedance capable of suppressing the basic reset noise associated with the photodiode capacitance via an on-chip circuit and by using a channel implant that increases the reset voltage level for creating the reset channel.
[0009] 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 accompanying claims.
BRIEF DESCRIPTION OF THE FIGURES
[0010] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principals of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.
[0011] [0011]FIG. 1 is a schematic diagram depicting an exemplary implementation of a sensor having a photo-detector and a reset switch in accordance with the invention.
[0012] [0012]FIG. 2 is a cross sectional view illustrating the sensor of FIG. 1 having a FET transistor reset switch.
[0013] [0013]FIG. 3 is a cross sectional view illustrating another example of the sensor of FIG. 1 having a FET transistor reset switch.
[0014] [0014]FIG. 4 is a cross sectional view illustrating still another exemplary implementation the sensor of FIG. 1 having a FET transistor.
[0015] [0015]FIG. 5 is a flow diagram illustrating an example process for resetting the sensor of FIG. 4.
[0016] [0016]FIG. 6 is a signal diagram illustrating a tapered reset voltage applied to the FET of FIG. 4.
[0017] [0017]FIG. 7 is a flow diagram illustrating example process for resetting the sensor of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] In FIG. 1, a schematic diagram depicting a sensor 100 having a photo-detector 102 and a transistor 104 acting as a reset switch is shown. The sensor 100 includes a photo-detector 102 having of a p-n junction and the transistor 104 acting as a reset switch. The transistor has a source 106 , a gate 108 , and a drain 110 . The gate 108 of transistor 104 is electrically connected to a reset voltage supply 112 . The source 106 of transistor 104 is electrically connected to a reset voltage sink 114 , preferably ground. The drain 110 of transistor 104 is electrically connected to the anode 116 of the photo-detector 102 and a readout circuit 118 . The readout circuit 118 samples and processes the output of the photo-detector 102 during a read operation of the sensor 100 . However, one skilled in the art appreciates, that in an alternate embodiment the photo-detector may selectively be electrically associated with the source 106 as opposed to the drain 110 to facilitate a reset of the photo-detector 102 .
[0019] Upon a reset voltage being applied to the gate 108 of transistor 104 (acting as a reset switch) via the reset voltage supply 112 , a positive charge on the photo-detector 102 passes from the drain 110 to the source 106 of transistor 104 and ultimately to the reset voltage sink 114 . Once the reset operation is complete and the transistor 104 is turned off (i.e. the voltage on the gate 108 is removed), the remaining charge on the photo-detector 102 is measured and stored in memory (not shown) via readout circuit 118 . The stored charge value is utilized for correlated double sampling (CDS) in order to reduce reset noise via post processing and is a measure of offset error including the offset associated with the readout circuit 118 amplification, the random offsets generated by charge redistribution, and the classical reset noise. The offset error is described by the expression:
reset noise ( carriers ) = kTC sense e
[0020] where “k” is Boltzman's constant, “T” is the temperature, “C sense ” is the sense capacitance and “e” is the electron charge. In FIG. 1, C sense is comprised of the capacitance of photodiode 102 , the input capacitance of the readout circuit 118 , and the stray capacitance associated with the transistor 104 acting as a reset switch. Minimizing the capacitances reduces the maximum reset noise in sensor 100 with out utilizing the additional hardware and costs associated with CDS.
[0021] Radiation or light is then permitted to accumulate on the photo-detector 102 for a predefined time (i.e. integration period), before the charge is read again via the readout circuit 118 . Ideally, the error in this second read is corrected by compensating for the earlier measurement for offset and reset noise. The reset error, however, may be significant and vary depending on the length of time of the reset and the construction of transistor 104 utilized as the reset switch.
[0022] [0022]FIG. 2 is an illustration of a cross sectional view of the sensor 100 . The sensor 100 has a photo-detector 102 , a FET transistor 104 reset switch. The transistor 104 has a gate 108 with a dielectric insulator 200 , a source 106 , and a drain 110 formed in a substrate 202 . The source 106 is formed within a p-type well 204 (p-type atoms include Phosphorus, Arsenic, Nitrogen Antimony, and Bismuth) and is partially beneath the gate 108 . The p-type well 204 is implanted or formed within the substrate 202 . The source 106 is preferably formed as a shallow surface implant on the p-type well 204 . The drain 110 is preferably formed with the substrate 202 to be partially beneath the gate 108 . The drain 110 is electrically associated with a photo-detector 102 formed with the surface implant of the drain 110 , deep implant 210 , and substrate 202 . Additionally, a person skilled in the art would recognize that the source 106 may selectively be interchanged with the drain 110 and associated with the photo-detector 102 .
[0023] The transistor 104 of sensor 100 further includes a material in the space defined by the separation of the source 106 from the drain 110 beneath the gate 108 . In an example implementation of the transistor 104 , the length 206 of the material is at least 20 percent longer than a process minimum. For example, the process minimum gate length for a conventional 3.3 volt logic process range is approximately 0.35 microns. The recommended minimum gate length to avoid exaggerated short channel effects would be approximately 0.4 microns. While increasing the length 206 of the material consumes additional die area, increasing the material length 206 by approximately 20 percent of the process minimum increases the potential required to deplete the reset channel. But, the increase in potential required to deplete the reset channel significantly decreases the likelihood of a soft reset during a read operation (i.e. sub-threshold leakage does not degrade low light operation) and promotes the proper functioning of the various forms of tapered reset. An additional result of increasing the length of the gate 108 is that the doping of the gate 108 , source 106 , drain 110 , and associated channel may be decreased.
[0024] The channel has a well portion and a shallow implant 208 . The implant 208 may be formed with a Boron dopant, but other implementations may selectively utilize hole-increasing dopants such as Aluminum, Gallium, Indium, and Thallium. The well portion of the channel constitutes a portion of the p-type well 204 . The implant 208 is disposed between the channel well portion 204 of the source 106 and the drain 110 . Additionally, one skilled in the art would appreciate, the channel implant 208 may be disposed between the channel well portion and the source 106 when the photo-detector 102 is formed to be operably associated with the source 106 .
[0025] The implant 208 is preferably formed to be sufficiently shallow such that the concentration of dopant near the channel surface under the gate 108 further increases the potential that must be applied to the gate 108 in order to deplete the reset channel and the implant 208 dose may be reduced to below the dopant level of the channel well portion. In this instance, because the implant 208 has a lower dopant level than the channel well portion, the drain 110 dose may be advantageously reduced from 3e 13 cm −3 n-type, the typical level for a conventional NMOS FET, to approximately 6e 12 cm −3 n-type. This has the additional advantage of reducing the capacitance of the photo-detector 102 relative to its volume and lowering junction leakage associated with arsenic implant damage and gate 108 .
[0026] In FIG. 3, a cross sectional view of an exemplary implementation of the sensor 300 of FIG. 1 is illustrated. The FET transistor 302 has a gate 304 , a source 306 , and a drain 308 . The drain 308 of the transistor 302 is connected to the deep implant 316 of photo-detector 310 . The gate 304 has a n-type region 312 , a p-type region 314 , and a dielectric insulator 316 . The source 306 includes a p-type well 318 located in a substrate 320 . In this implementation, material is located between the p-type well 318 of the source 306 and the drain 308 . The length 322 of the material is defined by the separation of the source 306 from the drain 308 beneath the gate 304 . The length 322 of the material is preferably at least 20 percent longer than the process minimum.
[0027] As depicted in FIG. 3, the gate 304 has an n-type region 312 , and a p-type region 314 that form gate 304 . The gate 304 is preferably formed with polysilicon regions of opposite polarity (examples of polysilicons are; Boron, Aluminum, Gallium, Indium, Thallium, Nitrogen, Phosphorus, Arsenic, Antimony, and Bismuth). The potential that is applied to gate 304 in order to deplete the reset channel is increased (i.e. due to the resulting increase in the work function of the gate 304 ) without having to use high doping levels in the transistor 302 .
[0028] The source 306 is formed with a p-type well 318 , and partially beneath the n-type gate portion 312 of gate 304 . The p-type well 318 is diffused into or formed with the substrate 320 . The source 306 is preferably formed as a shallow surface implant on the p-type well 318 .
[0029] The drain 308 is formed with the substrate 320 and partially beneath the p-type region 314 of the gate 304 . The drain 308 is electrically associated with a photo-detector 310 that is formed by the deep implant 316 and the drain 308 in the substrate 320 . The drain 308 is preferably formed as a shallow surface implant on the deep implant 316 and underlying substrate 320 .
[0030] The material between the p-well 318 of the source 306 and drain 308 define a length 322 of a channel in the substrate 320 . The well portion of the channel constitutes a portion of the p-type well 318 of the source 306 . The channel substrate portion has a first conductivity type (e.g. n-type) while the p-well portion 318 has a second conductivity type (e.g. p-type). Therefore, because the p-well portion 318 is disposed away from the drain 308 (i.e. away from the photo-detector 310 side of the transistor), the capacitance typically associated with the p-type well 318 and drain junction in a conventional NMOS FET is effectively removed (i.e. channel substrate portion has the same conductivity type as the drain 308 ) that substantially suppresses reset noise. In addition, the drain 308 dose may be reduced from 3e 13 cm −3 n-type, the typical level for a conventional NMOS FET, to approximately 2e 12 cm −3 n-type since there is no need to overcome the high p-type doping of the p-well 318 .
[0031] In FIG. 4, a cross sectional view of still another example of an implementation of the sensor 400 having a FET transistor 402 is illustrated. The transistor 402 includes a gate 404 , a source 406 , a drain 408 . The gate 404 has an n-type region 410 and a p-type region 412 overlying dielectric insulator 414 . The source 406 includes a p-type well 416 formed in a substrate 418 . The drain 408 of transistor 402 , however, is formed with a p-type surface implant 420 . The p-type surface implant 420 is formed in the drain 408 partially beneath the p-type region 412 of the gate 404 , such that the drain 408 is not in direct contact with the surface of gate 404 (i.e., is in contact with the dielectric insulator 414 of the gate 404 ). The material under the dielectric insulator 414 has a length 422 defined by the separation of the p-type well 416 and drain 408 located beneath the gate 404 .
[0032] Turning to FIG. 5 is a flow diagram illustrating an example process for resetting the sensor 100 shown in FIG. 2. The process begins 500 when a potential is applied to the gate 108 (FIG. 2), resulting in the channel well portion being depleted 502 (FIG. 5). The drain 110 is not in direct contact with the surface channel of gate 108 due to the insulator 200 . The gate 108 forces conduction (i.e. during a reset operation) away from the gate 108 edge nearest the drain 110 . Therefore, substantially no conduction occurs through the channel substrate 418 until the potential on the source 106 and the depleted channel p-well portion 204 is sufficient to punch through to the drain 110 .
[0033] As the applied potential to the gate 108 and the channel well portion is increased during the tapered reset (See FIG. 6 for representative tapered reset voltage waveform). The depletion regions associated with the p-type well 204 of the source 106 and drain 110 merge below the implant 208 to accomplish the punch through of the channel 504 (FIG. 5). Once punch through occurs, carriers are swept through the merged depletion region 506 from the drain 110 to the p-type well 204 of the source 106 . In other words, the potential or reset voltage applied to the gate 108 must be increased beyond the level required for the channel well portion to be depleted in order to punch through the substrate 202 portion. Once punch through is accomplished a electrical field is establish to release or diffuse the charge on the photo-detector through the created reset channel. The voltage applied to the gate 108 is reduced allowing the channel below the implant 208 to collapse starting at the drain 110 end of the channel before the source end. Thus, sweeping the charges away from the photo-detector 508 . Because there are very few minority carriers in the fully depleted channel, there is reduced thermal noise associated with this charge transfer process. Processing is completed 510 and the photo-detector 102 discharged when the voltage is removed from gate 108 .
[0034] In FIG. 6, a voltage plot is shown. The reset voltage 600 is applied and then tapered or lowered slowly, preferably over one clock cycle 602 , to gradually maintain the potential difference between the channel ends (i.e. between source and drain) such that the charge on the photo-detector is sufficiently removed. As the reset voltage is tapered or lowered, the portion of the channel created by punching through the channel substrate portion is pinched off or collapses before the depleted portion of the reset channel (i.e. the channel well portion) causing charges remaining in the reset channel to be swept towards the source and away from the drain or photo-diode 102 .
[0035] [0035]FIG. 7 is a flow diagram of another example process for resetting the sensor 100 is shown. The process begins 700 with the potential required to deplete a channel associated with a material between the source 204 (FIG. 2), and the drain 110 under the gate 108 being increased 702 . A Boron implant 208 (FIG. 2), is added to half of the reset channel that is nearest the photo-detector 210 during fabrication. The implant raises the surface threshold for creation of a depletion region in the transistor by approximately 0.8 volts or higher. A tapered voltage of FIG. 6 is applied to the gate 108 causing a channel to be created 704 under the implant 208 . While the channel exist under the implant 208 , a path exist for a charge to flow from the photo detection device, such as a photo-detector 102 or photodiode, to the source 204 and eventually to the reset voltage sink 114 (FIG. 1). Thus, the channel drains the charge 706 from the photo-detector 102 to the p-well 204 of the source 106 . Upon removal of the voltage at the gate 202 the channel between the source and drain is interrupted and the process is finished 208 .
[0036] 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 that are within the scope of this invention.
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A sensor may be formed with a transistor comprising a gate that has both n-type and p-type regions to increase the gate work function. In combination with moving the p-type well such that the p-type well only partially dopes the channel of the transistor, the increased gate work function further increases the reset voltage level required to create the reset channel without having to use high doping levels in the critical regions of the sensor structure including the photo-detector and the reset transistor. The source of the reset transistor is partially beneath the n-type region of gate, while the transistor's drain is partially beneath the p-type region of the gate. The channel has a p-type well portion and a substrate portion. This construction of the sensor may eliminate the reset noise associated with the uncertainty of whether the charge left in the transistor's channel will flow back towards the photo-detector after the transistor has been turned off.
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[0001] The present application is related to and claims the benefit of foreign priority to Japanese application 2007-133502, filed on May 18, 2007 in the Japan Patent Office, which is incorporated herein by reference in its entirety.
BACKGROUND
Description of the Related Art
[0002] For a module connecting an optical fiber to an optical communication apparatus, a pluggable module that can be mounted or replaced from a front side of the optical apparatus has widely been used. With an increasing speed of optical communication in recent years, it is demanded to enhance suppression of ESD (Electrostatic Discharge)/EMI (Electro Magnetic Interference) of pluggable modules as well as optical communication apparatus bodies.
[0003] To obtain better suppression of ESD/EMI of pluggable module, a configuration having a member causing static electricity in the module to propagate to a cage for protecting the module is known, such as one disclosed in Japanese Patent Application Laid-Open No. 2006-113455.
[0004] FIG. 11 is a diagram showing a pluggable module according to a related art. As shown in FIG. 11 , a pluggable module 10 is a module to be connected to an optical connector 50 containing an optical fiber 501 . The pluggable module 10 is inserted into an apparatus 8 through an insertion opening provided in a cabinet 30 of the apparatus 8 before being electrically connected to a circuit board 40 inside the apparatus 8 via a connector 401 .
[0005] A cage 20 is mounted on the circuit board 40 to protect the pluggable module 10 . A spring 201 is provided inside the cage 20 to cause static electricity charged to the outside portion of pluggable module 10 to propagate to the cage 20 . A metallic member 202 is fixed to the cage 20 and the cabinet 30 by spot welding 202 a and the static electricity propagated to the cage 20 is conducted to the cabinet 30 acting as a ground through the metallic member 202 .
SUMMARY
[0006] A connecting apparatus includes: equipment having a cabinet with an opening and a connector inside the cabinet. A module which is attachable to the cabinet through the opening and thereby pluggable to the equipment, has an electrical circuit and a resilient conductor. When the module is plugged to the equipment, the electrical circuit of the module is connected to the connector of the equipment, the resilient conductor fills a gap in the opening between the module and the cabinet, and the module and the cabinet are electrically connected. Static electricity charged on the module propagates through the resilient conductor to the cabinet.
[0007] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a diagram showing a pluggable module according to an embodiment;
[0009] FIG. 2 is a perspective view of the pluggable module according to an embodiment;
[0010] FIG. 3 is a diagram showing a pluggable module according to an embodiment;
[0011] FIG. 4 is a diagram showing a pluggable module according to an embodiment;
[0012] FIG. 5 is a diagram showing a pluggable module according to an embodiment;
[0013] FIG. 6 is a diagram showing a pluggable module according to an embodiment;
[0014] FIG. 7 is a diagram showing a pluggable module according to an embodiment;
[0015] FIG. 8 is a diagram showing a pluggable module according to an embodiment;
[0016] FIG. 9 is a diagram showing a pluggable module according to an embodiment;
[0017] FIG. 10 is a diagram showing a pluggable module according to an embodiment; and
[0018] FIG. 11 is a diagram showing a pluggable module according to a related art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
[0020] First, a relationship between decreasing a size of a module and the corresponding ESD issue is described. By decreasing a size of a module, a distance between a cabinet of the module and a circuit board inside the module is shortened.
[0021] Accordingly, in the related art shown in FIG. 11 , for example, even if a structure to allow static electricity charged to the outside portion of the module to escape to a cage is present, there are cases where static electricity discharges to a circuit board and causes malfunctioning, circuit component breakdown and the like.
[0022] Also, a gap present between an insertion opening for inserting a module into an apparatus and the module can act as a path for EMI. Such gap is due to a dimensional tolerance or the like.
[0023] Referring to FIG. 11 , it is preferable that static electricity 1 is conducted from outside the apparatus 8 to the cabinet 30 by passing through a discharge route 2 , from the pluggable module 10 , through the spring 201 , the cage 20 , and the metallic member 202 , to the cabinet 30 .
[0024] However, since a distance d 1 between the spring 201 and a circuit board 101 , which controls optical elements inside the pluggable module 10 , is short, there are cases where static electricity discharges to the circuit board 101 and causes a malfunction, circuit component breakdown and the like. This problem becomes more serious with further decrease in the size of the pluggable module 10 due to communication speedups or composition with higher densities.
[0025] Also in FIG. 11 , since there arises a gap between the insertion opening provided in the cabinet 30 and the pluggable module 10 due to a dimensional tolerance or the like, there is another problem that EMI 3 emitted from the pluggable module 10 or the connector 401 or EMI (not shown) generated inside the apparatus, leaks out as EMI 4 .
[0026] FIG. 1 is a diagram showing a pluggable module 11 a according to an embodiment. As shown in FIG. 1 , the pluggable module 11 a includes a shield spring 112 a. The shield spring 112 a fills a gap between an insertion opening provided in the cabinet 30 and the pluggable module 11 a. The pluggable module 11 a comes into contact with the cabinet 30 by the shield spring 112 a due to elastic force, after being inserted into an apparatus 8 . The shield spring 112 a can be a resilient conductor that can isolate the module outside the cabinet and the inside the cabinet, made of a conductive material, for example, metal, metalized resin, or the like.
[0027] Static electricity 1 conducted to the pluggable module 11 a from outside the apparatus 8 , propagates through the discharge route 2 a from the pluggable module 11 a to the shield spring 112 a and the cabinet 30 . Thus, it is not necessary to provide a spring 201 for the cage 21 or the metallic member 202 in order to protect the pluggable module 11 a.
[0028] In this configuration, since the shield spring 112 a in the pluggable module 11 a is directly in contact with the cabinet 30 of the apparatus 8 , the static electricity reaches the cabinet 30 through the discharge route 2 a without coming close to the circuit board 101 . This makes it easier to protect the circuit board 101 inside the pluggable module 11 a.
[0029] Also in this configuration, as the gap between the insertion opening provided in the cabinet 30 and the pluggable module 11 a is filled by the shield spring 112 a, it is possible to inhibit leakage of the EMI 3 or the like emitted from the pluggable module 11 a or the connector 401 through the gap.
[0030] FIG. 2 is a perspective view of the pluggable module 11 a. As shown in FIG. 2 , the pluggable module 11 a includes a plurality of shield springs 112 a on a top surface, both sides, and an undersurface thereof. In order to inhibit leakage of EMI, a gap g between each of the shield springs 112 a is preferably not higher than ⅕ of a wavelength X of EMI.
[0031] Referring to FIG. 3 , a pluggable module 11 b has a structure in which a shield spring 112 b is in contact with the cabinet 30 not only inside the apparatus 8 , but also outside the apparatus 8 . By this configuration, a discharge route 2 b is remote from the circuit board 101 , and the circuit board 101 is less likely to be affected by static electricity.
[0032] Referring to FIG. 4 , a pluggable module 11 c has a structure in which a portion where a shield spring 112 c is in contact with the cabinet 30 outside the apparatus is apart from the center of the pluggable module 11 a. Therefore, a discharge route 2 c is made further remote from the circuit board 101 and the circuit board 101 is less likely to be affected by static electricity.
[0033] Referring to FIG. 5 , a pluggable module lid has two bending portions of the shield spring 112 d extending in the same direction, different from the pluggable module 11 b shown in FIG. 3 and the pluggable module 11 c shown in FIG. 4 . That is, a bending portion that brings the shield spring 112 d into contact with the cabinet 30 outside the apparatus 8 and a bending portion that is exposed to the outside of the apparatus 8 extends the same direction. Therefore, while having an effect similar to that of the pluggable module 11 b shown in FIG. 3 or the pluggable module 11 c shown in FIG. 4 , the pluggable module lid in FIG. 5 has a structure that is easier to work on than that of these pluggable modules.
[0034] Referring to FIG. 6 , a pluggable module 11 e has a structure in which a shield spring 112 e is in contact with the cabinet 30 outside the apparatus with a structure similar to the shield spring 112 b of the pluggable module 112 b in FIG. 3 . Additionally, the shield spring 112 e is not in contact with the cabinet 30 inside the apparatus, but is in contact with the cage 21 . Accordingly, the pluggable module 11 e has a structure that inhibits leakage of EMI from inside the cage.
[0035] Referring to FIG. 7 , a pluggable module 11 f has a structure in which a shield spring 112 f is in contact with the cabinet 30 outside the apparatus with a structure similar to the shield spring 112 c of the pluggable module 112 c in FIG. 4 . Additionally, the shield spring 112 f is not in contact with the cabinet 30 inside the apparatus, but is in contact with the cage 21 . Accordingly, the pluggable module 11 f has a structure that inhibits leakage of EMI from inside the cage.
[0036] Referring to FIG. 8 , a pluggable module 11 g has a structure in which a shield spring 112 g is in contact with the cabinet 30 outside the apparatus with a structure similar to the shield spring 112 d of the pluggable module 112 d in FIG. 5 . Additionally, the shield spring 112 g is not in contact with the cabinet 30 inside the apparatus, but is in contact with the cage 21 . Accordingly, the pluggable module 11 g has a structure that inhibits leakage of EMI from inside the cage.
[0037] Referring to FIG. 9 , a pluggable module 11 h has a structure in which a shield spring 112 h is in contact with the cabinet 30 outside the apparatus. Additionally, the shield spring 112 h is not in contact with the cabinet 30 inside the apparatus, but is in contact with the cage 21 . Thus, the pluggable module 11 h has a structure that inhibits leakage of EMI from inside the cage.
[0038] As described above, in the embodiments shown in FIGS. 1 to 9 , a shield spring is provided near a gap between a pluggable module and a cabinet of an apparatus to allow static electricity charged to the outside portion of the pluggable module to escape to the cabinet of the apparatus and also to fill the gap between the pluggable module and the cabinet of the apparatus by the shield spring. Therefore, suppression of ESD/EMI of the pluggable module is increased.
[0039] In the above embodiments, examples of suppressing ESD/EMI of a pluggable module by using a shield spring are shown, but suppression of ESD/EMI can also be enhanced by using members other than the shield spring.
[0040] Referring to FIG. 10 , in a pluggable module 11 i a conductive resin is used in combination to enhance suppression of ESD/EMI of the pluggable module 11 i.
[0041] As shown in FIG. 10 , the pluggable module 11 i includes a conductive resin 112 i in addition to the shield spring 112 a shown in FIG. 1 . When the pluggable module 11 i is inserted into the insertion opening of the cabinet 30 , the conductive resin 112 i comes into contact with the cabinet 30 and also a space between the pluggable module 11 i and the cabinet 30 is filled. The conductive resin 112 i is, for example, a rubber with metallic filler or conductive fiber around a circumference thereof and preferably has elasticity.
[0042] Since the conductive resin 112 i provided by the pluggable module 11 i is directly in contact with the cabinet 30 of the apparatus in this configuration, static electricity reaches the cabinet 30 without coming close to the circuit board 101 on the discharge route 2 i. This makes protection of the circuit board 101 inside the pluggable module 11 i easier.
[0043] Also in this configuration, the space between the cabinet 30 and the pluggable module 11 i is filled by the conductive resin 112 i. Therefore, the EMI 3 and the like emitted from the pluggable module 11 i and the connector 401 can be inhibited from leaking out through the gap between the cabinet 30 and the pluggable module 11 i. By using a conductive resin in combination, as described above, better suppression of ESD/EMI of the pluggable module.
[0044] As described above, a conductive member is provided in a pluggable module to allow static electricity charged to the outside portion of the pluggable module to escape to a cabinet of an apparatus by way of the conductive member and also to fill a gap between the pluggable module and the cabinet of the apparatus to inhibit leakage of EMI. Therefore, better suppression of ESD/EMI of the pluggable module is provided with a simple structure.
[0045] Although a few preferred embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claim and their equivalents.
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A connecting apparatus includes equipment having a cabinet with an opening and a connector inside the cabinet. A module has an electrical circuit and a resilient conductor and is attachable to the cabinet through the opening and thereby pluggable to the equipment. When the module is plugged to the equipment, the electrical circuit of the module is connected to the connector of the equipment, the resilient conductor fills a gap in the opening between the module and the cabinet and the module and the cabinet is electrically connected, and static electricity charged on the module propagates through the resilient conductor to the cabinet.
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This invention relates to braking devices for downhill skiing and particularly to an improved device for effecting control of a downhill skier's speed.
BACKGROUND AND PRIOR ART
Various devices have been provided heretofore which employ sails for changing the speed and, in some cases, the direction of a skier on a downhill run. Some of these devices, such as that of U.S. Pat. No. 2,213,754, employ loose sails attached to the skier; and others, such as that of Austrian Pat. No. 169,440, employ rigid poles or spars to hold and spread the sail. Some use the sail solely as a brake, while others use the sail for lifting the skier and facilitating long jumps. While these devices have been suitable for some applications, they do not provide the desired characteristics for effecting a high degree of control by the skier during downhill runs. Accordingly, it is an object of the present invention to provide an improved aerodynamic braking device for effecting a high degree of control by a skier during a downhill run.
It is another object to provide an improved aerodynamic braking device for downhill skiing which does not interfere with or limit the use of the skier's legs in normal skiing maneuvers.
It is another object of this invention to provide an aerodynamic braking device for downhill skiing including an improved arrangement for applying the entire force of the device above the waist of the skier without restricting the movement of the skier's legs.
It is another object of this invention to provide an improved aerodynamic brake for skiing which may be adjusted readily for use in a wide range of positions.
It is a further object of this invention to provide an aerodynamic brake for downhill skiing, including an improved arrangement for minimizing the torque applied to the hands of the skier.
Further objects and advantages of the invention will become apparent from the following description taken in connection with the accompanying drawing, and the features of novelty which characterize the invention will be pointed out with particularity in the claims annexed to and forming a part of this specification.
SUMMARY OF THE INVENTION
In carrying out the objects of the invention in one embodiment thereof, a braking sail is constructed in the form of two equal sail halves. The sail halves are of generally trapezoidal form, the bases of the trapezoids being the sides of the sail and having sheaths along their edges to receive and retain respective ski poles. The sail is held by the skier by gripping the poles centrally of the sides of the sail and extending the arms laterally to spread the sail so that the pressure of the wind is balanced above and below the horizontal axis between the skier's hands. Thus, little if any torque is applied to the skier's hands. The sail comprises four pockets of pyramidal configuration arranged in top and bottom pairs. When the skier is making a downhill run and grips the poles to extend the sail along its central horizontal axis, the forces of the wind created by his movement and applied above and below the axis are balanced. The sail is then easily manipulated by turning and slanting to provide the desired speed; and by moving the skier's hands toward and away from the outstretched position, the degree of pressure may be controlled. The maximum braking effect is provided when the sail is held taut and upright between the poles. When the skier wishes to reduce the braking effect, he may move the poles together; and by turning them forward to a horizontal position, he can minimize the drag on the sail. He may also lessen the resistance offered by the fully stretched sail by moving his grip upward on the poles and allowing the wind to push back the lower portion of the sail.
In a second embodiment, intended for the strong expert skier, the sail has about double the area of the first; it includes an upper half extending above the skier's head and providing an opening for the skier's head.
These braking devices become noticeably effective at speeds of over about fifteen miles per hour. The device gives the skier a sense of lift and control and also reduces the strain on his legs; it is not, like some of the prior art devices, a device for lifting the skier and enabling him to make long jumps.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric rear view of the skier using a braking device embodying the invention;
FIG. 2 is a rear elevation view of the device in its full open or spread-out position;
FIG. 3 is a side elevation view of the device;
FIG. 4 is a top plan view of the device;
FIG. 5 is an enlarged elevation veiw, partly broken away, of the left-hand top ski-pole-handle-retaining portion of the device of FIG. 2;
FIG. 6 is an enlarged elevation view of the bottom left-hand portion of the device of FIG. 2;
FIG. 7 is a front elevation view of a modification of the device shown as held in its full-spread position by a skier;
FIG. 8 is a side elevation view of the device of FIG. 7;
FIG. 9 is a top plan view of the device of FIG. 7; and
FIG. 10 is an enlarged view of one of the bottom corners of the device of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, the sections of cloth from which the sails are assembled are shown by straight lines along which the sections are sewn together; and, except for the hems for the sheaths, no stitching has been indicated. Furthermore, the drawings show all sections as essentially flat sheets. It will be understood that when in use the pockets of the sails will be bulged out by the wind.
Referring now to the drawings, in FIG. 1 a skier 10 on skis 11 is shown holding between his hands an aerodynamic braking device 12 which embodies the invention. The device is shown stretched by the skier between left- and right-hand ski poles 13 and 14. The device is secured to the skier's waist by a belt 15. The device is a sail or wing of suitable light, strong cloth such as a nylon fabric and includes four symmetrically arranged pockets 16, 17, 18, and 19. The upper pockets 16 and 17 extend upwardly from a cross member 20, and the lower pockets 18 and 19 extend downwardly therefrom. The pockets are of generally pyramidal configuration and act to increase the drag, making the wing a more effective brake.
The ski poles 13 and 14 are retained in respective pairs of upper and lower sheaths formed by hemming the cloth along its outer straight sides. The upper and lower sheaths for the pole 13 are indicated at 21 and 22, respectively; and for the pole 14, at 23 and 24, respectively. The sheaths of each pair have between them a substantial central space which provides a pole-gripping area so that the user may select his preferred gripping positions. For most uses, gripping the center of the poles is desirable so that the forces of the sail tending to rotate the device about the axis of the grips will be balanced and minimum torque will be exerted on the user's hands, thus giving the braking device an even and stable reaction to the wind which the skier creates by his forward movement while the wing or sail maintains a perpendicular alignment to the wind. Thus, the full effort of the skier may be used to hold the sail taut against the wind.
As shown in FIG. 2, the ski poles 13 and 14 are positioned with their handles within the upper sheaths 21 and 23, respectively, and are retained in position by straps 25 and 26, respectively, at the bottom of the sheaths 22 and 24, respectively. The straps 25 and 26 are each attached at one end to the sheath and are passed through the pole baskets 27 and 28, respectively, with the other end being attached to the sheath by a suitable fastener such as the "teasel-and-fleece-type" fastener available on the market under the trademark "Velcro." The straps are thus adjustable so that they may hold ski poles of various lengths within the range of adjustment and will hold the outer edges of the sail taut along the poles.
In the enlarged view, FIG. 5, the upper closed end of the sheath 21 is broken away to show the handle of the ski pole 13 at 29 and the hand strap at 30. In FIG. 6, the strap 25 for fastening the bottom of the ski pole is shown, the fastener being indicated at 25a; this fastening secures the pole within the sheaths during the use of the braking device. The front side of the sheath is cut away along a line 22a to expose the bottom of the rear inner side and make it easy to insert the end of the pole in the sheath.
As shown in FIG. 2, the two halves of the device are secured together by a central sail portion 31 which is shown as a part of the cross member 20. The belt 15 is attached to the lower end of the portion 31 so that the lower end of the central portion is secured to the skier's waist. During use of the sail, the central portion 31 is held against the user's body so that the braking force is applied over a substantial area of the body above the waist. The belt 15, which is shown partly broken away, also is preferably secured about the body by a Velcro fastener, one member of which is indicated at 32.
Reinforcing patches are sewn to the sail cloth at corners such as those at the inner ends of the sheaths adjacent the hand openings. The reinforcing corners are indicated at 33. The belt 15 may be constructed with an elongated pocket or pouch for containing the sail when it is not in use, the sail being folded to a size suitable for this purpose.
The beginning skier may find little use for the wing as its effects are not felt until a speed of nearly fifteen miles per hour is reached. The intermediate-to-expert skier, however, will discover a new element added to the sport as the skier's descent is eased by the wing. Its braking effect allows one to ski more down the fall line with improved balance while making easier and fewer turns. The legs are also relieved by having a portion of the upper body's weight supported by the wind as the skier leans on the wing. With arms outstretched and holding the stable wing, the skier finds his balance is improved, much as if he were holding a balance pole. It is a new pleasure to feel the wind press against the wing on the chest and arms producing a floating sensation and allowing the skier to address the slope as if it had fresh powder.
The wing is easy to control even if the skier should encounter a high and gusty wind. When desired, the braking effect can be eliminated by moving the hands to the topmost position allowed in the cutout and placing the hands in front of the chest.
An alternate position for the wing requires no change in the grip or belt. The skier simply holds the wing with the pole handles down and the pole tips behind his back. The wing thus pivots on the belt and extends from the waist to the upper thighs. The braking pressure is now felt below the waist while still allowing free use of the legs as the only fixed point of attachment is on the waist.
Landing and riding the ski lift can be easily and safely done with the wing on. The skier simply holds both poles in one hand and the wing remains unobtrusively between the poles and his waist with the other hand free to hold the lift.
If the use of the poles is needed to maneuver in the lift line or on a flat place, the skier simply unfastens the strap around the bottom of each pole and pulls the lower sheath partially up the pole. The pole handles can now be held over the wing material, and the skier has full range of his poles.
The modification of FIGS. 7, 8, and 9 is designed to provide an intensified braking effect and is intended for use by strong, expert skiers. Such skiers when using this modification will experience a slower, more floating sensation while employing their regular skiing style on steep slopes. This modification provides over twice the sail area of the first embodiment. In this modification, a single large scoop or pocket 34 is provided above the lower half of the braking device; the lower half, which is similar to the device of FIG. 2, is provided with two laterally spaced pockets 35 instead of the four pockets of FIG. 2. The pockets or scoops can be deeper in this larger version of the braking device. The opening between the upper and lower sheaths 36 and 37 on each outer edge of the sail provides the handhold which is central of each pole but is higher when in use than the handhold position of FIG. 2. As shown in FIG. 7, the axis of the handholds may be at the level of the skier's eyes. A balancing of the forces on the upper and lower portions is accomplished in essentially the same manner as with the device of FIG. 2.
The device as illustrated in FIG. 7 is provided with a pair of poles 38 longer than a pair of conventional ski poles and without tips or points and pole baskets. These poles may be of straight aluminum tubing.
The pockets 35 of the lower sail half are attached to a central, generally rectangular portion 39 which is positioned to rest against the skier's body during use. The upper pocket 34 is secured along its bottom edges to cross members 40, which are parallelograms extending upwardly from the upper half of the portion 39 toward the respective spaces between the sheaths 36 and 37. The upper pocket 34 is constructed of sections of cloth which form a truncated pyramid. The lower portion, indicated at 41, is of a generally diamond configuration. The side sections of the pocket 34, indicated at 42, and the top section 43 are of a trapezoidal configuration. The four sections are secured to respective sides of rectangular section 44.
The lower pockets 35 are constructed of sections of cloth in a manner similar to that of the pocket 34. Trapezoidal side sections 45 and generally triangular sections 46 and 47 are sewn to a rectangular center section 48 which is sewn along its inner edge to a section 49, which is a parallelogram.
The section 41 of the upper pocket 34 is provided with an opening 50 adjacent the body, engaging section 39 and the lower ends of the cross members 40. The top end of the section 39 is cut away to add to the size of the opening 50. The opening 50 is provided so that the skier may position his head on the front side of the section 41 and thus place the upper portion over and behind his head.
The device of FIG. 7 is secured to the skier's waist by a belt 15, which is provided, preferably, with the same type of fastening as the belt 15 of the first embodiment shown in FIG. 2. The belt 15 also may be provided with an elongated pouch to contain the folded sail when it is not in use.
When the braking device is being prepared for use, the poles 38 are inserted in the sheaths 37 and 36, respectively, at the bottom of sheaths 37. In FIG. 10, the sloping cut, line 37a, which exposes the rear inner side of sheath 37 at the front bottom edge, is provided to facilitate the insertion of the pole 38.
In order to retain the pole 38 in the sheath 37, a closure 52 is provided for the bottom end of the sheath 37 as shown in FIG. 10. The flap or closure 52 has a teasel and fleece fastener 53 attached to the inner face thereof a short distance from the outer edge of the flap or closure 52 so that a narrow portion of the inner face of the flap or closure 52 is exposed to provide a tab for grasping the flap or closure 52 while adhering the fastener 53 to, or unfastening the fastener 53 from, the fastener strip 54, attached to the lower end of the sheath 37 as indicated in FIG. 10. When the pole 38 is in place in the sheaths 37 and 36, the flap or closure 52 is closed over the fastener strip 54; and fasteners 53 and 54 are pressed together to adhere the flap or closure 52 to the sheath 37.
While the invention has been described in connection with specific embodiments, other modifications and applications will occur to those skilled in the art; therefore, it is not desired that the invention be limited to the specific modifications illustrated and described; but it is intended, by the appended claims, that the invention cover all modifications within the spirit and scope of the invention.
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An aerodynamic braking device comprises a sail having halves of equal area which are symmetrical about a central vertical axis and are balanced when held in the wind created during a skier's downhill run. The sail has straight outer edges remote from the axis and hems along the edges forming sheaths to receive ski poles or the like. The sheaths leave central areas in which the ski poles can be gripped, and the position of the grips is such that the areas above and below the line of the grips are equal so that the skier can effect counterbalancing of the wind forces above and below the line. Indented pockets or balloon areas enhance the braking effect and provide more effective balance and speed control. In use, the sail is held taut between the skier's outstretched hands and, with the counterbalancing of the forces and ease of manipulation of the sail, easy and effective control of the skier's descent can be accomplished.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation and claims priority to U.S. patent application Ser. No. 12/110,729 filed Apr. 28, 2008 for “METHODS AND SYSTEM FOR DISASSEMBLING A MACHINE,” which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] The field of the invention relates generally to gas turbine engines, and more particularly, to a system and methods for removing stator vane segments from a turbine engine.
[0003] At least some known gas turbine engines include, in serial flow arrangement, a high-pressure compressor for compressing air flowing through the engine, a combustor wherein fuel is mixed with the compressed air and ignited to form a high temperature gas stream, and a high pressure turbine. Hot combustion gases are channeled downstream from the combustor towards the turbine, wherein energy is extracted from the combustion gases for use in powering the compressor, as well as producing useful work to propel an aircraft in flight or to power a load, such as in an electrical generator. Some known gas turbine engines may also include a low-pressure compressor, or booster compressor, to supply compressed air to the high pressure compressor.
[0004] Known compressors include a compressor casing that may include upper and lower casing sections that are coupled about a rotor assembly. Known compressors include a plurality of alternating rows of circumferentially-spaced stator and rotor blades. Each row of rotor and stator blades includes a series of airfoils that each include a pressure side and a suction side that are coupled together at leading and trailing edges. Each stator blade airfoil extends radially inward from a stator support ring that is inserted into channels that are circumferentially formed in axial succession within a radially-inner side of the combustor casing. Each stator ring is sized and shaped to receive a plurality of stator blade segments that extend circumferentially in a row between a pair of adjacent rows of rotor blade assemblies.
[0005] During operation, leading and trailing edges and/or an outer tip of the stator blade may deteriorate or become damaged due to oxidation, thermal fatigue cracking, or erosion caused by abrasives and corrosives in the flowing gas stream. Over time such deterioration may cause some known stator blades to fail, resulting in the airfoil portion becoming detached from a dovetail portion of the blade. In some instances, blade failures have caused catastrophic damage within their engine. To facilitate mitigating such operational effects, blades are periodically inspected for damage, to enable a determination of an amount of damage and/or deterioration to be made. Blades are generally replaced if the damage and/or deterioration meets a certain pre-determined threshold. Alternatively, if the blades have not lost a substantial quantity of material, the blades may be repaired.
[0006] For example, at least one known method of replacing stator support ring segments requires the removal of the upper compressor section casing and rotor assemblies. Following rotor assembly removal, each stator blade segment is heated and after reaching a desired temperature, the segment is quenched to facilitate rapid cooling. Each segment is then withdrawn from its respective channel using, for example, a pneumatic peening hammer. A newly fabricated segment is then inserted into the casing channel. Alternatively, after being removed from the rotor assembly, each damaged or deteriorated segment is repaired and refurbished prior to being replaced within the casing channel. However, rotor assembly removal, reinsertion, and compressor reassembly may be a time-consuming and expensive process that may significantly increase repair time and power generator outages.
BRIEF DESCRIPTION OF THE INVENTION
[0007] In one aspect, a method for disassembling a rotary machine is provided. The method includes at least partially disassembling a casing of the rotary machine to provide access to an arcuate channel defined in the casing. The method also includes coupling a reaction bridge to the casing of the rotary machine. The reaction bridge includes a first leg, a second leg, and a support beam extending therebetween. The reaction bridge also includes a force device removably coupled to the reaction bridge. The method further includes engaging a segment positioned in the arcuate channel using a force device, applying a force to the segment such that the segment is repositioned within a portion of the arcuate channel, and removing the segment from the arcuate channel.
[0008] In another aspect, a system for disassembling a rotary machine is provided. The rotary machine includes a casing including a plurality of arcuate channels defined therein. The system includes a reaction bridge configured to removably couple to the casing of the rotary machine such that the reaction bridge is moveable along a length of the casing. The reaction bridge includes a front support and a rear support that is substantially parallel to the front support. Each of the front and rear supports include a first leg, a second leg, and a support beam extending therebetween. The system also includes a force device including an actuator and an engaging rod extending therefrom. The force device is removably coupled to the reaction bridge. The force device is configured to apply a force substantially tangentially to a segment positioned in one of the casing arcuate channels.
[0009] In yet another aspect, a method for disassembling a rotary machine is provided. The rotary machine includes a casing having an arcuate channel defined therein. The method includes applying an inward force to a segment positioned in the arcuate channel of the rotary machine using a first force device that is removably coupled to a reaction bridge. The reaction bridge is coupled to the casing of the rotary machine and includes a first leg, a second leg, and a support beam extending therebetween. The inward force is applied such the segment is repositioned within a portion of the arcuate channel. The method also includes determining that the segment is mechanically frozen within the channel, and applying an outward force to the segment using a second force device removably coupled to the reaction bridge such that the segment is further repositioned within a portion of the arcuate channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic view of an exemplary gas turbine engine;
[0011] FIG. 2 is an enlarged cross-sectional view of a portion of a compressor that may be used with the gas turbine engine shown in FIG. 1 and taken along area 2 ;
[0012] FIG. 3 is a perspective view of an exemplary stator blade ring segment that may be used with the compressor shown in FIG. 2 ;
[0013] FIG. 4 is a top view of an exemplary drilling system.
[0014] FIG. 5 a fragmentary elevation view of the drilling system shown in FIG. 4 .
[0015] FIG. 6 is an end perspective view of a segment removal system coupled to the compressor shown in FIG. 2 .
[0016] FIG. 7 is a side perspective view of the segment removal system coupled to the compressor shown in FIG. 2 .
[0017] FIG. 8 is an elevation view of an exemplary force device that may be used with the segment removal system shown in FIGS. 6 and 7 .
[0018] FIG. 9 is a side perspective view of the force device used with the segment removal system shown in FIGS. 6 and 7 .
[0019] FIG. 10 is an elevation view of a force device used with segment removal system shown in FIGS. 6 and 7 .
[0020] FIG. 11 is a side view of the force device shown in FIG. 10 and used with segment removal system shown in FIGS. 6 and 7 .
[0021] FIG. 12 is an assembly view of an exemplary clevis assembly used with the force device shown in FIGS. 10 and 11 .
[0022] FIG. 13 is a partial elevation view of the exemplary clevis assembly shown in FIG. 12 .
[0023] FIG. 14 is an elevation view of a pivot cradle assembly that may be used with the force device shown in FIGS. 10 and 11 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIG. 1 is a schematic illustration of an exemplary gas turbine engine 100 . Engine 100 includes a compressor 102 and a plurality of combustors 104 . Combustor 104 includes a fuel nozzle assembly 106 . Engine 100 also includes a turbine 108 and a common compressor/turbine rotor 110 (sometimes referred to as rotor 110 ).
[0025] FIG. 2 is an enlarged cross-sectional view of a portion of compressor 102 taken along area 2 (shown in FIG. 1 ). Compressor 102 includes a rotor assembly 112 and a stator assembly 114 that are positioned within a casing 116 that at least partially defines a flow path 118 in cooperation with at least a potion of a casing radially inner surface 119 . In the exemplary embodiment, rotor assembly 112 forms a portion of rotor 110 and is rotatably coupled to a turbine rotor (not shown). Rotor assembly 112 also partially defines an inner flow path boundary 120 of flow path 118 , and stator assembly 114 partially defines an outer flow path boundary 122 of flow path 118 , in cooperation with inner surface 119 . Alternatively, stator assembly 114 and casing 116 are formed as a unitary and/or integrated component (not shown).
[0026] Compressor 102 includes a plurality of stages 124 , wherein each stage 124 includes a row of circumferentially-spaced rotor blade assemblies 126 and a row of stator blade assemblies 128 , sometimes referred to as stator vanes. Rotor blade assemblies 126 are coupled to a rotor disk 130 such that each blade assembly 126 extends radially outwardly from rotor disk 130 . Moreover, each assembly 126 includes a rotor blade airfoil portion 132 that extends radially outward from a blade coupling portion 134 to a rotor blade tip portion 136 . Compressor stages 124 cooperate with a motive or working air including, but not limited to, air, such that the motive air is compressed in succeeding stages 124 .
[0027] Stator assembly 114 includes a plurality of rows of stator rings 137 , sometimes referred to as segmented stators, stator-in-rings, stator support rings, and/or stator dovetail rings. Rings 137 are inserted into passages or channels 139 that extend circumferentially, in axial succession, within at least a portion of casing 116 . Each channel 139 is defined to be substantially axially adjacent to a portion of casing 116 that is radially outward from and opposite rotor blade tip portions 136 . Each stator ring 137 is sized and shaped to receive a plurality of stator blade assemblies 128 such that each row of blade assemblies 128 is positioned between a pair of axially adjacent rows of rotor blade assemblies 126 . In the exemplary embodiment, each blade assembly 128 includes an airfoil portion 140 that extends from a stator blade dovetail portion (not shown in FIG. 2 ) to a stator blade tip portion 144 . Compressor 102 includes one row of stator vanes 138 per stage 124 , some of which are bleed stages (not shown in FIG. 2 ). Moreover, in the exemplary embodiment, compressor 102 is substantially symmetric about an axial centerline 152 .
[0028] In operation, compressor 102 is rotated by turbine 108 via rotor 110 . Air collected from a low pressure region 148 via a first stage of compressor 102 is channeled by rotor blade airfoil portions 132 towards airfoil portions 140 of stator blade assemblies 128 . The air is at least partially compressed and a pressure of the air is at least partially increased as the air is channeled through flow path 118 . More specifically, the air continues to flow through subsequent stages that are substantially similar to the first stage 124 with the exception that flow path 118 narrows with successive stages to facilitate compressing and pressurizing the air as it is channeled through flow path 118 . The compressed and pressurized air is subsequently channeled into a high pressure region 150 for use within turbine engine 100 .
[0029] FIG. 3 is a perspective view of an exemplary stator blade ring segment 154 that may be used with compressor 102 (shown in FIG. 2 ). In the exemplary embodiment, segment 154 includes a plurality of stator blade passages 156 that are each defined within segment 154 . Moreover, each passage 156 is sized and shaped to receive a stator blade assembly 128 therein. Each assembly 128 includes a stator blade dovetail portion 158 that enables stator blade assemblies 128 to be coupled to casing 116 via stator blade passages 156 . In the exemplary embodiment, each stator blade ring segment 154 is coupled to casing 116 via coupling methods that include, but are not limited to, a friction fit, the use of retention hardware (not shown), a welding process, and/or any other mechanical coupling means, and forming segments 154 integrally with casing 116 . A plurality of ring segments 154 are inserted into each channel 139 such that segments 154 extend substantially circumferentially within compressor casing 116 and such that circumferentially adjacent segments 154 abut each other. As such, ring segments 154 form at least a portion of outer path flow boundary 122 .
[0030] Referring to FIGS. 4 and 5 , FIG. 4 is a top view of an exemplary compressor 200 that includes a casing section 202 and an exemplary drilling system 203 . FIG. 5 is a fragmentary elevation view of compressor 200 and drilling system 203 , and illustrates five stator blade stages S 0 , S 1 , S 2 , S 3 and S 4 within casing section 202 . Arrow 204 represents an airflow direction through compressor 200 . In the exemplary embodiment, casing section 202 includes a first horizontal flange 206 and a second horizontal flange 208 that each extend radially outward from a mid compressor case 209 . Casing section 202 includes a plurality of channels 210 , including channel ends 211 , that are circumferentially defined in axial succession within at least a portion of casing section 202 . A plurality of blade segments 212 including stator blades (not shown) are inserted into each channel 210 such that segments 212 extend substantially circumferentially within casing section 202 and such that circumferentially adjacent segments 212 abut each other. In the exemplary embodiment, each channel 210 includes three segments 212 . Alternatively, each channel 210 may include any number of segments 212 that enables compressor 200 to function as described herein.
[0031] In preparation for removing blade segments 212 , at least one mounting plate 214 including a top surface 215 , is coupled to either first horizontal flange 206 and/or to second horizontal flange 208 . Mounting plate 214 includes a plurality of holes 216 that enable drilling system 203 to be coupled securely thereto, as described in detail below. A mounting plate inner surface 218 includes a series of recessed portions 220 that substantially align with channel ends 211 . Mounting plate inner surface 218 is aligned with segment inner surface 221 at a mating surface 222 and is coupled thereto. In the exemplary embodiment, mounting plate 214 is fabricated from steel. Alternatively, mounting plate 214 may be fabricated from any material that enables drilling system 203 to function as described herein.
[0032] In the exemplary embodiment, drilling system 203 includes at least one drill 230 , a bushing locator plate 232 , a plurality of drill guide bushings 234 and a plurality of fasteners 236 extending therebetween. Bushing locator plate 232 is sized to be positioned upon mounting plate top surface 215 such that plate 232 is substantially aligned with mounting plate 214 and such that a plurality of recessed sections 238 defined within plate 232 are aligned with mounting plate recessed portions 220 . In the exemplary embodiment, drill 230 is magnetically coupled to mounting plate 214 . Alternatively, drill 230 may be coupled to mounting plate 214 using any means that enables drill 230 to function as described herein. In the exemplary embodiment, drill guide bushings 234 are positioned at each channel end 211 , and coupled to bushing locator plate 232 via a plurality of fasteners 236 .
[0033] In operation, drilling system 203 facilitates removal of stator vane segment 212 . Specifically, in the exemplary embodiment, drill 230 forms a reference bore (not shown) in segment end 240 . Bushing locator plate 232 , drill guide bushings 234 , and fasteners 236 are then removed and drill 230 forms three holes (shown in FIG. 12 ) in segment end 240 that each extend from a predetermined depth. More specifically, in the exemplary embodiment, the three holes are bored into segment outer portion 241 , through stator blade dovetail portion 242 , and partially into an adjacent stator blade segment portion 244 .
[0034] Referring to FIGS. 6 and 7 , FIGS. 6 and 7 are a respective end perspective view and a side perspective view of compressor 200 with an exemplary segment removal system 300 installed. As described herein, compressor 200 includes casing section 202 and rotor 110 . In the exemplary embodiment, segment removal system 300 includes a reaction bridge 305 that includes a forward support 308 and rear support 310 that are substantially parallel to each other. Moreover, each support 308 , 310 includes a first leg 312 that includes an upper end 314 and a lower end 316 , a second leg 318 that includes an upper end 320 and a lower end 322 , and a support beam 323 that, in the exemplary embodiment, extends between upper end 314 and upper end 320 . In the exemplary embodiment, reaction bridge 305 is coupled to casing section 202 via mounting plate 214 . More specifically, and in the exemplary embodiment, lower end 316 is coupled to first horizontal flange 206 via mounting plate 214 , and lower end 322 is coupled to second horizontal flange 208 via mounting plate 214 , such that reaction bridge 305 extends over casing section 202 and rotor 110 . Moreover, in the exemplary embodiment, segment removal system 300 includes a pair of multi-position slides 324 that are each coupled to first leg upper end 314 and a pair of multi-position slides 324 that are coupled to second leg upper end 320 . Multi-position slides 324 each include a plurality of placement holes 326 , as described in more detail herein. Alternatively, segment removal system 300 may include any number of multi-position slides 324 that enables segment removal system 300 to function as described herein. In operation, reaction bridge 305 is movable along a length L 1 of mounting plate 214 , and is coupled to mounting plate 214 using holes 216 and at least one fastening mechanism (not shown).
[0035] Referring to FIGS. 8 and 9 , FIG. 8 is an elevation view of compressor 200 and segment removal system 300 , with an exemplary force device 400 installed. FIG. 9 is a side perspective view of compressor 200 and segment removal system 300 with force device 400 installed. In the exemplary embodiment, force device 400 includes an actuator 410 and an engaging rod 420 that extends therefrom. Rod 420 has a defined stoke length L 2 . In the exemplary embodiment, actuator 410 is a 75-ton hydraulic ram and force device has a 13 inch stroke length. Alternatively, force device 400 maybe any device that enables segment removal system 300 to function as described herein. Force device 400 is coupled to reaction bridge 305 via multi-position slide 324 . Specifically, multi-position slide 324 is configured, via placement holes 326 , to enable force device 400 to be positioned at a various positions along a length L 3 along multi-position slide 324 depending on a location of reaction bridge 305 relative to mounting plate 214 .
[0036] In operation, and in the exemplary embodiment, actuator 410 forces engaging rod 420 against segment outer end 240 (see FIGS. 4 and 5 ) to facilitate removing segment 212 from channel 210 . More specifically, in the exemplary embodiment, engaging rod 420 induces pressure substantially tangentially against segment end 240 for a stroke length L 2 . Upon achieving the maximum stroke length L2, engaging rod 420 is retracted and a mock segment 430 is inserted into segment 212 to enable force device 400 to maintain contact with the segment end 240 beyond the maximum stroke length L2. In the exemplary embodiment, actuator 410 then pushes engaging rod 420 to re-engage segment end 240 via mock segment 430 . In the exemplary embodiment, force is applied against segment end 240 until segment 212 is fully removed from channel 210 . Alternatively, force is applied to segment end 240 until segment 210 reaches a position where it may be pulled from channel 210 , as described herein.
[0037] Referring to FIGS. 10 and 11 , FIG. 10 is an elevation view of compressor 200 and segment removal system 300 , with an exemplary force device 500 installed. FIG. 11 is a side perspective view of compressor 200 and segment removal system 300 with force device 500 installed. In the exemplary embodiment, force device 500 includes an actuator 510 , a clevis assembly 512 and an engaging rod assembly 514 that extends therebetween. In the exemplary embodiment, actuator 510 is coupled to reaction bridge 305 and multi-position slide 324 via a pivot cradle assembly 516 . Actuator 510 includes an enclosed axial channel (not shown). In the exemplary embodiment, engaging rod assembly 514 includes a threaded rod 522 that includes a first end 524 and an opposite second end 526 and is coupled to actuator such that first end 524 extends through axial chamber (not shown) of actuator 510 and extends a length L 4 outward from actuator 510 . In the exemplary embodiment, attachment rod second end 526 is threadedly coupled to clevis assembly 512 , as described in detail herein. Moreover, in the exemplary embodiment, actuator 510 is a 30 ton hydraulic actuator. Alternatively, actuator 510 may be any pneumatic, mechanical or electrical actuator that enables segment removal system to function as described herein.
[0038] Referring to FIGS. 12 and 13 , FIG. 12 is an exploded view of an exemplary clevis assembly 512 . FIG. 13 is a partial elevation view of exemplary casing section 202 with exemplary clevis assembly 512 coupled to segment outer end 240 . In the exemplary embodiment, clevis assembly 512 includes a first component 602 , a second component 604 and a joint component 606 . First component 602 includes a first end 608 and a second end 610 and is threadedly coupled to attachment rod second end 526 via threaded hole 612 . In the exemplary embodiment, first component second end 610 includes a T-shaped extension 614 and mating hole 616 defined therein.
[0039] In the exemplary embodiment, second component 604 has a substantially rectangular cross-sectional profile and includes a first side 630 , a second side 632 , a third side 634 that is opposite first side 630 . Moreover, component 604 also includes a forth side 636 that is opposite second side 632 , and an upper portion 640 that includes an open channel 642 passing from second side 632 to fourth side 636 . Upper portion first side 630 and third side 634 each include a mating hole 644 defined therein that are aligned such that mating hole 644 extends through channel 642 . In the exemplary embodiment, channel 642 includes a lower surface 646 and second component 604 includes a bottom surface 648 . Three bolt holes 650 extend between channel lower surface 646 and bottom surface 648 . Bolt holes 650 enable second component 604 to be coupled to blade segment 212 to facilitate removing segment 212 from stator channels 210 .
[0040] Joint component 606 , in the exemplary embodiment, includes a cubic portion 660 and an extension portion 662 . Cubic portion 660 includes a first side 664 , a second side 666 , a third side 668 that is opposite first side 664 , and a fourth side 670 that is opposite second side 666 . Portion 660 also includes a mating hole 672 that extends from second side 666 to fourth side 670 . Cubic portion 660 includes an open channel 674 that extends from first side 664 to third side 668 , and that is sized and oriented to receive first component extension 614 such that first component mating hole 616 and cubic portion mating hole 672 are aligned and receive a first clevis pin 675 when assembled, such that components 602 and 606 are rotatable about pin 675 . Extension portion 662 includes a hole 676 defined therein. Second component open channel 642 is sized and oriented to receive joint component extension portion 662 and is oriented such that second component mating hole 644 and extension portion mating hole 676 are aligned to receive a second clevis pin 678 when assembled, such that components 604 and 606 are rotatable about pin 678 . In the exemplary embodiment, first clevis pin 675 and second clevis pin 678 are substantially perpendicular to each other.
[0041] FIG. 14 is an elevation view of actuator 510 with pivot cradle assembly 700 . Reaction bridge 702 includes a forward support 704 and rear support 706 that is substantially parallel to support 704 . A multi-position slide 708 is coupled to forward support 704 and to rear support 706 . A trunnion assembly 710 is coupled to a top surface 712 of each multi-position slide 708 . Trunnion assembly 710 includes a first support 720 , a second support 722 and a rotatable support 724 coupled therebetween. Rotatable support 724 includes a first side 726 , a second side 728 , a third side 730 that is opposite first side 726 , a fourth side 732 that is opposite second side 728 , a top surface 734 and a bottom surface 736 . In the exemplary embodiment, a trunnion pin (not shown) extends substantially perpendicularly outward from both second side 728 and fourth side 732 . First support 720 has a hole 738 defined therein that is sized to receive a second side trunnion pin (not shown). Similarly, second support 722 has a hole defined therein that is sized to receive fourth side trunnion pin (not shown).
[0042] Rotatable support 724 includes a channel (not shown) defined therein that extends from top surface 734 to bottom surface 736 and that is sized and oriented to receive threaded rod 522 . Actuator 510 is positioned against rotatable member top surface 734 such that actuator axial channel (not shown) and rotatable support channel (not shown) are substantially aligned. Threaded rod 522 is positioned within the actuator axial channel and the rotatable support channel such that a length extends L 3 from actuator 510 . An encapsulating bushing assembly 800 is coupled to the length L 3 of exposed rod 522 .
[0043] During operation, actuator 510 exerts a pulling force to threaded rod 522 , that, when coupled to segment outer end 240 , facilitates the removal of segment 212 from channel 210 . Encapsulating bushing assembly 800 is positioned upon the length of exposed threaded rod to facilitate preventing threaded rod 522 from disconnected from the system, should thread rod 522 experience a structural failure during operations. Pivot cradle assembly 700 and trunnion assembly 710 facilitate rotation of actuator 510 during operations.
[0044] The above-described methods and system provide a cost-effective and reliable means to facilitate the disassembly of gas turbine engine components. Specifically, stator vane segment removal may be accomplished without removing the rotor assembly from the engine. As such, system outage duration due to repairs may be significantly reduced. Additionally, the segment removal system described herein facilitates reducing segment removal time by enabling a user to quickly change from a segment pushing device to a segment pulling device.
[0045] Exemplary embodiments of a process and system for disassembling a machine, particularly removing stator vane sections from a gas turbine engine is described above in detail. The process and system are not limited to the specific embodiments described herein, but rather, steps of the process and components of the system may be utilized independently and separately from other steps and components described herein.
[0046] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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A system and methods for disassembling a rotary machine are provided. The rotary machine includes a casing having a plurality of arcuate channels. The system includes a reaction bridge that is configured to couple to the casing of the rotary machine such that the reaction bridge is moveable along a length of the casing. The reaction bridge includes a front support and a rear support that is substantially parallel to the front support. Each of the supports includes a first leg, a second leg, and a support beam extending therebetween. A force device including an actuator and an engaging rod extending therefrom is coupled to the reaction bridge. The force device is configured to apply a force substantially tangentially to a segment positioned in one of the casing arcuate channels.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. Ser. No. 13/671,559 filed 2012 Nov. 8, which is a continuation of U.S. Ser. No. 13/347,519 filed 2012 Jan. 10, which is a continuation of U.S. Ser. No. 12/941,035 filed 2010 Nov. 6, which is a continuation of U.S. Ser. No. 12/434,795 filed 2009 May 4, which is a continuation of U.S. Ser. No. 11/428,330 filed 2006 Jun. 30, which is a continuation of U.S. Ser. No. 10/711,990 filed 2004 Oct. 18, which claims the benefit of U.S. Provisional Application No. 60/481,871 filed 2004 Jan. 8, all of which are hereby incorporated herein by reference in their entirety.
BACKGROUND OF INVENTION
The invention relates to navigation system and more particularly to that of airplanes, space shuttles, gliders, railway trains, buses, taxis, and all other types of carriers and transportation systems.
U.S. Pat. No. 6,751,801 is introduced as a prior art of the present invention of which the summary is the following: ‘An aircraft in-flight entertainment system includes a satellite TV receiver, at least one video display connected to the receiver, and a multi-beam antenna on the aircraft for receiving signals from a plurality of satellite TV transponders. The multi-beam antenna may have right-hand circularly polarized (RHCP) and left-hand circularly polarized (LHCP) beams offset from one another by a beam offset angle. The beam offset angle may be less than an angle defined by the spacing of the DBS transponders. The system may also include an antenna steering positioner connected to the multi-beam antenna, and an antenna steering controller for steering the multi-beam antenna based upon received signals from at least one of the RHCP and LHCP beams. The antenna steering controller may comprise a processor for steering the multi-beam antenna based on a selected master one of the RHCP and LHCP beams and slaving the other beam therefrom. Alternately, the processor may steer the multi-beam antenna based on a predetermined contribution from each of the RHCP and LHCP beams.’
U.S. Pat. No. 6,512,921 is introduced as a prior art of the present invention of which the summary is the following: ‘A GSO satellite constellation (10) and an NGSO constellation (20) may be used to send various types of communication signals and multimedia signals to an aircraft (30). The video signals are demodulated by a demodulator (46) and routed by a router (64) to TV monitors (72 and 74), as well as short-term video storage (78). Data can be received and transmitted by a low gain, narrowband transmitter/receiver (100) in order to provide voice, computer and control communications at all times during the flight of aircraft (30).’
U.S. Pat. No. 6,208,307 is introduced as a prior art of the present invention of which the summary is the following: ‘An aircraft in-flight entertainment system includes an antenna, a satellite TV receiver connected to the antenna, at least one video display connected to the satellite TV receiver, and wherein the antenna is steered using received signals from the relatively wide bandwidth from at least one satellite TV transponder, such as a direct broadcast satellite (DBS) transponder. The system may include an antenna steering positioner connected to the antenna, and an antenna steering controller comprising the received signal detector for generating a received signal strength feedback signal based upon signals from the at least one satellite TV transponder. A processor may be connected to the detector for controlling the antenna steering positioner during aircraft flight and based upon the received signal strength feedback signal. The antenna steering controller may further comprise at least one inertial rate sensor, and the processor may calibrate the sensor based upon the received signal strength feedback signal. The antenna steering controller may also include a global positioning system (GPS) receiver connected to the processor, and the processor may further calibrate the rate sensor based upon the GPS receiver.’
U.S. Pat. No. 5,381,139 is introduced as a prior art of the present invention of which the summary is the following: ‘A detector system for a roll-stabilized aircraft includes a hollow rotatable toroidal ring within which a suitable sensor such as a TV sensor is fixed. The sensor observes the exterior of the aircraft through an observation window in the outer peripheral wall of the ring, which can be rotated about the roll axis of the aircraft. The apparatus includes appropriate instrumentation for determining the position relative to the aircraft of an object detected by the sensor.’
U.S. Pat. No. 5,195,709 is introduced as a prior art of the present invention of which the summary is the following: ‘A supporting structure for supporting a TV set on an armrest of a seat of an aircraft or other vehicle so that the TV set can be turned in a vertical plane between an operating position outside a cavity formed in the front portion of the armrest and a housing position within the cavity, can be turned about a vertical axis at the operating position, and can be tilted with respect to the vertical axis. The supporting structure includes a hinge mechanism provided at the front upper end of the cavity, and a turning mechanism supported on the hinge mechanism and supporting the TV set so that the TV set can be turned at the operating position in both horizontal and vertical planes. A hinge pin included in the hinge mechanism is provided at one end with a diametrical through hole expanding toward the opposite open ends. One end of a locking pin, included in a locking mechanism, engages one of the open ends of the diametrical through hole of the hinge pin when the hinge pin is at a first predetermined angular position and engages the other open end of the diametrical through hole when the hinge pin is at a second angular position differing from the first predetermined angular position by an angle of about 180.degree. The hinge mechanism is interlocked with a shock absorbing mechanism.’
U.S. Pat. No. 4,756,528 is introduced as a prior art of the present invention of which the summary is the following: ‘A video system incorporated into the back of a typical passenger seat, as on an airplane, bus, etc. The system includes a TV screen disposed normally in an upright position and recessed at least in part in the usual recess in a seat back. The arm rest of the seat next rearwardly carries various controls by means of which several modes of TV operation are available, along with the playing of music, commentaries and the like via cassettes in the arm rest, a master array of cassettes located centrally in the aircraft, disk drives, and improved power supply.’
U.S. Pat. No. 4,688,046 is introduced as a prior art of the present invention of which the summary is the following: ‘An aircraft locating system identifies on a TV format radar display the position of a specific aircraft based on an RF transmission from the aircraft on an RF channel. The locating system includes at least a pair of receive stations located within several miles of an airport and separated by a base line which is in near proximity to at least one runway at the airport or a theoretical extension thereof. Each receive station includes a passive receiver for determining a bearing angle to a source of RF on the RF channel for generating a signal representative of the bearing angle. The locating system further includes a processor which is responsive to bearing angle signals derived from the receive stations for generating line count and line delay information. The line count and line delay information correlate a position determined by the bearing angle signals from at least a pair of receive stations with a frame of reference of the TV display. The system further includes a video mixer which responds to two different input signals. A first input signal to the video mixer is a scan converted radar return signal. The second input signal to the video mixer is the line count and line delay information. The output of the video mixer is used to drive a video display. The video display, subjected to the two identified inputs can highlight a location identified by the line count and line delay information so that for example a person viewing the display would be able to identify which of perhaps plural radar returns shown on the display is associated with an aircraft which is actively transmitting on the RF channel.’
U.S. Pat. No. 4,630,821 is introduced as a prior art of the present invention of which the summary is the following: ‘There is disclosed a video game apparatus to be employed by a passenger of an airplane. The apparatus includes a tray which is mounted on the rear of an airplane seat. The tray has an internal hollow with a rectangular aperture on a top surface which surface faces the passenger when the tray is placed in a usable position. Located in the rectangular aperture is a TV display screen. Located in the internal hollow of the tray is a video game apparatus which operates to provide a video game display on the surface of said TV display screen. The surface of the tray containing the TV display screen also includes a plurality of control elements which are coupled to the video game apparatus to enable the passenger to operate the game. To energize the game, the tray contains a cable coupling assembly whereby when a cable is inserted into the assembly, the video game is energized to provide a display of a game selected by means of a selector switch also mounted on the top surface of the tray.’
U.S. Pat. No. 4,135,817 is introduced as a prior art of the present invention of which the summary is the following: ‘Apparatus for measuring an aircraft's horizontal speed and height above ground without the need for airborne cooperative devices. Two ground level TV cameras separated by a measured distance and pointed at zenith are placed in line with the projection of the expected path of the aircraft. Speed is determined by measuring the time that it takes the aircraft to travel between the fields of view of the two TV cameras using zenith crossings as the reference points. Height is determined by correlating the speed with the time required to cross the field of view of either of the two cameras.’
U.S. Pat. No. 3,945,716 is introduced as a prior art of the present invention of which the summary is the following: ‘A rotatable head up display system is provided to furnish target coorindate nformation to the pilot of an aircraft, for example. The head up display may be slaved to a FLIR or TV tracker to display the scene viewed thereby as well as the azimuth with respect to the aircraft. A small cathode ray tube is used for the display and the scene is viewed through a holographic lens so that the display appears at infinity focus. The pilot is also provided with means for controlling the aiming of the sensor (FLIR, TV, or the like).’
U.S. Patent Publication No. 20040078821 is introduced as a prior art of the present invention of which the summary is the following: ‘An aircraft in-flight entertainment system preferably includes, in one embodiment, a satellite TV receiver, at least one passenger video display connected to the receiver, and a processor connected to the receiver for determining an undesired condition and for generating a substitute image on the passenger video display rather than permit display of an undesired image which would otherwise be produced. The undesired condition may relate to a weak signal or component malfunction. Accordingly, the undesired image may be an undesired default text message or a degraded picture image. Other embodiments of the in-flight entertainment system are directed to providing a moving map image flight information channel integrated with the programming channels of the system.’
U.S. Patent Publication No. 20030200547 is introduced as a prior art of the present invention of which the summary is the following: ‘An aircraft in-flight entertainment system includes an adaptive antenna, a terrestrial television (TV) receiver connected to the adaptive antenna for receiving TV programming channels from more than one terrestrial TV transmitter, and at least one display connected to the terrestrial TV receiver. A controller is connected to the adaptive antenna for determining a desired terrestrial TV transmitter, and for directing the adaptive antenna towards the desired terrestrial TV transmitter. If a new desired terrestrial TV transmitter is determined by the controller, then the controller redirects the adaptive antenna towards the new desired terrestrial TV transmitter.’
U.S. Pat. No. 6,448,906 is introduced as a prior art of the present invention of which the summary is the following: ‘A device uses bluetooth techniques to communicate with electronic devices in an airplane. During take off or landing, the radio on board the airplane operates in bluetooth mode to send a global poll to all devices requesting that they respond. If a device responds, then it indicates that the device is on at an unauthorized time. This informs the crew that they should try to find the unauthorized device and turn it off.’
U.S. Pat. No. 6,321,084 is introduced as a prior art of the present invention of which the summary is the following: ‘To set up a telecommunication link to a person who is in a substantially enclosed facility such as an airplane, inside which there are several internal communication transmitting terminals operated by a private branch exchange of the facility, a personal call number is assigned to a private telecommunication transmitting terminal of the person in a public telecommunication network at least during the person's stay in the facility, the assignment is stored of his/her personal call number to the internal communication transmitting terminal assigned to the person during his/her stay in the facility. A call directed to the personal call number of the person is rerouted together with the personal call number or a corresponding ID to the private branch exchange. The internal communication transmitting terminal assigned to the personal call number/ID is then determined using the stored assignment and the call is forwarded to this internal communication transmitting terminal, whereby the person remains able to be reached under his/her personal call number.’
U.S. Pat. No. 6,285,878 is introduced as a prior art of the present invention of which the summary is the following: ‘A new use for the (already existing) fleets of commercial airline aircraft to replace low-earth orbit (LEO) communication satellites. This invention will provide low-cost, broadband wireless communication infrastructure among points-to-points accomplished by using and modifying existing, small, lightweight low power, low cost microwave relay station equipment onboard the commercial airline aircraft. Each equipped aircraft would have a broadband wireless communication link (within line-of-sight coverage ranges) to one or more neighboring aircraft or ground stations and form a chain of seamless airborne repeaters providing broadband wireless communication gateways along the entire flight path. Broadband wireless communication services also provide for customers onboard in-flight as well as customers overboard, along the line-of-sight ranges of flight path from the commercial airline aircraft.’
U.S. Pat. No. 5,950,129 is introduced as a prior art of the present invention of which the summary is the following: ‘A system and method for providing two-way in-flight radio telecommunications on board an aircraft is disclosed. The radio telecommunication system includes a Gateway Mobile Switching Center (G-MSC), an Aircraft In-flight System Controller (AISC) located on board a subscriber's aircraft, a Ground In-flight System Controller (GISC), a satellite to relay messages and calls from the GISC and AISC, and a Home Location Register (HLR) which provides routing and location information for use by the GISC and the G-MSC. In an alternate embodiment of the invention, a system and method for using a mobile phone on an aircraft is disclosed. A mobile phone is connected to a seat terminal located on an aircraft by a co-ax cable. The radio frequency (RF) signals produced by a mobile phone pass through a coax cable to an Airborne Radio Base Station (A-RBS). The A-RBS converts the RF signals into signals which do not interfere with the aircraft's navigational and communication equipment and are compatible with the GISC and multiple cellular networks. These converted signals are then transmitted via satellite to a cellular network.’
U.S. Pat. No. 5,559,865 is introduced as a prior art of the present invention of which the summary is the following: ‘The airborne communication system enables one or more radiotelephones to communicate with a ground based cellular radiotelephone system. In the preferred embodiment, the aircraft is equipped with a repeater that relays a signal from the airborne radiotelephone to the ground base station and vice versa. Alternate embodiments use an airborne base station to register the radiotelephones before registering them with the ground system. Alternately, the antennas on the ground could be used to form aerial cell sites by pointing the antennas upward to where the aircraft flies through the cells. The system of the present invention provides the additional benefit of enabling the ground based cellular radio systems to source a call to the aircraft radiotelephone.’
U.S. Pat. No. 5,519,761 is introduced as a prior art of the present invention of which the summary is the following: ‘The airborne radio communications system of the present invention enables an airborne radio to communicate with the ground based cellular radiotelephone system. The present invention also enables the ground based system to keep track of the location of the airborne radiotelephone and page it when a call from the ground based telephone system is received. The ground base station is connected to upward radiating antennas that form airborne cells. As the aircraft with the radio flies through the airborne cells, the airborne relay receives the signals from the base station and relays them to the radio. If the radio is transmitting signals, the relay transmits those signals, through the airborne cells, to the base station. As the aircraft moves from cell to cell, the radio is handed off to the next cell to maintain communications with the ground.’
U.S. Pat. No. 5,444,762 is introduced as a prior art of the present invention of which the summary is the following: ‘Directional antennae on aircraft and on cellular telephone base stations, having a polarity opposite that of potentially interfering ground system signals, minimize signal strength of air cellular signals received by ground cellular stations. Aircraft directional antennae comprise patch antennae or vertical arrays of loop elements or vertical arrays of virtual loop elements. Additionally, air cellular signals are switched to channels not currently in use by ground cellular systems.’
U.S. Pat. No. 5,408,515 is introduced as a prior art of the present invention of which the summary is the following: ‘A ground-to-air telephone calling system is provided including a computer for receiving an airborne telephone number and a call-back number from a calling party and forming the telephone numbers into a data signal comporting with existing protocol filed in the FCC, an uplink unit for uplinking the data signal to a satellite and a plurality of downlink stations for receiving the data signal from the satellite; a plurality of ground stations corresponding to each of the downlink units for receiving the data signals and passing a call signal identifying the airborne telephone and particular ground station to a corresponding transmit/receive unit for subsequent transmission to the aircraft; a call being initiated from the ground station to the calling party over the public switched telephone network if the aircraft responds to the call signal. An alternative embodiment provides for a plurality of telephones on board the aircraft, and is capable of directing a call from a ground based caller to a particular telephone assigned to a passenger on the aircraft.’
U.S. Pat. No. 5,123,112 is introduced as a prior art of the present invention of which the summary is the following: ‘An air-to-ground communications system is described for controlling multiple two way radiotelephone conversations between a large number of aircraft (53) and a network of base stations (51) that are capable of being interconnected to landline telephone networks (54, 116). Plural base station controllers (90) of the system, each dedicated to control one base station (51), are in turn controlled by a single central processor (52). Means are provided for matching each aircraft with an optimal base station to afford it the strongest available communication signals, and for dynamically allocating communication channels between the base stations. The central processor (52) is designed to manage the system by recording and recognizing usage patterns (525-530) and allocating channels to most efficiently use the available radio spectrum among all the aircraft (517, 519).’
U.S. Pat. No. 5,073,900 is introduced as a prior art of the present invention of which the summary is the following: ‘A cellular communications system is provided having both surface and satellite nodes which are fully integrated for providing service over large areas. A spread spectrum system is used with code division multiple access (CDMA) employing forward error correction coding (FECC) to enhance the effective gain and selectivity of the system. Multiple beam, relatively high gain antennas are disposed in the satellite nodes to establish the satellite cells, and by coupling the extra gain obtained with FECC to the high gain satellite node antennas, enough gain is created in the satellite part of the system such that a user need only use a small, mobile handset with a non-directional antenna for communications with both ground nodes and satellite nodes. User position information is also available. A digital data interleaving feature reduces fading.’
U.S. Pat. No. 5,067,172 is introduced as a prior art of the present invention of which the summary is the following: ‘An air-to-ground communications system wherein the communicating frequency channels are assigned dependent on the amplitude of the signals received at the base sites and dependent on the altitude of the aircraft.’
U.S. Pat. No. 4,607,389 is introduced as a prior art of the present invention of which the summary is the following: ‘The present invention is a communication system for transmitting an electrical signal from a transmission tower and includes a first transceiver located adjacent the base of the tower and which is in communication with a source of an electrical signal which is to be transmitted. An enclosure is removably located adjacent the top of the tower and includes a second transceiver for receiving the transmitted electrical signal from the first transceiver and a third transceiver for retransmitting the electrical signal from the tower. By this arrangement there is no need for stringing coaxial cable from a ground based transmitter to the antenna mounted to the top of the tower, thereby eliminating the power loss associated with the use of such coaxial cable. In one embodiment of the present invention, the second and third transceivers are conveyed to and from the top of the tower via a pulley arrangement for maintenance purposes, and in an alternate embodiment, the second and third transceivers are enclosed within a housing and are conveyed to and from the top of the tower within a conduit by means of compressed air.’
U.S. Pat. No. 4,419,766 is introduced as a prior art of the present invention of which the summary is the following: ‘An improved system and method for providing air/ground communications compatible with ground based telephone systems. The airborne equipment incorporates means for comparing signals received from various ground stations located along the flight path so as to allow the selection of the “best” signal to provide good telephone communications service for a reasonable length telephone conversation.’
U.S. Pat. No. 4,249,181 is introduced as a prior art of the present invention of which the summary is the following: ‘In cellular mobile radiotelephone systems employing reuse of a predetermined set of channels in adjacent iterations of a pattern of cells (FIG. 1), average signal-to-interference ratio in at least one cell region of interest is improved by tilting the antenna (11,12) gain pattern center-beam line of an antenna serving that region below the horizontal (FIG. 3). In one embodiment the tilt (.theta.) is sufficient to create a reduced-gain notch (FIG. 8) in the center-beam portion of the pattern.’
U.S. Patent Publication No. 20020160773 is introduced as a prior art of the present invention of which the summary is the following: ‘A system for permitting passengers on board an aircraft to send and receive electronic data is described. The components of the system on board the aircraft include a server having a plurality of nodes to which computer terminals are attached, as desired. The components of the system on board the aircraft include a wireless access point having a plurality nodes, where the wireless access point is attached to the server and to a plurality of wireless cards inserted into computer terminals, as desired. The computer terminals are laptop or palm-top personal computers belonging to the various passengers on board or fixed terminals within the aircraft. The server communicates with a wide variety of different terminals running different operating systems and with the access point. Each computer terminal is connected to the server via an aircraft cable or wireless network. Server has mass storage which contains a database of WWW pages which can be browsed by passengers using terminals. Server provides a domain name server (DNS) that masquerades as the passenger's usual DNS. Server then links the passenger to the appropriate locally stored WWW page. Server also contains storage for e-mail messages. Connected to server is one or more radios. This permits data to be transferred to base station using communications network. A virtual private network (VPN) connects station to communications service provider networks, web content processor, and via links to the Internet, including access to subscriber ISPs/corporate mail servers and other mail servers. Points of Presence (POP) provide Internet access and e-mail service to subscribers of the service while not on the aircraft. POPs can also be used by communications service provider networks and web content processors as an alternate means to connect to VPN.’
U.S. Patent Publication No. 20020168975 is introduced as a prior art of the present invention of which the summary is the following: ‘An electronic communication system for use onboard an aircraft includes a server and a plurality of input ports for connection with passenger computing devices. Passengers can send and retrieve electronic messages (e-mail and/or attachments) using a proxy-based web server access to the user's own e-mail service provider. The system receives proxy-based commands from the user's computing device and translates those commands into web-based commands that enable communication with the passenger's e-mail accounts. The passenger may send e-mail communications by composing a message on the passenger computing device and sending it via the web-based proxy server. E-mail messages may also be retrieved from one or more passenger e-mail accounts. In one embodiment, the system transmits only e-mail summary information to the airborne server and provides the summary information to the passenger. The passenger may select one or more e-mails and/or attachments for subsequent retrieval, thus limiting passenger expense for retrieval of unwanted or unnecessary e-mails and/or attachments. The system may also display cost information associated with uploading the e-mail and/or attachments to enable the passenger to select those desired messages for subsequent transmission.’
However, the foregoing pieces prior art do not disclose the vehicle, such as airplane, which comprises the internal wireless communicating device and the external antenna device, wherein the passenger(s) in the vehicle may access network (e.g., the Internet) via the internal wireless communicating device and the external antenna device.
SUMMARY
It is an object of the present invention to provide a transportation system which enables the passengers therein to allow wireless communication in a convenient manner.
It is another object of the invention to provide a transportation system which enables the passengers therein to use the communication devices they own while they are in such transportation system.
It is another object of the invention to provide a transportation system which enables to entertain the passengers therein while they are in such transportation system.
It is another object of the invention to provide a transportation system which provides more convenience to the passengers therein while they are in such transportation system.
It is another object of the invention to provide a transportation system which implements a plurality of functions, systems, and/or services provided to the passengers therein.
It is another object of the invention to provide a transportation system with a reliable security system installed therein.
It is another object of the invention to provide a commercially successful transportation system which attracts more users of such system.
The present invention introduces the transportation system, wherein the 1 st type data, the 2 nd type data, the 3 rd type data, and the 4 th type data, which are received by the internal wireless communicating system simultaneously, are transferred to the satellite via the external wireless communicating system simultaneously, wherein the 1 st type data and the 2 nd type data are transferred from the first wireless mobile device located in the transportation system, and the 3 rd type data and the 4 th type data are transferred from the second wireless mobile device located in the transportation system.
BRIEF DESCRIPTION OF DRAWINGS
The above and other aspects, features, and advantages of the invention will be better understood by reading the following more particular description of the invention, presented in conjunction with the following drawings, wherein:
FIG. 1 a is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 1 b is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 2 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 3 is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 4 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 5 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 6 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 7 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 8 a is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 8 b is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 9 is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 10 is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 11 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 12 a is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 12 b is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 13 is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 14 is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 15 is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 16 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 17 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 18 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 19 is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 20 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 21 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 22 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 23 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 24 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 25 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 26 is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 27 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 28 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 29 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 30 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 31 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 32 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 33 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 34 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 35 is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 36 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 37 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 38 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 39 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 40 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 41 is a simplified illustration illustrating an exemplary embodiment of the present invention.
FIG. 42 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 43 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 44 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 45 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 46 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 47 is a simplified illustration of data utilized in the present invention.
FIG. 48 is a simplified illustration of data utilized in the present invention.
FIG. 49 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 50 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 51 is a simplified illustration of the exemplary embodiment of the present invention.
FIG. 52 is a simplified illustration of the exemplary embodiment of the present invention.
FIG. 53 is a block diagram illustrating an exemplary embodiment of the present invention.
FIG. 54 is a simplified illustration of the exemplary embodiment of the present invention.
FIG. 55 is a digital information illustrating an exemplary embodiment of the present invention.
FIG. 56 a is a digital information illustrating an exemplary embodiment of the present invention.
FIG. 56 b is a digital information illustrating an exemplary embodiment of the present invention.
FIG. 56 c is a digital information illustrating an exemplary embodiment of the present invention.
FIG. 57 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 58 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 59 is a simplified illustration of the prior art of the present invention.
FIG. 60 is a simplified illustration of the prior art of the present invention.
FIG. 61 is a simplified illustration of the exemplary embodiment of the present invention.
FIG. 62 is a simplified illustration of the exemplary embodiment of the present invention.
FIG. 63 is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 64 a is a flowchart illustrating an exemplary embodiment of the present invention.
FIG. 64 b is a flowchart illustrating an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
The following description is of the best presently contemplated mode of carrying out the present invention. This description is not to be taken in a limiting sense but is made merely for the purpose of describing the general principles of the invention. For example, each description of random access memory in this specification illustrates only one function or mode in order to avoid complexity in its explanation, however, such description does not mean that only one function or mode can be implemented at a time. In other words, more than one function or mode can be implemented simultaneously by way of utilizing the same random access memory. In addition, the figure numbers are cited after the elements in parenthesis in a manner for example ‘RAM 206 (FIG. 1 )’. It is done so merely to assist the readers to have a better understanding of this specification, and must not be used to limit the scope of the claims in any manner since the figure numbers cited are not exclusive. There are only few data stored in each storage area described in this specification. This is done so merely to simplify the explanation and, thereby, to enable the reader of this specification to understand the content of each function with less confusion. Therefore, more than few data (hundreds and thousands of data, if necessary) of the same kind, not to mention, are preferred to be stored in each storage area to fully implement each function described herein. The scope of the invention should be determined by referencing the appended claims.
The following description is of the best presently contemplated mode of carrying out the present invention. This description is not to be taken in a limiting sense but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined by referencing the appended claims.
As illustrated in FIG. 1 a , Carrier 300 includes Computer 200 . Computer 200 is responsible of controlling the navigation of Carrier 300 . Here, Carrier 300 may be any carrier or transportation system designed to carry passenger(s), such as automobile, motorcycle, railway train, taxi, bus, space ship, space station.
FIG. 1 b illustrates the block diagram of the computer installed in the cockpit portion of Carrier 300 . CPU 211 controls and administers the overall function and operation of Computer 200 . CPU 211 uses RAM 206 to temporarily store data and/or to perform calculation to perform its function. RAM 206 is also used to store a plurality of data and programs necessary to perform the present invention. Video Generator 202 generates analogue and/or digital video signals which are displayed on Monitor 201 . Sound Generator 205 generates analogue and/or digital audio signals that are transferred to Speaker 204 . ROM 207 stores data and programs which are necessary to perform the present invention. Antenna 212 sends and receives communication data, location data and various types of wireless signals. Signal Processor 208 converts a stream of data produced by CPU 211 into a specific format (for example, data compression) in order to be sent by Antenna 212 in a wireless fashion, and also converts a stream of wireless data received by Antenna 212 into a specific format which is readable by CPU 211 . Input signals are input by Input Device 210 , such as keyboard, ON/OFF switch, joystick, and the signal is transferred to CPU 211 via Input Interface 209 and Data Bus 203 . Direction Controller 213 controls the direction of Carrier 300 ( FIG. 1 a ) in which Computer 200 is installed under the control and administration of CPU 211 . Altitude Controller 214 controls the altitude of Carrier 300 in which Computer 200 is installed under the control and administration of CPU 211 . Speed Controller 215 controls the speed of Carrier 300 in which Computer 200 is installed under the control and administration of CPU 211 . Angle Controller 216 controls the angle of Carrier 300 in which Computer 200 is installed under the control and administration of CPU 211 . GPS Navigation System 217 calculates and identifies the present location of Carrier 300 in the actual three-dimensional space by way of utilizing the method so-called GPS or global positioning system.
<<Three-Dimensional Map>>
As illustrated in FIG. 2 , RAM 206 includes Area 501 . Area 501 stores a three-dimensional map of the surface of the earth in a digital format. All of the objects stored as the part of the three-dimensional (3D) map reflect the actual objects exist in the real world, such as mountains, buildings, bridges, islands and other objects which have height of more than one foot above sea level. These objects are stored in Area 501 in three-dimensional format and height, width, and depth of each object are utilized for performing the present invention.
FIG. 3 illustrates the method of utilizing the three-dimensional (3D) map stored in Area 501 ( FIG. 2 ). In the example illustrated in FIG. 3 , several objects, such as buildings, exist in the three-dimensional space, i.e., Object 401 , Object 402 , Object 403 , Object 404 , and Object 405 . GPS Navigation System 217 ( FIG. 1 a ) identifies the actual location of Carrier 300 and applies the location data to the three-dimensional map stored in Area 501 . In the present example, the altitude of Carrier 300 exceeds the heights of Objects 401 , 402 , 403 , and 405 , but does not exceed the height of Object 404 . Assuming that all of these objects are located on the path of Carrier 300 . If Carrier 300 does not alter its course, it will result in colliding with Object 404 .
<<Auto Collision Avoiding Function>>
FIG. 4 illustrates the method of Carrier 300 to avoid colliding with any objects during actual flight before such flight is initiated. The destination data which represents the destination of Carrier 300 is manually input by Input Device 210 ( FIG. 1 b ) (S1). CPU 211 ( FIG. 1 b ) calculates the course to the destination based on the destination data and compares with the three-dimensional data stored in Area 501 of RAM 206 ( FIG. 2 ) (S2). If any of the objects stored in Area 501 , which is in the path of Carrier 300 , is higher than its navigation altitude (S3), CPU 211 outputs a warning sign and/or sound from Monitor 201 ( FIG. 1 b ) and/or Speaker 204 ( FIG. 1 b ) and cancels the input data input from Input Device 210 (S4).
FIG. 5 illustrates another method of Carrier 300 to avoid colliding with any objects during actual flight before such flight is initiated. The destination data which represents the destination of Carrier 300 is manually input by Input Device 210 ( FIG. 1 b ) (S1). CPU 211 ( FIG. 1 b ) calculates the course to the destination based on the destination data and compares with the three-dimensional data stored in Area 501 of RAM 206 ( FIG. 2 ) (S2). If any of the objects stored in Area 501 , which is in the path of Carrier 300 , is higher than its navigation altitude (S3), CPU 211 calculates an alternative course to the destination and outputs a notice sign and/or sound which indicates that the course has been altered from Monitor 201 ( FIG. 1 b ) and/or Speaker 204 ( FIG. 1 b ) (S4).
FIG. 6 illustrates the method of Carrier 300 to avoid colliding with any objects during actual flight after such flight is initiated. CPU 211 ( FIG. 1 b ) periodically checks the present location of Carrier 300 during flight by utilizing the navigation data received from GPS Navigation System 217 ( FIG. 1 b ) via Data Bus 203 ( FIG. 1 b ) ( 51 ). Such navigation data is periodically compared with the three-dimensional data stored in Area 501 of RAM 206 ( FIG. 2 ) (S2). If any of the objects stored in Area 501 , which is in the path of Carrier 300 , is higher than its navigation altitude (S3), CPU 211 outputs a warning sign and/or sound from Monitor 201 ( FIG. 1 b ) and/or Speaker 204 ( FIG. 1 b ) (S4).
FIG. 7 illustrates another method of Carrier 300 to avoid colliding with any objects during actual flight after such flight is initiated. CPU 211 ( FIG. 1 b ) periodically checks the present location of Carrier 300 during flight by utilizing the navigation data received from GPS Navigation System 217 ( FIG. 1 b ) vial Data Bus 203 ( FIG. 1 b ) (S1). Such navigation data is periodically compared with the three-dimensional data stored in Area 501 of RAM 206 ( FIG. 2 ) (S2). If any of the objects stored in Area 501 , which is in the path of Carrier 300 , is higher than its navigation altitude (S3), CPU 211 calculates an alternative course to the destination and outputs a notice sign and/or sound which indicates that the course has been altered from Monitor 201 ( FIG. 1 b ) and/or Speaker 204 ( FIG. 1 b ) (S4). If the alternative course is attempted to be overwritten by signal input from Input Device 210 ( FIG. 1 b ) (S5), CPU 211 cancels such input signal (S6).
<<Remote Controlling System>>
FIG. 8 a through FIG. 10 illustrate the remote controlling system of Carrier 300 .
As illustrated in FIG. 8 a and FIG. 8 b , Carrier 300 may be remotely controlled by Host H. Host H includes a computer system same or similar to Computer 200 ( FIG. 1 b ) which enables to remotely control Carrier 300 by signals input from input device same or similar to Input Device 210 ( FIG. 1 b ). When the remote controlling system is initiated, Host H which is located in a remote location sends a control signal to Carrier 300 in a wireless fashion (S1a). Carrier 300 periodically receives various types of signals via Antenna 212 ( FIG. 1 b ). The received signal is processed (e.g., decompressed) by Signal Processor 208 ( FIG. 1 b ) and is transferred to CPU 211 ( FIG. 1 b ) via Data Bus 203 ( FIG. 1 b ) (S1b). If CPU 211 determines that the received signal is a control signal produced by Host H (S2), all signals input from Input Device 210 ( FIG. 1 b ) thereafter are blocked and nullified (S3). CPU 211 sends Response Signal 601 (S4a), which is received by Host H (S4b). Then Host H sends a command signal (S5a), which is received by Carrier 300 in the manner described in S1b above (S5b). CPU 211 operates Carrier 300 in compliance with Command Signal 605 received from Host H (S7). The sequence of S4a through S7 is repeated until a cancellation signal which indicates to deactivate the remote controlling system is included in Command Signal 605 (S6). Once the remote controlling system is deactivated, signals input from Input Device 210 ( FIG. 1 b ) are valid thereafter and operation of Carrier 300 from its cockpit is resumed (S8).
FIG. 9 illustrates the basic structure of Response Signal 601 described in S4a and S4b in FIG. 8 a . Response Signal 601 is composed of Header 602 , Response Data 603 , and Footer 604 . Header 602 and Footer 604 indicate the beginning and end of Response Signal 601 . Response Data 603 includes data regarding the present altitude, speed, direction, and angle of Carrier 300 .
FIG. 10 illustrates the basic structure of Command Signal 605 described in S5a and S5b in FIG. 8 a . Command Signal 605 is composed of Header 606 , Command Data 607 , and Footer 608 . Header 606 and Footer 608 indicate the beginning and end of Command Signal 605 , respectively. Command Data 607 includes data regarding the renewed altitude, speed, direction, and angle of Carrier 300 . As another embodiment, Command Data 607 may include the data regarding destination instead. The remote controlling system is cancelled if Command Data 607 includes a cancellation signal instead of data regarding renewed altitude, speed, direction, and angle of Carrier 300 .
<<Emergency Landing System>>
FIG. 11 through FIG. 12 b illustrate the emergency landing system of Carrier 300 .
As illustrated in FIG. 11 , RAM 206 includes Area 502 . Area 502 stores a plurality of location data representing the locations of a plurality of airports. Here, the term airport includes any facility which is capable of landing airplanes, space shuttles, gliders, and any other carriers. In the present example, Location Data V represents the location of Airport #1, Location Data W represents the location of Airport #2, Location Data X represents the location of Airport #3, and Location Data Y represents the location of Airport #4. The plurality of location data are linked with three-dimensional map stored in Area 501 of RAM 206 ( FIG. 2 ), therefore, these location data can be identified on the three-dimensional map stored in Area 501 .
FIG. 12 a and FIG. 12 b illustrate the emergency landing system by utilizing the location data stored in Area 502 of RAM 206 ( FIG. 11 ). Host H which is located in a remote location sends a control signal to Carrier 300 in a wireless fashion (S1a). Carrier 300 periodically receives various types of signals via Antenna 212 ( FIG. 1 b ). The received signal is processed (e.g., decompressed) by Signal Processor 208 ( FIG. 1 b ) and transferred to CPU 211 ( FIG. 1 b ) via Data Bus 203 ( FIG. 1 b ) (S1b). If CPU 211 determines that the received signal is a control signal produced by Host H (S2), all signals input from Input Device 210 ( FIG. 1 b ) thereafter are blocked and nullified (S3). CPU 211 identifies the present location by utilizing GPS Navigation System 217 ( FIG. 1 b ) and compares with the location data stored in Area 502 of RAM 206 ( FIG. 11 ). CPU 211 selects the nearest airport and inputs the location data of the selected airport as the new destination (S5). Carrier 300 sends a response signal (S6a), which is received by Host H (S6b), and Carrier 300 initiates an automatic landing process to the location of the selected airport (S7). As another embodiment, the location data can be selected manually by utilizing Input Device 210 and render Input Device 210 remain activated only for that purposes, and select the nearest airport only when no airport was selected within a specified time. Or as another embodiment, Carrier 300 may select a predetermined location and initiate the automatic landing process thereto.
As another embodiment, the emergency landing system can be performed without involving Host H. This embodiment is not shown in any drawings. CPU 211 ( FIG. 1 b ) periodically checks the signal from Input Device 210 ( FIG. 1 b ). If an emergency signal is input from Input Device 210 which indicates that Carrier 300 must be landed at the nearest airport, all signals input from Input Device 210 ( FIG. 1 b ) thereafter are blocked and nullified. CPU 211 identifies the present location by utilizing GPS Navigation System 217 ( FIG. 1 b ) and compares with the location data stored in Area 502 of RAM 206 ( FIG. 11 ). CPU 211 selects the nearest airport and inputs the location data of the selected airport as the new destination and initiates an automatic landing process to the location of the selected airport. As another embodiment, the location data can be selected manually by utilizing Input Device 210 and render Input Device 210 remain activated only for that purposes, and select the nearest airport only when no airport was selected within a specified time. Or as another embodiment, Carrier 300 may select a predetermined location and initiate the automatic landing process thereto.
<<Connection Between Host H and Carrier 300 >>
FIG. 13 illustrates the first embodiment of the connection between Host H and Carrier 300 . As described in the present drawing, Host H and Carrier 300 are connected via Network NT, such as the Internet and Base Station BS. The data sent from Host H is transferred to Network NT, which forwards the data to Base Station BS. Base Station BS transfers the data to Carrier 300 in a wireless fashion. The data sent from Carrier 300 is transferred to Base Station BS in a wireless fashion, which forwards the data to Network NT. Network NT transfers the data to Host H.
FIG. 14 illustrates the second embodiment of the connection between Host H and Carrier 300 . As described in the present drawing, Host H and Carrier 300 are connected directly. The data sent from Host H is transferred directly to Carrier 300 in a wireless fashion, and vice versa.
FIG. 15 illustrates the third embodiment of the connection between Host H and Carrier 300 . As described in the present drawing, Host H and Carrier 300 are connected via three artificial satellites, i.e., Artificial Satellite AS 1 , Artificial Satellite AS 2 , and Artificial Satellite AS 3 . The data sent from Host H is transferred to Artificial Satellite AS 1 in a wireless fashion, which forwards the data to Artificial Satellite AS 2 in a wireless fashion. Artificial Satellite AS 2 forwards the data to Artificial Satellite AS 3 in a wireless fashion. Artificial Satellite AS 3 forwards the data to Carrier 300 in a wireless fashion. The data sent from Carrier 300 is transferred to Artificial Satellite AS 3 in a wireless fashion, which forwards the data to Artificial Satellite AS 2 in a wireless fashion. Artificial Satellite AS 2 forwards the data to Artificial Satellite AS 1 in a wireless fashion. Artificial Satellite AS 1 forwards the data to Host H in a wireless fashion.
<<3D Map Data Updating Function>>
FIGS. 16 through 30 illustrate the 3D map data updating function which updates the 3D map data stored in Carrier 300 .
FIG. 16 illustrates the storage area included in Host H. As described in the present drawing, Host H includes Navigation Information Storage Area H 01 a of which the data and the software program stored therein are described in FIG. 17 .
FIG. 17 illustrates the storage areas included in Navigation Information Storage Area H 01 a ( FIG. 16 ). As described in the present drawing, Navigation Information Storage Area H 01 a includes Navigation Data Storage Area H 01 b and Navigation Software Storage Area H 01 c . Navigation Data Storage Area H 01 b stores the data necessary to implement the present function on the side of Host H, such as the ones described in FIGS. 18 through 21 . Navigation Software Storage Area H 01 c stores the software program necessary to implement the present function on the side of Host H, such as the one described in FIG. 22 .
FIG. 18 illustrates the storage areas included in Navigation Data Storage Area H 01 b ( FIG. 17 ). As described in the present drawing, Navigation Data Storage Area H 01 b includes 3D Map Data Storage Area H 01 b 1 , Version Data Storage Area H 01 b 2 , and Work Area H 01 b 3 . 3D Map Data Storage Area H 01 b 1 stores the data described in FIGS. 19 and 20 . 3D Map Data Storage Area H 01 b 1 stores the same or similar data stored in Area 501 ( FIG. 2 ), which stores a three-dimensional map of the surface of the earth in a digital format. All of the objects stored as the part of the three-dimensional (3D) map reflect the actual objects exist in the real world, such as mountains, buildings, bridges, islands and other objects which have height of more than one foot above sea level. These objects are stored therein in three-dimensional format and height, width, and depth of each object are utilized for performing the present invention. Version Data Storage Area H 01 b 2 stores the data described in FIG. 21 . Work Area H 01 b 3 is utilized as a work area to perform calculation and temporarily store data.
FIG. 19 illustrates the 3D map data stored in Navigation Data Storage Area H 01 b ( FIG. 18 ). As described in the present drawing, the 3D map data is composed of nine blocks, i.e., 3D Area Block#1, 3D Area Block#2, 3D Area Block#3, 3D Area Block#4, 3D Area Block#5, 3D Area Block#6, 3D Area Block#7, 3D Area Block#8, and 3D Area Block#9.
FIG. 20 illustrates the data stored in 3D Map Data Storage Area H 01 b 1 ( FIG. 18 ). As described in the present drawing, 3D Map Data Storage Area H 01 b 1 comprises two columns, i.e., ‘3D Area ID’ and ‘3D Area Data’. Column ‘3D Area ID’ stores the 3D area IDs, and each 3D area ID is an identification of the corresponding 3D area data stored in column ‘3D Area Data’. Column ‘3D Area Data’ stores the 3D area data, and each 3D area data represents the three-dimensional data of the corresponding 3D area block described in the previous drawing figure. In the example described in the present drawing, 3D Map Data Storage Area H 01 b 1 stores the following data: the 3D area ID ‘3D Area#1’ and the corresponding 3D area data ‘3D Area Data#1’; the 3D area ID ‘3D Area#2’ and the corresponding 3D area data ‘3D Area Data#2’; the 3D area ID ‘3D Area#3’ and the corresponding 3D area data ‘3D Area Data#3’; the 3D area ID ‘3D Area#4’ and the corresponding 3D area data ‘3D Area Data#4’; the 3D area ID ‘3D Area#5’ and the corresponding 3D area data ‘3D Area Data#5’; the 3D area ID ‘3D Area#6’ and the corresponding 3D area data ‘3D Area Data#6’; the 3D area ID ‘3D Area#7’ and the corresponding 3D area data ‘3D Area Data#7’; the 3D area ID ‘3D Area#8’ and the corresponding 3D area data ‘3D Area Data#8’; and the 3D area ID ‘3D Area#9’ and the corresponding 3D area data ‘3D Area Data#9’.
FIG. 21 illustrates the data stored in Version Data Storage Area H 01 b 2 ( FIG. 18 ). As described in the present drawing, Version Data Storage Area H 01 b 2 comprises two columns, i.e., ‘3D Area ID’ and ‘Version Data’. Column ‘3D Area ID’ stores the data described in FIG. 20 . Column ‘Version Data’ stores the version data, and each version data represents the version of the 3D area data stored in 3D Map Data Storage Area H 01 b 1 ( FIG. 20 ) of the corresponding 3D area ID. In the example described in the present drawing, Version Data Storage Area H 01 b 2 stores the following data: the 3D area ID ‘3D Area#1’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#2’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#3’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#4’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#5’ and the corresponding version data ‘Version 2’; the 3D area ID ‘3D Area#6’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#7’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#8’ and the corresponding version data ‘Version 1’; and the 3D area ID ‘3D Area#9’ and the corresponding version data ‘Version 1’. In the present example, the version data of the 3D area ID ‘3D Area#5’ is ‘Version 2’ whereas the other version data of the 3D area IDs are ‘Version 1’. This means that the 3D area data corresponding to the 3D area ID ‘3D Area#5’, i.e., ‘3D Area Data#5’ stored in 3D Map Data Storage Area H 01 b 1 ( FIG. 20 ) should be updated.
FIG. 22 illustrates the software programs stored in Navigation Software Storage Area H 01 c ( FIG. 17 ). As described in the present drawing, Navigation Software Storage Area H 01 c stores 3D Area Data Updating Software H 01 c 1 . 3D Area Data Updating Software H 01 c 1 is the software program described in FIG. 30 .
FIG. 23 illustrates the storage area included in RAM 206 ( FIG. 2 ) of Carrier 300 . As described in the present drawing, RAM 206 includes Navigation Information Storage Area 20601 a of which the data and the software program stored therein are described in FIG. 24 .
FIG. 24 illustrates the storage areas included in Navigation Information Storage Area 20601 a ( FIG. 23 ). As described in the present drawing, Navigation Information Storage Area 20601 a includes Navigation Data Storage Area 20601 b and Navigation Software Storage Area 20601 c . Navigation Data Storage Area 20601 b stores the data necessary to implement the present function on the side of Carrier 300 , such as the ones described in FIGS. 25 through 28 . Navigation Software Storage Area 20601 c stores the software program necessary to implement the present function on the side of Carrier 300 , such as the one described in FIG. 29 .
FIG. 25 illustrates the storage areas included in Navigation Data Storage Area 20601 b ( FIG. 24 ). As described in the present drawing, Navigation Data Storage Area 20601 b includes 3D Map Data Storage Area 20601 b 1 , Version Data Storage Area 20601 b 2 , and Work Area 20601 b 3 . 3D Map Data Storage Area 20601 b 1 stores the data described in FIGS. 26 and 27 . 3D Map Data Storage Area 20601 b 1 stores the same or similar data stored in Area 501 ( FIG. 2 ), which stores a three-dimensional map of the surface of the earth in a digital format. All of the objects stored as the part of the three-dimensional (3D) map reflect the actual objects exist in the real world, such as mountains, buildings, bridges, islands and other objects which have height of more than one foot above sea level. These objects are stored therein in three-dimensional format and height, width, and depth of each object are utilized for performing the present invention. Version Data Storage Area 20601 b 2 stores the data described in FIG. 28 . Work Area 20601 b 3 is utilized as a work area to perform calculation and temporarily store data.
FIG. 26 illustrates the 3D map data stored in Navigation Data Storage Area 20601 b ( FIG. 25 ). As described in the present drawing, the 3D map data is composed of nine blocks, i.e., 3D Area Block#1, 3D Area Block#2, 3D Area Block#3, 3D Area Block#4, 3D Area Block#5, 3D Area Block#6, 3D Area Block#7, 3D Area Block#8, and 3D Area Block#9.
FIG. 27 illustrates the data stored in 3D Map Data Storage Area 20601 b 1 ( FIG. 25 ). As described in the present drawing, 3D Map Data Storage Area 20601 b 1 comprises two columns, i.e., ‘3D Area ID’ and ‘3D Area Data’. Column ‘3D Area ID’ stores the 3D area IDs, and each 3D area ID is an identification of the corresponding 3D area data stored in column ‘3D Area Data’. Column ‘3D Area Data’ stores the 3D area data, and each 3D area data represents the three-dimensional data of the corresponding 3D area block described in the previous drawing figure. In the example described in the present drawing, 3D Map Data Storage Area 20601 b 1 stores the following data: the 3D area ID ‘3D Area#1’ and the corresponding 3D area data ‘3D Area Data#1’; the 3D area ID ‘3D Area#2’ and the corresponding 3D area data ‘3D Area Data#2’; the 3D area ID ‘3D Area#3’ and the corresponding 3D area data ‘3D Area Data#3’; the 3D area ID ‘3D Area#4’ and the corresponding 3D area data ‘3D Area Data#4’; the 3D area ID ‘3D Area#5’ and the corresponding 3D area data ‘3D Area Data#5’; the 3D area ID ‘3D Area#6’ and the corresponding 3D area data ‘3D Area Data#6’; the 3D area ID ‘3D Area#7’ and the corresponding 3D area data ‘3D Area Data#7’; the 3D area ID ‘3D Area#8’ and the corresponding 3D area data ‘3D Area Data#8’; and the 3D area ID ‘3D Area#9’ and the corresponding 3D area data ‘3D Area Data#9’.
FIG. 28 illustrates the data stored in Version Data Storage Area 20601 b 2 ( FIG. 25 ). As described in the present drawing, Version Data Storage Area 20601 b 2 comprises two columns, i.e., ‘3D Area ID’ and ‘Version Data’. Column ‘3D Area ID’ stores the data described in FIG. 27 . Column ‘Version Data’ stores the version data, and each version data represents the version of the 3D area data stored in 3D Map Data Storage Area 20601 b 1 ( FIG. 27 ) of the corresponding 3D area ID. In the example described in the present drawing, Version Data Storage Area 20601 b 2 stores the following data: the 3D area ID ‘3D Area#1’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#2’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#3’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#4’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#5’ and the corresponding version data ‘Version 2’; the 3D area ID ‘3D Area#6’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#7’ and the corresponding version data ‘Version 1’; the 3D area ID ‘3D Area#8’ and the corresponding version data ‘Version 1’; and the 3D area ID ‘3D Area#9’ and the corresponding version data ‘Version 1’. In the present example, the version data of the 3D area ID ‘3D Area#5’ is ‘Version 2’ whereas the other version data of the 3D area IDs are ‘Version 1’. This means that the 3D area data corresponding to the 3D area ID ‘3D Area#5’, i.e., ‘3D Area Data#5’ stored in 3D Map Data Storage Area 20601 b 1 ( FIG. 27 ) should be updated.
FIG. 29 illustrates the software programs stored in Navigation Software Storage Area 20601 c ( FIG. 24 ). As described in the present drawing, Navigation Software Storage Area 20601 c stores 3D Area Data Updating Software 20601 c 1 . 3D Area Data Updating Software 20601 c 1 is the software program described in FIG. 30 .
FIG. 30 illustrates 3D Area Data Updating Software H 01 c 1 ( FIG. 22 ) of Host H ( FIG. 429 ) and 3D Area Data Updating Software 20601 c 1 ( FIG. 29 ) of Carrier 300 , which update the 3D area data stored in 3D Map Data Storage Area 20601 b 1 ( FIG. 23 ). Referring to the present drawing, Host H retrieves all version data from Version Data Storage Area H 01 b 2 ( FIG. 21 ) (S1). Host H sends the version data retrieved in the previous step, which are received by Carrier 300 (S2). CPU 211 ( FIG. 1 b ) of Carrier 300 stores the version data in Work Area 20601 b 3 ( FIG. 25 ) (S3). CPU 211 compares the version data stored in the previous step with the version data stored in Version Data Storage Area 20601 b 2 ( FIG. 24 ) (S4). CPU 211 identifies the 3D area ID of the latest version data in Version Data Storage Area 20601 b 2 ( FIG. 24 ) (e.g., 3D Area#5) and updates the version data thereof (S5). CPU 211 sends the 3D area ID (e.g., 3D Area#5) identified in the previous step, which is received by Host H (S6). Host H retrieves the 3D area data (e.g., 3D Area Data#5) of the corresponding 3D area ID (e.g., 3D Area#5) from 3D Map Data Storage Area H 01 b 1 ( FIG. 20 ), and sends the data To Carrier 300 (S7). CPU 211 of Carrier 300 receives the 3D area data (e.g., 3D Area Data#5), and stores the data in 3D Map Data Storage Area 20601 b 1 ( FIG. 23 ) (S8).
<<3D Map Data Updating Function—Summary>>
A carrier comprising a map data storage means, wherein said map data storage means stores a map data comprising a plurality of area data, said map data stores the data regarding a plurality of objects which reflect the real world, one or more of said plurality of area data are updated to the latest version, a destination data representing the destination of said carrier is input to said carrier, said carrier identifies a guiding-to-the-destination path which represents the path to the destination indicated by said destination data, and compares said guiding-to-the-destination path with said plurality of area data, and said carrier outputs a warning sign if an obstacle exists within said guiding-to-the-destination path of said carrier.
<<Auto Collision Avoiding Function—Other Embodiments>>
FIG. 31 illustrates another embodiment of the auto collision avoiding function described in FIG. 4 to avoid colliding with any object during actual flight before such flight is initiated, wherein Host H plays the major role in performing the present function. Referring to the present drawing, a destination data is input via Input Device 210 ( FIG. 1 b ) of Carrier 300 ( 51 ). Here, the destination data indications the destination of Carrier 300 in (x, y, z) format. CPU 211 of Carrier 300 sends the destination data, which is received by Host H (S2). Host H calculates the course to the destination based on the destination data and compares the destination data with the 3D map data stored in 3D Map Data Storage Area H 01 b 1 ( FIG. 20 ) (S3). If any of the objects stored in 3D Map Data Storage Area H 01 b 1 , which is in the path of Carrier 300 , is higher than its navigation altitude (S4), Host H sends a warning data, which is received by Carrier 300 (S5). Here, the warning data is the data indicating that one or more of obstacles are in its way. CPU 211 outputs a warning sign and/or sound from Monitor 201 ( FIG. 1 b ) and/or Speaker 204 ( FIG. 1 b ) and cancels the data input from Input Device 210 in 51 (S6).
FIG. 32 illustrates another embodiment of the auto collision avoiding function described in FIG. 5 to avoid colliding with any object during actual flight before such flight is initiated, wherein Host H plays the major role in performing the present function. Referring to the present drawing, a destination data is input via Input Device 210 ( FIG. 1 b ) of Carrier 300 ( 51 ). Here, the destination data indications the destination of Carrier 300 in (x, y, z) format. CPU 211 of Carrier 300 sends the destination data, which is received by Host H (S2). Host H calculates the course to the destination based on the destination data and compares the destination data with the 3D map data stored in 3D Map Data Storage Area H 01 b 1 ( FIG. 20 ) (S3). If any of the objects stored in 3D Map Data Storage Area H 01 b 1 , which is in the path of Carrier 300 , is higher than its navigation altitude (S4), Host H sends a warning data, which is received by Carrier 300 (S5). Here, the warning data is the data indicating that one or more of obstacles are in its way. CPU 211 calculates an alternative course to the destination and outputs a notice sign and/or sound which indicates that the course has been altered from Monitor 201 ( FIG. 1 b ) and/or Speaker 204 ( FIG. 1 b ) (S6).
FIG. 33 illustrates another embodiment of the auto collision avoiding function described in FIG. 6 to avoid colliding with any object during actual flight before such flight is initiated, wherein Host H plays the major role in performing the present function. Referring to the present drawing, CPU 211 ( FIG. 1 b ) checks the present location of Carrier 300 during flight by utilizing the navigation data received from GPS Navigation System 217 ( FIG. 1 b ) via Data Bus 203 ( FIG. 1 b ) ( 51 ). CPU 211 sends the X,Y,Z Location Data, which is received by Host H (S2). Here, the X,Y,Z Location Data is the data representing the current geographic location of Carrier 300 in (x, y, z) format. The navigation data is compared with the three-dimensional data stored in 3D Map Data Storage Area H 01 b 1 ( FIG. 20 ) (S3). If any of the objects stored in 3D Map Data Storage Area H 01 b 1 , which is in the path of Carrier 300 , is higher than its navigation altitude (S4), Host H sends a warning data, which is received by Carrier 300 (S5). CPU 211 outputs a warning sign and/or sound from Monitor 201 ( FIG. 1 b ) and/or Speaker 204 ( FIG. 1 b ) (S6). The foregoing sequence is performed periodically.
FIG. 34 illustrates another embodiment of the auto collision avoiding function described in FIG. 6 to avoid colliding with any object during actual flight before such flight is initiated, wherein Host H plays the major role in performing the present function. Referring to the present drawing, CPU 211 ( FIG. 1 b ) checks the present location of Carrier 300 during flight by utilizing the navigation data received from GPS Navigation System 217 ( FIG. 1 b ) via Data Bus 203 ( FIG. 1 b ) ( 51 ). CPU 211 sends the X,Y,Z Location Data, which is received by Host H (S2). Here, the X,Y,Z Location Data is the data representing the current geographic location of Carrier 300 in (x, y, z) format. The navigation data is compared with the three-dimensional data stored in 3D Map Data Storage Area H 01 b 1 ( FIG. 20 ) (S3). If any of the objects stored in 3D Map Data Storage Area H 01 b 1 , which is in the path of Carrier 300 , is higher than its navigation altitude (S4), Host H sends a warning data, which is received by Carrier 300 (S5). CPU 211 calculates an alternative course to the destination and outputs a notice sign and/or sound which indicates that the course has been altered from Monitor 201 ( FIG. 1 b ) and/or Speaker 204 ( FIG. 1 b ) (S6). If the alternative course is attempted to be overwritten by signal input from Input Device 210 ( FIG. 1 b ) (S7) CPU 211 cancels such input signal (S8).
<<Auto Collision Avoiding Function (Other Embodiments)—Summary>>
A navigation system comprising a host computer and a carrier, wherein said carrier periodically produces a location data of said carrier, said host computer stores a plurality of three-dimensional data regarding a plurality of three-dimensional objects which reflect the objects in the real world, said host computer compares the path of said carrier with said plurality of three-dimensional data, and a warning sign is output if one or more of said three-dimensional objects are within said path of said carrier thereby avoiding said carrier to collide one or more of said objects in the real world.
<<Satellite TV Function>>
FIG. 35 through 50 illustrate the satellite TV function which enables the passengers of Carrier 300 to enjoy watching satellite TV programs at their seats.
FIG. 35 illustrates the major elements utilized to implement the present function. As described in the present drawing, Carrier 300 comprises Satellite Dish 300021 , Computer 200 , Terminal T 02 , and Seat ST 02 (for the avoidance of doubt, a plurality of Seat ST 02 may be installed in Carrier 300 ). Satellite Dish 300021 is an antenna to receive Satellite TV Signal STVS 02 described in FIG. 47 which is sent from Artificial Satellite AS 3 ( FIG. 15 ). Computer 200 described hereinbefore distributes TV data to Terminal T 02 . Terminal T 02 is a small computer which comprises a display and a speaker to output the TV data. Seat ST 02 is a seat for a passenger to sit while travelling by Carrier 300 . Terminal T 02 is located in front of or next to Seat ST 02 within the range at which the passenger sitting on Seat ST 02 is enabled to watch the display of Terminal T 02 . The distance between Terminal T 02 and Seat ST 02 may be in the range of 30 cm and 10 m. One Terminal T 02 may be shared by more than one passenger.
FIG. 36 illustrates the storage area included in RAM 206 of Computer 200 installed in Carrier 300 . As described in the present drawing, RAM 206 includes Satellite TV Information Storage Area 20602 a of which the data and the software programs stored therein are described in FIG. 37 .
FIG. 37 illustrates the storage areas included in Satellite TV Information Storage Area 20602 a ( FIG. 36 ). As described in the present drawing, Satellite TV Information Storage Area 20602 a includes Satellite TV Data Storage Area 20602 b and Satellite TV Software Storage Area 20602 c . Satellite TV Data Storage Area 20602 b stores the data necessary to implement the present function on the side of Computer 200 , such as the ones described in FIGS. 38 through 39 . Satellite TV Software Storage Area 20602 c stores the software programs necessary to implement the present function on the side of Computer 200 , such as the ones described in FIG. 40 .
FIG. 38 illustrates the storage areas included in Satellite TV Data Storage Area 20602 b ( FIG. 37 ). As described in the present drawing, Satellite TV Data Storage Area 20602 b includes TV Data Storage Area 20602 b 1 and Work Area 20602 b 2 . TV Data Storage Area 20602 b 1 stores the data described in FIG. 39 . Work Area 20602 b 2 is utilized as a work area to perform calculation and temporarily store data.
FIG. 39 illustrates the data stored in TV Data Storage Area 20602 b 1 ( FIG. 38 ). As described in the present drawing, TV Data Storage Area 20602 b 1 comprises two columns, i.e., ‘Channel ID’ and ‘TV Data’. Column ‘Channel ID’ stores the channel IDs, and each channel ID is an identification of the corresponding TV data stored in column ‘TV Data’. Each channel ID is composed of numeric data designed to be displayed on LCD T 201 ( FIG. 41 ) of Terminal T 02 ( FIG. 35 ). Column ‘TV Data’ stores the TV data, and each TV data is a video data designed to be output from LCD T 201 ( FIG. 41 ) and Speaker 216 ( FIG. 41 ) of Terminal T 02 ( FIG. 35 ). In the example described in the present drawing, TV Data Storage Area 20602 b 1 stores the following data: the channel ID ‘Channel#1’ and the corresponding TV data ‘TV Data#1’; the channel ID ‘Channel#2’ and the corresponding TV data ‘TV Data#2’; the channel ID ‘Channel#3’ and the corresponding TV data ‘TV Data#3’; and the channel ID ‘Channel#4’ and the corresponding TV data ‘TV Data#4’.
FIG. 40 illustrates the software programs stored in Satellite TV Software Storage Area 20602 c ( FIG. 37 ). As described in the present drawing, Satellite TV Software Storage Area 20602 c stores TV Data Receiving Software 20602 c 1 and TV Data Displaying Software 20602 c 2 . TV Data Receiving Software 20602 c 1 is the software program described in FIG. 49 . TV Data Displaying Software 20602 c 2 is the software program described in FIG. 50 .
FIG. 41 illustrates the major elements included in Terminal T 02 . As described in the present drawing, Terminal T 02 includes CPU T 211 , RAM T 206 , LCD T 201 , and Speaker T 216 . CPU T 211 controls and administers the overall function and operation of Computer 200 . CPU T 211 utilizes RAM T 206 to temporarily store data, perform calculation to perform its own function, and/or implement the present function. LCD T 201 is a monitor to output video data of TV data ( FIG. 39 ). Speaker T 216 is a speaker to output audio data of TV data ( FIG. 39 ).
FIG. 42 illustrates the storage area included in RAM T 206 ( FIG. 41 ) of Terminal T 02 . As described in the present drawing, RAM T 206 includes Satellite TV Information Storage Area T 20602 a of which the data and the software programs stored therein are described in FIG. 43 .
FIG. 43 illustrates the storage areas included in Satellite TV Information Storage Area T 20602 a ( FIG. 42 ). As described in the present drawing, Satellite TV Information Storage Area T 20602 a includes Satellite TV Data Storage Area T 20602 b and Satellite TV Software Storage Area T 20602 c . Satellite TV Data Storage Area T 20602 b stores the data necessary to implement the present function on the side of Terminal T 02 , such as the ones described in FIGS. 44 and 45 . Satellite TV Software Storage Area T 20602 c stores the software programs necessary to implement the present function on the side of Terminal T 02 , such as the one described in FIG. 46 .
FIG. 44 illustrates the storage areas included in Satellite TV Data Storage Area T 20602 b ( FIG. 43 ). As described in the present drawing, Satellite TV Data Storage Area T 20602 b includes TV Data Storage Area T 20602 b 1 and Work Area T 20602 b 2 . TV Data Storage Area T 20602 b 1 stores the data described in FIG. 45 . Work Area T 20602 b 2 is utilized as a work area to perform calculation and temporarily store data.
FIG. 45 illustrates the data stored in TV Data Storage Area T 20602 b 1 ( FIG. 44 ). As described in the present drawing, TV Data Storage Area T 20602 b 1 comprises two columns, i.e., ‘Channel ID’ and ‘TV Data’. Column ‘Channel ID’ stores the channel IDs, and each channel ID is an identification of the corresponding TV data stored in column ‘TV Data’. Each channel ID is composed of numeric data designed to be displayed on LCD T 201 ( FIG. 41 ) of Terminal T 02 ( FIG. 35 ). Column ‘TV Data’ stores a TV data which is the audiovisual data designed to be output from LCD T 201 ( FIG. 41 ) and Speaker T 216 ( FIG. 41 ) of Terminal T 02 ( FIG. 35 ). In the example described in the present drawing, TV Data Storage Area 20602 b 1 stores the following data: the channel ID ‘Channel#1’ and the corresponding TV data ‘TV Data#1’. The TV data corresponding to the rest of the channel IDs are blank, which indicates that the passenger is currently watching TV Data#1 represented by Channel#1.
FIG. 46 illustrates the software programs stored in Satellite TV Software Storage Area T 20602 c ( FIG. 43 ). As described in the present drawing, Satellite TV Software Storage Area T 20602 c stores TV Data Displaying Software 20602 c 2 . TV Data Displaying Software 20602 c 2 is the software program described in FIG. 50 .
FIG. 47 illustrates Satellite TV Signal STVS 02 sent from Artificial Satellite AS 3 ( FIG. 15 ), which is received by Carrier 300 . As described in the present drawing, Satellite TV Signal STVS 02 includes Header STVS 02 a , Channel ID&TV Data Signal STVS 02 b , and Footer STVS 02 c . Header STVS 02 a and Footer STVS 02 c indicate the start and end of Satellite TV Signal STVS 02 , respectively. Channel ID&TV Data Signal STVS 02 b is the data described in FIG. 48 .
FIG. 48 illustrates the data included in Channel ID&TV Data Signal STVS 02 b ( FIG. 47 ). As described in the present drawing, Channel ID&TV Data Signal STVS 02 b includes Channel#1, TV Data#1, Channel#2, TV Data#2, Channel#3, TV Data#3, Channel#4, and TV Data#4. The TV data ‘TV Data#1’ is stored in TV Data Storage Area 20602 b 1 ( FIG. 39 ) of Computer 200 at the corresponding channel ID ‘Channel#1’; the TV data ‘TV Data#2’ is stored in TV Data Storage Area 20602 b 1 ( FIG. 39 ) at the corresponding channel ID ‘Channel#2’; the TV data ‘TV Data#3’ is stored in TV Data Storage Area 20602 b 1 ( FIG. 39 ) at the corresponding channel ID ‘Channel#3’; and the TV data ‘TV Data#4’ is stored in TV Data Storage Area 20602 b 1 ( FIG. 39 ) at the corresponding channel ID ‘Channel#4.
FIG. 49 illustrates TV Data Receiving Software 20602 c 1 ( FIG. 40 ) of Computer 200 , which receives and stores Channel ID&TV Data Signal STVS 02 b ( FIG. 48 ) sent from Artificial Satellite AS 3 ( FIG. 15 ). Referring to the present drawing, Carrier 300 receives Satellite TV Signal STVS 02 ( FIG. 47 ) via Satellite Dish 300021 ( FIG. 35 ) from Artificial Satellite AS 3 ( FIG. 15 ), which is stored in Work Area 20602 b 2 ( FIG. 38 ) ( 51 ). Computer 200 of Carrier 300 retrieves Channel ID&TV Data Signal STVS 02 b ( FIG. 48 ) from Satellite TV Signal STVS 02 ( FIG. 47 ) (S2). Computer 200 refers to the channel IDs and stores the TV data at the corresponding channel ID in TV Data Storage Area T 20602 b 1 ( FIG. 45 ) (S3). The foregoing sequence is performed periodically.
FIG. 50 illustrates TV Data Displaying Software 20602 c 2 ( FIG. 40 ) of Computer 200 and TV Data Displaying Software T 20602 c 2 ( FIG. 46 ) of Terminal T 02 , which display TV data on LCD T 201 ( FIG. 41 ). Referring to the present drawing, the passenger sitting on Seat ST 02 ( FIG. 35 ) selects the channel ID (e.g., Channel#1) via an input device (not shown) of Terminal T 02 and selects ID is displayed on LCD T 201 ( 51 ). CPU T 211 ( FIG. 41 ) of Terminal T 02 sends the channel ID selected in the previous step (e.g., Channel#1), which is Received by Computer 200 (S2). Computer 200 retrieves the TV data (e.g., TV Data#1) corresponding to the channel ID identified in the previous step (e.g., Channel#1) from TV Data Storage Area 20602 b 1 ( FIG. 39 ) (S3). Computer 200 sends the TV data retrieved in the previous step (e.g., TV Data#1), which is received by Terminal T 02 (S4). CPU T 211 stores the TV data in Work Area T 20602 b 2 ( FIG. 44 ) (S5). CPU T 211 retrieves the TV data from Work Area T 20602 b 2 ( FIG. 44 ) and displays the data on LCD T 201 ( FIG. 41 ) (S6).
<<Satellite TV Function—Summary>>
(1) A carrier comprising a satellite dish, storage area and a terminal, wherein a plurality of TV data is received by said satellite dish in a wireless fashion, said plurality of TV data are stored in said storage area, a certain TV data identified by a channel ID selecting signal input to said terminal is retrieved from said storage area, and said certain TV data is output from said terminal.
(2) The carrier of summary (1), wherein said carrier further comprises a seat, and said terminal is located adjacent to said seat.
(3) The carrier of summary (1), wherein said carrier further comprises a seat, and said terminal is located adjacent to said seat, thereby enables the passenger sitting on said seat is able to operate said terminal.
(4) The carrier of summary (1), wherein said carrier is an airplane.
(5) The carrier of summary (1), wherein said carrier is an automobile.
<<Wireless Communication Facilitating System>>
FIGS. 51 through 64 b illustrate the method of enabling the passengers in Carrier 300 to perform wireless communication in a convenient manner.
FIG. 51 describes the general idea of the system in which the present invention is utilized. Referring to FIG. 51 , Carrier 300 is connected to Ground Host GH which is located on the ground by having the communication data sent therefrom routed by Artificial Satellites AS 1 , AS 2 , and AS 3 . Artificial Satellite AS 1 is connected to Artificial Satellite AS 2 , Artificial Satellite AS 2 is connected to Artificial Satellite AS 3 , and Artificial Satellite AS 3 is connected to Ground Host GH in a wireless manner, respectively. Ground Host GH is connected to Network NT, such as the Internet, by phone line, cable or any other non-wireless methods. Here, Ground Host GH is a computer located on the ground or on the surface of the earth which functions as a gateway or an entrance to Network NT. Ground Host GH may be substituted by Host H described hereinbefore. Carrier 300 is enabled to contact Network NT by way of connecting to the nearest artificial satellite, which is Artificial Satellite AS 1 in the present example.
FIG. 52 describes the structure of Carrier 300 shown in FIG. 51 . As described in FIG. 52 , Carrier 300 has two major cabins, i.e. Operating Cabin OC and Main Cabin MC. Operating Cabin OC is primarily utilized for operating and controlling Carrier 300 , and Main Cabin MC is primarily utilized for carrying a plurality of passengers. Computer 200 is a computer which is utilized for operating and controlling Carrier 300 by control signals input from Operating Cabin OC and for implementing the present invention which is discussed in details hereinafter. Computer 200 is located adjacent to Operating Cabin OC. Operating Cabin OC may or may not have pilots or drivers to manoeuvre Carrier 300 . If no pilots or drivers are present in Operating Cabin OC, Computer 200 is responsible for the overall control of Carrier 300 .
FIG. 53 illustrates another embodiment of Computer 200 described in FIG. 1 b to perform the present system. Referring to FIG. 53 , CPU 211 controls and administers the overall function and operation of Computer 200 . CPU 211 uses RAM 206 to temporarily store data and/or to perform calculation to perform its function. RAM 206 is also used to store a plurality of data and programs necessary to perform the present invention which are utilized by CPU 211 for calculation. Video Generator 202 generates analogue and/or digital video signals which are displayed on Monitor 201 . Sound Generator 205 generates analogue and/or digital audio signals that are transferred to Speaker 204 . ROM 207 stores data and programs which are necessary for CPU 211 to control and administer the overall function and operation of Computer 200 . Transmitters TR 1 and TR 2 send and receive communication data, location data and various types of wireless signals. Signal Processor 208 converts a stream of data produced by CPU 211 into a specific format (for example, data compression) in order to be sent by Transmitters TR 1 and/or TR 2 in a wireless fashion, and also converts a stream of wireless data received by Transmitters TR 1 and/or TR 2 into a specific format which is readable by CPU 211 . Input signals, most of which are to manoeuvre Carrier 300 ( FIG. 52 ), are input by Input Device 210 , such as keyboard, ON/OFF switches, joysticks, and such signals are transferred to CPU 211 via Input Interface 209 and Data Bus 203 . Direction Controller 213 controls the direction of Carrier 300 under the control and administration of CPU 211 . Altitude Controller 214 controls the altitude of Carrier 300 under the control and administration of CPU 211 . Speed Controller 215 controls the speed of Carrier 300 under the control and administration of CPU 211 . Angle Controller 216 controls the angle of Carrier 300 under the control and administration of CPU 211 . GPS Navigation System 217 calculates and identifies the present geographic location of Carrier 300 in the actual three-dimensional space by way of utilizing the method so-called “GPS” or “global positioning system”. Such function can be enabled by the technologies primarily introduced in the following inventions and the references cited thereof: U.S. Pat. No. 6,429,814; U.S. Pat. No. 6,427,121; U.S. Pat. No. 6,427,120; U.S. Pat. No. 6,424,826; U.S. Pat. No. 6,415,227; U.S. Pat. No. 6,415,154; U.S. Pat. No. 6,411,811; U.S. Pat. No. 6,392,591; U.S. Pat. No. 6,389,291; U.S. Pat. No. 6,369,751; U.S. Pat. No. 6,347,113; U.S. Pat. No. 6,324,473; U.S. Pat. No. 6,301,545; U.S. Pat. No. 6,297,770; U.S. Pat. No. 6,278,404; U.S. Pat. No. 6,275,771; U.S. Pat. No. 6,272,349; U.S. Pat. No. 6,266,012; U.S. Pat. No. 6,259,401; U.S. Pat. No. 6,243,647; U.S. Pat. No. 6,236,354; U.S. Pat. No. 6,233,094; U.S. Pat. No. 6,232,922; U.S. Pat. No. 6,211,822; U.S. Pat. No. 6,188,351; U.S. Pat. No. 6,182,927; U.S. Pat. No. 6,163,567; U.S. Pat. No. 6,101,430; U.S. Pat. No. 6,084,542; U.S. Pat. No. 5,971,552; U.S. Pat. No. 5,963,167; U.S. Pat. No. 5,944,770; U.S. Pat. No. 5,890,091; U.S. Pat. No. 5,841,399; U.S. Pat. No. 5,808,582; U.S. Pat. No. 5,777,578; U.S. Pat. No. 5,774,831; U.S. Pat. No. 5,764,184; U.S. Pat. No. 5,757,786; U.S. Pat. No. 5,736,961; U.S. Pat. No. 5,736,960; U.S. Pat. No. 5,594,454; U.S. Pat. No. 5,585,800; U.S. Pat. No. 5,554,994; U.S. Pat. No. 5,535,278; U.S. Pat. No. 5,534,875; U.S. Pat. No. 5,519,620; U.S. Pat. No. 5,506,588; U.S. Pat. No. 5,446,465; U.S. Pat. No. 5,434,574; U.S. Pat. No. 5,402,441; U.S. Pat. No. 5,373,531; U.S. Pat. No. 5,349,531; U.S. Pat. No. 5,347,286; U.S. Pat. No. 5,341,301; U.S. Pat. No. 5,339,246; U.S. Pat. No. 5,293,170; U.S. Pat. No. 5,225,842; U.S. Pat. No. 5,223,843; U.S. Pat. No. 5,210,540; U.S. Pat. No. 5,193,064; U.S. Pat. No. 5,187,485; U.S. Pat. No. 5,175,557; U.S. Pat. No. 5,148,452; U.S. Pat. No. 5,134,407; U.S. Pat. No. 4,928,107; U.S. Pat. No. 4,928,106; U.S. Pat. No. 4,785,463; U.S. Pat. No. 4,754,465; U.S. Pat. No. 4,622,557; and U.S. Pat. No. 4,457,006.
FIG. 54 illustrates how the series of communication data produced in Main Cabin MC are sent from and received by Carrier 300 . Here, communication data includes both voice data which is primarily used for oral communication in a wireless fashion and non-voice data which is primarily used for non-oral communication, such as, but not limited to, text data, software data, video data, image data, log data, and other data necessary to access Network NT ( FIG. 51 ). Main Cabin MC is designed to carry a plurality of passengers. In the present example, three passengers are currently in Main Cabin MC, i.e., Passenger PA 1 , Passenger PA 2 , and Passenger PA 3 . Passenger PA 1 is carrying Communication Device CD 1 , Passenger PA 2 is carrying Communication Device CD 2 , and Passenger PA 3 is carrying Communication Device CD 3 . Here, the communication device (CD 1 , CD 2 , and/or CD 3 ) can be a personal computer which is capable to send and receive data in a wireless fashion, a PDA, a PHS, and/or a cellular phone. Transmitter TR 1 is an antenna which is located adjacent to the ceiling of Main Cabin MC so as to receive a series of communication data produced by Communication Devices CD 1 , CD 2 , and/or CD 3 . The series of communication data received by Transmitter TR 1 are sent to Computer 200 and, having being converted into a specific form as described in FIG. 53 and hereinafter, sent to the nearest artificial satellite (Artificial Satellite AS 1 in FIG. 51 ) from Transmitter TR 2 in a wireless fashion. A series of communication data received by Transmitter TR 2 are transferred to Computer 200 by which such communication data are converted into a specific form as described in FIG. 53 and hereinafter. The converted communication data are transferred to Transmitter TR 1 which distributes the communication data in a wireless fashion to the communication device (CD 1 , CD 2 , and/or CD 3 ) in Main Cabin MC.
FIG. 55 illustrates one of the series of communication data converted by Computer 200 ( FIG. 54 ) and transferred from Transmitter TR 2 ( FIG. 54 ). Referring to FIG. 55 , Header HD indicates the beginning of the communication data, Footer FT indicates the end of the communication data. Airplane ID Number AI indicates the identification number of Carrier 300 ( FIG. 54 ) which is unique to each Carrier 300 . Data D 1 represents the communication data produced by Communication Device CD 1 owned by Passenger PA 1 in FIG. 54 . In the same manner, Data D 2 and D 3 represent the communication data produced by Communication Device CD 2 and CD 3 , respectively. Here, Data D 1 , D 2 , and D 3 include both voice data and/or non-voice data which are explained hereinabove.
FIGS. 56 a , 56 b , and 56 c illustrate other embodiments of transferring communication data described in FIG. 55 . Referring to FIG. 56 a , Header HD indicates the beginning of the communication data, Footer FT indicates the end of the communication data. Airplane ID Number AI indicates the identification number of Carrier 300 ( FIG. 54 ) which is unique to each Carrier 300 . Data D 1 represents the communication data produced by Communication Device CD 1 owned by Passenger PA 1 in FIG. 54 . Data D 2 and D 3 can be sent separately as described in FIGS. 6 b and 6 c respectively in the same manner. Just like the communication data explained in FIG. 5 , data D 1 , D 2 , and D 3 include both voice data and/or non-voice data.
For transferring communication data, FDMA, TDMA, CDMA, and/or W-CDMA can be utilized.
FIG. 57 illustrates the operation of Computer 200 ( FIG. 54 ), more precisely the operation of CPU 211 ( FIG. 53 ), in order to convert the communication data into a specific format. First of all, CPU 211 periodically checks the signals received by Transmitter TR 1 ( FIG. 53 ) (S1). If the received signal is a communication data (S2), CPU 211 identifies the types of the communication data received, i.e., whether voice data or non-voice data as well as the user ID which is embedded into such communication data (S3). Here, the user ID represents the user identification number or code which is unique to each communication device (i.e., CD 1 , CD 2 , and CD 3 ) described in FIG. 54 . After identifying the types of the communication data received, voice data is converted into a specific format which is particular to voice data (S4a), and non-voice data is converted into a specific format which is particular to non-voice data (S4b). Both converted voice data and non-voice data are then integrated into one format (S5) and are arranged into a specific format as described in FIG. 55 and/or FIGS. 56 a , 56 b and 56 c . As another embodiment, the steps of S4a and S4b may be merged into one step and employ the same method of formatting (i.e., not distinguishing the type of data and format accordingly to such type) since both voice data and non-voice data are digital.
FIG. 58 illustrates the operation of Computer 200 ( FIG. 54 ), more precisely of CPU 211 ( FIG. 53 ), to send the converted communication data which is described in FIG. 57 to Artificial Satellite AS 1 ( FIG. 51 ) from Transmitter TR 2 ( FIG. 54 ). Referring to FIG. 58 , CPU 211 checks the connection status between Carrier 300 ( FIG. 54 ) and the nearest artificial satellite, i.e., Artificial Satellite AS 1 in the present example (S1). If Carrier 300 is not connected to Artificial Satellite AS 1 (S2), the connection process is initiated and such process is repeated until the connection between Carrier 300 and Artificial Satellite AS 1 is confirmed (S3). Communication data in the format described in FIG. 55 and/or
FIGS. 56 a , 56 b and FIG. 56 c are then transferred from Transmitter TR 2 ( FIG. 54 ) under the control of CPU 211 (S4). Such process is continued until all communication data are transferred. The communication data which are to be sent are temporarily registered in RAM 206 ( FIG. 53 ) and erased thereafter. The communication log can be saved in RAM 206 and also can be output from Monitor 201 ( FIG. 53 ) as well as from Speaker 204 ( FIG. 53 ). A GPS navigation data produced by GPS Navigation System 217 ( FIG. 53 ) can be embedded into the series of communication data described in FIG. 55 and/or FIGS. 56 a , 56 b , and 56 c . All of the software programs necessary to operate the function described in FIG. 58 are stored in RAM 206 ( FIG. 53 ) and/or ROM 207 ( FIG. 3 ).
FIGS. 59 through 64 b illustrate the method of enhancing the quality of wireless communication when utilizing a plurality of artificial satellites.
As described in FIG. 59 , Carrier 300 is connected to Artificial Satellite AS 1 in a wireless fashion, Artificial Satellite AS 1 is connected to Artificial Satellite AS 3 in a wireless fashion, and Artificial Satellite AS 3 is connected to Ground Host GH in a wireless fashion. Here, Ground Host GH is a computer located on the ground or on the surface of the earth which functions as a gateway or an entrance to Network NT. Ground Host GH may be substituted by Host H described hereinbefore. Ground Host GH is connected to Network NT, such as the Internet, by a non-wireless method, such as by phone line, cable, or any other non-wireless methods. Artificial Satellite AS 2 is also connected to Artificial Satellite AS 3 in a wireless fashion. In such manner, Carrier 300 is able to connect to Network NT via Artificial Satellite AS 1 , Artificial Satellite AS 3 , and Ground Host GH. Assuming that Carrier 300 is travelling to the direction indicated by arrow (or to the right of the drawing), Carrier 300 is connected to Artificial Satellite AS 1 so long as Carrier 300 is in the communication rage of Artificial Satellite AS 1 . As described in FIG. 60 , Carrier 300 moves further from Artificial Satellite AS 1 and comes closer to Artificial Satellite AS 2 so long as Carrier 300 maintains its course. In other words, Carrier 300 will exit the communication range of Artificial Satellite AS 1 and enter the communication range of Artificial Satellite AS 2 , thereby maintain connection with Network NT via Artificial Satellite AS 2 , Artificial Satellite AS 3 , and Ground Host GH. However, when Carrier 300 terminates connection with Artificial Satellite AS 1 by exiting its communication range and initiates connection with Artificial Satellite AS 2 by entering its communication range, Carrier 300 is forced to endure a gap” or blank” in its communication with Network NT which will cause degradation in wireless communication. For example, if a series of voice data are being sent and received between Carrier 300 and Network NT and switching from Artificial Satellite AS 1 to Artificial Satellite AS 2 occurs during such communication, the voice data is forced to be dropped” or not being transferred properly to Network NT while Carrier 300 is switching its connection from Artificial Satellite AS 1 to Artificial Satellite AS 2 . If Carrier 300 is connected to Network NT and transferring non-voice data, for example but not limited to, text data, software data, video data, image data, log data, and other data necessary to access Network NT and such gap” or blank” occurs by switching from Artificial Satellite AS 1 to Artificial Satellite AS 2 , some portion of such non-voice data will not be transferred to Network NT. In some cases, the connection between Carrier 300 and Network NT is forced to be terminated if the gap” or blank” in communication is too long. In order to avoid such inconvenience and inferiority in wireless communication, Carrier 300 initiates connection with Artificial Satellite AS 2 when it is about to terminate connection with Artificial Satellite AS 1 as described in FIG. 61 . In other words, Carrier 300 is connected to both Artificial Satellite AS 1 and Artificial Satellite AS 2 for a certain period of time in order to avoid gap” or blank” in wireless communication, or to avoid being dropped off’ from connection with Network NT. The method described in FIGS. 59 through 61 is called the “soft handover”.
FIG. 62 is a reiteration of FIGS. 59 through 61 , i.e., the soft handover. As described in FIG. 62 , Artificial Satellite AS 1 has a communication range described by Area AR 1 and Artificial Satellite AS 2 has a communication range described by Area AR 2 . Assuming that Carrier 300 ( FIG. 61 ) is travelling to the direction indicated by Arrow AW 1 . When Carrier 300 is at Point P 01 , a location in Area AR 1 , Carrier 300 is connected to Artificial Satellite AS 1 . However, when Carrier 300 is at Point P 02 , i.e., maintains it course as described by Arrow AW 1 and about to exit Area AR 1 and enters Area AR 3 , the communication range of Artificial Satellite AS 2 , Carrier 300 initiates connection with AS 2 while connection is maintained with Artificial Satellite AS 1 . When Carrier 300 completely exits Area AR 1 and is in Area AR 3 as described by Point P 03 , Carrier 300 has terminated connection with Artificial Satellite AS 1 and maintains connection only with Artificial Satellite AS 2 .
FIG. 63 illustrates the operation of CPU 211 ( FIG. 53 ) in order to initiate connection with Artificial Satellite AS 1 ( FIG. 62 ) before implementing the soft handover. First of all, CPU 211 periodically checks the incoming signals received by Transmitter TR 2 ( FIG. 53 ) (S1). If the signal level of the received signal is more than a specific level x″ (S2), the received signal is decomposed by signal processor 208 ( FIG. 53 ) in order to convert the signals to a specific format readable by CPU 211 . The converted signal is temporarily registered in RAM 206 ( FIG. 53 ). CPU 211 reads the converted signal from RAM 206 and if such signal is determined to be from an artificial satellite and identifies the ID number of such artificial satellite (in the present example, Artificial Satellite AS 1 ) (S3), it initiates connection process therewith (S4). All software programs necessary to perform such operations are stored in RAM 206 ( FIG. 53 ) and/or ROM 207 ( FIG. 53 ).
FIG. 64 a and FIG. 64 b illustrate the operation of CPU 211 ( FIG. 53 ) in order to implement the soft handover. While connection with Artificial Satellite AS 1 is maintained (S1), CPU 211 periodically checks the signal level of the signals received from Artificial Satellite AS 1 ( FIG. 12 ). If the signal level is above level x″, no further action is necessary and Carrier 300 is solely connected to Artificial Satellite AS 1 (S2). However, if Carrier 300 moves further from Artificial Satellite AS 1 and approaches to the boundary of Area AR 1 ( FIG. 62 ) and thereby the signal level is no longer above level x″ (S2), CPU 211 initiates a certain process to search for another artificial satellite (S3). If the signal level of the received signal is more than a specific level x″ (S4), the received signal is decomposed by signal processor 208 ( FIG. 53 ) in order to convert the signals to a specific format readable by CPU 211 . The converted signal is temporarily registered in RAM 206 ( FIG. 53 ). CPU 211 reads the converted signal from RAM 206 and if such signal is determined to be from an artificial satellite and identifies the ID number of such artificial satellite (in the present example, Artificial Satellite AS 2 ) (S5), it initiates connection therewith (S6). After confirming that the connection with Artificial Satellite AS 2 is secured, CPU 211 terminates the connection with Artificial Satellite AS 1 (S7). All software programs necessary to perform such operations are stored in RAM 206 and/or ROM 207 ( FIG. 53 ).
For purposes of implementing the soft handover, various types of communication method may be utilized, such as FDMA, TDMA, CDMA, and/or W-CDMA.
As another embodiment of the present invention Carrier 300 ″ can be read as communication device” such as personal computer which is capable to send and receive data in a wireless fashion, a PDA, a PHS, and/or a cellular phone, and thereby enables such communication device to be connected to Network NT ( FIG. 61 ) without having gap” or blank” or connection drop-off by way of utilizing the present invention.
Having thus described a presently preferred embodiment of the present invention, it will not be appreciated that the aspects of the invention have been fully achieved, and it will be understood by those skilled in the art that many changes in construction and circuitry and widely differing embodiments and applications of the invention will suggest themselves without departing from the spirit and scope of the present invention. The disclosures and the description herein are intended to be illustrative and are not in any sense limiting of the invention, more preferably defined in scope by the following claims.
<<Wireless Communication Facilitating System—Summary>>
A transportation system comprising a main cabin, a first antenna, a second antenna, and a host; said main cabin comprises a plurality of seats, said first antenna is connected to or located close to said main cabin, said second antenna is connected to or located close to the outer-surface of said transportation system, said host is connected to said first antenna and said second antenna wherein a plurality of wireless signals produced in said main cabin are received by said first antenna which transfers said wireless signals to said host, and said host converts said wireless signals to a specific format, which are transferred from said second antenna.
A transportation system comprising a main cabin, a first antenna, a second antenna, and a host; said main cabin comprises a plurality of seats, said first antenna is connected to or located close to said main cabin, said second antenna is connected to or located close to the outer-surface of said transportation system, said host is connected to said first antenna and said second antenna wherein a plurality of wireless signals produced outside the transportation system are received by said second antenna which transfers said wireless signals to said host, and said host converts said wireless signals to a specific format, which are transferred from said first antenna to said main cabin.
A transportation system comprising a main cabin, a first antenna, a second antenna, and a host; said main cabin comprises a plurality of seats, said first antenna is connected to or located close to said main cabin, said second antenna is connected to or located close to the outer-surface of said transportation system, said host is connected to said first antenna and said second antenna wherein a plurality of wireless signals produced in said main cabin are received by said first antenna which transfers said wireless signals to said host, and said host converts said wireless signals to a specific format, which are transferred from said second antenna, wherein said transportation system thereby enables the passengers in said main cabin to communicate in a wireless fashion with people or things which cannot directly be contacted with the communication devices they possess in said main cabin.
A transportation system comprising a main cabin, a first antenna, a second antenna, and a host; said main cabin comprises a plurality of seats, said first antenna is connected to or located close to said main cabin, said second antenna is connected to or located close to the outer-surface of said transportation system, said host is connected to said first antenna and said second antenna wherein a plurality of wireless signals produced outside the transportation system are received by said second antenna which transfers said wireless signals to said host, and said host converts said wireless signals to a specific format, which are transferred from said first antenna to said main cabin, wherein said transportation system thereby enables the passengers in said main cabin to communicate in a wireless fashion with people or things which cannot directly be contacted with the communication devices they possess in said main cabin.
The transportation system of summary 1, 2, 3, or 4, wherein said wireless signals comprise digital data.
The transportation system of summary 1, 2, 3, or 4, wherein said wireless signals comprise voice data and non-voice data.
The transportation system of summary 1, 2, 3, or 4, wherein said wireless signals comprise text data.
The transportation system of summary 1, 2, 3, or 4, wherein said wireless signals comprise software data.
The transportation system of summary 1, 2, 3, or 4, wherein said wireless signals comprise video data.
The transportation system of summary 1, 2, 3, or 4, wherein said wireless signals comprise image data.
The transportation system of summary 1, 2, 3, or 4, wherein said transportation system thereby enables the passengers in said main cabin to communicate in a wireless fashion with people or things which cannot directly be contacted with the communication devices they possess in said main cabin.
The transportation system of summary 1 or 2, wherein said transportation system is enabled to implement soft hand over between a first Artificial Satellite and a second Artificial Satellite in order to maintain a seamless connection with another device.
Having thus described a presently preferred embodiment of the present invention, it will be understood by those skilled in the art that many changes in construction and circuitry and widely differing embodiments and applications of the invention will suggest themselves without departing from the spirit and scope of the present invention. The disclosures and the description herein are intended to be illustrative and are not in any sense limiting of the invention, more preferably defined in scope by the following claims. There are only few data stored in each storage area described in this specification. This is done so merely to simplify the explanation and, thereby, to enable the reader of this specification to understand the content of each function with less confusion. Therefore, more than few data (hundreds and thousands of data, if necessary) of the same kind, not to mention, are preferred to be stored in each storage area to fully implement each function described herein. For the avoidance of doubt, the applicant has no intent to surrender any equivalent of any element included in the claims by any amendment of the claims unless expressly and unambiguously stated otherwise in the amendment. Further, for the avoidance of doubt, the number of the prior arts introduced herein (and/or in IDS) may be of a large one, however, the applicant has no intent to hide the more relevant prior art(s) in the less relevant ones.
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The vehicle, such as airplane, which comprises the internal wireless communicating device and the external antenna device, wherein the passenger(s) in the vehicle may access network (e.g., the Internet) via the internal wireless communicating device and the external antenna device.
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BACKGROUND OF THE INVENTION
The present invention relates to a modular refrigeration assembly for use in conjunction with a refrigerated structure such as a walk-in cooler or freezer employed in retail and wholesale food outlets. More specifically, the invention relates to an assembly which provides an easily replaced unit for generating a refrigerated air flow for such a structure. The term "refrigerated" in accordance with the present invention is intended to incorporate structures wherein the temperature of the contained air mass is maintained at or in excess of 32° F., such as storage structures utilized for milk and fresh foods and those structures in which the air is maintained below 32° F., for the maintenance of frozen food.
An increased market demand has occurred in the retail food outlet equipment industry for low energy consumption refrigerated storage structures in order to reduce operating costs wherever possible. In the operation of all types of refrigerated structures, it is desirable to include a system for automatically defrosting the evaporator coils. The defrost cycle can be actuated either at set periodic time intervals or when the frost build-up within the coils has reached a certain predetermined condition. The latter type of system is typically thermostatically controlled so as to switch from a refrigeration cycle to a defrost cycle of operation. In this manner of operation, it is possible to avoid any significant frost build-up within the display cabinet such that inoperability and spoilage of food products would occur.
There have been three different approaches for defrosting refrigerated display cabinets in this art. These are, utilizing the electric resistance heaters; passing a compressed refrigerant gas having a high specific heat through the refrigeration coils; and, circulating ambient air through an air conduit in which the refrigeration coils are positioned. Due to the increased cost of energy, more emphasis has been placed on the utilization of ambient air defrost systems as an alternative to the electrical resistant heaters or compressed refrigerant gas defrost systems.
Ambient air defrost systems are more economical to operate due to the fact that the existing specific heat in the ambient air can be employed as the energy source to melt the frost and ice which has accumulated on the evaporator coils. In either the electric resistance heaters or the compressed refrigerant gas systems, additional energy must be expended in order to defrost the coils. The structural components of the air defrost systems must be arranged in such a manner that the warm ambient air is brought into contact with the evaporator coils in a direct and positive manner without incurring large capital costs for the necessary ducts and additional air moving machinery. If an overly complicated air defrost system is employed, the additional capital costs can only be recovered after long operating time periods which have been recently significantly extended due to the rising cost of investment capital.
Another problem in the construction of refrigerated structures for the storage of food products is that the refrigeration systems are sometimes incorporated into the structure in such a way that repair and maintenance is rendered extremely difficult. Another problem with the inaccessibility of the refrigeration machinery is that retail store managers cannot upgrade the energy efficiency of the existing equipment without additional significant retrofitting investments.
The present invention is a solution to the above problems in that a modular refrigeration assembly having an ambient air defrost system incorporated therein is provided for use with walk-in coolers and freezers. The assembly is of a unitary construction which enables the low cost retrofitting of existing refrigeration structures.
U.S. Pat. Nos. 2,923,137 to Swanson; 2,961,845 to Kennedy; 3,698,205 to Perez; 4,023,378 to Kennedy, Butts and Steelman; 4,117,697 to Myers and Kennedy; and 4,124,996 to Kennedy, Butts and Steelman describe refrigerated structures in which a food storage space is incorporated together with a merchandiser display section. By construction, the refrigeration equipment used in conjunction with these structures is contained within them in such a manner that repair and maintenance access is limited. U.S. patent application Ser. No. 6,074 filed Jan. 24, 1979 to Myers, Kennedy, and Perez and assigned to the same assignee as is the present application shows another type of a refrigerated structure. In U.S. Pat. No. 4,117,697 an ambient air band B is utilized as a third air curtain, but ambient air is not employed in order to defrost the refrigeration coils.
U.S. Pat. No. 4,072,488 to Johnston shows a glass door reach-in refrigerated display case in which an evaporator coil is located in the top portion of the case and wherein horizontal trap doors are opened in the top wall of the case in order to provide for an ambient air flow. The refrigeration coils of this case are integral with the entire cabinet structure and are not capable of independent use as a refrigeration assembly for separate structures containing cooled air masses. The refrigeration coil package is not a unit separate from the refrigerated display cases. The horizontal arrangement of the defrost doors also permits the accumulation of dust and debris on and around the horizontally disposed top which then results in contamination of the food storage space. This patent does not provide blocking baffles to protect the mass of the cooled air within the case from contact by the ambient air during the defrost cycle of operation.
Various types of air defrost systems have been employed with respect to refrigerated display cabinets used in retail food outlets. Exemplary of such prior art are: U.S. Pat. Nos. 3,403,525; 3,850,003 and 3,937,033 all to Beckwith et al; 3,082,612 to Beckwith; and 3,226,945 to Spencer.
SUMMARY OF THE INVENTION
An improvement in refrigeration assemblies for use in conjunction with structures which enclose cooled air masses for the preservation of food products is provided. The assembly is of unitary, modular construction and can be utilized to selectively provide the refrigeration of air for a wide variety of storage structures. The assembly is provided with an air defrost system.
The assembly has provision for a smooth flow-through of ambient air during the defrost cycle. Cover gates are arranged to block the ambient air inlet and outlet openings during the refrigeration cycle of operation. In the preferred embodiments, blocking baffles are also employed to close the refrigerated air inlet and outlet ports during the defrost cycle of operation. Also, auxiliary air moving means can be employed during the defrost cycle of operation. The assembly may be incorporated into the wall structure of modular designed refrigerated structures as well as being constructed as a separate unitary, modular system.
It is therefore, an object of the present invention to provide an improved refrigeration assembly for interchangeable use in conjunction with structures which enclose a mass of cooled air and a method for operating the same.
Another object of the present invention is to provide a modular refrigeration assembly in which refrigeration coils are positioned for defrosting by an ambient air defrost system in a simple and direct manner.
Specific preferred embodiments of the invention will be described below with reference to the appended drawing figures.
Yet another object is to provide a modular refrigeration assembly in which cover gates are arranged to block ambient air flow during the refrigeration cycle of operation and to permit an ambient air flow-through during a defrost cycle of operation.
A further object is to provide the refrigeration assembly with blocking baffles to positively prevent the ambient air flow during the defrost cycle from flowing into the refrigerated air mass contained within a refrigerated structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the refrigeration assembly taken in cross-section when mounted on the top wall of a refrigerated structure;
FIG. 2 is a detailed view of the refrigeration assembly shown in FIG. 1;
FIG. 3 is a schematic view of a second modification of the refrigeration assembly shown in side elevation when mounted on the top of a refrigerated structure;
FIG. 4 shows a detailed cross-sectional elevation view of the refrigeration assembly shown in FIG. 3;
FIG. 5 shows a third modification of the refrigeration assembly of the present invention in which the assembly is formed as a modular portion of a refrigerated structure;
FIG. 6 shows a second embodiment of the modular portion of the refrigerated structure shown in FIG. 5 which incorporates the refrigeration assembly, and
FIG. 7 shows a schematic control hierarchy for the refrigerated assemblies of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, a refrigeration assembly 10 of modular, unitary form is shown mounted over an opening 12 formed in the top wall or ceiling 14 of a structure or room 16 which has side walls 18 and 20 and a rear wall 22 resting on a floor 24. Rear wall 22 is provided with an access door 26 which has an operating handle 28 and viewing ports 30.
Refrigeration assembly 10 is formed of a modular housing 32 which is supported over opening 12 by base extension portions 34 and 36. A low temperature element 38 consisting of a flowthrough box with refrigerator evaporator coils arranged therein is supported from the under surface of top wall 40 of assembly housing 32. An air moving means 42 consisting of a fan 44 and a connected motor 46 is also arranged within assembly housing 32 so that air can be circulated through the evaporator coils of low temperature element 38. An ambient air inlet opening 48 is formed in end wall 50 of assembly housing 32. An inlet cover gate 52 is arranged for pivotal movement into and away from closed position with respect to the air inlet opening 48. The movement of cover gate 52 is provided by a linkage system 54 operated by an operating means 56 which consists of a motor-gear box unit. On the opposite end of the modular assembly housing 32 an ambient air outlet opening 58 is formed in end wall 60 and an outlet cover gate 62 is pivotally attached to the outside of end wall 60 and arranged to move into blocking position with respect to the air outlet opening 58. Cover gate 62 is pivoted by means of motive force transmitted through mechanical linkage system 64 which is powered by an operating means 66 which consists of a second motor-gear box unit.
When the air inlet cover gate 52 and the outlet cover gate 62 are in open position as shown in FIG. 1, ambient air, shown by the dotted arrows A can be moved through assembly housing 32 by air moving means 42 and passed through the evaporator coils of the low temperature element 38 in order to defrost the same. A condensate collection tray 68 is arranged below element 38 for the collection of run-off water during the defrost cycle of operation.
During the defrost cycle, when the air inlet cover gate 52 and the outlet cover gate 62 are in opened position, the refrigerated air inlet port 70 is blocked by blocking baffle 72. Baffle 72 is pivotally connected to bottom wall 74 of assembly housing 32 and is operated between blocking and open positions by a kinked operator link 76 which is connected to the inside surfaces of the blocking baffle 72 and the cover gate 52. In a like manner, the refrigerated air outlet port 78 is provided with a blocking baffle 80 which is pivotally connected to bottom wall 74 of the assembly housing 32. The blocking baffle 80 is moved between blocking positions and open positions by means of an operator link 82 which is connected between the interior surfaces of the blocking baffle 80 and the ambient air cover gate 62.
The operation of the refrigeration assembly 10 is shown in FIG. 2 wherein the ambient air band A is moved through the ambient air inlet port 48, through low temperature element 38 and out of ambient air outlet opening 58 by air moving means 42 when the cover gates 52 and 62 are in opened positions as shown by the solid lines. This flow of ambient air A occurs during the defrost cycles of operation of the refrigeration assembly 10. The use of ambient air as a defrost energy source results in the savings of operational energy.
At the termination of a defrost cycle of operation, a defrost control means (not shown) causes the operator means 56 and 66 to move the cover gates 52 and 62, respectively, into blocking positions with respect to the ambient air inlet and outlet openings, respectively. This movement is transmitted through the linkage systems 54 and 64 and via the fixed-angle operator links 76 and 82 to the blocking baffles 72 and 80 which are then pivoted away from the blocking positions into the opened positions shown by the dotted lines. Refrigerated air can then flow through the air inlet port 70 and the refrigerated air outlet port 78. The air moving means 42 is then operated to cause a refrigerated air band to flow through the air inlet port 70, through the low temperature element 38 and into contact with the evaporator coils which then remove heat from the cooled air. The air is then circulated downwardly through refrigerated air outlet port 78 and back into the mass of air contained within structure 16. This refrigerated air flow is utilized as needed during the refrigeration cycle of operation.
At the termination of the refrigeration cycle, the defrost control means causes the operator means 56 and 66 to move the cover gate into the outwardly opened positions as shown in the solid lines which then cause blocking baffles 72 and 80 to block the refrigerated air inlet and outlet ports 70 and 78, respectively. The air moving means 42 then causes the ambient air band A to move through the low temperature 38 in order to defrost the same. A drain line 84 is shown connected to the condensate run-off tray 68. If desired, a partition 86 can be placed under the mid portion of the refrigeration assembly 10 in order to prevent circulation of the refrigerated air band in a circular fashion through the refrigerated air inlet and outlet ports.
The top wall 40, and end walls 50 and 60 of refrigeration assembly 10 can be insulated in order to decrease heat transfer into the assembly.
The arrangement of cover gates 52 and 62 so that they open toward the outside of the refrigeration assembly 10 is advantageous in that these cover gates do not freeze shut as would occur if they opened inwardly. The refrigeration assembly 10 also provides for easy serviceability and maintenance by reason of the fact that all of the components are above the upper most surface of top wall or ceiling 14 of the structure to be cooled. Hence, the unitary assembly 10 can be used to drop into place on an opening 12 formed in the upper wall 14 of a structure to be cooled. The assembly can, of course, be used on a vertical wall or other structural member of an enclosed space. It can be easily interchanged between structures to be refrigerated.
The assembly bottom wall 74 can have various configurations with respect to the end walls 50 and 60 and the fixed angles B and C of operator links 76 and 82 can be correspondingly changed. The operator link 76 is attached to the inner surface of cover gate 52 by a pivot connection 88 and to the interior surface of blocking baffle 72 by another pivotal connection 90. In a like manner, the operator link 82 is attached to the inner surface of cover gate 62 by a pivotal connection 92 and is connected on its other end to the interior surface of blocking baffle 80 by a pivotal connection 94.
If desired, the refrigeration assembly 10 can be used without the blocking baffles 72 and 80 which then also means that the operator links 76 and 82 are not needed. In such a modification, the flow through of ambient air band A during the defrost cycle is arranged to be the lowest pressure drop path for the ambient air whereby the air is not forced down into the interior of the structure 16 which contains the mass of cooled air.
It should be noted that all of the operating elements of the refrigeration assembly 10 are connected to and contained within the modular assembly housing 32. Consequently, the refrigeration assembly 10 can be manufactured and installed as a complete "drop-in" unit which requires no other modification of the structure 16 which is to be cooled thereby. The assembly housing 32 can be moved between structures and lifted off of top wall 14 for maintenance.
The operator links 54 and 64 consist of crank arms 96 and 98 which are connected to the armatures of the motor-gear box assemblies 56 and 66, respectively. The motor-gear box assemblies disclosed herein are designed to provide oscillatory motion for the crank arms 96 and 98. Push rods 97 and 99 are pivotally connected by one end thereof to the crank arm ends and by the other end thereof to the outside surfaces of the cover gates 52 and 62.
Referring now to FIGS. 3 and 4, a second embodiment of the present invention is shown as refrigeration assembly 100 which is set into an opening in the top wall or ceiling 102 of structure 104 which contains a mass of cooled air. The structure 104 rests on a floor surface 106 and has end walls 108 and 110 and a rear wall 112. An access door 114 is also provided in rear wall 112.
As shown by FIG. 3, refrigeration assembly 100 has a side wall 118 on which are mounted an air inlet operating means 120 which has a linkage system 122 connected thereto and an air outlet operating means 124 which has an operator linkage system 126 attached thereto. The right hand end portion of refrigeration assembly 100 contains an auxiliary fan housing 128. An access door 130 is formed on side wall 118 and has an operating handle 132 thereon.
FIG. 4 shows a detailed cross-sectional view of the refrigeration assembly 100 wherein a bottom wall 134 contains a refrigerated air inlet port 136 and a refrigerated air outlet port 138. End wall 140 has an ambient air inlet opening 144 and opposite end wall 142 contains an ambient air outlet opening 145 formed therethrough. A top wall 146 and a rear wall 148 complete the modular housing 150 of the refrigeration assembly 100.
Assembly housing 150 is maintained within an opening in top wall 102 by a first and a second bracket 152 and 154.
The ambient air inlet opening 144 can be closed by an inlet cover gate 156 which pivots about rod 158 within the interior chamber 160 in the assembly housing 150. An air seal ring 162 is formed in the core portion 164 of cover gate 156 which is also provided with an external extension area 166 and a internal extension area 168. Extension area 166 is designed to fit into blocking position within ambient air inlet opening 144. A second air sealing ring 170 is formed on the opposite side of the core portion 164 about the internal extended area 168 for forming an air tight seal with respect to the refrigerated air inlet port 136 located in bottom wall 134 of the assembly housing 150. Cover gate 156 is operated between blocking positions with respect to the ambient air inlet opening 144 and the refrigerated air inlet port 136 through the operation of operating means 120 which consists of a motor-gear box assembly 172 which has the output crank arm 174 pivotally connected to a push rod 176 which is, in turn, pivotally connected to the crank arm 178 of the access member 158. The crank arm is fixed to one end of rod 158. The crank arms and push rod are shown in FIG. 3.
Operating means 120 is actuated by a defrost control means to cause the cover gate 156 to move between the two above described blocking positions. When the cover gate 156 closes off the ambient air inlet opening 144, refrigerated air can be circulated upwardly through refrigerated air inlet port 136 from the cooled air mass contained within structure 104 by means of the air moving means 180 which consists of a fan 182 powered by a motor 184 which are both supported within a cage 186 on one side of the low temperature element 188. This element 188 is supported by the top wall 146 and bottom wall 134 of the refrigerated assembly 150. The refrigerated air band established by circulation of fan 182 is then caused to flow downwardly through the refrigerated air outlet port 138 during the refrigeration cycle of operation.
At the initiation of a defrost cycle of operation, the defrost control means causes the operator means 120 to move the cover gate 156 into blocking position with respect to the refrigerated air inlet port 136 and to thus open the ambient air inlet opening 144. Simultaneously therewith, cover gate 190 in the outlet end of the refrigeration assembly 150 is caused to move away from blocking position with respect to the ambient air outlet opening 145 and into the blocking position with respect to the refrigerated air outlet port 138. Cover gate 190 is constructed in a similar fashion with respect to cover gate 156 in that first and second air seal rings 192 and 194 are formed on a core portion 196 and extended areas 198 and 200 are formed for moving into blocking positions with respect to the air outlet opening 145 and the refrigerated air outlet port 138, respectively. A deflector shield 202 is formed on extended area 200 in order to provide for a smoother flow of the refrigerated air downwardly through outlet port 138. As shown in FIG. 4, an additional deflector baffle 204 can be affixed to the undersurface of bottom wall 134 in order to aid in the flow of refrigerated air in a generally circulatory pattern within the refrigerated structure 104.
Also formed on cover gate 190 is a condensate skirt 206 which is secured to the outer extended area 198 in order to provide for the run-off of condensate water into drain 208 located on the lower edge portion of skirt 206. This drain can have a flexible tube 209 to provide for movement of the skirt 206. This condensate run-off sleeve allows the water condensed from the atmosphere to run-off without freezing to seal ring 192 which might otherwise occur due to the action of the refrigerated air against the interior surface of the cover gate 190.
The cover gate 190 is pivoted about a rod 210 which is supported in the outer walls of assembly 150 and is rotated by the operator linkage system 126 which is powered by operating means 124. This operator means consists of a motor and gear box assembly 212 which has the output crank 214 pivotally connected by one end thereof to a push rod 216 which is, in turn, pivotally connected to the crank arm 218 which is affixed to the end of rod 210.
As can be seen from a comparison of FIGS. 3 and 4, the access door 130 allows repair and maintenance to the evaporator coils in the low temperature element 188 and to the fan and motor combination 182 and 184.
If desired, an auxiliary air moving means 220 can be installed on end wall 140 in order to force ambient air into and through the ambient air inlet opening 144 during the defrost cycle. An auxiliary fan housing 222 is secured to wall 140 and for supporting the fan 224 and the associated motor 226. The auxiliary air moving means 220 is actuated by the defrost control means after the cover gates 156 and 190 have been moved into blocking positions over the refrigerated air inlet and outlet ports, respectively. The operation of the auxiliary air moving means allows the volumetric flow of ambient air to be greater during the defrost cycle of operation than during the refrigeration cycle of operation.
A drain 230 is shown located immediately under the low temperature 188 in order to drain off water during the defrost cycle of operation.
The operation of the refrigeration assembly 100 between the refrigeration and defrost cycle is the same as described with respect to FIGS. 1 and 2 above. The evaporator coil boxes 38 and 188 are, of course, connected in a refrigeration system including a compressor and condenser located at another position.
Referring now to FIGS. 5 and 6, a refrigeration assembly 240 is formed integrally in the top wall 242 of a structure 244 in which a mass of cooled air is to be maintained. The structure 244 has end walls 246 and 248 and a rear wall 250 which rests on a ground surface 252 such as a cement floor in a retail food outlet. The structure 244 is formed with an access door 254 having a handle and latch 256 and viewing ports 258.
The refrigeration assembly 240 is elevated above the upper plane of top wall 242 in order to provide for the ambient air inlet opening 260 and the ambient air outlet opening 262 which are arranged along a line L which passes through the low temperature element 264 which consists of an evaporator coil box 266 affixed to the upper wall 268 of the refrigeration assembly 240. An air moving means 270 is supported by a bracket 272 and consists of a fan 274 and a motor 276. The ambient air inlet and outlet openings 260 and 262 have cover gates 278 and 280 arranged for pivotally closing thereupon about the pivot axes 282 and 284, respectively. The cover gates 278 and 280 are pivoted by action of the operator means 286 and 288 which consist of motor-gear box assemblies arranged to have oscillatory armature motion. The oscillating output crank arms 290 and 292 are each connected to fixed angle push rods 294 and 296, respectively, which are each, in turn, pivotally connected by pins 298 and 300 to the outer surfaces of the cover gates 278 and 280, respectively. Upon the actuation of the operator means 286 and 288 by the defrost control means the cover gates 278 and 280 shown as being substantially planar are lifted into the solid line positions shown in FIG. 5 in order to permit the flow through of an ambient air band A in order to defrost the low temperature element 264. The return motion for closing the cover gates 278 and 280 allows closure through the operation of the push rods and operator levers aided by gravitational force. Low temperature element 264 is equipped with a condensate drain line 302. The lower resistance to air flow in along the line L is relied upon in this modification to prevent excessive circulation of the ambient air within the mass of the cooled air contained within the structure 244.
The evaporator coils in low temperature element 264 are connected via lines 304 and 306 to an externally mounted condensing unit 308 which contains a motor and compressor combination 310 and a condensing coil set 312. The condensing unit 308 can be mounted on a side wall of the structure 244 as shown and conventional fan and motors are arranged therefor. The mounting of the external condensing unit can be at various heights D from from the surface of floor 252, for example, four to five feet.
During the operation of the refrigeration assembly 240, upon the completion of the defrost cycle of operation, the motor-gear boxes 286 and 288 are operated to move the cover gates 278 and 280 into blocking positions with respect to the ambient air inlet and outlet ports 260 and 262 and the fan 274 continues to operate in order to circulate the mass of cooled air within the structure 244 through the evaporator coils in the low temperature element 264 in order to maintain the low temperature thereof.
As shown in FIGS. 5 and 6, the walls 244, 246, and 248 of structure 244 and the top wall 268 of the refrigeration assembly are insulated in order to restrict heat transfer from the ambient air into the cooled air within the structure 244. The entire structure 244 together with the refrigeration assembly 240 can be manufactured as a unit and installed in retail food markets. Alternatively, the assembly 240 and the condensing unit 308 can be joined to a modular portion of the refrigerated structure 244 such as illustrated by the break lines B and C in FIG. 5 and by the FIG. 6 view. In this modular form the assembly 240 and the unit 308 can be used to form an integral, inter-fitted part of a refrigerated structure 244.
As shown in FIG. 6, an auxiliary air moving means 314 can be provided by incorporating a fan 316 and an associated motor 318 in an auxiliary fan housing 320 which can be also designed to accommodate an air filter 322 which will then rest within the housing 320 on the upper surface of top wall 242. The auxiliary air fan housing 320 can form a conduit for the ambient air band A upon the full opening of the cover gate 278 into the position as shown in FIG. 6. A support baffle 324 is provided for positioning fan 316 and motor 318 within the housing 320.
If desired, seal rings 325 and 326 can be provided about the base portions 328 and 330 of the two cover gates 278 and 280, respectively.
As can be seen in FIG. 6 and in each of the FIGS. 1, 2, 4, and 5 the low temperature elements 38, 188 and 264 are formed with an air inlet area 332 which is located in a first plane P-1 and an air outlet area 334 which is located in a second plane P-2. Both the ambient air band A and the refrigerated air band are circulated through the inlet area 332 and the outlet areas 334 during the operation of both the defrost and the refrigeration cycles of operation. The planes P-1 and P-2 can be positioned at acute angles with respect to the planes passing through the air inlet and outlet opening 260 and 262 or these two planes can be substantially parallel to planes passing through the ambient air inlet and outlet openings as shown in FIGS. 1-4. Alternatively, an A-frame evaporator coil set can be employed for any of the embodiments of the present invention whereby the planes of the outer surfaces of the low temperature element 264 will be more closely parallel with respect to the corresponding ambient air inlet and outlet openings as illustrated in FIGS. 5 and 6.
The modular refrigeration assemblies described herein function as refrigerated air supply units for cooler structures, particularly, walk-in coolers. These units operate with low relative energy consumption due to the provision for air defrosting by ambient air flow-through. In operation, the units refrigerate a circulated air band by passing the air contained within the structure through an evaporator coil set which is connected to other elements of a refrigeration system. The refrigeration system is controlled for intermittent operation by a master control means which senses the need for operation of the refrigeration system by monitoring the temperature inside and outside of the structure and by integrating these with other inputs such as atmospheric conditions including humidity.
The master control means includes a defrost control subsystem which senses the need for defrosting the evaporator coil set through the sensing of the passage of time or the buildup of ice on the coils. The latter type of sensing can be implemented by employing a thermostat known as a Klixon. When the need for defrosting occurs the defrost control subsystem means causes the following sequence of operational steps:
1. The master control for the refrigeration system is switched over to the defrost control system and the flow of refrigerant in the evaporator coils is terminated.
2. The cover gates are moved out of the blocking positions in which these gates covered the ambient air inlet and outlet ports.
3. Step 2 also results in the blocking baffles closing the refrigerated air inlet and outlet ports by transmission of the motion of the gates to the blocking baffles through the connecting linkage systems.
4. The air circulation fan continues to operate, whereby ambient air is now drawn through the air inlet and outlet ports to defrost the coils.
5. The condensate water is then taken off through a drain line.
6. When the accumulated ice has been melted off from the coils the combined steps 2 and 3 are reversed so that the cover gates are returned to the blocking positions and the blocking baffles are opened to permit the flow of refrigeration air.
7. The refrigeration system is released to the control of the master control means whereby the refrigeration function is resumed.
The above sequence can be instituted at any time, day or night, due to the automatic functioning of the master control and defrost control means.
An existing structure to be refrigerated can be retrofitted by arranging top openings matched to the understructure of the refrigeration assembly structure. Installation and line connections are simple. The assembly can be used as needed and can be easily removed for use on another such structure.
The air circulation fan of the refrigerated assembly can be operated in a number of ways. It can be continuously operated at a constant speed in both the refrigeration and the defrost modes or the operation can be interrupted to follow the refrigeration and defrost demands. It can be interrupted during the change over from refrigeration to defrost modes. The speed of the fan during the defrost cycle can be greater than, less than, or the same as the speed used during the refrigeration cycle. The fan establishes the flow of both the refrigerated air band and the defrost air band. These bands can have flow paths which pass through different air outlet and inlet areas as shown by FIGS. 1-4 or through the same areas as shown by FIGS. 5-6.
The cover gates and blocking baffles can have separate operating mechanisms if desired as an alternative to the inter-connected linkages described herein. In this embodiment the separate mechanisms are individually controlled by the defrost control means.
The resilient air seal rings 162, 170, 192, 194, 325, and 326 shown in FIGS. 4 and 6 for preventing air blow-by can be formed from an elastomeric or rubber material of either the solid or pore-formed types.
FIG. 7 shows the control hierarchy for the refrigerant assemblies 10, 100, and 240 described with respect to the second of these assemblies wherein a master control 340 receives electrical signals from sensors 342 to enable control of the refrigeration system 344 which includes the low temperature element 188 as well as the air moving fan means 180 during refrigeration cycles. Use condition sensors which provide signals based to use of the refrigerate structure can be provided as shown.
When a need for defrosting the low temperature is sensed by frost sensor 346 an electrical signal is transmitted to the master control 340 which then switches on the defrost control subsystem 348. This defrost control means then actuates the cover gates and blocking baffles, shown in assembly 100 (FIG. 4) as the dual function gates 156 and 190. The air fan means 180 can also be preferably operated during this defrost cycle. Upon completion of the defrost action by the ambient air flow-through the signal from the frost sensor 346 then actuates a return of the gates 156 and 190 to the ambient air blocking positions and termination of the operation of auxiliary fan 220 followed by a return of the control to the master control means 340 to permit the above sequence of operational steps to be carried out.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are, therefore, intended to be embraced therein.
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An improvement in refrigeration assemblies for use in conjunction with cooler structures in which food products are preserved in which an assembly of unitary, modular construction is utilized to selectively provide the refrigeration of the air mass. The assembly can be air defrosted by arranging for the flow through of ambient air to defrost the evaporator coils. At the same time, the flow of ambient air can be blocked against entry into the refrigerated air mass by the use of movable baffles. Cover gates are arranged on the assembly to permit the through flow of ambient air during the defrost cycle of operation.
The refrigeration assemblies can be employed for retrofitting and on an interchangeable basis for structures to be refrigerated.
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DEDICATORY CLAUSE
The invention described herein may be manufactured, used, and licensed by or for the Government for governmental purposes without the payment to me of any royalties thereon.
BACKGROUND OF THE INVENTION
Various approaches have been pursued to achieve higher and higher burning rates of solid propellants used in the propulsion subsystems of ballistic missile interceptors. Some of these approaches have involved, as time as gone by, the use of progressively finer and finer-ground ammonium perchlorate, combustion catalysts, such as, ferrocenyl and carboranyl burning rate accelerators, and staples of aluminum, zirconium, and graphite. Although the burning rates achieved have been considered outstanding when compared to the prior art, the needs of future advanced terminal interceptors, especially those of the low altitude commit type, will require propellants having burning rates several times faster than those which are currently available.
Characteristics, such as, burning rate controllability, extinguishability, and a high pressure exponent were obtained through use of porous ammonium perchlorate in the specially-compounded solid propellant which was developed for a Controllable Solid Propellant Rocket Program. The results obtained from the use of porous ammonium perchlorate as a portion of the oxidizer in such a propellant resulted in a motor which had a start-stop and restart capability. This contributed significantly to the advancement of the state-of-the art of controllable, solid-propelled propulsion subsystems.
The compatibility of ammonium perchlorate and porous ammonium perchlorate with propellant ingredients has been well established in composite propellant formulations. The high burning rate level which could be achieved by using porous ammonium perchlorate was not assessed since the emphasis has been on the use of more and more finely-ground ammonium perchlorate to provide the major increase in the propellant's burning surface area, and thus achieve the necessary ultrahigh burning rates.
The processing and dispersing problems of high solids loadings propellants have been well recognized. A major problem attendant with the use of the ultrafine ammonium perchlorate, the agglomeration of the ultrafine ammonium perchlorate, has pointed out the need for other approaches which must be pursued in order to raise the burning rates of composite modified double-base propellants required for future advanced terminal interceptors which may use these propellants.
Therefore, an object of this invention is to provide a solid composite modified double-base propellant composition which employs porous ammonium perchlorate oxidizer to achieve an ultra-ultrahigh burning rate for the propellant composition.
Another object of this invention is to provide an ultra-high burning rate composite modified double-base propellant composition which employs about 34 to about 38 weight percent porous ammonium perchlorate to achieve a more than twofold increase in the burning rate without the employment of a special burning rate catalyst.
SUMMARY OF THE INVENTION
A composite modified double-base solid propellant comprised of 34 to 38 weight percent of porous ammonium perchlorate which has a polymeric coating of an N-arylalkeneimine to protect penetration of the pores during propellant processing, 1-3 weight percent aluminum powder, 4-8 weight percent aluminum staples, a binder of 16-20 weight percent nitrocellulose and 28-32 weight percent nitroglycerin, 4-8 weight percent of an inert plasticizer, triacetin, and 1-3 weight percent of stabilizers selected from resorcinol and 2-nitrodiphenylamine yields an ultra-ultrahigh burning rate as compared to an ultrahigh-burning rate propellant wherein the oxidizer is comprised of all ultrafine ammonium perchlorate.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The ultra-ultrahigh burning rate composite modified double-base propellant composition of this invention is listed as Propellant Composition B of Table I compared with Propellant Composition A that contains ultra-ultrafine ammonium perchlorate oxidizer blended with 90-micrometer ammonium perchlorate. The weight percent ranges of the ingredients for Propellant B are also shown.
TABLE I______________________________________A COMPARISON OF PROPELLANTS CONTAININGULTRA-ULTRAFINE AMMONIUM PERCHLORATE ANDPOROUS AMMONIUM PERCHLORATE PROPELLANT COMPOSITION A B Weight Weight WeightFORMULATION Per- Per- PercentINGREDIENTS cent cent (RANGE)______________________________________Nitrocellulose (12.6% N) 18.0 18.0 16-20Nitroglycerin 30.0 30.0 28-32Ammonium Perchlorate* 36.0 0.0Porous Ammonium Perchlorate** 0.0 36.0 34-38Aluminum Powder 1.4 1.4 1-3Aluminum Staples 5.8 5.8 4-8Triacetin 6.7 6.7 4-8Resorcinol 1.1 1.1 0.5-1.52-Nitrodiphenylamine 1.0 1.0 0.5-1.5PROPELLANTCHARACTERISTICSBurning Rate (@2000 psi) 3.60 7.8Burning Rate Exponent 0.56 0.5Density (l bm/in.sup.3) 0.0621 0.0615Delivered Specific Impulse 253 253(lbf-s/lbm)______________________________________ *Ultra-Ultrafine ammonium perchlorate (0.6 micrometer, average weight diameter) Oxidizer blended with 90 micrometer ammonium perchlorate (12 parts ultraultrafine with 24 parts 90 micrometer) **Prepared by SlowSpeed Mikropulverizer, ground and coated with about 5 weight percent of an Narylalkeneimine
Based on thermodynamic calculation, two basic propellant formulations A and B have been selected for evaluation purposes. These formulations A and B contained 36% oxidizer. Propellants A and B contained 36% ammonium perchlorate oxidizer, 1.4% aluminum powder, 5.8% aluminum flake, 18% nitrocellulose (12.6% N), 30% nitroglycerin, 6.7% triacetin, 1.1% of resorcinol stabilizer, and 1.0% 2-nitrodiphenylamine stabilizer. Additives, trace amounts can be used, to achieve desired processing conditions and properties of the finished propellant. Propellant B had all the ammonium perchlorate in the form of porous ammonium perchlorate; otherwise, compositions A and B are the same.
Table 1 contains a percentage breakout of the compositions of the two representative baseline high-burning propellant formulations which are presented to provide the comparative evaluation between porous ammonium perchlorate (Propellant B) and a mixture consisting of bimodal sizes of ammonium perchlorate (Propellant A).
Table I also shows data relating to Propellants A and B. A comparison of propellant properties, including burning rate exponent, burning rate, density, and delivered specific impulse are presented.
A review of ballistic properties of Propellant B as compared to Propellant A indicates over a twofold increase in the burning rate, a lower burning rate exponent, a lower density, and a specific impulse that is retained at the same high level as for the more dense propellant containing no porous ammonium perchlorate.
Porous ammonium perchlorate employed in this invention is prepared from unground or slow-speed ammonium perchlorate (180-micrometers) or from Micropulverized ammonium perchlorate (90 micrometers). The porosity in the crystal pattern is produced by heating the commercially available ammonium perchlorate at 265° C. for approximately 45 minutes, or until the material has undergone a weight loss of 20-25%. The resulting porous crystals of ammonium perchlorate are then coated with a thin layer of homopolymerizable monomer dissolved in an appropriate solvent which is a non-solvent for the ammonium perchlorate. Routine propellant processing procedures which are standard to the industry can be used in fabricating solid propellants containing porous ammonium perchlorate without abrading off the coating or crushing the porous ammonium perchlorate.
The polymeric coating for porous ammonium perchlorate (5% based on the weight of ammonium perchlorate) was found to be adequate to protect the porosity even under the rigorous conditions of propellant mixing. The polymeric coating is produced by the homopolymerization of an N-arylalkeneimine. The reaction is acid-catalyzed, and takes place rapidly when applied to the porous ammonium perchlorate. The coating process is carried out in a solvent, such as, hexane, in which the ammonium perchlorate is insoluble. After the homopolymerization has taken place, the solvent is removed completely under reduced pressure at low temperatures.
Retention of the porosity that has been produced in the porous ammonium perchlorate through the use of a surface coating is necessary because processing studies have demonstrated that any reduction in the void content results in a decrease in the effectiveness of porous ammonium perchlorate to produce the ultra-ultrahigh burning rates.
Porous ammonium perchlorate offers several advantages over the nonporous ultra-ultrafine ammonium perchlorate, and these make it particularly attractive for application in high burning rate propellant compositions. Some of these advantages are:
(1) The ultra-ultrafine ammonium perchlorate requires an inordinately large quantity of organic coating on the ammonium perchlorate particles to prevent their agglomeration. Since the organic coating is the propellant binder, a smaller amount of free binder is available as a working fluid for propellant mixing and processing. This makes propellant processing difficult.
(2) An appreciable amount of dispersant is necessary to prevent the ultra-ultrafine ammonium perchlorate from agglomerating. The dispersant needs to be subsequently removed, otherwise it would interfere with the satisfactory compounding of the propellant.
(3) A highly effective surfactant is necessary to lower the working viscosity of the propellant to workable levels. This is especially so as the particle size of the ammonium perchlorate is reduced more and more.
(4) A diluent mix process appears as if it is going to be necessary so that the ultra-ultrafine ammonium perchlorate can be incorporated into the propellant. This is unnecessary for the porous ammonium perchlorate.
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Ultra-ultrahigh burning rate composite modified double-base propellants arebtained by use of porous ammonium perchlorate as a replacement for the ultra-ultrafine ammonium perchlorate. The porous ammonium perchlorate is used in combination with aluminum powder fuel and aluminum staples, nitroglycerin as an explosive plasticizer, triacetin as a non-explosive plasticizer, stabilizers selected from resorcinol and 2-nitrodiphenylamine and other selected additives for achieving desired processing, mechanical, ballistic, and other properties of the propellant.
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CROSS REFERENCE TO PRIOR APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 11/075,922, filed Mar. 10, 2005, which is a continuation of U.S. patent application Ser. No. 09/795,683, filed Feb. 28, 2001, now abandoned and further claims priority to U.S. Provisional Patent Application No. 60/185,610, filed Feb. 29, 2000, the entire disclosures of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to compounds and methods for inhibiting the activity of melanocyte tyrosinase in mammalian skin, in order to reduce the expression and production of skin pigmentation, and thereby lighten the color of mammalian skin.
BACKGROUND OF THE INVENTION
Melanogenesis is the process of production and subsequent distribution of melanin by melanocytes within the skin and hair follicles [1, 2]. Melanocytes have specialized lysosome-like organelles, termed melanosomes, which contain several enzymes that mediate the production of melanin. The copper-containing enzyme tyrosinase catalyzes the oxidation of the amino acid tyrosine into DOPA and subsequently DOPA-quinone. At least two additional melanosomal enzymes are involved in the eumelanogenesis pathway that produces brown and black pigments, including TRP-1 (DHICA oxidase), and TRP-2 (DOPAchrome tautomerase). Depending on the incorporation of a sulfur-containing reactant (e.g. cysteine or glutathione) into the products, the melanogenesis pathway diverges to produce pheomelanins (amber and red pigments).
The perceived color of skin and hair is determined by the ratio of eumelanins to pheomelanins, and in part on blood within the dermis. The balance in skin hue is genetically regulated by many factors, including but not limited to: (a) the levels of expression of tyrosinase, TRP-2, and TRP-1; (b) thiol conjugation (e.g. with glutathione or cysteine) leading to the formation of pheomelanins; (c) the α-melanocyte-stimulating hormone (α-MSH) and melanocortin receptor, which is coupled to the adenylate cyclase/protein kinase A pathway; [15] (d) the product of the agouti locus, agouti signal protein, which has been documented to down-regulate pigmentation of hair melanocytes in rodents; [16] and (e) yet unknown mechanisms that regulate the uptake and distribution of melanosomes in recipient epidermal and hair matrix keratinocytes. [2, 13, 14]
Abnormalities of human skin pigmentation occur as a result of both genetic and environmental factors. Exposure of skin (especially Caucasian) to ultraviolet radiation, particularly in the UVB (i.e. intermediate) wavelengths, upregulates synthesis of melanocyte tyrosinase resulting in increased melanogenesis and thus tanning. However, acute or persistent UVB exposure can result in the formation of hyperpigmented lesions or regions of skin, including malignant melanoma skin cancer. [17] Both actinic damage and constitutional abnormalities can produce affected regions such as melasma, age spots, liver spots, freckles and other lentigenes. [3, 18, 19]
Vitiligo is the converse of hyperpigmentation, in which cutaneous melanocytes are either ablated or fail to produce sufficient pigment. [17, 18, 20] Although it would be desirable to restore lost pigmentation in vitiligo-affected skin with topical therapies, this has proven to be quite difficult to accomplish in a high proportion of subjects. As an alternative to PUVA therapy or cosmetic camouflage with dihydroxyacetone sunless-tanning lotions, [18] one might reduce the normal pigmentation of the unaffected skin to reduce contrast. Furthermore, a global market demand has developed for skin-lightening agents as “vanity” cosmeceutical products, because lighter skin color is preferred by some dark-skinned individuals in many countries and races, for psychological or sociological reasons. [4, 5]
Some purportedly “active” or “functional” agents for lightening skin color (e.g. arbutin, kojic acid, niacinamide, licorice, magnesium ascorbyl phosphate, among others) have not been demonstrated yet to be clinically efficacious when critically analyzed in carefully controlled studies [5, 6, 25]. The U.S. FDA-approved pharmaceutical products containing 2-4% hydroquinone (“HQ”) are minimally to moderately efficacious. However, HQ has been demonstrated to be cytotoxic to cultured mammalian melanocytes, and mutagenic in Salmonella and mammalian Chinese hamster V79 cells [3-6, 10, 11, 25]. HQ appears to be an important intermediate in the bioactivation of the carcinogen benzene [12]. Although it has been repeatedly asserted in the dermatologic literature for many years, without substantiation, that HQ is an inhibitor of tyrosinase, this compound is not an effective inhibitor of the mammalian enzyme [5, 6, 25]. Hydroquinone's in vitro mechanism of action appears to be primarily a melanocytic cytotoxic effect. Its clinical mechanism of action on whole skin remains uncertain.
In view of these biochemical disadvantages of the standard skin bleaching agent, HQ, it is highly desirable to identify other compounds with improved efficacy and safety characteristics. Methyl gentisate (“MG”), the methyl ester of gentisic acid (GA; 2,5-dihydroxybenzoic acid), is a moderately potent inhibitor of melanin accumulation in a murine melanocyte cell culture primary screen [6, 25]. GA is a natural product from the root of the genus Gentiana , named after Gentius, an Illyrian (Greco-Roman) king of the 2 nd century B.C., said to have first discovered the medicinal properties of the plant [7]. The sodium salt of GA is thought to be an analgesic and an anti-inflammatory agent. GA is a ubiquitous metabolite, produced not only by plants, but also by Penicillium patulum and Polyporus tumulosus , and is excreted into the urine of mammals following ingestion of salicylates [8, 9]. MG and GA are simple phenolic compounds structurally similar to HQ, yet lacking the mutagenic activity of HQ [25]. MG has not been developed as a commercially available topical skin lightener product to date.
Two patent publications of Sansei Seiyaku also disclose a number of compounds, which allegedly are active as either tyrosinase inhibitors or as skin lightening agents, JP 5-124925 and JP 5-124922. The compounds are various benzimidazolethiols, but have not been developed as commercially available topical skin lightener products to date. In addition, phenylthiourea (PTU) has been reported as an inhibitor of tyrosinase, but has not been developed as a commercially available topical skin lightener product to date [30-32].
It is an object of this invention to provide methods and compositions for reducing pigmentation in skin from mammals, including humans.
Another object is to provide methods and compositions for reducing pigmentation of skin for cosmetic, beauty-enhancing, or esthetic effects.
It is another object to provide methods and compositions for treating hyperpigmentation-related medical conditions such as melasma, age spots, freckles, ochronosis, postinflammatory hyperpigmentation, lentigo, and other pigmented skin blemishes.
Another object of the present invention is to provide methods and compositions for inhibiting mammalian melanocyte tyrosinase, the rate-limiting enzyme in the production of melanin from tyrosine and DOPA.
Still another object of the invention is to provide methods and compositions to absorb ultraviolet radiation (UVR), and thus to protect skin from UVR and photoaging.
An additional object of the invention is to provide antioxidant compositions that protect skin from oxidative damage, and/or to prevent oxidative decomposition of product formulations.
Another object is to facilitate discovery of compounds that inhibit mammalian tyrosinase in cell-free extracts from mammalian melanocyte or melanoma cells, using either a colorometric DOPA oxidation or a radiolabeled tyrosine or DOPA substrate assay (IC 50 ≦300 μM).
Another object is to facilitate discovery of compounds that inhibit de novo pigment production (synthesis and/or accumulation) in cultured mammalian melanocyte or melanoma cells (IC 50 ≦300 μM).
Another object is to facilitate evaluation of compounds for toxicity in mammalian melanocyte, melanoma, or other cell cultures (IC 50 ≦300 μM.
Another object is to provide composition of matter and/or identity of compounds that are efficacious and/or exhibit reduced toxicity using one or more of the bioassays described in other objects, with biochemical characteristics equivalent to or superior to hydroquinone or methyl gentisate.
Another object is to provide active and/or functional compounds from diverse structural classes, including but not limited to the following examples: benzoimidazoles, phenylamines, phenylthioureas, phenols, and phenylthiols.
Still another object is to provide synthesis of derivatives of active and/or functional compounds of the invention, including by organic synthesis, combinatorial chemistry, medicinal chemistry, X-ray crystallography, rational drug design, and other methods.
Another object is to provide the use of formulations of the present invention for cosmetic, cosmeceutical, over-the-counter drug, and prescription drug products.
Another object is to provide formulations of the present invention for the purpose of reducing or preventing pigmentation in hair, albeit during the biosynthesis of hair, as a result of blocking pigment production within the melanocytes of hair follicles.
Another object is to provide the active and/or functional compounds of the present invention for use in inhibiting tyrosinase or tyrosinase-like enzymes from non-mammalian species, for instance for use in the food science industry for the inhibition of enzymatic browning.
Still another object is to provide the active and/or functional compounds of the present invention for use in inhibiting tyrosine hydroxylase enzymes, in order to reduce the biosynthesis of DOPA and/or catecholamines.
SUMMARY OF THE INVENTION
Several classes of compounds are provided that reduce or prevent the production of pigment by mammalian melanocytes. The compounds preferably inhibit the enzymatic activity of melanocyte tyrosinase, though some compounds control pigment production in melanocyte cells without being potent inhibitors of the enzyme. Therefore, the compounds can be used in applications wherein controlling or preventing the production of pigments in mammalian skin is desired. A few examples of such applications include:
1. As a vanity product, to lighten the skin of an individual, especially of dark skinned individuals; 2. To lessen the hue of pigmented skin blemishes such as freckles and age spots; 3. To diminish uneven pigmentation marks and surface color irregularities; 4. To treat hyperpigmentation-related medical conditions such as melasma, ochronosis, and lentigo; 5. To lighten hair pigmentation when applied to skin containing pigmented hair follicles; 6. To lessen postinflammatory hyperpigmentation resulting from trauma or invasive surgery from a face lift, laser treatment, or cosmetic surgery, and 7. To reduce skin pigmentation in normal skin adjacent to areas affected by vitiligo, thereby diminishing the contrast in color between normal and vitiligo affected skin.
Several classes of active skin lightening compounds have been discovered with which the present invention can be practiced. These compounds exhibit activity in the mammalian tyrosinase and/or melanocyte cell culture pigmentation assays, yet with minimal or no cytotoxicity. These compounds exhibit characteristics that are equivalent to or superior to the known standard skin-bleaching agent, hydroquinone, or the known standard tyrosinase inhibitor, methyl gentisate.
The compounds are typically applied topically to the skin wherein tyrosinase activity is sought to be reduced through a lotion or occlusive patch. The compounds can be spread over a larger area to produce an even skin tone fade, or they can be applied locally to skin blemishes and other localized conditions to minimize skin irregularities. Moreover, because most of the compounds are selective against melanocyte tyrosinase, the compounds can also be administered systemically by methods including oral, intradermal, transdermal, intravenous, and parenteral administrations. The product works by inhibiting the production of melanin in cells beneath the skin surface. Because the skin naturally renews itself every ca. 28 days, when the compounds of the present invention are administered old (differentiated) pigmented keratinocytes cells are gradually sloughed off and keratinocytes with less melanin are eventually brought to the surface giving the skin a lighter, more even toned complexion.
In a first principal embodiment the compounds of the present invention are benzimidazole and phenylthiourea related compounds represented by the following formula (I):
wherein:
1) R 1 is H or a valence for bonding, 2) R 2 is S, or SH; 3) one of the dotted lines represents a bond; 4) R 4 , R 5 , R 6 , and R 7 are independently CR 8 , or N; 5) R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NHSO 2 —C 1-3 alkyl, (vii) —NHCO—C 1-5 alkyl, (viii) oxime, (ix) hydrazine, (x) —NR 9 R 10 , (xi) HSO 2 , (xii) HSO 3 , (xiii) thio-C 1-5 alkyl, (xiv) C 1-5 acyloxy, (xv) H 2 PO 3 , (xvi) thiol, (xvii) —COOR 9 , (xviii) C 1-5 alkynyl, or (xix) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 6) R 9 is hydrogen or C 1-3 alkyl; 7) R 10 is hydrogen, or C 1-5 alkyl optionally substituted with —OH; 8) R″ is C or CH; 9) when R″ is C:
a) R′ is CR 8 , C(R) 2 , N, or NH, and forms a bond with R″; b) 1 or 2 of R 5 and R 6 are NH or COR 10 other than COH, the remainder of R 4 , R 5 , R 6 , and R 7 being CH; and
10) when R″ is CH, R′ is CH 3 or NH 2 .
In a second principal embodiment the compounds of the present invention are benzimidazole and phenylthiourea related compounds represented by the following formula (II):
wherein:
1) R 1 is H; 2) R 2 is selenium; 3) R″ is C or CH; 4) when R″ is C, R′ is C(R 8 ) 2 or NR 3 , and forms a bond with R″; 5) when R″ is CH, R′ is CH 3 or NH 2 ; 6) R 4 , R 5 , R 6 , and R 7 are independently CR 8 , or N; 7) R 3 is (i) substituted or unsubstituted alkyl, alkenyl, aryl, or heterocycle, (ii) —C 1-5 alkoxy, (iii) —OH, (iv) hydrogen, (v) C(O)—C 1-3 alkyl, or (vi) —(CH 2 ) 1-5 C(O)NR 9 R 10 ; 8) R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NHSO 2 —C 1-3 alkyl, (vii) —NHCO—C 1-5 alkyl, (viii) oxime, (ix) hydrazine, (x) —NR 9 R 10 , (xi) HSO 2 , (xii) HSO 3 , (xiii) thio-C 1-5 alkyl, (xiv) C 1-5 acyloxy, (xv) H 2 PO 3 , (xvi) thiol, (xvii) —COOR 9 , (xiii) C 1-5 alkynyl, or (xix) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy; 9) R 9 is hydrogen or C 1-3 alkyl; and 10) R 10 is hydrogen, or C 1-5 alkyl optionally substituted with —OH.
In a third principal embodiment the compounds of the present invention are phenylthiol, phenylamine, and multicyclic-phenolic related compounds of the following structure (III):
wherein:
1) R 1 is (CH 2 ) n SR 7 , (CH 2 ) n NHR 7 , or OR 7 ; 2) n is 0, 1, 2, or 3, 3) R 2 , R 3 , R 4 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NHSO 2 —C 1-3 alkyl, (vii) —NHCO—C 1-5 alkyl, (viii) oxime, (ix) hydrazine, (x) —NR 9 R 10 , (xi) HSO 2 , (xii) HSO 3 , (xiii) thio-C 1-5 alkyl, (xiv) C 1-5 acyloxy, (xv) H 2 PO 3 , (XVI) thiol, (xvii) —COOR 9 , (xviii) C 1-5 alkyl, or (xix) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy; 4) alternatively, R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, pyridine, —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen, and —(CH) 6 —XH— wherein n″ is 2 and X is as defined above; 5) R 7 is (i) substituted or unsubstituted alkyl, alkenyl, aryl, or heterocycle, (ii) —C 1-5 alkoxy, (iii) hydrogen, (iv) —NR 9 R 10 , (v) C(O)—C 1-3 alkyl, or (vi) —(CH 2 ) m C(O)NR 9 R 10 ; 6) R 9 is hydrogen or C 1-3 alkyl; 7) R 10 is hydrogen, or C 1-5 alkyl optionally substituted with —OH; 8) m is 1, 2, 3, 4, or 5; and 9) provided that when R 1 is OR 7 , R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, pyridine, —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen, and —(CH) n″ XH— wherein n″ is 2 and X is as defined above.
In a fourth principal embodiment the compounds of the present invention are benzothiamide and thiophene amine derivatives defined by structures (IV) or (V):
wherein:
1) R 1 , R 2 , and R 3 are independently (i) substituted or unsubstituted alkyl, alkenyl, aryl, or heterocycle, (ii) hydrogen, (iii) C(O)—C 1-3 alkyl, or (iv) —(CH 2 ) 1-5 C(O)NR 9 R 10 ; 2) R 9 is hydrogen or C 1-3 alkyl; 3) R 10 is hydrogen, or C 1-5 alkyl optionally substituted with —OH; 4) Y and Y′ are independently oxygen or sulfur, 5) X is oxygen, sulfur, or nitrogen; and 6) R 4 is C 1-5 alkyl, optionally substituted by —OH, or NR 9 R 9 .
DETAILED DESCRIPTION OF THE INVENTION
Discussion
As noted above, compounds for inhibiting or preventing melanin formation in skin have been discovered for the treatment of various melanin-associated conditions. For example, the compound can be used as a “vanity” product, to lighten the skin of an individual, especially of dark skinned individuals. Alternatively, the compound can be used to reduce uneven pigmentation marks and surface color irregularities, or to diminish pigmented skin blemishes such as freckles and age spots and hyperpigmentation-related medical conditions such as melasma, ochronosis, and lentigo. The compounds can also be used to lighten hair when applied to skin containing pigmented hair follicles, and to lessen postinflammatory hyperpigmentation resulting from trauma or invasive surgery from a face lift, laser treatment, or cosmetic surgery. The active or functional compounds can also be used to reduce skin pigmentation in normal skin adjacent to areas affected by vitiligo, thereby diminishing the contrast in color between normal and vitiligo affected skin.
The invention thus provides a method for lightening mammalian skin that includes applying or otherwise administering an effective treatment amount of an active skin-lightening compound selected from a benzimidazole, a phenylthiourea, a phenylthiol, a bi- or multicyclic phenol, thiophenamine, a benzothiamide, a phenylamine, or a pharmaceutically acceptable salt or ester thereof, optionally in a pharmaceutically acceptable carrier, to a mammalian subject in need thereof. The invention also includes a pharmaceutical composition for topical or general systemic administration, including oral, intradermal, transdermal, occlusive patch, intraveneous, and parenteral formulations, that includes an effective pigment inhibiting amount of the compound. The present invention is principally concerned with compositions that inhibit mammalian tyrosinase activity, and which thus have medicinal and/or cosmetic value. However, the present invention can also extend to compounds that inhibit melanin formation within melanocytes through mechanisms other than tyrosinase activity.
Many of the compounds also possess other activities that are beneficial when integrated into the compositions of the present invention. For example, many of the compounds also absorb UV light, and can thus be used to block the harmful effects of the sun's rays. Some of the compounds also possess antioxidant properties, and thus can inhibit oxidative damage to the skin, or contribute to the stability of the formulation.
Furthermore, although unrelated to skin pigmentation per se, some of the compounds of the present invention may also inhibit tyrosine hydroxylase (TH). This enzyme is structurally dissimilar from tyrosine, but also catalyzes the formation of DOPA from tyrosine. TH is critical for the formation of catecholamines. Therefore, some of the compounds of the present invention which coincidentally inhibit TH activity may have utility in reducing catecholamine biosynthesis, for instance for use as inhibitor “probes” in laboratory experiments where reduction in catecholamine pools is desirable. [30-32]
Compounds of the Present Invention
In a first principal embodiment the compounds of the present invention are benzimidazolethiol and phenylthiourea related compounds represented by the following formula (I):
wherein:
a. R 1 is H or a valence for bonding;
b. R 2 is S, or SH;
c. one of the dotted lines represents a bond;
d. R 4 , R 5 , R 4 , and R 7 are independently CR 8 , or N;
e. R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NHSO 2 —C 1-3 alkyl, (vii) —NHCO—C 1-5 alkyl, (viii) oxime, (ix) hydrazine, (x) —NR 9 R 10 , (xi) HSO 2 , (xii) HSO 3 , (xiii) thio-C 1-5 alkyl, (xiv) C 1-5 acyloxy, (xv) H 2 PO 3 , (xvi) thiol, (xvii) —COOR 9 , (xviii) C 1-5 alkynyl, or (xix) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy;
f. R 9 is hydrogen or C 1-3 alkyl;
g. R 10 is hydrogen, or C 1-5 alkyl optionally substituted with —OH;
h. R″ is C or CH;
i. when R″ is C:
i. R′ is CR 8 , C(R 8 ) 2 , N or NH, and forms a bond with R″; ii. 1 or 2 of R 5 and R 6 are N or COR 10 other than COH, the remainder of R 4 , R 5 , R 6 and R 7 being CH; and
j. when R″ is CH, R′ is CH 3 or NH 2 .
A first series of subembodiments of the first principal embodiment is defined when R 1 , R 2 , and R′ are as defined above, R 4 , R 5 , R 6 , and R 7 are independently CR 8 , R″ is CH, and:
1) R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (viii) —NR 9 R 10 , (xi) C 1-5 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 2) R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) CN, (v) —OR 9 , (viii) —NR 9 R 9 , (xi) C 1-3 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-3 alkyl, —C 1-3 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 9 , C 1-3 thioether, or C 1-3 alkoxy, 3) R 8 is (i) hydrogen, (ii) halogen, (v) OR 9 , (viii) —N 9 R 9 , (xii) thiol, or (xiv) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 ; 4) R 8 is C 1-3 alkyl; 5) R 8 is OR 10 or OR 9 ; or 6) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, C(CF 3 ), and C(CHCHBr).
A second series of subembodiments of the first principal embodiment is defined when R 1 , R 2 , and R′ are as defined above, R″ is CH, and:
1) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NR 9 R 10 , (vii) C 1-5 acyloxy, (viii) thiol, (ix) COOR 9 , or (x) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 2) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R 8 is (i) hydrogen, (ii) halogen, (iii) —OR 9 , (iv) —OH, (v) —NR 9 R 9 , (vi) thiol, or (vii) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 ; 3) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R 8 is C 1-3 alkyl; 4) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is OR 9 , and 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH; or 5) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, C(CF 3 ), and C(CHCHBr), and 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH.
A third series of subembodiments of the first principal embodiment is defined when R 1 and R 2 are as defined above, R″ is CH, and:
1) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , and R′ is NH 2 ; 2) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (viii) —NR 9 R 10 , (xi) C 1-5 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 2 or 3 of R 4 , R 5 , R 6 and R 7 are CH, and R′ is NH 2 ; 3) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (v) —OR 9 , (vii) —OH, (viii) —NR 9 R 9 , (xii) thiol, or (xiv) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is NH 2 ; 4) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is C 1-3 alkyl, OR 10 , or OR 9 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is NH 2 ; 5) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, CCF 3 , and C(CHCHPBr), 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH; and R′ is NH 2 ; 6) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , and R′ is CH 3 ; 7) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (viii) —NR 9 R 10 , (xi) C 1-5 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is CH 3 ; 8) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (v) —OR 9 , (vii) —OH, (viii) —NR 9 R 9 , (xii) thiol, or (xiv) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is CH 3 ; 9) R 4 , R 5 , R 6 , and R 7 are independently selected from C 8 , R 8 is R 8 is C 1-3 alkyl or OR 9 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is CH 3 ; 10) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, CCF 3 , and C(CHCHBr), 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is CH 3 ;
A fourth series of subembodiments of the first principal embodiment is defined when R 1 and R 2 are as defined above, R″ is C, R′ is N or NH, and:
1) 1 or 2 of R 5 and R 6 are COR 10 other than COH, the remainder of R 4 , R 5 , R 6 , and R 7 being CH; 2) 1 or 2 of R 5 and R 6 are COR 9 other than COH, the remainder of R 4 , R 5 , R 6 , and R 7 being CH; 3) 1 or 2 of R 5 and R 6 are N, the remainder of R 4 , R 5 , R 6 , and R 7 being CH; 4) R 5 is COR 9 other than COH, and R 4 , R 6 , and R 7 are CH; 5) R 6 is COR 9 other than COH, and R 4 , R 5 , and R 7 are CH; or 6) R 5 and R 6 are COR 9 other than COH, and R 4 and R 7 are CH.
A fifth series of subembodiments of the first principal embodiment are defined when R 1 and R 2 are as defined above, R″ is C, R′ is CH or CH 2 , and:
1) 1 or 2 of R 5 and R 6 are COR 10 other than COH, the remainder of R 4 , R 5 , R 6 , and R 7 being CH; 2) 1 or 2 of R 5 and R 6 are COR 9 other than COH, the remainder of R 4 , R 5 , R 6 , and R 7 being CH; 3) 1 or 2 of R 5 and R 6 are N, the remainder of R 4 , R 5 , R 6 , and R 7 being CH; 4) R 5 is COR 9 other than COH, and R 4 , R 6 , and R 7 are CH; 5) R 6 is COR 9 other than COH, and R 4 , R 5 , and R 7 are CH; or 6) R 5 and R 6 are COR 9 other than COH, and R 4 and R 7 are CH.
A first series of preferred species of the first principal embodiment are defined when R 1 and R 2 are as defined above, R″ is C, R′ is NH or N, and:
1) R 5 is COCH 3 , and R 4 , R 6 , and R 7 are CH; 2) R 6 is COCH 3 , and R 4 , R 5 , and R 7 are CH; 3) R 5 and R 6 are COCH 3 , and R 4 and R 7 are CH;
A second series of preferred species of the first principal embodiment are defined when R 1 and R 2 are as defined above, R″ is CH, R′ is NH 2 , and:
1) R 4 , R 5 , R 6 , and R 7 are CH; 2) R 4 is CCH 3 , and R 5 , R 6 , and R 7 are CH; 3) R 5 is CCH 3 , and R 4 , R 6 , and R 7 are CH; 4) R 6 is CCH 3 , and R 4 , R 5 , and R 7 are CH; 5) R 7 is CCH 3 , and R 4 , R 5 , and R 6 are CH; 6) R 4 is COCH 3 , and R 5 , R 6 , and R 7 are CH; 7) R 5 is COCH 3 , and R 4 , R 6 , and R 7 are CH; 8) R 6 is COCH 3 , and R 4 , R 5 , and R 7 are CH; 9) R 7 is COCH 3 , and R 4 , R 5 , and R 6 are CH; 10) R 4 is CF, and R 5 , R 6 , and R 7 are CH; 11) R 5 is CF, and R 4 , R 6 , and R 7 are CH; 12) R 6 is CF, and R 4 , R 5 , and R 7 are CH; 13) R 7 is CF, and R 4 , R 5 , and R 6 are CH; 14) R 4 is COH, and R 5 , R 6 , and R 7 are CH; 15) R 5 is COH, and R 4 , R 6 , and R 7 are CH; 16) R 6 is COH, and R 4 , R 5 , and R 7 are CH; 17) R 7 is COH, and R 4 , R 5 , and R 6 are CH; 18) 2 of R 4 , R 5 , R 6 are R 7 are CCH 3 , and 2 of R 4 , R 5 , R 6 , and R 7 are CH; 19) 2 of R 4 , R 5 , R 6 are R 7 are COCH 3 , and 2 of R 4 , R 5 , R 6 , and R 7 are CH; 20) 2 of R 4 , R 5 , R 6 are R 7 are CF, and 2 of R 4 , R 5 , R 6 , and R 7 are CH; or 21) 2 of R 4 , R 5 , R 6 are R 7 are COH, and 2 of R 4 , R 5 , R 6 , and R 7 are CH;
A third series of preferred species of the first principal embodiment are defined when R″ is CH, R′ is CH 3 , and R 4 , R 5 , R 6 , and R 7 are as defined in any one of the second series of preferred species.
In a second principal embodiment the compounds of the present invention are benzimidazoles and phenylthiourea related compounds represented by the following formula (II):
wherein:
1) R 1 is H; 2) R 2 is selenium; 3) R″ is C or CH; 4) when R″ is C, R′ is C(R 8 ) 2 or NR 3 , and forms a bond with R″; 5) when R″ is CH, R′ is CH 3 or NH 2 ; 6) R 4 , R 5 , R 6 , and R 7 are independently CR 8 , or N; 7) R 3 is (i) substituted or unsubstituted alkyl, alkenyl, aryl, or heterocycle, (ii) —C 1-5 alkoxy, (iii) —OH, (iv) hydrogen, (v) C(O)—C 1-3 alkyl, or (vi) —(CH 2 ) 1-5 C(O)NR 9 R 10 ; 8) R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NHSO 2 —C 1-3 alkyl, (vii) —NHCO—C 1-5 alkyl, (viii) oxime, (ix) hydrazine, (x) —NR 9 R 10 , (xi) HSO 2 , (xii) HSO 3 , (xiii) thio-C 1-5 alkyl, (xiv) C 1-5 acyloxy, (xv) H 2 PO 3 , (xvi) thiol, (xvii) —COOR 9 , (xviii) C 1-5 alkynyl, or (xix) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy; 9) R 9 is hydrogen or C 1-3 alkyl; and 10) R 10 is hydrogen, or C 1-5 alkyl optionally substituted with —OH.
A first series of subembodiments of the second principal embodiment are defined when R 1 , R 2 , R′ and R″ are as defined above, R 4 , R 5 , R 6 and R 7 are CR 8 , and:
1) R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (viii) —NR 9 R 10 , (xi) C 1-5 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy; 2) R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 9 , (viii) —NR 9 R 9 , (xi) C 1-3 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-3 alkyl, —C 1-3 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 9 , C 1-3 thioether, or C 1-3 alkoxy; 3) R 8 is (i) hydrogen, (ii) halogen, (v) —OR 9 , (viii) —NR 9 R 9 , (xii) thiol, or (xiv) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 ; 4) R 8 is C 1-3 alkyl; 5) R 8 is OR 10 or OR 9 ; or 6) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, CCF 3 , and C(CHCHBr).
A second series of subembodiments of the second principal embodiment is defined when R 1 , R 2 , R′ and R″ are as defined above, and:
1) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NR 9 R 10 , (vii) C 1-5 acyloxy, (viii) thiol, (ix) COOR 9 , or (x) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 2) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R 8 is (i) hydrogen, (ii) halogen, (iii) —OR 9 , (iv) —OH, (v) —NR 9 R 9 , (vi) thiol, or (vii) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 ; 3) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R 8 is C 1-3 alkyl; 4) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is OR 9 , and 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH; and 5) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, CCF 3 , and C(CHCHBr), and 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH.
A third series of subembodiments of the second principal embodiment are defined when R 1 and R 2 are as defined above, R″ is C, and:
1) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , and R′ is NR 3 ; 2) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (viii) —NR 9 R 10 , (xi) C 1-5 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 2 or 3 of R 4 , R 5 , R 6 and R 7 are CH, and R′ is NR 3 ; 3) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (v) —R 9 , (vii) —OH, (viii) —NR 9 R 9 , (xii) thiol, or (xiv) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is NR 3 ; 4) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is R 8 is C 1-3 alkyl or OR 9 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is NR 3 ; 5) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, CCF 3 , and C(CHCHBr), 2 or 3 of R 4 , R 5 , and R 7 are CH; and R′ is NR 3 ; 6) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R′ is NR 3 , and R 3 is hydrogen, or C 1-5 alkyl optionally substituted with —OH; 7) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (viii) —NR 9 R 10 , (xi) C 1-5 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, R′ is NR 3 , and R 3 is hydrogen, or C 1-5 alkyl optionally substituted with —OH; 8) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (v) —OR 9 , (vii) —OH, (viii) —NR 9 R 9 , (xii) thiol, or (xiv) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, R′ is NR 3 , and R 3 is hydrogen, or C 1-5 alkyl optionally substituted with —OH; 9) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is R 8 is C 1-3 alkyl or OR 9 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, R′ is NR 3 , and R 3 is hydrogen, or C 1-5 alkyl optionally substituted with —OH; 10) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, CCF 3 , and C(CHCHBr), 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH; R′ is NR 3 ; and R 3 is hydrogen, or C 1-5 alkyl optionally substituted with —OH; 11) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R′ is NR 3 , and R 3 is hydrogen or C 1-3 alkyl; 12) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (viii) —NR 9 R 10 , (xi) C 1-5 acyloxy, (xii) thiol (xiii) COOR 9 , or (xiv) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, R′ is NR 3 , and R 3 is hydrogen or C 1-3 alkyl; 13) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (v) —OR 9 , (vii) —OH, (viii) —NR 9 R 9 , (xii) thiol or (xiv) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, R′ is NR 3 , and R 3 is hydrogen or C 1-3 alkyl; 14) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is R 8 is C 1-3 alkyl or OR 9 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, R′ is NR 3 , and R 3 is hydrogen or C 1-3 alkyl; or 15) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, CCF 3 , and C(CHCHBr), 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH; R′ is NR 3 , and R 3 is hydrogen or C 1-3 alkyl.
A fourth series of subembodiments of the second principal embodiment is defined when R 1 and R 2 are as defined above, R″ is CH, and:
1) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , and R′ is NH 2 ; 2) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) (N, (v) —OR 10 , (viii) —NR 9 R 10 , (xi) C 1-5 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is NH 2 ; 3) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (v) —OR 9 , (vii) —OH, (viii) —NR 9 R 9 , (xii) thiol, or (xiv) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is NH 2 ; 4) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is R 8 is C 1-3 alkyl or OR 9 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is NH 2 ; 5) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, CCF 3 , and C(CHCHBr), 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH; and R′ is NH 2 ; 6) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , and R′ is CH 3 ; 7) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (viii) —NR 9 R 10 , (xi) C 1-5 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, R′ is NR 3 , and R′ is CH 3 ; 8) R 4 , R 5 , R 6 , and R 7 are independently selected from CR 8 , R 8 is (i) hydrogen, (ii) halogen, (v) —OR 9 , (vii) —OH, (viii) —NR 9 R 9 , (xii) thiol, or (xiv) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is CH 3 ; 9) R 4 , R 5 , R 6 , and R 7 are independently selected from C 8 , R 8 is R 8 is C 1-3 alkyl or OR 9 , 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH, and R′ is CH 3 ; and 10) R 4 , R 5 , R 6 , and R 7 are independently selected from CH, C(OH), C(SH), CNH 2 , C(CH 3 ), C(OCH 3 ), CF, CCF 3 , and C(CHCHBr), 2 or 3 of R 4 , R 5 , R 6 , and R 7 are CH; and R′ is CH 3 .
A first series of preferred species of the second principal embodiment are defined when R 1 and R 2 are as defined above, R″ is C, R′ is NH, and:
1) R 4 , R 5 , R 6 , and R 7 are CH; 2) R 4 is CCH 3 , and R 5 , R 6 , and R 7 are CH; 3) R 5 is CCH 3 , and R 4 , R 6 , and R 7 are CH; 4) R 6 is CCH 3 , and R 4 , R 5 , and R 7 are CH; 5) R 7 is CCH 3 , and R 4 , R 5 , and R 6 are CH; 6) R 4 is COCH 3 , and R 5 , R 6 , and R 7 are CH; 7) R 5 is COCH 3 , and R 4 , R 6 , and R 7 are CH; 8) R 6 is COCH 3 , and R 4 , R 5 , and R 7 are CH; 9) R 7 is COCH 3 , and R 4 , R 5 , and R 6 are CH; 10) R 4 is CF, and R 5 , R 6 , and R 7 are CH; 11) R 5 is CF, and R 4 , R 6 , and R 7 are CH; 12) R 6 is CF, and R 4 , R 5 , and R 7 are CH; 13) R 7 is CF, and R 4 , R 5 , and R 6 are CH; 14) R 4 is COH, and R 5 , R 6 , and R 7 are CH; 15) R 5 is COH, and R 4 , R 6 , and R 7 are CH; 16) R 6 is COH, and R 4 , R 5 , and R 7 are CH; 17) R 7 is COH, and R 4 , R 5 , and R 6 are CH; 18) 2 of R 4 , R 5 , R 6 are R 7 are CCH 3 , and 2 of R 4 , R 5 , R 6 , and R 7 are CH; 19) 2 of R 4 , R 5 , R 6 are R 7 are COCH 3 , and 2 of R 4 , R 5 , R 6 , and R 7 are CH; 20) 2 of R 4 , R 5 , R 6 are R 7 are CF, and 2 of R 4 , R 5 , R 6 , and R 7 are CH; or 21) 2 of R 4 , R 5 , are R 7 are COH, and 2 of R 4 , R 5 , R 6 , and R 7 are CH;
A second series of preferred species of the second principal embodiment are defined when R″ is CH, R′ is NH 2 , and R 4 , R 5 , R 6 , and R 7 are as defined in any one of the first series of preferred species.
A third series of preferred species of the present invention are defined when R″ is CH, R′ is CH 3 , and R 4 , R 5 , R 6 , and R 7 are as defined in any one of the first series of preferred species.
In a third principal embodiment the compounds of the present invention are phenylthiol, phenylamine, and multicyclic-phenolic related compounds of the following structure (III):
wherein:
1) R 1 is (CH 2 ) n SR 7 , (CH 2 ) n NR 7 , or OR 7 ; 2) n is 0, 1, 2, or 3, 3) R 2 , R 3 , R 4 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NHSO 2 —C 1-3 alkyl, (vii) —NHCO—C 1-5 alkyl, (viii) oxine, (ix) hydrazine, (x) —NR 9 R 10 , (xi) HSO 2 , (xii) HSO 3 , (xiii) thio-C 1-5 alkyl, (xiv) C 1-5 acyloxy, (xv) H 2 PO 3 , (xvi) thiol, (xvii) —COOR 9 , (xviii) C 1-5 alkynyl, or (xix) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy, 4) alternatively, R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, pyridine, —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen, and —(CH) n″ —XH— wherein n″ is 2 and X is as defined above; 5) R 7 is (i) substituted or unsubstituted alkyl, alkenyl, aryl, or heterocycle, (ii) —C 1-5 alkoxy, (iii) hydrogen, (iv) C(O)—C 1-3 alkyl, or (v) —(CH 2 ) m C(O)NR 9 R 10 ; 6) R 9 is hydrogen or C 1-3 alkyl; 7) R 10 is hydrogen, or C 1-5 alkyl optionally substituted with —OH; 8) m is 1, 2, 3, 4, or 5; and 9) provided that when R 1 is OR 7 , R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, pyridine, —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen, and —(CH) n″ XH— wherein n″ is 2 and X is as defined above.
A first series of subembodiments of the third principal embodiment are defined when R 1 is (CH 2 )SR 7 , n is 0, 1, 2, or 3 but preferably 0, and:
1) R 2 , R 3 , R 4 , R 5 and R 6 are as defined above, and R 7 is hydrogen, C 1-5 alkyl optionally substituted with —OH, or C(O)C 1-3 alkyl; 2) R 2 , R 3 , R 4 , R 5 and R 6 are as defined above, and R 7 is hydrogen, C 1-3 alkyl, or C(O)C 1-3 alkyl; 3) R 2 , R 3 , R 4 , R 5 and R 6 are as defined above, and R 7 is hydrogen; 4) R 2 , R 3 , R 4 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (viii) —NR 9 R 10 , (xi) C 1-5 acyloxy, (xii) thiol, (xiii) COOR 9 , or (xiv) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 9 , C 1-5 thioether, or C 1-5 alkoxy, or (xv) —NHCO—C 1-5 alkyl; and R 7 is as defined above; 5) R 2 , R 3 , R 4 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 9 , (viii) —NR 9 R 9 , (xi) C 1-3 acyloxy, (xii) thiol, (xiii) COOR 9 , (xiv) —C 1-3 alkyl, —C 1-3 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 9 , C 1-3 thioether, or C 1-3 alkoxy, or (xv) —NHCO—C 1-3 alkyl; and R 7 is as defined above; 6) R 2 , R 3 , R 4 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (v) —OR 9 , (viii) —NR 9 R 9 , (xii) thiol, (xiv) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 , or (xv) —NHCO—C 1-3 alkyl; and R 7 is as defined above; 7) R 2 , R 3 , R 4 , R 5 and R 6 are independently selected from C 1-3 alkyl, OR 9 , or —NHCO—CH 3 aryl; and R 7 is as defined above; 8) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, pyridine, —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen, and —(CH) n″ XH— wherein n″ is 2 and X is as defined above; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi —NR 9 R 10 , (vii) C 1-5 acyloxy, (viii) thiol, (ix) COOR 9 , or (x) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy; and R 7 is as defined above; 9) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, pyridine, —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen, and —CH) n″ XH— wherein n″ is 2 and X is as defined above; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 9 , (vi) —NR 9 R 9 , (vii) C 1-3 acyloxy, (viii) thiol, (ix) COOR 9 , or (x) —C 1-3 alkyl, —C 1-3 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 9 , C 1-3 thioether, or C 1-3 alkoxy, and R 7 is as defined above; 10) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, pyridine, —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen, and —(CH) n —X— wherein n″ is 2 and X is as defined above; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) —OR 9 , (iv) —NR 9 R 9 , (v) thiol, or (vi) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 ; and R 7 is as defined above; 11) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, pyridine, —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen, and —(CH) n″ XH— wherein n″ is 2 and X is as defined above; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from C 1-3 alkyl or OR 9 ; and R 7 is as defined above; 12) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, and pyridine; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NR 9 R 10 , (vii) C 1-5 acyloxy, (viii) thiol, (ix) COOR 9 , or (x) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy; and R 7 is as defined above; 13) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, and pyridine; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 9 , (vi) —NR 9 R 9 , (vii) C 1-3 acyloxy, (viii) thiol, (ix) COOR 9 , or (x) —C 1-3 alkyl, —C 1-3 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 9 , C 1-3 thioether, or C 1-3 alkoxy; and R 7 is as defined above; 14) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, or pyridine; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) —OR 9 , (iv) —NR 9 R 9 , (v) thiol, or (vi) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 ; and R 7 is as defined above; 15) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from phenyl, cyclopentyl, cyclohexyl, pyrrole, furan, thiophene, pyrazole, or pyridine; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from C 1-3 alkyl or OR 9 ; and R 7 is as defined above; 16) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NR 9 R 10 , (vii) C 1-5 acyloxy, (viii) thiol, (ix) COOR 9 , or (x) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy; and R 7 is as defined above; 17) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 9 , (vi) —NR 9 R 9 , (vii) C 1-3 acyloxy, (viii) thiol, (ix) COOR 9 , or (x) —C 1-3 alkyl, —C 1-3 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 9 , C 1-3 thioether, or C 1-3 alkoxy; and R 7 is as defined above; 18) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) —OR 9 , (iv) —NR 9 R 9 , (v) thiol, or (vi) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 ; and R 7 is as defined above; 19) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from —X—(CH 2 ) n′ —X— wherein n′ is 1 and X is nitrogen, sulfur, or oxygen; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from C 1-3 alkyl or OR 9 ; and R 7 is as defined above; 20) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from —(CH) n″ XH— wherein n″ is 2 and X is nitrogen, sulfur, or oxygen; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 10 , (vi) —NR 9 R 10 , (vii) C 1-5 acyloxy, (viii) thiol, (ix) COOR 9 , or (x) —C 1-5 alkyl, —C 1-5 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 10 , C 1-5 thioether, or C 1-5 alkoxy; and R 7 is as defined above; 21) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from —(CH) n″ XH— wherein n″ is 2 and X is nitrogen, sulfur, or oxygen; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) NO 2 , (iv) —CN, (v) —OR 9 , (vi) —NR 9 R 9 , (vii) C 1-3 acyloxy, (viii) thiol, (ix) COOR 9 , or (x) —C 1-3 alkyl, —C 1-3 alkenyl, aryl, heteroaryl, or heterocycle, optionally substituted with one or more of —OH, —SH, C(O)H, COOR 9 , C 1-5 acyloxy, halogen, NR 9 R 9 , C 1-3 thioether, or C 1-3 alkoxy; and R 7 is as defined above; 22) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from —CH) n″ XH— wherein n″ is 2 and X is nitrogen, sulfur, or oxygen; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from (i) hydrogen, (ii) halogen, (iii) —OR 9 , (iv) —NR 9 R 9 , (v) thiol, or (vi) —C 1-3 alkyl or alkenyl optionally substituted with one or more of —OH, —SH, halogen, or NH 2 ; and R 7 is as defined above; 23) (a) R 3 and R 4 , or R 4 and R 5 , combine to form a fused ring-structure which is cycloalkyl, aryl, or heterocyclic selected from —(CH) n″ XH— wherein n″ is 2 and X is nitrogen, sulfur, or oxygen; and (b) the remainder of R 2 , R 3 , R 5 and R 6 are independently selected from C 1-3 alkyl or OR 9 ; and R 7 is as defined above;
A second series of subembodiments is defined when R 1 is (CH 2 ) n SR 7 , n is 0, 1, 2, or 3, R 7 is C 1-5 alkyl optionally substituted with —OH, or C(O)C 1-3 alkyl; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments. A subset of the second series of embodiments is defined when R 1 is SR 7 , R 7 is C 1-5 alkyl optionally substituted with —OH, or C(O)C 1-3 alkyl; R 4 , is —NHCO—C 1-3 alkyl; and R 2 , R 3 , R 5 and R 6 are CH.
A third series of subembodiments is defined when R 1 is (CH 2 ) n SR 7 , n is 0, 1, 2, or 3, R 7 is C 1-3 alkyl, or C(O)C 1-3 alkyl; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments. Preferably, R 4 , is —NHCO—C 1-3 alkyl; and R 2 , R 3 , R 5 and R 6 are CH.
A fourth series of subembodiments is defined when R 1 is (CH 2 ) n SR 7 , n is 0, 1, 2, or 3, R 7 is hydrogen; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments. Preferably, R 4 , is —NHCO—C 1-3 alkyl; and R 2 , R 3 , R 5 and R 6 are CH.
A fifth series of subembodiments is defined when R 1 is SR 7 , R 7 is C 1-5 alkyl optionally substituted with —OH; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments. Preferably, R 4 , is —NHCO—C 1-3 alkyl; and R 2 , R 3 , R 5 and R 6 are CH.
A sixth series of subembodiments is defined when R 1 is SR 7 , R 7 is C 1-3 alkyl; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments. Preferably, R 4 , is —NHCO—C 1-3 alkyl; and R 2 , R 3 , R 5 and R 6 are CH.
A seventh series of subembodiments is defined when R 1 is SR 7 , R 7 is hydrogen; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments. Preferably, R 4 , is —NHCO—C 1-3 alkyl; and R 2 , R 3 , R 5 and R 6 are CH.
An eighth series of subembodiments is defined when R 1 is (CH 2 ) n NHR 7 , n is 0, 1, 2, or 3, R 7 is C 1-5 alkyl optionally substituted with —OH; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments.
A ninth series of subembodiments is defined when R 1 is (CH 2 ) n NHR 7 , n is 0, 1, 2, or 3, R 7 is C 1-3 alkyl; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments.
An tenth series of subembodiments is defined when R 1 is (CH 2 ) n NHR 7 , n is 0, 1, 2, or 3, R 7 is hydrogen; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments.
An eleventh series of subembodiments is defined when R 1 is NHR 7 , R 7 is C 1-5 alkyl optionally substituted with —OH; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments.
A twelfth series of subembodiments is defined when R 1 is NHR 7 , R 7 is C 1-3 alkyl; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments.
A thirteenth series of subembodiments is defined when R 1 is NHR 7 , R 7 is hydrogen; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 4 th through 23d subembodiments of the first series of subembodiments.
An fourteenth series of subembodiments is defined when R 1 is OR 7 , R 7 is C 1-5 alkyl optionally substituted with —OH; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 8 th through 23d subembodiments of the first series of subembodiments.
A fifteenth series of subembodiments is defined when R 1 is OR 7 , R 7 is C 1-3 alkyl; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 8 th through 23d subembodiments of the first series of subembodiments.
A sixteenth series of subembodiments is defined when R 1 is OR 7 , R 7 is hydrogen; and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of the 8 th through 23d subembodiments of the first series of subembodiments.
A first series of species of the second principal embodiment are defined when R 1 is SH or SC(O)CH 3 , and:
1) R 2 is OCH 3 , and R 3 , R 4 , R 5 and R 6 are CH. 2) R 3 is OCH 3 , and R 2 , R 4 , R 5 and R 6 are CH. 3) R 4 is OCH 3 , and R 2 , R 3 , R 5 and R 6 are CH. 4) R 5 is OCH 3 , and R 2 , R 3 , R 4 and R 6 are CH. 5) R 6 is OCH 3 , and R 2 , R 3 , R 4 and R 5 are CH. 6) 2 of R 2 , R 3 , R 4 , R 5 , and R 6 are OCH 3 , and the remainder of R 2 , R 3 , R 4 , R 5 , and R 6 are CH. 7) R 2 is SCH 3 , and R 3 , R 4 , R 5 and R 6 are CH. 8) R 3 is SCH 3 , and R 2 , R 4 , R 5 and R 6 are CH. 9) R 4 is SCH 3 , and R 2 , R 3 , R 5 and R 6 are CH. 10) R 5 is SCH 3 , and R 2 , R 3 , R 4 and R 6 are CH. 11) R 6 is SCH 3 , and R 2 , R 3 , R 4 and R 5 are CH. 12) 2 of R 2 , R 3 , R 4 , R 5 , and R 6 are SCH 3 , and the remainder of R 2 , R 3 , R 4 , R 5 , and R 6 are CH. 13) R 2 is NHC(O)CH 3 , and R 3 , R 4 , R 5 and R 6 are CH. 14) R 3 is NHC(O)CH 3 , and R 2 , R 4 , R 5 and R 6 are CH. 15) R 4 is NHC(O)CH 3 , and R 2 , R 3 , R 5 and R 6 are CH. 16) R 5 is NHC(O)CH 3 , and R 2 , R 3 , R 4 and R 6 are CH. 17) R 6 is NHC(O)CH 3 , and R 2 , R 3 , R 4 and R 5 are CH.
A second series of preferred species are defined when R 1 is NH 2 , and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of species 1-17 of the first series of preferred embodiments.
A third series of preferred species are defined when R 1 is NHC(O)CH 3 , and R 2 , R 3 , R 4 , R 5 and R 6 are as defined in any one of species 1-17 of the first series of preferred embodiments.
In a fourth principal embodiment the compounds of the present invention are defined by structures (IV) or (V):
wherein:
1) R 1 , R 2 , and R 3 are independently (i) substituted or unsubstituted alkyl, alkenyl, aryl, or heterocycle, (ii) hydrogen, (iii) C(O)—C 1-3 alkyl, or (iv) —(CH 2 ) 1-5 C(O)NR 9 R 10 ; 2) R 9 is hydrogen or C 1-3 alkyl; 3) R 10 is hydrogen, or C 1-5 alkyl optionally substituted with —OH; 4) Y and Y′ are independently oxygen or sulfur, 5) X is oxygen, sulfur, or nitrogen; and 6) R 4 is C 1-5 alkyl, optionally substituted by —OH, or NR 9 R 9 .
A first series of subembodiments of the fourth principal embodiment are defined by structure (IV) when Y and Y′ are as described above, and:
1. R 1 is hydrogen, and R 2 and R 3 are C 1-5 alkyl optionally substituted with —OH; and 2. R 1 is hydrogen, and R 2 and R 3 are hydrogen or C 1-3 alkyl.
A second series of subembodiments of the fourth principal embodiment are defined by structure (V) when:
1. X is sulfur, R 1 is hydrogen, and R 2 is C 1-5 alkyl optionally substituted with —OH; 2. X is sulfur, R 1 is hydrogen, and R 2 is hydrogen or C 1-3 alkyl; 3. X is sulfur, R 1 is hydrogen, R 2 is C 1-5 alkyl optionally substituted with —OH; and R 4 is unsubstituted (CH 2 ) 1-5 ; or 4. X is sulfur, R 1 is hydrogen, R 2 is hydrogen or C 1-3 alkyl, and R 4 is unsubstituted (CH 2 ) 1-3 .
Preferred species are defined for structure (IV) when Y is sulfur, Y′ is oxygen, R 1 and R 2 are hydrogen, and R 3 is methyl, and for structure (V) when X is sulfur, R 4 is ethylene and R 1 and R 2 are hydrogen.
The compounds of this invention can be optionally substituted with substituents that do not adversely affect the activity of the compound as a skin lightener. Nonlimiting examples of substituents include, but are not limited to, alkyl (including lower alkyl), heteroalkyl, aryl, heterocyclic (including heteroaryl and heterocycloalkyl), halo, hydroxyl, carboxyl, acyl, acyloxy, amino, alkylamino, arylamino, alkoxy, aryloxy, alkylthio, alkylamido, nitro, cyano, sulfonic acid, sulfate, phosphonic acid, phosphate, or phosphonate, either unprotected, or protected as necessary, as known to those skilled in the air, for example, as taught in Greene, et al., Protective Groups in Organic Synthesis , John Wiley and Sons, Second Edition, 1991. It will be understood that the present invention also covers “prodrugs” for such compositions, and pharmaceutically acceptable salts and esters thereof.
Properties of the Compounds of the Present Invention
In the present invention, one or all of three in vitro bioassays can be utilized to evaluate the efficacy and toxicity of candidate skin-lightening compounds. The three bioassays characterize the compounds with regard to mammalian tyrosinase enzyme inhibition (cell free), pigmentation in melanocyte cultured cells, and cytotoxicity of mammalian cultured cells. Both cell-based pigmentation and cell-free enzymatic assays have been developed [5, 6, 25] using the mammalian melanocyte cell line, Mel-Ab, a C57BL/6 mouse-derived cell line that produces high levels of melanin. [21] A distinct advantage of this approach is that humans share substantial sequence similarities in their genes (DNA) and proteins (such as tyrosinase) with mice, relative to non-mammalian species (e.g., mushrooms). So, mouse Mel-Ab melanocytes can serve as adequate surrogates for human melanocytes for many pharmacologic purposes.
These adherent murine melanocytes are grown on tissue culture plastic in medium supplemented with fetal bovine serum, 12-O-tetradecanoylphorbol-13-acetate (TPA) to stimulate cell division via down-regulation of protein kinase C, [22, 23] and cholera toxin to stimulate adenylate cyclase activity in the absence of α-MSH. [15, 24] Cellular lysates of Mel-Ab cells may be used as tyrosinase enzyme preparations. Multi-well plate assays have been validated [5, 6, 25] for enzyme inhibition (e.g., DOPA oxidation by colorimetric measurement or radiolabeled substrate incorporation into melanin) and for pigmentation assays on cultured Mel-Ab cells. After 4 days of treatment of cultured cells, melanin content is determined using a spectrophotometer at 400+ nm. [6, 25] This assay can detect an apparent loss in pigmentation resulting from either inhibition of de novo synthesis (e.g. via inhibition of tyrosinase, or the adenylate cyclase pathway, or another pathway) or a cytostatic/cytotoxic mechanism. It is therefore a broad primary screen. It is used in parallel with the tyrosinase enzymatic assay to determine whether an inhibitor of pigmentation at the cellular level is acting primarily at the enzyme level.
To determine cytotoxicity, crystal violet or other staining methods may be used to quantify adherent cell numbers following a period of treatment by an agent HQ is typically used as a positive control in the assay, since it exhibits an IC 50 in the low micrograms per milliliter range on Mel-Ab culture using this assay, albeit owing to cytotoxicity and not inhibition of pigmentation per se. [6] It should be noted that many inhibitors identified in cell-free enzymatic assays might have subsequent difficulties with toxicity or delivery in melanocyte cell-based assays. Therefore, all three in vitro assays in combination provide an excellent characterization of candidate skin lightening compounds.
A distinct advantage of the screening systems (developed by the inventors of the present invention) is the focus on mammalian tyrosinase, as opposed to non-mammalian enzymes often used by other investigators, such as mushroom tyrosinase. Since the biochemical and pharmacologic characteristics of an enzyme or isozyme can vary dramatically between species of organisms (e.g., due to dissimilarities in primary, secondary, and tertiary structure), it is highly preferable that candidate topical skin lighteners intended for human use be discovered based on their biochemical action against a mammalian source of the enzyme. Mushroom tyrosinase (and in some instances plant polyphenol oxidases) has been used in the vast majority of prior inhibitor studies. [28, 29] Yet fungal tyrosinase exhibits substantial dissimilarities from mammalian tyrosinase(s), and is viewed as a substantially inferior strategy for pharmacologic screening. Thus, the methods reported by the inventors of the present invention for screening against mammalian tyrosinase or within melanocytes is highly preferred over other possible screening strategies. [5, 6, 25]
The substrate kinetic “affinity” of mammalian tyrosinase for L-tyrosine is approximately K M =600 μM. A potentially effective candidate skin lightening agent is considered to be desirable, active, and/or functional if it renders 50% inhibition of mammalian tyrosinase enzyme activity, at concentrations below half the enzyme's “affinity” for tyrosine in cell-free enzyme extracts (IC 50 ≦300 μM) and pigment production in melanocyte cell cultures (IC 50 ≦300 μM). In preferred embodiments the agent has an IC 50 against tyrosinase in cell-free enzyme extracts of less then 200, 100, 50, or 25 μM, and/or an IC 50 against pigment production in melanocyte cell cultures of less than 200, 100, 50, or 25 μM. In addition, it is desirable for the compounds to exhibit minimal cytotoxicity, e.g., thus retaining viability of 50% or more of the cultured cells (IC 50 ≧300 μM), as evidenced by adherent cell number. In preferred embodiments the agent exhibits toxicity at greater than 500, 750, or 1000 μM.
Curto, E. V., et al. (1999) [25] reports that methyl gentisate is an “effective” candidate skin-lightening agent based on in vitro bioassays, because it has an IC 50 of 11.2±4 (ug/mL) against tyrosinase activity in cell-free assays, an IC 50 of 30.9±5 (ug/mL) in melanocyte cell cultures, and melanocyte cytotoxicity IC 50 of 118.7±12 (ug/mL). Methyl gentisate thus poses a standard, against which the efficacy and cytotoxicity of other tyrosinase inhibiting compounds can be evaluated. By contrast to MG, hydroquinone is an inferior standard, exhibiting potent cytotoxicity and minimal enzymatic inhibition. [5, 6, 25]
Significantly, many of the particular compounds of this invention are comparable to or a more effective candidate skin lightening agents than methyl gentisate. Thus, in another embodiment the invention provides methods for inhibiting pigment production that includes administering an effective treatment amount of a pigment inhibiting compound wherein (i) the compound inhibits tyrosinase activity equivalent to or greater than methyl gentisate in cell-free enzyme extracts from mammalian melanocyte or melanoma cells, when evaluated using either a colorometric DOPA oxidation or a radiolabeled tyrosine or DOPA substrate assay as described in Curto, E. V., et al. (1999) [25], or (ii) the compound inhibits de novo pigment production (synthesis and/or accumulation) equivalent to or greater than methyl gentisate when evaluated in cultured mammalian melanocyte or melanoma cells. Curto, E. V., et al. (1999) [25]. In a preferred embodiment the toxicity of the compound in mammalian melanocyte, melanoma, or other cell cultures is equivalent to or less than the toxicity of methyl gentisate. Curto, E. V., et al. (1999) [25].
In another embodiment computer-based molecular orbital predictions can aid in the understanding and predictability of structure-activity relationships, such that other effective compounds can be identified and evaluated. See Sakurada, J., et al., “Kinetic and molecular orbital studies on the rate of oxidation of monosubstituted phenols and anilines by horseradish peroxidase compound II.” Biochemistry 29: 4093-4098 (1990) [26].
DEFINITIONS AND USE OF TERMS
The following definitions and term construction are intended, unless otherwise indicated:
Specific and preferred values listed below for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents.
Halo is fluoro, chloro, bromo, or iodo.
Alkyl, alkoxy, alkenyl, alkynyl, etc. denote both straight and branched groups; but reference to an individual radical such as “propyl” embraces only the straight chain radical, a branched chain isomer such as “isopropyl” being specifically referred to.
The term alkyl, as used herein, unless otherwise specified, refers to a saturated straight, branched, or cyclic, primary, secondary, or tertiary hydrocarbon of C 1 to C 10 , and specifically includes methyl, ethyl, propyl, isopropyl, cyclopropyl, butyl, isobutyl, t-butyl, pentyl, cyclopentyl, isopentyl, neopentyl, hexyl, isohexyl, cyclohexyl, cyclohexylmethyl, 3-methylpentyl, 2,2-dimethylbutyl, and 2,3-dimethylbutyl. When the context of this document allows alkyl to be substituted, the moieties with which the alkyl group can be substituted are selected from the group consisting of hydroxyl, amino, alkylamino, arylamino, alkoxy, aryloxy, aryl, heterocycle, halo, carboxy, acyl, acyloxy, amido, nitro, cyano, sulfonic acid, sulfate, phosphonic acid, phosphate, or phosphonate, either unprotected, or protected as necessary, as known to those skilled in the art, for example, as taught in Greene, et al., Protective Groups in Organic Synthesis , John Wiley and Sons, Second Edition, 1991, hereby incorporated by reference.
The term lower alkyl, as used herein, and unless otherwise specified, refers to a C 1 to C 4 saturated straight, branched, or if appropriate, a cyclic (for example, cyclopropyl) alkyl group, including both substituted and unsubstituted forms. Unless otherwise specifically stated in this application, when alkyl is a suitable moiety, lower alkyl is preferred. Similarly, when alkyl or lower alkyl is a suitable moiety, unsubstituted alkyl or lower alkyl is preferred.
The terms alkenyl and alkynyl refer to alkyl moieties, including both substituted and substituted forms, wherein at least one saturated C—C bond is replaced by a double or triple bond. Thus, (C 2 -C 6 )alkenyl can be vinyl, allyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, 3-butenyl, 1-pentenyl, 2-pentenyl, 3-pentenyl, 4-pentenyl, 1-hexenyl, 2-hexenyl, 3-hexenyl, 4-hexenyl, or 5-hexenyl. Similarly, (C 2 -C 6 )alkynyl can be ethynyl, 1-propynyl, 2-propynyl, 1-butynyl, 2-butynyl, 3-butynyl, 1-pentynyl, 2-pentynyl, 3-pentynyl, 4-pentynyl, 1-hexynyl, 2-hexynyl, 3-hexynyl, 4-hexynyl, or 5-hexynyl.
The term “alkylene” refers to a saturated, straight chain, divalent alkyl radical of the formula —(CH 2 ) n —, wherein n can be 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10.
As used herein, with exceptions as noted, “aryl” is intended to mean any stable monocyclic, bicyclic or tricyclic carbon ring of up to 8 members in each ring, wherein at least one ring is aromatic as defined by the Huckel 4n+2 rule. Examples of aryl ring systems include phenyl, naphthyl, tetrahydronaphthyl, and biphenyl. The aryl group can be substituted with one or more moieties selected from the group consisting of hydroxyl, amino, alkylamino, arylamino, alkoxy, aryloxy, alkyl, heterocycle, halo, carboxy, acyl, acyloxy, amido, nitro, cyano, sulfonic acid, sulfate, phosphonic acid, phosphate, or phosphonate, either unprotected, or protected as necessary, as known to those skilled in the art, for example, as taught in Greene, et al., Protective Groups in Organic Synthesis , John Wiley and Sons, Second Edition, 1991.
The term heterocycle or heterocyclic, as used herein except where noted represents a stable 5- to 7-membered monocyclic or stable 8- to 11-membered bicyclic heterocyclic ring which is either saturated or unsaturated, including heteroaryl, and which consists of carbon atoms and from one to three heteroatoms selected from the group consisting of N, O, S, and P; and wherein the nitrogen and sulfur heteroatoms may optionally be oxidized, and the nitrogen heteroatom may optionally be quaternized, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached at any heteroatom or carbon atom which results in the creation of a stable structure.
Nonlimiting examples of heteroaryl and heterocyclic groups include furyl, furanyl, pyridyl, pyrimidyl, thienyl, isothiazolyl, imidazolyl, tetrazolyl, pyrazinyl, benzofuranyl, benzothiophenyl, quinolyl, isoquinolyl, benzothienyl, isobenzofuryl, pyrazolyl, indolyl, isoindolyl, benzimidazolyl, purinyl, carbazolyl, oxazolyl, thiazolyl, isothiazolyl, 1,2,4-thiadiazolyl, isooxazolyl, pyrrolyl, quinazolinyl, cinnolinyl, phthalazinyl, xanthinyl, hypoxanthinyl, thiophene, furan, pyrrole, isopyrrole, pyrazole, imidazole, 1,2,3-triazole, 1,2,4-triazole, oxazole, isoxazole, thiazole, isothiazole, pyrimidine or pyridazine, and pteridinyl, aziridines, thiazole, isothiazole, 1,2,3-oxadiazole, thiazine, pyridine, pyrazine, piperazine, pyrrolidine, oxaziranes, phenazine, phenothiazine, morpholinyl, pyrazolyl, pyridazinyl, pyrazinyl, quinoxalinyl, xanthinyl, hypoxanthinyl, pteridinyl, 5-azacytidinyl, 5-azauracilyl, triazolopyridinyl, imidazolopyridinyl, pyrrolopyrimidinyl, pyrazolopyrimidinyl, adenine, N6-alkylpurines, N6-benzylpurine, N6-halopurine, N6-vinypurine, N6-acetylenic purine, N6-acyl purine, N6-hydroxyalkyl purine, N6-thioalkyl purine, thymine, cytosine, 6-azapyrimidine, 2-mercaptopyrmidine, uracil, N5-alkyl-pyrimidines, N5-benzylpyrimidines, N5-halopyrimidines, N5-vinyl-pyrimidine, N5-acetylenic pyrimidine, N5-acyl pyrimidine, N5-hydroxyalkyl purine, and N6-thioalkyl purine, and isoxazolyl. The heteroaromatic and heterocyclic moieties can be optionally substituted as described above for aryl, including substituted with one or more substituents selected from hydroxyl, amino, alkylamino, arylamino, alkoxy, aryloxy, alkyl, heterocycle, halo, carboxy, acyl, acyloxy, amido, nitro, cyano, sulfonic acid, sulfate, phosphonic acid, phosphate, or phosphonate, either unprotected, or protected as necessary, as known to those skilled in the art, for example, as taught in Greene, et al., Protective Groups in Organic Synthesis , John Wiley and Sons, Second Edition, 1991.
The heteroaromatic can be partially or totally hydrogenated as desired. As a nonlimiting example, dihydropyridine can be used in place of pyridine. Functional oxygen and nitrogen groups on the heteroaryl group can be protected as necessary or desired. Suitable protecting groups are well known to those skilled in the art, and include trimethylsilyl, dimethylhexylsilyl, t-butyldi-methylsilyl, and t-butyldiphenylsilyl, trityl or substituted trityl, alkyl groups, acyl groups such as acetyl and propionyl, methanesulfonyl, and p-toluenesulfonyl.
The term acyl refers to a carboxylic acid ester in which the non-carbonyl moiety of the ester group is selected from straight, branched, or cyclic alkyl or lower alkyl, alkoxyalkyl including methoxymethyl, aralkyl including benzyl, aryloxyalkyl such as phenoxymethyl, aryl including phenyl optionally substituted with halogen, C 1 to C 4 alkyl or C 1 to C 4 alkoxy, sulfonate esters such as alkyl or aralkyl sulphonyl including methanesulfonyl, the mono, di or triphosphate ester, trityl or monomethoxytrityl, substituted benzyl, trialkylsilyl (e.g. dimethyl-t-butylsilyl) or diphenylmethylsilyl. Aryl groups in the esters optimally comprise a phenyl group. The term “lower acyl” refers to an acyl group in which the non-carbonyl moiety is lower alkyl.
The term alkoxy, as used herein, and unless otherwise specified, refers to a moiety of the structure —O-alkyl, wherein alkyl is as defined above.
Synthetic Methods
Precursor: Mono- or multiple-substituted benzene. Most are commercially available or can be easily prepared from commercial compounds. The definition of benzene ring substituents R 1 , R 2 , R 3 and R 4 is given in formulas (I) and (II) in section of Summary of The Invention.
Reactants: Nitric acid, Zinc, Hydrochloric acid, Carbon disulfide, Methyl isothiocyanate, Thiourea, Sulfur, Sodium diethyldithiocarbamate, Selenourea.
Solvents: 1,4-Dioxane, Toluene, Pyridine, Dichloromethane, Tetrahydrofuran, Water.
References: Saxena, D. B.; Khajuria, R. K.; Suri, O. P. Synthesis and Spectral Studies of 2-Mercaptobenzimidazole Derivatives. J. Heterocycl. Chem., 19, 681-683, (1982).
The 1,2-phenylenediamine derivatives (V) can be prepared by twice nitration/reduction reactions on substituted benzene (I), some substituents may need protection under above reaction conditions. Cyclization of (V) with CS 2 , or CH 3 NCS, or thiourea, or S, or (C 2 H 5 ) 2 NCS 2 Na can give the desired 2-mercaptobenzimidazole derivatives (VI). Reaction of (VI) with R 5 X (R 5 can be alkyl or acyl group; X is Cl, Br, I) can produce alkylated products (VIII). 2-Benzimidazoline-selenium derivatives (VIII) and (IX) can be synthesized similarly by reacting selenourea with (V).
Precursor: Substituted benzene. Most are commercially available or can be easily prepared from commercial compounds. The definition of benzene ring substituents R 1 , R 2 , R 3 , R 4 and R 5 is given in formulas (I) and (II) in section of Summary of The Invention.
Reactants: Nitric acid, Zinc, Hydrochloric acid, Ammonium thiocyanate, Potassium thiocyanate, Potassium selenocyanate.
Solvents: Acetonitrile, Pyridine, Dichloromethane, Tetrahydrofuran, Water.
References: Rasmussen, C. R.; Villani, F. J., Jr.; Weaner, L. E.; Reynolds, B. E.; Hood, A. R.; Hecker, L. R.; Nortey, S. O.; Hanslin, A.; Costanzo, M. J.; et al. Improved Procedures for the Preparation of Cycloalkyl-, and Arylalkyl-, and Arylthioureas. Synthesis, 6, 456-459, (1988).
Various arylthiourea compounds (IV) can be prepared by reaction of corresponding aniline (III) with NH 4 SCN or KSCN in aqueous HCl solution. Alkylation of (I) by R 6 X (R 6 can be alkyl or acyl group; X is Cl, Br, I) can yield monoalkylated product (VI). By replacing KSCN with KSeCN, the selenium analogous (V) can also be prepared.
Precursor: Substituted benzene. Most are commercially available or can be easily prepared from commercial compounds. The definition of benzene ring substituents R 1 , R 2 , R 3 , R 4 and R 5 is given in formulas (I) and (II) in section of Summary of The Invention.
Reactants: Chlorosulfonic acid, Dichlorodimethylsilane, Zinc, Cl(CH 2 ) n Cl (n is 1-3), Aluminum chloride, Thiourea, Sodium hydroxide.
Solvents: Tetrahydrofuran, Benzene, Dimethyl sulfoxide, Water.
References: Uchiro, H.; Kobayashi, S. Non-aqueous Reduction of Aromatic Sulfonyl Chlorides to Thios Using a Dichlorodimethylsilane-zinc-dimethylacetamide System. Tetrahedron Lett., 40, 3179-3182, (1999).
Substituted arylsulfonyl chlorides (I) can be easily prepared from substituted aromatic compounds (I) by reaction with excess chlorosulfonic acid. Reduction of (II) with dichlorodimethylsilane/zinc will give desired phenylthiole derivatives (III). The substituted phenylalkyl mercaptans (VI) can be prepared from the corresponding chloro compounds (V) which can be obtained from alkylation reaction of (I) (Friedel-Crafts reaction). Both thiole compounds (III) and (VI) can react with alkyl halide R 6 X to form the corresponding sulfides (IV) and (VII).
Precursor: Substituted benzene. Most are commercially available or can be easily prepared from commercial compounds. The definition of benzene ring substituents R 1 , R 2 , R 3 , R 4 and R 5 is given in formulas (I) and (II) in section of Summary of The Invention
Reactants: Nitric acid, Zinc, Hydrochloric acid, Br(CH 2 ) n Br (n is 1-3), Aluminum chloride.
Solvents: Benzene, Tetrahydrofuran, Diethyl ether, Water.
The preparation of products (II), (IV) and (V) is same as described previously. Reaction of (V) with alkyl amine R 6 NH 2 (R 6 is hydrogen or alkyl) can give arylalkylamine derivatives (VI).
Precursor: Substituted thiophene. Most are commercially available or can be easily prepared from commercial sources. The definition of ring substituents R 1 , R 2 and R 3 is same as that given in formulas (I) and (II) in section of Summary of The Invention.
Reactants: Butyllithium, Cl(CH 2 ) n NMe 2 (n is 1-3), Ethyl chloroformate.
Solvents: Diethyl ether, Tetrahydrofuran, Benzene.
References: Hallberg, A.; Gronowitz, S. On The Reaction of Some Thienyllithium Derivatives with 1-Chloro-2-dimethylaminoethane. Chem. Scr., 16, 42-46, (1980).
Reaction of substituted thiophene with butyllithium can yield 2-thienyllithium salt (II), protection may be necessary for some substituents. Substituted 2-thiophenealkylamine (III) can be prepared by reaction of (a) with 1-chloro-2-dimethylaminoalkane. The products (III), (V) and (V) can be converted to each other by alkylation/dealkylation reactions using alkyl halide R 4 X and ClCO 2 Et, respectively.
Precursor: Substituted benzene. Most are commercially available or can be easily prepared from commercial compounds. The definition of benzene ring substituents R 1 , R 2 , R 3 , R 4 and R 5 is given in formulas (I) and (II) in section of Summary of The Invention
Reactants: Potassium thiocyanate, Polyphosphoric acid, Sulfuric acid.
Solvents: Benzene, Water.
References: Sastry, S.; Kudav, N. A. One-step Synthesis of Aromatic Thio Amides: Reaction of Aromatic Compounds with Potassium Thiocyanate in Polyphosphoric Acid or Sulfuric Acid. Indian J. Chem., Sect B, 18B, 455, (1979).
Benzothioamide derivatives (II) can be prepared from substituted benzene (I) in one single step by reaction with KSCN in polyphosphoric acid or sulfuric acid. The alkylated product (III) can be obtained by using alkyl halide R 6 X (X is Cl, Br, I).
Pharmaceutical Formulations and Dosing Regimes
In one embodiment, a compound of this invention is applied or administered to the skin during an appropriate period and using a sufficient number of dosages to achieve skin lightening. The concentration of active compound in the composition will depend on absorption, inactivation, and excretion rates of the compound as well as other factors known to those of skill in the art. It is to be noted that dosage values will also vary with the severity of the condition to be alleviated. It is to be further understood that for any particular subject, specific dosage regimens should be adjusted over time according to the individual need and the professional judgment of the person administering or supervising the administration of the compositions, and that the concentration ranges set forth herein are exemplary only and are not intended to limit the scope or practice of the claimed composition. The active ingredient may be administered as a single dose, or may be divided into a number of smaller doses to be administered at varying intervals of time.
Topical and other formulations of these active and/or functional compounds are of utility in lightening skin pigmentation in humans and other animals. These formulations may be useful for pure cosmetic purposes, simply to obtain a lighter skin color for perceived beautification. The formulations also have medicinal value and can, for example, decrease hyperpigmentation of melasma, age spots, freckles, and other skin blemishes. The compounds of this invention act primarily by inhibiting mammalian melanocyte tyrosinase, the rate-limiting enzyme in the production of melanin from tyrosine and DOPA. Some compounds also absorb ultraviolet radiation (UVR), and may thus protect skin from UVR and photoaging. In addition, some compounds may be antioxidants that protect skin from oxidative damage, and/or may prevent oxidative decomposition of product formulations.
If desirable these formulations could also be used to reduce pigmentation in hair, albeit during the biosynthesis of hair, by blocking pigment production within the melanocytes of hair follicles. The formulations would likely not affect the already emerged pigmented portions of hair, unlike a bleaching agent.
The formulations useful in the present invention contain biologically effective amounts of the functional and/or active compound(s). A biologically effective amount of the active compound is understood by those skilled in the art to mean that a sufficient amount of the compound in the composition is provided such that upon administration to the human or animal by, for example, topical route, sufficient active agent is provided on each application to give the desired result. However, the biologically effective amount of the active compound is at a level that it is not toxic to the human or animal during the term of treatment. By a suitable biologically compatible carrier, when the compound is topically applied, it is understood that the carrier may contain any type of suitable excipient in the form of cosmetic compositions, pharmaceutical adjuvants, sunscreen lotions, creams, and the like. In one embodiment the active compound is administered in a liposomal carrier.
The active compound is administered for a sufficient time period to alleviate the undesired symptoms and the clinical signs associated with the condition being treated, or to achieve the level of desired skin lightening. The individual dosage, dosage schedule, and duration of treatment may be determined by clinical evaluations by those of skill in the art.
Solutions or suspensions for topical application can include the following components: a sterile diluent such as water for injection, saline solution, fixed oils, polyethylene glycols, glycerin, propylene glycol or other synthetic solvents; antibacterial agents such as benzyl alcohol or methyl parabens; antioxidants such as ascorbic acid or sodium bisulfite; chelating agents such as ethylenediaminetetraacetic acid (EDTA); buffers such as acetates, citrates or phosphates; and agents for the adjustment of tonicity such as sodium chloride or dextrose. pH can be adjusted with acids or bases, such as hydrochloric acid or sodium hydroxide.
Suitable vehicles, carriers, or formulations for topical application are known, and include lotions, suspensions, ointments, oil-in-water emulsions, water-in-oil emulsions, creams, gels, tinctures, sprays, powders, pastes, and slow-release transdermal or occlusive patches. Thickening agents, emollients, and stabilizers can be used to prepare topical compositions. Examples of thickening agents include petrolatum, beeswax, xanthan gum, or polyethylene glycol, humectants such as sorbitol, emollients such as mineral oil, lanolin and its derivatives, or squalene. A number of solutions and ointments are commercially available, especially for dermatologic applications.
The compounds can be provided in the form of pharmaceutically-acceptable salts. As used herein, the term “pharmaceutically-acceptable salts or complexes” refers to salts or complexes that retain the desired biological activity of the parent compound and exhibit minimal, if any, undesired toxicological effects. Examples of such salts are (a) acid addition salts formed with inorganic acids (for example, hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid, and the like), and salts formed with organic acids such as acetic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, alginic acid, polyglutamic acid, naphthalenesulfonic acids, naphthalenedisulfonic acids, and polygalacturonic acid; (b) base addition salts formed with polyvalent metal cations such as zinc, calcium, bismuth, barium, magnesium, aluminum, copper, cobalt, nickel, cadmium, and the like, or with an organic cation formed from N,N-dibenzylethylene-diamine or ethylenediamine; or (c) combinations of (a) and (b); e.g., a zinc tannate salt or the like.
The compounds can be modified in order to enhance their usefulness as pharmaceutical compositions. For example, it is well know in the art that various modifications of the active molecule, such as alteration of charge, can affect water and lipid solubility and thus alter the potential for percutaneous absorption. The vehicle, or carrier, can also be modified to enhance cutaneous absorption, enhance the reservoir effect, and minimize potential irritancy or neuropharmacological effects of the composition. See, in general, Arndt, et al. [27].
Thus, the invention provides various formulations as topical skin lighteners containing the active and/or functional compounds described above. The invention further provides formulations as topical anti-oxidants containing the active and/or functional compounds described above. In still another embodiment the invention provides formulations as topical sunscreens containing the active and/or functional compounds described above. Such formulations can be made in combination with other active and/or functional ingredients used in skincare products (e.g. organic or inorganic sunscreen, antioxidant, anti-inflammatory, anti-erythema, anti-biotic, antimicrobial, humectant, or other ingredients). Other ingredients can be formulated with the compounds to augment their effect, including but not limited to Vitamin C, Vitamin E, magnesium ascorbyl phosphate, aloe vera extract, and retinoic acids. In addition, alpha-hydroxy acids can be included to speed up the skin lightening process by exfoliating surface colored skin.
The compounds of the present invention can also be formulated for alternative routes of administration other than topical application, including but not limited to general systemic, oral, intradermal, transdermal, occlusive patches, intravenous, or parenteral administration, and pharmaceutical compositions known generally to those skilled in the art.
The compounds can also be formulated along with other active and/or functional ingredients used in skincare products, depending on the intended use of the formulation. For example, the compounds can be formulated with organic or inorganic sunscreens, an antioxidant, an anti-inflammatory, an anti-erythema, an antibiotic, an antimicrobial, a humectant, or other ingredients.
The active and/or functional compounds described above may also be of use in inhibiting tyrosinase-like enzymes from non-mammalian species, for instance for use in the food science industry for the inhibition of enzymatic browning. [28, 29] Inhibition of plant polyphenol oxidases by agents described here may coincidentally have activity against these non-mammalian enzymes. Suitable formulations for spraying or treatment of fruits are known generally to those skilled in the art Treatment by these formulations containing the enzyme inhibitors of the present invention might improve shelf life of plant or fungal foods.
EXAMPLES
Example 1
Benzoimidazolethiols
A first class of compounds based upon the template compound benzimidazolethiol (lower left structure) were tested for tyrosinase inhibition, cell culture pigment inhibition, and toxicity, by methods described in Curto, E. V., et al. (1999) [25]. Results of the tests are given in Table 1.
TABLE 1
ID #
R 1
R 2
R 3
R 4
R 6
R
E
P
T
ε
λ max
138
NH
SH
N
H
H
C
0.25
—
—
14300
300
140
NH
SH
N
CH3
H
C
0.12
2.4
>1000
6300
305
084
NH
SH
N
OCH 3
H
C
0.07
1.6
>1000
10000
310
040
S
SH
N
H
H
C
8
—
—
091
S
SH
N
H
OCH 2 CH 3
C
>1000
>1000
>1000
205
NH
═S
N(CO)CH 3
H
H
C
0.5
8.3
35
098
NH
═Se
NH
H
H
C
0.8
14
132
135
NH
═S
NH
H
H
N
4
256
>1000
*Inhibition [μM] as measured in three assays.
Here “E” is the concentration of compound that produces 50% pigment inhibition in the cell-free mammalian-enzyme assay system.
“P” is for the concentration of compound that produces 50% inhibition in the mammalian-melanocyte-culture pigment assay system.
“T” is the concentration of compound that kills 50% of cells in the mammalian-melanocyte-culture toxicity assay system.
The compound extinction coefficient is ε [OD/M × cm] at the wavelength of maximum absorbency λ max [nm].
Example 2
Thiophenols
A second class of compounds based upon the template compound benzenethiol were tested for tyrosinase inhibition, cell culture pigment inhibition, and toxicity, by methods described in Curto, E. V., et al. (1999) [25]. Results of the tests are given in Table 2.
TABLE 2
ID #
R 1
R 2
R 3
R 4
R 5
E
P
T
ε
λ max
099
H
H
OCH 3
H
H
53
85
202
3000
265
102
H
H
H
SCH 3
H
0.24
115
126
2300
280
083
H
H
H
NH(CO)CH 3
H
19
82
542
4700
265
103
H
H
OCH 3
OCH 3
H
8
8
>1000
4300
250
093
H
OCH 3
H
H
OCH 3
500
200
200
2700
305
148
(CO)CH 3
H
H
NH(CO)CH 3
H
500
30
125
3300
255
*Inhibition [μM] as measured in three assays.
Here “E” is the concentration of compound that produces 50% pigment inhibition in the cell-free mammalian-enzyme assay system.
“P” is for the concentration of compound that produces 50% inhibition in the mammlian-melanocyte-culture pigment assay system.
“T” is the concentration of compound that kills 50% of cells in the mammalian-melanocyte-culture toxicity assay system.
The compound extinction coefficient is ε [OD/M × cm] at the wavelength of maximum absorbency λ max [nm].
Example 3
Phenylthioureas
A third class of compounds based upon the template compound phenylthiourea (lower left structure) were tested for tyrosinase inhibition, cell culture pigment inhibition, and toxicity, by methods described in Curto, E. V., et al. (1999) [25]. Results of the tests are given in Table 3.
TABLE 3
ID #
R 1
R 2
R 3
R 4
R
E
P
T
ε
λ max
033
H
H
H
H
NH 2
2
12
>1000
181
OCH 3
H
H
H
NH 2
>1000
>1000
105
H
F
H
H
NH 2
1.52
1.78
>1000
11000
255
104
H
OH
H
H
NH 2
4
8
>1000
131
H
CH 3
H
H
NH 2
0.82
2.28
>1000
053
H
H
OCH 3
H
NH 2
8
30
60
049
H
H
NH(CS)NH 2
H
NH 2
4
250
>1000
101
H
CH 3
H
CH 3
NH 2
250
125
>1000
054
H
H
H
H
CH 3
16
16
>1000
*Inhibition [μM] as measured in three assays.
Here “E” is the concentration of compound that produces 50% pigment inhibition in the cell-free mammalian-enzyme assay system.
“P” is for the concentration of compound that produces 50% inhibition in the mammalian-melanocyte-culture pigment assay system.
“T” is the concentration of compound that kills 50% of cells in the mammalian-melanocyte-culture toxicity assay system.
The compound extinction coefficient is ε [OD/M × cm] at the wavelength of maximum absorbency λ max [nm].
Example 4
Miscellaneous
A fourth group of miscellaneous compounds of diverse structure were also tested for tyrosinase inhibition, cell culture pigment inhibition, and toxicity, by methods described in Curto, E. V., et al. (1999) [25]. Results of the tests are given in Table 4.
TABLE 4
#
ID #
E
P
T
ε
λ max
1
082
5
81
500
1000
275
2
100
32
62
>1000
3
073
>1000
100
>1000
4
079
73
71
472
5
006
110
182
>1000
6
092
79
236
>1000
7
009
98
209
775
8
026
54
153
367
*Inhibition [μM] as measured in three assays.
Here “E” is the concentration of compound that produces 50% pigment inhibition in the cell-free mammalian-enzyme assay system.
“P” is for the concentration of compound that produces 50% inhibition in the mammalian-melanocyte-culture pigment assay system.
“T” is the concentration of compound that kills 50% of cells in the mammalian-melanocyte-culture toxicity assay system.
The compound extinction coefficient is ε [OD/M × cm] at the wavelength of maximum absorbency λ max [nm].
Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which this invention pertains.
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.
REFERENCES
1. Hearing V J Jr., “Monophenol monooxygenase (tyrosinase): Purification, properties, and reactions catalyzed.” Methods Enzymol 142: 154-165, 1987.
2. Spritz R A et al., “Genetic-disorders of pigmentation,” Adv Hum Genet 22: 1-45, 1994.
3. Frenk E, “Treatment of melasma with depigmenting agents.” Melasma: New Approaches to Treatment, pp. 9-15. Martin Dunitz Ltd., London, 1995.
4. Dooley T P, “Is there room for a moderate level of regularity oversight?” In: Drug Discovery Approaches for Developing Cosmeceuticals: Advanced Skin Care and Cosmetic Products (Ed. Hori W), Chap. 1.4. International Business Communications, Southborough, Mass., 1997.
5. Dooley T P, “Topical skin depigmentation agents: Current products and discovery of novel inhibitors of melanogenesis.” J. Dermatol. Treat. 8: 275-279, 1997.
6. Dooley T P, et al., “Development of an in vitro primary screen for skin depigmentation and antimelanoma agents.” Skin Pharmacol. 7: 188-200, 1994.
7. Morse J L (Ed.), “An Abridgment of The New Funk & Wagnalls Encyclopedia,” The Universal Standard Encyclopedia, Vol, 10, pp. 3662-3663. Unicorn, N.Y., 1955.
8. Budavari S (Ed.), “Gentisic acid,” Merck Index, 11 th Edn, Abstract No. 4290, p. 688. Merck & Co., Rahway, N.J., 1989.
9. J-Hua L, et al., “Direct analysis of salicylic acid, salicyl acyl glucuronide, salicyluric acid and gentisic acid in human plasma and urine by high-performance liquid chromatography.” J. Chromatogr. [B] 675: 61-70, 1996.
10. Glatt H R, et al., “Multiple activation pathways of benzene leading to products with varying genotoxic characteristics.” Environ Health Perspect 82: 81-89, 1989.
11. Glatt H R, “Endogenous mutagens derived from amino acids.” Mutat. Res. 238: 235-243, 1990.
12. La Du B N, “Alcaptonuria and ochronotic arthritis.” Mol. Biol. Med. 8: 31-38, 1991.
13 Hearing V J, “Mammalian monophenol monooxygenase (tyrosinase): purification, properties, and reactions catalyzed.” Methods Enzymol. 142: 154-65, 1987.
14. Spritz R A, et al., “Genetic disorders of pigmentation.” Adv. Hum. Genet. 22: 1-45, 1994.
15. Hadley M E et al, “Melanotropic peptides for therapeutic and cosmetic tanning of the skin.” NY Acad. Sci. 680: 424-39, 1993.
16. Sakai C et al, “Modulation of murine melanocyte function in vitro by agouti signal protein.” EMBO J. 16: 3544-52, 1997.
17. Dooley T P, “Recent advances in cutaneous melanoma oncogenesis research.” Onco. Res. 6: 1-9, 1994.
18. Benmaman O, et al., “Treatment and camouflaging of pigmentary disorders.” Clin. Dermatol. 6: 50-61, 1998.
19. Zaumseil R-P, et al., “Topical azelaic acid in the treatment of melasma: pharmacological and clinical considerations.” In: Castanet J, Frenk E, Gaupe K et al (Eds) Melasma: new approaches to treatment. Martin Dunitz: London, pp 16-40, 1995.
20. Schallreuter K U, “Epidermal adrenergic signal transduction as part of the neuronal network in the human epidermis.” J. Invest. Dermatol. 2: 3740, 1997.
21. Bennett D C, et al., “A line of non-tumorigenic mouse melanocytes, syngeneic with the B16 melanoma and requiring a tumour promoter for growth.” Int. J. Cancer 349: 414-18, 1987.
22. Dooley T P et al., “Polyoma middle T abrogates TPA requirement of murine melanocytes and induces malignant melanoma.” Oncogene 3: 531-6, 1988.
23. Brooks G et al., “Protein kinase C down-regulation, and not transient activation, correlates with melanocyte growth.” Cancer Res. 51: 3281-8, 1991.
24. O'Keefe E, et al., “Cholera toxin mimics melanocyte stimulating hormone in inducing differentiation in melanoma cells.” Proc. Natl. Acad. Sci. USA 71: 2500-4, 1974.
25. Curto, E. V., et al., “Inhibitors of Mammalian Melanocyte Tyrosinase: In Vitro Comparisons of Alkyl Esters of Gentisic Acid with Other Putative Inhibitors.” Biochem. Pharmacol. 57: 663-672, 1999.
26. Sakurada, J., et al., “Kinetic and molecular orbital studies on the rate of oxidation of monosubstituted phenols and anilines by horseradish peroxidase compound II.” Biochemistry 29: 4093-4098, 1990.
27. Arndt, et al., “The Pharmacology of Topical Therapy”, Dermatology in General Medicine, 1987; T. B. Fitzpatrick, A. Z. Eisen, K. Wolff, I. M. Freedberg and K. F. Austen, eds., 3d ed., McGraw Hill, Inc., New York, pp. 2532-2540.
28. Lee, C. Y. and Whitaker, J. R. (Eds.) Enzymatic Browning and its Prevention . Pub. American Chemical Society, Washington, D.C., 1995.
29. Lerch, K “Tyrosinase: Molecular and active-site structure.” In Lee, C. Y. and Whitaker, J. R. (Eds.) Enzymatic Browning and its Prevention. Pub. American Chemical Society, Washington, D.C., pp. 64-80, 1995.
30. Mishima, H., et al., “Fine structural demonstration of tyrosinase activity in the retinal pigment epithelium of normal and PTU-treated chick embryos.” Albrecht Von Graefes Arch. Klin. Exp. Ophthalmol. 211: 1-10, 1979.
31. Dryja, T. P., et al., “Demonstration of tyrosinase in the adult bovine uveal tract and retinal pigment epithelium.” Invest. Opthalmol. Vis. Sci. 17: 511-514, 1978.
32. Higashi, Y., et al., “Inhibition of tyrosinase reduces cell viability in catecholaminergic neuronal cells.” J. Neurochem. 75: 1771-1774, 2000.
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Methods and formulations are provided to reduce pigmentation in skin, using an array of compounds selected from benzimidazoles, phenylthioureas, phenylthiols, phenylamines, bi- and multicyclic phenols, thiopheneamines, and benzothiamides. The compounds preferably inhibit pigment synthesis in melanocytes through the tyrosinase pathway. The methods can be used for lightening skin, and for treating uneven skin complexions which result from hyperpigmentation-related medical conditions such as melasma, age spots, freckles, ochronosis, and lentigo. The compounds can be used medically or cosmetically.
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The present application is a Continuation-in-Part of U.S. Ser. No. 11/158,456 filed Jun. 22, 2005.
BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention relates to an internal clock generator used in a high-speed semiconductor device.
2. Description of the Prior Art
Generally, a synchronous semiconductor device controls an internal operation of the semiconductor device using an internal clock that is synchronized with an external clock. A representative synchronous semiconductor device may be a synchronous memory device (hereinafter referred to as a memory device) such as an SDRAM, DDR, SDRAM, etc.
Recently, with the development of technology, the operating frequency of a memory device is greatly being heightened and the size of the memory device is gradually increasing as well. Typically, the fact that the operating frequency of the memory device is increasing means that the frequency of the internal clock is also being heightened. Here, as a moving distance (i.e., transmission distance) of the internal clock is increasing, an RC loading of a transmission line is also increasing. However, in the case in which the loading of the transmission line is increasing, a problem may occur in transmitting a high-frequency signal.
Hereinafter, the conventional method of transmitting an internal clock will be explained with reference to the accompanying drawings.
FIG. 1 is a block diagram of a general memory device that uses the internal clock.
Referring to FIG. 1 , a clock buffer 101 receives an external clock signal of an SSTL level or a TTL level. A clock generator 102 receives an output signal of the clock buffer 101 , and generates an internal clock ICLK.
The internal clock ICLK is applied to a column control unit 11 , a row control unit 12 , a command control unit 13 , a data control unit 14 , etc., in the memory device, and controls the operating timing of the memory device. Here, the column control device 11 is a circuit for controlling a column operation of the memory device, and the row control unit 12 is a circuit for controlling a row operation of the memory device. Also, the command control unit 13 is a circuit for controlling a command such as an active, read, write, precharge, etc., and the data control unit 14 is an input/output (I/O) unit of the memory device.
FIG. 2 is a view illustrating an example of a conventional clock generator 102 used in the memory device of FIG. 1 .
As illustrated in FIG. 2 , a clock generator causes no trouble in the case in which a period of an input signal IN is longer than a delay time of a delay unit 21 .
However, if the period of the input signal IN is shorter than the delay time of the delay unit 21 , the memory device may malfunction. Specifically, if the input signal IN is a high-frequency signal over 500 MHz, it is difficult to apply such a clock generator to a high-speed memory device.
Additionally, in the case in which a signal transmission line is long, this may cause a problem in that the loading of the transmission line becomes extremely great and thus the high-frequency signal is not properly transferred.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art, and an object of the present invention is to provide an internal clock generator that modulates a high-frequency clock signal to a low-frequency signal to transmit the low-frequency signal if a transmission line for transmitting the high-frequency clock signal is long, and then restores the transmitted low-frequency signal to the high-frequency signal.
In a first embodiment of the present invention, there is provided an internal clock generator comprising a first signal generation unit for receiving a first signal having a first frequency and generating a second signal having a second frequency that is lower than the first frequency, and a second signal generation unit for receiving the second signal and generating a third signal having a frequency equal to the first frequency.
Here, the third signal is used as a signal for controlling an operating time point of an internal circuit of a synchronous memory device.
In a second embodiment of the present invention, there is provided an internal clock generator comprising a frequency modulation unit for receiving a first clock signal having a first frequency and outputting second and third clock signal having a second frequency, and a clock generation unit for receiving the second and third clock signals and outputting a fourth clock signal having the first frequency.
Here, if the first frequency is fo, the second frequency becomes fo/2.
Additionally, a rising edge of the second clock signal is in synchronization with a rising edge of the first clock signal, and a rising edge of the third clock signal is in synchronization with a falling edge of the first clock signal.
It is preferable that a high-level period of the second and third clock signals is equal to a period of the first clock signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram of a general memory device that uses the internal clock;
FIG. 2 is an exemplary circuit diagram of a conventional clock generator 102 used in the memory device of FIG. 1 ;
FIG. 3 is a block diagram of an internal clock generator according to an embodiment of the present invention;
FIG. 4 is an exemplary circuit diagram of a frequency modulator as illustrated in FIG. 3 ;
FIG. 5 is an exemplary circuit diagram of a clock generator as illustrated in FIG. 3 ; and
FIG. 6 is a waveform diagram illustrating clock signals IN, Up_clk, Down_clk and ICLK that appear in the circuits of FIGS. 3 to 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. In the following description and drawings, the same reference numerals are used to designate the same or similar components, and so repetition of the description on the same or similar components will be omitted.
FIG. 3 is a block diagram of an internal clock generator according to an embodiment of the present invention.
In FIG. 3 , the construction and operation of a clock buffer 301 that receives an external clock signal CLK are the same as those of the conventional clock buffer. For example, the clock buffer 301 is the same as the clock buffer 101 explained with reference to FIG. 1 . Also, the period of a clock signal IN output from the clock buffer 301 is the same as that of the external clock signal CLK (See FIG. 6 ).
A frequency modulation unit 302 modulates the frequency of the clock signal IN output from the clock buffer 301 . In an embodiment of the present invention, the frequency of output signals Up_clk and Down_clk of the frequency modulation unit 302 is a 1/2 of the frequency of the clock signal IN. That is, the frequency modulation unit 302 of FIG. 3 performs the same function as a frequency divider. Here, the clock signal Up_clk rises in synchronization with a rising edge of the clock signal IN, and falls in synchronization with a rising edge of the next clock signal IN (See FIG. 6 ). Additionally, the clock signal Down_clk rises in synchronization with a falling edge of the clock signal IN, and falls in synchronization with a falling edge of the next clock signal IN (See FIG. 6 ).
Clock generation units 35 to 38 receive in common the output signals Up_clk and Down_clk of the frequency modulation unit 302 , and output an internal clock signal ICLK. The clock generation units 35 to 38 correspond to a column control unit 31 , a row control unit 32 , a command decoder 33 and a data control unit 34 etc. in a one-to-one manner because there are differences in distance from frequency unit(differences in operating time points) among the column control unit 31 , row control unit 32 , command decoder 33 and data control unit 34 etc.
The clock generation units 35 to 38 that have received the clock signals Up_clk and Down_clk combine the clock signals and generate the internal clock signal ICLK having the same frequency as the clock signal IN.
The frequency modulation unit and the clock generation units as described above are constituent elements of the internal clock generator newly proposed in one embodiment of the present invention.
FIG. 4 is an exemplary circuit diagram of the frequency modulation unit as illustrated in FIG. 3 . In FIG. 4 , a circuit and method of doubling the period of the input clock signal IN using flip-flops is illustrated. Here, a power-up signal pwrup is a signal for sensing an input of an external power supply to the memory device and initializing internal circuits of the memory device when the external power is supplied to the memory device. Specifically, the power-up signal sets an initial level of the flip-flops.
In FIG. 4 , the flip-flop 41 receives the clock signal IN and outputs the clock signal Up_clk having a period that is twice the period of the clock signal IN, and the the flip-flop 42 receives the clock signal IN and outputs the clock signal Down_clk having a period that is twice the period of the clock signal IN. As described above, the clock signal Up_clk rises in synchronization with the rising edge of the clock signal IN and falls in synchronization with the rising edge of the next clock signal, and the clock signal Down_clk rises in synchronization with the falling edge of the clock signal IN and falls in synchronization with the falling edge of the next clock signal IN. For reference, the flip-flop 42 receives an inversed signal of the clock signal IN.
The frequency modulation unit of FIG. 4 is provided as an example, and it will be apparent to those skilled in the art that different circuits for dividing the frequency by 2 can be used in place of the frequency modulation unit shown in FIG. 4 .
FIG. 5 is a circuit diagram of an example of a clock generator illustrated in FIG. 3 .
The clock generator of FIG. 5 includes a NAND gate 51 for receiving the clock signals Up_clk and Down_clk, an inverter 52 for receiving an output signal of the NAND gate 51 , a NOR gate 53 for receiving the clock signals Up_clk and Down_clk, a NOR gate 54 for receiving an output signal of the inverter 52 and an output signal of the NOR gate 53 , and an inverter 55 for receiving an output signal of the NOR gate 54 . The inverter 55 outputs the internal clock signal ICLK.
FIG. 6 is a waveform diagram illustrating clock signals IN, Up_clk, Down_clk and ICLK that appear in the circuits of FIGS. 3 to 5 .
As can be seen in FIG. 6 , the period of the clock signals Up_clk and Down_clk is twice the period of the clock signal IN, and the period of the internal clock signal ICLK is equal to the period of the clock signal IN.
Hereinafter, the operation of the internal clock generator according to the present invention that is advantageous in high-frequency operation will be explained in detail with reference to FIGS. 3 to 6 .
The clock buffer 301 receives the external clock signal CLK of the SSTL level or the TTL level, and output the clock signal IN. Here, the low level of the clock signal IN corresponds to a ground voltage, and the high level thereof corresponds to a driving voltage VCC. That is, the clock signal IN is a clock signal that swings between the ground voltage and the driving voltage VCC. Here, the driving voltage VCC is for driving the clock buffer 301 .
The frequency modulation unit 302 generates and transmits the clock signals Up_clk and Down_clk having the period that is twice the period of the clock signal IN to the clock generation units 35 to 38 . In the case of doubling the period of the high-frequency clock signal IN as in the internal clock generator according to the present invention, a signal distortion is greatly reduced in comparison to the conventional clock generator. Particularly, if the loading of the transmission line is great, the signal distortion can properly be reduced by transmitting the low-frequency signal using the frequency modulation unit.
The clock generation units 35 to 38 receive the output signals of the frequency modulation unit 302 , generate and provide the internal clock signal ICLK having the same frequency as the operating frequency of the memory device to the column control unit 31 , the row control unit 32 , etc.
In the present invention, the clock signals Up_clk and Down_clk having the lower frequency than the clock signal IN are generated and transferred to the clock generation units, and then the internal clock signal ICLK is generated. Here, it is preferable to make the transmission distance of the clock signals Up_clk and Down_clk, which reach the clock generation units, longer than the distance of the internal clock signal ICLK which reaches the column control units 31 , etc. By doing so, the signal distortion which may occur during the transmission of the high-frequency signal can be prevented. As described above, the present invention can prevent the signal distortion occurring when the high-frequency signal is transmitted for a long distance through the transmission of the low-frequency signal instead of the high-frequency signal. Particularly, it may be possible that the clock signal transmission is performed using the same circuit as the conventional circuit if the internal transmission line is short, while the clock signal transmission is performed using the circuit proposed according to the present invention if the internal transmission line is long.
As described above, according to the present invention which is applicable to an ultrahigh-speed memory device, a stable internal clock signal can be generated by transmitting a low-frequency clock signal through a transmission line of a great loading and then generating an internal clock signal having the same frequency as an operating frequency using the transmitted low-frequency signal.
The present invention is not limited to this, but in the case in which the loading of the transmission line is extremely great, the clock signal having a frequency that is four times or more lower than the original clock signal may be generated and transmitted, and then the transmitted lower-frequency clock signal may be restored to the original clock signal.
In the case in which the internal clock generator according to the present invention is used, a stable internal clock can be generated even if the operating frequency is greatly high.
Although preferred embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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An internal clock generator that modulates a high-frequency clock signal to a low-frequency signal to transmit the low-frequency signal if a transmission line for transmitting the high-frequency clock signal is long, and then restores the transmitted low-frequency signal to the high-frequency signal. The internal clock generator includes a first signal generation unit for receiving a first signal having a first frequency and generating a second signal having a second frequency that is lower than the first frequency, and a second signal generation unit for receiving the second signal and generating a third signal having a frequency equal to the first frequency. Here, the third signal is used as a signal for controlling an operating time point of an internal circuit of a synchronous memory device.
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RELATED APPLICATIONS
[0001] This application claims priority to EP 06 014 316.1, filed Jul. 11, 2006, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] In the past, diabetics have used individual test strips for self-diagnosis in which the strips were analyzed photometrically after applying a small amount of blood to the strip to determine the glucose content of the fluid sample as accurately and reliably as possible. In order to improve the user-friendliness of this test system, it has been proposed that such testing be performed on a test tape in the form of a tape cassette. It is possible to insert tape cassettes as a disposable component into compact hand-held devices to automatically and rapidly carry out all required analytical steps. In these tape cassette testing systems, the disposable components are mass produced and high demand occurs due to the reliability.
[0003] Accordingly, document WO 2005/006985 discloses a test tape guide curved in an arch that exposes a section of test tape to receive an application of liquid on the front side and to perform an optical measurement on the rear side by means of a reflection-photometric measuring unit focusing on this area. However, with this arrangement having parallel arched rails, there is a risk that in the case of a thin flexible test tape the central tape area will arch inwards under tension in the free space between the rails and thereby making an accurate optical focus more difficult. Such tape deformation has already proven to be problematic in the case of small radii of curvature, especially with regard to measuring optics having a short focal distance.
[0004] In order to overcome this problem, it has been proposed that optical elements in the form of cylinder lens be used as an application tip, wherein the lens bundles the measuring light in the optical path of the photometer. However, just as in the case of simple optical windows, care must be taken that high quality requirements are achieved for the required measuring accuracy especially with regard to transmission, scratch resistance, temperature resistance, coefficient of expansion, optical quality, and other material parameters or faults such as those listed in International Standard ISO 10110.
SUMMARY OF INVENTION
[0005] Embodiments incorporating the present invention address the described disadvantages of the prior art and further improve test tape systems while being simple to manufacture, provide special application advantages and high measurement accuracy with a low strain on the test tape. In particular, these embodiments are arranged without an optical component or material window in the area of the tape guide and thus optical elements which interact or interfere with the passage of light are avoided.
[0006] One embodiment of the tape guide has a planar support frame which holds the test tape section flat at the measuring site, wherein the frame has legs that circumscribe or border a clear measuring opening which is kept free from optical elements for an optical measurement to be taken on the rear side of the tape. This provides good targeting accuracy and adequate support for the application of liquid on the front side of the tape, while the test tape is held in a narrowly defined measuring plane without significant or noticeable bending. The “clear” measuring opening is provided as a simple optical entrance that allows light to be emitted into the opening and permits the passage of reflected radiation under constant conditions. According to this embodiment, it is unnecessary to manufacture special optical components such as lens, filters, or material windows. Also, by avoiding tape constriction, this embodiment provides an energy efficient and gentle tape transport.
[0007] In a similar embodiment, the frame legs of the support frame advantageously border the measuring opening in a rectangular shape and also provide sufficient space for several light beams oriented towards the test tape.
[0008] In another exemplary embodiment, the support frame has two parallel frame legs extending in the longitudinal direction of the test tape and the distance between the outer edges of these two legs is less than the width of the test tape. The portion of the test tape border that extends past the frame legs can thus provide a screen against contamination of the device by a sample of body fluid.
[0009] In another embodiment, the support frame has two parallel frame legs at right angles, or transverse, to the direction the test tape is transported, the length of which corresponds to at least the width of the test tape. This avoids tape constriction in the deflection area and supports planar frame stretching. These frame legs are referred to as “the transverse frame legs.”
[0010] In order to further improve the tape guide, it is advantageous when the frame legs of the support frame, which support the test tape in its longitudinal direction, are flattened into a strip shape. It is also advantageous when the transverse frame legs are rounded at a deflecting edge for the test tape.
[0011] In another advantageous embodiment, the support frame is formed by a flat top surface of a truncated, pyramid-shaped projection of the tape guide. This projection is also referred to as being tapered at its top surface. This tapered projection improves handling and hygiene when applying liquid to the test tape.
[0012] For the application of body fluid to the test tape, it is advantageous when the tape guide has deflecting bevels adjoining the support frame in the longitudinal direction of the tape, wherein the deflecting bevels are positioned at an acute angle with the plane defined by the support frame.
[0013] In order to secure the test tape against lateral deflection, the tape guide can advantageously have side boundaries or walls which are arranged adjacently outside of the support frame so that the test tape can be precisely centered on the support frame.
[0014] In addition, it is advantageous when the test tape is unwound from the feed spool by driving the take-up spool. Also, to keep the test tape flat at the measuring site, the test tape should be held in tension by return forces of more than 1 N.
[0015] It is advantageous for mass production to occur when the support frame is molded as one piece onto a molded part. The molded part can be an injection-molded part consisting of polypropylene, whereby the optical area is screened against the entry of scattered external light by a black coloring.
[0016] If the body fluid sample application and measurement take place at the same site, transporting the test tape section to a distant measuring site is not necessary. In an exemplary embodiment, it is advantageous when the body fluid is applied to the front side of the test tape section, which is supported by the support frame, and a reflectometric measurement is taken from the rear side of the tape, which rests on the support frame, with free radiation through the measurement opening.
[0017] In order to simplify the use of the device, it is advantageous when a measuring chamber delimited by the tape guide is used with a measuring unit, wherein a light source and a light receiver of the measuring unit are focused above the measuring opening onto the test tape section that is located above it.
[0018] The tape guide is advantageously covered from the outside by a cover part or housing, wherein the support frame protrudes from an opening in the cover part or housing. A test tape unit is designed as a tape cassette for being inserted into a test device.
[0019] Embodiments incorporating the present invention also provide a test system comprising a reflectometric measuring unit, a tape drive, and a test tape unit which are inserted into a hand-held device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above-mentioned aspects of the present invention and the manner of obtaining them will become more apparent and the invention itself will be better understood by reference to the following description of the embodiments of the invention, taken in conjunction with the accompanying drawings, wherein:
[0021] FIG. 1 is a perspective view of a tape cassette for blood testing in which an outer cover or housing is removed to illustrate the interior components of the cassette;
[0022] FIG. 2 is an enlarged perspective view of a head portion of the tape cassette of FIG. 1 ;
[0023] FIG. 3 is a top view of the head portion of FIG. 2 ; and
[0024] FIG. 4 is a partial schematic view of a test system with a tape cassette inserted therein.
DETAILED DESCRIPTION
[0025] The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.
[0026] The tape cassette 10 shown in FIG. 1 enables large quantities of glucose analyses to be carried out on blood samples taken by a patient. In this exemplary embodiment, the tape cassette 10 comprises an analytical test tape 12 which is pulled from a feed spool 14 and wound over a tape guide 16 onto a take-up spool 18 . A section of test tape 20 is stretched flat over a planar support frame 24 at a measuring site 22 in order to apply body fluid to the front side of the test tape 20 and take a precise reflectometric measurement on the rear side.
[0027] The test tape 12 consists of a light-permeable carrier tape 26 on the front side in which test fields or elements 28 are applied in sections as labels. These test fields or elements contain dry chemicals which respond to the analyte, such as glucose, in the body fluid and lead to a measurable change in the light that is reflected back when the rear side is illuminated. The carrier tape 26 , for example, consists of a 5 mm wide and approximately 10 μm thick foil on the front side of which a detection film of 50 μm in thickness is applied in sections.
[0028] As the measurement is being taken, the measuring light is irradiated and reflected back through a measuring opening 32 bordered by the support frame 24 without optical elements such as lens, filters, or windows filled with material being present within the area of the opening, although the measuring opening can, optionally, be bordered by a diaphragm. This provides a defined rear-side focusing or alignment of the optical measuring unit on the test tape section 20 which is exposed flat over the measuring opening 32 .
[0029] In order to transport the test fields or elements 28 successively to the measuring site 22 , a tape drive engaging in the hub 34 of the take-up spool 18 enables the test tape 12 to be wound forward. In this embodiment, return forces of about 2 N are generated by friction on the feed spool 14 and in the area of the tape guide 16 (and especially at a passage seal 36 ) such that the test tape 12 is adequately placed under tension to ensure it lies flat on the support frame 24 .
[0030] The tape guide 16 is formed by an injection molded part made of polypropylene and provides support for the spools 14 , 18 . A cover part or housing 38 is provided to cover the tape guide 16 from the outside and has an opening in a tapered narrow side wall for an easily accessible exposure of the support frame 24 .
[0031] According to the embodiment shown in FIG. 2 , the support frame 24 is formed on a head portion 40 of the tape guide 16 . In this embodiment, the support frame 24 is formed at the flat top surface of a tapered projection 42 which has a truncated, pyramid-shape to facilitate a hygienic application of body fluid samples. Thus, in the longitudinal direction of the tape, deflecting bevels 44 , 46 adjoin the support frame 24 to guide the test tape 12 along the opposing longitudinal sidewalls of the cassette 10 . Side boundaries or walls 48 , 50 are provided in this area which secure the test tape 12 from lateral deflection and prevent the test tape 12 from slipping sideways and off the support frame 24 .
[0032] According to the exemplary embodiment shown in FIG. 3 , the support frame 24 has two frame legs 52 , 54 extending longitudinally in the same direction as the test tape moves (left-to-right in FIG. 3 ) and two frame legs 56 , 58 which are at right angles or transverse to frame legs 52 , 54 . The longitudinal frame legs 52 , 54 lay flat and the distance between the outer edges of the legs 52 , 54 is less than the width of the test tape 12 . In this embodiment, the width of the test tape 12 extends past the sides of the legs 52 , 54 and body fluid is prevented from reaching the projection 42 during application. The transverse frame legs 56 , 58 are rounded off with a radius of approximately 0.3 mm at the deflecting edges 43 and their length is such that the entire width of the test tape 12 is supported thereon. With the test tape having a width of approximately 5 mm, the frame legs 56 , 58 also have a length of 5 mm whereas the measuring opening 32 has a shorter length of 3 mm and width of 2 mm. This design of the support frame 24 , in addition to allowing hygienic handling, also prevents the stretched portion of test tape 20 at the measuring site from arching or bending.
[0033] In order to simplify handling the cassette 10 , the cassette 10 is inserted into a hand-held device 60 as illustrated in FIG. 4 . The device 60 has a control and evaluation unit 62 , a tape drive 64 acting on the hub 34 of the take-up spool 18 , and an optical measuring head 66 positioned in the measuring chamber 30 on the cassette side.
[0034] The measuring head 66 and the head portion 40 of the cassette 10 are shown in FIG. 4 in the transverse direction (i.e. to the right) from the test tape. The measuring head 66 comprises a light source 68 and a light receiver 70 on a printed circuit board 72 . A pair of lens 74 , 76 in the measuring head 66 focus the light source 68 and the light receiver 70 through the transparent carrier tape 26 onto the test field or element 28 . In this embodiment, light beams 78 , 80 on the transmission and receiving side pass through the measuring chamber 30 and, in particular, through the measuring opening 32 without any interaction or interference from optical components. This provides reflection-photometric detection in a defined measuring plane where the optical path is not adversely affected by components of the cassette 10 .
[0035] While exemplary embodiments incorporating the principles of the present invention have been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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The present invention provides a test tape unit suitable for testing blood sugar. The test tape unit comprises an analytical test tape, a feed spool for unwinding unused test tape, a take-up spool for winding used test tape, and a tape guide to expose a section of test tape at a measuring site for receiving an application of body fluid. The tape guide has a flat support frame which stretches the test tape at the measuring site and forms the border of a measuring opening which is kept free from optical elements for producing an optical measurement.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/118,676, filed Feb. 4, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to a neon light display and more particularly to a neon light system with interchangeable neon light bulbs.
2. Description of the Prior Art
Neon light fixtures have been known in the art for quite some time. These types of fixtures have long been used in commercial business establishments such as restaurants, taverns, beauty shops, department stores, liquor stores, drugstores and delicatessens. These fixtures take on many forms such as wall fixtures, suspended ceiling fixtures, stand-alone fixtures, billboards, and window signs. Neon fixtures are also combined with pictures or paintings. Further, household consumers buy neon signs for decorative purposes that come in all types of designs, shapes and sizes. Some fixtures display commercial advertisements, some fixtures are shaped as plants or animals while other have unique designs.
Neon fixtures are usually comprised of a neon light bulb, a transformer for converting 115 volts AC from a wall socket to DC voltage for illuminating the neon light bulb, and some sort of mounting apparatus or stand. They are manufactured and sold as a single unit. This means a purchaser must purchase another unit when the neon bulb no longer functions, the fixture becomes obsolete because of time, vendor changes, product changes or some other reason the purchasers want to change their neon bulb system. This requires a purchaser to buy a new fixture each time, paying the cost of the transformer, the neon bulb apparatus, the mounting mechanism and the manufacturing of these parts into a final assembly. Further, there is no longer any use for the old neon bulb fixture; therefore, perfectly good operating transformers and mounting apparatus or mounting stands get scrapped.
Accordingly, the present invention eliminates the need for purchasing a new neon light fixture, when a person decides to change themes or objectives of their currently owned neon fixture. Additionally, the present invention alleviates the problem associated with scrapping working neon light fixtures.
SUMMARY OF THE INVENTION
In accordance with a preferred embodiment of the present invention, a neon light system is provided comprising a neon bulb for emitting illumination upon applying a predetermined voltage, cap means affixed to the neon bulb(s) for allowing current to flow through the neon bulb(s) when a predetermined voltage is applied to the cap means, and transformer means for applying a predetermined voltage to the cap means. The transformer means is comprised of a housing, a transformer disposed in the housing, and receptacle means for releasably receiving the cap means and causing electrical contact between the transformer and the cap means. The receptacle means includes holding means for electrically contacting the neon bulb(s) to the transformer means.
The receptacle means is comprised of one or two cavities for accepting and securing the cap means. The receptacle means allows for easy insertion and removal of the cap means and the neon bulb(s), to and from the transformer means. A two cavity embodiment, requires that the cap means include separate caps for attaching to both ends of the neon bulb(s), so that when the caps are inserted they make separate contact with the anode and cathode of the transformer means. A single cavity embodiment will include a single receptacle, that must include a non-conductive partition to electrically isolate both the anode and the cathode of the transformer, and cap means that must include a non-conductive partition to electrically isolate both ends of the light member means. Both the cap means and receptacle means can take on many different complimentary shapes and sizes such as cylinders, squares, key shapes and the like.
The receptacle means, advantageously, will include cavities with inner tabs. This will ensure that when cap means is inserted into the receptacle means, a frictional force is applied to the cap means. This force will hold the cap means and light member means in place, while establishing electrical contact between the cap means and the transformer means. The invention is not limited by this method, but may employ any method that causes cap means and transformer means to have electrical contact and to cause the cap means and light member means to remain stationary.
This invention is intended to be used with neon light fixtures that are wall mounted, suspended from the ceiling, window mounted, self-standing and the like. The neon light system allows for use of a variety of neon light bulb shapes and sizes to interchangeably be used with a common transformer means, therefore, solving the problems with the prior art.
An object of the present invention is to provide a neon light system that allows for different lighting configurations and objectives more inexpensively than present neon light fixtures.
Another object of the present invention is to provide a neon light system that eliminates the scrapping of good fixtures because of the need for new lighting configurations.
Another object of the present invention is to provide a neon light system that allows for interchangeable neon light bulbs utilizing the same neon light base.
A further object of the present invention is to provide a neon light system that is easy and simple to assemble.
Another object of the present invention is to apply these prior objects to neon fixtures that are wall mounted, hang suspended, window mounted or self-standing.
These and other objects will become apparent from the following description of a preferred embodiment taken together with the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take physical form in certain parts and arrangement of parts, preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:
FIG. 1 is an isometric view of a neon light system having receptacle means comprised of two members;
FIG. 2 is a top view of a cavity of a receptacle having holding members comprised of inner metallic tabs;
FIG. 3 is an isometric view of a neon light system having receptacle means comprised of a single member;
FIG. 4 is a top view of a cavity of a receptacle having two jacks having the shape of half drums separated by a single membrane;
FIG. 5 is a top view of a cavity of a receptacle having two jacks having the shape of rectangles;
FIG. 6 is a side isometric view of an embodiment of the invention;
FIG. 7 is a top view of the invention shown in FIG. 6;
FIG. 8 is a perspective view of a ceiling mounted unit according to the invention;
FIG. 9 is a side perspective view of another embodiment of the invention;
FIG. 10 is a partial isometric view of the embodiment shown in FIG. 9;
FIG. 11 is a perspective view of another embodiment of the invention; and
FIG. 12 is a partially exploded view of the embodiment shown in FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein the showings are for the purpose of illustrating the preferred embodiments of the invention only, and not for purpose of limiting same, FIG. 1 shows the invention in a modification of one of its preferred forms. The embodiment shown is a neon light system 1 comprised of a neon light base 2 having a neon light bulb 4 in the shape of a truck. The neon light bulb has two ends, each end being electrically affixed to cylindrical conductive caps 10 , 12 by some form of nonconductive epoxy 6 , 8 . The caps preferably are brass electrode caps, but could consist of a variety of different conductive metals. Further, the caps can take on many forms and shapes as long as they can mate to the receptacle means to ensure electrical contact. The embodiment has a transformer assembly 14 comprising a housing 16 , a transformer 17 and receptacles 18 , 20 . The receptacles 18 , 20 include two circular apertures 22 , 24 in the housing and two cylindrical resilient walls defining cavities 26 , 28 for receiving the caps 10 , 12 , to make electrical contact from the transformer 17 to the caps 10 , 12 . In this embodiment, holding means are formed by making the diameter of the cylindrical resilient walls 26 , 28 , slightly smaller than the diameter of the conductive caps 10 , 12 . In this way, when the conductive caps 10 , 12 are inserted into the receptacles 18 , 20 , a small downward force causes the resilient cylindrical walls 26 , 28 , to expand and receive the conductive caps. A frictional force is then asserted on the caps from the resilient cylindrical walls as they retract, thus affixing the neon light base 2 to the transformer 17 . Similarly, a small upward force on the neon light bulb will cause the cylindrical resilient walls to release the caps and allow for the interchanging of a new neon light bulb.
The holding means for holding a two cap embodiment in place could take on a variety of forms, as long as the caps make electrical contact with the transformer and the neon bulb can be easily affixed in place, by the holding means. Further, the fixture must be easily removable from the transformer means to allow for the ability to interchange light bulbs. FIG. 2 shows a receptacle 30 that includes, cylindrical walls defining a cavity larger than the diameter of the caps, with holding members that are in the form of inner tabs 32 , 34 , 36 , 38 . When the cap is inserted into the cylindrical wall, the inner tabs apply a frictional force on the caps holding the caps in place. The inner tabs could be
Referring now to another embodiment, FIG. 3 shows another embodiment of the invention. The embodiment shown is a neon light system 40 , comprised of a neon light base 42 having a neon light bulb 44 in the shape of a truck. The neon light bulb has two ends, each end being electrically affixed to cylindrical conductive plugs 48 , 50 and surrounded by some form of insulated rubber or plastic cap 46 , which could be made of other materials and includes an insulated housing for containing plugs. The insulated rubber or plastic cap 46 is in the shape of a cylinder, but can take on many other shapes and sizes. The plugs 48 , 50 can be in many different shapes, because the electrical contact is made within the insulated material. This allows the plugs to be affixed within the insulated material, as opposed to using epoxy to hold the plugs electrically affixed on the neon light bulb itself. The transformer assembly 52 is comprised of a housing 53 , a transformer 64 and a receptacle assembly 54 . The receptacle assembly 54 includes a single circular aperture 56 in the housing and a resilient circular wall 58 defining a single cylindrical cavity for receiving plugs 48 , 50 and the insulating material 46 . At the bottom of the circular wall defining the cavity are two jacks 60 , 62 for receiving plugs 48 , 50 , to make electrical contact between the plugs 48 , 50 and the transformer 64 . In this embodiment, the diameter of the circular walls 58 defining the cylindrical cavity can be slightly smaller than the insulation 46 . Similarly, the diameter of the plugs 48 , 50 can be slightly smaller than the jacks 60 , 62 . Either will allow for holding means to apply frictional force on the caps and secure the neon light bulb to the neon base.
The single receptacle may have many different forms of jacks, as long as the cathode and the anode of the transformer supplying the predetermined voltage are isolated. For example, FIG. 4 shows a cavity 70 having jack inputs in the shape of two half drums 72 , 74 with a thin insulated membrane 76 dividing the cylinder in half and electrically isolating the anode and cathode of the transformer. FIG. 5 shows a cavity 80 with two jacks 82 , 84 in the shape of rectangles, similar to a typical wall socket, wherein insulation material can form the body surrounding the jacks.
Although the specific embodiments described pertain to self-standing neon light systems, this invention applies to all types of neon light bulbs and bases, such as wall hanging systems, ceiling hanging systems, window hanging systems and the like. In addition, the receptacle means and capping means shapes and sizes are not limited to the embodiments shown and could take on many sizes, shapes and configurations.
FIG. 6 is a perspective view of a ceiling, wall or base mounted unit 100 . Unit 100 has a flat surface 102 which can be mounted against a ceiling, with retainers such as screws, bolts or the like, extending through appropriate holes 104 . An electric cord with a plug 106 has jacks for insertion into an electrical outlet. A neon light bulb 108 has end caps 110 , 112 for reception into a pair of receptacles 114 for making electrical contact with the transformer inside of unit 100 .
Likewise, unit 100 can be attached to a wall, with retainers extending through holes 104 . The ends of a neon bulb would preferably extend through receptacles 114 .
Unit 100 can also be used as a base unit, with surface 102 sitting on a table, floor or other support. Referring to FIG. 7, unit 100 is shown with receptacles 116 on the raised upper portion 118 . The capped ends of a neon lamp would be inserted into receptacles 116 for electrically connecting the neon lamp with the transformer to provide the necessary illumination. An appropriate switch would be provided for turning the bulb on and off.
Another ceiling mounted unit is shown in FIG. 8 . In this case, a ceiling mounted unit 130 has a transparent support 132 for holding a transformer 134 . A top support 136 is secured to a ceiling through some appropriate retaining means, and a pair of support rods 138 holds support member 132 and transformer 134 to member 136 . A neon light 140 has a pair of capped ends 142 , 144 which can be received in electrical receptacles 146 . As with the other embodiments, actuation of an appropriate switch means would energize the transformer and illuminate the neon bulb.
Another variation of the invention is shown in FIGS. 9 and 10. FIG. 9 shows a neon light bulb assembly unit 150 having an L-shaped support made from Plexiglas or some other appropriate material. Support 152 has a horizontal portion 154 and an integral vertical portion 156 . An appropriate advertising message or the like can be included on support 152 such as on the vertical part 156 . A transformer housing 158 holds on its inside an appropriate transformer and a neon bulb 160 has a pair of capped ends 162 , 164 which are releasably held in electrical receptacles 166 of the transformer inside of housing 158 . Support 152 is shown in FIG. 10 .
A multiple bulb unit 170 is shown in FIGS. 11 and 12. Unit 170 is in the general shape of a Christmas tree, and has a transformer housing 172 . Transformer housing 172 includes a multiple set of receptacle pairs 174 , each having receptacles 176 and 178 . A set of neon bulbs 180 are each attached to a base 182 . Bulbs 180 are suspended from stems or wire holders 183 which extend from the base 182 and hold the electrical wire for powering neon bulbs 180 . From each base 182 extend a pair of capped bulb ends 184 , 186 . Since many bulbs 180 can be received in transformer housing 182 , a colorful and varied effect can be produced.
In all of the foregoing embodiments, the neon bulb or bulbs can be changed at will, without requiring that a new transformer or transformer base be changed as well. Therefore, if a different bulb is desired because it has a different message or a different design, the old bulb can be withdrawn, saved or destroyed, and the new bulb inserted. If the brand or type of products being advertised with the bulb changes, it is very simple to simply change the bulb as noted. The transformer base is not destroyed with an old bulb, and need not even be moved. This is a very simple and economic invention, and should provide ease of use and tremendous savings in the field.
The foregoing descriptions are specific embodiments of the present invention. It should be appreciated that these embodiments are described for the purposes of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.
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A neon light fixture system that allows for interchanging of various neon light fixtures. The neon light system comprises a neon light bulb for emitting illumination upon applying predetermined voltage, caps affixed to said light member for allowing current to flow through said light member when a predetermined voltage is applied to said cap, a transformer for applying voltage to said caps, said transformer comprising a housing, a transformer disposed in said housing, and one or more receptacles for releasably receiving said caps and causing electrical contact between said transformer and said caps, said receptacles further including holding apparatus for affixing said neon light bulb to said transformer.
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This application claims the priority benefits from the U.S. provisional application Ser. No. 60/081,764 filed Apr. 15, 1998.
FIELD OF THE INVENTION
The present invention is directed to the in situ regeneration of metal-molybdate catalysts suitably used for methanol oxidation to formaldehyde.
BACKGROUND OF THE INVENTION
New or fully regenerated catalysts will have both MoO 3 and Fe 2 (MoO 4 ) 3 phases uniformly throughout the catalyst. However, when these catalysts are employed industrially for the manufacture of formaldehyde via methanol oxidation, they preferentially lose the MoO 3 component. This component is mainly lost from the catalyst placed at the top (inlet) and any "hot" spot regions of the catalytic reactor, leaving this catalyst with surface regions having the less efficient Fe 2 (MoO 4 ) 3 component. This decreases the efficiency, activity and selectivity of the catalyst, thereby requiring regeneration of the catalyst.
Regeneration methods prior to the present invention have had a number of significant disadvantages. Notably, regeneration by prior art methods required removal of the catalyst bed, regeneration in a separate vessel, and reloading of the catalyst bed. Such a sequence of steps was very expensive and slow.
The non-uniform compositions of the resulting spent catalysts also created difficulties in uniform regeneration. In addition to the molybdenum trioxide component losses noted above from the top and hot spot regions, the catalyst at the bottom of the reactor collects and becomes enriched in molybdenum trioxide component.
Thus, there is a need for new methods of regeneration of these catalysts. More specifically, there is a need for methods that redistribute the molybdenum trioxide component of the individual catalyst particles in order to increase the composition homogeneity while increasing average catalyst activity and formaldehyde selectivity.
The present invention fulfills this need by providing a new in situ method for redistributing the molybdenum trioxide component. Another objective of the present invention is to provide a method for obtaining more active catalysts, thereby resulting in reduced energy requirements because lower reactor temperatures will be needed to achieve complete methanol conversion. Yet another objective of the present invention is to increase the yield of formaldehyde from methanol oxidation, again resulting in reduced energy requirements of the process. These and other benefits of the present invention are described below.
BRIEF SUMMARY OF THE INVENTION
It has now been discovered that in situ regeneration of metal-molybdate catalysts can be achieved by treating spent metal-molybdate catalysts with a methanol/inert gas stream in the absence of oxygen. During this in situ regeneration method, MoOCH 3 complexes are formed, which draw out and redistribute the Mo component from the interior of the catalyst to the exterior of the catalyst, i.e., the active zone. It has been found that such treated catalysts are significantly more active and more selective in oxidation of methanol and the formation of formaldehyde therefrom than untreated spent catalyst.
The present invention provides the following additional benefits over prior regeneration methods. More specifically, the present method can be performed in-situ and does not require that the catalyst bed be unloaded. Additionally, the more active and selective catalysts made according to the present invention permit lower reactor temperatures to achieve complete methanol oxidation to formaldehyde. The yield of formaldehyde production is also increased which reduces the energy requirements and cost of the oxidation process. Waste products of carbon monoxide and dioxide are minimized while consumption of methanol is closer to ideal stoichiometry. These and other advantages will be readily recognized by those of skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a series of temperature profiles at certain distances in the direction of flow through a catalyst bed at 2 days, 2.5 months, and 5 months of operation.
FIG. 2 is a graph showing the increase in conversion and formaldehyde yield and reducing dimethyl ether (DME) production with spent catalyst that has been regenerated for 0, 15, and 30 minutes according to experiment 1.
FIG. 3 is a graph of formaldehyde yield, conversion, and DME production in catalyst regenerated for 30, 60, and 180 mins.
FIGS. 4-7 are results of Raman analysis for horizontally sectioned catalysts from different regions of the reactor. Comparison of the peak shifts shows that iron--molybdate is generally enhanced in exterior catalyst surfaces at the reactor top and "hot spot" regions while the catalyst surfaces at the cooler bottom of the bed are relatively enriched in molybdenum trioxide.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to a process for regenerating metal-molybdate catalysts used in the conversion of methanol to formaldehyde by contact in a flowing stream of oxygen-free gas containing methanol and an inert gas at conditions including a temperature of at least that typically used for the conversion of methanol to formaldehyde. Typical conditions useful for the regeneration process of the invention include an elevated temperature within the range from about 150°-500° C., preferably within the range of about 250°-350° C. for a period of at least about 30 minutes.
While not wishing to be bound by theory, it is believed that metal-molybdate catalysts at the top of the catalyst bed becomes "spent" when hot, flowing methanol removes molybdenum trioxide from the exposed catalyst surfaces by forming a volatile molybdenum trioxide at typical formaldehyde conversion temperatures. The regeneration process is intended to encourage the migration of molybdenum trioxide from inside the catalyst to the exposed outside catalytic sites by the same mechanism, namely, redistribution by volatilization in flowing methanol at temperatures on the order of those typically encountered as the catalyst became deactivated. In ring shaped catalyst solids, the molybdenum trioxide component is encouraged to move from the inner ring surface to the outer ring surface.
The regeneration process can be performed by passing an oxygen-free stream containing methanol in an inert gas (i.e., neither reducing nor oxidative toward the catalyst) through the catalyst bed in a direction opposite to the normal flow of reactants through the system, in the same direction of typical reactant flow, or radially inwardly or outwardly.
Catalysts that can be regenerated according to the present invention include supported or unsupported metal-molybdate complexes where the metal-molybdate complex is active for the conversion of alcohols to the corresponding aldehydes. Suitable sources of catalytically active metal include iron, lead, cadmium, bismuth, sodium, manganese, gadolinium, magnesium, copper, cobalt, tellurium, aluminum, chromium, and combinations thereof. Exemplary forms of catalytically active compositions that are formed by this process include Fe 2 (MoO 4 ), PbMoO 4 , CaMoO 4 , Bi 2 Mo 2 O 9 , Bi 3 (FeO 4 )(MoO 4 ) 3 and other Bi--Mo--O family members, Na 2 MoO 4 , Na 2 Mo 2 O 7 , MnMoO 4 , Gd 2 (MoO 4 ) 3 , MgMoO 4 , CuMoO 4 , CoMoO 4 , Fe 2 (MoO 4 ) 3 , Te 2 MoO 7 , CoMoO 4 , Al 2 (MoO 4 ) 3 , and Cr 2 (MoO 4 ) 3 .
If supported, the preferred metal oxide supports include oxides of titanium, tin, aluminum, zirconium, cerium, niobium, tantalum, and mixtures thereof.
The catalysts of particular note for regeneration by the present process includes those containing iron--molybdate complexes. Such iron--molybdate catalysts for process have been made by coprecipitating ammonium molybdate (e.g., (NH 4 )Mo 7 O 24 .4H 2 O)) with iron nitrate solution at appropriate temperature and pH for precipitation. The precipitated solids are then washed, dried, and finished to make particulate catalysts for the oxidative conversion of methanol to formaldehyde. Alternatively, particles of each metal oxide are loaded into the reactor and allowed to form active catalyst in situ as described in my copending application, claiming the benefit of U.S. Provisional application 60/081,950 entitled: "In Situ Formation of Metal Molybdate Catalysts," the utility application of which is filed concurrently herewith, and which application is herein incorporated by reference.
EXAMPLES
The following examples employed spent or used cylindrically shaped rings of iron--molybdate catalyst that had been made by Perstorp AB of Perstorp, Sweden and sold by Perstorp Polyols of Toledo, Ohio under the product designation KH-26L. The experiments were performed in a conventional plug flow reactor.
Example 1
By way of comparison, commercial KH-26L catalyst was compared to catalysts containing MoO 3 , Fe 2 O 3 , NiO, coprecipitated MoO 3 /Fe 2 (MoO 4 ) 3 , and mechanical mixtures of particles containing MoO 3 , Fe 2 O 3 , NiO and Fe 2 (MoO 4 ) 3 . Table I sets forth methanol conversion to formaldehyde. As seen by the relative turnover frequencies (TOF, determined as the reaction rate divided by the number of surface active sites per surface area of catalyst), the most active catalysts are characterized by an excess of catalytic molybdenum trioxide. The number of surface active sites was determined by methanol chemisorption at 100° C.
TABLE 1__________________________________________________________________________Methanol Oxidation Turnover Frequencies ofPure Compounds and Mixtures Prepared by Different Synthesis Methods TOF S.sub.BET (308° C.) (m.sup.2 /g) Synthesis Selectivity (sec.sup.-1).sup.a__________________________________________________________________________MoO.sub.3 5.0 (Thermal Decomposition) 88.0 5.3Fe.sub.2 O.sub.3 21.4 (Commercial) 49.0 26.9NiO 34.4 (Thermal Decomposition) -- 53.1Fe2(MoO.sub.4).sub.3 (1.5).sup.b 9.6 (Inorganic Coprecipitation) 61.0 1.1Fe2(MoO.sub.4).sub.3 (1.5) 1.5 (Organic Coprecipitation) 58.0 1.8Fe2(MoO.sub.4).sub.3 (1.1) 3.9 (Inorganic Coprecipitation) 64.9 2.2MoO.sub.3 /Fe.sub.2 (MoO.sub.4).sub.3 (2.2) 3.0 (Inorganic Coprecipitation) 88.5 15.8MoO.sub.3 + /Fe.sub.2 (MoO.sub.4).sub.3 (2.2) 3.5 (Mechanical Mixture) 88.3 14.8MoO.sub.3 /Fe.sub.2 (MoO.sub.4).sub.3 (3.97) 2.6 (Mechanical Mixture) 88.3 35.1MoO.sub.3 + Fe.sub.2 O.sub.3 (2.2) 5.7 (Mechanical Mixture) 92.0 14.5MoO.sub.3 + NiO (2.2) -- (Mechanical Mixture) -- 4.2Industrial Catalyst 7.8 (Coprecipitation) 95.0 29.6__________________________________________________________________________ .sup.a The activity of the mixtures were obtained at 300° C. and extrapolated to 380° C. .sup.b (Mo/Fe molar ratio)
Example 2
Powder samples of iron--molybdate (synthesized), molybdenum trioxide (synthesized) and ferric oxide (commercially available) were used to catalyze the conversion of a 50-55 sccm stream of methanol/oxygen/helium in the molar ratio of 6/13/81 at a temperature of 300° C. The results showed that a mixture of iron--molybdate catalyst (MoO 3 /Fe 2 (MoO 4 ) 3 ) had a higher conversion than ferric oxide, which had a higher conversion than molybdenum trioxide which exhibited a higher conversion than iron--molybdate.
MoO.sub.3 /Fe.sub.2 (MoO.sub.4).sub.3 >>Fe.sub.2 O.sub.3 >MoO.sub.3 >Fe.sub.2 (MoO.sub.4).sub.3
Example 3
During a typical methanol conversion process using commercially prepared iron--molybdate catalyst in a cylindrical shape with methanol flowing downwardly through a 65 inch fixed bed of catalyst, the catalyst temperatures at several location were taken at 2 days (fresh system), 2.5 months (mid-life) and at five months (spent). FIG. 1 is a graph of that temperature profile history.
Immediately apparent from the changes in the temperature profile is the development of a "hot spot" in the reactor at a height of about 40 inches from the top of the reactor bed.
Samples of the spent catalyst were removed at three different locations and sectioned for analysis. Location 1 was 33.5 to 35 inches from the top of the reactor (i.e., approximately eleven (11) cylindrical rings weighing about 1.3-1.6 grams total). Location 2 was 42 to 43 inches from the top of the reactor (i.e., approximately eleven (11) cylindrical rings weighing about 1.3-1.6 grams total). Location 3 was 55.5 to 62 inches from the top of the reactor (i.e., one (1) cylindrical ring weighing about 0.074 grams). FIG. 1 shows the temperature profile of the catalyst in the reactor during its operation at various points during the life cycle of the catalyst.
Raman analysis was performed on horizontal cross sections of the fresh and various spent catalysts. The Raman spectra are shown on FIGS. 4 (new catalyst), 5 (top of bed at 5 mos.), 6 (hot spot) and 7 (bottom of bed). The four spectra on each Figure correspond to the interior of the catalyst body (1, 2), the exposed inner (3) surface, and the exposed outer (4,4') surface.
As seen in FIG. 4, the fresh catalyst is made of MoO 3 and Fe 2 (MoO 4 ) 3 phases that are uniformly distributed throughout the catalyst. Each scan shows a set of peaks that are in the same place and roughly the same relative heights. This is not the same set of peak profiles seen by catalysts either at the top of the spent bed (FIG. 5) or at the bottom of the spent bed (FIG. 7). Catalyst at the top of the bed shows a significant reduction in the relative amount of molybdenum trioxide. The catalyst at the bottom shows the reverse: significant excess of molybdenum trioxide. Catalyst at the hot spot (FIG. 6) shows some reduction in relative amount of molybdenum trioxide at 4' but a significant increase at outer location 4 and inner surface 3.
Examples 4 and 5
Spent catalyst from the top (i.e., 33.5-35 inches) of the catalyst bed was regenerated for 0 (control), 15, 30, 60, and 180 minutes in an oxygen-free, flowing stream (50-55 sccm) of 6% methanol in helium at 300° C. The regenerated catalyst was then used to catalyze the conversion of a 50-55 sccm stream containing methanol, oxygen, and helium at a molar ratio of 6:13:81 at a temperature of 300° C. The performance of the regenerated catalyst is shown in FIGS. 2 and 3 in terms of formaldehyde (HCHO) selectivity, methanol conversion percent, and selectivity for dimethyl ether (DME).
As shown in FIG. 2, the spent catalyst initially converted 26.4% of methanol to formaldehyde (67.9%) and dimethyl ether (21.5%). Other substances (methyl formate, dimethoxy methane), not shown in the graphs for simplicity, were also produced. No modifications of conversion or selectivity were observed after regeneration for 15 minutes. When regenerated for 30 minutes, an increase of about two (2) times with respect to the initial conversion was observed. Moreover, the selectivity to formaldehyde reached 84%. The observation that dimethyl ether dropped from 21.5% to 2.4% demonstrates that the weak acid sites were successfully coupled with molybdenum during the regeneration treatment.
The spent catalyst samples of example 5 that were regenerated for 0 (control), 60 and 180 mins presented a similar initial catalytic activity (conversion 19.4%) and selectivity (68.7% to HCHO and 19.4% to DME) to the spent catalyst control of example 4. As shown in FIG. 3, regeneration for 60 minutes increased the conversion of methanol with improved formaldehyde selectivity while the selectivity to dimethyl ether decreased. The trends in increased conversion (about two (2) times) and selectivity (78%) are similar to those obtained when the sample was treated for 30 minutes in accordance with the regeneration treatment of the present invention (ex. 4). No subsequent changes were detected after three hours of treatment with the methanol/helium stream.
Thus, spent iron--molybdate catalysts for formaldehyde production can be effectively and efficiently regenerated by treating the spent catalyst with a methanol/helium gas stream in the absence of oxygen. While helium was used in the preferred embodiment of the present invention, it is contemplated that any suitable inert gas can be used in the present invention.
As shown by comparing FIGS. 2 and 3, formaldehyde (HCHO) selectivity % increases with in situ regeneration provided that this in situ regeneration treatment is performed for at least about thirty (30) minutes. Further regeneration does not increase conversion % or formaldehyde (HCHO) selectivity % when the time is increased to one(1) hour or three (3) hours for the spent catalyst employed. It is believed that there may be some variations in the time for regeneration to the point of diminishing returns that one with no more than an ordinary level of skill in this art will be able to determine with no more than routine screening tests. Table 2 summarizes the test results.
TABLE 2__________________________________________________________________________ Conversion % Selectivity %Sample (300° C.) HCHO DME DMM MF Other__________________________________________________________________________Fe.sub.2 (MoO.sub.4).sub.3 1.0 56.1 43.8 -- -- --MoO.sub.3 1.7 84.1 12.0 3.9 -- --Fe.sub.2 O.sub.3 2.6 43.7 50.2 5.2 -- --Fe.sub.2 (MoO.sub.4).sub.3 /MoO.sub.3 7.4 85.3 11.7 3.0 -- --spent catalyst location.sup.1331/2-35 26.4 67.9 21.5 1.7 1.5 7.342-43 38.2 82.3 4.5 3.1 0.8 9.3551/2-62 53.5 87.3 2.8 0.7 0.6 8.6after regeneration treatment.sup.2331/2-35 58.8 84.0 2.4 1.0 0.95 11.542-43 59.2 84.1 2.5 1.0 1.3 11.1551/2-62 51.9 86.5 2.9 0.8 -- 9.7__________________________________________________________________________ HCHO: formaldehyde; DME: dimethyl ether; DMM: dimethoxy methane and MF: methyl formate. .sup.1 in inches from top of 65 inch reactor bed prior to regeneration treatment .sup.2 of spent catalyst
It should be noted that catalyst at the bottom of the fixed bed already exhibits an excess of molybdenum trioxide.
While various alterations and permutations of the invention are possible, the invention is to be limited only by the following claims and equivalents.
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The method of the present invention involves in situ regeneration of metal-molybdate catalyst for methanol oxidation to formaldehyde comprising the step of regenerating spent metal-molybdate catalyst with an oxygen-free gas stream comprising methanol and an inert gas for a sufficient time and at an elevated temperature to regenerate the metal-molybdate catalyst.
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RELATED APPLICATIONS
[0001] This application claims priority to provisional application Ser. No. 60/225,352, filed on Aug. 15, 2000.
FIELD OF THE INVENTION
[0002] The invention relates to screw compressors, and more particularly to axial unloading lift valves for screw compressors.
BACKGROUND OF THE INVENTION
[0003] Axial unloading lift valves are commonly used in screw compressors to vary the compression load produced by the screws. One or more valves are arranged axially towards the discharge side of the screws and the load is varied by selectively opening and closing the valves. Opening the valves to “unload” the compressor reduces the effective working length of the screws by opening communication pathways between portions of the screw and the low-pressure suction end of the compressor. The open pathways allow the pressure to equalize so that compression does not occur over the portions of the screw communicating with the suction end of the compressor. When the valves are closed to “load” the compressor, no pressure equalization occurs over the axial length of the screw. Therefore, the full working length of the screws is utilized for compression. The angular location of the valves around the discharge ends of the screws determines how much of the axial working length of the screws is used or eliminated when the valves are closed or opened.
[0004] [0004]FIGS. 1 and 2 are schematic representations showing a portion of a prior art compressor 10 having an axial unloading lift valve 14 . FIG. 1 shows the valve 14 in the loaded condition and FIG. 2 shows the valve 14 in the unloaded condition. The compressor 10 includes a pair of screws 15 , 16 (only one is shown in FIGS. 1 and 2) mounted for rotation in a screw housing 22 . The interior of the screw housing 22 defines a compression chamber 24 where the fluid is compressed by the screws 15 , 16 , as is understood by those skilled in the art. A discharge housing 26 supports the discharge end of the screws 15 , 16 and is coupled to one end of the screw housing 22 . A suction housing 30 supports the suction end of the screws 15 , 16 and is coupled to the other end of the screw housing 22 .
[0005] The axial unloading valve 14 typically includes a cylindrically-shaped valve member 34 housed in a valve chamber 38 . The valve chamber 38 is formed in the discharge housing 26 so that one end of the valve chamber 38 communicates both with the compression chamber 24 and with a vent passageway 42 . The vent passageway 42 is connected to a suction cavity 46 formed in the suction housing 30 . The other end of the valve chamber 38 communicates with a high-pressure fluid supply that controls the positioning of the valve member 34 . The high-pressure fluid supply is typically either high-pressure lubricating oil or refrigerant that has been discharged from the compressor.
[0006] To load the compressor 10 , the valve 14 is closed by flooding the valve chamber 38 with high-pressure fluid. The fluid in the valve chamber 38 forces the valve member 34 toward the screw housing 22 until the valve member 34 abuts the screw housing 22 , as shown in FIG. 1. When the valve member 34 is in the position shown in FIG. 1, there is no communication, and therefore no pressure equalization, between the suction cavity 46 and the compression chamber 24 . Because there is no pressure equalization, the entire working length of the screws 15 , 16 is utilized and maximum compression loading is generated by the compressor 10 .
[0007] To unload the compressor 10 , the valve 14 is opened by draining the fluid from the valve chamber 38 . The high-pressure fluid in the compression chamber 24 forces the valve member 34 away from the screw housing 22 , as shown in FIG. 2. When the valve member 34 is in the position shown in FIG. 2, the passageway 42 provides communication, and therefore pressure equalization, between the compression chamber 24 and the suction cavity 46 . This pressure equalization reduces the effective working length of the screws 15 , 16 , thereby reducing the compression load generated by the compressor 10 .
SUMMARY OF THE INVENTION
[0008] For the axial unloading valve 14 to function properly, the valve member 34 must be carefully manufactured and installed. FIG. 3 shows a prior art valve member 34 in greater detail. The valve member 34 is substantially cylindrical and includes opposing first and second axial sealing surfaces 50 and 54 , respectively. A radial sealing and positioning surface 58 extends between the axial sealing surfaces 50 and 54 .
[0009] With this symmetrical configuration, the valve member 34 could be installed in the valve chamber 38 in two ways. Therefore, both the first and the second axial sealing surfaces 50 and 54 must be machined to tight axial run-out tolerances to ensure that, regardless of how the valve member 34 is installed, proper axial sealing occurs when the valve 14 is closed. The term “run-out” is well-known to those in manufacturing and in this situation is generally understood to refer to the perpendicularity between a longitudinal axis 62 and each of the axial sealing surfaces 50 and 54 . In addition to sealing concerns, the tight run-out tolerance ensures that no portion of the valve member 34 will interfere with the screws 15 , 16 when the compressor 10 is operating at full load (i.e., when the valve 14 is closed). This is especially important on compressors having small axial screw endplay with respect to the discharge housing 26 . Maintaining the tight axial run-out tolerances requires expensive precision machining and, because both axial sealing surfaces 50 and 54 must be tightly toleranced, two separate machine setups are required for two separate precision machining operations. This significantly increases the manufacturing cost of the valve member 34 .
[0010] One way to eliminate the need for two tightly-toleranced axial sealing surfaces 50 , 54 on the valve member 34 is to change the design. FIG. 4 illustrates an alternative prior art valve member 66 that has only one axial sealing surface 70 . Additionally, the radial sealing surface 74 and the radial positioning surface 78 are separate surfaces. This ensures that the valve member 66 can only be installed in one way, thereby eliminating the need for a second axial sealing surface with a tight run-out tolerance.
[0011] While only one precision machining setup is necessary for achieving the desired run-out tolerance on the single axial sealing surface 70 , a separate machining operation is still required to form the radial positioning surface 78 . This second operation need not be precision machining, but nonetheless requires a second machine setup. The two separate machine setups required to manufacture the different radial surfaces 74 and 78 can create tolerance stack-up problems and often mandate the use of a gasket 82 to prevent leakage. The use of the gasket 82 also adds to the cost of the compressor 10 and increases the number of parts that may require periodic replacement.
[0012] The present invention provides an improved valve member for an axial unloading lift valve. The improved valve member has only one axial sealing surface requiring a tight run-out tolerance. Therefore, only one machine setup is needed to produce the sealing surfaces of the improved valve member. Additionally, the valve member of the present invention includes features that facilitate proper assembly and ensure that the valve member is properly installed. No gaskets are required to seal the valve member. Thus, the valve member of the present invention provides a less-expensive and more reliable valve member than the prior-art valve members described above.
[0013] More specifically, the invention provides a screw compressor having a housing, a drive screw supported by the housing, and an idler screw supported by the housing. The drive screw and idler screw assembly have a low-pressure end and a high-pressure end. The drive screw, driven by an outside force, drives the idler screw, to which the drive screw is operably engaged. Rotation of the screws moves a fluid from the low-pressure end to the high-pressure end. The screw compressor further has at least one vent passageway with one end in fluid communication with the low-pressure region and a second end in selective fluid communication with the high-pressure end. In addition, the screw compressor has at least one valve having a valve member. Each valve member has a sealing surface, a non-sealing surface, and a radial sealing surface partially extending between the sealing surface and the non-sealing surface, the non-sealing surface having a recess. The valve is positioned such that the valve member is installable in a correct orientation and an incorrect orientation. When installed in the correct orientation the valve member is movable between a loaded position, at which the valve member substantially prevents flow from the high-pressure end to the low-pressure end, and an unloaded position, at which fluid passes from the high-pressure region through the vent passageway to the low-pressure region. When the valve member is installed in the incorrect orientation, the valve member provides a flow path from the high-pressure end through the vent passageway to the low-pressure end when in the loaded position and the unloaded position.
[0014] Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims, and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a schematic illustration of a prior art screw compressor with an axial unloading lift valve shown in the full load position.
[0016] [0016]FIG. 2 is a schematic illustration of the prior art screw compressor of FIG. 1 with the axial unloading lift valve shown in the partial load position.
[0017] [0017]FIG. 3 is a perspective view of a prior art axial unloading lift valve.
[0018] [0018]FIG. 4 is a perspective view of another prior art axial unloading lift valve.
[0019] [0019]FIG. 5 is a perspective view of an axial unloading lift valve embodying the present invention.
[0020] [0020]FIG. 6 is a partial section view of a screw compressor having the axial unloading lift valve shown in FIG. 5 installed incorrectly.
[0021] [0021]FIG. 7 is a section view of a screw compressor having the axial unloading valve shown in FIG. 5 installed correctly in the loaded position.
[0022] [0022]FIG. 8 is a section view of a screw compressor having the axial unloading valve shown in FIG. 5 installed correctly in the unloaded position.
[0023] [0023]FIG. 9 is a section view of a screw compressor showing both screws and two valves.
[0024] Before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Screw type compressors 100 of the type described herein are commonly used to move fluids (liquid or gas) such as oil, water, refrigerant, or other like substances. Screw type compressors 100 , as shown in FIGS. 6 - 9 , use a housing 105 and a pair of screws to increase the pressure of a fluid and move the fluid through the compressor 100 . The two screws are called the drive screw 110 and the idler screw 115 . In addition to these components, most systems in which a screw type compressor 100 is used contain an unloading valve 120 . The unloading valve 120 can be separate from the compressor 100 , however more typically the unloading valve 120 is incorporated into the compressor housing 105 , as in the present invention. In addition, multiple unloading valves 120 can be employed in the same compressor 100 to provide redundant functions or to perform different functions. For example, FIG. 9 shows a compressor 100 with two unloading valves 120 . One of the unloading valves 120 has a valve member 125 installed properly while the other unloading valve 120 is shown with the valve member 125 installed improperly. It should be noted that the unloading valves 120 , in the figures provided, are arranged around the drive screw 110 only. It is however, possible to arrange unloading valves 120 around either, or both screws 110 , 115 .
[0026] In general, the compressor housing 105 is formed from three separate pieces, a suction end 130 , a discharge end 135 , and a screw housing 140 . The three pieces are then assembled to form a complete housing 105 . While it is possible to manufacture a housing 105 from less than three pieces, assembly of the other compressor components into the housing 105 becomes more complex as the number of housing pieces are reduced. For example, a housing 105 in which one of the end pieces 130 or 135 is combined with the screw housing 140 would require a very intricate casting or significant machining to complete. The three-piece arrangement, requires the same intricacy, however, with three pieces, access to the different regions requiring machining is simplified. Typically, the three pieces are cast into a rough shape, and then surfaces requiring a tighter tolerance or better surface finish are machined. The pieces are generally cast aluminum, steel, iron, bronze, or other material capable of containing fluid at the required operating pressures and temperatures.
[0027] The end pieces 130 , 135 each contain a chamber for the collection of a fluid. The suction end chamber or cavity 145 contains low-pressure fluid and defines a low-pressure region. The discharge end chamber 150 (see FIG. 9) contains high-pressure fluid and defines a high-pressure region. Generally, the regions are cast into the end pieces 130 , 135 and require no additional machining. Each end piece 130 , 135 further contains two bored regions, each sized to receive a bearing 155 which in turn supports either the drive screw 110 or the idler screw 115 . Any bearing type can be used to support the screws 110 , 115 within the end pieces 130 , 135 including roller bearings, ball bearings, needle bearings, and journal bearings. The illustration of FIG. 6 shows only one of the two screws 110 , 115 , the one screw using needle bearings 155 for support within the housing 105 . The bearings 155 are of a known design; capable of operating effectively under the conditions experienced by the compressor. Each end piece 130 , 135 attaches to the screw housing 140 using a known attachment, typically a series of bolts or screws. To improve the seal between the end pieces 130 , 135 and the screw housing 140 , gaskets can be used. The gasket material should provide a superior seal throughout the operating temperature and pressure ranges of the compressor.
[0028] The discharge end piece 135 contains one or more bores or valve chambers 160 , sized to receive the unloading valve member 125 . A smaller bore 165 opens the valve chamber 160 to the outside surface of the end piece 135 allowing for the connection of a control fluid supply. The control fluid can be hydraulic oil, or any fluid compressed by the compressor, such as refrigerant. The use and function of the control fluid is well known in the art and will not be described in detail.
[0029] The screw housing 140 is manufactured in a manner very similar to that used to make the end pieces 130 , 135 . In addition, similar materials are used. Two large bores placed in the screw housing 140 form a compression chamber 170 , which accommodates the screws 110 , 115 . The bores are spaced apart a distance which allows the two screws 110 , 115 to mesh while still providing enough clearance to allow free rotation of the screws 110 , 115 . The size of each bore is precisely controlled to achieve a minimum operating clearance between the bore and the screws 110 , 115 that rotate within the bore. Any excess clearance between the walls of the compression chamber 170 and the screws 110 , 115 will reduce the compressor's efficiency, volumetric output, and maximum pressure output. A vent passageway 175 , parallel to the compression chamber 170 , provides a flow path from the high-pressure end of the screws 110 , 115 to the low-pressure region, when the unloading valve 120 is in the unloaded position or is installed improperly. The vent passageway 175 can be any shape so long as it provides an adequate flow area, alone or in combination with other unloading valves 120 , to unload the compressor 100 . In addition, a wall 180 , typically formed as part of the housing 105 , exists between the vent passageway 175 and the compression chamber 170 . The function of the wall 180 will be described in detail in forthcoming paragraphs. While only one vent passageway 175 has been described, it is possible to have several vent passageways 175 spaced radially around the screws 110 , 115 . The only limitation to the number of unloading valves 120 and vent passageways 175 is the radial space surrounding the screws 110 , 115 .
[0030] A screw type compressor 100 uses two meshed screws 110 , 115 to move and pressurize fluid. The screws 110 , 115 are in fluid communication with two regions within the end pieces 130 , 135 . The suction region, or low-pressure region, contains a supply of low-pressure fluid, which is drawn into the screws 110 , 115 during operation. The discharge region, or high-pressure region, located in the discharge end piece 135 , collects the compressed fluid leaving the compressor 100 .
[0031] A screw type compressor 100 compresses a fluid by trapping the fluid in a series of pockets and then reducing the volume of the pockets, thus increasing the pressure therein. Rotation of the screws 110 , 115 forces the fluid toward the high-pressure end of the screws 110 , 115 where it is discharged producing a continuous flow of high-pressure fluid. Typically, one screw, the drive screw 110 , is coupled to an electric motor or other prime mover capable of turning the drive screw 110 . Rotation of the drive screw 110 forces the idler screw 115 , which is meshed with the drive screw 110 , to turn. The two screws 110 , 115 working together trap and force the fluid to move toward the high-pressure region. The screws 110 , 115 are sized to fit within the housing 105 such that there is very little endplay in the screws 110 , 115 . This means that the gap between the high-pressure end of the screws 110 , 115 and the housing 105 is small enough to prevent substantial leakage between adjacent pockets.
[0032] As the screws 110 , 115 rotate, fluid is trapped in a pocket formed between the mesh point of the screws 110 , 115 and the housing 105 at the high-pressure end of the screws 110 , 115 . Continued rotation allows the end of the pocket to eventually pass over the discharge opening 150 and discharge the high-pressure fluid. If an unloading valve 120 is open at some point before the discharge opening 150 , the pressure within the pocket will prematurely discharge. For example, if an unloading valve 120 were open at a point one-half of a revolution before the discharge opening 150 , the fluid would discharge at that point. However, fluid remains within the pocket at a pressure approximately equal to the pressure in the low-pressure region. After the pocket passes the open unloading valve 120 , the high-pressure end will again seal and the pocket volume will continue to reduce. The continued rotation of the screws 110 , 115 , after passing the open unloading valve 120 , will continue compressing the trapped fluid. Because the full rotation of the screws 110 , 115 is not utilized in compressing the fluid, the outlet pressure will be less than the maximum achievable, and the effective length of the screws 110 , 115 is reduced.
[0033] With this background in mind, the unloading valve 120 will now be discussed. Unloading valves 120 of the type described herein are capable of performing several known functions. For example, an unloading valve 120 can be used to maintain the pressure leaving the compressor 100 at a value below its maximum. The unloading valve 120 can be radially positioned such that the effective length of the screws 110 , 115 is reduced a desired amount. The rotational angle between the unloading valve 120 and the discharge area 150 control the effective length of the screws 110 , 115 . Shortening the effective length of the screws 110 , 115 reduces the compressor's output pressure. This and other uses for unloading valves 120 are well known in the art and will therefore not be described in further detail.
[0034] [0034]FIG. 5 illustrates an embodiment of an unloading valve member 125 of the present invention. It should be pointed out that the relief area 185 shown in FIG. 5 is greatly exaggerated in the figure and does not appear in the other figures. The unloading valve 120 of the present invention contains a movable cylindrical valve member 125 housed in a valve chamber 160 . The valve chamber 160 , and thus the valve member 125 , is positioned such that the valve member 125 , in the loaded position, is in sealable contact with the wall 180 . The wall 180 , positioned between the screw bore and the vent passageway 175 , allows the valve member 125 to prevent flow therebetween. The valve member 125 has a sealing side 190 and a non-sealing side 195 along with a radial sealing surface 200 . The sealing side 190 and the radial sealing surface 200 are manufactured to very tight tolerances to ensure that they provide adequate seals. For example, the maximum allowable run-out on the sealing side surface 190 is approximately 0.008 mm (0.0003 in), while the allowable run-out on the non-sealing surface 195 is approximately 0.02 mm (0.0008 in). Run-outs as high as about 0.010 mm (0.0004 in) for the sealing surfaces 190 and 200 , and as low as about 0.015 mm (0.0006 in) for the non-sealing surface will function with the present invention.
[0035] The radial sealing surface 200 of the valve member 125 acts as a seal between the control fluid and the compression chamber 170 . In addition, the radial sealing surface 200 prevents leakage around the valve member 125 to the vent passageway 175 when in the loaded position. Further, the radial sealing surface 200 acts as a guide during assembly and during movement of the valve member 125 . To aid in the assembly process, the radial sealing surface 200 is relieved slightly as shown in FIG. 5. The relieved portion 185 is inserted into the valve chamber 160 before bolting the discharge end piece 135 to the screw housing 140 . The relief area 185 allows the valve member 125 to slide into the valve chamber 160 more easily. In addition to simplifying assembly, the relieved portion 185 simplifies manufacturing by allowing for the creation of the relief or dimple 205 in the non-sealing axial surface 195 without upsetting the radial sealing surface 200 . Whether the dimple 205 is machined, stamped, or formed using other known processes, the relief area 185 allows for small movements of the relieved radial surface 185 without affecting the tight tolerance areas. To ensure that the dimple 205 does not affect the radial sealing surface 200 , the dimple 205 should extend no deeper than the relief area 185 . In other words, the axial length of the relieved area 185 , as measured from the non-sealing surface 195 , should be equal to or greater than the depth of the dimple 205 .
[0036] The sealing side 190 of the valve member 125 in the loaded position prevents flow between the high-pressure end of the screws 110 , 115 and the vent passageway 175 . The sealing side 190 is forced against the wall 180 between the screw bore and the vent passageway 175 to form a seal. The seal area is relatively narrow and the pressure drop from the high-pressure side to the low-pressure side is potentially large requiring a good seal surface, thus the tight run-out requirements.
[0037] The valve member 125 of the present invention is simple and inexpensive to produce and assemble correctly. The sealing surfaces 190 , 200 of the present invention can be machined in one setup, greatly reducing the cost of the component. Further, the dimple 205 can be produced in any number of ways available to typical manufacturing facilities. The valve member 125 is therefore inexpensive to manufacture. Assembly remains easy and the detection of an incorrect assembly is greatly simplified by the present invention.
[0038] The valve member 125 of the present invention uses a cylindrical-shaped body having a sealing side surface 190 manufactured to the rigid run-out requirements previously described. The non-sealing side 195 is dimpled to produce a leakage path if it is installed improperly and positioned in the loaded position. FIG. 6 illustrates the present embodiment of the valve member 125 installed incorrectly, and positioned in the loaded condition. One can see that a flow path 210 between the end of the screws 110 , 115 and the low-pressure region exists even when the valve member 125 is in the loaded position. During load testing of this compressor 100 , before its shipment to a customer, this problem will be evident and can be easily corrected by reversing the orientation of the valve member 125 . The compressor 100 of FIG. 6 will be incapable of producing a pressure output corresponding to its maximum design output.
[0039] [0039]FIG. 7 shows the compressor 100 in the loaded position with the valve member 125 installed correctly. Clearly, no flow path exists between the high and low-pressure regions, and the compressor 100 output will correspond to the maximum design output. FIG. 8 shows the compressor 100 of the present invention in which the valve member 125 is installed correctly and the valve 120 is in the unloaded position.
[0040] While a non-sealing surface 195 having a dimple 205 has been described, many other shapes are possible. Any shape protrusion or recess 205 will function as long as it provides a leakage flow path 210 . In addition, the shape used should provide a relatively symmetric support that contacts the wall 180 so that there is no tendency for the valve member 125 to twist, bind, or stick. For example, a large hole drilled into the center of the non-sealing surface 195 would provide a leak path around the wall 180 while still allowing adequate support. In addition, a plurality of slots cut across the non-sealing surface 195 at different angles relative to one another would provide leakage paths 210 as well as adequate contact support. It should be clear to a person skilled in the art that there are many ways to adapt the non-sealing surface 195 to assure leakage if the valve member 125 is installed incorrectly.
[0041] The resulting valve member 125 should, when installed properly, seal the high-pressure end of the screws 110 , 115 from the low-pressure region when in the loaded position and provide a substantial leakage path 210 when installed incorrectly. The leak path 210 should produce leakage that is detectable during a load test of the compressor 100 . Typically, the leakage will manifest itself as an inability to achieve the desired output pressure. When this condition is detected, it is a simple task to partially disassemble the compressor 100 , invert the valve member 125 , reassemble the compressor 100 , and retest the compressor 100 .
[0042] Although particular embodiments of the present invention have been shown and described, other alternative embodiments will be apparent to those skilled in the art and are within the intended scope of the present invention. Thus, the present invention is to be limited only by the following claims.
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A screw compressor having an unloader valve with a movable valve member, the unloader valve being capable of indicating when the valve member is installed incorrectly. The valve member is manufactured such that if it is installed incorrectly it provides a leakage path sufficiently large to be detected during full load testing of the compressor. When the screw compressor fails the load test, the compressor is partially disassembled, and the valve is reinstalled in the proper orientation and the compressor is re-tested. The valve member leakage path is provided while maintaining low costs for production and assembly of the compressor.
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BACKGROUND OF THE INVENTION
This invention relates to a simulated log building structure, and more particularly to such a building structure in which the log members are hollow.
Heretofore, conventional log construction utilizes solid log members in which the wood material of the logs provides a thermal insulating medium for the building.
The following U.S. patents disclose various building structures in which the logs or simulated logs are hollow:
2,040,110; Tahvonen et al; May 12, 1936
2,635,303; Poynter; Apr. 21, 1953
2,787,029; Johnson; Apr. 2, 1957
3,969,859; Hisey; July 20, 1976
4,309,851; Flagg; Jan. 12, 1982
4,619,089; Stein; Oct. 28, 1986
The patents to Tahvonen et al, Johnson, and Hisey disclose hollow logs for carrying electrical service, such as conduits or cable, and/or gas or plumbing lines.
The patents to Tahvonen et al and Johnson also disclose a vertical passage in the corner of the structure for carrying electrical service conduits and gas and plumbing lines.
Tahvonen et al discloses hollow logs which are in communication with each other through the vertical corner air passages disclosed in FIG. 6, for carrying electrical service conduits, gas or plumbing lines, and also to provide a continuous air passage for insulation purposes.
FIG. 12 of Tahvonen et al discloses a horizontal perforted water pipe extending along the ridge pole of the roof for use in discharging water over the roof in the event of a fire.
None of the above patents disclose a hollow log building structure particularly adapted for carrying air or water throughout all of the walls for heating or cooling purposes.
SUMMARY OF THE INVENTION
The simulated hollow log building construction made in accordance with this invention includes walls formed from a plurality of elongated hollow tubular log members preferably made of plastic material, such as polyvinylcholoride. A plurality of tubular elbow members stacked at the corner portions of the building interconnect the log members of adjacent walls. Upright perforated pipes extend through corresponiing vertically aligned holes or openings in the elbow members to provide continuous fluid communication between all of the elbow members and their corresponding log members.
Where the log members terminate against the frames of openings in the walls, such as windows and doors, the adjacent ends of corresponding pairs of log members are connected by vertically disposed, U-shaped tubular connector members.
Appropriate heating or cooling devices circulate a fluid heat transfer medium, such as air or water, through all of the walls of the building.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top front perspective view of a simulated log building structure made in accordance with this invention;
FIG. 2 is a fragmentary rear side portion of the structure disclosed in FIG. 1, illustrating a means for supplying the fluid medium to the hollow log members;
FIG. 3 is a fragmentary inside perspective view of a corner portion of the log structure, illustrating some of the stacked elbow members and some of the interconnecting log members;
FIG. 4 is an enlarged fragmentary section taken along the line 4--4 of FIG. 3, with portions broken away;
FIG. 5 is a fragmentary section taken along the line 5--5 of FIG. 4, illustrating a corner portion of the structure, with several of the log members removed, and with portions broken away;
FIG. 6 is an enlarged fragmentary front elevational view of the front door of the building with adjacent log members and U-shaped connector members;
FIG. 7 is an enlarged plan view of one of the elbow members, with interconnecting log members and the vertical riser disclosed in phantom; and
FIG. 8 is an end elevational view taken along the line 8--8 of FIG. 7, with an interconnecting log member and vertical riser shown fragmentarily in phantom.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in more detail, FIG. 1 discloses a building structure 10 in the form of a log cabin having a front wall 11, a side wall 12, and a roof 13. Formed in the front wall 14 is a rectangular front door frame 14 supporting a front door 15. The front door frame 14 includes a pair of upright side members 16 and a top frame member 17.
A window opening in the side wall 12 in defined by a rectangular window frame 18 having upright side frame members 19, horizontal top frame member 20, and a window sill 21. Although not disclosed in the drawings, the structure 10 includes an opposite side wall identical to the side wall 12, with or without a window frame 18. In like manner, the back wall, not shown, is identical to the front wall 11 and may or may not include a back door and back door frame corresponding to the front door 15 and the front door frame 14.
The ends of each of the front wall 11, the side wall 12, and the opposite side wall and back wall, not shown, terminate in upright corner portions 22.
Each of the building walls 11 and 12, as well as the opposite side wall and back wall, not shown, are constructed with a plurality of elongated hollow log members 24 which are vertically stacked and extend horizontally or transversely and terminate in opposite end portions 25.
Arranged in each of the corner portions 22 is a vertical stack of elbow members 26. Each elbow member 26 is an L-shaped, hollow tubular casing having opposite open ends 27 and 28, preferably circular in cross-section. The central axes of the open ends of each elbow member 26 intersect at an angle, preferably a right angle, so that the vertically stacked elbow members 26 form an upright right-angle corner portion 22. When the elbow members 26 are vertically stacked, the central axes of the open ends 27 and 28 are substantially horizontal.
Each of the open ends 27 and 28 is provided with an annular or circular internal recess 29 (FIGS. 4 and 5) terminating at its inner end in an annular or circular abutment ledge 30. The diameter of the recess 29 is substantially equal to the exterior diameter of the end portion 25 of each log member 24 so that the end portion 25 can be force-fitted and snugly received within the corresponding annular recess 39 and abut against the annular ledge 30.
Formed in the top and bottom walls of each of the elbow members 26 are a pair of vertically aligned holes 31 and 32, respectively, of equal diameter. However, in the bottom elbow member 26', only a top hole 31 is formed in the top wall, while the bottom wall of the bottom elbow member 26' is solid. Likewise, in the top elbow member 126 (FIG. 3), only a bottom hole 32 is formed in the bottom wall, while the top wall of the top elbow member 126 is solid. When the elbow members 26, 26' and 126 are vertically stacked in a corner portion 22, such as illustrated in the drawings, all of the top and bottom holes 31 and 32 are in vertical alignment for receiving an upright perforated pipe or riser 34 having a plurality of vertically spaced horizontal ports 35 therethrough. Preferably, there is at least one port 35 communicating with the interior of each elbow member 26, 26' and 126 when the perforated pipe 34 is fully assembled within all of the elbow members, as illustrated in the drawings.
The circumferential location of each port 35 is not of particular importance so long as the port 35 is in free fluid communication with the interior of its corresponding elbow member 26 and the log members 24 are connected to a corresponding elbow member 26.
As illustrated in FIGS. 1 and 6, the end portions 25 of the hollow log members 24 adjacent the upright side frame members 16 of the front door frame 14 are connected in pairs by a U-shaped connector member 36 having opposite circular open ends 37 (FIG. 6). The opposite end portions of each of the U-shaped connector members 36 is provided with circular internal recesses 38 similar in construction to the recesses 29 of the elbow members 26. The diameters of the open-ended recesses 38 are substantially the same as the outer diameter of each of the log members 24, or at least the end portions 25 of the log members. Thus, a corresponding pair of log members 24 may have their ends force-fitted into the corresponding open recesses 38 and have their ends abut against the corresponding annular ledge 39 of the inner end of each of the recesses 38.
Each of the U-shaped connector members is arranged with one open end 37 above the other, and all of the U-shaped connector members 36 are vertically stacked, as clearly shown in FIGS. 1 and 6. Thus, each adjacent pair of hollow log members 24 are in fluid communication with each other adjacent the door opening. The U-shaped connector members 36 are also used adjacent the upright window side frame members 19, as clearly illustrated in FIGS. 1 and 2.
Accordingly, by utilizing only four tubular elements, namely the hollow log members 24, the elbow members 26, the perforated vertical pipes or risers 34, and the U-shaped connector members 36, the entire house 10 may be assembled in which all of the walls include hollow spaces which are in fluid communication throughout all of the walls, even where the walls have window and door openings.
Because of the spacing between the log members 24 created by their slip-fit connections within their corresponding connector members 26 and 36, caulking 45 is introduced into the spaces between the log members 24 to completely seal the interior of the building structure 10, as disclosed in FIGS. 5 and 6.
Appropriate fluid, either air or water, or any other gas or liquid, may be supplied to any one of the log members 24 or elbow members 36 at any desired location. As illustrated in FIG. 2, a bottom back log member 24 (in phantom) is connected to an inlet pipe 40 from a heat pump, furnace, water pump, or air conditioner 42 mounted on the ground outside the rear of the building structure 10. The heat pump 42 may be supplied from an external water source through a water supply pipe 43, or it may be supplied with ambient air through the inlet fan 44, shown in phantom. FIG. 2 discloses the inlet water or air pipe 40 connected to the bottom log 24, which is advantageous in the event that the fluid is hot to permit the hot fluid to naturally rise, in addition to being forced upward through the walls of the building by the heat pump 42. The heat in the walls of the building structure 10 is then transmitted to the interior space of the structure 10.
On the other hand, if it is desired to cool the building, the heat pump or air conditioner could be connected to a top log to introduce the cold fluids so that the fluid would naturally gravitate downward and circulate through the log members 24 and their connector members throughout all the walls of the structure.
The building structure 10 could of course take many various forms, such as a residence, a commercial structure, an out building on a farm or a building to house animals or agricultural products.
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A simulated log building structure in which a plurality of simulated hollow log members are interconnected at their corners by corresponding tubular elbow members in fluid communication with each other so that a fluid medium may be freely circulated throughout all of the walls of a building structure for heating or cooling purposes.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/192,413, filed Sep. 18, 2008, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention generally relates to a control or switch arrangement for a medical instrument or tool, and specifically to an arrangement which automatically seals itself upon assembly and without the need for a sealing agent.
BACKGROUND OF THE INVENTION
[0003] Medical instruments or tools are utilized during surgery for various purposes. In this regard, cutting instruments, such as surgical saws, are utilized to shape and remove bone, for example, for the purpose of preparing a joint for receiving an implant, such as a hip implant. Other types of surgical tools may be used in what are generally termed endoscopic procedures. Endoscopy in the medical field allows internal features of the body of a patient to be viewed without the use of traditional, fully-invasive surgery. Endoscopic imaging systems incorporate an endoscope so as to enable a user to view a surgical site, and endoscopic tools enable non-invasive surgery at the site. Such tools may be shaver-type devices which mechanically cut bone and hard tissue, or radio-frequency (RF) probes which are used to remove tissue via ablation or coagulate tissue to minimize bleeding at the surgical site, to name a few.
[0004] In endoscopic surgery, the endoscope is placed in the body at the location at which it is necessary to perform a surgical procedure. Other surgical instruments, such the endoscopic tools mentioned above, are also placed in the body at the surgical site. The surgeon views the surgical site through the endoscope in order to manipulate the tool to perform the desired surgical procedure. Some endoscopes are usable along with a camera head, for the purpose of processing the image data received by the endoscope. The eyepiece of such an endoscope is typically coupled to the camera head, which camera head is connected to a camera control unit.
[0005] The development of endoscopes and their companion surgical tools has made it possible to perform minimally invasive surgery that eliminates the need to make a large incision in the patient to gain access to the surgical site. Instead, during endoscopic surgery, small openings, called portals, are formed. One advantage of performing endoscopic surgery is that since the portions of the body that are cut are reduced, the portions of the body that need to heal after the surgery are likewise reduced. Still another advantage of endoscopic surgery is that it exposes less of the interior tissue of the patient's body to the open environment. This minimal opening of the patient's body lessens the extent to which the patient's internal tissue and organs are open to infection.
[0006] Surgical instruments, such as surgical saws, shavers, RF devices, camera heads for use in conjunction with endoscopes and other surgical tools, typically incorporate some type of control arrangement located on the instrument which facilitates manual control of the instrument or tool by the surgeon. For example, a conventional RF probe typically includes a control or button arrangement to allow the user to select “CUT” to ablate tissue or “COAG” to coagulate tissue. Similarly, a shaver arrangement typically incorporates a handpiece to which a shaver probe is attached, wherein the handpiece includes a control arrangement with various buttons to control the direction, speed, etc. of the rotating shaver blade. Camera heads usable with endoscopes likewise incorporate control arrangements to allow the user to control various functions of the camera head, such as zoom, pan, white balance, picture, etc.
[0007] Due to the type of environment in which the above surgical instruments are utilized, it is necessary to seal internal electrical and mechanical components of the instruments from the external environment, which can have varying humidity levels, or fluids and/or other contaminants present which could harm the instruments and disrupt the functioning thereof. Control arrangements, such as switches, may be mounted in openings formed in the housings of the instruments, and such openings and control arrangements must be adequately sealed from the environment. One known method of sealing control arrangements of this type is to utilize a sealing agent, such as silicone, around the control or switch arrangement at the junction between the arrangement and the instrument housing. Such an arrangement is utilized on the commercially available FORMULA® shaver handpiece used in arthroscopy procedures, as sold by the Assignee hereof. Specifically, the control arrangement includes a keypad including one or more control buttons thereon, which keypad is then held in the housing opening by a cover plate. The cover plate is held in place by screws, and a sealing agent is applied to the juncture between the housing and the cover plate. While this method is effective for its intended purpose, same nonetheless requires additional components and assembly steps during assembly, which can be time-consuming and costly from a manufacturing perspective.
[0008] Other known methods include the use of switch components which are permanently press-fit or adhered to the instrument housing. This method, however, accordingly does not allow disassembly of the arrangement, which is sometimes desirable or necessary for maintenance or repair purposes.
[0009] In order to obviate or at least minimize the disadvantages of known sealing arrangements, the instant invention includes a control arrangement which cooperates with a housing of the instrument or tool to provide a seal therebetween upon assembly of the control arrangement to the tool housing. The control arrangement includes an actuator member or keypad having a button or buttons thereon associated with a control function of the instrument, a retaining clip configured for securing the control arrangement to the tool housing and a sealing member. The tool housing has a housing wall which defines an opening therein for receiving the control arrangement, and the housing wall includes a sealing surface adjacent the opening. The retaining clip is disposed within a portion of the housing opening defined outwardly of the actuating member, and is resiliently disposed in such opening portion to prevent dislodgement of the control arrangement from the tool housing. Further, the retaining clip, when engaged within the housing opening, causes sealing engagement of the sealing member with the sealing surface of the housing wall automatically upon assembly of the retaining clip to the housing.
[0010] This automatic sealing function of the control arrangement when assembled to the tool housing serves to fully seal the arrangement from the exterior environment of the housing, without the need for the application of a sealing agent, such as silicone or the like, to the junction between the control arrangement and the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an illustration of an endoscopic camera arrangement including an example of one type of scope assembly incorporating a sealed control arrangement pursuant to the invention;
[0012] FIG. 2 is an enlarged and fragmentary perspective view of the scope assembly of FIG. 1 ;
[0013] FIG. 3 is an enlarged and fragmentary exploded perspective view of portions of the scope assembly of FIG. 1 , illustrating the various components of the control or switch arrangement;
[0014] FIG. 4 is an enlarged and fragmentary view of the camera head of the scope assembly;
[0015] FIG. 5 is an enlarged, fragmentary cross-sectional view of the housing of the camera head as seen generally along line 5 - 5 in FIG. 3 ;
[0016] FIG. 6 is an enlarged, fragmentary cross-sectional view of the housing of the camera head as seen generally along line 6 - 6 in FIG. 3 and rotated clockwise by about 90 degrees;
[0017] FIG. 7 is an enlarged cross-sectional view of the keypad of the control arrangement as seen generally along line 7 - 7 in FIG. 3 ;
[0018] FIG. 8 is an enlarged plan view of the cover plate of the control arrangement;
[0019] FIG. 9 is an enlarged cross-sectional view of the cover plate as seen generally along line 9 - 9 in FIG. 8 ;
[0020] FIG. 10 is an enlarged plan view of the retainer clip of the control arrangement; and
[0021] FIG. 11 is an enlarged, fragmentary cross-sectional view of the control arrangement as seen generally along line 11 - 11 in FIG. 4 .
[0022] Certain terminology will be used in the following description for convenience in reference only, and will not be limiting. For example, the words “upwardly”, “downwardly”, “rightwardly” and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from, respectively, the geometric center of the arrangement and designed parts thereof. The words “forwardly” and “distally” will refer to the direction toward the end of the arrangement which is closest to the patient, and the words “rearwardly” and “proximally” will refer to the direction away from the end of the arrangement which is furthest from the patient. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.
DETAILED DESCRIPTION
[0023] For purposes of illustration, FIG. 1 shows an endoscopic camera arrangement 10 , including a scope assembly 11 which may be utilized in endoscopic procedures, for example. The scope assembly 11 incorporates an endoscope or scope 12 which is coupled to a camera head 13 by a coupler 14 located at the distal end of camera head 13 . Camera head 13 incorporates well-known circuitry, such as a charge-coupled device (CCD) or a complementary metal oxide semi-conductor (CMOS), for acquiring color video image data of internal features of the body through one or more lenses within the scope 12 . Light is provided to the scope 12 by a light source 14 A via a light conduit 15 , such as a fiber-optic cable. The camera head 13 is coupled to a camera control unit (CCU) 17 by a transmission cable 18 . Operation of the camera arrangement 10 is controlled, in part, by CCU 17 . Cable 18 conveys video image data from the camera head 13 to the CCU 17 and conveys various control signals bi-directionally between the camera head 13 and the CCU 17 . In one embodiment, the image data output by the camera head 13 is digital, in which case cable 18 may be Firewire, a Universal Serial Bus (USB) or another type of high-speed digital interface.
[0024] A control or switch arrangement 20 ( FIG. 2 ) is provided on the camera head 13 and allows the user to manually control various functions of the camera arrangement 10 . These camera functions may also be controlled by voice commands using a voice control unit 23 , which control unit 23 is coupled to CCU 17 . Voice commands are input into a microphone 24 mounted on a headset 25 worn by the surgeon and coupled to the voice control unit 23 . A hand-held control device 26 , such as a tablet with a touch-screen user interface or a pendant, may be coupled to the voice control unit 23 as a further control interface. In the illustrated embodiment, a DVD recorder 27 and a printer 28 are also coupled to the CCU 17 . Additional devices, such as an image capture and archiving device, may be included in arrangement 10 and coupled to CCU 17 . Video image data acquired by camera head 13 and processed by CCU 17 is converted to images, which can be displayed on a monitor 29 , recorded by recorder 27 , and/or used to generate static images, hard copies of which images can be produced by printer 28 .
[0025] With reference to FIGS. 3-6 , camera head 13 includes a housing 30 defined by a generally tubular housing wall 31 defining a hollow interior 32 . Interior 32 opens distally through an opening 33 which cooperates with coupler 14 , and sidewardly through a bore or opening 34 which extends completely through housing wall 31 and mounts therein control or switch arrangement 20 . Bore 34 is defined by an annular terminal edge portion of housing wall 31 having multiple stepped sections or portions as described below.
[0026] Housing wall 31 includes an annular flange 35 having an inner surface 36 oriented generally transverse to a longitudinal axis A of scope 11 (which axis A is generally parallel to a horizontal plane of bore 34 ), and generally parallel to a central axis B of bore 34 (which axis B is oriented transversely to axis A). Surface 36 defines a radially innermost portion 38 of bore 34 with respect to scope axis A, and in the illustrated embodiment portion 38 has the smallest diameter of all of the sections of bore 34 . Surface 36 is joined to a flat annular surface 39 which is generally parallel to scope axis A and generally perpendicular to bore axis B, which surface 39 , in turn, is joined to a further surface 40 of housing wall 31 . Surface 40 is essentially perpendicular to axis A and essentially parallel to axis B. Surfaces 39 and 40 are oriented transversely to one another, and in the illustrated embodiment together form a right angle. Further, surface 40 is located axially outwardly from surface 36 with respect to scope axis A, and is generally parallel to surface 36 , so as to define an intermediate portion 42 of bore 34 having a larger diameter than adjacent bore portion 38 .
[0027] An upper extent of surface 40 is joined to an annular sealing surface 44 which protrudes radially relative to scope axis A and is joined to a flat annular surface 45 . With respect to axis A, surface 45 is located radially inwardly from surface 44 and axially outwardly therefrom. Surface 45 is joined to a wall surface 48 which is generally parallel to surface 40 and is located axially outwardly (axis A) therefrom so as to define a further bore portion 50 of a larger diameter than adjacent bore portion 42 . Surface 48 , surface 45 and an outer surface of sealing surface or projection 44 together define an annular recess or notch 49 located immediately adjacent sealing projection 44 , and projecting radially inwardly relative thereto with respect to axis A. Surface 48 is joined to a flat annular surface 52 which adjoins an annular housing wall surface 53 located axially outwardly from wall surface 49 (axis A) and generally parallel thereto so as to define a further bore portion 60 of a greater diameter than adjacent bore portion 50 , but of a lesser radial dimension than bore portion 50 (axis A).
[0028] Bore portion 60 joins to an outermost bore portion 61 defined by an annular housing surface 63 located axially inwardly (axis A) from adjacent housing surface 53 such that housing wall 31 defines an outer flange 65 which overhangs bore portion 60 so as to form a retaining lip therearound. Outermost bore portion 61 is the radially outermost part of bore 34 (axis A). In the illustrated embodiment, flange 65 is annular. However, it will be appreciated that flange 65 may be embodied by a plurality of flanges or projections located about the periphery of bore 34 , or only a single flange of an adequate circumferential dimension may be provided along a portion of the outer periphery bore.
[0029] With reference to FIGS. 5 and 6 , in the illustrated embodiment, flange 65 angles upwardly as same projects radially inwardly with respect to and towards axis B, and thus defines a slightly upwardly inclined inner surface 67 which is oriented at an angle in the range of about 15 - 20 degrees relative to axis A.
[0030] Turning now to control arrangement 20 , and with reference to FIGS. 3 and 11 , same includes a membrane switch 70 having outer and inner members 71 and 72 . Outer member 71 mounts thereon a pair of switch contact pads 73 and 74 which are normally in the open position. Outer member 71 is generally planar and has an outer periphery sized so as to relatively snugly seat within bore portion 42 of housing bore 34 so that outer member 71 rests atop housing flange 35 , while inner member 72 projects into innermost bore portion 38 . Membrane switch 70 contains suitable circuitry electrically connected to the appropriate components within camera head 13 such that the appropriate control commands are carried out when contact pads 73 and 74 are actuated, as discussed further below.
[0031] Control arrangement 20 additionally includes an actuator or keypad 80 , as shown in FIGS. 3 , 7 and 11 . Keypad 80 has a base member 81 which surrounds and is joined to a pair of raised buttons 82 and 83 which project outwardly from base member 81 . Buttons 82 and 83 have respective upper or outer surfaces which include indicia thereon corresponding to various control functions of camera head 13 . In the illustrated embodiment, the buttons 82 and 83 respectively include the letters “P” and “W” thereon, which are representative of “picture” and “white balance” functions of camera head 13 .
[0032] Base member 81 of keypad 80 has an outer annular edge portion 85 which surrounds buttons 82 and 83 , and an inner web portion 86 disposed between buttons 82 and 83 . Edge portion 85 and web portion 86 are generally coplanar with one another, and in the illustrated embodiment are integrally formed as one-piece with buttons 82 and 83 . Web portion 86 includes a lower or inner generally flat surface 87 , and outer edge portion 85 includes a lower or inner surface 89 coplanar with surface 87 . Outer edge portion 85 defines an annular lip 88 which projects downwardly or inwardly from surface 89 .
[0033] Buttons 82 and 83 each have respective projections 90 and 91 which are cantilevered downwardly or inwardly and define respective lower or inner surfaces 92 and 93 which are generally planar and coplanar with one another. In the illustrated embodiment, keypad 80 is formed as a one-piece component constructed of an elastomeric and resilient material.
[0034] With reference to FIG. 11 , keypad 80 is located within bore portion 50 so that lip 88 of base 81 engages within notch 49 and against sealing projection 44 and so that lower surface 89 of base edge portion 85 and lower surface 87 of web 86 seat on the upper surface of membrane switch 70 . Further, the lower surfaces 92 and 93 of actuating projections 90 and 91 of keypad 80 are spaced slightly upwardly from the respective contact pads 73 and 74 of membrane switch 70 . As shown in FIG. 11 , when keypad 80 is assembled to housing 31 atop membrane switch 70 , actuating projections 90 and 91 are aligned with contact pads 73 and 74 .
[0035] Control arrangement 20 additionally includes a cover plate 100 as shown in FIGS. 3 and 8 . Cover plate 100 is shaped to cooperate with keypad 80 , and includes a planar base wall 101 which defines therein openings 102 and 103 which extend completely through base wall 101 and are shaped to correspond with the outer peripheries of buttons 82 and 83 . Buttons 82 and 83 extend upwardly or outwardly through the respective openings 102 and 103 in the assembled condition of control arrangement 20 . As shown in FIG. 11 , cover plate 100 seats atop base 81 of keypad 80 within bore portion 50 , with buttons 82 and 83 of keypad 80 located within the respective openings 102 and 103 .
[0036] With reference to FIGS. 3 and 10 , control arrangement 20 additionally includes a retainer clip 110 defined by an elongated body 111 generally having an elliptical shape. Clip body 111 is of a split-ring construction, and thus has a pair of terminal or free ends 112 which are spaced sidewardly from one another to allow compression of clip 110 . As shown in FIG. 10 , the free ends 112 have chamfers 113 which assist in removing clip 110 from housing 30 . Additionally, at the side of clip 110 diametrically opposite from ends 112 , body 111 projects inwardly so as to define a recess 114 which aids in installation of clip 110 by allowing easier compression thereof.
[0037] Referring to FIG. 11 , with membrane switch 70 , keypad 80 and cover plate 100 assembled within bore 34 of housing 31 , these components of control arrangement 20 are secured within housing 30 via retainer clip 110 . Specifically, according to one assembly method, retainer clip 110 is compressed by applying pressure to the opposite sides of body 111 located between ends 112 and recess 114 , so that clip 110 can be inserted into and pass through outermost bore portion 61 over flange 65 . Once clip 110 has cleared surface 63 of flange 65 which defines bore portion 61 , the pressure on clip 110 is removed so that the clip 110 resiliently returns to its normal or at rest configuration (as shown in FIG. 10 ) and moves into bore portion 60 atop cover plate 100 . In this regard, the angled surface 67 of flange 65 serves to guide the clip 110 downwardly during insertion or installation so that same seats within bore portion 60 and is brought into engagement with the cover plate 100 . With clip 110 in place within bore 34 of housing 31 , clip 110 prevents dislodgement of the underlying components of the control arrangement 20 , and also compresses keypad 80 and maintains lip 88 of keypad 80 in notch 39 and in contact with surfaces 48 , 45 and 44 of housing 31 so as to effectively create a fluid-tight seal between the external environment and the components internal to housing 31 , including membrane switch 70 and the electronic circuitry and other components located within housing 30 of camera head 13 . In the illustrated embodiment, the dimensions of flange 88 of keypad 80 are somewhat larger than the dimensions of housing notch 39 , such that when keypad 80 is compressed against housing 30 by clip 110 a fluid-tight seal is achieved. Further, the upward tilt of flange 65 of housing wall 31 at surface 67 allows easier insertion of clip 110 into bore 34 of housing 30 , and also serves to adjust the depth of the clip 110 downwardly within bore portion 60 and accommodate for varying tolerances of the components of control arrangement 20 .
[0038] According to another assembly method, the clip 110 can be angled downwardly and one edge of clip 110 can be inserted directly into bore portion 60 . The opposite edge of clip 110 is then pushed downwardly past flange 65 and into bore portion 60 .
[0039] If desirable or necessary, the control arrangement 20 can be removed from the housing wall 31 . Specifically, as shown in FIG. 4 , the clip 110 is removed from the housing 30 by inserting a tool behind one or both chamfers 113 of clip 110 and pushing the free ends 112 of clip 110 towards clip recess 114 . This action on clip 110 will cause same to disengage from bore portion 60 , and allow removal of cover plate 100 , keypad 80 and membrane switch 70 .
[0040] The control or switch arrangement 20 according to the invention as described above self-seals upon assembly of the retainer clip 110 into housing 31 , and thus avoids the need for application of a sealing agent, such as silicone, around or within bore 34 , which is time-consuming and costly from an assembly perspective. Additionally, the arrangement according to the invention allows disassembly of the control arrangement for purposes of repair or inspection.
[0041] It will be appreciated that the scope assembly 11 is shown herein for illustrative purposes only, and various types of surgical tools or instruments other than such scope assembly may incorporate the tool housing structure and control arrangement according to the invention. Some of these types of medical instruments are described above, such as surgical saws, shavers and RF probes. Other types of medical and surgical instruments may utilize the structure of the invention, and thus this invention is not to be construed as limited for use solely in a scope assembly or in the other surgical instruments described herein.
[0042] Although a particular preferred embodiment of the invention is disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangements of parts, lie within the scope of the present invention.
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A control arrangement for use in a medical or surgical instrument, which arrangement includes a keypad for providing manual control functions to a user of the instrument, a retainer clip and a sealing member. The keypad and retainer clip are located within an opening formed in the instrument housing, whereby when the retainer clip is assembled to the housing, the retainer clip automatically causes the sealing member to sealingly engage with a corresponding sealing surface defined adjacent the housing opening, without the need for the use of additional sealing agents.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is the US National Stage of International Application No. PCT/EP2005/057189, filed Dec. 28, 2005 and claims the benefit thereof. The International Application claims the benefits of German application No. 10 2005 003 916.2 DE filed Jan. 27, 2005, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
Monitoring the reliability-relevant characteristics of systems, for example internal combustion engines, is today guaranteed by a level structure, which is mapped to the reliability-relevant scope of functions of the system in the control device. An example is the EGAS (electronic gas pedal) monitoring concept according to the recommendations of the EGAS-AK of the VDA (Association of the German Automotive Industry).
BACKGROUND OF THE INVENTION
Such a purely level-oriented concept is complicated both in the case of software structures, the provision of which is distributed among different software suppliers, and in the case of distributed hardware structures, for example in the case of parallel or redundant structures, in which parts of the reliability-relevant functions are carried out in each case. In addition, the EGAS monitoring concept makes provision for independent hardware for monitoring the processor functions of the computer performing the functions. If different functions are carried out by different control devices, an independent hardware mechanism must be provided for monitoring each of these control devices, which results in considerably higher costs being incurred.
In the case of software structures, it has not yet been possible to satisfactorily resolve the synchronization and enabling or implementation of know-how problems, for example interface definitions for defining the monitoring structure. Distributed hardware structures are not yet being used widely, but will become increasingly important in the course of the so-called AUTOSAR initiative (Automotive Open System Architecture).
The grouping of functions, for example, ignition or injection, is at present undertaken in so-called units. In this way, it is for example possible to group together, in an organized manner, into one group called the DRRQ (driver request), the entire functionality concerned with the capture and the diagnosis of the driver's request via the accelerator pedal. This group also comprises the diagnosis of the gas pedal components. Because the function of capturing the driver's request is a reliability-relevant function, there has thus far been one module in a monitoring functional group concerned with the protection of the functions in the DRRQ unit. If the DRRQ functions are now supplied by another manufacturer as a product (black box) or if these functions are carried out in another control device (e.g. carbody controller), the technical and organizational synchronization of monitoring becomes difficult, if not completely impossible, because there are requirements with respect to time, for example real-time criteria, that may be damaged by an exchange of data between the control devices.
SUMMARY OF INVENTION
An object underlying the present invention is to find a new way in which to synchronize reliability-relevant structures in the face of restrictions on the side of the manufacturer or product-specific restrictions in the case of software development and hardware platforms.
This object is achieved by the inventions by means of the features of the independent claims. Advantageous embodiments of the inventions are described in the subclaims. The wording of all claims is herewith drafted with reference to the content of this description.
According to the invention, a control facility is proposed for a system of an internal combustion engine in particular. The control facility may consist of a plurality of microprocessors, a plurality of individual control devices or a single control device. As a rule it will be referred to below as the “control device”.
The control device comprises a plurality of functional units. Every reliability-relevant functional unit comprises at least one functional module and at least one monitoring module. The monitoring module is separate from the functional module and monitors the functioning of the functional module. The control device also comprises a higher-order monitoring functional group. The monitoring module has an entry point for communication with the higher-order monitoring functional group.
The modules can be implemented in hardware or software, perhaps as individual microcontrollers. An entry point can for example form or consist of an interface or program class, which is for example suitable for a parameter transfer or transfer in the sense of a transmission path.
The result is that intrinsically-safe structures are defined in accordance with the structure described above. The greater part of the monitoring is self-implemented by modules in the functional units. These monitoring modules communicate with the higher-order monitoring functional group.
The advantages of the inventive structure lie in the fact that a function as product is now always equipped with the monitoring structures associated therewith. Therefore, it is also possible for a provider of a function to keep secret a great deal of know-how, because said provider defines the monitoring structures himself. It is ensured, that the monitoring function (higher-order monitoring functional group) and the corresponding functions or functional units (e.g. DRRQ) are always synchronized with each other.
Even in the case of distributed hardware, the reliability-relevant functions and the monitoring associated therewith is consistently incorporated in the same hardware. This results in short signal paths between function and monitoring. This makes a rapid response behavior possible, i.e. short latency and high transmission reliability. In addition, should monitoring access to the hardware become necessary, for example an A/D converter or a timer, this is directly possible. This results in significant advantages in the real-time behavior.
The definition of intrinsically-safe functions allows these to be used optimally as far as organizational and technical aspects are concerned. In other words, adaptation losses during the development and hidden interpretation gaps are in particular already avoided in interface definitions, which are connected with the necessary know-how transfer in the case of conventional approaches.
In addition to the initiation of a central error processing or error reaction and its handling in the higher-order monitoring functional group, provision can also be made for the implementation of a structure of distributed error reactions. Thus far, when errors were identified in the engine control device, the error reaction for this facility was initiated globally, for example by switching off output-determining stages resulting in a switched-off engine or driving mechanism. Provision has been made in an advantageous manner that, on the occurrence of an error in one of the distributed control devices, for example in the gas pedal control device, the error information in the higher-order monitoring functional group or in the monitoring module can be evaluated in such a way with the DRRQ function, that only the specific faulty signal, for example, the pedal value, is set at a specific value, for example zero, and that the facility can otherwise be used with the remaining availability.
Furthermore, the reliability-relevant signals, in particular in the case of distributed control devices, can be transmitted in such a way that, for example, initially a transmitter and a receiver are defined for the transmission path between the specific monitoring module and the higher-order monitoring functional group. In addition, a reliable transmission can be defined in such a way that the sending control device for example always takes the responsibility for the reliability of the content of a message, a time stamp, or a measured value. Accordingly, the definition may determine that the receiving control device must in principle protect or check the plausibility of the transmission path. Therefore, the independent DRRQ unit, which for example sends the data content, is subsequently responsible for or authorizes the correctness of the content, for example by a suitable codification or an integrity check. The higher-order monitoring functional group is responsible for the operation of the transmission link, for example, for supplying an internal or an external data bus connection, for the signaling, for adhering to a transmission sequence, a time behavior or for similar functionalities.
Through the definition of intrinsically-safe functions according to the invention, it becomes possible to manufacture reliable functions or software as product in the sense of the Product Liability Act as well as support distributed hardware cells with reliable characteristics, also in the sense of a reliable product.
In addition, the definition of intrinsically-safe functions for example makes it possible to not only place or move a function together with its monitoring structures flexibly within a system, but also to keep these dynamically-relocatable in cross-linked systems even across so-called hardware boundaries, i.e. an engine control functionality can be moved into the transmission control functionality according to, for example, load-dynamic criteria of a network topology, with resources distributed across different areas.
The invention also allows a synchronized and a reliable development for an arrangement with reliability-relevant functions. The time to maturity is reduced and the costs are decreased.
An example of an embodiment of the present invention shows the essential, relevant functional groups of an EGAS engine control and its monitoring on the basis of the definition of intrinsically-safe functions.
The control facility can be structured in a very flexible manner. Provision can be made, in particular, for at least two reliability-relevant functional units, which can be regarded as stand-alone hardware components in each case. This means complete units or only individual functions, including their monitoring modules can be shifted across hardware boundaries. In this way, a distributed control facility is obtained.
The object of the invention is also achieved by a method. The individual procedural steps are described in detail below. The steps need not necessarily be carried out in the given order and the method can also have additional steps which have not been mentioned.
First of all a plurality of functional units are embodied to control the system, in which case the functional units are embodied in such a way that every functional unit contains a functional module and a monitoring module. The functional units are embodied in such a way that the monitoring module is separate from the functional module. A higher-order monitoring functional group is also embodied. The monitoring module has an entry point for communication with the higher-order monitoring functional group. The monitoring module monitors errors of the functional module. The monitoring module signals a detected error to the higher-order monitoring module using the entry point.
The scope of the invention moreover includes a computer program that, when run on a computer or on a plurality of computers of a computer network, executes the method according to the invention in one of its embodiments.
The scope of the invention furthermore includes a computer program with program code means in order to execute the method according to the invention in one of its embodiments when the program is run on a computer or on a plurality of computers of a computer network. The program code means can be stored, in particular, on a data carrier that can be read by a computer.
The scope of the invention in addition includes a data carrier on which a data structure has been stored, which after loading into a working memory and/or main memory of a computer or a plurality of computers of a computer network, can execute the method according to the invention in one of its embodiments.
The scope of the invention also includes a computer program product with program code means stored on a carrier that can be read by a machine in order to carry out the method according to the invention in one of its embodiments when the program is run on a computer or on a plurality of computers of a computer network.
In this case, a computer program product means the program as a tradable product. In principle, it can be provided in any form, in this way for example on paper or a data carrier that can be read by a computer and can be distributed in particular over a data transmission network.
Finally, the scope of the invention includes a modulated data signal, which comprises instructions that can be carried out by a computer system or by a plurality of computers of a computer network in order to execute the method according to the invention in one of its embodiments. Both a stand-alone computer and a network of computers are considered as a computer system, for example, an in-house, closed network or also computers that are connected with one another via the Internet. The computer system can also be realized via a client-server constellation, in which case parts of the invention run on the server and others on a client.
Further details and features of the invention emerge from the following description of preferred exemplary examples together with the subclaims. In this case, the specific features can be implemented on their own or as a number of features in combination with one another. The invention is not limited to the exemplary embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The exemplary embodiments are specified in the schematic diagrams. In the individual figures, the same reference characters refer to the same or functionally comparable elements and/or elements that correspond with one another with regard to their functions. The figures show:
FIG. 1 a schematic diagram of an electronic engine control;
FIG. 2 a section from a first-level model according to the prior art;
FIG. 3 a second-level model according to a first embodiment of the underlying invention; and
FIG. 4 a basic diagram of the method for monitoring the functional reliability of a system, in particular of an internal combustion engine.
DETAILED DESCRIPTION OF INVENTION
FIG. 1 shows a basic diagram of an engine control 100 . In engine control 100 , the signal flow 102 flows from the different sensors and set point devices (e.g. accelerator pedal position, throttle valve position, air mass, battery voltage, intake-air temperature, engine temperature, knock intensity, lambda probes) and the signal flow 104 (e.g. crankshaft speed, camshaft position, gear shifting, speed) flows through the input/output ports 106 and 108 and further from the ports via the connections 110 and 112 to the microcontroller 114 and its components. The program that is to be run by the microcontroller 114 is stored in the OTP-block (One-Time Programmable-Block) 116 . The data flows between the microcontroller 114 and the OTP block 116 via the connection 118 . The data is transferred between the microcontroller 114 and the CAN bus 122 via the connection 120 . The CAN bus 122 makes a network possible between all the devices via a single cable. The data is transferred between the microcontroller 114 and a diagnostic system 124 via the connection 126 .
The microcontroller 114 with its components implements its functions on the basis of the program stored in the OTP block 116 . After the signals from the sensors and the set point devices 102 , 104 have been processed in the microcontroller 114 , the further signals flow from the microcontroller 114 via the connections 128 , 130 , 132 , 134 and through the input/output ports 136 , 138 , 140 , 142 to the different actuators 144 (e.g. ignition coils and spark plugs), 146 (e.g. throttle valve actuators), 148 (e.g. injection valves) and 150 (e.g. main relay, tachometer, fuel pump relay, lambda probe heating, camshaft control, tank ventilation, intake pipe changeover, secondary air, recycling of exhaust gases).
Because of an increase in the number of their input and output variables, these control functions in motor vehicles are very complex, so that in order to implement these tasks, modern control systems based on the microcontrollers 114 are used.
Because different sensors, of which the measurement data must be taken into account in a timely manner, are increasingly being used in modern motor vehicles, the number of input/output ports 106 , 108 , 136 , 138 , 140 , 142 of an engine control 100 have continued to increase. That is why microcontrollers 114 with a very high computing power are increasingly being used in which case the functionalities of the control device software can be modified, so that they can be adapted to the specific needs of the different users in an effective manner.
FIG. 2 shows a diagram of the area of the control device as a level model 10 according to the prior art.
The level model 10 features a layer 20 , namely the monitoring functional group, which performs monitoring functions. On the monitoring layer 20 , building upwards, provision has been made for a functional layer 40 , which comprises additional modules or units and connects the two aforementioned layers 20 and 40 using entry points such as for example the entry point 60 . In this case the entry point 60 can for example represent or comprise an interface or a class of a programming language, which is for example suitable for a parameter transfer or a transfer in the sense of a transmission path. A plurality of transmission paths can be embodied as a channel bundle or a network connection on which the transmission protocols can be applied.
The functional layer 40 carries as a device reliability-relevant functions, which in the embodiment according to the invention for example are a DRRQ unit 80 and a plurality of additional units, in particular a first unit, namely, (AGGR_ 2 ) 151 as well as the additional units AGGR_x 152 , AGGR_y 153 and AGGR_z 160 .
Provision has been made for a plurality of modules in the monitoring layer 20 (shown by of a broken line), for example, a module 180 . In this case, the layer 20 carries or comprises the relevant monitoring functions of the DRRQ unit 80 or the other units 151 , 152 , 153 and 160 .
FIG. 3 shows the embodiment according to the invention in accordance with a level model 200 . Compared with the level model 10 shown in FIG. 2 , the DRRQ unit 220 and the AGGR_ 2 unit 240 selected from a plurality of units are structured in an encapsulated manner so that the modules for the reliability-relevant function and the monitoring function are connected in a block-like manner. In this process, a unit 220 has an internal dividing area 320 , which creates a subdivision within the unit between the reliability-relevant function 340 and the monitoring function 360 . In addition, in the DRRQ unit 220 , as a stand-alone module above the dividing area 320 , which is for example embodied as an interface area, a functional module 340 is embodied for reliability-relevant functions and a monitoring module 360 with monitoring functions is embodied below this area.
The DRRQ unit 220 and the plurality of other units further exhibit the special characteristic that at the level of the specific monitoring function there is an entry point in each case, with the entry point 520 have been taken here as an example, by means of which the specific monitoring function of the DRRQ unit 220 or the AGGR_ 2 unit 240 (using the entry point 540 ) is fed to the higher-order monitoring functional group 600 . In addition, the monitoring functions 360 are coupled to the higher-order monitoring functional group 600 at a few precisely defined points 520 , 540 .
On an example transmission path 700 formed between the entry point 520 and the higher-order monitoring functional group 600 , which can also be provided as a bidirectional path, functional commands and return signals for monitoring the processor functions can be transmitted in addition to the transmission of e.g. error information or secured output values. For this reason, individual protection hardware that carries out the reliability-relevant function is not required in an advantageous manner.
FIG. 4 explains the method. In a first step 400 , a plurality of reliability-relevant functional units are embodied to control the system. In a next step 402 , the functional units are embodied in such a way that every functional unit comprises a functional module and a monitoring module. In a next step 404 , the functional units are embodied in such a way that the monitoring module 360 is separate from the functional module 340 . In a next step 406 , a higher-order monitoring functional group 600 is embodied. In a subsequent step 408 , the monitoring module 360 has an entry point for communication with the higher-order monitoring functional group 600 . Errors of the functional module 340 are monitored in a next step 410 by the monitoring module 360 . In a next step 412 , a detected error is signaled by the monitoring module 360 to the higher-order monitoring module 600 using the entry point.
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An internal combustion engine is controlled by a plurality of partially reliability-relevant functional units. Every reliability-relevant functional unit comprises at least one functional module and at least one monitoring module. The monitoring module is separate from the functional module associated therewith and monitors the functioning of the functional module. The control device also comprises a higher order monitoring functional group. The monitoring module has an entry point for communication with the higher order monitoring functional group. When an error is detected, the monitoring module signals the error to the higher order monitoring functional group using the entry point.
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REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to Provisional U.S. Application No. 62/232,823, filed Sep. 25, 2015, entitled “REHABILITATION DEVICE FOR A DAMAGED OR SURGICALLY REPAIRED KNEE,” and is incorporated herein in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The invention is directed to a medical brace. More specifically, the invention is directed to a medical brace that incorporates elevating supports.
[0004] 2. Background of the Invention
[0005] It is accepted professional medical philosophy that the human knee requires a prolonged period of rehabilitation when damaged or subject to arthroscopic or replacement surgery. The prognosis for recovery is enhanced when the knee is elevated above the heart for draining of entrapped fluids while the patient is lying down and when the swelling and muscle contractions are subject to chilling. The mantra of “elevate and ice” is basic to joint recovery strategy.
[0006] Damage knees, elbows, ankles, wrists, shoulders, hips, and other joints, as well as joints subject to surgery, generally swell with entrapped bodily fluids and muscle expansion intended to cushion the damaged areas and to protect from pain and further trauma. Rehabilitation techniques are intended to reduce the swelling, pain and fluid buildup by mild and increasing exercise, movement, massage and cooling. Following rehabilitation physical therapy, it is advisable to elevate the damage joint slightly above the heart while lying prone to assist draining entrapped fluids and to apply semi frozen gel packs, moistened frozen small towels, or even packages of frozen peas or other small vegetables.
[0007] An injury, such as a knee or ankle sprain, pain and swelling, can be relieved and promote healing and flexibility can be promoted with “R.I.C.E.” or Rest, Ice, Compression, and Elevation. Rest includes resting and protecting the injured or sore area. For example, a person should stop, change, or take a break from any activity that may be causing pain or soreness. Ice involves applying an ice or cold pack right away to prevent or minimize swelling since cold will reduce pain and swelling. After 48 to 72 hours, if swelling is gone, application of heat to the area that is hurt may be beneficial. Compression, or wrapping the injured or sore area with an elastic bandage (such as an Ace wrap), will help decrease swelling. Elevating the injured or sore area while applying ice additionally helps minimize swelling, especially if elevated above the heart.
SUMMARY OF THE INVENTION
[0008] The present invention overcomes the problems and disadvantages associated with current strategies and designs and provides new devices and methods for treating injured joints.
[0009] An embodiment of the invention is directed to a brace. The brace comprises a first body coupling member and a second body coupling member, wherein the first and second body coupling members are adapted to surround a patient's joint; a cage coupling the first body coupling member to the second body coupling member, wherein the cage is adapted to traverse the joint; at least one elevating support coupled to the first body coupling member; at least one elevating support coupled to the second body coupling member; at least one clip coupled to the first body coupling member adapted to be coupled to a therapy device; and at least one clip coupled to the second body coupling member adapted to be coupled to the therapy device.
[0010] Preferably, the first and second body coupling members are saddle shaped plates securable to a patient with straps. The first body coupling member is preferably placed on a first side of the joint and the second body coupling member is preferably placed on a second side of the joint. In a preferred embodiment, the brace is adapted to promote the healing of a knee, an elbow, a wrist, or an ankle.
[0011] The cage is preferably comprised of at least one spine and a pair of hinges. Each spine is preferably comprised of at least one of two coaxial tubes or two parallel slides that accommodate movement of the patient. Preferably, the spines surround the therapy device. In a preferred embodiment, the hinges permit a specified range of motion of the joint.
[0012] Preferably, each elevating support is moveable from a closed position to an open position. Preferably, each elevating support is one of a swing-down arm or a telescoping arm. The elevating support are preferably one of adjustable or fixed. In a preferred embodiment, the elevating support is adapted to raise the joint above the patient's heart while the patient is prone. Preferably, the therapy device is a heating device or a cooling device. Preferably, the patient can transition between walking and laying prone with the brace elevating the patient's joint without removing the brace.
[0013] Other embodiments and advantages of the invention are set forth in part in the description, which follows, and in part, may be obvious from this description, or may be learned from the practice of the invention.
DESCRIPTION OF THE DRAWING
[0014] The invention is described in greater detail by way of example only and with reference to the attached drawing, in which:
[0015] FIG. 1 is a perspective view of an embodiment of the brace on a straight knee.
[0016] FIG. 2 is a perspective view of an embodiment of the brace on a bent knee.
[0017] FIG. 3 is a side view of an embodiment of the brace.
[0018] FIG. 4 is a front view of an embodiment of the brace.
[0019] FIG. 5 is a top view of an embodiment of the brace.
[0020] FIG. 6 is a perspective view of another embodiment of the brace.
DESCRIPTION OF THE INVENTION
[0021] As embodied and broadly described herein, the disclosures herein provide detailed embodiments of the invention. However, the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, there is no intent that specific structural and functional details should be limiting, but rather the intention is that they provide a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention
[0022] A problem in the art capable of being solved by the embodiments of the present invention is existing medical braces either do not provide an elevating mechanism and/or do not allow a patient the ability to walk comfortably and to return to the prone position. It has been surprisingly discovered that a device with integrated elevating supports and ice pack holders can permit continuous physical therapy to a damaged or surgically corrected joint as opposed to the need of the patient to frequently replace an ice pack that inhibits movement and potentially cuts off circulation. The device preferably permits the patient to walk normally while chilling the affected joint and to ascend and descend stairs without removing the device. Preferably, the patient can then return to the prone position without removing the device or the chilling pack.
[0023] FIGS. 1-5 depict various views of a brace 100 . The device is intended to provide a wearable rehabilitation aid that preferably permits a patient to both elevate and chill a damaged or surgically repaired joint. While the invention is described for use on a knee, the brace can be adapted for use on other joints, including but not limited to ankles, elbows, wrists, shoulders, and hips. Additionally, while the invention is described for use on humans, it may be usable on other animals. Brace 100 is preferably constructed of plastic or carbon fiber, is intended to provide a recovery patient with the ease of elevating a joint while lying down and to apply an ice or gel pack or other chilling media while also allowing the patient to stand up, walk for prolonged periods and then returning to the prone position without removing brace. While the invention is described using an ice or gel pack, the patient can use frozen vegetables, instant cold packs, a bag or other container of ice, a microwavable heat pack, an instant heat pack, a hot water container, or another cooling or heating device.
[0024] Preferably, brace 100 is comprised of an upper plate or saddle 105 and a lower plate or saddle 106 that when properly positioned straddles the joint. For example, as shown in FIG. 1 , upper saddle 105 is positioned on the patient's thigh while lower saddle 106 is positioned on the patient's shin. While saddles are the preferred embodiment, brace 100 may alternatively use straps, cuffs, sleeves, wraps, or other devices to secure brace 100 to the patient. Preferably, upper saddle 105 and lower saddle 106 are held securely to the patient via straps 107 . Preferably, straps 107 are hook and loop type devices to fit various sized patients and joints. Other fasteners can be employed as well, for example, ties, clasps, elastic bands, zippers, buttons, snaps, and toggles. Preferably, saddles 106 and 107 are stiff components comprised of, for example, plastic, carbon fiber, metal, wood, or another manmade or naturally occurring material. However, saddles 106 and 107 may be made of flexible materials such as, for example, cotton, wool, neoprene, nylon, mesh, or another manmade or naturally occurring material. While brace 100 is described as having an upper and lower saddle, the two saddles may be interchangeable, thereby allowing the device to be positioned in any orientation.
[0025] Bridging saddles 106 and 107 is preferably an adjustable cage 110 . Preferably, adjustable cage 110 is comprised of several spines 111 and two lower arms 112 that allow the cage 110 to rotate with the joint via a hinge 115 on either side of the lower arms 112 . Hinge 115 may only allow for a certain range of motion (e.g. 45°, 90°, or 115°). The patient or a medical caregiver may be able to select the range of motion or the range of motion may be fixed. Spines 111 may adjust to the same range of motion. Additionally, lower arms 112 may prevent unintentional twisting or other undesirable motion of the joint. As shown in FIGS. 1 and 2 , each spine 111 may be comprised of two coaxial tubes and as the patient flexes the joint (e.g. from the position in FIG. 1 to the position in FIG. 5 ), the inner tube may emerge from the outer tube, thereby increasing the size of cage 110 . Furthermore, as the patient returns the joint to the straight position ( FIG. 1 ), the inner tube may retract into the outer tube. Preferably, stops 113 control the coaxial movement of the tubes to prevent the tubes from becoming detached. Stops 113 may be adjustable to limit the amount of coaxial movement of the tubes. For example, the patient or a medical caregiver may adjust how far the inner tube can extend from the outer tube. In other embodiments, the spines 111 may be comprised of fabric straps, springs, elastic materials, sliding members, or other adjustable parts. Additionally, while two coaxial tubes are shown, each spine 111 may be comprised of three or more coaxial tubes. Spines 111 may be comprised of plastic, rubber, carbon fiber, fabric, metal, or another manmade or naturally occurring material. While the figures show three spines 111 , fewer or more spines may be used. For example, a child's size brace 100 may have two spines, while a brace 100 for an larger patient or a patient with swollen joints may have four or more spines. Brace 100 may come in various sizes (e.g. Small, Medium, Large, Extra Large, and Extra Extra Large) to fit various sized people and joints or brace 100 may be custom fit for each patient. Preferably, the size of brace 100 is chosen or made based on the patient's body size, degree of swelling, and damage to the joint.
[0026] Preferably, attached to each lower arm 112 on either side of the hinges 115 are supports 120 . Preferably, supports 120 are adapted to support the joint in an elevated position when the patient is in a prone position. Preferably, the elevated position raises the joint above the patient's heart. Supports 120 may be fixed in place or movable so that they are in a stored position when the patient is walking. Preferably, each support 120 is coupled to a lower arm 112 and a saddle 105 or 106 to provide support to the joint. However, each support 120 may be positioned at another location on the brace 100 . Supports 120 may lock into the open and closed positions to avoid unintentional movement of the support during use of brace 100 . Preferably, supports 120 move independently such that the patient need not use all of the supports 120 simultaneously. As shown in the embodiments of FIGS. 1-5 , supports 120 may be fixed length legs that swivel from a closed position 120 (A) to an open position 120 (B).
[0027] Alternatively, as shown in FIG. 6 , supports 620 may be pull-down or telescoping legs adjustable between a closed position 620 (A) and an open position 620 (B), that, when lowered to the desired length, can be locked in place, for example by twisting. The telescoping locked-in-place elevating legs may be pulled down to a length up to, for example 6 inches, 8 inches, or 10 inches. Twisting locks the supports into the desired height and untwisting allows the supports to be returned to their closed position. Similar reference numbers in FIG. 6 indicate similar elements.
[0028] A gap between the spines 111 and the lower arms 112 may provide access for the insertion of a gel pack 122 or other chilling or heating mechanism that then extends over the joint. Preferably, the gel pack 122 is held in place by the spins of the cage and clips 125 located in the corners of the cage. While two clips 125 are show, another number of clips can be used, for example 3, 4, or 6. Clips 125 may be hooks, clamps, vices, snaps, buttons, toggles, or other fastening device. Clips 125 may couple to a mating portion of gel pack 122 or may grab an edge of gel pack 122 . For example, gel pack 122 may have mating snaps or holes that are engaged by clips 125 . Preferably, gel pack 122 is replicable without taking off brace 100 . Preferably, brace 100 is adapted to hold a variety of cooling or heating devices. However, brace 100 may have an integrated, compatible, or proprietary cooling or heating device.
[0029] Preferably, the brace 100 is worn directly on the patient's skin. A cloth or other insulating material may be placed between the gel pack 122 and the patient to temper the cooling or heating effects to avoid further injury (e.g. frostbite or burning). Alternatively, the brace 100 may be worn over tights, leggings, stockings, hose, socks, compression clothing, or other form fitting clothing. Preferably, brace 100 is worn without a cover (such as pants, long sleeves, or a jacket). For example, brace 100 may be worn with shorts, a skirt, short sleeves, a tank top, or another item of clothing. However, brace 100 may be worn with longer items of clothing. Preferably, the clothing does not interfere with the motion and utility of brace 100 .
[0030] Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. All references cited herein, including all publications, U.S. and foreign patents and patent applications, are specifically and entirely incorporated by reference. It is intended that the specification and examples be considered exemplary only with the true scope and spirit of the invention indicated by the following claims. Furthermore, the term “comprising of” includes the terms “consisting of” and “consisting essentially of.”
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Systems and devices of providing therapy to injured joints are disclosed. The device comprises a first body coupling member and a second body coupling member, wherein the first and second body coupling members are adapted to surround a patient's joint; a cage coupling the first body coupling member to the second body coupling member, wherein the cage is adapted to traverse the joint; at least one elevating support coupled to the first body coupling member; at least one elevating support coupled to the second body coupling member; at least one clip coupled to the first body coupling member adapted to be coupled to a therapy device; and at least one clip coupled to the second body coupling member adapted to be coupled to the therapy device.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method, system, and program for establishing and requesting status on a computational resource.
[0003] 2. Description of the Related Art
[0004] Computing systems often include one or more host computers (“hosts”) for processing data and running application programs, direct access storage devices (DASDs) for storing data, and a storage controller for controlling the transfer of data between the hosts and the DASD. In operating systems that conform to the International Business Machines Corporation (“IBM”) Enterprise Systems Architecture (ESA) 360 , 370 , and 390 architectures, the storage controller, also referred to as a control unit or storage director, manages access to a storage space comprised of numerous hard disk drives connected in a loop architecture, otherwise referred to as a Direct Access Storage Device (DASD).
[0005] Hosts may communicate with the storage controller through logical paths also referred to as host channels, where there may be one or more logical paths for each physical communication path between a host port and storage controller port. Both the host and the storage controller must maintain a consistent view of their logical paths to avoid communication errors. However, situations may arise where the host and storage controller views of the logical paths differ. In such situations, the host may issue an Input/Output (I/O) request down a channel or logical path that the host believes exists, but that the storage controller does not recognize. In such case, an interface controller error would occur due to this inconsistent view of the logical path states between the controller and host.
[0006] For these reasons, there is a need in the art to provide techniques for ensuring that the host and storage controller maintain a consistent view of logical paths therebetween to avoid communication errors that result from inconsistent views.
SUMMARY OF THE DESCRIBED IMPLEMENTATIONS
[0007] Provided are a method, system, and program for establishing and requesting status on a computational resource. An operation is performed to establish a computational resource, wherein the computational resource is not available until the establish operation is completed. A determination is made as to whether a status request to determine status of the computational resource is pending before the establish operation has completed. Indication is made to resubmit the status request if there is a status request for the computational resource pending before the establish operation has completed.
[0008] In further implementations, a response is received to the status request and a determination is made on whether resubmit is indicated for the status request. The response to the status request is disregarded if the resubmit is indicated.
[0009] Still further, the computational resource may comprise a logical path between a host and server, wherein the host initiates the operation to establish the logical path, and wherein the server performs the operation to establish the logical path and initiates the status request.
[0010] Further provided are a method, system, and program for establishing and requesting status on a computational resource. A status request is processed to determine status of the computational resource. A determination is made on whether an establish operation is pending to establish the computational resource, wherein the computational resource is not available until the establish operation is completed. The status request is queued if the establish operation for the computational resource is pending.
[0011] In further implementations, a response is received to the status request and a determination is made as to whether the status request was pending when the establish operation to establish the computational resource was pending. The response to the status request is disregarded if the status request was pending at the same time as the establish operation for the computational resource.
[0012] Described implementations provide techniques to handle conflicts that may occur between an operation to establish a computational resource and an operation to determine the status of the computational resource. For instance, described implementations may maintain consistency to prevent conflicts that occur when the host and storage controller have inconsistent views of the availability of a channel or logical path.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
[0014] [0014]FIG. 1 illustrates a computing environment in which aspects of the invention are implemented;
[0015] [0015]FIGS. 2 and 3 illustrate logic to manage requests to establish a logical path and requests for status on a logical path in accordance with implementations of the invention; and
[0016] [0016]FIG. 4 illustrates an architecture of computing components in the network environment, such as the hosts and storage controller, and any other computing devices.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] In the following description, reference is made to the accompanying drawings which form a part hereof and which illustrate several embodiments of the present invention. It is understood that other embodiments may be utilized and structural and operational changes may be made without departing from the scope of the present invention.
Inconsistent Logical Paths in the Prior Art
[0018] In prior art systems, an inconsistent logical path state can occur when the storage controller issues a test initialization (TIN) to query the host if a particular logical path is available while the host is attempting to establish the same logical path to the storage controller. For instance, in a first prior art scenario, if the host issues a command to establish a logical path (ELP) and the storage controller sends a TIN to test the same logical path, then the host may receive the logical path established (LPE) message from the storage controller (indicating that the requested logical path was established in response to the ELP request) after sending a response to the TIN request. The response to the TIN request may be in the form of a Test Initialization Response (TIR) that indicates whether the host recognizes the logical path. The negative TIR is sent even after a path is established if the host does not receive the LPE indicating the establishment of the path before sending the negative TIR. Upon receiving the negative TIR, the storage controller may remove the logical path just established. Any attempts by the host to communicate down the logical the host believes was established due to receiving the LPE would fail because the storage controller, due to the negative TIR, does not recognize the existence of the logical path.
[0019] In a second prior art scenario, that is a variant of the first, after the storage controller sends the TIN and the host sends the ELP, the host may return the negative TIR before receiving the LPE indicating that the storage controller created the requested logical path. In such case, the storage controller would abort the ELP to produce an interface error. The host must then resend the ELP to reestablish a logical path on the channel.
[0020] In a third prior art scenario, the storage controller may send the TIN to test a logical path before the host sends the ELP to establish the logical path. If the storage controller establishes the logical path and returns the LPE to the host, then the host may return a negative TIR indicating that there is no such logical path before receiving the LPE from the storage controller. In such case, the storage controller would terminate the logical path and not recognize its presence, while the host would recognize the logical path due to receiving the LPE. In such case, errors would occur when the host attempts to use the logical path that the storage controller no longer recognizes.
[0021] Described implementations provide techniques to avoid an inconsistent logical path state that sometimes occurs in the prior art when a storage controller TIN and host ELP are concurrently pending.
Establishing Logical Paths to Avoid Inconsistent States
[0022] [0022]FIG. 1 illustrates a computer architecture in which aspects of the invention are implemented. One or more hosts 2 are in data communication with a storage system 4 , such as a DASD or any other storage system known in the art, via a storage controller 6 . The host 2 may be any computing device known in the art, such as a server, mainframe, workstation, personal computer, hand held computer, laptop, telephony device, etc. The storage controller 6 and host system(s) 2 communicate via a network 8 , which may comprise a Storage Area Network (SAN), Local Area Network (LAN), Intranet, the Internet, Wide Area Network (WAN), etc. The storage system 4 may be comprised of hard disk drives, tape cartridge libraries, optical disks, or any suitable non-volatile storage medium known in the art. The storage system 4 may be arranged as an array of storage devices, such as a Just a Bunch of Disks (JBOD), DASD, Redundant Array of Independent Disks (RAID) array, virtualization device, etc. The storage controller 6 may comprise any storage controller or server known in the art, such as the IBM Enterprise Storage Server (ESS).**
[0023] In certain implementations, both the host 2 and storage controller 6 may have multiple ports to provide multiple physical paths (not shown) to enable communication over the network 8 . The host 2 and storage controller 6 may also configure multiple logical paths 10 that are used to provide communication between the host 2 and storage controller 6 , where the host can issue I/O requests to the storage 4 over the logical paths 10 to the storage controller 6 . Logical path 10 refers to one or more of the logical paths between the host 2 and storage controller 6 that are implemented over one or more physical paths therebetween.
[0024] The host 2 includes an operating system 12 that has a host path manager 14 component to manage the logical paths between the host 2 to the controller. The storage controller 6 also includes an operating system 16 that has a controller path manager 18 to manage the logical paths to the host 2 . As discussed, the storage controller may issue a TIN (test initiative) command to test whether a specified logical path is available. If the host 2 recognizes the specified logical path 10 , then the host path manager 14 returns a positive TIR (test initiative response), else the host path manager 14 returns a negative TIR. The host path manager 14 may issue an ELP (establish logical path) command to establish a specified logical path. This causes the storage controller path manager 18 to create the requested logical path and return a LPE (logical path established) message to the requesting host path manager 14 indicating the creation and availability of the requested logical path 10 .
[0025] The storage controller memory 20 , which may comprise volatile memory or non-volatile storage, includes a TIN queue 22 in which the controller path manager 18 may queue TIN requests and access and submit TIN requests from the queue 22 . The TIN queue 22 may queue TIN requests for different logical paths 10 . A TIN resend flag 24 is used to indicate to the controller path manager 18 to resend a TIN request due to a pending ELP command that may render the TIR response irrelevant, e.g., such as the case if the TIR response is sent by the host before the host learns that the logical path was established through receiving the LPE notification.
[0026] [0026]FIGS. 2 and 3 illustrate logic implemented in the controller path manager 18 to handle ELP and TIN requests, respectively, in a manner that avoids inconsistent logical path states, such as occur in the prior art scenarios discussed above. With respect to FIG. 2, control begins at block 100 when the controller path manager 18 receives an ELP for a requested logical path from the host 2 . If (at block 102 ) there is an active TIN request pending on the requested logical path 10 , then the TIN resend flag 24 is set (at block 104 ) to “true”. A TIN request is active if the controller path manager 18 submitted the TIN request and has not yet received a TIR. From block 104 or the no branch of block 102 , the controller path manager 18 starts the operations to establish (at block 106 ) the requested logical path and sends (at block 108 ) the LPE message to the requesting host 2 after establishing the logical path 10 . If (at block 110 ) there is a queued TIN request in the TIN queue 22 for the logical path established at block 106 , then the queued TIN is sent (at block 112 ); otherwise, control ends.
[0027] With respect to FIG. 3, control begins at block 120 when the controller path manager 18 receives a TIN initiative for a requested logical path, where the TIN initiative is an invocation to create a TIN. As discussed, TIN initiatives may be generated when the controller path manager 18 detects a state change event notification indicating some change in the network 8 and/or logical paths 10 . In response to processing the TIN initiative, the controller path manager 18 would build (at block 122 ) the TIN by submitting a TIN request. If (at block 124 ) there is an ELP pending on the logical path 10 subject to the TIN request, then the TIN request is queued (at block 126 ) in the TIN queue 22 and would be later processed after the ELP request completes. Otherwise, if (at block 124 ) there is no pending ELP request, then the controller path manager 18 sends (at block 128 ) the built TIN request to the host 2 to determine the status of the logical path 10 . Upon receiving (at block 130 ) the TIR response to the sent TIN request, the controller path manager 18 determines (at block 132 ) whether the TIN resend flag 24 is “true”. If so, then the TIR is disregarded (at block 136 ) because the host path manager 14 may have generated the TIR prior to having knowledge of the existence of the logical path, e.g., if the host path manager 14 sent the TIR before sending the ELP or after sending the ELP but before receiving the LPE. In such situations, the TIR may indicate no existing logical path when in fact a logical path may have been established after the TIR was sent. When disregarding the TIR, the resend TIN flag 24 is set to “false” and control proceeds back to block 122 to rebuild a TIN request for the logical path 10 to resend. Any TIR response to the resent TIN request would indicate the existence of a logical path created by the intervening ELP.
[0028] If (at block 132 ) the resend TIN flag 24 is “false”, then the controller path manager 18 processes (at block 134 ) TIR because if the resend TIN flag 24 is false, there would have been no intervening ELP that could have created the logical path after the negative TIR was sent by the host path manager 14 .
[0029] The described implementations provide techniques for handling both requests to establish a resource, such as a logical path, and requests for the status of a resource, such as a TIN request, to ensure that the response to the status request is accurate and is not outdated by the establishment of the resource after the response to the status request is returned indicating the absence of the resource soon to be established.
Additional Implementation Details
[0030] The described techniques for managing the establishment and status checking of resources may be implemented as a method, apparatus or article of manufacture using standard programming and/or engineering techniques to produce software, firmware, hardware, or any combination thereof. The term “article of manufacture” as used herein refers to code or logic implemented in hardware logic (e.g., an integrated circuit chip, Programmable Gate Array (PGA), Application Specific Integrated Circuit (ASIC), etc.) or a computer readable medium, such as magnetic storage medium (e.g., hard disk drives, floppy disks, tape, etc.), optical storage (CD-ROMs, optical disks, etc.), volatile and non-volatile memory devices (e.g., EEPROMs, ROMs, PROMs, RAMs, DRAMs, SRAMs, firmware, programmable logic, etc.). Code in the computer readable medium is accessed and executed by a processor. The code in which preferred embodiments are implemented may further be accessible through a transmission media or from a file server over a network. In such cases, the article of manufacture in which the code is implemented may comprise a transmission media, such as a network transmission line, wireless transmission media, signals propagating through space, radio waves, infrared signals, etc. Thus, the “article of manufacture” may comprise the medium in which the code is embodied. Additionally, the “article of manufacture” may comprise a combination of hardware and software components in which the code is embodied, processed, and executed. Of course, those skilled in the art will recognize that many modifications may be made to this configuration without departing from the scope of the present invention, and that the article of manufacture may comprise any information bearing medium known in the art.
[0031] In described implementations, the status request (TIN) and establishment command (ELP) were performed with respect to logical paths between a host and storage controller. In alternative implementations, the computational resource subject to the status requests and establishment operations may comprise computational resources other than a logical path between a host and storage controller, such as a logical storage unit, physical path, etc. Further, the test and establishment operations described as performed between a host and storage controller may not occur between a host and storage as described with certain implementations, but may occur locally at a single computational system. For instance, the establishment operations may establish a logical device, such as a logical storage unit, logical printer, etc., without regard to any client or server communication over a network.
[0032] In described implementations, the host and storage used an ELP and TIN commands to establish and determine status concerning logical paths. In alternative network storage implementations, other commands may be used to establish a logical path between a client and server and determine the status of a path between the client and server.
[0033] The illustrated logic of FIGS. 3 and 4 shows certain events occurring in a certain order. In alternative implementations, certain operations may be performed in a different order, modified or removed. Morever, steps may be added to the above described logic and still conform to the described implementations. Further, operations described herein may occur sequentially or certain operations may be processed in parallel. Yet further, operations may be performed by a single processing unit or by distributed processing units.
[0034] [0034]FIG. 4 illustrates one implementation of a computer architecture 200 of the network components, such as the host and storage controller shown in FIG. 1. The architecture 200 may include a processor 202 (e.g., a microprocessor), a memory 204 (e.g., a volatile memory device), and storage 206 (e.g., a non-volatile storage, such as magnetic disk drives, optical disk drives, a tape drive, etc.). The storage 206 may comprise an internal storage device or an attached or network accessible storage. Programs in the storage 206 are loaded into the memory 204 and executed by the processor 202 in a manner known in the art. The architecture further includes a network card 208 to enable communication with a network. An input device 210 is used to provide user input to the processor 202 , and may include a keyboard, mouse, pen-stylus, microphone, touch sensitive display screen, or any other activation or input mechanism known in the art. An output device 212 is capable of rendering information transmitted from the processor 202 , or other component, such as a display monitor, printer, storage, etc.
[0035] The foregoing description of various implementations of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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Provided are a method, system, and program for establishing and requesting status on a computational resource. An operation is performed to establish a computational resource, wherein the computational resource is not available until the establish operation is completed. A determination is made as to whether a status request to determine status of the computational resource is pending before the establish operation has completed. Indication is made to resubmit the status request if there is a status request for the computational resource pending before the establish operation has completed.
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BACKGROUND OF THE INVENTION
(a) Field of the Invention
This invention relates to compounds that are useful in the treatment and prevention of ulcers. More particularly, this invention relates to [(1H-benzimidazol-2-ylsulfinyl)methyl)-2-pyridinamines that inhibit gastric acid secretion and which are, therefore, useful in the treatment of peptic ulcers. The compounds of this invention directly inhibit acid secretion by parietal cells of the stomach through inhibition of (H + +K + )-ATPase. For review, see, e.g., J. G. Spenney, "Biochemical Mechanisms of Acid Secretion by Gastric Parietal Cells," J. Clin. Gastro., 5 (Suppl. 1), 7-15 (1983). In addition, some of the compounds of this invention also exert cytoprotective activity. For review of cytoprotection, see, e.g., U.S. Pat. No. 4,359,465.
(b) Prior Art
Heterocyclylalkylsulfinylbenzimidazoles have been disclosed as gastric acid secretion inhibitors. See U.S. Pat. Nos. 4,472,409, 4,394,509, 4,337,257, 4,327,102, 4,255,431, 4,045,564, and 4,045,563; British Pat. No. 2,134,523; German Offenlegungeschrift No. 3,415,971 and Swedish Pat. No. 416649. Some heterocyclylalkylsulfinylbenzimidazoles have also been disclosed as cytoprotective agents. See U.S. Pat. No. 4,359,465. The following structure is illustrative of compounds disclosed in these patents: ##STR1## wherein R' and R" represent hydrogen, alkyl, halogen, trifluoromethyl, cyano, carboxy, hydroxy, acyl, and the like; R'" represents hydrogen, alkyl, acyl, alkoxysulfonyl, and the like; and Het represents heterocyclic groups containing at least one endocyclic (ring) nitrogen. No compound disclosed in these patents includes an exocyclic amino function attached to the Het group, a feature characteristic of the compounds of the present invention. Moreover, where the Het function is 2-pyridyl, antisecretory effects are reportedly absent when the pyridine ring is substituted at the 6-position with groups other than the amino groups of this invention. See A. Brandstrom, P. Lindberg, and U. Junggren, "Structure activity relationships of substituted benzimidazoles," Scand. J. Gastroenterol., 20 (suppl. 108), 15-22 (1985).
Heterocyclylalkylsulfinylnaphth[2,3-d]imidazoles have also been disclosed as gastric acid secretion inhibitors. See U.S. Pat. Nos. 4,248,880 and 4,182,766. The compounds disclosed in these patents are related to those illustrated the above structure, except for having a substituted naphth[2,3-d]imidazole group instead of the benzimidazole group. Similarly, other heterocyclylalkylsulfinylbenzimidazoles having a ring fused to the benzimidazole group have been disclosed as gastric acid secretion inhibitors and cytoprotective agents. See European Patent Application Nos. 130,729 and 127,763. Because of the additional ring fusions of these compounds, as well as for the same reasons stated in the preceeding paragraph, the compounds of the present invention are structurally distinguished from prior art compounds cited.
Benzylsulfinylbenzimidazoles have also been disclosed as antiulcer agents. Belgian Pat. No. 903,128. No compounds disclosed in the Belgian patent contain a pyridine ring, a feature characteristic of the compounds of this invention.
The invention relates to compounds of Formula I: ##STR2## or the pharmaceutically acceptable acid addition salts thereof; or the pharmaceutically acceptable base addition salts thereof;
wherein R 1 , R 2 , R 3 , and R 4 are independently:
(a) hydrogen;
(b) C 1 -C 6 alkyl;
(c) C 1 -C 6 alkoxy;
(d) C 2 -C 6 hydroxyalkyl;
(e) C 1 -C 4 fluorinated alkyl; or
(f) halogen; and
wherein R 5 and R 6 are independently:
(a) hydrogen; or
(b) C 1 -C 6 alkyl.
Although the structure shown for Formula I indicates one tautomeric form, it is understood that this representation is for convenience only and that the scope of this invention includes as equivalents all tautomeric forms of the compounds of this invention.
The term "C 1 -C 6 alkyl" refers to straight or branched chain alkyl groups having from 1 to 6 carbon atoms, also referred to as lower alkyl. Examples of C 1 -C 6 alkyl are methyl, ethyl, propyl, butyl, pentyl, hexyl, and the isomeric forms thereof.
The term "C 1 -C 6 alkoxy" refers to straight or branched chain alkoxy groups having from 1 to 6 carbon atoms. Examples of C 1 -C 6 alkoxy are methoxy, ethoxy, propoxy, butoxy, pentoxy, hexoxy, and the isomeric forms thereof.
The term "C 2 -C 6 hydroxyalkyl" refers to straight or branched chain hydroxyalkyl groups having from 2 to 6 carbon atoms. Examples of C 2 -C 6 hydroxyalkyl are 2-hydroxyethyl, 3-hydroxypropyl, 4-hydroxybutyl, 5-hydroxypentyl, 6-hydroxyhexyl, and the isomeric forms thereof.
The term "C 1 -C 4 fluorinated alkyl" refers to straight or branched chain alkyl groups in which one or more hydrogen atoms are replaced with fluorine atoms. Examples of C 1 -C 4 fluorinated alkyl are fluoromethyl, difluoromethyl, trifluoromethyl, 1- or 2-fluoroethyl, 1,1-difluoroethyl, 2,2,2-trifluoroethyl, perfluoroethyl; other similarly monofluorinated, polyfluorinated, and perfluorinated ethyl, propyl, and butyl groups; and the isomeric forms thereof.
Examples of halogen are fluorine, chloride, bromine, and iodine.
The term "pharmaceutically acceptable acid addition salt" refers to a salt prepared by contacting a compound of Formula I with an acid whose anion is generally considered suitable for human consumption. Examples of pharmacologically acceptable acid addition salts include the hydrochloride, hydrobromide, hydroiodide, sulfate, phosphate, acetate, propionate, lactate, maleate, malate, succinate, and tartrate salts.
The term "pharmaceutically acceptable base addition salt" refers to a salt prepared by contacting a compound of Formula I with a base whose cation is generally considered suitable for human consumption. Examples of pharmacologically acceptable base addition salts include lithium, sodium, potassium, magnesium, calcium, titanium, ammonium, alkylammonium, dialkylammomium, trialkylammonium, tetraalkylammonium, and guanidinium salts.
The compounds of this invention may be prepared by the methods illustrated in the following Schemes. Unless otherwise specified, the various substituents are defined as for Formula I, above. Scheme A illustrates the preparation of thio intermediates of Formula IV and of the sulfoxide compounds of this invention, Formula I.
SCHEME A
Thio intermediates of Formula IV may be prepared by at least two routes, each of which involves reaction of a ##STR3## 2-mercaptobenzimidazole of Formula II with a compound of Formula III. In the preferred route, the 2-mercaptobenzimidazole of Formula II reacts with a halomethyl-2-pyridinamine (Formula III in which Y is a halogen, preferably chlorine or bromine) in a suitable organic solvent at room temperature. Suitable organic solvents for the reaction are organic liquids in which reactants may be dissolved or suspended but which are otherwise chemically inert. Examples of suitable organic solvents include N,N-dialkylformamide; lower alkanols, such as methanol, ethanol, propanol, isopropyl alcohol, and the like; and other solvents known in the art. Preferred organic solvents are absolute ethanol or isopropy alcohol.
Except where both R 5 and R 6 are alkyl, the halomethyl-2-pyridinamine of Formula III is usually used as an acylated derivative, preferably where one of R 5 or R 6 is C 2 -C 6 alkanoyl. The term "C 2 -C 6 alkanoyl" refers to straight or branched chain alkanoyl groups having from 2 to 6 carbon atoms. Examples of C 2 -C 6 alkanoyl are acetyl, propanoyl, butanoyl, pentanoyl, hexanoyl, and the isomeric forms thereof. Preferred alkanoyl groups are trimethylacetyl or acetyl. After the corresponding alkanoyl derivative of a compound of Formula IV has been formed by the reaction of such an acylated halomethyl-2-pyridinamine derivative with a 2-mercaptobenzimidazole of Formula II, the acyl group can be removed by any of several methods known in the art. A preferred method for removing an alkanoyl group uses refluxing aqueous mineral acid, preferably aqueous hydrochloric acid or sulfuric acid. For those compounds of Formula IV that form acid addition salts, either during the initial reaction or during the removal of an alkanoyl group, the corresponding neutral compounds of Formula IV may be readily obtained by methods known to those skilled in the art. For example, treating an acid addition salt with a suitable base, followed by extraction into a suitable water-immiscible organic solvent, gives the free base form of the compound of Formula IV. Suitable bases for neutralization include alkali metal carbonates, such as lithium, sodium, or potassium carbonate; and tertiary amines, such as triethylamine, tributylamine, N-methylmorpholine, and the like; and other such bases known in the art. Preferred bases include sodium carbonate or potassium carbonate. Suitable water-immiscible organic solvents for extraction include alkanes and cycloalkanes; ethers and cyclic ethers; alkyl alkanoate ethers, such as ethyl acetate and the like; aromatic hydrocarbons; halocarbons, such as chloroform, dichloromethane, ethylene dichloride, and the like; and other solvents known in the art. Preferred water-immiscible organic solvents include ethyl acetate, dichloromethane, and chloroform. Compounds that crystallize spontaneously upon addition of the organic solvent may be collected without completing the extraction procedure.
A second route based on Scheme A is preferred if an appropriate halomethyl-2-pyridinamine of Formula III is not commercially available or easily prepared. Thio intermediates of Formula IV may be prepared by an acid-catalyzed reaction of a 2-mercaptobenzimidazole of Formula II with a hydroxymethyl-2-pyridinamine (Formula III in which Y is OH). Preferred conditions include heating a mixture of compounds of Formulas II and III in a suitable acidic medium. A suitable acidic medium is a chemical substance or mixture of chemical substances that dissolves the compounds of Formulas II and III and is sufficiently acidic to induce the desired reaction, but which does not itself form significant quantities if byproducts by reaction with the compounds of Formulas II and III. Preferred acidic media include mixtures of a hydrogen halide (such as hydrogen chloride or hydrogen bromide) in glacial acetic acid or an aqueous hydrohalic acid (such as hydrochloric or hydrobromic acid) in acetic acid. After the reaction is quenched by pouring the mixture over ice and the mixture is neutralized with a suitable base (such as potassium carbonate), the thio intermediate IV may be isolated and purified by methods known in the art, including recrystallization and chromatography.
The sulfoxide compounds of this invention, Formula I, may be prepared by oxidation of the thio intermediates of Formula IV using methods known to those skilled in the art. Commonly used oxidizing agents include, for example, peracids, such as m-chloroperoxybenzoic acid; peresters; peroxides, such as hydrogen peroxide; sodium metaperiodate; selenium dioxide; manganese dioxide; iodosobenzene; and the like. Preferred conditions for preparing sulfoxides of Formula I include oxidizing intermediates IV with an approximately equimolar quantity of m-chloroperoxybenzoic acid in a suitable organic solvent at temperatures below 0°. Suitable organic solvents for the oxidation include alkanes and cycloalkanes; aromatic hydrocarbons; halocarbons, such as chloroform, dichloromethane, ethylene dichloride, and the like; and other solvents known in the art. A preferred organic solvent is dichloromethane. Oxidization is then quenched by adding dimethylsulfide. The sulfoxides of Formula I may then be isolated and purified by methods known in the art, including recrystallization and chromatography.
Further oxidation of the sulfoxide compounds of Formula I yields corresponding sulfones of Formula V. The sulfones may form in situ during the initial oxidation reaction of thio intermediates of Formula IV or may be prepared by a separate oxidation of isolated sulfoxides of Formula I. The sulfones of Formula V may then be isolated and purified by methods known in the art, including recrystallization and chromatography. Where the sulfones of Formula V are prepared along with sulfoxides of Formula I during the initial oxidation reaction, the preferred method of isolation is chromatography.
Acid addition salts of this invention may be prepared during the course of the reactions (as described above), by ion exchange from those salts using methods known in the art, or by acidification of free bases of the compounds. Base addition salts of this invention by methods known in the art, including those methods disclosed in British Pat. No. 2,137,616.
Although some 2-mercaptobenzimidazoles of Formula II (used as described in Scheme A) are commercially available, they may also be prepared by methods known to those skilled in the art. For example, Scheme B illustrates the preparation of 2-mercaptobenzimidazoles from substituted diaminobenzenes of Formula VI.
SCHEME B
A preferred cyclization method employs an alkali metal alkylxanthate salt of the formula alkyl-O(C═O)S - M+, where M+ represents an alkali metal ion. Such alkylxanthate salts may be preformed by methods known in the art or may be formed in situ by mixing an alkali metal hydroxide (preferably sodium hydroxide) and carbon disulfide in an alcohol (preferably ethanol). Preferred cyclization conditions include heating an aqueous or ##STR4## alcoholic mixture of a diaminobenzene of Formula VI with sodium or potassium ethylxanthate at reflux under an inert atmosphere, such as argon.
Halomethyl-2-pyridinamines of Formula III (wherein Y is a halogen, preferably chlorine or bromine) may be prepared by any of various methods known in the art. Scheme C illustrates a preferred preparation of N 2 -alkanoyl halomethyl-2-pyridinamines (used as described in Scheme A, above).
SCHEME C
Halogenation of N 2 -alkanoyl methyl-2-pyridinamines of Formula VII using methods known in the art gives the corresponding N 2 -alkanoyl halomethyl-2-pyridinamines. Preferred halogenation conditions employ a light-induced reaction with an N-halosuccinimide, preferably N-bromosuccinimide, in carbon tetrachloride containing a catalytic amount of 2,2'-azabisisobutyronitrile.
Halomethyl-2-pyridinamines of Formula III may also be prepared from corresponding hydroxymethyl-2-pyridinamines of Formula III (wherein Y is hydroxy) by synthetic methods well known in the art. For example, reaction of such a hydroxymethyl compound with a suitable halogenating reagent in a suitable organic solvent will give the corresponding halomethyl-2-pyridinamine as a hydrochloride ##STR5## salt. Suitable halogenating agents include thionyl chloride, phosphorus oxychloride, oxalkyl chloride, and the like. Suitable organic solvents for halogenation include alkanes and cycloalkanes; ethers and cyclic ethers; aromatic hydrocarbons; halocarbons, such as chloroform, dichloromethane, ethylene dichloride, and the like: and other solvents known in the art. Preferred organic solvents include dichloromethane and chloroform. A related method involves heating a hydroxymethyl-2-pyridinamine in concentrated hydrochloric or hydrobromic acid at temperatures at 80° to 100° See B. Beilenson and F. M. Hamer, J. Chem. Soc., 98-102 (1942).
Hydroxymethyl-2-pyridinamines of Formula III (wherein Y is a hydroxy) may be prepared by any of various methods known in the art. Scheme D illustrates two preferred preparations of hydroxymethyl-2-pyridinamines (used as described in Scheme A, above). The methods illustrated in Scheme D are best performed on compounds in which both R 5 and R 6 are C 1 -C 6 alkyl or in which one of R 5 or R 6 is C 2 -C 6 alkanoyl.
SCHEME D
Hydroxylation of methyl-2-pyridinamines of Formula IX using a trialkyl borate or a trialkylborate and hydrogen peroxide gives the corresponding hydroxymethyl-2-pyridinamines of Formula XI. Preferred ##STR6## conditions involve an initial deprotonation at the methyl group using a suitable strong base in a suitable organic solvent maintained at temperatures below 0° C. Suitable strong bases are chemical compounds that are sufficiently basic to abstract a proton from the methyl group of a compound of Formula IX so that the subsequent reaction with the trialkyl borate or trialkylborane can take place. Examples of suitable strong bases include alkali metal hydrides, such as sodium hydride and potassium hydride; alkali metal alkyls, such as n-butyllithium and t-butyllithium; and the like. Suitable organic solvents for deprotonation include alkanes and cycloalkanes; ethers and cyclic ethers; aromatic hydrocarbons; and other solvents known in the art. A preferred organic solvent is tetrahydrofuran After deprotonation is effected, a trialkyl borate, preferably trimethyl borate, is added. Subsequent reaction with aqueous hydrogen peroxide gives the hydroxymethyl-2-pyridinamine of Formula XI.
Another preferred hydroxylation method involves an initial oxidation of methyl-2-pyridinamines of Formula IX to carboxylic acids of Formula X using methods known in the art. A preferred oxidation employs potassium permanganate in water heated to about 50° to 80° C. The carboxlic acid may then be reduced to the corresponding hydroxymethyl-2-pyridinamine of Formula XI using reduction methods known in the art. Examples of reduction methods include reaction with lithium aluminum hydride, a borane, and the like. A preferred reduction method employs borane in tetrahydrofuran.
The preferred embodiments of this invention include 3-[(1H-benzimidazol-2-ylsulfinyl)methyl]-2-pyridinamines and 6-[(1H-benzimidazol-2-ylsulfinyl)methyl]-2-pyridinamines of the following general structure: ##STR7## or the pharmaceutically acceptable acid addition salts thereof; wherein R 1 , R 2 , and R 3 are independently hydrogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, C 2 -C 6 hydroxyalkyl, C 1 -C 4 fluorinated alkyl, or halogen; and wherein R 5 and R 6 are independently hydrogen or C 1 -C 6 alkyl.
The most preferred embodiments of this invention include 6-[(1H-benzimidazol-2-ylsulfinyl)methyl]-2-pyridinamines of the following general structure: ##STR8## or the pharmaceutically acceptable acid addition salts thereof; wherein R 1 , R 2 , and R 3 are independently hydrogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, C 2 -C 6 hydroxyalkyl, C 1 -C 4 fluorinated alkyl, or halogen.
The compounds of this invention exhibited gastric antisecretory activity in canines, as indicated by inhibition in vitro of (H + +K + )-ATPase obtained from canine gastric mucosa and by inhibition in vivo of gastric acid secretion in dogs. The antisecretory activity of the compounds of this invention illustrated in the Examples was tested by the following methods.
Inhibition of (H + +K + )-ATPase from Canine Gastric Mucosa
Mongrel dogs weighing 15 to 25 kilograms were fasted for twenty-four hours, with water provided ad libitum. The animals were anesthetized with pentobarbital and the stomachs were removed. Subsequent tissue manipulations and subcellular fractionations were performed at 0° to 4° C. After the stomachs were cut open and rinsed with tap water, the antral and cardiac regions were removed and the remaining tissue was rinsed three times in saline. The glandular mucosa was removed mechanically, chopped finely in a medium containing 10 mM Tris hydrochloride (pH 7.4) and 250 mM sucrose, and homogenized. The homogenate was centrifuged at 20,000xg for twenty minutes and the pellet discarded. The supernatant was then centrifuged at 150,000xg for ninety minutes and the supernatant discarded. The pellet was resuspended in the Tris-HCl/sucrose medium by homogenization. Part (2 ml) of the resultant microsomal suspension was layered onto a step gradient consisting of 9 ml of 15% sucrose above 12 ml of 30% sucrose, each sucrose solution being buffered with 10 mM Tris hydrochloride (pH 7.4) containing 0.01% sodium azide. The microsomes retained at the 15%-30% sucrose interface, after centrifugation at 250,000xg for sixty minutes, were used as the source of (H + +K + )-ATPase. Microsomal preparations were lyophilized, a process that assured potassium ion permiability, and stored at -10° until used.
(H + +K + )-ATPase activity for each test compound was determined, in duplicate, by measuring the release of inorganic phosphate, which was assayed according to the method of J. ChandraRajan and L. Klein. Anal. Biochem., 72, 407-412 (1976). The (H + +K + )-ATPase assay medium consisted of 20 mM Mes-Tris (pH 6.0), 5 mM magnesium chloride, 25 mM sucrose, and 4 mM Tris-ATP with or without 20 mM potassium chloride in a total volume of 2 ml. Microsomal suspensions (20 to 60 mcl, containing about 25 mcg protein) were added to the assay medium, without Tris-ATP, and then preincubated with a test compound for thirty minutes at 37°. The assay was initiated by adding Tris-ATP and the mixture was incubated another thirty minutes at 37° A 200-mcl aliquot of the assay mixture was then added to 1.4 ml of a solution consisting of 0.1M sodium acetate (pH 4.0) and 10% sodium dodecylsulfate, followed by the addition of 200 mcl each of 1% ammonium molybdate and 1% ascorbic acid. At least fifteen minutes later, the optical absorbance at 870 nm (which was proportional to inorganic phosphate concentration up to 100 nmoles per tube, as determined by a standard curve) was obtained. Enzyme activity was linear with incubation time.
(H + +K + )-ATPase activity is represented by the difference between the measured activities in the presence of potassium ion (K + -stimulated) and in the absence of potassium ion (basal). The concentration of a test compound required to inhibit 50% of the (H + + + )-ATPase activity (i.e., the IC 50 ) was determined at least in duplicate using linear regression analysis of results obtained for three different compound concentrations ranging from 0.1 mcM to 0.2 mM. If the IC 50 for a test compound could not be determined for the concentration range tested, percent inhibition of (H + +K + )-ATPase was obtained for the compound at 0.1 mM.
Inhibition of Gastric Acid Secretion in Gastric Fistula Beagle Dogs
Adult female beagle dogs weighing 6 to 11 kilograms obtained from Laboratory Research Enterprises (Kalamazoo, Mich.) or from Hazelton Research Animals (Cumberland, Va.) were surgically implanted with a simple Thomas-type gastric cannula. After recovery from surgery, the dogs were trained to stand quietly, fully conscious, in Pavlov-type dog restraining slings and were acclimated to intravenous infusion of histamine dihydrochloride. During the course of these studies, no dog was used more than once a week. All dogs were deprived of food, but not water, for 18 hours prior to each assay. Each dog was initially infused with 0.15M sodium chloride solution at a constant rate of 6.5 mg/hr. The volume of gastric secretions, collected in plastic bottles affixed to the cannula, were measured to the nearest 0.1 ml at 30 minute intervals. One of the following protocols was followed, depending on the route chosen for administration of test compound.
Intravenous dosing: Following a 30-minute basal secretion period, test compounds were administered intravenously (i.v.). At the end of an additional 30 minute period, the saline infusion was replaced with histamine dihydrochloride in saline administered at a rate 15 mcg per kilogram of body weight per hour. Histamine stimulation was maintained for a maximum of four hours during which time gastric secretions were collected every 30 minutes. The pH and titratable acidity were determined for samples from each collection period.
Intragastric dosing: Following a 30-minute basal secretion period, the collection bottles were removed, dosing plugs were inserted, and test compounds were administered intragastrically (i.g.). At the end of a 30-minute drug absorption period, the stomachs were emptied, the collection bottles were reattached, and collections were resumed at 30-minute intervals. Simultaneously, the saline infusion was replaced with a continuous intravenous infusion of histamine dihydrochloride in saline administered for four hours at a rate 15 mcg per kilogram of body weight per hour.
Intraduodenal dosing: Dogs were also equipped with duodenal cannulas for intraduodenal (i.d.) administration of test compounds. Dosing was otherwise performed as described for intragastric dosing.
Data from each protocol were analyzed for three gastric sample variables: volume of gastric juice, acid concentration, and total acid output. Percent inhibition for each four-hour experimental period was determined for each parameter by comparison with 3 to 4 controls in which only food was given. Estimates of ED 50 's were determined from dose response curves.
By virtue of their gastric antisecretory activity, the compounds of Formula I are useful in treating ulcers in mammals. A physician or veterinarian of ordinary skill can readily determine whether a subject has ulcers. Regardless of the route of administration selected, the compounds of the present invention are formulated into pharmaceutically acceptable dosage forms by conventional methods known to those skilled in the art. The compounds may be formulated using pharmacologically acceptable acid addition or base addition salts. Moreover, the compounds or their salts may be used in a suitable hydrated form.
The compounds can be administered in such oral dosage forms as tablets, capsules, pills, powders, granules, elixirs, or syrups. The compounds may also be administered intravascularly, intraperitoneally, subcutaneously, or intramuscularly, using forms known to the pharmaceutical art. In general, the preferred form of administration is oral. For the orally administered pharmaceutical compositions and methods of the present invention, the foregoing active ingredients will typically be administered in admixture with suitable pharmaceutical diluents, excipients, or carriers (collectively referred to herein as "carrier" materials) suitably selected with respect to the intended form of administration, that is, oral tablets, capsules, elixirs, syrups, and the like, and consistent with conventional pharmaceutical practices. For example, for oral administration in the form of tablets or capsules, the active drug components may be combined with any oral non-toxic pharmaceutically acceptable inert carrier such as lactose, starch, sucrose, cellulose, magnesium stearate, dicalcium phosphate, calcium sulfate, mannitol, and the like, or various combinations thereof; for oral administration in liquid form, the active drug components may be combined with any oral non-toxic pharmaceutically acceptable inert carrier such as water, saline, ethanol, polyethylene glycol, propylene glycol, corn oil, cottonseed oil, peanut oil, sesame oil, benzyl alcohol, various buffers, and the like, or various combinations thereof. Moreover, when desired or necessary, suitable binders, lubricants, disintegrating agents, and coloring agents can also be incorporated in the mixture. Suitable binders include starch, gelatin, natural sugars, corn sweeteners, natural and synthetic gums such as acacia, sodium alginate, carboxymethylcellulose, polyethylene glycol, and waxes, or combinations thereof. Lubricants for use in these dosage forms include boric acid, sodium benzoate, sodium actate, sodium chloride, and the like, or combinations thereof. Disintegrators include, without limitation, starch, methylcellulose, agar, bentonite, guar gum, and the like, or combinations thereof. Sweetening and flavoring agents and preservatives can also be included where appropriate.
For intravascular, intraperitoneal, subcutaneous, or intramuscular administration, active drug components may be combined with a suitable carrier such as water, saline, aqueous dextrose, and the like.
By whatever route of administration selected, an effective but non-toxic quantity of the compound is employed in treatment. The dosage regimen for preventing or treating ulcers with the compounds of this invention is selected in accordance with a variety of factors, including the type, age, weight, sex, and medical condition of the patient; the severity of the condition; the route of administration; and the particular compound employed. An ordinarily skilled physician or veterinarian can readily determine and prescribe the effective amount of the drug required to prevent or arrest the progress of the condition. In so proceeding, the physician or veterinarian could employ relatively low doses at first and subsequently increase the dose until a maximum response is obtained. Dosages of the compounds of the invention may be in the range of about 1.0 mcg/kg to 500 mg/kg, preferably in the range of about 10 to 100 mg/kg orally or about 1.0 to 20 mg/kg intravenously.
The following examples further illustrate details for the preparation of the compounds of this invention. The invention, which is set forth in the foregoing disclosure, is not to be construed or limited either in spirit or in scope by these examples. Those skilled in the art will readily understand that known variations of the conditions and processes of the following preparative procedures can be used to prepare these compounds. All temperatures are degrees Celsius unless otherwise noted.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
3-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine hemihydrate ##STR9## A mixture of 9.6 g (63 mmole) of 2-mercaptobenzimidazole and 7.7 g (62 mmole) of 3-hydroxymethyl-2-pyridinamine was dissolved in 60 ml of 48% aqueous hydrobromic acid and 60 ml of acetic acid and heated to reflux. After being cooled to room temperature, the mixture was poured into water and made alkaline with potassium carbonate. The oil that separated solidified upon addition of diethyl ether to the aqueous mixture. The solid was collected by filtration, washed with portions of diethyl ether and water, and air dried to yield 12.4 g of the title compound as an analytically pure hemihydrate. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis. Analysis. Calcd. for C 13 H 12 N 4 S1/2H 2 O: C, 58.84; H, 4.93; N, 21.11; S, 12.08. Found: C, 59.06; H, 4.48; N, 20.82; S, 12.16.
EXAMPLE 2
3-[(1H-benzimidazol-2-ylsulfonyl)methyl]-2-pyridinamine ##STR10## A suspension of 4.0 g (15 mmole) of 3-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine hemihydrate (see Example 1) in 50 ml of dichloromethane was cooled in an ice bath. A solution of 3.0 g (15 mmole) of ca. 85% m-chloroperbenzoic acid in the minimum amount of dichloromethane needed to form a solution was then added dropwise with stirring. After addition was complete, another 3.0 g of ca. 85% m-chloroperbenzoic acid was added. The reaction was quenched with 10 drops of dimethylsulfide. The mixture was washed with saturated aqueous sodium bicarbonate. The organic phase was concentrated in vacuo and chromatographed on silica gel (using ethanol-dichloromethane-triethylamine as eluent). Initial fractions yielded 249 mg of the title sulfone. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 12 H 12 N 4 SO 2 : C, 54.15; H, 4.19; N, 19.43. Found: C, 53.79; H, 4.09; N, 19.29.
EXAMPLE 3
3-[(1H-benzimidazol-2-ylsulfinyl)methyl]-2-pyridinamine hydrate ##STR11## Later fractions from the chromatographic separation of Example 2 yielded 653 mg of the title sulfoxide. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 13 H 12 N 4 SO.H 2 O: C, 53.77; H, 4.16; N, 12.29; S, 11.04. Found: C, 53.59; H, 4.34; N, 18.93; S, 11.26.
EXAMPLE 4
3-[(1H-benzimidazol-2-ylthio)methyl]-N,N-dimethyl-2-pyridinamine ##STR12## To a cold (ca. -78°) solution of 2.9 g (21 mmole) of 3-methyl-2-(N,N-dimethylamino)pyridine in 35 ml of tetrahydrofuran was added dropwise 15 ml (23 mmole) of 1.55M butyllithium in hexane. The mixture was stirred at 0° for four hours and then recooled to ca. -78°.
Trimethyl borate (2.65 ml, ca. 23 mmole) was added dropwise and the mixture was stirred at 0°. After one hour 2.9 ml of 30% hydrogen peroxide was added and the mixture was stirred at 25°. After another hour the reaction mixture was poured into water and extracted with several portions of diethyl ether. The combined ether extracts were dried over magnesium sulfate, filtered, and concentrated in vacuo to an oil. Chromatography on silica gel (using ethanol-toluene as eluent) yielded 600 mg of 3-hydroxymethyl-2-(N,N-dimethylamino)pyridine, as confirmed by the nmr and infrared spectra. Using the method of Example 1 with 3-hydroxymethyl-2-(N,N-dimethylamino)pyridinamine instead of 3-hydroxymethyl-2-pyridinamine yielded the title compound, which was used in subsequent reactions without further purification. Structure assignment was supported by the nmr and infrared spectra.
EXAMPLE 5
3-[(1H-benzimidazol-2-ylsulfinyl)methyl]-N,N-dimethyl-2-pyridinamine 1/3 hydrate ##STR13## The title compound was prepared by the method of Example 2 using 1.5 g of 3-[(1H-benzimidazol-2-ylsulfinyl)methyl]-N,N-dimethyl-2-pyridinamine (see Example 4) instead of 3-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine hemihydrate and using chloroform as solvent instead of dichloromethane. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 15 H 16 N 4 OS.1/3/H 2 O: C, 58.84; H, 5.48; N, 18.29; S, 10.44. Found: C, 59.24; H, 5.31; N, 18.10; S, 10.05.
EXAMPLE 6
6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine hemihydrate ##STR14## To a cold (ca. 0°) solution of 86.4 g (0.88 mole) of 2-amino-6-methylpyridine and 101 g (0.96 mole) of triethylamine in 1.0 liter of dichloromethane was added dropwise a solution of 106.1 g (0.88 mole) of trimethylacetyl chloride in 100 ml of dichloromethane. After stirring an hour after addition was completed, the mixture was poured into water and the layers separated. The aqueous layer was extracted with dichloromethane. The organic layers were combined and washed with water, dried over magnesium sulfate, filtered, and concentrated in vacuo to an oil that crystallized upon standing. The solid was triturated with hexane and collected by filtration, giving 115 g of 2-(trimethylacetamido)-6-methylpyridine. A 22.6 g (0.12 mmole) portion of the amide derivative was suspended in 250 ml of carbon tetrachloride containing 22.9 g (0.12 mmole) of N-bromosuccinimide and 100 mg of 2,2'-azabisisobutyronitrile. The mixture was heated at reflux under a sun lamp for one hour, after which insolubles were removed by filtration. The filtrate was concentrated in vacuo to an oil consisting of a mixture of the 6-bromomethyl-2-(trimethylacetamido)pyridine and 6-dibromoethyl-2-(trimethylacetamido)pyridine derivatives. The crude mixture was heated at reflux for fifteen minutes with 11.7 g (78 mmole) of 2-mercaptobenzimidazole in 300 ml of isopropyl alcohol. Upon cooling, a precipitate formed and was collected and washed with portions of isopropyl alcohol and diethyl ether. The trimethylacetyl group was removed by heating at reflux for four hours in 300 ml of 10% aqueous hydrochloric acid. After cooling, the mixture was concentrated in vacuo to an oil. The oil was dissolved in water and made alkaline with aqueous potassium carbonate. The oil that separated solidified upon addition of dichloromethane to the aqueous mixture. The solid was collected by filtration, washed with portions of water and dichloromethane, and air dried to yield 9.6 g of the title compound as an analytically pure hemihydrate. (An additional 2.5 g of the title compound was isolated from the dichloromethane washes.) Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 13 H 12 N 4 S.1/2H 2 O: C, 58.84; H, 4.93; N, 21.11; S, 12.08. Found: C, 59.03; H, 4.40; N, 20.90; S, 12.30.
EXAMPLE 7
6-[(1H-benzimidazol-2-ylsulfinyl)methyl]-2-pyridinamine ##STR15## A suspension of 5.0 g (18.8 mmole) of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine hemihydrate (see Example 6) in 250 ml of chloroform was cooled to -5°. A solution of 4.2 g (20 mmole) of ca. 85% m-chloroperbenzoic acid in chloroform was added dropwise with stirring. After an additional fifteen minutes, the reaction was quenched with several drops of dimethylsulfide and concentrated in vacuo. The residue was triturated with diethyl ether, filtered, and washed with diethyl ether, yielding 2.6 g of the title compound. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 13 H 12 N 4 SO: C, 57.33; H, 4.44; N, 20.57; S, 11.77. Found: C, 57.04; H, 4.42; N, 20.50; S, 11.87.
EXAMPLE 8
6-[[(4-methyl-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine hemihydrate ##STR16## A solution of 20 g (0.13 mole) of 2-methyl-6-nitroaniline in 22.9 ml of concentrated aqueous hydrochloric acid, 200 ml of tetrahydrofuran, and 350 ml of methanol was hydrogenated at room temperature using 25 p.s.i. of hydrogen gas over 2.0 g of 5% palladium on carbon. The mixture was filtered and the filtrate was concentrated in vacuo. The residue was dissolved in 150 ml of ethanol and neutralized with 17.2 g (0.26 mole) of potassium hydroxide dissolved in 30 ml of water. Potassium ethylxanthate (23 g, 0.155 mole) was added and the mixture was heated at reflux for 18 hours. Upon cooling, a solid was collected, washed with water, and air dried to yield 6.2 g of 2-mercapto-4-methylbenzimidazole, as confirmed by the nmr and infrared spectra. The title compound (1.5 g) was prepared by the method of Example 6 using 1.6 g of 2-mercapto-4-methylbenzimidazole instead of 2-mercaptobenzimidazole. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 14 H 14 N 4 S1/2H 2 O: C, 60.19; H, 5.01; N, 20.05; S, 11.45. Found: C, 60.49; H, 5.03; N, 20.41; S, 11.76.
EXAMPLE 9
6-[[(4-methyl-1H-benzimidazol-2-yl)-sulfinyl]methyl]-2-pyridinamine ##STR17## The title compound (450 mg) was prepared by the method of Example 7 using 600 mg (2.2 mmole) of 6-[[(4-methyl-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine (see Example 8) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 14 H 14 N 4 SO: C, 58.72; H, 4.93; N, 19.57; S, 11.20. Found: C, 58.70; H, 4.86; N, 19.60; S, 10.88.
EXAMPLE 10
6-[[(5-methyl-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine hemihydrate ##STR18## A mixture of 12.2 g (0.1 mole) of 3,4-diaminotoluene, 35 ml of carbon disulfide, and 4.0 g (0.1 mole) of sodium hydroxide was heated at reflux in 350 ml of ethanol. After 2.5 hours the mixture was concentrated in vacuo. The residue was suspended in 200 ml of 4% aqueous hydrochloric acid, and the product was collected by filtration, washed sequentially with water and diethyl ether, and air dried to yield 12.2 g of 2-mercapto-5-methylbenzimidazole, as confirmed by the nmr and infrared spectra. The title compound (2.0 g) was prepared by the method of Example 6 using 1.6 g (9.7 mmole) of 2-mercapto-5-methylbenzimidazole instead of 2-mercaptobenzimidazole. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 14 H 14 N 4 S: C, 60.19; H, 5.01; N, 20.05; S, 11.47. Found: C, 59.80; H, 5.05; N, 20.00; S, 11.17.
EXAMPLE 11
6-[[(5-methyl-1H-benzimidazol-2-yl)sulfinyl]methyl]-2-pyridinamine ##STR19## The title compound (240 mg) was prepared by the method of Example 7 using 1.0 g (3.7 mmole) of 6-[[(5-methyl-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine (see Example 10) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 14 H 14 N 4 SO: C, 58.72; H, 4.93; N, 19.57; S, 11.20. Found: C, 58.62; H, 4.91; N, 19.60; S, 10.99.
EXAMPLE 12
6-[[(5-methoxy-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine ##STR20## The title compound was prepared by the method of Example 6 using 7.0 g of 2-mercapto-5-methoxybenzimidazole instead of 2-mercaptobenzimidazole. Structure assignment was supported by the nmr spectrum.
EXAMPLE 13
6-[[(5-methoxy-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine ##STR21## The title compound (940 mg) was prepared by the method of Example 7 using 4.67 g (16.3 mmole) of 6-[[(5-methoxy-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine (see Example 12) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 14 H 14 N 4 SO: C, 55.62; H, 4.67; N, 18.53; S, 10.60. Found: C, 55.52; H, 4.59; N, 17.86; S, 10.35.
EXAMPLE 14
6-[[(5-chloro-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine ##STR22## A solution of 20 g (0.12 mole) of 3-chloro-6-nitroaniline in 350 ml of methanol was hydrogenated over 5% palladium on carbon to yield 24.9 g of the corresponding diamino compound. Reaction of the diamino compound with potassium ethylxanthate using the method described in Example 8 yielded 19 g of 5-chloro-2-mercaptobenzimidazole, as confirmed by elemental analysis. The title compound (1.8 g) was prepared by the method of Example 6 using 3.6 g (19 mmole) of 5-chloro-2-mercaptobenzimidazole instead of 2-mercaptobenzimidazole. Structure assignment was supported by the nmr and infrared spectra.
EXAMPLE 15
6-[[(5-chloro-1H-benzimidazol-2-yl)sulfinyl]methyl]-2-pyridinamine ##STR23## The title compound (250 mg) was prepared by the method of Example 7 using 1.5 g (5.2 mmole) of 6-[[(5-chloro-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine (see Example 14) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr spectrum and by elemental analysis.
Analysis. Calcd. for C 13 H 11 N 4 ClSO: C, 50.90; H, 3.61; N, 18.26, S, 10.45; Cl, 11.56. Found: C, 50.97; H, 3.60; N, 18.45; S, 10.47; Cl, 11.74.
EXAMPLE 16
6-[[[5-(trifluoromethyl)-1H-benzimidazol-2-yl]thio]methyl]-2-pyridinamine ##STR24## A solution of 50 g (0.24 mole) of 4-(trifluoromethyl)-2-nitroaniline in 500 ml of ethanol was hydrogenated over 10% palladium on carbon to yield 21.0 g of the corresponding diamino compound. Reaction of 20.0 g of the diamino compound with carbon disulfide using the method described in Example 10 yielded 22.9 g of 5-(trifluoromethyl)-2-mercaptobenzimidazole, as confirmed by elemental analysis. The title compound (1.5 g) was prepared by the method of Example 6 using 5.7 g (26 mmole) of 5-(trifluoromethyl)-2-mercaptobenzimidazole instead of 2-mercaptobenzimidazole. Structure assignment was supported by the nmr and infrared spectra.
EXAMPLE 17
6-[[[5-(trifluoromethyl)-1H-benzimidazol-2-yl]sulfinyl]methyl]-2-pyridinamine ##STR25## The title compound (900 mg) was prepared by the method of Example 7 using 1.5 g (4.6 mmole) of 6-[[[5-trifluoromethyl)-1H-benzimidazol-2-yl]thio]methyl]-2-pyridinamine (see Example 16) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 14 H 11 N 4 F 3 SO: C, 49.41; H, 3.26; N, 16.46; S, 9.42. Found: C, 49.42; H, 3.29; N, 16.30; S, 9.49.
EXAMPLE 18
6-[[(5-ethoxy-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine ##STR26## A solution of 51.3 g (0.28 mole) of 4-ethoxy-2-nitroaniline in methanol was hydrogenated over 5% palladium on carbon to yield 63.4 g of the corresponding diamino compound. Reaction of the diamino compound with potassium ethylxanthate using the method described in Example 8 yielded 43.4 g of 5-ethoxy-2-mercaptobenzimidazole, as confirmed by the nmr and infrared spectra. The title compound (1.0 g) was prepared by the method of Example 6 using 3.7 g of 5-ethoxy-2-mercaptobenzimidazole instead of 2-mercaptobenzimidazole. The title compound was used in subsequent reactions without further characterization.
EXAMPLE 19
6-[[(5-ethoxy-1H-benzimidazol-2-yl)sulfinyl]methyl]-2-pyridinamine ##STR27## The title compound (700 mg) was prepared by the method of Example 7 using 900 mg (3.0 mmole) of 6-[[(5-ethoxy-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine (see Example 18) instead of 6-[(1H-benzimidazol-2-ylthio]methyl]-2-pyridinamine. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 15 H 16 N 4 SO 2 : C, 56.95; H, 5.10; N, 17.71; S, 10.14. Found: C, 56.67; H, 4.99; N, 17.48; S, 10.27.
EXAMPLE 20
6-[[(5,6-dimethoxy-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine 3/4 hydrate ##STR28## A solution of 62.2 g (0.31 mole) of 3,4-dimethoxy-6-nitroaniline in tetrahydrofuran was hydrogenated with Raney nickel to yield 52.7 g of the corresponding diamino compound. Reaction of the diamino compound with potassium ethylxanthate using the method described in Example 8 yielded 59 g of 5,6-dimethoxy-2-mercaptobenzimidazole as confirmed by the nmr and infrared spectra. The title compound (1.9 g) was prepared by the method of Example 6 using 4.3 g of 5,6-dimethoxy-2-mercaptobenzimidazole instead of 2-mercaptobenzimidazole. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 15 H 16 N 4 SO.3/4H 2 O: C, 54.61; H, 5.30; N, 16.98; S, 9.70. Found: C, 54.75; H, 5.13; N, 17.08; S, 9.72.
EXAMPLE 21
6-[[(5,6-dimethoxy-1H-benzimidazol-2-yl)sulfinyl]methyl]-2-pyridinamine 1/4 hydrate ##STR29## The title compound (600 mg) was prepared by the method of Example 7 using 1.6 g (5.0 mmole) of 6-[[(5,6-dimethoxy-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine (see Example 20) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr spectrum and by elemental analysis.
Analysis. Calcd. for C 15 H 16 N 4 SO 3 .1/4H 2 O: C, 53.48; H, 4.90; N, 16.63; S, 9.52. Found: C, 53.54; H, 4.57; N, 16.45; S, 9.79.
EXAMPLE 22
6-[[(5,6-dimethyl-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine ##STR30## Reaction of 30 g (0.22 mole) of 4,5-dimethyl-1,2-phenylenediamine with potassium ethylxanthate using the method described in Example 8 yielded 19 g of 5,6-dimethyl-2-mercaptobenzimidazole, as confirmed by the nmr and infrared spectra and by elemental analysis. The title compound (3.0 g) was prepared by the method of Example 6 using 3.5 g of 5,6-dimethyl-2-mercaptobenzimidazole instead of 2-mercaptobenzimidazole. Structure assignment was supported by the nmr spectrum.
EXAMPLE 23
6-[[(5,6-dimethyl-1H-benzimidazol-2-yl)sulfinyl]methyl]-2-pyridinamine ##STR31## The title compound was prepared by the method of Example 7 using 1.5 g (5.3 mmole) of 6-[[(5,6-dimethyl-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine (see Example 22) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr spectrum and by elemental analysis.
Analysis. Calcd. for C 15 H 16 N 4 SO: C, 59.98; H, 5.37; N, 18.65; S, 10.67. Found: C, 59.67; H, 5.20; N, 18.83; S, 10.87.
EXAMPLE 24
6-[[(4,6-dimethyl-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine ##STR32## A solution of 5 g (0.03 mole) of 2,4-dimethyl-6-nitroaniline in methanol was hydrogenated over 5% palladium on carbon to yield 4.0 g of the corresponding diamino compound. Reaction of the diamino compound with potassium ethylxanthate using the method described in Example 8 yielded 4.9 g of 4,6-dimethyl-2-mercaptobenzimidazole, as confirmed by the nmr and infrared spectra and by elemental analysis. The title compound (1.5 g) was prepared by the method of Example 6 using 3.5 g (20 mmole) of 4,6-dimethyl-2-mercaptobenzimidazole instead of 2-mercaptobenzimidazole. Structure assignment was supported by the nmr spectrum.
EXAMPLE 25
6-[[(4,6-dimethyl-1H-benzimidazol-2-yl)sulfinyl]methyl]-2-pyridinamine ##STR33## The title compound was prepared by the method of Example 7 using 1.0 g (3.5 mmole) of 6-[[(4,6-dimethyl-1H-benzimidazol-2-yl)thio]methyl]-2-pyridinamine (see Example 24) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 15 H 16 N 4 SO: C, 59.98; H, 5.37; N, 18.65; S, 10.67. Found: C, 59.60; H, 5.32; N, 18.47; S, 10.75.
EXAMPLE 26
6-[[[5-(hydroxymethyl)-1H-benzimidazol-2-yl]thio]methyl]-2-pyridinamine ##STR34## The title compound (600 mg) was prepared by the method of Example 6 using 2.7 g of 5-hydroxymethyl-2-mercaptobenzimidazole instead of 2-mercaptobenzimidazole. Structure assignment was supported by the nmr spectrum.
EXAMPLE 27
6-[[[5-(hydroxymethyl)-1H-benzimidazol-2-yl]sulfinyl]methyl]-2-pyridinamine 1/4 hydrate ##STR35## The title compound was prepared by the method of Example 7 using 350 mg of 6-[[[5-(hydroxymethyl)-1H-benzimidazol-2-yl]thio]methyl]-2-pyridinamine (see Example 26) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 14 H 14 N 4 SO 2 .1/4H 2 O: C, 54.80; H, 4.60; N, 18.25; S, 10.44. Found: C, 54.85; H, 4.70; N, 18.01; S, 10.26.
EXAMPLE 28
6-[(1H-benzimidazol-2-ylthio)methyl]-N-(2,2-dimethylpropyl)-2-pyridinamine ##STR36## A suspension of 40 g (0.21 mole) of 2-(trimethylacetamido)-6-methylpyridine (prepared as described in Example 6) in 500 ml of water was heated to 70°. Potassium permanganate (65 g, 420 mmole) was added in eight portions over four hours and the mixture was then heated at 90°. After 18 hours the mixture was filtered hot. The filtrate was concentrated in vacuo to about 50 ml and adjusted to about pH 3 with concentrated hydrochloric acid. The resultant precipitate was collected, washed with water, and dried in vacuo to yield 7.5 g of the 6-carboxylic acid derivative. To a suspension of 7.0 g of the carboxylic acid derivative in 50 ml of cold (ca. 0°) tetrahydrofuran was added dropwise 85 ml (ca. 85 mmole) of 1M borane in tetrahydrofuran. The mixture was allowed to stir at room temperature for two hours and at 50° for another 18 hours. After the mixture was allowed to cool, the reaction was quenched with water. The mixture made basic with 10% aqueous sodium hydroxide and extracted with several portions of ethyl acetate. The combined organic layers were dried over magnesium sulfate, filtered, and concentrated in vacuo to an oil. Chromatography on silica gel (using ethanol-dichloromethane as eluent) yielded 1.3 g of 6-hydroxymethyl-N-(2,2-dimethylpropyl)-2-pyridinamine, as confirmed by the nmr and infrared spectra. The title compound (1.9 g) was prepared by the method of Example 1 using 1.3 g (6.7 mmole) of 6-hydroxymethyl-N-(2,2-dimethylpropyl)-2-pyridinamine instead of 3-hydroxymethyl-2-pyridinamine. Structure assignment was supported by the nmr spectrum.
EXAMPLE 29
6-[(1H-benzimidazol-2-ylsulfinyl)methyl]-N-(2,2-dimethylpropyl)-2-pyridinamine 1/4 hydrate ##STR37## The title compound (100 mg) was prepared by the method of Example 7 using 1.52 g (4.65 mole) of 6-[(1H-benzimidazol-2-ylthio)methyl]-N-(2,2-dimethylpropyl)-2-pyridinamine (see Example 28) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 18 H 22 N 4 SO.1/4H 2 0: C, 62.31; H, 6.48; N, 16.15; S, 9.24. Found: C, 62.19; H, 6.47; N, 15.76; S, 9.09.
EXAMPLE 30
6-[(1H-benzimidazol-2-ylthio)methyl]-N-ethyl-2-pyridinamine ##STR38## The title compound (2.1 g) was prepared by the method of Example 28 using 45 g (0.30 mole) of 2-acetamido-6-methylpyridine (prepared from 2-amino-6-methylpyridine as described in Example 6 using acetyl chloride instead of trimethylacetyl chloride) instead of 2-(trimethylacetamido)-6-methylpyridine. Structure assignment was supported by the nmr and infrared spectra.
EXAMPLE 31
6-[(1H-benzimidazol-2-ylsulfinyl)methyl]-N-ethyl-2-pyridinamine ##STR39## The title compound was prepared by the method of Example 7 using 2.0 g (7.03 mmole) of 6-[(1H-benzimidazol-2-ylthio)methyl]-N-ethyl-2-pyridinamine (see Example 30) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 15 H 16 N 4 SO: C, 59.98; H, 5.37; N, 18.65; S, 10.67. Found: C, 60.07; H, 5.37; N, 18.45; S, 10.61.
EXAMPLE 32
5-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine 1/4 hydrate ##STR40## The title compound was prepared by the general method described in Example 6 using 2-amino-5-methylpyridine instead of 2-amino-6-methylpyridine. The crystalline solid was collected and washed with portions of water and diethyl ether to yield 1.8 g of the title compound. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 13 H 12 N 4 S.1/4H 2 O: C, 59.86; H, 4.83; N, 21.48; S, 12.29. Found: C, 59.91; H, 4.67; N, 21.86; S, 12.45.
EXAMPLE 33
5-[(1H-benzimidazol-2-ylsulfinyl)methyl]-2-pyridinamine 1/4 hydrate ##STR41## The title compound was prepared by the method of Example 7 using 1.0 g (3.9 mmole) of 5-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine (see Example 32) instead of 6-[(1H-benzimidazol-2-ylthio)methyl]-2-pyridinamine. Structure assignment was supported by the nmr and infrared spectra and by elemental analysis.
Analysis. Calcd. for C 13 H 12 N 4 SO.1/4H 2 0: C, 56.40; H, 4.55; N, 20.24; S, 11.58. Found: C, 56.35; H, 4.46; N, 20.25; S, 11.66.
EXAMPLE 34
Table of Pharmacological Test Results
______________________________________ Gastric-FistulaCompound (H.sup.+ + K.sup.+)- Beagle[Product of ATPase % InhibitionExample No.] IC.sub.50 (mcM) (3 mg/kg dose)______________________________________ 3 100 41 i.v. 5 8.6 15 i.d. 7 2.5 59 i.d. 9 2.211 1.6813 4.5 46 i.v.15 6.917 6.9519 3.121 23.723 0.7225 1.827 9.529 9.131 20.0 58 i.d.33 34.8______________________________________
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This invention relates to [(1H-benzimidazol-2-ylsulfinyl)methyl]-2-pyridinamines that are useful in the treatment and prevention of ulcers.
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FIELD OF THE INVENTION
[0001] This invention relates to medical instruments and systems for creating a path or cavity in vertebral bone to receive bone cement to treat a vertebral compression fracture. The features relating to the methods and devices described herein can be applied in any region of bone or hard tissue where the tissue or bone is displaced to define a bore or cavity instead of being extracted from the body such as during a drilling or ablation procedure. In addition, the present invention also discloses methods and devices for ablating or coagulating tissues, including but not limited to ablating tumor tissue in vertebral and/or cortical bone.
SUMMARY OF THE INVENTION
[0002] Methods and devices described herein relate to improved creation of a cavity within bone or other hard tissue where the cavity is created by displacement of the tissue. In a first example, a method according to the present disclosure includes treating a vertebral body or other bone structure. In one variation, the method includes providing an elongate tool having a sharp tip configured for penetration into vertebral bone, the tool having an axis extending from a proximal end to a working end thereof, where the working end comprises at least a first sleeve concentrically located within a second sleeve and a third sleeve located concentrically about the second sleeve, where each sleeve comprises a series of slots or notches to limit deflection of the working end to a first curved configuration in a single plane and where the respective series of slots or notches are radially offset in each sleeve; advancing the working end through vertebral bone; causing the working end to move from a linear configuration to a curved configuration by translating the first sleeve relative to the second sleeve in an axial direction; and moving the working end in the curved configuration within the bone to create a cavity therein. Translating of the first sleeve relative to the second sleeve can include moving either sleeve or both sleeves in an axial direction. Additional variations include moving one or both sleeves in a rotational direction to produce relative axial displacement between sleeves.
[0003] In an additional variation, the present devices include medical osteotome devices that can for treat a hard tissue (e.g., in a vertebral body) by mechanically displacing the hard tissue and/or applying therapeutic energy to ablate or coagulate tissue. For example, one such variation includes an osteotome type device that is coupled to a power supply and further includes a handle having an actuating portion and a connector for electrically coupling the osteotome device to the power supply; a shaft comprising a first sleeve located concentrically within a second sleeve, the shaft having a distal portion comprising a working end capable of moving between a linear configuration and an articulated configuration where the articulated configuration is limited to a single plane, and where each sleeve comprises a series of slots or notches to limit deflection of the working end to the articulated configuration, where the respective series of slots or notches are radially offset in adjacent sleeves, where a first conductive portion of the shaft is electrically coupleable to a first pole of the power supply; a sharp tip located at a distal tip of the first sleeve of the working end, the sharp tip adapted to penetrate bone within the vertebral body, where the distal tip is coupleable to a second pole of the power supply, such that when activated, current flows between a portion of the distal tip and the shaft; a non-conductive layer electrically isolating the first sleeve from the first conductive portion; and where the shaft and sharp tip have sufficient column strength such that application of an impact force on the handle causes the distal portion of the shaft and the distal tip to mechanically displace the hard tissue. The power supply can be coupled to the outer sleeve (either the second or third sleeve discussed herein.)
[0004] Another variations of the method disclosed herein can include the application of energy between electrodes on the device to ablate tissues (e.g., tumor) or to perform other electrosurgical or mapping procedures within the tissue. In one such example for treating a vertebral body, the method can include providing an elongate tool having a sharp tip configured for penetration into vertebral bone, the tool having an axis extending from a proximal end to a working end thereof, where the working end comprises at least a first sleeve concentrically located within a second sleeve, where each sleeve comprises a series of slots or notches to limit deflection of the working end to a first curved configuration in a single plane and where the respective series of slots or notches are radially offset in adjacent sleeves, where a first conductive portion of the first sleeve is electrically coupled to a first pole of a power supply; advancing the working end through vertebral bone; causing the working end to move from a linear configuration to a curved configuration by translating the first sleeve relative to the second sleeve in an axial direction; and applying energy between the first conductive portion and a return electrode electrically coupled to a second pole of the energy supply to ablate or coagulate a region within the vertebral body.
[0005] In variations of the method, moving the working end to from the linear configuration to the curved configuration can include moving the working end to move through a plurality of curved configurations.
[0006] In an additional variation, causing the working end to move from a linear configuration to the curved configuration comprises actuating a handle mechanism to move the working end from the linear configuration to the curved configuration. The handle mechanism can be moved axially and/or rotationally as described herein.
[0007] In one variation, actuating of the handle mechanism causes the working end to move to the first curved configuration without torquing the third sleeve.
[0008] In additional variations, the working end of the osteotome or tool is spring biased to assume the linear configuration.
[0009] The working end can move from the linear configuration to the curved configuration by applying a driving force or impact to the elongate tool wherein penetration in the cortical bone moves the working end from the linear configuration to the curved configuration. For example, as a hammering or impact force is applied to the working end, the interaction of the sharp tip against bone causes the working end to assume an articulated and/or curved configuration. Where further axial movement of the tool causes compression of the bone and creation of the cavity.
[0010] The method can further include the use of one or more cannulae to introduce the tool into the target region. Such a cannula can maintain the tool in a straight or linear configuration until the tool advances out of the cannula or until the cannula is withdrawn from over the tool.
[0011] As described herein, upon creation of the cavity, the method can further include the insertion of a filler material or other substance into the cavity. The filler material can be delivered through the tool or through a separate cannula or catheter.
[0012] This disclosure also includes variations of devices for creating a cavity within bone or hard tissue. Such variations include devices for treating a vertebral body or other such structure. In one variation a device includes a handle having an actuating portion; a shaft comprising a first sleeve located concentrically within a second sleeve and a third sleeve located concentrically about the second sleeve, the shaft having a distal portion comprising a working end capable of moving between a linear configuration and an articulated configuration where the second articulated configuration is limited to a single plane, and where each sleeve comprises a series of slots or notches to limit deflection of the working end to the articulated configuration, where the respective series of slots or notches are radially offset in each sleeve; and a sharp tip located at a distal tip of the working end, the sharp tip adapted to penetrate vertebral bone within the vertebral body.
[0013] In one variation, the devices described herein can include a configuration where the first sleeve is affixed to the second sleeve at the working end such that proximal movement of the first sleeve causes the working end to assume the articulated configuration. The sleeves can be affixed at any portion along their length via a mechanical fixation means (e.g., a pin or other fixation means), an adhesive, or one or more weld points. In some variations, fixation of the sleeves occurs at the working end so that movement of the inner or first sleeve causes the working end to assume the curved configuration. In some cases, the third sleeve can be affixed outside of the working end so long as when the first and second sleeves articulate, the third sleeve still articulates.
[0014] Devices described herein can optionally include a force-limiting assembly coupled between the actuating portion and the first sleeve such that upon reaching a threshold force, the actuating portion disengages the first sleeve. In one variation, the force-limiting mechanism is adapted to limit force applied to bone when moving the working end from the first configuration toward the second configuration.
[0015] In additional variations, devices for creating cavities in bone or hard tissue can include one or more spring elements that extending through the first sleeve, where the spring element is affixed to the shaft (within or about either the first, second, or third sleeve). Such spring elements cause the working end to assume a linear configuration in a relaxed state.
[0016] In additional variations, a device can include an outer or third sleeve where the slots or notches (that allow deflection) are located on an exterior surface of the third sleeve. The exterior surface is typically the surface that faces outward from a direction of the curved configuration. This configuration allows for an interior surface (the surface located on the interior of the curved portion) to be smooth. As a result, if the device is withdrawn through tissue or a cannula or other introducer, the smooth surface on the interior of the curve minimizes the chance that the device becomes caught on the opening of the cannula or any other structure.
[0017] Variations of the device can include one or more lumens that extend through the shaft and working end. These lumens can exit at a distal tip of the device or through a side opening in a wall of the device. The lumen can include a surface comprising a lubricious polymeric material. For example, the material can comprise any bio-compatible material having low frictional properties (e.g., TEFLON®, a polytetrafluroethylene (PTFE), FEP (Fluorinated ethylenepropylene), polyethylene, polyamide, ECTFE (Ethylenechlorotrifluoro-ethylene), ETFE, PVDF, polyvinyl chloride and silicone).
[0018] As described herein, the devices can include any number of configurations to prevent rotation between adjacent sleeves but allow axial movement between the sleeves. For example, the sleeves can be mechanically coupled via a pin/slot or key/keyway configuration. In an additional variation, the sleeves can be non-circular to prevent rotation.
[0019] In an additional variation, the disclosure includes various kits comprising the device described herein as well as a filler material (e.g., a bone cement or other bone filler material).
[0020] Variations of the access device and procedures described above include combinations of features of the various embodiments or combination of the embodiments themselves wherever possible.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is a plan view of an osteotome of the invention.
[0022] FIG. 2 is a side view of the osteotome of FIG. 1 .
[0023] FIG. 3 is a cross sectional view of the osteotome of FIG. 1 .
[0024] FIG. 4 is an enlarged sectional view of the handle of the osteotome of FIG. 1 .
[0025] FIG. 5 is an enlarged sectional view of the working end of the osteotome of FIG. 1 .
[0026] FIG. 6A is a sectional view of the working end of FIG. 5 in a linear configuration.
[0027] FIG. 6B is a sectional view of the working end of FIG. 5 in a curved configuration.
[0028] FIGS. 7A-7C are schematic sectional views of a method of use of the osteotome of FIG. 1 .
[0029] FIG. 8 is another embodiment of an osteotome working end.
[0030] FIG. 9 is another embodiment of an osteotome working end.
[0031] FIG. 10 is another variation of an osteotome with an outer sleeve.
[0032] FIG. 11 is a cut-away view of the working end of the osteotome of FIG. 10 .
[0033] FIG. 12A is sectional view of another embodiment of working end, taken along line 12 A- 12 A of FIG. 11 .
[0034] FIGS. 12B and 12C illustrate additional variations of preventing rotation between adjacent sleeves.
[0035] FIG. 13 is sectional view of another working end embodiment similar to that of FIG. 11 .
[0036] FIG. 14 is a cut-away perspective view of the working end of FIG. 13 .
[0037] FIG. 15 illustrates a variation of an osteotome as described herein having electrodes on a tip of the device and another electrode on the shaft.
[0038] FIG. 16 illustrates an osteotome device as shown in FIG. 15 after being advanced into the body and where current passes between electrodes.
[0039] FIG. 17 illustrates a variation of a device as described herein further including a connector for providing energy at the working end of the device.
[0040] FIGS. 18A and 18B illustrate a device having a sharp tip as disclosed herein where the sharp tip is advanceable from the distal end of the shaft.
[0041] FIG. 19 shows a cross sectional view of the device illustrated in FIG. 18B and also illustrates temperature sensing elements located on device.
[0042] FIG. 20 shows a variation of a device where the inner sleeve is extended from the device and where current is applied between the extended portion of the inner sleeve and the shaft to treat tissue.
DETAILED DESCRIPTION
[0043] Referring to FIGS. 1-5 , an apparatus or osteotome 100 is shown that is configured for accessing the interior of a vertebral body and for creating a pathway in vertebral cancellous bone to receive bone cement. In one embodiment, the apparatus is configured with an extension portion or member 105 for introducing through a pedicle and wherein a working end 110 of the extension member can be progressively actuated to curve a selected degree and/or rotated to create a curved pathway and cavity in the direction of the midline of the vertebral body. The apparatus can be withdrawn and bone fill material can be introduced through a bone cement injection cannula. Alternatively, the apparatus 100 itself can be used as a cement injector with the subsequent injection of cement through a lumen 112 of the apparatus.
[0044] In one embodiment, the apparatus 100 comprises a handle 115 that is coupled to a proximal end of the extension member 105 . The extension member 105 comprises an assembly of first (outer) sleeve 120 and a second (inner) sleeve 122 , with the first sleeve 120 having a proximal end 124 and distal end 126 . The second sleeve 122 has a proximal end 134 and distal end 136 . The extension member 105 is coupled to the handle 115 , as will be described below, to allow a physician to drive the extension member 105 into bone while contemporaneously actuating the working end 110 into an actuated or curved configuration (see FIG. 6 ). The handle 115 can be fabricated of a polymer, metal or any other material suitable to withstand hammering or impact forces used to drive the assembly into bone (e.g., via use of a hammer or similar device on the handle 115 ). The inner and outer sleeves are fabricated of a suitable metal alloy, such as stainless steel or NiTi. The wall thicknesses of the inner and outer sleeves can range from about 0.005″ to 0.010″ with the outer diameter the outer sleeve ranging from about 2.5 mm to 5.0 mm.
[0045] Referring to FIGS. 1 , 3 and 4 , the handle 115 comprises both a first grip portion 140 and a second actuator portion indicated at 142 . The grip portion 140 is coupled to the first sleeve 120 as will be described below. The actuator portion 142 is operatively coupled to the second sleeve 122 as will be described below. The actuator portion 142 is rotatable relative to the grip portion 140 and one or more plastic flex tabs 145 of the grip portion 140 are configured to engage notches 146 in the rotatable actuator portion 142 to provide tactile indication and temporary locking of the handle portions 140 and 142 in a certain degree of rotation. The flex tabs 145 thus engage and disengage with the notches 146 to permit ratcheting (rotation and locking) of the handle portions and the respective sleeve coupled thereto.
[0046] The notches or slots in any of the sleeves can comprise a uniform width along the length of the working end or can comprise a varying width. Alternatively, the width can be selected in certain areas to effectuate a particular curved profile. In other variation, the width can increase or decrease along the working end to create a curve having a varying radius. Clearly, it is understood that any number of variations are within the scope of this disclosure.
[0047] FIG. 4 is a sectional view of the handle showing a mechanism for actuating the second inner sleeve 122 relative to the first outer sleeve 120 . The actuator portion 142 of the handle 115 is configured with a fast-lead helical groove indicated at 150 that cooperates with a protruding thread 149 of the grip portion 140 of the handle. Thus, it can be understood that rotation of the actuation portion 142 will move this portion to the position indicated at 150 (phantom view). In one embodiment, when the actuator portion 142 is rotated a selected amount from about 45° to 720°, or from about 90° to 360°, the inner sleeve 122 is lifted proximally relative to the grip portion 140 and outer sleeve 120 to actuate the working end 110 . As can be seen in FIG. 4 the actuator portion 142 engages flange 152 that is welded to the proximal end 132 of inner sleeve 122 . The flange 152 is lifted by means of a ball bearing assembly 154 disposed between the flange 152 and metal bearing surface 155 inserted into the grip portion 140 of the handle. Thus, the rotation of actuator 142 can lift the inner sleeve 122 without creating torque on the inner sleeve.
[0048] Now turning to FIGS. 5 , 6 A and 6 B, it can be seen that the working end 110 of the extension member 105 is articulated by cooperating slotted portions of the distal portions of outer sleeve 120 and inner sleeve 122 that are both thus capable of bending in a substantially tight radius. The outer sleeve 120 has a plurality of slots or notches 162 therein that can be any slots that are perpendicular or angled relative to the axis of the sleeve. The inner sleeve 122 has a plurality of slots or notches indicated at 164 that can be on an opposite side of the assembly relative to the slots 162 in the outer sleeve 120 . The outer and inner sleeves are welded together at the distal region indicated at weld 160 . It thus can be understood that when inner sleeve 122 is translated in the proximal direction, the outer sleeve will be flexed as depicted in FIG. 6B . It can be understood that by rotating the actuator handle portion 142 a selected amount, the working end can be articulated to a selected degree.
[0049] FIGS. 4 , 5 , 6 A and 6 B further illustrate another element of the apparatus that comprises a flexible flat wire member 170 with a proximal end 171 and flange 172 that is engages the proximal side of flange 152 of the inner sleeve 122 . At least the distal portion 174 of the flat wire member 170 is welded to the inner sleeve at weld 175 . This flat wire member thus provides a safety feature to retain the working end in the event that the inner sleeve fails at one of the slots 164 .
[0050] Another safety feature of the apparatus comprises a torque limiter and release system that allows the entire handle assembly 115 to freely rotate for example if the working end 110 is articulated, as in FIG. 6B , when the physician rotates the handle and when the working end is engaged in strong cancellous hone. Referring to FIG. 4 , the grip portion 142 of the handle 115 engages a collar 180 that is fixed to a proximal end 124 of the outer sleeve 120 . The collar 180 further comprises notches 185 that are radially spaced about the collar and are engaged by a ball member 186 that is pushed by a spring 188 into notches 185 . At a selected force, for example a torque ranging from greater than about 0.5 inch*lbs but less that about 7.5 inch*lbs, 5.0 inch*lbs or 2.5 inch*lbs, the rotation of the handle 115 overcomes the predetermined limit. When the torque limiter assembly is in its locked position, the ball bearing 186 is forced into one of the notches 185 in the collar 180 . When too much torque is provided to the handle and outer sleeve, the ball bearing 186 disengages the notch 185 allowing the collar 180 to turn, and then reengages at the next notch, releasing anywhere from 0.5 inch*lbs to 7.5 inch*lbs of torque.
[0051] Referring to FIGS. 6A and 6B , it can be understood that the inner sleeve 122 is weakened on one side at its distal portion so as to permit the inner sleeve 122 to bend in either direction but is limited by the location of the notches in the outer sleeve 120 . The curvature of any articulated configuration is controlled by the spacing of the notches as well as the distance between each notch peak. The inner sleeve 122 also has a beveled tip for entry through the cortical bone of a vertebral body. Either the inner sleeve or outer sleeve can form the distal tip.
[0052] Referring to FIGS. 7A-7C , in one variation of use of the device, a physician taps or otherwise drives a stylet 200 and introducer sleeve 205 into a vertebral body 206 typically until the stylet tip 208 is within the anterior ⅓ of the vertebral body toward cortical bone 210 ( FIG. 7A ). Thereafter, the stylet 200 is removed and the sleeve 205 is moved proximally ( FIG. 7B ). As can be seen in FIG. 7B , the tool or osteotome 100 is inserted through the introducer sleeve 205 and articulated in a series of steps as described above. The working end 110 can be articulated intermittently while applying driving forces and optionally rotational forces to the handle 115 to advance the working end through the cancellous bone 212 to create path or cavity 215 . The tool is then tapped to further drive the working end 110 to, toward or past the midline of the vertebra. The physician can alternatively articulate the working end 110 , and drive and rotate the working end further until imaging shows that the working end 100 has created a cavity 215 of an optimal configuration. Thereafter, as depicted in FIG. 7C , the physician reverses the sequence and progressively straightens the working end 110 as the extension member is withdrawn from the vertebral body 206 . Thereafter, the physician can insert a bone cement injector 220 into the path or cavity 215 created by osteotome 100 . FIG. 7C illustrates a bone cement 222 , for example a PMMA cement, being injected from a bone cement source 225 .
[0053] In another embodiment (not shown), the apparatus 100 can have a handle 115 with a Luer fitting for coupling a bone cement syringe and the bone cement can be injected through the lumen 112 of the apparatus. In such an embodiment FIG. 9 , the lumen can have a lubricious surface layer or polymeric lining 250 to insure least resistance to bone cement as it flows through the lumen. In one embodiment, the surface or lining 250 can be a fluorinated polymer such as TEFLON® or polytetrafluroethylene (PTFE). Other suitable fluoropolymer resins can be used such as FEP and PFA. Other materials also can be used such as FEP (Fluorinated ethylenepropylene), ECTFE (Ethylenechlorotrifluoro-ethylene), ETFE, Polyethylene, Polyamide, PVDF, Polyvinyl chloride and silicone. The scope of the invention can include providing a polymeric material having a static coefficient of friction of less than 0.5, less than 0.2 or less than 0.1.
[0054] FIG. 9 also shows the extension member or shaft 105 can be configured with an exterior flexible sleeve indicated at 255 . The flexible sleeve can be any commonly known biocompatible material, for example, the sleeve can comprise any of the materials described in the preceding paragraph.
[0055] As also can be seen in FIG. 9 , in one variation of the device 100 , the working end 110 can be configured to deflect over a length indicated at 260 in a substantially smooth curve. The degree of articulation of the working end 100 can be at least 45°, 90°, 135° or at least 180° as indicated at 265 ( FIG. 9 ). In additional variations, the slots of the outer 120 and inner sleeves 120 can be varied to produce a device having a radius of curvature that varies among the length 260 of the device 100 .
[0056] In another embodiment of the invention, the inner sleeve can be spring loaded relative the outer sleeve, in such a way as to allow the working end to straighten under a selected level of force when pulled in a linear direction. This feature allows the physician to withdraw the assembly from the vertebral body partly or completely without further rotation the actuating portion 142 of handle 115 . In some variations, the force-limiter can be provided to allow less than about 10 inch*lbs of force to be applied to bone.
[0057] In another embodiment shown in FIG. 8 , the working end 110 is configured with a tip 240 that deflects to the position indicated at 240 ′ when driven into bone. The tip 240 is coupled to the sleeve assembly by resilient member 242 , for example a flexible metal such as stainless steel or NiTi. It has been found that the flexing of the tip 240 causes its distal surface area to engage cancellous bone which can assist in deflecting the working end 110 as it is hammered into bone.
[0058] In another embodiment of the invention (not shown), the actuator handle can include a secondary (or optional) mechanism for actuating the working end. The mechanism would include a hammer-able member with a ratchet such that each tap of the hammer would advance assembly and progressively actuate the working end into a curved configuration. A ratchet mechanism as known in the art would maintain the assembly in each of a plurality of articulated configurations. A release would be provided to allow for release of the ratchet to provide for straightening the extension member 105 for withdrawal from the vertebral body.
[0059] FIGS. 10 and 11 illustrate another variation of a bone treatment device 400 with a handle 402 and extension member 405 extending to working end 410 having a similar construction to that FIGS. 1 to 6B . The device 400 operates as described previously with notched first (outer) sleeve 120 and cooperating notched second (inner) sleeve 122 . However, the variation shown in FIGS. 10 and 11 also includes a third concentric notched sleeve 420 , exterior to the first 120 and second 122 sleeves. The notches or slots in sleeve 420 at the working end 410 permit deflection of the sleeve as indicated at 265 in FIG. 11 .
[0060] FIG. 10 also illustrates the treatment device 400 as including a luer fitting 412 that allows the device 402 to be coupled to a source of a filler material (e.g., a bone filler or bone cement material). The luer can be removable from the handle 402 to allow application of an impact force on the handle as described above. Moreover, the luer fitting 402 can be located on the actuating portion of the handle, the stationary part of the handle or even along the sleeve. In any case, variations of the device 400 permit coupling the filler material with a lumen extending through the sleeves (or between adjacent sleeves) to deposit filler material at the working end 410 . As shown by arrows 416 , filler material can be deposited through a distal end of the sleeves (where the sharp tip is solid) or can be deposited through openings in a side-wall of the sleeves. Clearly, variations of this configuration are within the scope of those familiar in the field.
[0061] In some variations, the third notched sleeve 420 is configured with its smooth (non-notched) surface 424 disposed to face inwardly on the articulated working end ( FIG. 11 ) such that a solid surface forms the interior of the curved portion of the working end 410 . The smooth surface 424 allows withdrawal of the device 110 into a cannula or introducer 205 without creating a risk that the slots or notches become caught on a cannula 205 (see e.g., FIG. 7B ).
[0062] As shown in FIGS. 10-11 , the third (outermost) sleeve 420 can extend from an intermediate location on the extension member 405 to a distal end of the working end 410 . However, variations of the device include the third sleeve 420 extending to the handle 402 . However, the third sleeve 420 is typically not coupled to the handle 402 so that any rotational force or torque generated by the handle 402 is not directly transmitted to the third sleeve 420 .
[0063] In one variation, the third sleeve 420 is coupled to the second sleeve 120 at only one axial location. In the illustrated example shown in FIG. 11 , the third sleeve 420 is affixed to second sleeve 420 by welds 428 at the distal end of the working end 410 . However, the welds or other attachment means (e.g., a pin, key/keyway, protrusion, etc.) can be located on a medial part of the sleeve 420 . The sleeve 420 can be fabricated of any bio-compatible material. For example, in one variation, the third sleeve is fabricated form a 3.00 mm diameter stainless steel material with a wall thickness of 0.007″. The first, second and third sleeves are sized to have dimensions to allow a sliding fit between the sleeves.
[0064] FIG. 12A is a sectional view of extension member 405 of another variation, similar to that shown in FIGS. 10-11 . However, the variation depicted by FIG. 12A comprises non-round configurations of concentric slidable sleeves (double or triple sleeve devices). This configuration limits or prevents rotation between the sleeves and allows the physician to apply greater forces to the bone to create a cavity. While FIG. 12A illustrates an oval configuration, any non-round shape is within the scope of this disclosure. For example, the cross-sectional shape can comprise a square, polygonal, or other radially keyed configuration as shown in FIGS. 12B and 12C . As shown in FIG. 12C the sleeves can include a key 407 and a receiving keyway 409 to prevent rotation but allow relative or axial sliding of the sleeves. The key can comprise any protrusion or member that slides within a receiving keyway. Furthermore, the key can comprise a pin or any raised protrusion on an exterior or interior of a respective sleeve. In this illustration, only the first 122 and second 120 sleeves are illustrated. However, any of the sleeves can be configured with the key/keyway. Preventing rotation between sleeves improves the ability to apply force to bone at the articulated working end.
[0065] FIGS. 13-14 illustrate another variation of a working end 410 of an osteotome device. In this variation, the working end 410 includes one or more flat spring elements 450 , 460 a , 460 b , 460 c , 460 d , that prevent relative rotation of the sleeves of the assembly thus allowing greater rotational forces to be applied to cancellous bone from an articulated working end. The spring elements further urge the working end assembly into a linear configuration. To articulate the sleeves, a rotational force is applied to the handle as described above, once this rotational force is removed, the spring elements urge the working end into a linear configuration. As shown in FIG. 13 , one or more of the spring elements can extend through the sleeves for affixing to a handle to prevent rotation. Furthermore, the distal end 454 of flat spring element 450 is fixed to sleeve assembly by weld 455 . Thus, the spring element is fixed at each end to prevent its rotation. Alternate variations include one or more spring elements being affixed to the inner sleeve assembly at a medial section of the sleeve.
[0066] As shown in FIGS. 13-14 , variations of the osteotome can include any number of spring elements 460 a - 460 d . These additional spring elements 460 a - 460 d can be welded at either a proximal or distal end thereof to an adjacent element or a sleeve to allow the element to function as a leaf spring.
[0067] In an additional variation, the osteotome device can include one or more electrodes 310 , 312 as shown in FIG. 15 . In this particular example, the device 300 includes spaced apart electrodes having opposite polarity to function in a bi-polar manner. However, the device can include a monopolar configuration. Furthermore, one or more electrodes can be coupled to individual channels of a power supply so that the electrodes can be energized as needed. Any variation of the device described above can be configured with one or more electrodes as described herein.
[0068] FIG. 16 illustrates an osteotome device 300 after being advanced into the body as discussed above. As shown by lines 315 representing current flow between electrodes, when required, the physician can conduct RF current between electrodes 310 and 312 to apply coagulative or ablative energy within the bone structure of the vertebral body (or other hard tissue). While FIG. 16 illustrates RF current 315 flow between electrodes 310 and 312 , variations of the device can include a number of electrodes along the device to apply the proper therapeutic energy. Furthermore, an electrode can be spaced from the end of the osteotome rather than being placed on the sharp tip as shown by electrode 310 . In some variations, the power supply is coupled to the inner sharp tip or other working end of the first sleeve. In those variations with only two sleeves, the second pole of the power supply is coupled with the second sleeve (that is the exterior of the device) to form a return electrode. However, in those variations having three sleeves, the power supply can alternatively be coupled with the third outer sleeve. In yet additional variations, the second and third sleeves can both function as return electrodes. However, in those devices that are monopolar, the return electrode will be placed outside of the body on a large area of skin.
[0069] FIGS. 17 to 20 illustrate another variation of an articulating probe or osteotome device 500 . In this variation, the device 500 includes a working end 505 that carries one or more RF electrodes that can be used to conduct current therethrough. Accordingly, the device can be used to sense impedance of tissue, locate nerves, or simply apply electrosurgical energy to tissue to coagulate or ablate tissue. In one potential use, the device 500 can apply ablative energy to a tumor or other tissue within the vertebra as well as create a cavity.
[0070] FIGS. 17 , 18 A, 18 B and 19 , illustrate a variation of the device 500 as having a handle portion 506 coupled to a shaft assembly 510 that extends along axis 512 to the articulating working end 505 . The articulating working end 505 can be actuatable as described above. In addition, FIG. 17 shows that handle component 514 a can be rotated relative to handle component 514 b to cause relative axial movement between a first outer sleeve 520 and second inner sleeve 522 ( FIG. 19 ) to cause the slotted working ends of the sleeve assembly to articulate as described above. The working end 505 of FIG. 19 shows two sleeves 520 and 522 that are actuatable to articulate the working end, but it should be appreciated that a third outer articulating sleeve can be added as depicted above. In one variation, the articulating working end can articulate 90° by rotating handle component 514 a between ¼ turn and ¾ turn. The rotating handle component 514 a can include detents at various rotational positions to allow for controlled hammering of the working end into bone. For example, the detents can be located at every 45° rotation or can be located at any other rotational increment.
[0071] FIG. 17 depict an RF generator 530 A and RF controller 530 B connectable to an electrical connector 532 in the handle component 514 a with a plug connector indicated at 536 . The RF generator is of the type known in the art for electrosurgical ablation. The outer sleeve 520 comprises a first polarity electrode indicated at 540 A (+). However, any energy modality can be employed with the device.
[0072] FIGS. 18A and 18B illustrate yet another variation of a working end of a device for creating cavities in hard tissue. As shown, the device 500 can include a central extendable sleeve 550 with a sharp tip 552 that is axially extendable from passageway 554 of the assembly of first and second sleeves 520 and 522 ( FIG. 19 ). The sleeve 550 can also include a second polarity electrode indicated at 540 B (−). Clearly, the first and second electrodes will be electrically insulated from one another. In one variation, and as shown in FIG. 19 , the sleeve assembly can carry a thin sleeve 555 or coating of an insulative polymer such as PEEK to electrically isolate the first polarity electrode 540 A (+) from the second polarity electrode 540 B (−). The electrode can be deployed by rotating knob 558 on the striking surface of handle component 514 a ( FIG. 17 ). The degree of extension of central sleeve 550 can optionally be indicated by a slider tab 557 on the handle. In the illustrated variation, the slider tab is located on either side of handle component 514 a ( FIG. 17 ). Sleeve 550 can be configured to extend distally beyond the assembly of sleeves 520 and 522 a distance of about 5 to 15 mm.
[0073] Referring to FIG. 19 , the central extendable sleeve 550 can have a series of slots in at least a distal portion thereof to allow it to bend in cooperation with the assembly of first and second sleeves 520 and 522 . In the embodiment shown in FIG. 18B , the central sleeve 550 can optionally include a distal portion that does not contain any slots. However, additional variations include slots on the distal portion of the sleeve.
[0074] FIG. 19 further depicts an electrically insulative collar 560 that extends length A to axially space apart the first polarity electrode 540 A (+) from the second polarity electrode 540 B (−). The axial length A can be from about 0.5 to 10 mm, and usually is from 1 to 5 mm. The collar can be a ceramic or temperature resistant polymer.
[0075] FIG. 19 also depicts a polymer sleeve 565 that extends through the lumen in the center of electrode sleeve 550 . The polymer sleeve 565 can provide saline infusion or other fluids to the working end and/or be used to aspirate from the working end when in use. The distal portion of sleeve 550 can include one or more ports 566 therein for delivering fluid or aspirating from the site.
[0076] In all other respects, the osteotome system 500 can be driven into bone and articulated as described above. The electrodes 540 A and 540 B are operatively coupled to a radiofrequency generator as is known in the art for applying coagulative or ablative electrosurgical energy to tissue. In FIG. 20 , it can be seen that RF current 575 is indicated in paths between electrodes 540 A and 540 B as shown by lines 575 . RF generator 530 A and controller 530 B for use with the devices described herein can include any number of power settings to control the size of targeted coagulation or ablation area. For example, the RF generator and controller can have Low (5 watts), medium (15 Watts) and High (25 watts) power settings. The controller 530 B can have a control algorithm that monitors the temperature of the electrodes and changes the power input in order to maintain a constant temperature. At least one temperature sensing element (e.g., a thermocouple) can be provided on various portions of the device. For example, and as shown in FIG. 19 , a temperature sensing element 577 can be provided at the distal tip of sleeve 550 tip while a second temperature sensing element 578 can be provided proximal from the distal tip to provide temperature feedback to the operator to indicate the region of ablated tissue during the application of RF energy. In one example, the second temperature sensing element was located approximately 15 to 20 mm from the distal tip.
[0077] Although particular embodiments of the present invention have been described above in detail, it will be understood that this description is merely for purposes of illustration and the above description of the invention is not exhaustive. Specific features of the invention are shown in some drawings and not in others, and this is for convenience only and any feature may be combined with another in accordance with the invention. A number of variations and alternatives will be apparent to one having ordinary skills in the art. Such alternatives and variations are intended to be included within the scope of the claims. Particular features that are presented in dependent claims can be combined and fall within the scope of the invention. The invention also encompasses embodiments as if dependent claims were alternatively written in a multiple dependent claim format with reference to other independent claims.
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Methods and devices that displace bone or other hard tissue to create a cavity in the tissue. Where such methods and devices rely on a driving mechanism for providing moving of the device to form a profile that improves displacement of the tissue. These methods and devices also allow for creating a path or cavity in bone for insertion of bone cement or other filler to treat a fracture or other condition in the bone. The features relating to the methods and devices described herein can be applied in any region of bone or hard tissue where the tissue or bone is displaced to define a bore or cavity instead of being extracted from the body such as during a drilling or ablation procedure.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a dielectric material useful in plasma display panels (PDPs) and, in particular, to a dielectric composition used for forming a light transparent dielectric layer on a front glass plate of a high strain point in PDPs.
[0002] A plasma display panel is known as a self-luminescent type flat display having excellent properties of such as a small weight, a thin type etc. and draws considerable attention because of its possibility of a large screen face.
[0003] Generally speaking, a PDP has a front glass plate on which a plurality of electrodes are disposed for generating plasma discharge by cooperation with electrodes deposited on a rear glass plate confronting the front glass plate with a gap therebetween. A light transparent dielectric layer is formed with a thickness of about 30-40 micrometers on the glass plate to cover the electrodes so as to maintain the plasma discharge generated.
[0004] Usually, the front glass plate is made of soda-lime glass or other high strain point glass and Ag is used for the electrodes, while the light transparent dielectric layer is formed from dielectric material comprising low fusion point glass powder, for example, high Pb-content glass powder.
[0005] When forming the light transparent dielectric layer, the dielectric material is fired or baked at the softening point of the low-fusion point glass powder so as to avoid the reaction with metal of the electrodes.
[0006] However, the conventional dielectric material has a problem that the glass powder and the Ag electrodes react with each other to make the dielectric layer color (change to yellow).
[0007] Further, it is important as known in the art that the dielectric material has various properties such as (1) thermal expansion coefficient compatible with glass plate, (2) firing temperature at 500-600° C., (3) excellent defoamability in firing to produce the dielectric layer of high light transmittance and high withstand voltage with a reduced amount of bubbles.
[0008] JP-A 11-21148 discloses a dielectric material using a glass powder of PbO—B 2 O 3 —SiO 2 —BaO glass which has the thermal expansion coefficient compatible with that of the high strain point glass plate. The PbO—B 2 O 3 —SiO 2 —BaO glass is rapid in viscosity change across the softening point and is, therefore, readily defoamed.
[0009] Although the dielectric material using PbO—B 2 O 3 —SiO 2 —BaO glass powder can provide a dielectric layer having a high light transmittance because of its excellent defoamability, it has a problem that the produced dielectric layer has residual large bubbles having diameters of 30 μm (micrometers) or more.
SUMMARY OF THE INVENTION
[0010] It is an object of this invention to provide a dielectric material which is useful for providing a light transparent dielectric layer hardly reacting with Ag electrodes in PDPs thereby not to make color change.
[0011] It is another object of this invention to provide a dielectric material which is compatible with the high strain point glass plate in the thermal expansion coefficient, defoamable in firing about the softening point, and able to provide a light transparent dielectric layer without large bubbles left therein.
[0012] According to this invention, a dielectric composition for use in formation of a dielectric layer in a plasma display panel is obtained which comprises a powder material. The powder material comprises a powder of glass characterized by containing PbO of 50% or less and CuO as one of essential elements contained in the glass.
[0013] A content of CuO is preferably 0.01-20% by weight.
[0014] According to an embodiment of this invention, the glass consists essentially of, by weight, a total amount of 2-30% of BaO, CaO and Bi 2 O 3 , 0-35% ZnO, 10-40% B 2 O 3 , 1-15% SiO 2 , 25-50% PbO, and 0.01-20% CuO.
[0015] According to another embodiment, the glass consists essentially of, by weight, 15-45% BaO, 20-45% ZnO, 12-35% B 2 O 3 , 3-15% SiO 2 , 0-24.5% PbO and 0.01-20% CuO.
[0016] According to another embodiment of this invention, the glass consists essentially of, by weight, 25-45% ZnO, 15-35% Bi 2 O 3 , 10-30% B 2 O 3 , 0.5-8% SiO 2 , a total amount of 8-24% of CaO, SrO and BaO, and 0.01-20% CuO.
[0017] According to another embodiment, the glass consists essentially of, by weight, 26-60% B 2 O 3 , 15-50% ZnO, 0-30% SiO 2 , 0-10% Al 2 O 3 , 3-20% K 2 O, a total amount of 0-10% of Na 2 O and Li 2 O, a total amount of 0-15% of CaO and BaO, and 0.01-20% CuO.
[0018] The glass powder preferably has an average particle size D50 of 3.0 micrometers (μm) or less, and the maximum particle size Dmax of 20 micrometers (μm) or less.
[0019] According to another aspect of this invention, the dielectric composition is a paste which comprises, by weight, the powder material of 30-90%, binder of 0.1 -20%, plasticizer of 0-10%, and solvent of 10-30%.
[0020] In an embodiment, the binder is at least one selected from a group of poly butyl methacrylate, polyvinyl butyral, poly methyl methacrylate, poly ethyl methacrylate, and ethyl cellulose. The plasticizer is at least one selected from a group of butyl benzyl phthalate, dioctyl phthalate, di-isooctyl phthalate, dicapryl phthalate, and dibutyl phthalate. The solvent is at least one selected from a group of terpineol, diethylene glycol monobutyl ether acetate, and 2,2,4-trymethyl-1,3-pentanediolmonoisobutylate.
[0021] According to another aspect of this invention, the dielectric composition is a green sheet which comprises, by weight, the powder material of 60-80%, the binder of 5-30%, and the plasticizer of 0-10%.
[0022] The glass powder can be mixed with ceramics powder selected from a group of alumina, zircon, zirconia, and titania (titanium oxide), to form an admixture. The admixture comprises the glass powder of 90-100 weight % and the ceramics powder of 0-10 weight %.
DESCRIPTION OF THE INVENTION
[0023] In order to prevent not only many fine bubbles but also large bubbles having a diameter of 30 μm or more from remaining in the dielectric layer formed by use of the dielectric composition, it is important to use glass having PbO content of 50 wt. % or less. Specifically, in case of PbO content more than 50 wt. %, glass composition containing SiO 2 of a relatively large amount is, on one side, excessively slow in viscosity change at the firing temperature to expel bubbles so that the dielectric layer has many fine bubbles, and glass composition containing SiO 2 of a relatively small amount is, on the other side, excessively rapid in viscosity change to promote growth of bubbles so that large bubbles remain in the dielectric layer formed.
[0024] The dielectric composition according to this invention includes, as a main component, powder of CuO containing glass. Inclusion of CuO in the glass as an essential ingredient makes the formed dielectric layer hardly change to yellow even when Ag is used for the electrode material. Therefore, the dielectric layer formed has a high light transmittance.
[0025] An example of glass of the glass powder consists essentially of, by weight, a total amount of 2-30% of BaO, CaO and Bi 2 O 3 , 0-35% ZnO, 10-40% B 2 O 3 , 1-15% SO 2 , 25-50% PbO, and 0.01-20% CuO. The glass will be referred to as glass A and has properties that the viscosity change is rapid across the softening point so that bubbles are expelled at a relatively low temperature at a start of the firing operation, thus less fine bubbles remaining in the dielectric layer formed.
[0026] In the glass A, BaO, CaO and Bi 2 O 3 are contained for lowering the softening point of the glass and for adjusting viscosity at a high temperature to affect defoamability of the glass. The total content of BaO, CaO and Bi 2 O 3 is 2-30%, preferably 3-25%, by weight. If the total content is less than 2%, the intended function of these elements described above cannot be achieved. The total content more than 30% excessively lowers the softening point to promote foamability as well as elevates the thermal expansion coefficient of the resultant glass. Individual contents of BaO, CaO and Bi 2 O 3 are preferably 2-30%, 0-10%, and 0-10%, respectively.
[0027] ZnO is an element for lowering the softening point and adjusting the thermal expansion coefficient of the glass. The content of ZnO is selected at 0-35% by weight, preferably 5-30%. When the content is selected at more than 35%, the resultant glass is easily devitrified in firing operation.
[0028] B 2 O 3 is a glass forming element for widening a vitrification range of a composition. The content should be 10-40% by weight, preferably 15-35%. B 2 O 3 contents less than 10% makes vitrification difficult. When the content is more than 40%, the resultant glass is easily brought into phase separation.
[0029] SiO 2 is also a glass forming element and should be selected, in content, at 1-15% by weight, preferably 2-13%. SiO 2 content less than 1% makes vitrification difficult. Use of SiO 2 more than 15% excessively raises the resultant glass in the softening point to excessively slow the viscosity change across the softening point so that degassing becomes difficult.
[0030] PbO is an element for lowering the softening point of the glass and should be selected at contents of 25-50% by weight, preferably 28-50%. If the content of PbO is selected at less than 25%, the resultant glass has a high softening point and many bubbles possibly remain in the dielectric layer fired. If the content of PbO is selected at more than 50%, the thermal expansion coefficient is excessively high, and the viscosity change of the resultant glass is excessively rapid across the softening point to promote growth of bubbles, this resulting in residual large bubbles remaining in the fired layer. The fired dielectric layer has a low withstand voltage or low insulating strength and is thereby readily brought into insulation failure.
[0031] CuO content should be selected at 0.01-20% by weight, preferably 0.1-15%. If the content is less than 0.01%, it is difficult to prevent the fired dielectric layer from changing into yellow due to reaction with Ag electrode in PDP. CuO content more than 20% lowers the water resistance of the resultant glass.
[0032] Another example of glass of the glass powder consists essentially of, by weight, 15-45% BaO, 20-45% ZnO, 12-35% B 2 O 3 , 3-15% SiO 2 , 0-24.5% PbO and 0.01-20% CuO.
[0033] The glass is referred to as glass B and has properties that the viscosity change across the softening point is adjusted to be slower than that in glass A so that residual bubbles not expelled at the start of the firing operation are prevented from growing into large bubbles by temperature elevation as the firing operation progresses. Therefore, use of powder of glass B effectively reduces number of residual large bubbles in the dielectric layer formed by firing the dielectric composition.
[0034] In glass B, BaO is an element for adjusting viscosity at a high temperature to affect defoamability of the glass and for elevating the thermal expansion coefficient of the glass. The content of BaO is 15-45%, preferably 20-40%, by weight. BaO content less than 15% lowers the defoamability and also lowers the thermal expansion coefficient of the resultant glass to an excessively low level which is not compatible with that of the high strain point glass plate. If BaO content is more than 45%, the resultant glass has an excessively high thermal expansion coefficient which is not compatible with that of the high strain point glass.
[0035] ZnO is an element for lowering the softening point and adjusting the thermal expansion coefficient of the glass. The content of ZnO is selected at 20-45% by weight, preferably 22-42%. When the content is selected at less than 20%, the above-described function of ZnO is not achieved. When it is selected at more than 45%, the thermal expansion coefficient is excessively lowered.
[0036] B 2 O 3 is a glass forming element for widening a vitrification range of a composition and should be contained at 12-40% by weight, preferably 15-33%. Less than 12% of B 2 O 3 results in probable devitrification of the glass during the firing. When the content is more than 40%, the glass becomes excessively high in the softening point to make it difficult to fire at a temperature of 600° C. or less.
[0037] SiO 2 is also a glass forming element and should be selected, in content, at 3-15% by weight, preferably 4-13%. If SiO 2 is less than 3%, the resultant glass is readily devitrified during the firing. On the other hand, use of SiO 2 more than 15% excessively raises the resultant glass in the softening point to excessively slow the viscosity change across the softening point so that degassing becomes difficult.
[0038] PbO is an element for lowering the softening point of the glass and should be selected at contents of 0-24.5% by weight, preferably 0-24%. If the content of PbO is selected at more than 24.5%, the viscosity change of the resultant glass is excessively rapid across the softening point to promote growth of bubbles, this resulting in residual large bubbles remaining in the fired layer.
[0039] CuO content should be selected at 0.01-20% by weight, preferably 0.1-15%. If the content is less than 0.01%, it is difficult to prevent the fired dielectric layer from changing into yellow due to reaction with Ag electrode in PDP. CuO content more than 20% lowers the water resistance of the resultant glass.
[0040] Another example of glass of the glass powder consists essentially of, by weight, 25-45% ZnO, 15-35% Bi 2 O 3 , 10-30% B 2 O 3 , 0.5-8% SiO 2 , a total amount of 8-24% of CaO, SrO and BaO, and 0.01-20% CuO. The glass will be referred to as glass C and has properties like glass A. Namely, the viscosity change is rapid across the softening point so that bubbles are expelled at a relatively low temperature at a start of the firing operation, thus less fine bubbles remaining in the dielectric layer formed. Further, the glass C is PbO free considering environmental pollution.
[0041] In glass C, ZnO is an element for lowering the softening point and adjusting the thermal expansion coefficient of the glass. The content of ZnO is selected at 25-45% by weight, preferably 30-40%. When it is selected less than 25%, the above-described function of ZnO is not achieved. When it is selected at more than 45%, the resultant glass is easily devitrified in firing operation.
[0042] Bi 2 O 3 is an element for lowering the softening point of the glass and should be selected at contents of 15-35% by weight, preferably 17-30%. If the content of Bi 2 O 3 is selected at less than 15%, the resultant glass has a high softening point and many bubbles possibly remain in the dielectric layer fired. If the content of Bi 2 O 3 is selected at more than 35%, the thermal expansion coefficient is excessively high.
[0043] B 2 O 3 is a glass forming element for widening a vitrification range of a composition and should be contained at 10-30% by weight, preferably 17-25%. B 2 O 3 content less than 10% results in difficulty of vitrification. When the content is more than 30%, the glass is easily brought into phase separation.
[0044] SiO 2 is also a glass forming element and should be selected, in content, at 0.5-8% by weight, preferably 3-7%. If SiO 2 is less than 0.5%, vitrification is difficult. On the other hand, use of SiO 2 more than 8% excessively raises the resultant glass in the softening point to excessively slow the viscosity change across the softening point so that degassing becomes difficult.
[0045] CaO, SrO and BaO are contained for lowering the softening point of the glass and for adjusting viscosity at a high temperature to affect defoamability of the glass. The total content of CaO, SrO and BaO is 8-24%, preferably 10-20%, by weight. If the total content is less than 8%, the intended function of these elements described above cannot be achieved. The total content more than 24% excessively lowers the softening point to promote foamability as well as elevates the thermal expansion coefficient of the resultant glass. Individual contents of CaO, SrO and BaO are preferably 0-20%, 0-20%, and 0-20%, respectively.
[0046] CuO content should be selected at 0.01-20% by weight, preferably 0.1-15%. If the content is less than 0.01%, it is difficult to prevent the fired dielectric layer from changing into yellow due to reaction with Ag electrode in PDP. CuO content more than 20% lowers the water resistance of the resultant glass.
[0047] Another example of glass of the glass powder consists essentially of, by weight, 26-60% B 2 O 3 , 15-50% ZnO, 0-30% SiO 2 , 0-10% Al 2 O 3 , 3-20% K 2 O, a total amount of 0-10% of Na 2 O and Li 2 O, a total amount of 0-15% of CaO and BaO, and 0.01-20% CuO. The glass will be referred to as glass D and has properties that the viscosity change across the softening point is adjusted to be slower than that in glass C so that residual bubbles not expelled at the start of the firing operation are prevented from growing into large bubbles by temperature elevation as the firing operation progresses. Therefore, use of powder of glass D effectively reduces the number of residual large bubbles in the dielectric layer formed by firing the dielectric composition. Further, glass D is PbO free like glass C.
[0048] In the glass D, B 2 O 3 is a glass forming element for widening a vitrification range of a composition. The content of B 2 O 3 is 26-60% by weight, preferably 28-50%. When B 2 O 3 content is less than 26%, the resultant glass is easily devitrified during the firing operation to lose the transparency. When the content is more than 60%, the glass is raised in softening point so that it becomes difficult to fire the resultant glass at a temperature of 600° C. or less.
[0049] ZnO is a glass forming element and has a function to lower the softening point. The content of ZnO is selected at 15-50% by weight, preferably 20-40%. When the content is selected at less than 15%, the above-described function of ZnO is not sufficiently achieved. When it is selected at more than 50%, the resultant glass is easily devitrified during the firing operation to lose the transparency.
[0050] SiO 2 is a glass forming element. The content of B 2 O 3 is 0-30% by weight, preferably 1-25%. When SiO 2 content is more than 30%, the glass is raised in softening point so that it becomes difficult to fire the resultant glass at a temperature of 600° C. or less.
[0051] Al 2 O 3 is an element for adjusting the phase separation of the glass. The content of Al 2 O 3 is 0-10% by weight, preferably, 0-8%. Use of Al 2 O 3 more than 10% raises the softening point of the glass so that it becomes difficult to fire the resultant glass at a temperature of 600° C. or less.
[0052] K 2 O has functions of lowering the fusion point of the glass as well as adjusting the thermal expansion coefficient, and further suppressing the glass to be colored into yellow due to reaction with Ag electrodes in PDP. The content of K 2 O is 3-20% by weight, preferably, 5-15%. When K 2 O content is less than 3%, the above-described functions of K 2 O is not achieved. When the content is more than 20%, the thermal expansion coefficient is raised to a level higher than that of the front glass plate in PDP.
[0053] Both of Na 2 O and Li 2 O have functions of lowering the fusion point of the glass as well as adjusting the thermal expansion coefficient. However, they make the glass be easily colored into yellow due to reaction with Ag electrodes in PDP. Therefore, the total content of them is restricted 0-10% by weight, preferably 0-5%.
[0054] Both of CaO and BaO have functions for lowering the fusion point of the glass as well as adjusting the thermal expansion coefficient. The total content of them is restricted to 0-15% by weight, preferably 0-10%. When the total content is more 15%, the thermal expansion coefficient is raised higher than that of the front glass plate in PDP.
[0055] CuO content should be selected at 0.01-20% by weight, preferably 0. 1-15%. If the content is less than 0.01%, it is difficult to prevent the fired dielectric layer from changing into yellow due to reaction with Ag electrode in PDP. CuO content more than 20% lowers the water resistance of the resultant glass.
[0056] It is possible for achieving certain objects to add other ingredients in each of glass A-D, for example, SnO 2 up to 10%, and/or P 2 O 5 , CeO 2 , TiO 2 , and Fe 2 O 3 up to 3% in a total amount of them so as to promotably prevent the dielectric layer fired from color-changing to yellow. It is also possible to add Sb 2 O 3 up to 20% so as to prevent the dielectric layer fired from browning as well as promotably prevent from the yellow change.
[0057] According to another aspect of this invention, the glass powder preferably has an average particle size D50 of 3.0 micrometers (μm) or less, and the maximum particle size Dmax of 20 micrometers (μm) or less. If the average particle size and the maximum particle size exceeds the upper limits, there exist large gaps between adjacent glass particles, which promote generation of residual large bubbles in the fired dielectric layer.
[0058] The dielectric composition according to the present invention can include ceramics powder in addition to the glass powder to form a powdery admixture, so as to improve the strength of the fired layer and adjust the appearance thereof. The ceramics powder comprises alumina, zircon, zirconia, and/or titania (titanium oxide). It is preferable that the maximum particle size Dmax of the ceramics powder is 15 μm or less.
[0059] In contents, the glass powder and the ceramics powder are 90-100% and 0-10% by weight, respectively. If the ceramic powder content is more than 10%, the resultant dielectric layer fired scatters the visible ray thereby to be opaque.
[0060] In actual use, the dielectric composition according to this invention can be provided as a form of a paste or a green sheet.
[0061] In order to prepare the dielectric composition as a paste, the glass powder or the powdery admixture described above is mixed with binder, plasticizer and solvent. The glass powder alone and the powdery mixture will collectively be referred to as “powder material”, hereinafter.
[0062] The paste comprises, by weight, the powder material of 30-90% preferably 50-80%, the binder of 0.1-20% preferably 0.5-10%, the plasticizer of 0-10% preferably 0-9%, and the solvent of 10-30% preferably 15-25%.
[0063] In use of the paste for forming a light transparent dielectric layer on a front glass plate for a PDP, the paste is coated on the front glass plate by the screen printing or the batch coating process to form a coating layer with a thickness of 30-100 μm. The front glass plate has previously deposited with electrodes on the surface. The coating layer is dried at a temperature of 80-120° C. and then, fired at a temperature of 500-600° C. for 5-15 minutes. Thus, the light transparent dielectric layer is completed on the front glass plate to cover the electrode.
[0064] The binder is used for strengthening the dried coating layer as well as providing softness to the layer. The binder is at least one selected from a group of poly butyl methacrylate, polyvinyl butyral, poly methyl methacrylate, poly ethyl methacrylate, and ethyl cellulose.
[0065] The plasticizer is for adjusting a drying speed of the coating layer and providing softness to the dried layer. The plasticizer is at least one selected from a group of butyl benzyl phthalate, dioctyl phthalate, di-isooctyl phthalate, dicapryl phthalate, dibutyl phthalate.
[0066] The solvent is used for dissolving or suspending the powder material, the binder and the plasticizer therein. The solvent is at least one selected from a group of terpineol, diethylene glycol monobutyl ether acetate, and 2,2,4-trymethyl-1,3-pentanediolmonoisobutylate.
[0067] In order to prepare the dielectric composition as a green sheet, the powder material is mixed with binder, plasticizer, and organic solvent such as toluene or toluole together with or without an auxiliary solvent such as isopropyl alcohol to form slurry. The slurry is coated on a film of, for example PET (polyethylene terephthalate) by the doctor blade method to form a thin layer. The thin layer preferably has a thickness such that it can provide a thickness of about 20-100 μm after dried. Thereafter, the layer is dried to remove the solvent to obtain the green sheet.
[0068] The green sheet comprises, by weight, the powder material of 60-80% preferably 65-77%, the binder of 5-30% preferably 10-25%, and the plasticizer of 0-10%, preferably 0.1-7%.
[0069] The binder is for providing strength, softness, and self-bonding property to the green sheet. The binder is at least one selected from a group of poly butyl methacrylate, polyvinyl butyral, poly methyl methacrylate, poly ethyl methacrylate, and ethyl cellulose.
[0070] The plasticizer is used for providing softness and self-bonding property to the green sheet. The plasticizer is at least one selected from a group of butyl benzyl phthalate, dioctyl phthalate, di-isooctyl phthalate, dicapryl phthalate, dibutyl phthalate.
[0071] In use of the green sheet for forming the light transparent dielectric layer on a front glass plate having electrodes for a PDP, the green sheet is released from the film and then is thermo-compression bonded onto the front glass plate to cover the electrodes. The thermo-compression bonding is carried out under conditions of, preferably, a temperature of 50-200 ° C. and a pressure of 1-5 kgf/cm 2 . Thereafter, firing operation is carried out at a temperature of 500-600° C. for 5-15 minutes. Thus, the transparent dielectric layer is formed on the front glass plate.
[0072] Examples of this invention will be described below.
[0073] Tables 1-3 demonstrate examples (sample Nos. 1-14) of this invention and comparative example (sample Nos. 15-17).
TABLE 1 Invention Sample No. 1 2 3 4 5 6 Glass powder (wt %) BaO 17 28 20 28 28 35 ZnO 20 5 12 33 28 38 B 2 O 3 15 20 30 21.8 25 20.5 SiO 2 8 5 7 7 4 6 PbO 35 40 29.5 10 10 — CuO 5 2 0.5 0.2 5 0.5 Softening point (° C.) 580 520 585 595 600 620 Thermal expansion 75 77 80 77 79 82 coefficient (×10 −7 /° C.) Firing temperature 560 520 580 580 590 600 (° C.) Fired layer 28 31 30 32 31 28 thickness (μm) transmittance (%) 81 80 79 80 79 81 Number of 12 11 1 2 1 0 large bubbles Yellow change No No No No No No
[0074] [0074] TABLE 2 Invention Sample No. 7 8 9 10 11 12 Glass powder (wt %) BaO 31 22 20 30 30 15 ZnO 40 23 24 33 33 35 B 2 O 3 16 17 18 19 19 20 SiO 2 7 7 9 7 7 5 PbO 4 20 24 5 5 — Bi 2 O 3 — — — — — 20 CuO 2 11 5 6 6 5 Ceramics Powder alumina — Amount (wt %) — — — — 3 — Softening point (° C.) 610 605 580 600 600 570 Thermal expansion 76 82 76 77 77 80 coefficient (×10 −7 /° C.) Firing temperature 595 570 560 580 580 560 (° C.) Fired layer 29 34 33 31 31 29 thickness (μm) Transmittance (%) 80 79 78 80 78 78 Number of large bubbles 1 0 3 1 1 10 Yellow change No No No No No No
[0075] [0075] TABLE 3 Invention Comparative Sample No 13 14 15 16 17 Glass powder (wt %) BaO — 10 28 17 — ZnO 34 27 33 20 — B 2 O 3 40 30 22 20 5 SiO 2 10 20 7 8 30 PbO — — 10 35 60 Al 2 O 3 — 4 — — 2 Li 2 O — 2 — — — K 2 O 14 6 — — — CuO 1 1 — — 3 Softening point (° C.) 580 590 595 575 610 Thermal expansion 85 82 77 73 70 coefficient (×10 −7 /° C.) Firing temperature 570 580 580 560 600 (° C.) Fired layer 30 29 30 28 30 thickness (μm) Transmittance (%) 79 78 80 81 68 Number of 3 2 1 15 5 large bubbles Yellow change No No Yes Yes No
[0076] Each of samples was prepared by the following steps.
[0077] A charge of raw materials was blended for each of samples shown in Tables 1-3 and was melted in a platinum crucible at 1,300° C. for two hours. Then, the molten glass was formed in a thin plate shape, which was in turn crushed and classified to obtain a glass powder having an average particle size D50 of 3.0 μm or less and maximum particle size Dmax of 20 μm or less.
[0078] The softening point of the glass powder was measured and recorded. The glass powder of No. 11 sample was mixed with aluminum powder to obtain a mixed powder thereof.
[0079] The average particle size D50 and maximum particle size Dmax were confirmed by use of a particle size distribution meter of a laser diffractive type “Microtrack SPA” manufactured by Nikkiso Ltd.
[0080] With respect to each sample, measuring was done of the thermal expansion coefficient, the firing temperature, the thickness of the fired dielectric layer, and the spectral transmittance at a wavelength of 550 nm. It was also carried out to count the number of bubbles having a diameter of 30 μm or more present in the fired dielectric layer. Further, it was observed whether or not the fired dielectric layer was colored into yellow due to reaction with Ag of the electrodes. The measured data are shown in Tables 1-3.
[0081] It is seen from Tables 1-3 that samples Nos. 1-14 of examples of this invention do not cause the yellow change of the dielectric layer due to reaction with Ag electrodes. In comparison with these samples, the comparative samples No. 15 and 16 cause the yellow change of the dielectric layer due to reaction with Ag electrodes. Another comparative sample No. 17 does not cause the yellow change. But it was observed that the dielectric layer of the comparative sample No. 17 has many fine bubbles and is low in transmittance.
[0082] In measuring the softening point, a differential thermal analyzer of a macro type was used and values of the first and fourth inflection points were selected as the glass transition point and the softening point, respectively.
[0083] The thermal expansion coefficient was measured according to JIS R 3102 at a temperature range of 30-300 ° C. of a sample piece which was formed by the following steps. Each of the sample powders was press-formed, fired, and ground to form the sample piece of a cylindrical rod having a diameter of 4 mm and a length of 40 mm.
[0084] The thickness, the transmittance and number of large bubbles of the fired layer were obtained in the following manner. The each sample powder was mixed in a 5% terpineol solution of ethyl cellulose and kneaded by use of a three-roll mill to form a paste which was, in turn, applied by the screen printing process to obtain a fired layer of 30 μm thickness onto a high-strain point soda-lime glass plate having a thickness of 1.7 mm and fired in an electric furnace for 10 minutes at the firing temperature. The thickness of the fired layer was confirmed by use of a digital micrometer.
[0085] The transmittance was measured for the wavelength of 550 nm by use of an integration sphere of a spectrophotometer by setting the high-strain point glass plate having the fired layer at a sample setting side of the spectrophotometer.
[0086] Using a stereoscope (30 magnitude), it was carried out to count number of large bubbles having a diameter of 30 μm or more as seen within an area of 3 cm×4 cm in the surface of the fired layer.
[0087] Further, it was determined by observing appearance of the fired layer formed on the soda-lime glass plate having Ag electrode thereon whether or not yellow change is caused due to reaction with the Ag electrode.
[0088] As described above, the dielectric composition of this invention is useful for forming a light transparent dielectric layer onto a front glass plate of PDP which is not caused by yellow change due to reaction with Ag electrodes.
[0089] It is of course that the dielectric composition according to this invention can be used for forming a dielectric layer at desired parts of the PDP as well as the front glass plate having electrodes of other metals than Ag.
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In a dielectric composition for use in formation of a dielectric layer in a plasma display panel, comprising glass powder, the glass powder is powder of glass which contains PbO of 50% or less and CuO as one of essential elements contained in the glass for preventing color change of the dielectric layer from being caused due to reaction with Ag electrodes in the plasma display panel. Ceramics powder can be mixed with the glass powder. The dielectric composition can also be provided in a form of paste, alternatively in a form of a green sheet.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit under 35 U.S.C. §119 of Korean Patent Application No. 10-2006-0132234, filed Dec. 21, 2006, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] In order to highly integrate a semiconductor device and to obtain high performance of the semiconductor device, a metal line having a multi-layer structure has been widely used. Although aluminum (Al) is widely used for the metal line, recently, copper (Cu) having superior conductivity has been substituted for aluminum (Al).
[0003] However, since a copper line layer is not easily patterned, the copper line layer is mainly formed through a damascene process and a chemical mechanical polishing (CMP) process.
[0004] FIGS. 1A to 1B are cross-sectional views showing a method for manufacturing a related semiconductor device.
[0005] Referring to FIG. 1A , an interlayer dielectric layer 110 is formed on a semiconductor substrate 100 . A via hole 113 is formed in the interlayer dielectric layer 110 through a damascene process.
[0006] A barrier layer 120 is formed on the interlayer dielectric layer 110 including the via hole 113 to block the diffusion of copper (Cu).
[0007] A seed layer 130 is formed on the barrier layer 120 to enable copper (Cu) to be easily deposited. The seed layer 130 may be formed through a physical vapor deposition (PVD) process.
[0008] When the seed layer 130 is formed through the PVD process, the seed layer 130 becomes relatively thicker at an inlet of the via hole 113 , that is, at a corner area 133 of an upper portion of the via hole 113 , so that an overhang may be formed. Accordingly, the seed layer 130 is not easily formed on the barrier layer 120 at the side surface of the via hole 113 due to the overhang. Accordingly, an area in which the seed layer 130 is not formed on the barrier layer 120 at the side surface of the via hole 113 , that is, a discontinuous step coverage area 136 exists.
[0009] Since the seed layer 130 does not exist in the discontinuous step coverage area 136 , the copper material may not be easily deposited in the discontinuous step coverage area 136 when the copper material is buried in the following process.
[0010] Referring to FIG. 1B , a copper layer 140 is formed on the seed layer 130 including the via hole 113 .
[0011] In this case, although the copper layer 140 is not sufficiently formed at the side surface of the via hole 113 due to the overhang, the copper layer 140 is easily formed on the bottom surface of the via hole 113 . Accordingly, a void 143 or a long seam may be created in the copper layer 140 of the via hole 113 .
[0012] Meanwhile, recently, as the line width of a metal line is reduced, the barrier layer 120 and the seed layer 130 gradually become thinner.
[0013] However, as the barrier layer 120 becomes thinner, the performance of the barrier layer may be degraded.
[0014] In addition, as the seed layer 130 becomes thinner, the discontinuous step coverage frequently occurs, so that the probability of creating the void is increased.
[0015] Thus, there exists a need in the art for an improved metal line for a semiconductor device.
BRIEF SUMMARY
[0016] Embodiments of the present invention provide a semiconductor device and a method for manufacturing the same, capable of improving the performance of a barrier of a metal line.
[0017] An embodiment of the present invention also provides a semiconductor device and a method for manufacturing the same, capable of inhibiting a void from being created by forming a continuous step coverage and restricting an overhang.
[0018] According to an embodiment, a semiconductor device includes an interlayer dielectric layer disposed on a semiconductor substrate and having a via hole, a first layer disposed in the via hole and including ruthenium (Ru), a second layer disposed on the first layer and including ruthenium oxide (RuO 2 ), and a metal line disposed on the second layer and including a copper material.
[0019] According to an embodiment, a method for manufacturing a semiconductor device includes forming an interlayer dielectric layer on a semiconductor substrate, wherein the interlayer dielectric layer has a via hole, forming a first layer on the interlayer dielectric layer including the via hole using a ruthenium material, forming a second layer on the first layer through an anodizing process, wherein the second layer includes ruthenium oxide (RuO 2 ), forming a copper layer on the second layer using the second layer as a seed layer, and forming a metal line in the via hole from the copper layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIGS. 1A and 1B are cross-sectional views showing a manufacturing process of a related semiconductor device.
[0021] FIG. 2 is a cross-sectional view showing a semiconductor device according to an embodiment of the present invention.
[0022] FIGS. 3A to 3F are cross-sectional views showing a manufacturing process of a semiconductor device according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0023] Hereinafter, embodiments of the present invention will be described in detail with reference to accompanying drawings.
[0024] When the terms “on” or “over” are used herein, when referring to layers, regions, patterns, or structures, it is understood that the layer, region, pattern or structure can be directly on another layer or structure, or intervening layers, regions, patterns, or structures may also be present. When the terms “under” or “below” are used herein, when referring to layers, regions, patterns, or structures, it is understood that the layer, region, pattern or structure can be directly under the other layer or structure, or intervening layers, regions, patterns, or structures may also be present.
[0025] Referring to FIG. 2 , a semiconductor device can include an interlayer dielectric layer 210 with a via hole provided on a semiconductor substrate 200 .
[0026] A first layer 220 can be provided in the via hole of the interlayer dielectric layer 210 . The first layer 220 can include ruthenium (Ru). The first layer 220 may have the thickness in the range of about 100 Å to about 800 Å. The first layer 220 can have a barrier characteristic to inhibit copper (Cu) from being diffused into the interlayer dielectric layer 210 .
[0027] A second layer 230 can be provided on the first layer 220 . The second layer 230 may have a thickness in the range of about 50 Å to about 200 Å. The second layer 230 can include ruthenium oxide (RuO 2 ). The ruthenium (Ru) of the first layer 220 can be reacted with a hydroxyl radical (OH) solution, so that the second layer 230 can be directly formed from the first layer 220 . Ruthenium oxide (RuO 2 ) has a conductivity of about 36 Ω-cm, and can sufficiently serve as a seed layer to form a metal line including copper (Cu).
[0028] According to an embodiment, the first layer 220 including ruthenium (Ru) is used as a barrier layer, and the second layer 230 including ruthenium oxide (RuO 2 ) may be used as a seed layer to form a metal line including copper (Cu).
[0029] Accordingly, since an overhang is not created in a corner area provided at an upper portion of the via hole, a void or a seam is not created in a metal line when the metal line is formed.
[0030] In addition, since the overhang is not created in the corner area provided at the upper portion of the via hole, the second layer 230 provided below the corner area at the side surface of the via hole has a continuous step coverage.
[0031] Further, the diffusion of copper (Cu) can be blocked by the first and second layers 220 and 230 , so that the performance of the barrier can be improved.
[0032] A metal line 250 including a copper material can be provided on the second layer 230 in the via hole.
[0033] FIGS. 3A to 3F are cross-sectional views showing a manufacturing process of a semiconductor device according to an embodiment.
[0034] Referring to FIG. 3A , an interlayer dielectric layer 210 can be formed on a semiconductor substrate 200 . The semiconductor substrate can include predetermined structures including, but not limited to a conductive device (e.g., a line), a driving device (e.g., transistor), or a capacitor. The interlayer dielectric layer 210 can be formed of, for example, boron silicate glass (BSG), boron phosphorous silicate glass (BPSG), or undoped silicate glass (USG).
[0035] The interlayer dielectric layer 210 can be formed through, for example, a physical vapor deposition (PVD) process.
[0036] Referring to FIG. 3B , the interlayer dielectric layer 210 can be patterned to form a via hole 213 . The via hole 213 may be formed such that a structure or region on the semiconductor substrate 200 is exposed. For example, the via hole 213 may be formed such that a conductive device, a driving device, or a capacitor formed on the semiconductor substrate 200 is exposed.
[0037] Referring to FIG. 3C , a ruthenium (Ru) material can be deposited on the interlayer dielectric layer 210 including the via hole 213 to form a first layer 220 .
[0038] The first layer 220 may be formed through, for example, a PVD process or an atomic layer deposition (ALD) process. The PVD process can include a sputtering process, an e-beam evaporation process, a thermal evaporation process, a laser molecular beam epitaxy (L-MBE) process, or a pulse laser deposition (PLD) process.
[0039] It is preferred that the first layer 220 is as thin as possible while maintaining a barrier characteristic of inhibiting copper (Cu) from being diffused. Accordingly, in one embodiment, the first layer 220 may have a thickness in the range of about 100 Å to about 800 Å.
[0040] Referring to FIG. 3D , an anodizing process can be performed with respect to the first layer 220 , thereby forming the second layer 230 including ruthenium oxide (RuO 2 ) on the first layer 220 .
[0041] The anodizing process can include immersing the semiconductor substrate 200 in a hydroxyl radical (OH) solution, and applying an anode current to the first layer 220 including ruthenium (Ru). The ruthenium (Ru) reacts with the hydroxyl radical (OH) solution by the anode current, thereby forming ruthenium oxide (RuO 2 ). Ruthenium oxide (RuO 2 ) can be continuously formed to from the second layer 230 .
[0042] In an embodiment, the anode current has an intensity in the range of about 0.5 A to about 2 A.
[0043] The second layer 230 may have a thickness in the range of about 50 Å to about 200 Å in order to serve as a seed layer to form a metal line including copper (Cu). Ruthenium oxide (RuO 2 ) has a conductivity of about 36 Ω-cm and can sufficiently serve as a seed layer of copper (Cu).
[0044] As described above, the second layer 230 is formed through an anodizing process to serve as a seed layer for forming a metal line including copper (Cu). Accordingly, an overhang can be inhibited from being created at a corner area in the upper portion of the via hole 213 . In addition, the second layer 230 can be uniformly formed on the first layer 220 through an anodizing process, so that the second layer 230 may have a continuous step coverage.
[0045] In addition, a double layer including the first and second layers 230 can sufficiently serve as a barrier to inhibit copper (Cu) from being diffused, so that a barrier characteristic can be improved.
[0046] Referring to FIG. 3E , a copper layer 240 can be formed on the second layer 230 through an electrochemical plating (ECP) process by employing the second layer 230 as a seed layer.
[0047] Referring to FIG. 3F , a (Chemical Mechanical Polishing) CMP process can be performed in order to remove the first layer 220 , the second layer 230 , and the copper layer 240 from the interlayer dielectric layer 210 except for at the via hole, thereby forming the metal line 250 in the via hole 213 of the interlayer dielectric layer 210 . Although embodiments have been described with respect to a via hole 213 , a trench can also be provided in contact with the via hole 213 in the interlayer dielectric layer 210 for the metal line 250 .
[0048] Accordingly, an overhang or a discontinuous step coverage is not created on the second layer 230 serving as a seed layer, so that a void or a seam is not created in the metal line 250 when the metal line 250 is formed. Therefore, gap-fill performance can be improved.
[0049] As described above, according to an embodiment, ruthenium oxide (RuO 2 ) is formed using ruthenium, thereby inhibiting an overhang or a discontinuous step coverage from being created.
[0050] According to embodiments of the present invention, the creation of the overhang or the discontinuous step coverage is restricted, thereby inhibiting a void or a seam from being created in the metal line.
[0051] According to an embodiment, the diffusion of copper (Cu) is inhibited by a double layer including ruthenium (Ru) and ruthenium oxide (RuO 2 ), so that the characteristic of a barrier can be improved.
[0052] Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments.
[0053] Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
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Disclosed are a semiconductor device and a method for manufacturing the same, capable of improving the performance of a barrier and inhibiting a discontinuous step coverage and an overhang. The semiconductor device includes an interlayer dielectric layer having a via hole disposed on a semiconductor substrate, a first layer disposed in the via hole and including ruthenium (Ru), a second layer disposed on the first layer and including ruthenium oxide (RuO 2 ), and a metal line disposed on the second layer and including a copper material.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 61/513,230 filed Jul. 29, 2011, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to hydroprocessing systems and methods, in particular for efficient reduction of catalyst-fouling aromatic nitrogen components in a hydrocarbon mixture.
2. Description of Related Art
Hydrocracking operations are used commercially in a large number of petroleum refineries. They are used to process a variety of feeds boiling in the range of 370° C. to 520° C. in conventional hydrocracking units and boiling at 520° C. and above in the residue hydrocracking units. In general, hydrocracking processes split the molecules of the feed into smaller, i.e., lighter, molecules having higher average volatility and economic value. Additionally, hydrocracking typically improves the quality of the hydrocarbon feedstock by increasing the hydrogen to carbon ratio and by removing organosulfur and organonitrogen compounds. The significant economic benefit derived from hydrocracking operations has resulted in substantial development of process improvements and more active catalysts.
Mild hydrocracking or single stage hydrocracking operations, typically the simplest of the known hydrocracking configurations, occur at operating conditions that are more severe than typical hydrotreating, and less severe than typical full pressure hydrocracking. Single or multiple catalysts systems can be used depending upon the feedstock and product specifications. Multiple catalyst systems can be deployed as a stacked-bed configuration or in multiple reactors. Mild hydrocracking operations are generally more cost effective, but typically result in both a lower yield and reduced quality of mid-distillate product as compared to full pressure hydrocracking operations.
In a series-flow configuration the entire hydrocracked product stream from the first reaction zone, including light gases (e.g., C 1 -C 4 , H 2 S, NH 3 ) and all remaining hydrocarbons, are sent to the second reaction zone. In two-stage configurations the feedstock is refined by passing it over a hydrotreating catalyst bed in the first reaction zone. The effluents are passed to a fractionating zone column to separate the light gases, naphtha and diesel products boiling in the temperature range of 36° C. to 370° C. The hydrocarbons boiling above 370° C. are then passed to the second reaction zone for additional cracking.
Conventionally, most hydrocracking processes that are implemented for production of middle distillates and other valuable fractions retain aromatics, e.g., boiling in the range of about 180° C. to 370° C. Aromatics boiling higher than the middle distillate range are also included and produced in the heavier fractions.
In all of the above-described hydrocracking process configurations, cracked products, along with partially cracked and unconverted hydrocarbons, are passed to a distillation column for fractionating into products including naphtha, jet fuel/kerosene and diesel boiling in the nominal ranges of 36° C.-180° C., 180° C.-240° C. and 240° C.-370° C., respectively, and unconverted products boiling in the nominal range of above 370° C. Typical jet fuel/kerosene fractions (i.e., smoke point>25 mm) and diesel fractions (i.e., cetane number>52) are of high quality and well above the worldwide transportation fuel specifications. Although the hydrocracking unit products have relatively low aromaticity, aromatics that do remain lower the key indicative properties (smoke point and cetane number) for these products.
A need remains in the industry for improvements in operations for heavy hydrocarbon feedstocks to produce clean transportation fuels in an economical and efficacious manner.
SUMMARY OF THE INVENTION
In accordance with one or more embodiments, the invention relates to systems and methods of hydrocracking heavy hydrocarbon feedstocks to produce clean transportation fuels. An integrated hydrocracking process includes hydroprocessing an aromatic-rich fraction of the initial feed separately from an aromatic-lean fraction.
In a two-stage hydrocracker configuration provided herein, an aromatic separation unit is integrated in which:
the feedstock is separated into an aromatic-rich fraction and an aromatic-lean fraction;
the aromatic-rich fraction is passed to a first stage hydroprocessing reaction zone operating under conditions effective to hydrotreat and/or hydrocrack at least a portion of aromatic compounds contained in the aromatic-rich fraction and to produce a first stage hydroprocessing reaction zone effluent;
the first stage hydroprocessing reaction zone effluent is separated to produce a product stream and a bottoms stream, and at least a portion of the bottoms stream is mixed with aromatic-lean fraction; and
the mixture is passed to a second stage hydroprocessing reaction zone to produce a second stage hydroprocessing reaction zone effluent which is separated.
Unlike typical known methods, the present process separates the hydrocracking feed into fractions containing different classes of compounds with different reactivities relative to the conditions of hydrocracking. Conventionally, most approaches subject the entire feedstock to the same hydroprocessing reaction zones, necessitating operating conditions that must accommodate feed constituents that require increased severity for conversion, or alternatively sacrifice overall yield to attain desirable process economics.
Since aromatic extraction operations typically do not provide sharp cut-offs between the aromatics and non-aromatics, the aromatic-lean fraction contains a major proportion of the non-aromatic content of the initial feed and a minor proportion of the aromatic content of the initial feed, and the aromatic-rich fraction contains a major proportion of the aromatic content of the initial feed and a minor proportion of the non-aromatic content of the initial feed. The amount of non-aromatics in the aromatic-rich fraction, and the amount of aromatics in the aromatic-lean fraction, depend on various factors as will be apparent to one of ordinary skill in the art, including the type of extraction, the number of theoretical plates in the extractor (if applicable to the type of extraction), the type of solvent and the solvent ratio.
The feed portion that is extracted into the aromatic-rich fraction includes aromatic compounds that contain heteroatoms and those that are free of heteroatoms. Aromatic compounds that contain heteroatoms that are extracted into the aromatic-rich fraction generally include aromatic nitrogen compounds such as pyrrole, quinoline, acridine, carbazoles and their derivatives, and aromatic sulfur compounds such as thiophene, benzothiophenes and their derivatives, and dibenzothiophenes and their derivatives. These nitrogen- and sulfur-containing aromatic compounds are targeted in the aromatic separation step(s) generally by their solubility in the extraction solvent. In certain embodiments, selectivity of the nitrogen- and sulfur-containing aromatic compounds is enhanced by use of additional stages and/or selective sorbents. Various non-aromatic sulfur-containing compounds that may have been present in the initial feed, i.e., prior to hydrotreating, include mercaptans, sulfides and disulfides. Depending on the aromatic extraction operation type and/or condition, a preferably very minor portion of non-aromatic nitrogen- and sulfur-containing compounds can pass to the aromatic-rich fraction.
As used herein, the term “major proportion of the non-aromatic compounds” means at least greater than 50 weight % (W %) of the non-aromatic content of the feed to the extraction zone, in certain embodiments at least greater than about 85 W %, and in further embodiments greater than at least about 95 W %. Also as used herein, the term “minor proportion of the non-aromatic compounds” means no more than 50 W % of the non-aromatic content of the feed to the extraction zone, in certain embodiments no more than about 15 W %, and in further embodiments no more than about 5 W %.
Also as used herein, the term “major proportion of the aromatic compounds” means at least greater than 50 W % of the aromatic content of the feed to the extraction zone, in certain embodiments at least greater than about 85 W %, and in further embodiments greater than at least about 95 W %. Also as used herein, the term “minor proportion of the aromatic compounds” means no more than 50 W % of the aromatic content of the feed to the extraction zone, in certain embodiments no more than about 15 W %, and in further embodiments no more than about 5 W %.
Still other aspects, embodiments, and advantages of these exemplary aspects and embodiments, are discussed in detail below. Moreover, it is to be understood that both the foregoing information and the following detailed description are merely illustrative examples of various aspects and embodiments, and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. The accompanying drawings are included to provide illustration and a further understanding of the various aspects and embodiments, and are incorporated in and constitute a part of this specification. The drawings, together with the remainder of the specification, serve to explain principles and operations of the described and claimed aspects and embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary as well as the following detailed description will be best understood when read in conjunction with the attached drawings. It should be understood, however, that the invention is not limited to the precise arrangements and apparatus shown. In the drawings the same or similar reference numerals are used to identify to the same or similar elements, in which:
FIG. 1 is a process flow diagram of a hydroprocessing system operating in a two-stage configuration;
FIG. 2 is a schematic diagram of an aromatic separation apparatus; and
FIGS. 3-8 show various examples of apparatus suitable for use as the aromatic extraction zone.
DETAILED DESCRIPTION OF THE INVENTION
An integrated system is provided for efficient hydroprocessing of heavy hydrocarbon feedstocks to produce clean transportation fuels. In general, the process and apparatus described herein for producing cracked hydrocarbons are applied to two-stage hydrocracking configurations.
An aromatic separation unit is integrated in a two-stage hydrocracker configuration as follows:
a feedstock is separated into an aromatic-rich fraction and an aromatic-lean fraction;
the aromatic-rich fraction is passed to a first stage hydroprocessing reaction zone operating under conditions effective to hydrotreat and/or hydrocrack at least a portion of aromatic compounds contained in the aromatic-rich fraction and to produce a first stage hydroprocessing reaction zone effluent;
the first stage hydroprocessing reaction zone effluent is fractionated in a fractionating zone to produce one or more product streams and one or more bottoms streams that can be separately recovered, and at least a portion of fractionating zone bottoms stream is mixed with aromatic-lean fraction; and
the mixture is passed to a second stage hydroprocessing reaction zone to produce a second stage hydroprocessing reaction zone effluent which is conveyed to the fractionating zone.
FIG. 1 is a process flow diagram of an integrated hydrocracking apparatus 100 in the configuration of a two-stage hydrocracking unit apparatus. Apparatus 100 includes an aromatic extraction zone 140 , a first stage hydroprocessing reaction zone 150 containing a first stage hydroprocessing catalyst, a second stage hydroprocessing reaction zone 180 containing a second stage hydroprocessing catalyst and a fractionating zone 170 .
Aromatic extraction zone 140 typically includes a feed inlet 102 , an aromatic-rich stream outlet 104 and an aromatic-lean stream outlet 106 . In certain embodiments, feed inlet 102 is in fluid communication with fractionating zone 170 via an optional recycle conduit 120 to receive all or a portion of the bottoms 174 . Various embodiments and unit-operations contained within aromatic extraction zone 140 are described in conjunction with FIGS. 2-8 .
First stage hydroprocessing reaction zone 150 generally includes an inlet 151 in fluid communication with aromatic-rich stream outlet 104 and a source of hydrogen gas via a conduit 152 . First stage hydroprocessing reaction zone 150 also includes a first stage hydroprocessing reaction zone effluent outlet 154 . In certain embodiments, inlet 151 is in fluid communication with fractionating zone 170 via an optional recycle conduit 156 to receive all or a portion of the bottoms 174 .
First stage hydroprocessing reaction zone 150 is operated under severe conditions. As used herein, “severe conditions” are relative and the ranges of operating conditions depend on the feedstock being processed. In certain embodiments of the process described herein, these conditions include a reaction temperature in the range of from about 300° C. to 500° C., in certain embodiments from about 380° C. to 450° C.; a reaction pressure in the range of from about 100 bars to 200 bars, in certain embodiments from about 130 bars to 180 bars; a hydrogen feed rate below about 2,500 standard liters per liter of hydrocarbon feed (SLt/Lt), in certain embodiments from about 500 to 2,500 SLt/Lt, and in further embodiments 1,000 to 1,500 SLt/Lt; and a feed rate in the range of from about 0.25 h −1 to 3.0 h −1 , in certain embodiments from about 0.5 h −1 to 1.0 h 1 .
The catalyst used in the first stage hydroprocessing reaction zone has one or more active metal components selected from the Periodic Table of the Elements Group VI, VII or VIIIB. In certain embodiments the active metal component is one or more of cobalt, nickel, tungsten and molybdenum, typically deposited or otherwise incorporated on a support, e.g., alumina, silica alumina, silica, or zeolites.
Fractionating zone 170 includes an inlet 171 in fluid communication with first stage hydroprocessing reaction zone effluent outlet 154 and second stage hydroprocessing reaction zone effluent outlet 184 , a product stream outlet 172 and a bottoms stream outlet 174 . Note that while one product outlet is shown, multiple product fractions can also be recovered from fractionating zone 170 .
Second stage hydroprocessing reaction zone 180 includes an inlet 181 in fluid communication with aromatic-lean stream outlet 106 , fractionating zone bottoms stream outlet 174 , and a source of hydrogen gas via a conduit 182 . Second stage hydroprocessing reaction zone 180 also includes a second stage hydroprocessing reaction zone effluent outlet 184 that is in fluid communication with inlet 171 of the fractionating zone 170 .
In general, the second stage hydroprocessing reaction zone 180 is operated under mild conditions. As used herein, “mild conditions” are relative and the ranges of operating conditions depend on the feedstock being processed. In certain embodiments of the process described herein, these conditions include a reaction temperature in the range of from about 300° C. to 500° C., in certain embodiments from about 330° C. to 420° C.; a reaction pressure in the range of from about 30 bars to 130 bars, in certain embodiments from about 60 bars to 100 bars; a hydrogen feed rate below 2,500 SLt/Lt, in certain embodiments from about 500 to 2,500 SLt/Lt and in further embodiments from about 1,000 to 1,500 SLt/Lt; and a feed rate in the range of from about 1.0 h −1 to 5.0 h −1 , in certain embodiments from about 2.0 h −1 to 3.0 h −1 .
The catalyst used in the second stage hydroprocessing reaction zone has one or more active metal components selected from the Periodic Table of the Elements Group VI, VII or VIIIB. In certain embodiments the active metal component is one or more of cobalt, nickel, tungsten and molybdenum, typically deposited or otherwise incorporated on a support, e.g., alumina, silica alumina, silica, or zeolites.
A feedstock is introduced via inlet 102 of the aromatic extraction zone 140 for extraction of an aromatic-rich fraction and an aromatic-lean fraction. Optionally, the feedstock can be combined with all or a portion of the bottoms 174 from fractionating zone 170 via recycle conduit 120 .
The aromatic-rich fraction generally includes a major proportion of the aromatic nitrogen- and sulfur-containing compounds that were in the initial feedstock and a minor proportion of non-aromatic compounds that were in the initial feedstock. Aromatic nitrogen-containing compounds that are extracted into the aromatic-rich fraction include pyrrole, quinoline, acridine, carbazole and their derivatives. Aromatic sulfur-containing compounds that are extracted into the aromatic-rich fraction include thiophene, benzothiophene and its long chain alkylated derivatives, and dibenzothiophene and its alkyl derivatives such as 4,6-dimethyl-dibenzothiophene. The aromatic-lean fraction generally includes a major proportion of the non-aromatic compounds that were in the initial feedstock and a minor proportion of the aromatic nitrogen- and sulfur-containing compounds that were in the initial feedstock. The aromatic-lean fraction is almost free of refractory nitrogen-containing compounds, and the aromatic-rich fraction contains nitrogen-containing aromatic compounds.
The first stage hydroprocessing reaction zone 150 is operated under relatively severe conditions. In certain embodiments, these relatively severe conditions of the first stage 150 are more severe than conventionally known severe hydroprocessing conditions due to the comparatively higher concentration of aromatic nitrogen- and sulfur-containing compounds. However, the capital and operational costs of these more severe conditions are offset by the reduced volume of aromatic-rich feed processed in the first stage 150 as compared to a full range feed that would be processed in a conventionally known severe hydroprocessing unit operation.
The aromatic-rich fraction discharged via outlet 104 is passed to inlet 151 of the first stage hydroprocessing reaction zone 150 and mixed with hydrogen gas via conduit 152 . Optionally, the aromatic-rich fraction is combined with all or a portion of the bottoms 174 from fractionating zone 170 via recycle conduit 156 . Compounds contained in the aromatic-rich fraction including aromatics compounds are hydrotreated and/or hydrocracked.
The first stage hydroprocessing reaction zone effluent is sent to one or more intermediate separator vessels (not shown) to remove gases including excess H 2, H 2 S, NH 3 , methane, ethane, propane and butanes. The liquid effluents are passed to inlet 171 of the fractionating zone 170 for recovery of liquid products via outlet 172 , including, for instance, naphtha boiling in the nominal range of from about 36° C. to 180° C. and diesel boiling in the nominal range of from about 180° C. to 370° C. The bottoms stream discharged via outlet 174 includes unconverted hydrocarbons and/or partially cracked hydrocarbons, for instance, having a boiling temperature above about 370° C. It is to be understood that the product cut points between fractions are representative only and in practice cut points are selected based on design characteristics and considerations for a particular feedstock. For instance, the values of the cut points can vary by up to about 30° C. in the embodiments described herein. In addition, it is to be understood that while the integrated system is shown and described with one fractionating zone 170 , in certain embodiments separate fractionating zones can be effective.
All or a portion of the bottoms can be purged via conduit 175 , e.g., for processing in other unit operations or refineries. In certain embodiments to maximize yields and conversions a portion of bottoms 174 is recycled within the process to the aromatic extraction zone 140 and/or the first stage hydroprocessing reaction zone 150 (represented by dashed-lines 120 and 156 , respectively).
A mixture of all or a portion of fractionating zone bottoms stream discharged via conduit 174 , aromatic-lean fraction discharged via outlet 106 and hydrogen gas via conduit 182 is passed to inlet 181 of the second stage hydroprocessing reaction zone 180 . The second stage hydroprocessing reaction zone effluent is discharged via outlet 184 and processed in fractionating zone 170 . Compounds contained in the mixture of the first stage hydroprocessing reaction zone bottoms and the aromatic-lean fraction, including paraffins and naphthenes, are hydrotreated and/or hydrocracked. The second stage hydroprocessing reaction zone 180 is operated under relatively mild conditions, which can be milder than conventional mild hydroprocessing conditions due to the comparatively lower concentration of aromatic nitrogen- and sulfur-containing compounds thereby reducing capital and operational costs.
In addition, either or both of the aromatic-lean fraction and the aromatic-rich fraction also can include extraction solvent that remains from the aromatic extraction zone 140 . In certain embodiments, extraction solvent can be recovered and recycled, e.g., as described with respect to FIG. 2 .
Further, in certain embodiments aromatic compounds without heteroatoms (e.g., benzene, toluene and their derivatives) are passed to the aromatic-rich fraction and are hydrogenated and hydrocracked in the first stage, relatively more severe, hydrocracking zone to produce light distillates. The yield of these light distillates that meet the product specification derived from the aromatic compounds without heteroatoms is greater than the yield in conventional hydrocracking operations due to the focused and targeted hydrocracking zones.
In the above-described embodiment, the feedstock generally includes any liquid hydrocarbon feed conventionally suitable for hydrocracking operations, as is known to those of ordinary skill in the art. For instance, a typical hydrocracking feedstock is vacuum gas oil (VGO) boiling in the nominal range of from about 300° C. to 900° C. and in certain embodiments in the range of from about 370° C. to 520° C. De-metalized oil (DMO) or de-asphalted oil (DAO) can be blended with VGO or used as is. The hydrocarbon feedstocks can be derived from naturally occurring fossil fuels such as crude oil, shale oils, or coal liquids; or from intermediate refinery products or their distillation fractions such as naphtha, gas oil, coker liquids, fluid catalytic cracking cycle oils, residuals or combinations of any of the aforementioned sources. In general, aromatics content in VGO feedstock is in the range of from about 15 to 60 volume % (V %). The recycle stream can include 0 W % to about 80 W % of stream 174 , in certain embodiments about 10 W % to 70 W % of stream 174 and in further embodiments about 20 W % to 60 W % of stream 174 , for instance, based on conversions in each zone of between about 10 W % and 80 W %.
The aromatic separation apparatus is generally based on selective aromatic extraction. For instance, the aromatic separation apparatus can be a suitable solvent extraction aromatic separation apparatus capable of partitioning the feed into a generally aromatic-lean stream and a generally aromatic-rich stream. Systems including various established aromatic extraction processes and unit operations used in other stages of various refinery and other petroleum-related operations can be employed as the aromatic separation apparatus described herein. In certain existing processes, it is desirable to remove aromatics from the end product, e.g., lube oils and certain fuels, e.g., diesel fuel. In other processes, aromatics are extracted to produce aromatic-rich products, for instance, for use in various chemical processes and as an octane booster for gasoline.
As shown in FIG. 2 , an aromatic separation apparatus 240 can include suitable unit operations to perform a solvent extraction of aromatics, and recover solvents for reuse in the process. A feed 202 is conveyed to an aromatic extraction vessel 208 in which in which a first, aromatic-lean, fraction is separated as a raffinate stream 210 from a second, generally aromatic-rich, fraction as an extract stream 212 . A solvent feed 215 is introduced into the aromatic extraction vessel 208 .
A portion of the extraction solvent can also exist in stream 210 , e.g., in the range of about 0 W % to about 15 W % (based on the total amount of stream 210 ), in certain embodiments less than about 8 W %. In operations in which the solvent existing in stream 210 exceeds a desired or predetermined amount, solvent can be removed from the hydrocarbon product, for example, using a flashing or stripping unit 213 , or other suitable apparatus. Solvent 214 from the flashing unit 213 can be recycled to the aromatic extraction vessel 208 , e.g., via a surge drum 216 . Initial solvent feed or make-up solvent can be introduced via stream 222 . An aromatic-lean stream 206 is discharged from the flashing unit 213 .
In addition, a portion of the extraction solvent can also exist in stream 212 , e.g., in the range of about 70 W % to about 98 W % (based on the total amount of stream 215 ), in certain embodiments less than about 85 W %. In embodiments in which solvent existing in stream 212 exceeds a desired or predetermined amount, solvent can be removed from the hydrocarbon product, for example, using a flashing or stripping unit 218 or other suitable apparatus. Solvent 221 from the flashing unit 218 can be recycled to the aromatic extraction vessel 208 , e.g., via the surge drum 216 . An aromatic-rich stream 204 is discharged from the flashing unit 218 .
Selection of solvent, operating conditions, and the mechanism of contacting the solvent and feed permit control over the level of aromatic extraction. For instance, suitable solvents include furfural, N-methyl-2-pyrrolidone, dimethylformamide, dimethylsulfoxide, phenol, nitrobenzene, sulfolanes, acetonitrile, furfural, or glycols, and can be provided in a solvent to oil ratio of about 20:1, in certain embodiments about 4:1, and in further embodiments about 1:1. Suitable glycols include diethylene glycol, ethylene glycol, triethylene glycol, tetraethylene glycol and dipropylene glycol. The extraction solvent can be a pure glycol or a glycol diluted with from about 2 to 10 W % water. Suitable sulfolanes include hydrocarbon-substituted sulfolanes (e.g., 3-methyl sulfolane), hydroxy sulfolanes (e.g., 3-sulfolanol and 3-methyl-4-sulfolanol), sulfolanyl ethers (i.e., methyl-3-sulfolanyl ether), and sulfolanyl esters (e.g., 3-sulfolanyl acetate).
The aromatic separation apparatus can operate at a temperature in the range of from about 20° C. to 120° C., and in certain embodiments in the range of from about 40° C. to 80° C. The operating pressure of the aromatic separation apparatus can be in the range of from about 1 bar to 10 bars, and in certain embodiments in the range of from about 1 bar to 3 bars. Types of apparatus useful as the aromatic separation apparatus in certain embodiments of the system and process described herein include stage-type extractors or differential extractors.
An example of a stage-type extractor is a mixer-settler apparatus 340 schematically illustrated in FIG. 3 . Mixer-settler apparatus 340 includes a vertical tank 381 incorporating a turbine or a propeller agitator 382 and one or more baffles 384 . Charging inlets 386 , 388 are located at the top of tank 381 and outlet 391 is located at the bottom of tank 381 . The feedstock to be extracted is charged into vessel 381 via inlet 386 and a suitable quantity of solvent is added via inlet 388 . The agitator 382 is activated for a period of time sufficient to cause intimate mixing of the solvent and charge stock, and at the conclusion of a mixing cycle, agitation is halted and, by control of a valve 392 , at least a portion of the contents are discharged and passed to a settler 394 . The phases separate in the settler 394 and a raffinate phase containing an aromatic-lean hydrocarbon mixture and an extract phase containing an aromatic-rich mixture are withdrawn via outlets 396 and 398 , respectively. In general, a mixer-settler apparatus can be used in batch mode, or a plurality of mixer-settler apparatus can be staged to operate in a continuous mode.
Another stage-type extractor is a centrifugal contactor. Centrifugal contactors are high-speed, rotary machines characterized by relatively low residence time. The number of stages in a centrifugal device is usually one, however, centrifugal contactors with multiple stages can also be used. Centrifugal contactors utilize mechanical devices to agitate the mixture to increase the interfacial area and decrease the mass transfer resistance.
Various types of differential extractors (also known as “continuous contact extractors,”) that are also suitable for use as an aromatic extraction apparatus include, but are not limited to, centrifugal contactors and contacting columns such as tray columns, spray columns, packed towers, rotating disc contactors and pulse columns.
Contacting columns are suitable for various liquid-liquid extraction operations. Packing, trays, spray or other droplet-formation mechanisms or other apparatus are used to increase the surface area in which the two liquid phases (i.e., a solvent phase and a hydrocarbon phase) contact, which also increases the effective length of the flow path. In column extractors, the phase with the lower viscosity is typically selected as the continuous phase, which, in the case of an aromatic extraction apparatus, is the solvent phase. In certain embodiments, the phase with the higher flow rate can be dispersed to create more interfacial area and turbulence. This is accomplished by selecting an appropriate material of construction with the desired wetting characteristics. In general, aqueous phases wet metal surfaces and organic phases wet non-metallic surfaces. Changes in flows and physical properties along the length of an extractor can also be considered in selecting the type of extractor and/or the specific configuration, materials or construction, and packing material type and characteristics (i.e., average particle size, shape, density, surface area, and the like).
A tray column 440 is schematically illustrated in FIG. 4 . A light liquid inlet 488 at the bottom of column 440 receives liquid hydrocarbon, and a heavy liquid inlet 491 at the top of column 440 receives liquid solvent. Column 440 includes a plurality of trays 481 and associated downcomers 482 . A top level baffle 484 physically separates incoming solvent from the liquid hydrocarbon that has been subjected to prior extraction stages in the column 440 . Tray column 440 is a multi-stage counter-current contactor. Axial mixing of the continuous solvent phase occurs at region 486 between trays 481 , and dispersion occurs at each tray 481 resulting in effective mass transfer of solute into the solvent phase. Trays 481 can be sieve plates having perforations ranging from about 1.5 to 4.5 mm in diameter and can be spaced apart by about 150-600 mm.
Light hydrocarbon liquid passes through the perforation in each tray 481 and emerges in the form of fine droplets. The fine hydrocarbon droplets rise through the continuous solvent phase and coalesce into an interface layer 496 and are again dispersed through the tray 481 above. Solvent passes across each plate and flows downward from tray 481 above to the tray 481 below via downcomer 482 . The principal interface 498 is maintained at the top of column 440 . Aromatic-lean hydrocarbon liquid is removed from outlet 492 at the top of column 440 and aromatic-rich solvent liquid is discharged through outlet 494 at the bottom of column 440 . Tray columns are efficient solvent transfer apparatus and have desirable liquid handling capacity and extraction efficiency, particularly for systems of low-interfacial tension.
An additional type of unit operation suitable for extracting aromatics from the hydrocarbon feed is a packed bed column. FIG. 5 is a schematic illustration of a packed bed column 540 having a hydrocarbon inlet 591 and a solvent inlet 592 . A packing region 588 is provided upon a support plate 586 . Packing region 588 comprises suitable packing material including, but not limited to, Pall rings, Raschig rings, Kascade rings, Intalox saddles, Berl saddles, super Intalox saddles, super Berl saddles, Demister pads, mist eliminators, telerrettes, carbon graphite random packing, other types of saddles, and the like, including combinations of one or more of these packing materials. The packing material is selected so that it is fully wetted by the continuous solvent phase. The solvent introduced via inlet 592 at a level above the top of the packing region 588 flows downward and wets the packing material and fills a large portion of void space in the packing region 588 . Remaining void space is filled with droplets of the hydrocarbon liquid which rise through the continuous solvent phase and coalesce to form the liquid-liquid interface 598 at the top of the packed bed column 540 . Aromatic-lean hydrocarbon liquid is removed from outlet 594 at the top of column 540 and aromatic-rich solvent liquid is discharged through outlet 596 at the bottom of column 540 . Packing material provides large interfacial areas for phase contacting, causing the droplets to coalesce and reform. The mass transfer rate in packed towers can be relatively high because the packing material lowers the recirculation of the continuous phase.
Further types of apparatus suitable for aromatic extraction in the system and method herein include rotating disc contactors. FIG. 6 is a schematic illustration of a rotating disc contactor 640 known as a Scheiebel® column commercially available from Koch Modular Process Systems, LLC of Paramus, N.J., USA. It will be appreciated by those of ordinary skill in the art that other types of rotating disc contactors can be implemented as an aromatic extraction unit included in the system and method herein, including but not limited to Oldshue-Rushton columns, and Kuhni extractors. The rotating disc contactor is a mechanically agitated, counter-current extractor. Agitation is provided by a rotating disc mechanism, which typically runs at much higher speeds than a turbine type impeller as described with respect to FIG. 3 .
Rotating disc contactor 640 includes a hydrocarbon inlet 691 toward the bottom of the column and a solvent inlet 692 proximate the top of the column, and is divided into number of compartments formed by a series of inner stator rings 682 and outer stator rings 684 . Each compartment contains a centrally located, horizontal rotor disc 686 connected to a rotating shaft 688 that creates a high degree of turbulence inside the column. The diameter of the rotor disc 686 is slightly less than the opening in the inner stator rings 682 . Typically, the disc diameter is 33-66% of the column diameter. The disc disperses the liquid and forces it outward toward the vessel wall 698 where the outer stator rings 684 create quiet zones where the two phases can separate. Aromatic-lean hydrocarbon liquid is removed from outlet 694 at the top of column 640 and aromatic-rich solvent liquid is discharged through outlet 696 at the bottom of column 640 . Rotating disc contactors advantageously provide relatively high efficiency and capacity and have relatively low operating costs.
An additional type of apparatus suitable for aromatic extraction in the system and method herein is a pulse column. FIG. 7 is a schematic illustration of a pulse column system 740 , which includes a column with a plurality of packing or sieve plates 788 , a light phase, i.e., solvent, inlet 791 , a heavy phase, i.e., hydrocarbon feed, inlet 792 , a light phase outlet 794 and a heavy phase outlet 796 .
In general, pulse column system 740 is a vertical column with a large number of sieve plates 788 lacking down comers. The perforations in the sieve plates 788 typically are smaller than those of non-pulsating columns, e.g., about 1.5 mm to 3.0 mm in diameter.
A pulse-producing device 798 , such as a reciprocating pump, pulses the contents of the column at frequent intervals. The rapid reciprocating motion, of relatively small amplitude, is superimposed on the usual flow of the liquid phases. Bellows or diaphragms formed of coated steel (e.g., coated with polytetrafluoroethylene), or any other reciprocating, pulsating mechanism can be used. A pulse amplitude of 5-25 mm is generally recommended with a frequency of 100-260 cycles per minute. The pulsation causes the light liquid (solvent) to be dispersed into the heavy phase (oil) on the upward stroke and heavy liquid phase to jet into the light phase on the downward stroke. The column has no moving parts, low axial mixing, and high extraction efficiency.
A pulse column typically requires less than a third the number of theoretical stages as compared to a non-pulsating column. A specific type of reciprocating mechanism is used in a Karr Column which is shown in FIG. 8 .
Distinct advantages are offered by the selective hydrocracking apparatus and processes described herein when compared to conventional processes for hydrocracking selected fractions. Aromatics across a full range of boiling points contained in heavy hydrocarbons are extracted and separately processed in hydroprocessing reaction zone operating under conditions optimized for hydrotreating and/or hydrocracking aromatics, including aromatic nitrogen compounds that are prone to deactivate the hydrotreating catalyst.
According to the present processes and apparatus, the overall middle distillate yield is improved as the initial feedstock is separated into aromatic-rich and aromatic-lean fractions and hydrotreated and/or hydrocracked in different hydroprocessing reaction zones operating under conditions optimized for each fraction.
EXAMPLE
A sample of vacuum gas oil (VGO) derived from Arab light crude oil was extracted in an extractor. Furfural was used as the extractive solvent. The extractor was operated at 60° C., atmospheric pressure, and at a solvent to diesel ratio of 1.1 : 1.0. Two fractions were obtained: an aromatic-rich fraction and an aromatic-lean fraction. The aromatic-lean fraction yield was 52.7 W % and contained 0.43 W % of sulfur and 5 W % of aromatics. The aromatic-rich fraction yield was 47.3 W % and contained 95 W % of aromatics and 2.3 W % of sulfur. The properties of the VGO, aromatic-rich fraction and aromatic-lean fraction are given in Table 1.
TABLE 1
Properties of VGO and its Fractions
VGO-Aromatic-
VGO-Aromatic-
Property
VGO
Rich
Lean
Density at
Kg/L
0.922
1.020
0.835
15° C.
Carbon
W %
85.27
Hydrogen
W %
12.05
Sulfur
W %
2.7
2.30
0.43
Nitrogen
ppmw
615
584
31
MCR
W %
0.13
Aromatics
W %
47.3
44.9
2.4
N + P
W %
52.7
2.6
50.1
The aromatic-rich fraction was hydrotreated in a fixed-bed hydrotreating unit containing Ni—Mo on silica alumina as hydrotreating catalyst at 150 Kg/cm 2 hydrogen partial pressure, 400° C., liquid hourly space velocity of 1.0 h −1 and a hydrogen feed rate of 1,000 SLt/Lt. The Ni—Mo on alumina catalyst was used to desulfurize and denitrogenize the aromatic-rich fraction, which includes a significant amount of the nitrogen content originally contained in the feedstock.
The aromatic-lean fraction was hydrotreated in a fixed-bed hydrotreating unit containing Ni—Mo on silica alumina as hydrotreating catalyst at 70 Kg/cm 2 hydrogen partial pressure, 370° C., liquid hourly space velocity of 1.0 h −1 and a hydrogen feed rate of 1,000 SLt/Lt. The Ni—Mo on alumina catalyst was used to desulfurize and denitrogenize the aromatic lean fraction.
The total reactor effluents from the first stage reactors were combined and sent to the second stage reactor for further cracking of the unconverted bottoms. The second stage reactor contains a zeolitic hydrocracking base catalyst designed for nitrogen containing compounds (Ni—Mo on USY Ti—Zr inserted zeolite catalyst) at 120 Kg/cm 2 hydrogen partial pressure, 393° C., a liquid hourly space velocity of 1.0 h −1 and a hydrogen feed rate of 1,000 SLt/Lt.
The once-thru conversion in the second reactor was 56 W % and 30 W % (of feedstock) of bottoms were recycled back to the fractionator. The product yields resulting from the first stage and the integrated process are given in Table 2:
TABLE 2
Product Yields
1st Stage
Overall
Property
VGO-Aromatic Rich
Overall
Stream #
154
174
Hydrogen
2.39
4.01
H 2 S
2.42
2.84
NH 3
0.07
0.07
C 1 -C 4
2.78
2.53
Naphtha
19.08
41.00
Mid Distillates
38.04
57.20
Unconverted Bottoms
40.00
0.37
Total
102.39
104.01
The method and system herein have been described above and in the attached drawings; however, modifications will be apparent to those of ordinary skill in the art and the scope of protection for the invention is to be defined by the claims that follow.
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Aromatic extraction and hydrocracking processes are integrated to optimize the hydrocracking units design and/or performance. By processing aromatic-rich and aromatic-lean fractions separately, the hydrocracking operating severity and or catalyst reactor volume requirement decreases.
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RELATED PATENT DOCUMENTS
[0001] Closely related documents are other, coowned U.S. utility-patent applications filed in the U.S. Patent and Trademark Office—and hereby incorporated by reference in their entirety into this document. Two are copending U.S. provisional applications of Such et al., serials Nos. 60/294,925 and 60/316,945, whose priority benefit is hereby claimed. A third is in the names of Jodra et al., Ser. No. 09/832,638, later issued as U.S. Pat. No. ______, A fourth is in the names of Vilanova et al., Ser. No. 09/945,492, later U.S. Pat. No. ______. A fifth is in the names of Soler et al., Ser. No. 09/919,260, later U.S. Pat. No. ______—together with references cited therein. A sixth is in the names of Subirada et al., Ser. No. 09/919,207, later U.S. Pat. No. ______. A seventh is attorney docket 60013597Z152 in names of Gonzalez et al., titled “REMOTE HARDCOPY PROOFING SERVICE ADAPTIVELY ISOLATED FROM THE INTERNET”, in preparation concurrently herewith, and later U.S. Pat. No. ______. Also potentially of interest and wholly incorporated herein are U.S. Pat. Nos. 6,043,909 and 6,157,735 of Richard A. Holub.
FIELD OF THE INVENTION
[0002] This invention relates generally to remote hardcopy proofing; and more particularly to integration of business systems and procedures for remote hardcopy proofing of printing jobs including color images. Preferred embodiments include integrated features for incorporating the efficiencies and consumer benefits of electronic commerce and advanced technology into buying, soft proofing and data transfer for such printing jobs. Preferred embodiments are especially effective in association with closed-loop-color proofing.
BACKGROUND OF THE INVENTION
[0003] (a) Classical relationships in the industry—Classical participants in the printing or so-called “graphic arts” industry generally fell into these categories:
[0004] a primary customer or client—i.e., a publisher or other entity that wished to have printed goods for its own purposes, ranging from advertising to fiction, technical data or poetry;
[0005] a printing house, which physically produced the final printed goods—and which could vary from a neighborhood family “instant printer” business to a giant international producer of fine-quality books and magazines;
[0006] a prepress entity, which could be a free-standing business serving small printing houses or could be a department or makeready room within a large printing house—and whose function was to receive camera-ready copy and sometimes raw text copy (manuscript) to be typeset, and from these materials to generate printing negatives and plates for use in actual printing production;
[0007] a graphic artist or advertising agency, which could be a free-standing business or could be associated with either the primary customer or the prepress entity—and whose function was to generate, from a customer's instructions and other inputs, the camera-ready copy which would then become the prepress entity's input materials;
[0008] a customer-service representative, ordinarily an individual associated with the printing or prepress house (often the proprietor or manager of that entity), who typically met at that entity's makeready room, or conference room, with the artist's or customer's representative to “show proof”—i.e., personally take from the makeready-room job bins and hand to that representative, for discussion, a preproduction specimen of the job, based on negatives (or plates) that had been readied for production of the finished piece;
[0009] a courier, who simply carried the specimen physically from the prepress or printing house to the artist's or customer's representative in event the latter did not wish to travel to the prepress or printing facilities; and
[0010] a buyer, who once again could be either a free-standing business (sometimes denominated a “printing broker”), or who could be associated with the primary customer or with the graphic artist or ad agency Such and whose function was to select and negotiate with, most commonly on behalf of the primary customer, suitable printing and prepress institutions for the kind and scope of job to be printed.
[0011] Most of these classical categories of participants survive to the present day. Sea changes, however, have arrived with the electronic age—more specifically with its character as a so-called “information age”, and especially with the advent of wide-area networks in general and the Internet in particular, and the WorldWide Web, and the now-familiar concept of a “website”.
[0012] (b) Websites, and other FTP sites—As is well known in this field, the acronym “FTP” means “file transfer protocol”. FTP is a standard procedure for operation of two computers, commonly but not necessarily remote from each other, to copy a computer file from one of the machines to the other.
[0013] The data may pass through the Internet, or through another type of network such as but not necessarily a private network. Alternatively FTP data may pass through a peer-to-peer telephone connection—or even simply a direct cable—between the two computers.
[0014] People skilled in this field will understand that an FTP site or in particular a website enables a user in control of the connection to copy data in one direction or the other, or possibly in both directions. A website is in essence a special case of an FTP site, namely one to which connection is made through the Internet, using its WorldWide Web capabilities.
[0015] A website or other FTP site ordinarily encompasses some sort of user interface, but this may be of a very primitive type—for example, responding only to simple typed-in FTP syntax as through a DOS or Unix console application. Thus for purposes of the present document such a site does not necessarily provide GUI interactions, or even full-screen DOS or Unix data-reading and data-entry functions, although modernly a GUI format is extremely common and popular.
[0016] FTP sites are usually automatic—that is, in normal operation largely free from human intervention. For present purposes, however, most such sites require some level of security, authentication etc. All of that, if present, is considered part of the well-known infrastructure of the FTP site and associated network connections.
[0017] (c) The printing-broker ASP—One way in which the electronic age naturally modified the classical system was to undermine the position of the buyer or broker. The broker's major role was as a purveyor of accumulated information and wisdom about printing and prepress—in other words, as a guide and shepherd who conducted primary customers, in relative safety and surefootedness, to suitable production people.
[0018] The guide, however, extracted a relatively sizable toll (commission) for the guidance, which was a mixture of interpersonal skills with basic information about the industry. In an information age it has been natural for money to seek an alternative route.
[0019] Thus some computer-wise buyers or brokers undertook to gain an economic advantage over other buyers and brokers by automating the process. The familiar introductions, questions, answers and contractual arrangements were easy to convert into text, checkboxes and “FAQS” (frequently asked question-and-answer lists) in websites, and through use of this mechanism a single industry-experienced broker could easily service perhaps an order of magnitude greater clientele, at far lower cost to each customer.
[0020] Great variation in skill, communication, pricing and overall effectiveness is inevitable in such efforts, and many brokers and agents doubtless continue to operate in the classical manner. Their function has given way, however, to a new niche in the industry: a broker/agent “application service provider” or “ASP”. (The acronym and therefore the terminology are likely derived, in that order, by analogy to the better-known “ISP”, or Internet service provider—who simply receives telephone calls and automatically connects the callers to high-speed optic-fiber or cable Internet ports.).
[0021] This printing-broker ASP, or transactional ASP, or by abbreviation transASP serves a function very much akin to the traditional broker/agent function—but does so by inviting customers and printshops alike to come on-line electronically. While on-line they meet, negotiate, and do business with one another through a website intermediary and user interface (e.g., a graphical user interface, “GUI”) protocol rather than through personally guided introductions and personally conducted negotiations.
[0022] (d) The proofer ASP—Another natural modification of the classical scheme arose from the classical industry custom called “showing proofs” (preproduction approximate samples of print jobs)—and the viewing and approving of those proofs. The earlier-mentioned Jodra patent document discusses this function at length, pointing out in particular that it is a central function related to the economics of allocating costs of error or disagreement.
[0023] At the same time, however, classically the viewing of hardcopy proofs itself generated very substantial costs in travel by people whose time was expensive, and in delay, and even in additional disagreements. This process of showing proofs accordingly became another sensitive high-pressure point in the flow of money and other resources through the graphic-arts industry.
[0024] Various computerized proof-related workflow models have rapidly evolved in the natural seeking of lower impedances to the flow of work, time and cash. Since it is now common for customers to supply original artwork in the form of a computer data file, it is natural for a graphic artist, prepress or printing house to want to send back some kind of picture of how the finished job will appear.
[0025] The easiest way to do this is in the form of a set of image data files that can be displayed on a computer screen or monitor, showing with varying degrees of roughness how the makeready work has progressed. Such a file in many cases can be simply sent by e-mail to the customer or agent.
[0026] An incidental benefit has been to reduce the need for commitment of time and talent by the classical customer-service representative mentioned above. Much of what that individual typically did can now be reduced, once again, to carefully drafted text and checkboxes in a website. With care, a personal touch can be maintained at this critical point, while both the enterprise and its customer enjoy improved efficiency and economics—without adverse effects on quality or competition, or survival of the small business entity.
[0027] Already a great deal of convention has grown up around this approach, in the nature of somewhat standardized image-presentation formats (e.g. the “portable document file” or “PDF” introduced by the Adobe company), and likewise somewhat standardized transaction summary formats (e.g. the “job definition file” or “JDF”). Printing out a PDF image on a computer printer is quite commonplace, but introduces myriad complications and still further sources of disagreement—and therefore many operators have focused on the far more straightforward process of showing proof on a computer monitor.
[0028] Since no hardcopy proof is involved, this type of proof is called a “soft proof” or sometimes even a “virtual proof”. It is understood that in many ways what appears on the monitor is intrinsically different from what will appear eventually on some printing medium (such as paper), but such are the pressures of the industry that many participants are glad to accept such variations as a sufficient approximation.
[0029] In fact it is possible that the intrinsic differences are so obvious and striking that they actually defuse a large part of the complication that can arise in showing proofs. For example, the customer may perhaps be warned that “of course” colors and even proportions may appear “very” different from the finished product, and the proof is being shown only to give the customer a “rough” idea that the job is being assembled correctly.
[0030] Because of the very plain intrinsic differences of the self-luminous screen display with its vivid additive primaries and the purely reflective printed matter, rendered in subtractive primaries, customers and artists undoubtedly tend to discount and overlook relatively major differences. In this way, interestingly, many of the most difficult confrontations between printer/prepress and artist/customer may be simply sidestepped. Also interestingly, for many customers and even many artists this is sufficient.
[0031] Soft proofing is particularly useful and adequate at an earlier stage of project development when an artist or advertising agency is showing a concept proof to a customer or buyer. Here it is understood that the final colors, proportions, papers etc. are all only a matter of fine detail; and what is being shown is an original creative idea, fresh from the artistic mind and just first reduced to a tentative wording and layout. It is also usually understood that the final product will be subject to showing of a hardcopy proof.
[0032] In any event the preparation of even a virtual or soft proof is not without its hazards, and this stage of work has engendered another kind of application service provider: the proofing ASP. Such an entity is likely to start off in business with preparation and transmission of soft proofs, and negotiations over them—but perhaps in the nature of the business a proofing ASP tends to gravitate into preparation of hardcopy proofs as well, as customers inquire whether the ASP cannot provide something more permanent and more satisfying.
[0033] The proofing ASP typically enjoys an advantage of having a business outlet with geographical proximity to the primary customer or artist, and by dint of experience and professionalism can do a reasonably creditable job of making a hardcopy proof look generally similar to the anticipated eventual production piece. At this point, however, what is being shown is a printed item on a piece of printing medium that can be held in the hand—and not incidentally can be kept for comparison with what is later delivered.
[0034] Accordingly the customer and artist are much less willing to accept significant variations. The greater capability actually ups the ante as to what is demanded.
[0035] (e) The e-transport ASP—The Internet, although initially it may have sparked much of the computer revolution in the graphic-arts industry, was neither the first nor the last computer network. Furthermore it was neither the first nor last service operated by most of its primary users over telephone connections—examples of particularly successful such services being in the field of legal caselaw research.
[0036] It is also natural that many users have found the Internet unsatisfactory for industrial purposes. The medium was almost pristine in its academic atmosphere as recently as fifteen years ago, but since its invasion by the Windows-driven general public the Internet has now become susceptible to excessive congestion and dropped connections. Particularly for relatively unsophisticated computer users in small businesses, the Internet is also now susceptible to massive proliferation of advertising, junk mail and other distractions from a businesslike procedure. Fast lines (digital service lines or cable) are not available everywhere.
[0037] Offering an escape from all such annoyances—and also offering ancillary services such as large-volume website storage, software escrow, and delivery follow-up—is the private-network ASP. This type of business focuses primarily upon maintaining and operating a reliable fast optic-fiber/coax-cable backbone between major hubs.
[0038] These capabilities are rapidly replacing the classical courier service. The trend is natural since what is to be moved from one place to another is already information in digital form; and the transportation of physical mass (e.g. paper) is fundamentally irrelevant to the transport of image information.
[0039] Some such businesses offer ample dial-up telephone numbers, as do the familiar ISPs. Some offer a customer an on-site termination directly, or almost directly, to the backbone.
[0040] Through various migrations some private-net ASPs have become associated with one or another industry. The graphic-arts industry is one natural magnet for such association, since it supports a very large and steady flow of very large (megabyte and even gigabyte) files.
[0041] (f) ASP hybridization—Some ASPs in and servicing the graphic-arts industry have tended to acquire complementary ASP activities. For example, a private-network ASP may begin to offer specific soft-proofing support services—perhaps because of a bad experience with a graphic-arts customer who went down the street to visit a broker or soft proofer one day, discovered that the broker or proofer had a good deal with another network, and never came back.
[0042] Similarly a printing-industry transASP (e-broker) may begin to offer some limited form of proofing for its customers. The quieter reason may be to keep its customers from straying out of the fold to local graphic artists or local prepress shops that may have convenient proofing capabilities—but who may also want to divert the middleman function to their own channels.
[0043] Analogously a virtual-proofing ASP may begin to offer the so-called “digital asset management” more naturally expected of the private-net ASP. Once again the underlying motivation may be to offer the most comprehensive service possible, with an eye to minimizing a customer's motivation to wander out into the digital-asset-management marketplace and perhaps inadvertently stumble into a cheaper virtual-proof ASP.
[0044] Of course it is not intended to suggest that all ASP hybrids have developed from such protective instincts or specific negative experiences. Some are simply a matter of natural business expansion—into areas, for example, of inquiry from existing customers.
[0045] Nevertheless the phenomenon of vertical expansion among these ASP functions is surely driven in significant part by wariness. Time, talent and even money devoted to cultivating a good customer can evaporate quickly and devastatingly in the maximally competitive, extremely volatile and minimally loyal printing industry.
[0046] One may question, however, the overall efficiency and the primary-customer benefits of such integration. A first impact of this trend appears to be greater redundancy for each of the functions involved—and then an even-more-heightened competitiveness, in an industry already marked by low margins and a frenetic work ethic. In the end a resulting trend is to squeeze out small operators, who have traditionally tended to preserve the primary customer's options for diversity, enduring economy, and personal service.
[0047] Although a certain amount of copartnering is seen among some successful graphic-arts ASP enterprises, the cautionary character of the printing-business mind tends to deter full and fruitful exploitation of this healthy alternative to vertical expansion. This limited degree of copartnering may be seen as a significant problem in the printing industry.
[0048] Another deterrent, adding to the same problem in the industry, is a lack of full interoperability between different service ASPs. A certain degree of effort to build standards for linking various printing ASPs has been proposed in the trade, as for example in the PrintTalk Consortium, but this thrust has not been successful—at least not yet.
[0049] Furthermore it appears to focus most on e-commerce aspects, rather than technical aspects, of coventuring. That is, PrintTalk defines basically a protocol to perform print-job brokering—request for quote, quote, order and so forth.
[0050] Implementation of such proposals for interASP integration is strongly hindered by the present state of the art. The reason for this is that diverse so-called “job models”—or “life cycles”, or “workflow management” designs—are barriers to interoperability. These terms are all in essence synonymous, and refer to the basic functions of knowing and changing either the status of a job (whether or not a proof is involved) or actions that can be taken in relation to a job.
[0051] For example, a remote-hardcopy-proofing ASP may not have a job model that supports closed-loop color proofing in which colors on the printing medium are objectively measured and checked. As another example, in order to job-out a single client's work to two different remote proofing ASPs, a transASP would have to somehow integrate different remote-proofing workflows with different job models.
[0052] These barriers are problematic. Increased copartnering would benefit not only the consumer (by fostering a healthy form of efficiency and a healthy degree of competition while deterring more-savage aspects of competition), but also the smaller operators in the field—by enabling them to compete more effectively without resorting to cutthroat strategies. Therefore, enhancement of stimuli to such coventuring efforts among complementary ASPs would be beneficial across the board.
[0053] An example of what is basically a graphic-arts transactional ASP is the company known as PrintCafe. Examples of businesses whose primary focus has been service as a virtual-proof ASP are RealTime Proof and the former Vio. An example of the private-net ASP is Wam!net.
[0054] Each of these three businesses has moved into aspects of the graphic-arts industry that overlap with the primary functions of one or both of the other two businesses.
[0055] (g) The hardcopy proofing service—Into the classical picture of the graphic-arts industry, the previously mentioned patent document of Jodra introduced a new blend of technology and business relationships. One key characteristic of that new blend was a novel directionality of proofing-data flow between a prepress or printing house and a buyer or primary customer: the prepress/printing entity prepared a proofing data file containing not only image data as such but also embedded information about the production press on which the job was to be printed.
[0056] Remote proofing is also the topic of U.S. Pat. Nos. 6,043,909 and 6,157,735 of Richard A. Holub—though it seems with primary emphasis upon soft proofing. His patents focus on the mathematics of color science.
[0057] Holub recounts the known facts that it is possible to characterize the color-rendering details of proofing devices (and production printers as well) in a way that is perceptually based and mathematically general. He also reminds his readers that it is possible to invert such characterizations so that a proofing device can generate perceptually standardized, or nearly standardized, color appearances.
[0058] By simply aggregating such known methods Holub outlines how to operate production and proofing systems over a broad network so that color variations between proofs and production runs are minimized, and production of the same job at widely separated plants produces near-identical output. By virtue of this essentially conventional scheme, multiple production facilities can run duplicate portions of a very large, geographically disparate pressrun to minimize shipping distances, delays and costs.
[0059] Holub, however, says little about the dynamic of interplay between complementary enterprises, or of competition, within the printing business. Although the Jodra approach represented an important refinement of relationships among the classical participants in the industry, it too stopped short of dealing fully with the newly evolved application service providers discussed above.
[0060] (h) Software application interentity menu sharing—Another known technology, not heretofore associated with remote hardcopy proofing services for the printing industry, is the modification of application menus of one business entity's user software, to incorporate menu items of another entity's complementary programs. Due to the modularity of modern programming, particularly in the graphical user interface (GUI) environment, such incorporation is usually straightforward and without disruption to operation of the host application. Below are commercially important examples relating to the extremely popular Word-Perfect® word-processing software.
[0061] A user of WordPerfect software who installs Lexis® legal-research software in the user's computer will find that certain Lexis program icons and dropdown menus thereafter appear within the WordPerfect menu—simplifying extraction of Lexis search results into WordPerfect documents. If a WordPerfect user installs MathType® software for generating mathematical equation images, subsequently a MathType program icon and dropdown menu appear in the user's WordPerfect menu to facilitate embedding MathType equation images into WordPerfect documents.
[0062] After installation of AddressMate® software, which operates a dedicated small serial printer for printing individual address labels, an AddressMate icon and dropdown menu then appear in the WordPerfect menu. Thereafter when the user drafts a coverletter for a package, the AddressMate software automatically undertakes to find the recipient address in that coverletter and copy it into a label format for automatic addressing of a corresponding package label on the attached serial printer.
[0063] Analogous installation of HotDocs® software, and automatic incorporation of a HotDocs® icon into WordPerfect menus enables a user to quickly and semiautomatically embed a HotDocs form commercial lease—or employment contract, or promissory note, or other legal form—into a WordPerfect document. In some cases these two-application integrations are by permission of the publisher of the preexisting host application (i.e. in the foregoing examples the publisher of the WordPerfect application) and perhaps even collaborative—being facilitated by assistance from the host publisher with necessary source code and programming recommendations to facilitate and optimize the integration.
[0064] Such collaborations sometimes prove so popular that the host publisher may include the satellite program (as with e.g. MathType) into later editions of the host application. In other cases such integrations may be essentially parasitic, a relatively benign form of commercial piracy—perhaps quietly overlooked by the host publisher when it appears that the incursion is beneficial to users and therefore garners additional profitable business for the host publisher.
[0065] For present purposes it is instructive to contrast the mutually beneficial commercial symbiosis of all such incorporations with the recent well-known struggle between legitimate and arguably illegitimate publishers in a wholly different industry: the music business. There the piracy of the seemingly renegade “Napster” enterprise undertook to convert and disperse the established value of thousands of copyrights with no benefit whatever to the original creative artists or their legitimate successors. Thus in the present context, though it is desirable to stimulate complementary ASP activities for the remote hardcopy-proofing art, it would be undesirable to do so by any mechanism that could facilitate piracy or like efforts to make off with the value of talented people and industrious enterprises.
[0066] (i) Conclusion—Accordingly, the prior art in the remote hardcopy-proofing field has failed to show the way to effectively integrating the efforts of complementary ASPs, particularly in ways healthy for competition and consumers. This failing has continued to impede achievement of uniformly excellent remote proofing. Thus important aspects of the technology and business structures used in the field of the invention remain amenable to useful refinement.
SUMMARY OF THE DISCLOSURE
[0067] The present invention introduces such refinement. In its preferred embodiments, the present invention has several aspects or facets that can be used independently, although they are preferably employed together to optimize their benefits.
[0068] In preferred embodiments of a first of its facets or aspects, the invention is a remote proofing computer system. The system includes a closed-loop-color remote hardcopy proofing service (RHCPS).
[0069] The service provides an RHCPS user interface having data about a printing job to be hardcopy-proofed. From this phrasing, “having data about”, people skilled in this field will understand that such an interface enables a user to read such data, or to enter such data—or possibly both, as appropriate.
[0070] The interface is not necessarily a Windows®-style or McIntosh®-style graphical user interface (“GUI”), although this may be preferred for its marketing advantages. Rather the interface may take any of a great variety of forms, especially including DOS- or Unix-style control screens with multiple data-display or -entry fields (but no icons or other elaborate graphics)—in the typical style of a classical DOS or Unix application.
[0071] The system also includes a graphic-arts application service provider (ASP). The ASP provides a remotely accessible ASP FTP site or website having data about its service—meaning, again, that such data can be copied to the site, or from it, or in appropriate cases both.
[0072] The RHCPS interface includes an RHCPS link to the ASP data, when an RHCPS user is also a user of the ASP. Thus, whether or not the FTP site or website itself provides a GUI or other high-level interface, when dealing with data transfers to or from the ASP the user typically (but not necessarily) enjoys the benefit of some formatting and interactivity provided by the RHCPS interface.
[0073] The foregoing may represent a description or definition of the first aspect or facet of the invention in its broadest or most general form. Even as couched in these broad terms, however, it can be seen that this facet of the invention importantly advances the art.
[0074] In particular, this aspect of the invention as just described provides a key feature that enables and facilitates solutions to the problem of effective and smooth cooperation or coventuring of complementary graphic-arts enterprises. As will be seen, this aspect of the invention tends to soften or remove coventuring barriers discussed earlier and ranging from distrust to simple interoperability mismatches. With these obstacles minimized, small and large enterprises alike—and consumers as well—benefit from a simpler and more efficient way of doing business that is thereby created.
[0075] Although the first major aspect of the invention thus significantly advances the art, nevertheless to optimize enjoyment of its benefits preferably the invention is practiced in conjunction with certain additional features or characteristics. In particular, preferably the closed-loop-color RHCPS is based on a printer device that prints and reads a calibration pattern, and that returns a calibration report to a user who is in a different location from that printer device.
[0076] Another preference is that the RHCPS link to the ASP data appear only if the ASP is an established copartner with the RHCPS. Still another basic preference is that, for each user, the link to the ASP data includes a visible tabulation of that user's graphic-arts jobs with the ASP. (As suggested earlier, the ASP interface as considered at this particular point need not be a GUI or even a multi-field DOS/Unix screen for input and output, provided only that data elements within the ASP computer system are subject to reading or manipulation through control screens of the RHCPS.)
[0077] If the latter preference (i.e. a visible tabulation of the user's jobs with the ASP) is observed, then preferably the tabulation includes an active graphic-arts dialog window for addition or modification of that user's own graphic-arts jobs. In this case, then another preference in turn is that the modification in the graphic-arts dialog window include an option of deleting that user's own graphic-arts jobs.
[0078] Another subpreference to the basic visible-tabulation feature is that the RHCPS maintain data linking each RHCPS user to each ASP which has such a remotely accessible FTP site or website, and with which that user is registered. In this case, then—also preferably for each user—the RHCPS interface link to the ASP data appears only for an ASP with which that user is registered. A still-further subpreference, if this registration constraint is implemented, is that—for each particular job that a user has associated with an ASP—the RHCPS automatically routes proof reports and related details to the user through that ASP rather than to the user directly, unless the user specifically instructs the RHCPS to the contrary.
[0079] Another basic preference, i.e. applicable directly to the first main aspect of the invention, is that the ASP's FTP site or website include a user interface with the data about the ASP services. In this case, a subpreference is that the ASP interface include a link to the RHCPS interface when an ASP user is also an RHCPS user. In other words, this is a link going in the reverse direction relative to the previously discussed link from RHCPS to ASP.
[0080] If this reverse-link preference is put into effect, then a hierarchy of further subpreferences is applicable: first, in the ASP interface, the link to the RHCPS interface preferably appears only if the RHCPS is an established copartner with the ASP. In this case then further preferably—for each user—the ASP interface link to the RHCPS interface includes a visible tabulation of that user's jobs that are subject to remote hardcopy proofing. If this is so, then in turn it is further preferable that the tabulation include an active remote-hardcopy-proofing (RHCP) dialog window for addition or modification of that user's own RHCP jobs. Yet further preferably, this modification in the dialog window includes an option of deleting that user's own RHCP jobs.
[0081] If the reverse-direction link is present, then in another hierarchy of preferences the ASP preferably maintains data linking that ASP's users to the RHCPS. In this case then also preferably for each user the RHCPS interface link to the ASP data appears only for an ASP with which that user is registered. If this is so, then also preferably for each particular job that a user has associated with the RHCPS, the ASP automatically routes proofing jobs from the user to the RHCPS rather than to another proofing entity, unless the user specifically instructs the ASP to the contrary.
[0082] Some additional basic preferences relate to types of users and other participants. First, preferably the RHCPS user interface and the ASP's FTP site or website are for operation by:
[0083] a primary customer, including but not limited to a publisher, printing customer, or printing client; or
[0084] a buyer representing a primary customer; or
[0085] a graphic artist; or
[0086] a printing broker; or
[0087] a user that is any hybrid of two or more of the preceding four user types.
[0088] An alternative basic preference, focusing instead on ASP types, is that the ASP is preferably:
[0089] a printing-brokerage ASP; or
[0090] a soft-proofing ASP; or
[0091] a private-network ASP; or
[0092] an ASP that is any hybrid of two or more of the preceding three ASP types.
[0093] In this ASP-type case, the RHCPS link to the ASP data also preferably includes access to further service of the ASP other than RHCPS procedures. If this is so, then further preferably the further service includes:
[0094] if the ASP is a printing-brokerage ASP (transASP) or hybrid thereof, service relating particularly to transactional matters;
[0095] if the ASP is a soft-proofing ASP or hybrid thereof, service relating particularly to generation, checking or approval of a soft proof; and
[0096] if the ASP is a private-network ASP or hybrid thereof, service relating particularly to data transmission or storage.
[0097] Other preferences, relative to the ASP-type basic preference, include these: if an RHCPS user is not an established user of any particular ASP (of any one type of the three ASP types or a hybrid thereof), then the RHCPS interface preferably includes an RHCPS link to data of all ASPs—
[0098] which are established copartners with the RHCPS; or
[0099] of that one type or hybrid, which are established copartners with the RHCPS.
[0100] In preferred embodiments of its second major independent facet or aspect, the invention is a computerized remote proofing method. It includes the step of operation, by a user, of a closed-loop-color remote hardcopy proofing service (RHCPS) user interface, to gain access to data about a printing job to be hardcopy-proofed.
[0101] It also includes the step of granting, by a graphic-arts application service provider (ASP), of access to data about the ASP's service. This step is in response to the user's activation of a link, within the RHCPS interface, to a user interface of the ASP. The RHCPS user is also a user of the ASP.
[0102] The foregoing may represent a description or definition of the second aspect or facet of the invention in its broadest or most general form. Even as couched in these broad terms, however, it can be seen that this facet of the invention importantly advances the art.
[0103] In particular, this aspect of the invention calls for complementary behavior, on part of the ASP, to system establishment and operation of the RHCPS itself. More specifically this is a first one of two distinctly different kinds of complementary function provided by the ASP—this first kind being simple access, for an ASP user, to the ASP's own data (but through the RHCPS).
[0104] As suggested earlier, for purposes of this first kind of ASP cooperation, the ASP's interface can be very simple, even limited to type-in console-application syntax. That is because this mode of operation can depend on the RHCPS to provide for a nice presentation. On the other hand, as will be seen in the “DETAILED DESCRIPTION” section, this minimalist arrangement is not a requirement; i.e. the ASP if desired may provide the data preformatted in the ASP's own customized GUI or multifield-DOS/Unix presentation, which may be as elaborate as desired.
[0105] Although the second major aspect of the invention thus significantly advances the art, nevertheless to optimize enjoyment of its benefits preferably the invention is practiced in conjunction with certain additional features or characteristics. In particular, preferably the operating step includes actions supporting preparation of a remote closed-loop-color hardcopy proof, by a printer device that prints and reads a calibration pattern and returns a calibration report to an entity in a different location from that printer device.
[0106] Another basic preference is that the granting step occur only if the ASP is an established copartner with the RHCPS. Yet another is that the granting step include presenting to the user a visible tabulation of that user's graphic-arts jobs with the ASP.
[0107] As in the first main aspect of the invention, if this visible-tabulation preference is met then it is further preferable that the presenting step include opening an active graphic-arts dialog window for the user's addition or modification of that user's own graphic-arts jobs. If this is done, then it is also preferable in turn that the opening step include permitting the user to delete that user's own graphic-arts jobs, by means of the dialog window.
[0108] Another subpreference to the visible-tabulation feature is to include the step of maintenance, by the RHCPS, of data linking each RHCPS user to each ASP with which that user is registered. In this case it is further preferable that, for each user, the granting step be performed only by an ASP with which that user is registered. If this registration constraint is in effect, then preferably the method further includes—for each particular job that a user has associated with a particular ASP—automatic routing, by the RHCPS, of proof reports and related details to the user through that ASP rather than to the user directly. This automatic routing, however, is not performed if the user specifically instructs the RHCPS to the contrary.
[0109] In preferred embodiments of its third major independent facet or aspect, the invention is a computerized remote proofing method. It includes the step of operation, by a user, of a graphic-arts ASP user interface, to gain access to data about the ASP's service.
[0110] It also includes the step of granting, by a closed-loop-color remote hardcopy proofing service (RHCPS), of access to data about the RHCPS. This granting is in response to the user's activation of a link, within the ASP interface, to a user interface of the RHCPS—i.e. a reverse link as mentioned earlier. The ASP user is also a user of the RHCPS.
[0111] The foregoing may represent a description or definition of the third aspect or facet of the invention in its broadest or most general form. Even as couched in these broad terms, however, it can be seen that this facet of the invention importantly advances the art.
[0112] In particular, this aspect of the invention highlights a second kind of complementary behavior, on the part of the ASP, to system establishment and operation of the RHCPS. Here a greater burden is placed on the characteristics of the ASP's interface.
[0113] The ASP's interface now is assumed to be sufficiently user friendly for its customers' purposes—whether an elaborate GUI or a type-in console-application syntax or anything in between (multifield reading/entry etc.). For some sophisticated operators, type-in syntax is quite sufficient, although for most at least a multifield control screen is preferable.
[0114] In this reverse-link environment, the RHCPS interface may or may not be invoked: here it is the ASP interface that may, if preferred, be allocated all the tasks of formatting and presenting the RHCPS data. As will be understood, for most ASPs there will be no adequate motivation to provide this extra service.
[0115] Some ASPs, however, may want to distinguish themselves over their competitors by providing a more-helpful interface; or may want to provide a richer look and feel; or simply may wish to obscure, for their customers, the fact that the service is available through other arrangements. All of these variations and also all of these motivations are within the overall flexibility, and also within the individuality- and competition-enhancing objectives, of the present invention.
[0116] Although the third major aspect of the invention thus significantly advances the art, nevertheless to optimize enjoyment of its benefits preferably the invention is practiced in conjunction with certain additional features or characteristics. In particular, preferably the granting step occurs only if the RHCPS is an established copartner with the ASP.
[0117] When this is so, then for each user the granting step preferably includes displaying a visible tabulation of that user's jobs that are subject to remote hardcopy proofing. If so, then the displaying step preferably includes opening an active remote-hardcopy-proofing (RHCP) dialog window for addition or modification of that user's own RHCP jobs.
[0118] This opening step in turn preferably includes enabling the user to delete that user's own RHCP jobs. Other preferences described above in relation to the reverse-link preference for the first aspect of the invention are applicable here as well.
[0119] In preferred embodiments of its fourth major independent facet or aspect, the invention is a method of operating a closed-loop color remote hardcopy proofing service (RHCPS). The method includes the step of making available a computerized, network-based RHCPS operated through at least one user interface.
[0120] Another step is, for each project of the RHCPS, establishing functioning computerized relationships among the RHCPS and entities that include at least a primary customer and a printshop. Yet another step is enabling any of those entities to initiate a project—and thereby define default operating conditions that determine which of the entities sees, in the at least one user interface, each other one of the entities respectively.
[0121] A still further step is—regardless of which of the entities initiates the project and defines the default relationships—reserving to at least one of the entities (i.e., a participant other than the RHCPS) an option of redefining operating conditions to override the default conditions.
[0122] The foregoing may represent a description or definition of the fourth aspect or facet of the invention in its broadest or most general form. Even as couched in these broad terms, however, it can be seen that this facet of the invention importantly advances the art.
[0123] In particular, this aspect of the invention as just described provides another key feature that balances features associated with the earlier facets. One element that is especially helpful here is the preservation of a specified participant's control over the relationships. As will be seen, selection of the most appropriate participant to hold this role may perfect this aspect of the invention.
[0124] Although the fourth major aspect of the invention thus significantly advances the art, nevertheless to optimize enjoyment of its benefits preferably the invention is practiced in conjunction with certain additional features or characteristics. In particular, preferably the “at least one of the entities”—i.e., the entity that can override the default conditions—includes the primary customer.
[0125] Thus, whereas any of the vendor entities may facilitate establishment of the relationships, fundamentally it is the customer who drives the economics of the entire situation and should usually be entitled to reconfigure those relationships. A further preference is that the method include the step of making available to the primary customer information about the option: it would be a hollow privilege if the customer didn't know about it.
[0126] One preferred way of making the information available is including in an RHCPS user interface seen by the primary customer a link to terms of the RHCPS, which include the information about the option. Mere presence of such a visible link does not itself unduly press upon the customer—particularly a satisfied one—the availability of the option. Plainly these principles are somewhat in tension, and their proper balance is a matter to be carefully considered in configuring the wording, graphics and general level of conspicuousness of the link and of the customer-override terms, in the RHCPS user interface.
[0127] Another, more-specific preference is that the reserving step include enabling the primary customer to redefine which of the entities the primary customer can see. By operation of this fourth facet of the invention, together with these several preferences, the method stimulates competition—while tending to deter redundancy—among enterprises in the printing industry.
[0128] Previously described preferences, particularly relating to the types of entities involved, are applicable for this fourth aspect of the invention too. As noted earlier, the several independent aspects of the invention are most advantageously all practiced together.
[0129] In preferred embodiments of its fifth major independent facet or aspect, the invention is a method of operating a closed-loop color remote hardcopy proofing service (RHCPS) that stimulates competition while tending to deter redundancy, among enterprises in the printing industry. This method includes the step of making available a computerized, network-based RHCPS operated through at least one user interface.
[0130] Another step is, for each project of the RHCPS, establishing functioning computerized relationships among the RHCPS and entities that include at least a primary customer and a printshop. Still another step is enabling any of the entities to initiate a project and thereby define default operating conditions that determine which of the entities sees, in the at least one user interface, each other of the entities respectively.
[0131] Yet another step is—regardless of which of the entities initiates the project and defines the default relationships—reserving to the primary customer an option of redefining operating conditions to override the default conditions. A further step is making available to the primary customer information about the option, by including the information in the at least one user interface or in separate communications to the primary customer.
[0132] The foregoing may represent a description or definition of the fifth aspect or facet of the invention in its broadest or most general form. Even as couched in these broad terms, however, it can be seen that this facet of the invention importantly advances the art by expressly preserving a proper position of the primary as in control, while allowing vendors great latitude in individual style and character of operation—as long as, basically, the primary feels well treated. Preferences here are closely related to those introduced earlier.
[0133] In preferred embodiments of its sixth major independent facet or aspect, the invention is a user interface for a closed-loop color remote hardcopy proofing service (RHCPS). The interface includes RHCPS input/output elements for gaining access to a computerized, network-based RHCPS. These input/output elements are also for entering data and instructions into the RHCPS, or reading data and status from the RHCPS—or both.
[0134] The interface also includes application service provider (ASP) input/output elements for each project of the RHCPS. These elements reflect functioning computerized relationships among entities that include the RHCPS and at least one ASP.
[0135] The foregoing may represent a description or definition of the sixth aspect or facet of the invention in its broadest or most general form. Even as couched in these broad terms, however, it can be seen that this facet of the invention importantly advances the art.
[0136] In particular, this interface provides a basic building-block mechanism for accomplishing the several advances discussed in relation to the first five aspects. Preferences are closely identifiable with preferences for those earlier-introduced aspects.
[0137] As mentioned earlier in connection with the first independent aspect of the invention, the interface is not necessarily a graphical user interface (“GUI”), although this may be preferred for some types of users. Rather the interface may take any of a great variety of forms, especially including the classical DOS- or Unix-style control screens with multiple data-display or -entry fields but no icons or other elaborate graphics. As is well known, such forms are orders of magnitude more efficient in terms of using computer resources—particularly including considerations of speed, storage, and reliability.
[0138] All of the foregoing operational principles and advantages of the present invention will be more fully appreciated upon consideration of the following detailed description, with reference to the appended drawings, of which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0139] [0139]FIG. 1 is a diagram, highly schematic, of a representative hardware system according to preferred embodiments of the invention;
[0140] [0140]FIG. 2 is a picture of a graphical user interface (GUI) for a printshop using the remote hardcopy proofing service (RHCPS), in the case of a direct customer-to-printshop relationship—and particularly where the customer is the first RHCPS customer of that shop (or where the shop operator has already selected the customer from among plural customers);
[0141] [0141]FIG. 3 is a picture of a related interface screen for choosing a job-selection log-in mode, where the customer is not the first RHCPS customer for the shop—or for proceeding directly by customer, job-ticket number, JDF, or date, if the system designers prefer to include such parameters (and default values) in this mode-selection screen;
[0142] [0142]FIG. 4 is a picture of an interface screen resulting from the above-described choice of mode, and displaying a list of customers;
[0143] [0143]FIG. 5 is an alternative screen like FIG. 3 but without the default parameter-entry fields;
[0144] [0144]FIG. 6 is a screen that appears—if the operator selects the JDF job-ticket entry mode in FIG. 3 or 5 , but in FIG. 3 fills in no JDF number—for presentation of the data field for log-in by JDF job-ticket number;
[0145] [0145]FIG. 7 is a screen like FIG. 2, but including inactive jobs;
[0146] [0146]FIG. 8 is a GUI screen showing setup for semiautomatic progression of a job from proofing-file preparation to transmission, nominally using a hot folder;
[0147] [0147]FIG. 9 is a GUI screen for an operator's use in manual movement of the file into a hot folder;
[0148] [0148]FIG. 10 is a screen like FIG. 9, but for the operator's use in only confirming automatic movement into the hot folder;
[0149] [0149]FIG. 11 is a
[0150] [0150]FIG. 12 is a picture like FIG. 3 for the same case but for use by the customer, at the customer's facility, rather than for use by the shop;
[0151] [0151]FIG. 13 is a picture of the GUI screen, analogous to that of FIG. 2 and for the same case of a direct customer-to-shop relationship, but displaying the job list as the customer (rather than the printshop) sees it upon log-in through the FIG. 11 screen;
[0152] [0152]FIG. 14 is a set of three views of a log-in GUI dialog like FIG. 3 in that it is for use at the printing house, and for job selection—but for the case of a proofing ASP added to the parties in the relationship and particularly showing three exemplary link precursors (i.e., reflecting knowledge of an ASP's being involved in at least one of the printshop's jobs): in the “A” view, displaying the log-in choices within data fields; in the “B” view, displaying them as an integral part of the GUI itself, with radio buttons or check-boxes; and in the “C” view showing the choices in an even more structurally integrated way, with labeled click-buttons;
[0153] [0153]FIG. 15 is a set of four examples of a screen that may follow after job selection, i.e. once it is known whether an ASP is involved in the particular job selected—the operator can connect into the system through the ASP (rather than directly) if preferred, and this can be indicated by clicking, as in the “A” view, on a minimal kind of link (an ordinary URL-style hyperlink) from the printshop to the ASP site; or as in the “B” view, using an intermediate level of link (displaying the choices within data fields); or as in the “C” view, using a still higher level of link (displaying the log-in choices as an integral part of the GUI itself—with radio buttons or check-boxes); or as in the “D” view, showing another exemplary link form that is more highly preferred, a maximal level of link integration (displaying the log-in choices as an even more structurally integrated part of the GUI with labeled click-buttons);
[0154] [0154]FIG. 16 is a picture like FIG. 14D, but for the GUI seen by the primary customer rather than operators at the printing house;
[0155] [0155]FIG. 17 is a picture like FIG. 2-which is to say, for use by an operator at the production house—but for the FIGS. 13 and 14 case of a proofing ASP included in the parties, together with the customer and printing shop;
[0156] [0156]FIG. 18 is a GUI data-display picture like FIG. 16, but for use by the customer rather than the printshop;
[0157] [0157]FIG. 17A is an alternative to FIG. 17, a display that may be provided if one of the vendors—here the proofing ASP—has been principally responsible for RHCPS arrangements with the primary customer and wishes to link the customer to that vendor's own GUI rather than the standard RHCPS interface (the vendor's interface in the example being a hybrid with the standard RHCPS interface);
[0158] [0158]FIG. 19 is a GUI data-display picture like FIGS. 16 and 17 but for use by the proofing ASP rather than the customer or shop;
[0159] [0159]FIG. 20 is a picture like FIGS. 2 and 16 (i.e., once again for use by an operator at the printing house), but for the case of a private-network ASP added to at least the first two of the three parties assumed in FIG. 16;
[0160] [0160]FIG. 21 is a picture like FIG. 19, but once again for the customer;
[0161] [0161]FIG. 22 is a picture like FIGS. 19 and 20, but again for the proofing ASP if participating;
[0162] [0162]FIG. 23 is a picture like FIGS. 19 through 21, but now for the network ASP;
[0163] [0163]FIG. 24 is a picture like FIG. 19 (i.e. for use at the printshop), but for the case of a middleman or transaction ASP added to at least the first two of the parties assumed in FIG. 19—and also incorporating yet another party such as an outside prepress house, supplementing the efforts of the final offset shop (any other type of specialty service may be substituted where there is room in the GUI, or by adding a horizontal scroll bar for further participants);
[0164] [0164]FIG. 25 is a picture like FIG. 23, but for use by the customer rather than the printing house;
[0165] [0165]FIG. 26 is a picture like FIGS. 23 and 24, but for use by the proofing ASP if participating;
[0166] [0166]FIG. 27 is a picture like FIGS. 23 through 25, but for use by the network ASP if participating; and
[0167] [0167]FIG. 28 is a picture like FIGS. 23 through 26, but for use by the transaction ASP.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0168] 1. Open Coventuring, with Preserved Clientele
[0169] Preferred embodiments of the invention enable the several types of participants in the printing industry to use a service such as a remote hardcopy proofing service (RHCPS)—and in fact services of any of certain other ASP copartners, and any other vendors that are registered in the system—with only a reasonably minimal concern for the possibility of clientele lost to competitors as a direct result of participation in the service. Yet each client, customer, and in fact each participant at any level, is always free (subject to separate contractual constraints, of course) to change allegiances at will, provided only that the client exercises initiative to find a preferred vendor through means other than behavior of the copartnering ASPs.
[0170] For example the yellow pages phonebook, or a trade directory, can always be used to actively seek an alternative vendor for any of the services involved. None of the copartnering entities or other registered vendors can reasonably expect to prevent such efforts on the seeker's own initiative, unless the customer and vendor have entered into an exclusive service contract of some sort. What is, however, disfavored is subversion of the objectives of copartners and vendors through seductions on the part of the copartnering application service providers themselves.
[0171] These benefits are produced for the participants by programming into the service infrastructure a capability to recognize which of the participating business entities it was that introduced each primary customer to each component, respectively, of the overall interlinked service. That customer is thereafter associated with that introducing entity, or array of introducing entities—unless the customer itself undertakes to revise the association.
[0172] In computer jargon, the customer and the introducing entity are associated simply as a “default”. As those in the programming field know, the quoted word means that this association is the operating assumption, in the absence of contrary information—which can be entered into the system databases by one or more of the parties, perhaps using some other menu and dialog window.
[0173] This arrangement does not imply that the customer's ability to make such revisions should be kept a secret from the customer. In fact that way of operating would not be fair to service participants other than the initially introducing entity. To the contrary, in preferred embodiments of the invention the customer's option of reconfiguring the basic relationships is part of the terms of the RHCPS and is available to be read at some appropriate level in, for example, the “help” screens of the service.
[0174] For example, a particular printing house that signs on for use of the RHCPS should ordinarily be entitled to use it for any primary customer that elects to buy printing from that particular house—including one that wishes to transfer its business from some other printshop. To provide the primary customer less flexibility than that would be rather contrary to the general principle of free enterprise and possibly subject to legal sanction.
[0175] Ideally a proper balance is maintained between, on the one hand, preserving the customer's right to know that such options are available; and, on the other hand, undermining the copartners and other participating vendors by pushing such options onto the customer. In effect the system as thus configured implements basic traditional trade courtesies on the part of printers, ad agencies, graphic artists and ASPs alike—i.e. to refrain from rudely abusing a complementary enterprise in return for a kind referral by sending the customer off to some competitor of the referring enterprise.
[0176] In the classical scheme of things, if a customer expressed to the initial beneficiary of a referral an active discontent with services of the referring entity—then the initial beneficiary would be faced with a difficult professional and interpersonal task. This might call for balancing kind words for the referring entity with suggestions to the customer (based upon principled reasoning as to the substance of the situation rather than personalities) that perhaps, “for this type of project”, a larger enterprise, or smaller one, or differently specializing one, might be more appropriate. (If done well, this behavior might in truth benefit even the initially referring entity, if in fact that entity and the customer were a poor match based upon size, specializations or the like; for the referring entity constantly might be expending extra resources in a hopeless effort to please a customer who represented only marginally profitable business.).
[0177] That sort of delicate weighing and discreet choice of wording is generally unavailable in the conventional electronic-commerce environment; hence the problem outlined in an earlier section of this document. Preferred embodiments of the invention therefore construct an alternative mechanism for striking a different kind of balance, which approximates the classical trade courtesies without demanding so much of the participating vendors. In this way the invention exploits an easily practiced technological solution to reintroduce and maintain a special kind of professional integrity within the e-commerce segment of the trade.
[0178] 2. Network Environment
[0179] The technology itself while novel in application is relatively straightforward technologically, as suggested by the earlier discussion of integrating software peripherals into a major word-processing program. The present invention contemplates establishment and operation of an RHCPS 11 (FIG. 1) over two or more networks—one being the Internet 16 , for those participants who are satisfied with that level of service; and another being at least one private network 25 such as that operated by the company called “Wam!net”.
[0180] In general, transactions and services between particular customers, vendors and e-service entities may proceed partly by Internet and partly by private network, to the extent that those participants prefer; or may instead be entirely on the Internet or entirely on a private network. Users gain access to the most-local portion of the selected network by traditional phone dial-up, or by DSL-style or cable-modem connection, or by ports connected directly to high-speed optic-fiber or coaxial lines that are linked directly to the network backbone.
[0181] A primary customer 12 may itself initiate arrangements for connection and commerce with the RHCPS or other participant 13 , 21 - 24 directly—or one of the other participants (the RHCPS, or other ASP 22 , 24 , 25 , or a trade vendor) may offer to set up the customer's initial connections to get the customer started. As a practical matter, all or substantially all the relevant services involve interconnection of apparatuses, i.e. equipment, of the respective participants; these devices may range from a common personal computer for soft proofing to an extremely specialized prepress (“PP”) facility 23 , or inkjet proofing printer 14 , 15 ; or to network equipment itself.
[0182] An underlying objective of preferred embodiments of the invention is to preserve the value of business-generating efforts by all and any participants, i.e. of entrepreneurial industriousness and goodwill. At the same time these embodiments preserve a maximum degree of utilization of available technology, for the benefit of all involved, i.e. for maximum interoperability of the several systems involved. As suggested earlier, the relatively open-structured but essentially coventuring relationship of entities that is established in preferred embodiments of the invention tends to deter less-salutary motivations, e.g. for piracy, parasitic behavior and the like.
[0183] Shown connected to the networks in FIG. 1 are examples of the several types of participants in preferred embodiments of the present invention. These typically include the principal participants in a basic graphic-arts transaction, namely the customer 12 , printshop 13 and RHCPS 11 .
[0184] In event those are the only participants, then a local proofing printer 14 may be housed at the printshop 13 itself rather than in a separate enterprise as illustrated; and a remote proofing printer 15 may be housed at the primary customer's facility 12 rather than elsewhere as also illustrated. Nevertheless both the local and remote printers are labeled as “RP” (remote proofing) devices because they preferably are both units in a product line of inkjet printers particularly designed and optimized for consistent and reliable closed-loop-color performance in an overall remote-proofing environment.
[0185] Ideally the two printers are essentially identical, and preferably Hewlett Packard products. The principal users 12 , 13 can be connected entirely through the Internet 16 , or entirely through a private-network ASP 25 ; or as suggested partway through one and partway through the other. In such a hybrid network configuration, the interface between the two nets is not necessarily at the facility of some other participant (as shown), but rather may instead at a terminal box or other facility maintained by, e.g., the network ASP.
[0186] Many other possible combinations of participants are possible and frequently encountered in operation of the RHCPS. The example illustrated includes a relatively full complement of such participants: a prepress house 23 associated with the printshop 13 and possibly providing the local proofing equipment 14 ; and a graphic arts (“GA”) house 21 or ad agency etc. somewhat more closely associated with the customer 12 .
[0187] The PP and GA enterprises may be computerized services, i.e. e-commerce ASPs, but in their most common forms they are instead conventional businesses. For example much or most of the communication and materials passing between the primary 12 and the GA 21 are commonly implemented by traditional methods 26 —telephone, or courier, or actually going to see one another, or the like.
[0188] More commonly taking the form of ASPs are the other participants illustrated: a soft-proofing ASP 22 , enhancing its services by maintaining a remote RP device 15 and serving also as a terminal for the RHCPS 11 ; a broker or middleman ASP 24 , here also called a transactional ASP (transASP); and the private-network ASP 25 . In the particular configuration shown, neither the primary 12 nor the GA 21 has a remote-proofing device; hence they depend on the soft-proof ASP 22 and perhaps typically use traditional methods 27 , 26 in making arrangements for and in retrieving the hardcopy proof, carrying it to the primary 12 , and giving approval.
[0189] Emphatically, these methods can be bypassed if the primary or GA, or both, prefer to invest in equipment 15 for receiving and viewing proofs in-house.
[0190] 3. Components of Preferred Embodiments
[0191] For successful operation, it has proven helpful to provide certain distinct elements—listed below—in preferred embodiments of the invention. This should not, however, be mistaken as meaning that all these components are required:
[0192] availability of a printer device able to do closed-loop remote hardcopy proofing (RHCP), including automatic return of a definitive report on color reproducibility—and preferably absolute accuracy—in perceptual or calorimetric terms, or both;
[0193] emplacement of a hardware infrastructure for carrying data—including queries, approvals, exceptions and so on—among or between defined participants;
[0194] establishment of a standardized document-content format which is widely available to industry participants—and which is amenable to streamlining for efficient and unambiguous specification of images to be proofed;
[0195] parallel establishment of a standard job-definition format—also amenable to streamlined specification, but of overall commercial/industrial processing steps; and
[0196] a workflow-management protocol or component that defines the participants, shapes and constrains all their interactions, and thereby integrates the above components to implement the RHCP objective.
[0197] In most-highly-preferred embodiments of the invention, the printer device is a Hewlett Packard product that has the above-mentioned RHCP functions built-in. The hardware infrastructure, for reasons already suggested, is ideally a hybrid of Internet and participating private networks—which latter can be operated by ASPs as noted earlier.
[0198] One of the network subelements is preferably an electronic “gateway” or file-server infrastructure operated by the Hewlett Packard Company or other manufacturer of the printer device. This subelement helps to ensure a proper interlinking of the printers, their updating with software upgrades from time to time, and overseeing of their color-calibration maintenance and basic operating integrity.
[0199] The document-content format preferably is a portable document file (“PDF”) of the Adobe company—but with a stringently reduced parameter set, for streamlining, as will be exemplified in a later section of this document. The job-definition format is likewise a reduced-parameter version of the industry's job definition file (“JDF”).
[0200] Modernly the PDF specification has branched into other standards definitions, based on PDF, and particularly including PDF/X-1 and PDF/X-3. These specifications go along the same general lines of restricting the types of data and parameters that can be used; and in fact one highly preferred embodiment of the invention now uses the PDF/X3 specification.
[0201] (a) Workflow protocol features—The “workflow management protocol”, on which the present patent document particularly focuses, in turn preferably has key features:
[0202] (1) a delicately defined set of rules that interlink diverse participating entities and strike a careful balance among certain competing measures of fairness, loyalty, and autonomy—in an intuitively acceptable way;
[0203] (2) an interentity interface-sharing technique that implements those rules in a manner which, once again, represents a fine balance between discreet, decorous conduct of business and an open, nonsecretive regime;
[0204] (3) support of JDF-based workflow in the abstract;
[0205] (4) notification of job activity to relevant participants;
[0206] (5) logging of job activity; and
[0207] (6) a user interface—preferably but not necessarily a graphical interface, e.g. based on extensible markup language (XML)—that is compatible with the interentity interface-sharing objective—while interacting with all interested users to expedite the entry, retrieval, modification and use of all the information in the system.
[0208] As to feature (1) in this list, the principles of loyalty and autonomy are intrinsically in tension with each other; in other words, they trend oppositely—and the principle of fairness is a kind of moderating influence that may keep them from tearing each other apart or destroying potentially beneficial business relationships. As to feature (2), analogously, discreet and decorous behavior trend in directions that often conflict with openness or nonsecretiveness.
[0209] In preferred embodiments, the workflow-management protocol is not complex so much as it is carefully contoured, at difficult points—so as to accomplish the desired balancing of the contrary-trending business and societal considerations that have been introduced here.
[0210] Features (3) through (5) in the list are more mechanistic. They essentially represent backbone chores that the procedures should accomplish. Feature (6), a programmed computer interface used directly by all or most participants in the system, is at once a medium of communication, an automatic implementer of the mechanistic tasks, and an enforcer of the rules and the technique.
[0211] (b) Proofing ASPs (or primary customers) and the work protocol—A service ASP that wishes to offer a remote-proofing service to its own customers can use the workflow-management component or protocol of the present invention to delegate the management of proof status, as will be explained shortly. In such a situation the ASP infrastructure can itself implement the following functions, or parts of them.
[0212] the method for sharing a proof between the originator and the receiver or receivers, possibly using different models—for example, a mailbox for each user or a shared working site on the network
[0213] (The corresponding element in the classical environment, previously mentioned, is the printer's makeready room, with its job bins and sometimes an adjacent conference room.)
[0214] the transport method and protocols for the proof files, for example provision of a high-bandwidth private network to connect users
[0215] (The classical analog of this element, also mentioned earlier, is a courier.)
[0216] the method or methods for interaction between the final user and the interfaces provided according to the invention
[0217] (Here the earlier-noted classical analog is work of the prepress manager, or the business proprietor, or a salesman.)
[0218] integration with other services provided by the ASP, such as digital-asset management
[0219] (This function corresponds to file cabinets, or a safe-deposit box, or a vault—for holding archival plates, negatives and artwork.)
[0220] The ASP, however, would delegate the management of the proof jobs to the workflow-management component (or protocol) of the present invention. As stated in an earlier section, this workflow- or proof-management function consists of knowing and changing (1) the status of the proofs, and (2) possible actions that can be performed on a proof job at any given moment.
[0221] The service ASP is therefore free to establish a system and protocol that are independent of the details of the “life cycle” of a proof. These elements of the ASP's operations need not be changed when proof-management details are changed.
[0222] The workflow-management protocol or component of the present invention provides an interface that is based on, but moves beyond, industry-standard hypertext transfer protocols (HTTP) and extensible markup language (XML), to provide three groups of functions:
[0223] proof activity—The ASP uses these functions whenever an action is to be taken on a proof, as for example when a user uploads a proof document to the ASP service. The actions are used as input by the workflow-management component and may cause changes in the status of proofs.
[0224] proof status queries—The ASP can perform queries on the status of a certain proof or a set of proofs. The workflow-management component provides replies, which the ASP can use to provide information to the primary customer.
[0225] proof event notifications—These events are initiated by the workflow-management component itself, to notify the ASP and its client of changes in status of a proof job.
[0226] While these functions represent a relatively high degree of interaction between the ASP and the workflow-management component—as to details of a proofing project—that is true in large part because this first example discussed here is for a proofing-service ASP.
[0227] As indicated previously, upon logging on to the RHCPS the service ASP sees only its own projects—and, once the particular customer involved has been identified, sees only its own projects with that customer. This is normally true even if the same customer has projects with, for instance, other service ASPs.
[0228] In many cases such an ASP operates essentially on behalf of a primary customer. A generally comparable degree of close interaction occurs if the workflow-management protocol is operated by the primary's own technical people directly, rather than through the ASP.
[0229] As seen in the following subsections, however, the workflow-management component is also capable of interacting with other types of ASPs beneficially but much less intimately than described above.
[0230] (c) Transaction ASPs (or buyers) and the work protocol—A broker, agent, intermediary, middleman, matchmaker or other print-transaction ASP (transASp) can use the workflow-management component or protocol of the present invention in ways generally analogous to those described above. Such a transaction ASP, however, most commonly does not wish to set up full remote proofing capabilities in its environment.
[0231] The focus of a transASP is in fact the commercial aspects of the industry rather than the operational aspects. Accordingly the transASP more commonly prefers to use remote proofing services provided by service ASPs to supply operational functions for the transactional service.
[0232] In this case, most transASPs, using the workflow-management protocol or component of the present invention, do not care to know specific details of the remote proofing service operations provided by the service ASP. The transASP can use several different ASPs simultaneously for different clients or even for different projects of a common client.
[0233] A transASP that does not implement its own remote-proofing service most typically uses only the proof status query interface module (mentioned in the preceding subsection), to occasionally consult information about proof status. The transaction ASP usually does not want to see the proof, or its approval, or any other related activity unless the transaction is in danger of failing.
[0234] At that point, however, the transaction ASP—if a participant in the RHCPS—at its own facilities can log on to the service. The transaction ASP can then quickly determine whether and exactly when proof material was transmitted to the proofer, when and how a proof was returned, what response was made upon inspection of the proof by the authorized party, and thereby generally just when, how and why the process may have broken down.
[0235] Concerned for the satisfaction of its client, upon which a commission ordinarily depends, the transaction ASP can promptly and efficiently learn what might be done to put the transaction back on track to completion. To accomplish this, as in the other situations described in this document, the transaction ASP will not have to search through many entries pertaining either to its competitors, or to transactions that happen to use no transaction ASP at all, or to transactions with the same printer but other customers of the same ASP, or perhaps even to transactions which the same customer may have placed with a different transaction ASP.
[0236] Rather, the transaction ASP simply need identify its own customer. The ASP then sees only relevant projects, i.e. its own projects with that customer.
[0237] A similar degree of arm's-length interaction with the workflow-management component of the present invention may be appropriate for, e.g., the business manager or financial officer of a primary customer using the RHCPS of the present invention—where the primary customer's technical people are operating the protocol directly as mentioned at the end of the last subsection.
[0238] (d) Transport ASPs (or IT managers, or couriers) and the work protocol—Yet another kind and degree of interaction arises between the workflow-management component of the present invention and a different entity entrusted with transmission of proofing materials for use in proofing, or with return delivery of a proof for viewing. This sort of interaction is ordinarily limited to information about the transmission or delivery itself, a function that usually arises only when some aspect of those events is not fully automatic.
[0239] For instance, if the primary customer or a service ASP has elected to use the services of a transport ASP (private network operator) for such transmissions and deliveries, ordinarily the transport ASP in such workflow is transparent—and also essentially content neutral. The transmitting entity logs on to the network in a generally conventional (and usually automatic) way, and sends; the receiving entity logs on likewise and receives.
[0240] Ordinarily there is no need to otherwise contact or communicate with the transport ASP. If, however, deliveries fail because the connection drops out or is noisy during transmission—or if the sender believes that transmission was complete but the recipient does not have the file—then they can query the transport ASP.
[0241] In preferred embodiments of the invention, if the transport ASP is an active coventurer in the RHCPS, then that ASP can supplement its usual procedures for checking into such situations. Specifically, and very advantageously, at its own facilities the ASP can log on to the RHCPS interface to inspect technical data about the transmission.
[0242] Where there has actually been any passage of data to the private net, the transport ASP can see log-ins by the sender, associated with traceable information about the transmission to see what happened next. This level of interaction with the service is comparable to the contact which occurs if the sender is in a large firm with its own “information-technology” (computer) department, and the sender contacts that department to investigate a failed transmission.
[0243] Another example of the same degree of contact is the relatively unlikely instance of a buyer, prepress service etc. that actually uses a courier service to complete proof delivery through the last leg of a delivery chain, to a primary customer who is not on-line at all. In that case the entity which logs on to determine status may be the courier service.
[0244] In these various situations, as in the earlier sections and subsections of this document related to interactions with the workflow-management component of the RHCPS, what the courier, or IT department, or transport ASP sees tabulated is only its own relevant tasks with relevant parties. This is ordinarily the case even if those parties are engaged in other projects using other couriers, or other transport ASPs, respectively.
[0245] (e) Advantages of the workflow-management component of the RHCPS—The service thus promotes and enhances cooperative coexistence and complementary operations by separate (as opposed to vertically integrated) small and large printshops, ASPs, primary customers, and incidental service firms such as manual couriers. While the primary customers and indeed all of the participants are at liberty to realign themselves with other participants, the RHCPS does not encourage them to do so.
[0246] If a printshop wishes to use the RHCPS to transmit data for proofs, and actually create proofs, for customers, the printshop can do so without concern that the customer—in the actual process of checking projects with that printshop—will see the names of competing printshops. If the customer were directly led by the RHCPS to see those competitors, the printshop might be disposed to make other remote-proofing arrangements.
[0247] On the other hand, if a customer on its own initiative wishes to search the RHCPS for participating printshops, the customer is able to do so. All the same can be said of ASPs and incidental services that has been said of printshops.
[0248] In this way the operating rules of the service promote—but do not enforce—loyalty within the trade. Participants in promoting their own services, whether by direct one-to-one marketing contacts or by media advertising, are at liberty to advertise that they can provide remote hardcopy printing through the RHCPS.
[0249] This protocol thus tends to mitigate and sometimes resolve the previously outlined difficult problems within the industry. In this way the service benefits the economy in general and the several different kinds of participants in particular.
[0250] Further, the workflow-management component is advantageously centralized for use by plural different remote proofing services. In this situation the protocols can be adapted to take advantage of the operating characteristics of specific proofing printers. To consider a case in pertinent point, when a printer is manufactured to perform remote closed-loop color operations, the service can be programmed to facilitate such operations.
[0251] More generally the service can be refined or enhanced internally without requiring any change by participants. The latter simply are free to benefit from whatever additional services or features the RHCPS brings on line—as for instance to support new proof-printer features.
[0252] By virtue of sharing a common job model, or workflow-management protocol, different remote-proofing services can be interoperable. Proofs created by a user in one service can be used by users in other services.
[0253] If a proofing service chooses to provide its own user interface to its users, each of those users can operate with that particular distinctive interface—without needing to know details of features in a counterpart service. Yet plural counterpart proofing services using the centralized RHCPS can communicate with each other through the RHCPS's master interface, sharing and trading excess capacity, overflow work, jobs requiring specialized capabilities, etc.—for the benefit of all.
[0254] The RHCPS also has the benefit of naturally giving users of every type only the information those users require or want. For instance a transASP—perhaps using the workflow-management component simply to obtain a proof-status report—need not know details of the remote proofing services being used.
[0255] 4. User Interface
[0256] This section takes up the element identified as (6) in subsection 3(a) above. A journeyman programmer of ordinary skill can straightforwardly create this interface.
[0257] Its craftsmanly execution is key to success, since most of the advantages discussed above depend upon implementation of the stated principles by the user interface itself. For purposes of definiteness the following presentation will show and discuss a graphical user interface (“GUI”), but as noted elsewhere in this document a much less resource-demanding user interface can be used instead. An overall benefit of the invention is that the objectives and principles are easily but directly embedded in a DOS/Unix-style interface or in a GUI as preferred.
[0258] Once that is done, those objectives and principles become in essence self-fulfilling as the users collectively operate the system from that interface through their respective computers. Here are examples for several different cases:
[0259] (a) Primary customer direct to printshop—Suppose that a primary customer uses no intermediary ASP and has sent materials for a printing job to a printing house directly, and the customer itself has a proofing press at its own facility. When that printshop has the proofing file ready, the shop personnel log onto the RHCPS.
[0260] If this is the shop's first-ever RHCPS customer (direct or indirect), then the RHCPS interface simply displays the name of that customer and a list of all that customer's jobs (FIG. 2); otherwise, the shop's operator looks on the screen for the direct customer, either:
[0261] searching by name in a list of established customers (moving from the screen of FIG. 3, solely for selection of finding-by-customer mode; to that of FIG. 4 for actual entry of initials for, and/or scrolling to, a particular customer); or
[0262] manually typing in the direct customer's name in a data-entry field (FIG. 3).
[0263] In the first, mode-selection screen, the specific default entries (the entries last used) are grayed out for the mode options next to inactive radio buttons. In the option next to the active button (here “customer”), the default entry appears in reverse characters on a dark field, as shown—so that an operator who wishes to return to that entry can do so simply by clicking “OK” or pressing “Enter” on the keyboard. If instead the operator types anything in that field, the reverse-character default entry disappears and the operator's entry appears in normal (not reverse) characters.
[0264] Searching in a list (the first option noted above) is often better, to avoid using a nonstandard or nonpreferred form of the customer's name; nevertheless the second, type-in option may be preferred by fast typists, and can be used even if the customer is an established customer of the shop. In that event, however, the system ordinarily completes the customer's name based upon the operator's entry of just the first few letters—as is nowadays familiar in the address-book functions of e-mail handling programs and the like.
[0265] In either case the RHCPS interface responds with a listing (FIG. 2) of all of that customer's projects—and also, at the top, information about the customer and the printshop itself. This upper part of the display indicates by headings and also by font distinctions which data are for the customer and which for the printshop. To further keep these differences very clear, the printshop data (at right) may be displayed as an integral part of the virtual control panel pictured on the screen, while the customer data (at left) may instead appear within a data subwindow as shown.
[0266] The displayed listing includes several key parameters of the current project, for ready reference—but not all of the parameters for that project. Such a fuller tabulation would typically occupy a large fraction of the screen for just one project, and would contain many pieces of data interesting only to prepress technicians at the printshop, or proofing technicians at the proofing facility. A full or categorized partial tabulation for any project of the current customer is available to the operator upon operating a related control in the RHCPS interface—such as the buttons marked “details/edit” in the bottom half of FIG. 2, at left of the individual job entries.
[0267] Much of the displayed data may be in the database of the RHCPS. Certain other data, however, available in the fuller tabulation—or even in the abbreviated summary (FIG. 2)—may instead reside in the computers of the printshop itself or of the primary customer.
[0268] Those data are called up by links into the shop's or customer's own site. The customer's reference number (“HU-241”) in the example may be such a value, which changes as the operator moves the dark-background selection bar vertically through the ten entries visible in the list, or operates the scroll bar to move other entries into view, or both.
[0269] Up-to-date information for reaching the customer by phone, e-mail, or physical shipment may also be picked up by link into the customer's site, for use by the shop in quickly contacting the customer—as seen from the cluster of controls under the heading “CUSTOMER” at left. Replacing such data, however, with information for specific contact personnel at the customer's facilities is possible too, and represented by the “change” buttons in the same region of the screen.
[0270] (Analogous “change” controls at the right end of the screen are for actually revising the printshop's own site, as telephone and mail contact data change. These are available to the customer by links to the printshop site in the GUI [FIG. 12] as seen by the customer.).
[0271] The operator at the shop next scans the listing for the project whose proofing file is ready. The customer or the printshop may already have entered the project at hand into the RHCPS system; if not, the operator at the shop clicks the “File” menu item at top left, to obtain a generally conventional drop-down menu (not shown) that includes an entry “New” for creating a new entry for the project. Creation of a new job entry typically requires initial entry of some basic facts about the job.
[0272] There is another entirely different way for the shop operator to get to the job at hand, within the RHCPS system—namely, to type-in the printing house's own internal job-ticket number, which the operator knows. This can be done by entering the number directly into FIG. 3—or, in event it is preferred by the system designer not to include that data-entry block in the mode-selection screen—then instead moving from FIG. 5, for selection of job-number finding mode, to FIG. 6 for scrolling to the specified number.
[0273] (Throughout almost all of this document, the phrase “job ticket” refers to a strictly standardized document 9 and computer file known as “JDF” or “job definition format”. At this particular point in the discussion, however, particularly with reference to the illustrations mentioned above, two different kinds of job tickets are under discussion at the same time: here [1] the phrase “job ticket” without more refers to the printshop's conventional internal job ticket, whereas [2] “JDF” refers to the strictly standardized document with its computer file. The JDF is the only kind of job ticket whose use is fully integrated into the RHCPS—but for purposes of meshing with the internal systems of many and probably most printing houses, it is necessary to deal, in the same breath, with the simple, traditional paper job ticket, and its nomenclature “job ticket”. Ideally, where the printshop's internal procedures can stand the change, those procedures are revised so that the JDF is the only job ticket used for any job that is in the RHCPS, and thus the JDF number is the only job-ticket number for those jobs.).
[0274] An operator may know the job-ticket number because, for instance, the operator is holding a paper job ticket in hand. Alternatively a colleague may have just finished the proofing-file preparation and asked the operator to take the project to the next stage.
[0275] As will be seen, the job-ticket number may be known to the RHCPS interface intrinsically through association with the service's own JDF entries; or may be picked up from the shop's site when needed. The operator, however, alternatively can search by (FIG. 3) JDF number or date. (The system can be configured to use the date of entry into the system, or instead the deadline date.).
[0276] For preferred embodiments of the invention the parameters displayed in the mode-selection screen (FIG. 3) are themselves determined by the commercial environment surrounding the job. If the printshop does business with parties other than primary customers, then presumably the shop operator may find it easier to search for some jobs by the names of those other parties—brokers, proofers, network couriers etc. In such a printshop advantageously the list of possible search modes in the mode-selection screen includes additional choices (e.g. FIG. 13B).
[0277] If desired for comparative or other purposes, the operator at the shop may elect to display not only current, open projects but also earlier, now-closed jobs of the subject customer (FIG. 7). More commonly, to focus quickly on needed information for a task at hand, the operator elects to exclude those from the displayed list—when the operator's chore is simply to send a current proof to the customer. If preferred, the designers may also provide the operator yet another display alternative, namely that of listing closed jobs only (not shown).
[0278] Once the shop's operator has an entry on-screen for the project, the operator verifies that this entry includes the already prepared proofing file. Then the operator may click on an icon or button (advantageously in the “details/edit” screen, not shown) to transmit that file through (for the present example) the Internet—including necessary color characterizations based on the production printer and any custom inking etc. that will be used.
[0279] A related way for the proof to be expedited along its path is for the proof-generating equipment (FIG. 8), or operator (FIG. 9), to place the file in a so-called “hot folder”—a known phenomenon in the remote-proofing field, and in other related computer fields (e.g. FAXing software) as well. This can be an entirely automatic operation triggered by completion of the preceding step, or can be a drag-and-drop operation performed by the operator; or can be both of these, e.g. with an operator confirming (FIG. 10) the step initiated by completion of the previous equipment operation. (For this last-mentioned case if desired the system designers can include another choice, namely “Remove from hot folder”—with suitable new status commands on the same or a following screen.).
[0280] The system is programmed to monitor the hot folder and send whatever file is found in it. The transmission path is preset when the arrangements between the customer and printshop are established at the outset, with other parameters of the job.
[0281] At the customer's facility the file may be received automatically or on demand. Depending on the specific Internet access provisions (e.g. DSL line or 56 k modem) in use—and operating options or settings selected—at the customer's facility, the customer's RHCPS terminal (1) may simply acquire the proofing file, or (2) may acquire only a notification that the proofing file is available for downloading, or (3) may acquire nothing unless an operator of the customer's staff logs on to the RHCPS system, via the ‘Net, and checks for incoming documents.
[0282] In some of these cases, if the customer patronizes more than one printing shop the customer's operator may be called upon to locate the job that corresponds to the incoming proof—a procedure analogous to that described above for the printshop operator in finding an entry in the system for the then-outgoing proof. If this step is required, the customer's operator eventually notes from the RHCPS interface a list of printing houses which that particular customer uses.
[0283] If the customer uses more than one printshop, then, in a procedure like that already pursued at the printshop, the customer selects or types-in the name of the shop (FIG. 11). As the RHCPS design variants at this point are directly analogous to those previously described at length for the printshop operator, pictures of the corresponding screen views that follow are omitted here.
[0284] If the customer uses only one printer then the system simply bypasses the printshop-selection step. In any event the RHCPS interface displays (FIG. 12) all the customer's jobs with the particular identified printing shop. (From this it will be understood that the customer's operator can log on to the system to see whether any proof file is waiting, even when no such file is waiting—and naturally will find that there is no proof to be printed just then.).
[0285] This operator selects, from the displayed list, a desired job that has a proofing file waiting—and by operations at the GUI (advantageously through the associated “details/edit” screen, not shown) queues that job to the proofing printer device. For fullest realization of the RHCPS objectives, that printer device is one of the model line which provides closed-loop color functions—particularly including the ability to print, read and interpret a color-calibration test pattern.
[0286] Alternatively the proofing printer device too may operate on a hot-folder principle. In this case any proofing file that is downloaded, even automatically, from an authorized entity—as in this exemplary case the printing house—proceeds to the printer device, preferably, or at least to the printer-device queue.
[0287] The printer device may also have the capability to scan and interpret color data for particular selected regions of the image area within an actual proof to be printed, as distinguished from a calibration pattern. These two kinds of information have their own respective advantages for various kinds of printing jobs and situations.
[0288] A key characteristic of preferred embodiments of the RHCPS is that the proofing printer device automatically transmits back to the printshop, in a different location from the printer device—i.e. not only provides to the proofing operator at the customer's own facility—a report of the pseudocolorimetry operations just described. Thus all parties to the core technical transaction which constitutes “showing proof” can satisfy themselves that what the customer is seeing is truly representative of what the final product (not yet produced) will be—or, in the alternative, can know for themselves in just what ways the proof appearance diverges from a truly representative image.
[0289] If the customer finds that what the proof shows is not acceptable—in particular in terms of color—then the customer may simply send back a notification to that effect, through the RHCPS user interface as before; or may instead, or in addition, communicate with the printshop by phone, e-mail etc. to help pinpoint the objection. The parties usually consult the closed-loop-color technical data to determine whether perhaps the problem may actually be only one of inaccuracy in rendering at the proof press.
[0290] If not, then the printshop usually tries to correct the color in the data file from which it intends to print; and iterates the proofing and review process until the customer is satisfied with the representation of the final product-to-be. Advantageously the operator initiates all of these detailed steps by using controls in one of the “edit/details” screens (not shown), where all of the relevant image technical data are assembled and directly seen—and where there is no question which image or which job is under consideration.
[0291] As before, the data in such screens are assembled by links into both participants' sites as well as the RHCPS database—particularly including the site that is remote from the user at each end of the proofing respectively. Preferred embodiments of the invention thus make the most of both the business and the technical aspects of linking from the RHCPS user interface into the vendor's site, and possibly the vendor's user interface. As will be seen, however, these interlinkings are particularly striking and beneficial for transactions involving one or more additional participants.
[0292] The foregoing chronology has been made rather complete as to not only the contribution of the GUI to the communication process but also several details of the interaction between the customer and the shop—so that it can be seen clearly how the GUI fits into or in some ways simulates parts of the classical interaction between these parties. This level of detail has been presented here because this example is perhaps the simplest commercial situation which the RHCPS implements. Many of these details are the same in the more-complex commercial situations described below, and so will be omitted from descriptions of those situations, which now follow.
[0293] (b) Primary customer via a proofing ASP, to the printshop—This case encompasses several variants or subcases. The customer may use the proofing ASP for only some jobs, or for all; the customer may use only one such ASP exclusively—or may use one for certain jobs and one or more other such ASPs for other jobs.
[0294] The customer may use the ASP to make all the arrangements with a printshop; or instead may use the ASP only for soft proofing and nothing else. Still again, the customer may use the service ASP as an intermediary to the RHCPS, for all the functions of the RHCPS. (Although a customer in purest principle needs no intermediary to the RHCPS, this last option may be beneficial to a customer that is not adept in the workings of the printing industry and seeks a more-gentle buffer to the production people.).
[0295] The customer may use other types of ASPs for some projects, or for all; or may never use other types of ASPs. The customer may either use or elect not to use traditional outside consultants or service entities such as graphic artists, advertising agencies, and couriers.
[0296] To consider fully and separately each of the possible combinations of these several arrangements would be bewildering, and also unnecessary as the basic principles are straightforwardly extended from a description of just one or two ASPs. Therefore, with the basic operation in mind as described in subsection (a) above, only the more-significant departures from that basic operation are noted here.
[0297] The user interface established by the RHCPS has a link to that established by the proofing ASP—and thereby to data on the ASP's site (i.e. computer or computers). There may be a semantic question whether the link is to (1) the ASP's interface, or (2) the ASP's site, or (3) the ASP's computer system. To avoid debates over any such question, for purposes of this document those three concepts shall be considered synonymous.
[0298] In preferred embodiments of the invention the link is not merely a common hyperlink that leads (when “clicked”) to the ASP's site, but rather is a graphical modification of the RHCPS interface itself, which selectively incorporates certain data, and graphical elements if desired, and related functions of the ASP into operation of the remote hardcopy service's GUI.
[0299] The first manifestation of expanded participation when an ASP is involved appears when the printshop's or customer's operator wishes to locate data for a job at hand. Once again it is necessary to begin by deciding how to search—and now there is another option not encountered before, namely to search by proofing ASP (rather than by customer, job number etc.).
[0300] Behind this option is a difference in the character and number of links from the RHCPS site to sites of the customer, printing house, and ASP. In accordance with preferred embodiments of the invention, links to an ASP are now incorporated where before only the RHCPS, customer and printshop were interlinked.
[0301] The degree of apparent integration into the structure of the GUI is advantageously chosen by the system designers. The selection of job-search mode may give the different modes the appearance of data, presented in data windows (FIG. 13A); or the appearance of a part of the virtual control panel flat labeling, selected by marking within radio buttons (FIG. 13B); or the appearance of a part of the virtual controls, selected by clicking virtual raised pushbuttons (FIG. 13C). Similar and other choices are made with regard to the degree of integration suggested in screens (FIGS. 14A through 15) for selecting customer, printshop or ASP, after mode selection is complete.
[0302] It will be understood that in reality all of these modes are equally structural—namely, not structural at all but only a matter of different graphics. The different graphics styles nevertheless are important in that they convey to operators of the system some conceptualization of the business relationships among the RHCPS operator, the ASP and even the customer.
[0303] Where an ordinary Worldwide-Web URL notation is used for a link (FIG. 14A), most Web-wise users will receive a connotation of little or no proprietary connection between parties. It suggests little more than a courtesy referral. A data-window presentation (FIG. 14B) may instead possibly suggest that the parties' relationship is in the nature of arm's-length service by the RHCPS to the other participants: the RHCPS recognizes the parties but treats their data, their identities, and even their functions as essentially fungible.
[0304] A radio-button or check-box presentation (FIG. 14C), with the parties' identities and even their types (e.g. “proofer”) appearing as part of flat-panel labeling, probably connotes strongly to many GUI users that the parties have at least some sort of mutual cooperative agreement. Presenting the identities or even their types at the faces of virtual raised pushbuttons (FIGS. 14D and 15) can suggest to observant users that the parties may be engaged in a copartnering or coventuring form of enterprise.
[0305] Thus—now extending the customer/printshop example of subsection (a) above—when either the customer's or the printshop's operator brings up the opposite party's listing of transactions, a reference to the service ASP may appear in addition (FIGS. 16 through 17A), or instead. The specific situations, and the specific ways, in which this interception of transactions by the ASP, or interjection of the ASP into the printshop/customer workflow, depends intimately upon the specifics of the relationship between the customer and ASP.
[0306] For example if the ASP is handling all proofing details for the client, then when the printshop's proofing file is ready—and the shop personnel log onto the RHCPS to transmit the file—what will be displayed may at first be an identification not of the primary customer but rather of the service ASP. In the same transaction some functions unrelated to proofing as such may instead bypass the ASP and go directly to the primary, provided that the customer or ASP has set up the account that way for the particular job. In that case, if the printshop attempts to brings up the ASP to arrange e.g. delivery, then the GUI can reroute the shop staff to the customer directly.
[0307] Examples of these sorts of shielding or diversion of contacts will be presented shortly in connection with broker-ASP arrangements. As to the proofing ASP under discussion here, however, no such guarded presentation appears. Thus FIG. 16 shows to the printshop operator, in an evenhanded way, all the information needed to contact the primary or the ASP.
[0308] This interface leaves it to an operator's preknowledge of the participants, or otherwise to that operator's experience, intelligence and best instincts, to select the appropriate party for each kind of contact. Such selection may be e.g. technical people for technical questions, business people for business questions, proofer for matters relating to proofing, and so forth.
[0309] [0309]FIG. 17 conversely shows the customer all the information all that is needed to contact the printshop or the proofer. An interesting example of a hybrid setup appears in the alternative form of FIG. 17A: here the RHCPS has linked the customer through to the proofer's site including custom graphics that encourage the primary to contact the proofer rather than the printing house—but do not actively constrain the primary to do so. The data portions of the interface are strictly drawn from the standard RHCPS setup.
[0310] For showing proof, the GUI as seen at the printshop too may lead the shop staff to transmit to the proofing ASP—whether the particular proof is to be a soft/virtual proof for viewing on-screen, or a hardcopy proof. (Here, however, the ASP has perhaps wisely chosen not to approach the shop operator with a conspicuously marketing-oriented style, rather hewing to a just-business-between-tradesmen sort of presentation.) The proofing ASP, most commonly close to the primary customer geographically, is then responsible for contacting the customer to arrange for actual viewing of the proof.
[0311] In the hardcopy case, that contact generally entails arranging a physical movement of printed document to customer, or of the customer to the ASP's facility. The ASP operators can take the opportunity to check the proof themselves, preliminarily, if they in fact see part of their function as providing the “buffer” suggested earlier.
[0312] In this case the ASP may choose to advise the primary how best to deal with irregularities in the proof—what the options and associated cost/benefit relationships are, etc. Alternatively the ASP may instead undertake, on its own responsibility, to reject or even to accept the proof, if that reasonably appears to be within the scope of the understanding between primary and ASP.
[0313] (Such understanding is probably best reduced to writing, but such writing may be conveyed and approved through the same electronic systems as other portions of the communications. In any event, such contractual specifics are outside the scope of this document.).
[0314] [0314]FIG. 18, the view as seen by the proofer's operator, reverts to fully standardized form. These four views thus represent a relatively low-key, open and trusting set of relationships, and this is one very popular business style in the trade.
[0315] As these views suggest, if the ASP elects to use the RHCPS service for part of its communications with the primary customer, then the primary can either be set up to see the RHCPS interface or—if one exists—the ASP's own interface. If the arrangement is the former, i.e. if the customer is to see the RHCPS interface, then in effect the ASP and the customer are operating in parallel; they both see some of the same lists and data from the RHCPS.
[0316] On the RHCPS interface as seen on the customer's computer, however, what appears is the ASP in addition to the printshop—or instead of the printshop—again depending upon the arrangements made. In either event, the customer will see only its own jobs, not other customers' jobs, with the ASP and/or the printshop.
[0317] What appears on the ASP's computer (FIG. 18) in this case is either (1) the customer and the customer's jobs, if the ASP operator elects to call them up that way, or (2) the printshop and the customer's jobs, if the ASP operator elects that approach. The same group of jobs is displayed in either event, provided that the ASP in fact elects to see that customer's jobs (as distinguished from checking on all its jobs with the same printshop).
[0318] If instead the customer is set up to see the ASP's user interface rather than the RHCPS's, then in preferred embodiments of the invention the customer will see its same jobs at the printshop—but only those being handled by this particular ASP. Those data are passed through by the ASP's interface to the customer, but not necessarily with identification of the printshop.
[0319] The latter issue is determined by the setup of the ASP's own interface, which in turn is configured based upon the ASP's preferred way of doing business. Some will operate on the philosophy that openness is an ideal basis for dealing with customers; others on the philosophy that the customer will sooner or later decide to eliminate the middleman and should not be tempted.
[0320] Thus as noted earlier the RHCPS workflow-management component of the present invention accommodates many different business and interpersonal styles, and in many ways encourages divergent healthy forms of competition. What it does not do, in the example under discussion, is either force the ASP to be open when there is concern that this will lead to loss of business; or conversely force the ASP to be guarded when the ASP's philosophy is open—or when there is concern that, for instance, the customer will eventually perceive the guardedness and change vendors as a result.
[0321] The workflow-management protocol is extremely flexible and versatile. In particular the ASP is at liberty to follow the guarded philosophy with one customer—as for instance a customer who is regarded as volatile, or overly price conscious—but simultaneously to follow the open philosophy with another customer, as for instance one who seems inclined toward vendor loyalty, or toward interpersonal criteria in selecting or maintaining vendors, or perhaps simply one who is too sophisticated to be kept in the dark. The RHCPS interface options are set up as a tool whereby the ASP can implement its own philosophies as convolved with its assessment of individual customers.
[0322] Although the array of these several variants may seem complex in discussion, as will be understood indication of the selections is very straightforward in terms of user-interface options. Once so entered, the RHCPS system continues to implement the agreed-upon arrangements unless and until others are substituted.
[0323] (c) Primary customer via a network ASP to the proof ASP or printshop, or both—The variants of this case, in comparison with those taken up in the preceding section, represent both a different function and another level of complexity. Functional contributions of a network or “transport” ASP to completion of projects that entail remote proofing is qualitatively different from those of the proofing ASP considered in subsection (b) above; yet as will be seen the RHCPS workflow-management component readily accommodates the transport function as well as the proofing function.
[0324] As to complexity, the involvement of a network/transport ASP is not necessarily simply a substitute for the proofing ASP arrangements discussed above, but can instead be an overlay on the several variants of the proofing ASP. In other words, the commercial relationships are not limited to being linear or three cornered at most, but can involve four and five parties to the same transaction.
[0325] In fact the feasibility of using so many different specializing enterprises for the same job is strongly and distinctly enhanced, not obstructed, by preferred embodiments of the present invention. The workflow-managing module helps greatly in keeping all the participants in step, informed, and ready to make their contributions at the right times without tripping over one another—as they might if all the arrangements had to be made by, for instance, FAXes and telephone calls.
[0326] First as to the different function, again positing the basic situation of a printshop that has a proofing file ready for transmission, suppose first that there is a network ASP involved but no proofing ASP. The printshop then seeks to provide the file to the primary customer.
[0327] The network ASP may be engaged either by the printshop or by the customer. Furthermore, if it is the shop that elects to use the private network it may do so either for all customers or for just the particular customer in question—or even for just certain jobs, or certain jobs of that customer.
[0328] Conversely if it is the customer's election to use a network ASP, that may be for all printing work, or only for jobs with the particular printshop, or only for just certain jobs, or certain jobs with that printshop. In any event, when the printing-house operator is ready to send the proof to the customer, as with the proofing ASP the operator can log onto the RHCPS interface and locate the job either by customer or by ASP (in this case, probably the ASP whose function is involved, namely the network provider).
[0329] Also if preferred, the operator can identify the job by searching with some internal indicator (job ticket number, for instance) which the operator happens to know just as in the linear or two-party case. Here as before, once the operator has called up the job on the remote-proofing interface the correct contact is invoked inherently by those same keystrokes. (Other options mentioned earlier, including a hot folder, are equally applicable here.).
[0330] The system, in other words, is ordinarily preconfigured, when the job is first set up, to transmit in some particular way specified at the outset as between the customer and the shop. Thus if a network ASP is to be used, then when the operator instructs the system to proceed with the transmission it is most commonly ready to do so by routing the file through that designated network. Most typically the necessary connections for the transmission are preset for that network.
[0331] All of these choices are directly analogous to those illustrated earlier. Accordingly the illustrations (FIGS. 3 through 6, 11 , and 13 A through 15 ) presented in the preceding subsections for job search shall be considered to illustrate the present subject matter as well—the differences in screen appearance being only a matter of inserting a different participant type and identity, manifesting the involvement of links to a different sort of participant.
[0332] At the other end of the transmission, in this relatively simple case of printshop and primary customer working through a private network, from the perspective of the customer's operator the scene is again rather simple. As before, that operator can receive, or watch for, or look up, its pending jobs by printshop, or by network ASP (unless that information is inhibited by arrangements with the printing house, as will be explained shortly)—or once again by an RHCPS JDF job ticket number, or simply by the customer's own internal reference number for the project, or a relevant date.
[0333] In any of these events the customer operator is drawn quickly to the incoming proofing file. An alternative arrangement, as mentioned in an earlier example, is along the model of a hot folder that sets up the job to run on the customer's proofing printer upon receipt, without necessarily involving any operator action.
[0334] This subsection focuses upon participation of the network ASP, and positive benefits flow from the present invention in this regard as well. More specifically, when any question arises about the transmission, not only the primary-customer and the printing-house operators but also an network-ASP technician readily gain access to all the identical particulars of the transmission.
[0335] This means that precisely the data seen by the two operators about the transmission, as initiated from the printing house and into the ASP's own equipment, can be seen by the ASP technician. Usually the net-ASP's screen display is augmented with additional technical data developed at the point of launching the file into the network.
[0336] In the absence of this RHCPS workflow control, the scene is instead one that is nowadays very familiar. An upset user telephones a harried technician, trying to describe something relatively nebulous that happened sometime earlier in the day, or perhaps the previous day.
[0337] When instead two or all three concerned parties can quickly be looking at the same data, at the same time, the results are salutary in several ways. This commonality of information among three parties to a troubleshooting conference contributes greatly to a valuable calming sense of orderliness and confidence, as well as to speediest possible actual resolution of any flaw in the transmission. This collaborative model is strikingly different from an all-too-common scenario of the computer era—two vendors each telling a primary customer to check with the other vendor.
[0338] These technological benefits, however, to a certain extent are transcended by commercial advantages introduced earlier. Thus for example the printing-house operator may be concerned that in conversation with the customer the network ASP may give away too much information about competing printshops that also happen to use the net ASP; and in this case the workflow-management service can be configured to minimize contact between customer and ASP.
[0339] Even in attempting to resolve a transmission-failure situation it is not strictly necessary to convene all three of the operators. Rather, if the printshop has a policy of minimizing exposure of customers to use of the network ASP then ordinarily the problem can be promptly resolved between the shop and the ASP.
[0340] In such a situation the printshop elects to take on a slightly greater part of the burden of resolving the matter, in return for maintaining its more-guarded stance as to its supporting net ASP. Even the use of the private network itself can be made particularly inconspicuous if that network serves primarily a leg of the connections which is between the printshop and the Internet.
[0341] If desired, the RHCPS interface as seen at a customer's facility can be made to see only the printshop identification, and not the network ASP's at all. The net-ASP activities in effect then become a part of the printshop services.
[0342] Of course the customer is always free to inquire separately into the full character of the RHCPS or of the net ASP. In that event the customer can if desired establish, or reestablish as the case may be, a fuller control of its own commerce.
[0343] Now secondly, as stated at the beginning of this subsection (c) it is possible that the participants are not only three—the customer, shop, and net ASP—but also a proofing ASP such as discussed in the previous subsection (b). Representative forms of the user interface for these four-cornered situations appear in FIGS. 19 through 22—here too the basic model being one that is relatively open, yet with room for fine adjustments. In this case once again the RHCPS workflow manager seamlessly integrates all these elements, sending the file to the right party (whether customer or proofing ASP, or both) and through the prearranged network.
[0344] In this environment any failure of smooth operations would ordinarily—that is, in the absence of the RHCPS workflow component—be a source of major abrasion. It is a well-known irritant, in the computer age, that every participant seems to suggest some other participant as the root source of any failure. The greater the number of parties involved, the more frustrating and even exasperating this phenomenon can be.
[0345] The RHCPS, however, instead enables efficient resolution of service interruptions on a participative basis, in even a four- or five-cornered transaction, where the participants are operating in a relatively open understanding about the relationships among the several services. At the same time preferred embodiments of the RHCPS can accommodate other forms of understanding—e.g. they may permit some of the vendors involved to shoulder some added fraction of effort required to keep operations running smoothly, in return for the ability to partly isolate customers from other operators in the trade.
[0346] Although the desire to work openly or guardedly has been discussed above in relation to printshops, other parties may wish to exercise such options. Preferences of this sort may be felt by ASPs and even by customers—for reasons of simply wishing to control their own costs, or business confidences, or operating image; or whatever personal reasons may arise.
[0347] In these ways the RHCPS resolves many of the business tensions discussed in the “BACKGROUND” section of this document. It thereby promotes and enhances competition of an economically healthy kind, and minimizes the problems set forth in that earlier section.
[0348] (d) Primary customer via a transaction ASP to other parties—Here too, this transASP may be in a relatively simple direct business relation between the primary and the printshop, with no other ASPs involved; or this ASP's relationship may be only one of several. That is, in addition to the middleman ASP there may also be any of the previously described relationships with ASPs for proofing or for data transmission, or both.
[0349] The general principles for preferred embodiments of the invention here, however, are analogous to those discussed above. In view of the relatively extensive earlier discussions, these general principles are only summarized here: the RHCPS interface, as before preferably though not necessarily a graphical type, gives each user log-in options custom-established for that specific user—and based upon several factors.
[0350] Factors include (1) all entities that are party to the particular transaction of interest; and (2) preferences of the entity that initiates the RHCPS arrangements for the particular transaction—sometimes subject to understandings with some other entity or entities, as noted earlier. In particular, usually log-in and other operating options are set up as a so-called “default” (in the computer-jargon sense, not the financial sense).
[0351] The default settings are usually subject to override by the user or users who are—or who are positioned in the chain of commerce relatively closer to—the primary customer. Although the primary customer, and those in position to act on the primary's behalf, thus most commonly have authority to override the default arrangements, the full extent of such options may not always be clear to parties that have them.
[0352] Of all the parties that may purposely leave such options incompletely explained, transaction or broker ASPs are perhaps the most prominent. This may be a natural and understandable result of the nature of such businesses, in view of the following considerations.
[0353] As most transASPs do not participate directly in physical creation of the final product, the primary economic reward for their activity cannot be linked to any esthetic or mechanical function. Rather they provide convenience, and familiarity with trade practice, and ideally sound guidance of the primary customer to a printing house and other vendors that are optimum for the nature of the project.
[0354] These functions—although real, and potentially of extremely great value—are hard to quantify, and may be difficult for some primary customers to appreciate at all. Vulnerability to diversion of clientele therefore may be greatest for the transASP, of all the participants in these transactions.
[0355] Representative versions of a GUI for broker-ASP situations appear in FIGS. 23 through 27. In the example here, only the broker (transASP) has full view (FIG. 27) of all details and data.
[0356] At the opposite extreme is the sharply restricted visibility of the primary customer, who in this example sees (FIG. 24) only two ASPs—the broker and the proofer. The proofer's business contact line in the upper, data-window screen section is removed entirely—obscuring absence of the contact's name—as are the “business” radio-button legends for both e-mail and shipping label. Additional screen titles within the frame appear automatically, adjusting to the absence of information in two columns—which as shown can be kept in their usual positions if desired to minimize confusion between different participating operators.
[0357] Between these two poles of relative visibility are some intermediate information-access levels. Thus in the printshop operator's screen (FIG. 23) the names of all contacts at the primary customer's facility are unlisted, the phone and e-mail controls for contacting that facility are grayed out, and the GUI reveals only the customer's project reference number, and address data for a mailing label—so that finished magazines can be shipped to the customer.
[0358] A like level of information access is accorded to the network ASP (FIG. 26), who it is presumed may have to ship some piece of network equipment to the primary customer, or even service such an item at that customer's facility. Contours of information access are formed in yet another way for the proofing ASP (FIG. 25), who is enabled to consult with the primary customer's artistic or technical people—but not with management: the proscribed contact's name is unlisted in the “CUSTOMER” column, and the phone and e-mail “business” options are grayed out.
[0359] This example is constructed to include another ASP, in the column headed “PREPRESS/SPECIAL”—e.g. a trade prepress house, or other special-purpose vendor. (In the event that both a prepress firm and another special vendor are present, either condensed [narrow] fonts can be used to permit displaying all participants within the width of the screen or as noted earlier suitable horizontal-scroll capability can be provided for the upper portion of the screen.).
[0360] The prepress house is functionally closest to the printshop and proofer. Prepress therefore might logically receive e.g. access to both those entities—plus the same need-to-know customer artistic/technical access as the proofer.
[0361] As shown, the system primarily directs the customer to the broker ASP, who in effect becomes symbolic of the customer's overall project or projects. From the customer's perspective, in effect the sole vendor involved is the broker.
[0362] In the most-highly preferred embodiments of the invention, as noted earlier the primary customer has the option of overriding all such arrangements. This option is enabled—but not encouraged, and certainly never pushed on the customer—by making available to the primary customer information about the option.
[0363] The information is ideally included in an RHCPS user interface seen by the primary customer. This can be done in the form of an external link to the contractual terms of the RHCPS, which include the information about the option; or in the form of an internal “help” screen that includes the terms.
[0364] In implementing either of these arrangements, careful attention must be given to the wording and graphics used in leading to and presenting the customer's override option. It is a sensitive point and best worked out among specialists in law, marketing, customer relations, and professional editing.
[0365] The extent to which the link and terms are conspicuous, in the RHCPS user interface, is important. The basic mechanics may encompass use of the “Help” menu item that appears in the many tabulation screens shown in the accompanying drawings.
[0366] As one presentational technique, words such as “RHCPS contract terms” simply may be included in the drop-down submenu that appears when that main menu item is clicked. This may seem overly conspicuous, but it should be borne in mind that the terms themselves are typically lengthy, including many more clauses than just the user-override option that is under discussion here.
[0367] Another technique is to respond to a user's click on the “Help” item in the main menu by opening an intermediate selection dialog box (not shown) that contains a button or link to invoke the contract terms (instead of moving along to the main help screens). Alternatively such a button or link can be incorporated directly into a main help screen itself (FIG. 28). Depending on the layout and wording in such an intermediate help dialog or main help screen, the impact of the contract-terms availability may be either strengthened or weakened, relative to putting it into the help menu as first suggested above.
[0368] In either event, the placement of the override option within the terms, and the nature of the wording used as a title for it, are extremely variable. This variability still leaves room for further fine tuning of the content and tone of the presentation.
[0369] 5. Integration with a Soft-Proofing A. S. P.
[0370] To facilitate some aspects of the invention, advantageously some features are implemented within printer-device systems, and complementary features appear in the remote soft-proofing ASP. Although these implementations may not be strictly necessary, the result is an optimization of the invention that also optimizes integration between the remote soft-proofing ASP and the remote hardcopy proofing service.
[0371] The new printer-device systems will be characterized here as “remote-proof enabled” or “RP-enabled”. They include a printing device with front-end software.
[0372] These features make it realistic for users to trust the integrated service, basically by ensuring output consistency of hardcopy proofs—i.e., by providing for consistent printing (same contents, layout, color etc.) on any remote-proof printer of the line. The features also facilitate the remote-proofing workflow.
[0373] (a) PDF plus JDF as a basis for workflow—To ensure output consistency, it is very helpful to provide that:
[0374] all the information required to correctly print a proof is included in the data sent from the proof originator to the proof receiver; and
[0375] the setups used both on the originating and receiving printers to print the proofs are consistent.
[0376] These requirements are achieved by using a combination of PDF (Adobe “portable document file”) and JDF (“Job Definition File”) to carry all the required information, as follows.
[0377] Contents of the proof itself are carried in the PDF. This file preferably meets very strict requirements in terms of the information included—i.e., for ideal results it includes all the color, relevant information, fonts and images.
[0378] The JDF job ticket stores all the information on how the proof has to be printed to ensure a consistent output. It can also store the information on status of the remote proofing workflow for the specific proof.
[0379] The RP-enabled printer systems include the tools required to create the PDF and JDF parts of a remote proof. These tools are fully integrated into the front-end software (for example in a raster image processor that is in or associated with the printer), so that a user can easily create a proof to be sent to a remote user—and not only send it but also print it in the user's local printer.
[0380] On the receiver side, before printing a remote proof some checking is performed. This ensures that the proof data meet the requirements to ensure output consistency.
[0381] (b) Managed and calibrated color system—Use of the automatic color calibration and the color-management features in the printer ensures that the color behavior of RP-enabled printers is consistent. This means that any proof which contains the correct color information can be printed consistently, in terms of color, in any RP-enabled printer or at least any such printer of the product line.
[0382] Both the automatic color calibration and color-management features are implemented by interaction of the printer device and the front-end software.
[0383] (c) Proof checking and feedback—The RP-enabled printer systems has the ability to check for successful and correct printing of a hardcopy proof, and its quality as well. This information can be made available to the user who printed the proof, and also sent back through the RHCPS to the proof originator (e.g. the user who originated the proof) so that the originator can know when the proof was printed and what the quality of that proof was.
[0384] Thus the entire RHCPS operates on a closed-loop basis. In this way the system is made very trustable, thus resolving one of the major inadequacies of the art.
[0385] The proof-checking functionality advantageously uses the same hardware in the printer that is used in automatic color calibration. The entire procedure (proof checking and status feedback) is integrated into the front-end software so that it can be triggered automatically—and can be transparent to the user, depending on the settings of the RHCPS or the proof itself, or both.
[0386] (d) Obligations imposed on the remote soft-proofing ASP—To enable the RHCPS to make full use of the RP-enabling features integrated into the printer system, several provisions should be made by the soft-proof ASP:
[0387] support PDF-plus-JDF workflow—The soft-proof ASP should be able to transfer the proof data from the sender to the receiver. Ideally the ASP should also use the JDF job ticket to store essentially all information related to its own services—for example the originator and intended receiver(s), and the status of the proof—so that the JDF ticket is the only job ticket used.
[0388] integration of the proof-generating tools and the soft-proof ASP—As described above, proof-generating tools are integrated into the printer front-end software. There should be some way to pass proof data, once generated, to the soft-proofing ASP. For this purpose the ASP can provide a hot folder (discussed earlier) or equivalent arrangement.
[0389] integration of the proof-consuming tools and the soft-proof ASP—When proofing data are received through the soft-proofing ASP, the data should be passed to the printer front end for processing and printing. Again, this calls for a hot folder or other feature—most typically a feature of the user interface, graphical or otherwise.
[0390] support status feedback—The printer front end triggers automatic checking of the proof, once printed, and generation of information on the printing result. There should be a way to send this information from the front end to the soft-proof ASP so that it can be forwarded to the proof originator.
[0391] support user-collaboration features—The ASP should make provision for the proof receiver to add comments, i.e. annotations, and preferably to approve the proof in writing after having printed it. All such information should be accessible to the proof originator.
[0392] These may be considered basic obligations of the ASP, although people skilled in this field will appreciate that a reduced level of functionality and service may yet be obtained in the absence of some such provisions. In addition to these basic features, some additional provisions improve workflow and usability:
[0393] proof data checking—To ensure output consistency, ideally a check is always performed at the receiver side before the proof is printed. To save time and bandwidth, however, it is useful that either the ASP or RHCPS itself—depending on the circumstances also prevalidate the data before downloading by the receiver.
[0394] hosting proof-generation tools by the ASP—Since the RP-enabled printer systems integrate the tools for generating correct proofing data, any user with such a printer can generate remote proofs. In some cases, however, it is also useful to have the ability to run those tools on the ASP's system—thereby enabling collaboration by ASP subscribers who have no such printer.
[0395] integration of soft and hardcopy proofing—Some soft-proofing ASPs may themselves use a commercial service, such as RealTimeProof™ service, for soft proofing. That service allows soft proofing of several types of files.
[0396] In order to integrate it with the RHCPS, the soft-proofing application (i.e. the ASP) should be able to:
[0397] (i) send data to the RHCPS that satisfies the obligations outlined above (PDF-plus-JDF, containing all the color characterization, fonts, and so on); and
[0398] (ii) process RHCPS proofs and use the embedded color-characterization data (color profiles in the PDF file, etc.)
[0399] The first of these can be accomplished by integrating into the ASP software at least a part of the proof-generation tools of the present invention, e.g. a software kernel.
[0400] (e) Integration between the ASP and RHCPS—The present invention encompasses a service that can be offered by a sponsoring company—to consider an example in point, the Hewlett Packard Company. The service is made available, possibly for a fee, to users who register their RP-enabled printer systems in that sponsor's customer-registration system.
[0401] The RHCPS is a basic service that itself provides remote hardcopy proofing only. A user desiring other services than that—e.g. high-bandwidth transmission, file storage (so-called “digital asset management”) or soft proofing—should engage one or more ASPs to obtain those services.
[0402] To facilitate an upgrade path to such ASP services, as well as interaction between customers of the RHCPS and ASP respectively, preferably these features are included:
[0403] As indicated at some length in previous sections of this document, the RHCPS customer database is able to identify the users who have decided to be customers of, e.g., a soft-proofing ASP. Proofs sent to or from one of these users through the RHCPS are redirected to the ASP, through the agency of the many interface features previously detailed.
[0404] The database also advantageously enables each user to search for other registered users, of any type, including both potential vendors and customers—except for registrants who elect privacy, i.e. elect to opt out of such tabulation.
[0405] The RHCPS and the soft-proofing ASP each allow specifying, as a proof receiver, a user that is on the other service. For example, a remote-proof originator who is using a soft-proof ASP can specify that the receiver is using the RHCPS—and in this case the proof is forwarded from the ASP to the RHCPS.
[0406] Accordingly a protocol is included for forwarding proofs between the two services. This protocol is advantageously bidirectional so that that receiving service can return to the originator various kinds of information such as error data, closed-loop proofing feedback. The protocol is a standard one and can be used to expand the integration—between the two companies, to include other services of theirs—and also to encompass ASPs of other types as discussed earlier.
[0407] All such integration can be accomplished through the Internet or by more-direct backbone connection as preferred. Generally integration is facilitated thus:
[0408] The RHCPS maintains a full user database for all participating ASPs as well as its own.
[0409] A data field flags each respective ASP's subset of these users. These can overlap, since customers are at liberty to engage multiple ASPs of different types and even of the same type for different jobs.
[0410] The RHCPS tests that data field on receipt of a proof for transmission to a user.
[0411] These arrangements are regarded as nominally reciprocal—each ASP is expected, though not required, to do the same.
[0412] Both exclusive and nonexclusive forms of these arrangements are encompassed within the invention as defined in certain of the appended claims, and may be regarded as species of the invention. Exclusivity is thus a matter of business preference and business arrangements between the participants.
[0413] In these ways, as earlier pointed out, the RHCPS expands the capabilities of the soft-proofing ASP—which already has a useful service. The RHCPS does not obsolete that service, which continues to be particularly viable for highest speed, for concept proofing, and for preliminary proofing. Thus the RHCPS of the present invention does not compete with so much as mutually complement the soft-proofing ASP.
[0414] 6. Integration with a Transaction A. S. P.
[0415] As described earlier, a transaction or buyer ASP focuses on management of a job, and order data—and the integration of order processing and status tracking with various functions managed by a printshop. Typically this type of ASP provides very little support (representatively perhaps just an FTP server) to the sharing of content files between a buyer and a printer, or digital asset management. It usually imposes no restriction on the contents shared, and provides no tool for proof generation or related functions.
[0416] One representative transASP offers customized and branded websites for both buyers and printers, with ongoing management and support. The firm does not have a general standard website design.
[0417] This sort of enterprise concerns itself with management of the electronic commerce between buyer and printer, particularly job specification and status tracking. Such operation is well complemented by the RHCPS of the present invention or, alternatively, by another service ASP such as a soft proofer or private network.
[0418] The transASP sets up websites for both the buyer and printer, and directs the two to each other through a protocol. Thereafter the ASP continues as a sort of arm's-length printing broker or facilitator.
[0419] (a) Workflow—Integration of a transASP with an RHCPS, according to the present invention, produces workflow generally as described below.
[0420] When creating a project, the buyer specifies (by a computer-interface checkbox or the like) that remote proofing should be used on the project or at least certain components. If the buyer is using the printer's site to specify the job, the remote-proofing proof type appears only if the printer has remote-proofing capabilities.
[0421] The converse is also true: if the buyer is using the buyer's own site to specify the job, the “remote proofing” option will only appear if the buyer has remote-proofing capabilities. The main difference is that, in this case, the remote proofing capabilities of the printer could be used as selection criteria. That is, only printers that can generate remote proofs would be able to bid for that job when an RFQ is promulgated.
[0422] In any case, there is preferably a link from the corresponding transASP page to a page served by the RHCPS sponsor, describing the RHCPS. This link is a particularly nonintrusive way to promote the RHCPS concept, provided that it is offered in a low-key manner—and at a strategically situated point in the process, where the user is likely to be amenable to education on basics of such a service.
[0423] The RFQ, bidding and ordering process otherwise proceeds as in any other project of the transASP.
[0424] When the printer generates the proof(s) for the job, or contracted component of it, the transASP accesses the RHCPS (or a soft-proof ASP) to send those proofs to the buyer. The RHCPS has all necessary information to establish that this particular user (e.g., the printer) is also using the particular transASP.
[0425] Accordingly, before sending the proof the RHCPS offers the possibility of linking it to an order (or order component) of the specified transASP. This function is readily implemented in the form of a checkbox—one that may appear to linked parties, depending on what setup has been put in place.
[0426] For example, when a printshop operator—using the RHCPS interface—enters the intended receiver of a proof, a window appears with all the open projects in that printshop operator's transASP website (assuming that the printer has one) corresponding to that buyer, i.e. the proof receiver. The printshop operator can then select a project (or component) as the one to which the proof being sent is linked.
[0427] Alternatively, the remote proofing process can be launched directly from the transASP web page for the job. Through a web link, the user directly accesses the RHCPS page to create the proof, with all the information about sender, receiver and link to the transASP project already filled in.
[0428] The remote-proofing workflow is managed by the RHCPS as a regular remote proof (upload, download, then print, approval, etc.). The only difference is that, when there is a change in the proof status, the data about the new status is sent to the transASP system for use in updating the project status.
[0429] Printers or buyers, or both, can consult the remote-proof status through the transASP website or RHCPS. As will now be clear, in accordance with the invention the two are crosslinked—in other words, from the transASP site, when accessing the proofing status of a project, the user should be able to access the RHCPS page for that proof; and vice versa.
[0430] Workflow is very similar if the entree to the RHCPS is through a different sort of provider—e.g. a soft-proof or network ASP.
[0431] (b) Interface—The following interfaces are defined. Parallels to the arrangements for the soft-proof ASP should now be recognized.
[0432] an interface for retrieving information on open projects for a certain pair of users—printer and buyer
[0433] (Implementation calls for a well-defined way of mapping users between the RHCPS user space and the transASP user space.)
[0434] a programmatic interface to allow the creation of remote-proofing jobs and filling-in part of the information
[0435] (This is a user-operational facility for “programming in” new jobs, actually data entry.)
[0436] a method for linking proofs with transASP projects or components—i.e. a job (or component) identifier that can be stored in the proof job ticket and vice versa;
[0437] an interface for retrieving information on status of a certain proofing job, so that it can be displayed in the transASP's site
[0438] (This interface should support two kinds of operating modes: synchronous, i.e. status queries about a certain proof; and event-trapping, i.e. automatic update whenever status of a certain proof job changes.)
[0439] Some transASPs, as well as the other ASP types, may have a tendency to respond to marketplace pressures by expanding their services beyond the original and natural areas of interest—and perhaps talent—of their operators. The present invention can relieve them of that, fostering competition without redundancy (in particular wasteful, inefficient redundancy).
[0440] (c) Additional transASP features—Advantageously the user sees some new elements in the transASP website. One of these is a new RHCPS proof type added to the prepress parameters in the project or component description, preferably with links from that page to descriptions of the RHCPS.
[0441] Also preferably added is a new display area within the previous project-status tabulations—to display remote-proofing status of the various components. This area displays summarized status and log-in information for the proofs, and provides links for access to the proof itself and its more-detailed status in the RHCPS.
[0442] (d) Additional RHCPS features—Conversely, for an RHCPS user who creates and uploads a proof into the system, if the user is also a transASP user, the RHCPS opens a window showing all the user's open projects—with that transASP—corresponding to the intended.
[0443] The RHCPS window showing proof status also provides a link to the transASP website page that has data on the related transASP project. If a proof relates to a transASP project, the project or component identifier is stored in the job ticket.
[0444] 7. Content and Transaction Standardization Formats
[0445] Because the number of parameters to be brought under control as between different printing systems is high, this topic is potentially encyclopedic. Comprehensive presentation of all those variables, however, would be of little service to a person of ordinary skill in the art, because this part of the RHCPS operation simply comes down to a massive technological-bookkeeping problem.
[0446] On the other hand, since that problem is rather open-ended and does involve many variables it is one that can leave the person of ordinary skill groping for a solid place to begin. To avoid any need for extensive trial and error, there follows below a presentation of a preferred accounting methodology, together with selected examples, providing a clear picture of the approach adopted by the present inventors.
[0447] (a) Data subdivision, standard formatting, and restriction—The fundamental orientation begins with use of two industry-standard formats for, respectively, document appearance and processing information. Here “appearance” encompasses color, layout, and content—which in turn means all the graphic objects (text, images, graphics) with their correct respective fonts and dimensions.
[0448] Processing information includes printing conditions and settings—the printer model and all parameters peculiar to that model, the printing-medium type, resolution for each image, and the print quality (and printmode). The appearance and processing data are complementary: to perform remote proofing, both are required.
[0449] While appearance information is carried in a special form of the industry-standard Adobe® Portable Document File (“PDF”), the processing information is held in a job ticket—for which the standard Job Definition Format (“JDF”) is used. Thus the JDF job ticket is part of the data exchange, but is a separate entity from the appearance information.
[0450] This division of the data greatly facilitates any needed proof retargeting, i.e. changing printer-setting characteristics to use a different printer model or medium. Retargeting should be performed at the proof originator site, as suggested in the previously mentioned Jodra patent document; however, the JDF should be configured to accommodate information relevant to different printer models, so that the system in the originating site need not be told the specific printer model that will be used in the receiver's site.
[0451] Key to the most highly preferred embodiments of the invention is use of these standard formats with, in essence, reduced parameter sets—that is to say, with:
[0452] entries in many standard fields prohibited or ignored, and
[0453] only limited ranges or discrete values, of the respective variables, permitted or accepted in certain other standard fields.
[0454] For several reasons this has been found greatly preferable to creating a custom format with only the desired fields present.
[0455] (b) Additional nomenclature—The PDF and JDF together constitute the data exchange or “proofing file”. Some workers in the industry have come to instead call this computer-readable file simply the “proof”—but in the present text and appended claims the more traditional usage is followed, i.e. the word “proof” refers to the hardcopy document or on-screen computer image that is directly visible to the human eye.
[0456] In a specific implementation of the RHCPS, a particular entity may have the ability to act as an originator or a receiver; however, it is convenient for the specification to view them as separate entities. A routing service such as a network ASP may add information to enable or facilitate transmission from an originator to a receiver, but any such changes must be transparent to the requirements of the data exchange—in other words, data both into and out from the routing service should comply with all rules established for the exchange.
[0457] To avoid ambiguity the terms “local” and “remote” sometimes require a point of reference. For present purposes “local” usually refers to the location of the generator of a proofing file; hence unless otherwise specified or suggested by context a “local proof” is one printed (or viewed on-screen) in the same location where its proofing file is generated; and a “local proofing file” is a proofing document generated in a local system and susceptible to transmission through the RHCPS to a receiver.
[0458] Correspondingly unless otherwise specified “remote” refers to the location of the receiver, and a “remote proofing file” is one that has been received through the RHCPS by the entity “remote” from the originator (the “local” entity). A hardcopy proof physically printed at that remote location is accordingly a “remote proof”; hence the phrases “remote proofing”, “remote hardcopy proofing service” etc.
[0459] (c) Proof types—It is important that the RHCPS be able to handle not only single-page proofs but also signature proofs (sometimes called “imposition proofs”). Although consistent, accurate remote hardcopy color proofing of page modules is extremely useful and valuable in itself, the power of the invention is greatly expanded by incorporation of signature-proofing capability.
[0460] Accordingly the proofing data contain (in the PDF) information on the contents of each page, and (in the JDF) layout information describing the signature scheme to be used in printing the document on a press. In preferred embodiments of the invention, the proof generator can produce two types of proofs: page, and signature.
[0461] The difference between them is not in the proofing data, but rather in how the layout information is used by the recipient's proofing device when printing the proof:
[0462] For page proofs the device may use the layout information to print the proof, but is not required to do so. If the proofing device cannot print the signature(s) as described in the layout, it is not required to so inform the user.
[0463] For signature proofs the proofing device must use the layout information to print the proof. If the proofing device cannot print the signature(s) as described in the layout (due, most commonly, to media-size limitations) it must inform the user and provide different options for printing the proof or canceling it.
[0464] The specific user interface is device dependent. For example, suppose that an originating entity creates a proofing file for an eight-A4-page document, describing an eight-up signature that will be used in the press. If those proofing data are sent to an A3-size proofer, the behavior may depend on the type of proof requested:
[0465] If a page proof was requested, the proofer can print four A3 sheets, each containing two of the original document pages. To group the document pages, the device may use the information in the layout data to ensure that the two A4 pages printed in each sheet are adjacent in the signature; or it may use any other algorithm—such as printing pages in the order in which they appear in the assembled document.
[0466] If a signature proof was requested, the proofer issues a warning informing the user that it cannot print the signature because that would exceed the maximum page size of the device. It may offer the user several options, such as dividing the signature (tiling), scaling down the whole form proof or reverting to a page proof.
[0467] (d) PDF/Proof contents—To ensure that the output proof can be printed consistently in different devices it is helpful to strictly define the characteristics of the file. PDF is a very powerful, general-purpose format, whose features and functionality are far more versatile than the RHCPS can use; hence many of these features and functionality are restricted. In this document a file that complies with these requirements is sometimes called a “PDF/Proof file”.
[0468] Compliance with PDF/Proof restrictions does not ensure output hardcopy consistency. A receiver must process the data in a specific way to achieve it.
[0469] Thus a conforming PDF/Proof file is a PDF in which are found those features necessary for the exchange of proofing data and to enable output consistency at any receiving entity. Receiving entities must ensure output consistency for files conforming to PDF/Proof constraints.
[0470] In the embodiment now preferred, a PDF/Proof file must be a valid PDF 1.3 file, as described in the “PDF Reference Manual/Version 1.3”. Thus any requirement of PDF 1.3 or higher is also a requirement of PDF/Proof but is not further mentioned or repeated below.
[0471] Although nonprinting-related PDF constructs—such as annotations and thumbnails—might be present in a PDF/Proof file, they are ignored by the remote-proofing entities and consequently are not included in this discussion of the file format. (It can make sense to use these features if it is desired to use other PDF standard tools in the workflow.) In particular, specification of the PDF/Proof format contemplates only the objects in the pages tree, catalog, and file information dictionaries in a PDF.
[0472] Advantageously there are two versions of PDF/Proof, defined relative to a raster image processor (“RIP”) that is currently used in the preferred printing systems to prepare images for the printing engine:
[0473] “PDF/Proof-Image” supports only “postRIPped” remote-proofing workflow.
[0474] “PDF/Proof-Object” supports both “postRIPped” and “preRIPped” remote-proofing workflow. As these relationships suggest, PDF/Proof-Image is a subset of PDF/Proof-Object; i.e. any file that complies with PDF/Proof-Image also complies with PDF/Proof-Image.
[0475] The presentation of exemplary PDF/Proof restrictions will begin now with “PDF/Proof-Image”.
[0476] All the components of the proof contents are contained in the body of a single PDF/Proof-Image file. It is not permitted to present only as an embedded file any component required to process the proof contents.
[0477] To help see how to implement the general rules, following are only just a few examples of several dozen constraints that make up a PDF/Proof-Image specification. This part of the present document assumes familiarity with parameter and field names (such as “DefaultForPrinting”, “OutputIntent”, “ExtGState”, “MediaBox”, etc.) defined in the PDF 1.3 specification.
[0478] As a consequence of the contents-in-body requirement last stated above, streams cannot reference external files. That is to say, the F, FFilter and FDecodeParams entries in a stream dictionary cannot be used.
[0479] As examples of constraints to contents, each page can contain only image objects; they can be either external images (so-called “image “XObjects”) or inline images. The only commands allowed in a page “Contents” stream are:
[0480] q, Q: save and restore the graphics state;
[0481] cm: modify the current transformation matrix;
[0482] Do: include an external object (so-called “XObject”)—and images are the only XObject types allowed;
[0483] BI, ID, EI: inline images
[0484] As examples of constraints to bounding boxes, each page object must include a MediaBox and TrimBox; MediaBox may be included by the object-oriented programming concept known as “inheritance”. A CropBox or BleedBox, or both, may also be included in the page. If the BleedBox is present, the TrimBox will not extend beyond the BleedBox boundaries. If the CropBox is present, the TrimBox will not extend beyond the boundaries of the CropBox.
[0485] As examples of constraints to color, the only color spaces allowed are DeviceCMYK and DeviceGray; all the images (either inlined in the contents stream of pages or in an image XObject) must be in DeviceCMYK, DeviceGray or Indexed color space. If Indexed color is used, the base color space should be DeviceGray or DeviceCMYK.
[0486] Still as to PDF/Proof-Image constraints—as examples of restrictions on Identification, a PDF/Proof-Image file is so identified using the HWEP_PDFProofVersion key in the Info dictionary; the type of a HWEP_PDFProofVersion key is string, and its value is (HWEPProofImage0.1).
[0487] Turning now to PDF/Proof-Object constraints, a PDF/Proof-Object file must meet additional requirements, on top of the requirements described in the “ PDF Reference Manual, Version 1.3”. As examples of data-structure restrictions, all components of the proof contents must be contained in the body of a single PDF/Proof-Object file and this refers to all the PDF resources (as described under “Resource Dictionaries” in the previously mentioned PDF Manual) used in the file including all fonts, font metrics, font encodings, full resolution images, ICC profiles etc.; and print elements must be included in the file.
[0488] As examples of content restrictions, operators not allowed in the Contents stream for a page are PS (PostScript code embedded in page contents); BX, EX (compatibility operators); and in general any operator not described in the PDF Manual. Images cannot have the OPI entry in the image dictionary set. If the Alternates entry in the dictionary is set, none of the alternate images can have the DefaultForPrinting entry set to true; that is, the base image is the one that must be used for printing the proof.
[0489] As examples of constraints to bounding boxes, the same rules apply as stated above for PDF/Proof-Image. As examples of constraints to color, a color rendering intent must be specified for the contents for all pages; rendering intent can be specified in the ExtGState resource or in the Image dictionary for images. Color space and Identification restrictions are generally as stated above for PDF/Proof-Image.
[0490] (e) JDF contents—As suggested in earlier discussion, a JDF job ticket is required to ensure that the front end of the remote printing system processes the proofing file with the correct settings, compatible with those used when printing the proof on the local file, in order to ensure output consistency. Specification of the “JDF Job Ticket” requirements for remote proofing are based on the “ JDF Specification Release 1.0”, with a few variant details (names and permitted values of some elements in the resource elements).
[0491] That specification covers two areas: processes allowed in the remote-proofing JDF job ticket, and resources (and their syntax) required for those processes. The specification does not cover other areas in that job ticket, such as customer-related information, or audit. Although such information may appear in the job ticket it is not required—for purposes of this invention—that originating entities generate it or receiving entities process it.
[0492] The RHCPS is an implementation of the JDF proofing process and inherits the characteristics of that process. Extensions are added to support the specifics of the remote-proofing use case and thermal-inkjet printing technology. Also, due to limitations on printing devices and to simplify implementation, just as for the PDF some restrictions are desired on possible values and characteristics. The JDF job ticket should have one node (the root node) specifying the Proofing process.
[0493] For examples of constraints as to resources, if the ColorantControl, ColorPool, or ColorSpaceConversionParams resources are present in the proofing-input resources they are ignored in the proofing file; the color space used (press CMYK) has to be fully defined using an ICC profile. The Layout resource is required if the ProofType field in the ProofingParams resource is set to Imposition (i.e. signature).
[0494] As to constraints concerning media, since the JDF job ticket is generated without knowing on which device or devices the hardcopy proof will be printed, this resource is only a hint. Behavior when the media available on the proofing device fail to match the requirements in this resource is device dependent. As examples of constraints on interpretation of each of the fields in the Media resource, Dimension is not required but if present describes the minimum printing-medium dimension required to print the proof. If the proof type is set to Imposition, this is the size of the signature; if it is instead set to Color, this is the size of the largest page in the document.
[0495] As examples of constraints to the ProofingParams resource, ProofType is required and describes the type of proof requested. ColorConceptual or Contone is used for page proofs and Imposition of signature proofs. Halftone proof types are not supported. Several parameters that are just ignored if present include ImageViewingStrategy, DisplayTraps, and ProoferProfile.
[0496] The document RunList describes the document that is to be proofed and includes a link to the document contents file. In the initial version of the RHCPS that is the current most highly preferred embodiment, proofing is restricted to documents contained in a single PDF/Proof file. In consequence there are some restrictions on the characteristics of the document RunList.
[0497] For example Npages, if defined, should be set to the total number of pages in the document; and Run can only contain one RunElement. Examples of constraints on the RunElement include these: if EndOfDoc or DynamicInput is present, the field contents are ignored. The RunElement can contain only one RunSeparation.
[0498] Yet further limits in turn apply to RunSeparation, including its LayoutElement, and still further constraints apply to contents of the LayoutElement. RunList “marks” are not supported in the present version of the RHCPS. If a proof must include printing marks, they should be included in the page descriptions in the proofing file.
[0499] For local proofs, the two components of the proofing data are packaged using the MIME File Packaging method descried in Appendix A of the “ JDF Specification Release 1.0”. References to external files are allowed neither in the job ticket nor the document contents.
[0500] For remote proofs, the two components can be packaged using the same MIME method. It is also possible that the job ticket contains only a URL specifying the location of the document contents portion of the proof data. Constraints on URL type can be helpful.
[0501] Again, the foregoing specification details are only examples of some dozens of such restrictions actually used. From the considerable length of this merely exemplary presentation it will be clear why the full set is not detailed here. Those presented are intended to convey a clearer understanding of the reduced-parameter-set approach to use of industry-standard PDF and JDF formats.
[0502] The above disclosure is intended as merely exemplary, and not to limit the scope of the invention—which is to be determined by reference to the appended claims.
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Conventional obstacles to entry and survival of small graphic-arts service providers are softened—particularly for those businesses that operate as computerized “ASP” enterprises involving wide-area networks—by encouraging small operators to coexist effectively in use of a pivotal network-based service. One key mechanism promoting this capability is a system of optionally mutual links between the pivotal service and the ASPs. The service also counteracts a tendency in the industry to favor wastefully redundant vertical integration. On the other hand, the system also implements the prerogatives of an enterprise (such as a printing-broker ASP) that has an established customer, to closely channel the attention of that customer—but subject, importantly, to being overruled by the customer. Ideally the system is carefully tuned to enable such customer action without unduly pressing the option upon the customer.
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BACKGROUND OF THE INVENTION
In recent years, with the increasing introduction of electronics to the automotive field, solutions which provide for the automatic control of one or more functions of the motor vehicle, such as, for example, the ignition, the fuel injection, the braking (in an antiskid function), the automatic engagement and disengagement of four-wheel drive, etc., have become widespread.
However, the problem of the interaction between the vehicle and the ground over which it is moving has not hitherto been dealt with in a completely satisfactory manner, particularly as regards the development of the forces and moments which act on the individual regions bearing on the ground, that is, on the tires.
It appears to be essential to be able to tackle and resolve this problem in order to be able to produce vehicles in which the modulated management of its bearing on the ground is possible during driving.
OBJECTS AND SUMMARY OF THE INVENTION
In order to satisfy the requirements stated above, a first aspect of the present invention relates to the fact that a motor vehicle may be considered as a system which interacts with the ground by means of the footprints of the tires, on which continually varying families of forces and moments are established.
More specifically, the present invention relates to a method for controlling the movement of a motor vehicle provided with tires which cooperate with the ground to define respective footprints including the steps of monitoring the behavior of the footprints and generating at least one respective footprint signal indicated of the behavior of the footprints, using the at least one footprint signal to control the movement of the motor vehicle, which is known--per se--e.g. from the Patent Abstracts of Japan, vol. 8, No. 143 (M-306) (1580) 04.07.1984 and JP-A-59 40 906 or DE-A-3 607 369. The object of the present invention is to provide means which enable the distribution of the forces between the various bearing regions to be controlled automatically so as to optimize the behavior of the motor vehicle according to the wishes of the driver and to prearranged reference programs, for example, for normal, sports, or off-road driving or for dry, wet or snowy road conditions, etc.
According to the present invention, that object is fulfilled by means of a method which further includes detecting at least one driving control signal generated by the driver of the motor vehicle and then processing that at least one driving control signal in dependence on the at least one footprint signal which a view to controlling the movement of the motor vehicle. The present invention also relates to a corresponding system wherein the step of monitoring the footprint of a motor vehicle tire on the ground includes the step of incorporating in the flexible structure of the tire, extensometric transducer means which can deform as a result of the tire bearing on the ground, and thus generate signals indicative of the behavior of the footprint.
The invention has been developed with particular attention to its possible use in motor vehicles having four wheels, all of which are driven and steerable (obviously with a braking capability) and are connected to the body of the motor vehicle by means of electronically-controlled suspension units.
A relevant characteristic of the invention is the fact that the behavior of the footprint of each tire on the ground can be monitored.
For this purpose, a further aspect of the present invention provides for the insertion of sensors associated to the wheels of the vehicle (which solution is known--per se--e.g. fro EP-A-0 233 357), such as piezoresistive elastomer elements constituted, for example, by toroidal bands inserted in the structure of the tire, in the tread region of each tire. The state of the forces and moments acting on the footprint of the tire can be monitored by means of these sensors.
On the basis of the footprint-behavior monitoring signals generated by these sensors and of other signals indicative, for example, of:
the dynamics of the center of gravity of the vehicle,
the rotation of the wheels in the vertical plan (that is, the driving and braking forces acting about the axis of each wheel),
the rotation of the wheels in the horizontal plane (that is, the steering angle), and
the vertical movements of the wheels (that is, the forces acting o the suspension units), an automatic processing system enables the traveling conditions of the motor vehicle to be monitored in real time with separate reference to the conditions of each footprint, that is, of each wheel on the ground.
As well as performing the monitoring function, the processing system of the vehicle (which usually includes a processor for each wheel, provided principally for the purposes of detecting and calculating the characteristics of the respective footprint, and an intelligent central processor which correlates the various interactions of the processors associated with the individual wheels) also has a data base in which comparison and/or reference parameters are stored.
The parameters can be modified selectively according to the specific requirements of the driver, for example, for sports driving, for more relaxed driving, or for driving with maximum attention to safety conditions.
On the basis of the correlation of the various interactions of the processors and of the comparison of the monitoring data with the control parameters stored in its data base, the central processing system (which, at its upper level, preferably includes a so-called "expert system" with artificial intelligence functions, such as an ability to process heuristic decision-making methods) controls the various transmission, braking, steering and suspension members of the vehicle so as to optimize the performance and/or safety capabilities of the vehicle according to the driver's decisions. In particular, the system can continuously check the conditions of the footprint of each tire and make fine adjustments (trimming) moment by moment in order to achieve the best general balance of the motor vehicle.
The invention is preferably for use in a vehicle which has a mechanical-electrical-hydraulic system for the driving-braking, steering and suspension functions. Such a system includes an internal combustion engine which drives a high-pressure hydraulic pump, a set of hydraulic distributors for distributing the pressure to the various operating regions of the vehicle, hydraulic brakes-motors for each wheel, electro-hydraulic actuators for the steering and electro-hydraulic shock-absorber-actuators for the suspension units.
A vehicle provided with a system of the type specified above has an intrinsic natural "antiskid" function, as well as an automatic differential effect both transversely (as regards the wheels associated with the same axle) and longitudinally (as regards the distribution of the forces between the various axles).
DETAILED DESCRIPTION OF THE DRAWINGS
The invention will now be described, purely by way of nonlimiting example, with reference to the appended drawings, in which:
FIG. 1 is a vertical median sectional view of a motor vehicle wheel produced according to the invention, shown with some of the operating members associated therewith;
FIG. 2 is a three-dimensional cartesian graph showing a possible distribution of the forces and moments acting on a motor vehicle wheel produced according to the invention; and
FIG. 3 shows schematically, in the form of a block diagram, the general architecture of a system according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, one of the wheels of a motor vehicle such as a motor car, not shown as a whole, is generally indicated 1.
According to a solution which is repeated in a practically identical manner in all the other wheels of the vehicle (for which detailed descriptions will not therefore be given since they would be redundant) the tire P of the wheel R carries within it, incorporated in its tread region, a plurality of piezoelectric sensors 1, preferably constituted by continuous or discontinuous toroidal bands made of piezoresistive rubber or another elastomer having the same properties and coextensive with the tread itself.
Rubbers of this type have recently been made available commercially. The essential characteristic of these rubbers is constituted by their capacity to generate electrical signals indicative of the amount by which they are deformed, and hence of the intensity of the forces causing the deformation, in dependence on the mechanical stresses to which they are subject.
The fact that rubbers with piezoelectric or piezoresistive characteristics can be used instead of other types of sensors (for example, conventional extensometers or strain gauges) offers the advantage that the sensors can be incorporated in the body of the tire P. In particular, the sensors 1 can be arranged in the tread region at a certain distance from the wearing layer of the tread so that they are at any rate protected from the outside environment.
As can be seen better in the schematic view of FIG. 2, in correspondence with the footprint (that is, the region Z of the tire P which bears on the ground), the sensors 1 (the number of which is such as to cover the monitored region with a sufficient density) follow the monitored region with a sufficient density) follow the deformation of the tread and are deformed along a line which is generally chordal relative to the shape of the wheel.
Since the amount and state of their deformation depend on the amount and state of the deformation of the tread which in turn are determined by the intensity of the forces and moments acting on the tread and hence on the wheel as a whole, the signals generated by the sensors obviously carry all the information relating to these forces and moments.
By processing the signals provided by the sensors 1 (processing which may be carried out according to wholly known criteria that do not therefore require a specific description) the forces can be resolved according to an x, y, z cartesian system centered about the point O which constitutes the center of the footprint Z, as shown schematically in FIG. 2. A similar result can also be obtained relating to the moments M f acting on the wheel R.
In particular, the value of the local coefficient of friction μ 1 at a particular time can be calculated for each wheel R of the vehicle from the footprint-monitoring signals generated by the sensors 1.
With reference again to the diagram of FIG. 3, a drive-shaft, indicated A, rotates the rotating bearing S to which the wheel R is fixed according to the usual criteria. The drive-shaft A is driven by a motor M constituted, in the currently preferred embodiment, by a hydraulic motor which receives the pressurized fluid necessary for its operation from an engine-pump unit MP.
The unit in question is usually constituted by the internal combustion engine of the motor vehicle and an associated hydraulic pump.
The same engine-pump unit MP pilots a hydraulic actuator, such as a jack J, the rod J1 of which controls the steering movement of the wheel R.
A further jack K acts as a suspension unit which regulates the vertical position of the wheel relative to the body of the motor vehicle.
The pipes through which the engine-pump unit MP sends the operating fluid to the hydraulic motor M and the jacks J, K are schematically indicated T 1 , T 2 , T 3 .
The passage of the operating fluid through the pipes is controlled by respective valves V 1 , V 2 and V 3 which are controlled by a distributor D governed by a central control unit according to criteria which will be described further below.
However, it should be stated that, although the present description refers to the use of electro-hydraulic distributors, motors and actuators for controlling the driving-braking, steering and suspension functions of the wheels, this selection should not be considered critical for carrying out the invention. In fact, the invention can also be used in connection with motors and actuators of different kinds, for example, fully electrical motors and actuators. The use of electro-mechanical or mechanical systems should also be regarded as included in the scope of the present invention.
The progressive reference numbers 2 to 5 indicate a plurality of sensors constituted, more precisely, by:
a sensor 2 for sensing the dynamics of the center of gravity of the motor vehicle and constituted, for example, by a sensor located substantially at the center of gravity of the motor-vehicle body for measuring acceleration along three axes,
a sensor 33 for sensing the "vertical" position of the wheel, that is, the attitude of the suspension.
Sensors which satisfy the applicational requirements described are widely known in the art and have been proposed many times for use in the automotive field.
A processor, generally indicated 6 (constituted, for example, by a microprocessor or by a functional area of such a component) is connected to the sensors 1 (by the criteria used in the art for the connection, for example, of tire-pressure sensors) as well as to the other sensors 3 to 5 just described.
The function of the processor 6 is essentially to process the set of signal supplied by the various sensors so as to provide a complete picture in real time of the conditions under which the wheel is operating at any particular time, that is, the set of data relating to the forces and moments acting on the wheel and the data relating to the rate of rotation, the orientation and the "height" of the wheel relative to the vehicle body, possibly with the addition of data relating to the general kinematics of the motor vehicle, detected at the center of gravity by the sensor 2.
The data generated by the processor 6 or data resulting from further processing of these starting data (for example, the data relating to the local coefficient of friction μ 1 ) are compared with corresponding control and reference parameters stored in a data base 7.
In this connection, it should be noted that a respective processor is associated with each wheel R of the vehicle. The data generated by the various processors 6 (as well as the signal generated by the accelerometric sensor 2) are then sent to a centralized, higher-level processor B which acts on a central control unit 8a for controlling the distributor D, possibly with adaptive feedback to the various processors 6 (line 8b).
As regards the data base 7, it is therefore possible to opt for either a decentralized solution (each processor 6 having a respective data base 7 of control or reference data) or a centralized solution (the signals generated by the various processor 6 being sent to a single centralized data base 7 for comparison), or even for a hybrid solution in which some functions are decentralized and other functions are centralized. Naturally, the selection of one solution or another is dictated by the specific requirements applying at the time in questions.
The purpose of the comparison with the data contained in the data base 7 is to check whether the operating conditions of each wheel at a particular time fall within a range which coincides with or deviates to an acceptable degree from the ideal conditions represented by the reference or comparison parameters stored in the data base 7.
For example, a value of the coefficient of friction μ 1 which is considered ideal for the conditions of the road surface may be stored in the data base 7 and the value μ 1 detected locally at a particular time compared therewith.
The driving control operations carried out by the driver are taken into account when the comparison is made.
For this purpose, respective sensors of known type are associated with the control members operated by the driver (for example, the steering wheel W, the brake pedal B and the accelerator pedal G) but only one of the sensors, that is, the one associated with the steering box W and indicated by the reference number 9, is shown. The sensors in question send signals indicative of the control operations carried out by the driver (steering, acceleration, braking, etc.) to the central processor 8 on respective output lines W 1 , B 1 and G 1 .
In general terms, the function of the central processor 8 is to transfer to the operating members of the wheel (that is, the drive motor M, the steering jack J, the suspension-control jack K) respective movement--or steering-control signals which translate the commands given by the driver when he operates the steering wheel W and the pedals, B, G. However, the transmission (or the comparison between the data relating to the operation conditions of the wheels R, generated by the processors 6) and the control or reference data stored in the data base or data bases 7, with the interactive correlation of the data received from the various process calculators 6.
In practice, for example, if the driver operates the accelerator pedal G and attempts to impose on the vehicle an acceleration and/or a speed which is incompatible with the road-holding conditions of the wheels (as indicated by the reference or comparison data stored in the data base 7), the processor 8 modifies the acceleration signal which is effectively transmitted to the drive motors M of the wheels so as to keep the acceleration and/or speed imparted to the vehicle within the safety limits.
As has been seen, the data base 7 may contain several sets of control or reference data which can be used as alternatives to one another (for example, in the form of memory arrays which can be introduced alternatively by the user at will). The comparison data or parameters, that is, the level of criticality of the traveling conditions to be reached can thus be varied selectively, for example, it is thus possible to choose a closer approach to critical conditions if a sporting style of driving is desired or, for example, when the vehicle is entrusted to a learner driver--to choose to restrict the performance of the motor vehicle to the conditions of maximum safety.
To advantage, the processor 8 may be arranged so that it is brought automatically to the latter condition when a breakdown is detected.
The management achieved by the system in a motor vehicle with four driven and steerable wheels is extremely flexible to the extent that it even enables apparently conflicting comments to be imparted to the various wheels, for example, to increase the rate of rotation of some wheels while braking others, to modify the steering attitude of one wheel even to an attitude opposite that which would be imparted thereto in a conventional steering system, or even selectively to modify the suspension characteristics of the various wheels even in competition with each other.
This independent control function for each wheel can easily be achieved by the processor 8 through the central control unit 8a (which can also be produced either in a decentralized form--with a module for each wheel--or in a centralized form--with a single centralized control unit) by means of the distributor or distributors D which control the valves V 1 , V 2 and V 3 for controlling the supply of operating fluid to the motors M and the jacks J and K.
It is thus possible for the motor vehicle as a whole to be configured as a system which interacts with the road by means of the footprints Z of the tires, by virtue of the monitoring of the continually varying forces and moments acting thereon. It is thus possible automatically to control the distribution of these forces between the various tires, that is, between the various bearing regions of the vehicle, so as to optimize the behavior of the motor vehicle according to the wishes of the driver and to prearranged reference programs, perhaps even for different driving styles or for different road-surface conditions.
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A method for controlling the movement of a motor vehicle provided with tires which cooperate with the ground to define respective footprints includes monitoring the behavior of the footprints and generating at least one respective footprint signal indicative of the behavior of the footprints, using the footprint signal to control the movement of the motor vehicle and detecting at least one driving control signal generated by the driver and processing the driving control signal in dependence on the footprint signal for controlling the movement of the motor vehicle. A suitable system for carrying out the method is provided which includes extensometric transducers incorporated in the flexible structure of the tire which will deform as a result of the tire bearing on the ground so as to generate signals indicative of the behavior of the bearing region of the tread.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation Application of, and as such claims priority to, PCT International Application No. PCT/JP2014/060274 (filed Apr. 9, 2014), the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] In a front-wheel-drive vehicle, an engine installed in a front of the vehicle body generates torque and a differential receives and distributes the torque to right and left front-wheels. In a case of a four-wheel-drive vehicle, generally in combination with a transmission including the differential, a power transfer unit (PTU) for extracting and transmitting part of the torque to rear-wheels is used.
[0003] The PTU has to change axial direction from an output shaft of the transmission to a propeller shaft and also has to absorb an offset between these shafts. Design thereof must bear a severe restriction as locations of these shafts are determined in advance. Further, the fact that the PTU is required to be installed in a relatively small space among other devices such as an engine and a transmission is also a requirement that limits the design.
[0004] Japanese Patent Application Laid-open No. 2008-208947 discloses a related art.
SUMMARY
[0005] The disclosure herein relates to a power transmission device in an automobile, and in particular to a power transfer unit for an automobile for distributing torque from one set of axles to another set of axles particularly in a four-wheel-drive vehicle.
[0006] Respective shafts in the PTU, an input shaft in particular, must be often elongated in a lengthwise direction to meet the aforementioned design requirements. To support such long shafts without eccentric motion or precessional motion is often difficult. Eccentric motion or precessional motion affects other members combined with the shaft in question or imposes a non-negligible load on oil seals for example, or, in severer cases, causes the device to vibrate.
[0007] The device described below has devised in light of the aforementioned problems. According to an aspect, a power transfer unit for extracting torque from a transmission of an automobile is comprised of: a casing having a first side having a coupling portion for combining with the transmission and a second side opposed to the first side; a first shaft being rotatably supported by a first bearing sitting on the first side of the casing and a second bearing sitting on the second side of the casing, penetrating the casing from the coupling portion to the second side, and combining with the transmission to receive the torque; a second shaft being rotatably supported by a third bearing sitting on the first side of the casing and a fourth bearing sitting on the second side of the casing and gearing with the first shaft to rotate in parallel with the first shaft, the second shaft comprising a bevel gear; and a third shaft being rotatably supported by the casing and extending in a direction distinct from the first shaft and the second shaft, the third shaft comprising an internal end including a pinion gear in mesh with the bevel gear and an external end led out of the casing, wherein the first bearing is disposed closer to the coupling portion than the bevel gear is.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a sectional plan view of an example power transfer unit, which is taken from a section running along axes of respective shafts.
[0009] FIG. 2 is a side view of the power transfer unit viewed from a side opposed to a transmission.
[0010] FIG. 3 is a side view of the power transfer unit viewed from a side on the transmission.
DESCRIPTION
[0011] Examples will be described hereinafter with reference to FIGS. 1 through 3 .
[0012] Throughout the following description and the appended claims, a direction where first and second shafts run is defined as a lateral direction and a direction perpendicular thereto is defined as a longitudinal direction. Further, when the casing 11 is illustrated in a plan view, a series of wall sections thereof at one extremity in the lateral direction is defined as a first side and a series of wall sections at another extremity is defined as a second side.
[0013] In the meantime, presently illustrated relations of the right and the left, and the top and the bottom, are but one example. Modifications where the right and the left are reversed or upside down are of course possible.
[0014] Referring to FIG. 1 , a power transfer unit (PTU) according to the present example can be used in an application for taking out part of torque from a transmission of a vehicle and transmitting it to a propeller shaft directed in a direction distinct from a shaft of the transmission.
[0015] The PTU 1 is comprised substantially the whole of a casing 11 housing. The casing 11 has a coupling portion 13 at the first side projecting leftward, which is combined with the transmission and fixed by means of a coupling flange 14 shown in FIG. 3 . The propeller shaft is combined with a shaft 7 led downward out of the casing 11 .
[0016] The PTU 1 is comprised of a first shaft 3 , a second shaft 5 , a third shaft 7 , gears 37 , 55 , 57 , 73 for drivingly coupling them, and bearings 33 , 35 , 51 , 53 , 71 for supporting them. Any of them can be housed in the casing 11 . The first shaft 3 is combined with the transmission to receive the torque, the second shaft 5 gearing therewith to rotate in parallel therewith mediates the torque transmission, the bevel gear 57 and the pinion gear 73 change direction of rotation, and the PTU 1 then outputs the torque through the third shaft 7 to the propeller shaft.
[0017] Referring to FIGS. 2 and 3 , these shafts 3 , 5 and 7 do not lie in the same plane but mutually have offsets in height. The sum of these offsets absorbs a relatively large offset between the transmission and the propeller shaft. Conversely, it may be difficult to absorb the large offset without these three shafts.
[0018] Referring again to FIG. 1 , the casing 11 is so constructed as to be dividable into a first part 11 a including the first side and a second part 11 b including the second side. Each of the first part 11 a and the second part 11 b may be further dividable but is preferably formed in a unitary body. Being formed in a unitary body is beneficial for convenience of assembly and also for strength and stiffness.
[0019] The casing 11 is comprised of an opening 15 opened at the coupling portion 13 and an opening 17 opened at the second side, and the first shaft 3 penetrates the casing 11 from the opening 15 to the opening 17 . The first shaft 3 is, at an end projecting from the opening 15 , comprised of a coupling means such as splines 31 , thereby being drivingly combined with the transmission.
[0020] The first shaft 3 may be tubular in its lengthwise direction. While the transmission has a differential installed therein for output, its output shaft 9 is led out through the first shaft 3 rightward. The output shaft 9 is, for example, coupled with the axle.
[0021] The first shaft 3 is rotatably supported by a pair of bearings 33 , 35 at least. These bearings can be ball bearings, for example, but bearings of any other type may be instead used.
[0022] To seat the first bearing 33 , the first part 11 a of the casing 11 is, on the internal face and at the first side, comprised of a first race 21 . The first race 21 fits on the entire circumference of the first bearing 33 . To seat the second bearing 35 , the second part 11 b of the casing 11 is, on the internal face and at the second side, comprised of a second race 27 . The second race 27 also fits on the entire circumference of the second bearing 35 .
[0023] Around an entrance of the opening 13 and between its internal face and the first shaft 3 , an oil seal 81 is interposed. The oil seal 81 is configured not only to seal the oil therein but also to prevent oil inflow from the exterior, thereby preventing both leakage and mixture of oil. Similarly, around an entrance of the opening 15 and between its internal face and the first shaft 3 , an oil seal 83 is interposed. As will be understood from the above description, the first race 21 and the oil seal 81 inherently get close to each other and the second face 27 and the oil seal 83 inherently get close to each other.
[0024] The first shaft 3 is comprised of the first gear 37 for gearing with the second shaft 5 . The first gear 37 may be formed in a unitary body with the first shaft 3 if possible but may be formed in a separate body as shown in the drawing. In a case of the first gear 37 being a separate body, spline coupling may be used for coupling it with the first shaft 3 , but welding or any other means may be instead used. To set the first gear 37 in place, the first shaft 3 may have a step 39 . As a side face of the first gear 37 gets in contact with the step 39 , it falls into place. Or, the part in question may be welded or any other means may be applied thereto.
[0025] The second shaft 5 runs in parallel with the first shaft 3 and its total length is generally housed in the casing 11 . The second shaft 5 is also rotatably supported by a pair of bearings 51 , 53 , at least. To bear thrust reaction force from the bevel gear 57 , these bearings 51 , 53 can be taper roller bearings, for example, but any other type may be instead used.
[0026] To seat the third bearing 51 , the first part 11 a of the casing 11 is, on the internal face and at the first side, comprised of a third race 23 . The third race 23 fits on the entire circumference of the third bearing 51 . To seat the fourth bearing 53 , the second part 11 b of the casing 11 is, on the internal face and at the second side, comprised of a fourth race 29 . The fourth race 29 also fits on the entire circumference of the fourth bearing 53 .
[0027] The first race 21 and the third race 23 may have no offset in the lateral direction as shown in the drawing but may have some offset. Similarly the second race 27 and the fourth race 29 may have no offset in the lateral direction as shown in the drawing but may have some offset.
[0028] The second shaft 5 is comprised of the second gear 55 for gearing with the first shaft 3 . The second gear 55 may be formed in a unitary body with the second shaft 5 as shown in the drawing but may be formed in a separate body.
[0029] The second shaft 5 is further comprised of the bevel gear 57 . The bevel gear 57 is a so-called hypoid gear and may be formed in a unitary body with the second shaft 5 if possible. The bevel gear 57 is, however, normally formed in a separate body and is coupled with the second shaft 5 by means of splines, for example. The bevel gear 57 is disposed between the gear set 37 , 55 and the bearings 33 , 51 . To set the bevel gear in place, the second shaft 5 may have a step 61 and a bolt 59 may be used for the purpose of fixation and regulation of the position.
[0030] The bevel gear 57 may fit in the third bearing 51 and be directly supported thereby. As the third bearing 51 directly bears the reaction force received by the bevel gear 57 , the bevel gear 57 is prevented from making eccentric motion or precessional motion and accordingly the second shaft 5 is prevented from making eccentric motion or precessional motion.
[0031] The third shaft 7 is, at its internal end, comprised of the pinion gear 73 . Corresponding to the bevel gear 57 , the pinion gear 73 is also a hypoid gear. The third shaft 7 is further, at the external end, comprised of a flange 75 , for example, for combining with the propeller shaft. Any combination means can be used in place of the flange 75 .
[0032] The third shaft 7 may be formed in a unitary body but may be formed from two or more members, which are mutually axially movable so as to regulate relative positions. In the example illustrated in the drawing, for instance, it is constituted of a part including the pinion gear 73 and a part including the flange 75 , which are mutually combined by means of splines. It is thereby capable of transmitting torque from the pinion gear 73 to the flange 75 , and the pinion gear 73 is capable of regulating its axial position relative to the flange 73 . It may be comprised of a nut 77 in order to regulate pressure to the bevel gear 57 . More specifically, the present example has an advantage to allow regulation of tooth contact of the pinion gear 73 onto the bevel gear 57 .
[0033] The casing 11 is comprised of an opening 25 for receiving the third shaft 7 . The third shaft 7 is, along with a tubular portion 71 housing the unit bearing 78 , for example, inserted into the opening 25 . The internal end of the third shaft 7 is within the casing 11 and makes the pinion gear 73 move from the second side to the bevel gear 57 to engage with the bevel gear 57 . In order to regulate the axial position, a shim 74 is interposed between the casing 11 and the tubular portion 71 and tightening the bolt 76 gives pressure to the unit bearing 78 .
[0034] The external end of the third shaft 7 is led out of the casing 11 and is combined with the propeller shaft via the flange 75 . Around an external end of the tubular portion 71 , and between the tubular portion 71 and the third shaft 7 , an oil seal 72 is interposed. This prevents both leakage and mixture of oil as with the other oil seals.
[0035] As will be understood from the above explanation, the first race 21 and the third race 23 are included in the first part 11 a, and the second race 27 and the fourth race 29 are included in the second part 11 b. When separating the second part 11 b from the first part 11 a, the first race 21 and the third race 23 are exposed in the deepest part within the first part 11 a. The first shaft 3 and the second shaft 5 , along with the bearings and the gears accompanying them, can be readily fit in the exposed races 21 and 23 , and mutual gearing can be simultaneously established. When the second part 11 b is combined with the first part 11 a so as to cover these parts, the bearings 35 , 53 are simultaneously fit in the second race 27 and the fourth race 29 . Assembly of these components is thereby finished. After finishing the assembly, the third shaft 7 is inserted therein and then tooth contact between the pinion gear 73 and the bevel gear 57 can be regulated. More specifically, the present example prominently facilitates assembly of the PTU 1 .
[0036] As will be readily understood as well, the first bearing 33 comes close to the coupling portion 13 , the opening 15 , and the oil seal 81 of the casing 11 ; and the second bearing 35 comes close to the opening 17 and the oil seal 83 . Therefore, if the first shaft 3 makes an eccentric motion or precessional motion, an influence on the oil seals or components combined therewith would be small. Further the pair of bearings 33 , 35 staying away from each other supports the first shaft 3 , the eccentric motion or the precessional motion per se hardly occurs.
[0037] As the second shaft 5 is also supported at both ends, the eccentric motion or the precessional motion hardly occurs. Further, as the bevel gear 57 that receives the thrust reaction force is supported directly by the bearing 51 , the source of the eccentric motion or the precessional motion is done away with per se.
[0038] Further, as any of the bearings has its entire circumference supported by each race, off-center force will not act on any of the bearings and the races, thereby ensuring firm support for the shafts. As the first race 21 and the third race 23 constitute a unitary body and the second race and the fourth race constitute a unitary body, the whole structure has a high stiffness and also a high strength. Therefore each shaft is more firmly supported.
[0039] Further, as the bearing 33 is disposed further leftward as compared with the bevel gear 57 , interference therebetween is avoided and the bevel gear 57 is not required to deviate upward in order to avoid the bevel gear 57 . Further it is also not required to make the diameter of the bearing 33 larger in order to prevent the eccentric motion or the precessional motion. The casing 11 can be therefore reduced in size in the longitudinal direction and thus a region 12 shown in FIGS. 1 and 3 , enclosed by dotted chain lines, can be cut off. As described already, the PTU has a restriction on installation, by which the PTU must be installed in a space among other devices. While this reduction in size might appear relatively minor, this significantly improves freedom of design.
[0040] Although certain examples have been described above, modifications and variations of the examples described above will occur to those skilled in the art, in light of the above teachings.
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A power transfer unit is comprised of: a casing having a first side and a second side; a first shaft being rotatably supported by a first bearing sitting on the first side and a second bearing sitting on the second side, penetrating the casing from a coupling portion to the second side, and combining with the transmission to receive torque; a second shaft being rotatably supported by a third bearing sitting on the first side and a fourth bearing sitting on the second side and gearing with the first shaft to rotate in parallel with the first shaft, the second shaft comprising a bevel gear; and a third shaft being rotatably supported by the casing and gearing with the bevel gear, wherein the first bearing is disposed closer to the coupling portion than the bevel gear is.
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BACKGROUND OF THE INVENTION
[0001] A. Field of Invention
[0002] The present invention relates to the field of medical devices and, more specifically, to an inflatable device used to assist an invalid or physically disadvantaged person in moving from a seated position to a standing position.
[0003] B. Description of the Related Art
[0004] The impact of the aging population of the United States is well recognized and has profound socioeconomic implications, not the least of which is the conversion of nursing home care into a major industry. Also, not the least of the inevitable effects of aging is the loss of lean body (muscle) mass with the result of muscle weakness. There are several contributing factors involve in this loss. Loss of appetite, poor dentition, lack of exercise, dwindling blood supply (particularly to the lower extremities) and down regulation of metabolism are all conspirators in this process. While these factors can be offset by improved nutrition and regulated exercise, the results are related to a maintained status quo rather than a return to physical vigor. Further loss may be forestalled but regeneration of lost muscle is dependent on synthesis of muscle protein and restoration of cellular activity. Both of these requisites are the victims of the aging process of muscle. The bottom line of this aspect of the aging process is that muscle weakness is the expected companion of the senior population.
[0005] Significant physical strength is not a prerequisite to a self-sufficient life style, but physical mobility is, and a level of muscle strength is a requirement for mobility. A consistent feature of early impairment of mobility is difficulty in getting up from a chair. Weakness of the extensors of the knee (the quadriceps femoris) results in difficulty rising from a chair, stair climbing and even walking. Limitations in those functions contribute to further activity restrictions which in turn result in progressive muscle weakness. Progressive limitations of physical activity complete a cycle of physical deterioration and diminishing lifestyle.
[0006] The preservation of mobility is thus the key to the maintenance of a useful, independent and psychologically fulfilling lifestyle. To that end the use of a device that permits the capability of rising from a chair and allowing walking is offered as a practical solution to the problem of physical imprisonment by the inability to move independently.
[0007] Various types of devices have been proposed to address this problem such as U.S. Pat. Nos. 3,479,087 to Burke, 5,375,910 to Murphy and 5,505,518 to Pike. These patents all disclose a pneumatic powered seat erector that consists of an upper and lower plate hinged together at one end. The devices also include an inflatable bladder positioned between the plates. As the bladder inflates, the plates begin to separate at the edge opposite the hinge causing the upper plate to pivot forward—thereby raising the individual from a seated position to a standing position. All three patents do not mimic the initial movement of the seated individual as he or she begins stand. At inflation, the upper plate pivots forward so that the individual is lifted only from the back and not from the front. This pivot only action causes the individual to slide off the seat.
[0008] U.S. Pat. No. 4,629,162 to Porché discloses a portable pneumatic lift that includes an inflatable single chamber air bag, a pressurized air source and a remote control for operation of the air source. The air bag is wedged shape in that when inflated the height at the back of the air bag is about 13 inches and the height at the front of the air bag is about 10 inches. Although inflation of the air bag in Porché better mimics the initial movement of a seated individual as he or she begins to stand, the angle of pitch is not sufficient to fully assist the individual to stand from a seated position.
[0009] U.S. Pat. No. 4,905,329 to Heilner discloses an inflatable seat cushion consisting of an inflatable ring whereby the front portion of the ring is restricted during inflation thereby allowing the back portion of the ring to inflate at a height 3-7 times that of the front portion. Although Heilner allows for some elevation in the front portion, the inflatable ring must be sized appropriately to prevent an individual from falling through the center of the ring.
[0010] U.S. Pat. Nos. 5,361,433 and 5,742,957, both to Vanzant, disclose an inflatable bag having multiple cavities that inflate sequentially. The devises of these patents, however, do not provide a means for a washable fabric cover or the ability to place the compressor within a pocket or compartment on either side of the bladder.
[0011] What is needed is a device that elevates and pitches forward the seated individual, which mimics the change to a standing position. This will facilitate the effective contraction of quadriceps muscles by reducing the extent of muscle shortening necessary to allow straightening of the legs at the knee. As the present invention discloses, a forward pitch level of approximately thirty degrees is sufficient to produce the desired effect. This degree of inclination can be achieved by an approximate seven inch elevation of the dorsal plane of the seated position over the ventral plane. This effect can be accentuated by a two inch elevation of the seat cushion itself. The positional change produced by this device thus mimics the initial movements of the unassisted rise from a seated position in a normal circumstance. Therefore, performance of the initial movement by the device allows the completion of the standing process by the user. In this way the disadvantages known in the art cam be overcome in a way that is better, more efficient and that provides better overall results.
SUMMARY OF THE INVENTION
[0012] The present invention overcomes the aforementioned disadvantages by providing an inflatable device that produces a forward pitch level of approximately 30 degrees that is sufficient to produce the desired effect. In addition, the degree of inclination can be achieved by an approximate 7 inch elevation of the dorsal plane of the seated position over the ventral plane. This effect can be accentuated by a 2 inch elevation of the seat cushion itself. The positional change produced by this device thus mimics the initial movements of the unassisted rise from a seated position in a normal circumstance. Therefore, performance of the initial movement by the device allows the completion of the standing process by the user.
[0013] It is therefore one object of the present invention to provide an inflatable lift device that mimics the initial movement of a seated person to a standing position.
[0014] It is another object of the present invention to provide an inflatable lift device where the front portion rises to assist the seated person to a standing position.
[0015] It is yet another object of the present invention to provide an inflatable lift device that is portable and lightweight.
[0016] It is yet another object of the present invention to provide an inflatable lift device with one embodiment that contains a single valve for inflation and rapid deflation.
[0017] It is yet another object of the present invention to provide an inflatable lift device that provides a removable washable cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:
[0019] FIG. 1 is a perspective view of the present invention showing the bladder with the cover removed.
[0020] FIG. 2 is a perspective view of the bladder with the cover attached.
[0021] FIG. 3 is a top view of the support plate.
[0022] FIG. 4 is a side view of the base showing the location of the compressor compartment.
[0023] FIG. 5 is a side view of the inflatable bladder.
[0024] FIG. 6 is a perspective view of the inflated bladder showing one embodiment with separate intake and exhaust valves.
[0025] FIG. 7 illustrates the exhaust valve in the closed position.
[0026] FIG. 8 illustrates the exhaust valve in the opened position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring now to the drawings wherein the showings are for purposes of illustrating a preferred embodiment of the invention only and not for purposes of limiting the same, FIGS. 1 and 2 show an air lift seat apparatus 10 that includes a base 12 , a bladder 14 , an intake/exhaust valve 16 , a pocket or compartment 18 , a self-contained air compressor 20 and a removable cover 22 ( FIG. 2 ). The base 12 is preferably made of a rigid polystyrene material to provide stability to the apparatus when placed on a chair. The base 12 has a front 24 , a back 26 and two sides 28 , 29 and is preferably about 18 inches wide, 18 inches deep and 1 inch in height. However, the base 12 can be any suitable size to fit a standard sized chair, seat cushion of a sofa or similar type of sitting apparatus as along as chosen with sound engineering judgment.
[0028] Referring now to FIGS. 2 and 3 , in the preferred embodiment a connecting means 27 is provided to selectively attach the cover 22 to the base 12 . The connecting means 27 may be of any type chosen with sound engineering judgment such as snaps 30 , hook and loop fasteners such as Velcro® (not shown) or a zipper (not shown). The cover 22 can be made of any material chosen with sound engineering judgment but preferably is formed of a washable fabric. In the preferred embodiment, a slip prevention material 38 is provided on at least a portion of the top 23 of the cover 22 . This slip prevention material 38 makes it difficult for a person to slip off of the lift seat apparatus 10 while the bladder 14 is inflating. The cover 22 is preferably sized slightly larger than the bladder 14 when the bladder 14 is fully inflated to facilitate easy application and removal of the cover 22 .
[0029] With reference now to FIGS. 3 and 4 , the compartment 18 that holds or houses the air compressor 20 can be located on either side of the bladder 14 to facilitate use by either hand of the seated person. The compartment 18 is preferably attached to either side 28 , 29 of the base 12 and is located near the front 24 of the base as shown in FIG. 3 . The compartment 18 can either be an integral part of the base 12 or can be a separate piece that attaches to the base 12 by any means chosen with sound engineering judgment. The preferred height of the compartment 18 is approximately 2 inches. The length and the width of the compartment 18 are determined by the type of air compressor used to inflate the bladder 14 . The preferred air compressor 20 is a portable, commercially available, rechargeable type compressor commonly known in the art and thus will not be described further. An air hose 32 is provided to transport air from the air compressor 20 to the bladder 14 . As shown in FIG. 1 , the first end 34 of the hose 32 is connected to the air-compressor 20 and the second end 36 of the hose 32 is connected to the intake/exhaust valve 16 by means commonly known in the art.
[0030] Referring to FIGS. 1 and 5 , the bladder 14 is preferably made from a single piece of material. The material can be any type of flexible material chosen with sound engineering judgment that allows the bladder 14 to expand upon inflation and contract upon deflation. The bladder 14 further contains a front portion 40 , a rear portion 42 , two trapezoidal shaped side panels 44 , 45 , a top 46 and a bottom 48 . The length and width of the bottom 50 are similarly sized to fit the base 12 as described above. The bladder 14 is designed to mimic the initial movements of a seated person when that person begins to stand. Therefore, when the bladder 14 begins to inflate the front portion 40 and the rear portion 42 will inflate simultaneously. When fully inflated, the rear portion 42 is at least three times higher than the front portion 40 . In one embodiment the rear portion 42 is nine inches high and the front 40 portion is 2 inches high.
[0031] With reference now to FIG. 1 , an intake/exhaust valve 16 is located on the side 44 of the bladder. The valve can be located on either side 44 , 45 to facilitate use by either hand of the seated person as with the compartment 18 as described above. The valve 16 can be any type of mechanical valve commonly known in the art. In one embodiment the valve 16 is a ball type valve 50 as shown in FIGS. 7 and 8 . The ball valve 50 further consists of a handle 52 , a core 54 and an aperture 56 and a housing 58 . FIG. 7 shows the ball valve 50 in the open position. When the ball valve 50 is in the open position the aperture 56 is parallel to the housing 58 and air can enter or escape from the bladder 14 . FIG. 8 shows the ball valve 50 in the closed position. When the ball valve 50 is in the closed position the aperture 56 is perpendicular to the housing 58 and air cannot enter into or escape from the bladder 14 . Another embodiment of the present invention is shown in FIG. 6 . In this embodiment the apparatus contains two valves. The first valve 60 is the intake valve and the second valve 62 is the exhaust valve. In this embodiment, the hose 32 connects the air compressor 20 to the intake valve 60 . The exhaust valve 62 , when opened, permits air to exit the bladder to the atmosphere. As a result, the bladder can be deflated without removal of the air compressor hose 32 .
[0032] Operation of the present invention will now be described. The air lift seat apparatus 10 can be used to assist a person in moving from a standing position to a seated position and from a seated position to a standing position. To move from a seated position to a standing position, the person simply turns the handle 52 on the ball valve 50 and rotates it 90 degrees until the aperture 56 is parallel to the housing 58 . The person then activates the air compressor 20 thus allowing air to enter the bladder 14 . As the bladder 14 begins to inflate the front portion 40 and the rear portion 42 begin to rise simultaneously thereby slowly lifting the seated person. As the front portion 40 reaches its maximum height as described above, the rear portion 42 will continue to inflate thereby creating a pitch angle. As the rear portion 42 continues to inflate, the seated person is further lifted until the rear portion 42 reaches its maximum height as described above thereby gently assisting the seated person to a standing position. Conversely, in assisting a person to move from a standing position to a seated position, the person simply inflates the bladder 14 as previously described. Once the bladder 14 is fully inflated the person deactivates the air compressor 20 . The person then rotates the ball valve 50 by 90 degrees until the aperture 56 is perpendicular to the housing 58 . This will prevent air from escaping from the bladder 14 until the person is ready to be seated. The person then backs into the apparatus 10 and places his/her weight onto the cover 22 that is positioned over the bladder 14 . Once the person is leaning against the apparatus 10 , the person then rotates the ball valve 50 by 90 degrees until the aperture 56 is parallel to the housing 58 thereby permitting the air to escape from the bladder 14 thus gently assisting the person to move from a standing position to a seated position.
[0033] The preferred embodiments have been described, hereinabove. It will be apparent to those skilled in the art that the above methods may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.
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A lightweight and portable pneumatic lifting device includes an inflatable, trapezoidal side shaped and self-contained bladder housed in a removable, washable material. The inferior surface of the bladder contains a rigid base for stability. Located on one side of the bladder is a compartment to house the self-contained air compressor. A valve or valves is provided for inflation and deflation of the bladder.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/063,920, now U.S. Pat. No. 8,426,345, filed Jun. 19, 2008, which is a National Phase application under 35 U.S.C. §371 of International Application No. PCT/AU2006/001431, filed Oct. 3, 2006 and claims the benefit of Australian Application No. 2005905465, filed Oct. 4, 2005, the disclosures of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The invention relates to a method of identifying biologically active compounds, libraries of compounds.
BACKGROUND
Small molecules involved in molecular interactions with a therapeutic target, be it enzyme or receptor, are often described in terms of binding elements or pharmacophoric groups which directly interact with the target, and non-binding components which form the framework of the bioactive molecule. In the case of peptide ligands or substrates for instance, usually a number of amino add side chains form direct interactions with their receptor or enzyme, whereas specific folds of the peptide backbone (and other amino acid residues) provide the structure or scaffold that controls the relative positioning of these side chains. In other words, the three dimensional structure of the peptide serves to present specific side chains in the required fashion suitable for binding to a therapeutic target. The problem is that such models do not allow for rapid identification of drug candidates owing to the necessity to synthesize an enormous amount of compounds to identify potential active compounds.
A pharmacophoric group in the context of these libraries is an appended group or substituent, or part thereof, which imparts pharmacological activity to the molecule.
Molecular diversity could be considered as consisting of diversity in pharmacophoric group combinations (diversity in substituents) and diversity in the way these pharmacophoric groups are presented (diversity in shape). Libraries of compounds in which either diversity of substituents, or diversity of shape, or both of these parameters are varied systematically are said to scan molecular diversity.
Carbohydrate scaffolds provide a unique opportunity to create libraries of structurally diverse molecules, by varying the pharmacophoric groups, the scaffold and the positions of attachment of the pharmacophoric groups in a systematic manner. Such diversity libraries allow the rapid identification of minimal components or fragments containing at least two pharmacophoric groups required for an interaction with a biological target. These fragments can be further optimized to provide potent molecules for drug design. Therefore these types of carbohydrate libraries provide an excellent basis for scanning molecular diversity.
In previous applications (WO2004014929 and WO2003082846) we demonstrated that arrays of novel compounds could be synthesized in a combinatorial manner. The libraries of molecules described in these inventions were synthesized in a manner such that the position, orientation and chemical characteristics of pharmacophoric groups around a range of chemical scaffolds, could be modified and/or controlled. These applications demonstrate the synthesis and biological activity of a number of new chemical entities.
Many drug discovery strategies fall owing to lack of knowledge of the bioactive conformation of, or the inability to successfully mimic the bioactive conformation of the natural ligand for a receptor. Libraries of compounds of the present invention allow for the systematic “scanning” of conformational space to identify the bioactive conformation of the target.
Typically in the prior art, libraries based on molecular diversity are generated in a random rather than a systematic manner. This type of random approach requires large number of compounds to be included in the library to scan for molecular diversity. Further, this approach may also result in gaps in the model because of not effectively accessing all available molecular space.
Therefore, one of the problems in the prior art is the necessity to synthesize an enormous amount of compounds to identify potential active compounds. Attempts have been made to develop peptidomimetics using sugar scaffolds by Sofia et al. ( Bioorganic & Medicinal Chemistry Letters (2003) 13, 2185-2189). Sofia describes the synthesis of monosaccharide scaffolds, specifically containing a carboxylic acid group, a masked amino group (N 3 ) and a hydroxyl group as substitution points on the scaffold, with the two remaining hydroxyl groups being converted to their methyl ethers. Sofia teaches a specific subset of scaffolds not encompassed by the present invention and does not contemplate methods to simplify the optimization of pharmacophoric groups.
Therefore there remains a need to provide a method of effectively scanning libraries designed from compounds with a wider range of different pharmacophoric groups.
The present invention is directed to a method of drug design utilizing iterative scanning libraries, resulting in surprisingly efficient identification of drug candidates, starting from a selected number of pharmacophores (e.g., two) in the first library and designing subsequent libraries with additional pharmacophores based on SAR information from the first library.
The invention can provide a new method for the rapid identification of active molecules.
In an embodiment, and to demonstrate the versatility of our invention, one of the G-protein coupled receptors (GPCR's) was chosen as a target the somatostatin receptor (SST receptor). The tetradecapeptide somatostatin is widely distributed in the endocrine and exocrine system, where it has an essential role in regulating hormone secretion [1-3]. Five different subtypes have been identified to date (SST1-5), which are expressed in varying ratios throughout different tissues in the body. Somatostatin receptors are also expressed in tumours and peptide analogues of somatostatin affecting mainly SST5, such as octreotide, lanreotide, vapreotide and seglitide [4-7] have antiproliferative effects. They are used clinically for the treatment of hormone-producing pituitary, pancreatic, and intestinal tumours. SST5 is also implicated in angiogenesis, opening up the possibility of developing anti-angiogenic drugs that act on the SST5 receptor, for example for the use in oncology. The “core sequence” in somatostatin responsible for its biological activity is Phe-Trp-Lys (FWK), representing a motif of two aromatic groups and a positive charge, which is found in almost all SST receptor active compounds.
It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.
SUMMARY OF THE INVENTION
In one form, the invention provides a method of identifying biologically active compounds comprising:
(a) designing a first library of compounds of formula 1 to scan molecular diversity wherein each compound of the library has at least two pharmacophoric groups R1 to R5 as defined below and wherein compound of the library has same number of pharmacophoric groups; b) assaying the first library of compounds in one or more biological assay(s); and (c) designing a second library wherein each compound of the second library contains one or more additional pharmacophoric group with respect to the first library;
such that the/each component of the first and second library is a compound of formula 1:
wherein the ring may be of any configuration;
Z is sulphur, oxygen, CH 2 , C(O), C(O)NR A , NH, NR A or hydrogen, in the case where Z is hydrogen then R 1 is not present, R A is selected from the set defined for R 1 to R 5 , or wherein Z and R1 together form a heterocycle,
X is oxygen or nitrogen providing that at least one X of Formula I is nitrogen, X may also combine independently with one of R 1 to R 5 to form an azide.
R 1 to R 5 are independently selected from the following nor groups H, methyl and acetyl, and pharmacophoric groups, R 1 to R 5 are independently selected from the group which includes but is not limited to C 2 to C 20 alkyl or acyl excluding acetyl; C 2 to C 20 alkenyl, all heteroalkyl; C 2 to C 20 aryl, heteroaryl, arylalkyl or heteroarylalkyl, which is optionally substituted, and can be branched or linear,
or wherein X and the corresponding R moiety, R 2 to R 5 respectively, combine to for a heterocycle.
In another form, the invention comprises biologically active compounds when identified by the method described above.
In a preferred embodiment, the invention relates to said method wherein in the first library, three of the substituents R 1 -R 5 are non-pharmacophoric groups and are selected from hydrogen or methyl or acetyl.
In a preferred embodiment, the invention relates to said first method wherein in the first library, two of the substituents R 1 -R 5 are non-pharmacophoric groups and are selected from hydrogen or methyl or acetyl.
In a preferred embodiment, the invention relates to said first method wherein Z is sulphur or oxygen;
In a preferred embodiment, the invention relates to said first method wherein at least one of the pharmacophoric groups is selected from aryl, arylalkyl, heteroaryl, heteroarylalkyl or acyl
In a preferred embodiment, the invention relates to a library of compounds selected from compounds of formula 1 wherein in the first library, three of the non-pharmacophoric groups R 1 -R 5 are hydrogen or methyl or acetyl when used according to said first method.
In a preferred embodiment, the invention relates to a library of compounds selected from compounds of formula 1 wherein in the second library, two of the non-pharmacophoric groups R 1 -R 5 are hydrogen or methyl or acetyl when used according to said first method.
In a preferred embodiment, the invention relates to said first method wherein the/each component of the library is a compound selected from formula 2 or formula 3 or formula 4
In a preferred embodiment, the invention relates to said first method wherein the/each component of the library is a compound selected from formula 2 or formula 3 or formula 4 and wherein the/each compound is of the gluco- or galacto- or allo-configuration.
In a preferred embodiment, the invention relates to said first method wherein the/each component of the library is a compound selected from formula 2 or formula 3 or formula 4 wherein the/each compound is of the galacto-configuration.
In a preferred embodiment, the invention relates to said first method wherein the/each component of the library is a compound selected from formula 2 or formula 3 or formula 4 and wherein the/each compound is of the gluco-configuration.
In a preferred embodiment, the invention relates to said first method wherein each component of the library is a compound selected from formula 2 or formula 3 or formula 4 and wherein the/each compound is of the allo-configuration.
In a preferred embodiment, the invention relates to said first method wherein designing the library comprises molecular modeling to assess molecular diversity.
In a preferred embodiment, the invention rebates to said first method wherein R 1 to R 5 optional substituents include OH, NO, NO 2 , NH 2 , N 3 , halogen, CF 3 , CHF 2 , CH 2 F, nitrile, alkoxy, aryloxy, amidine, guanidiniums, carboxylic acid, carboxylic acid ester, carboxylic acid amide, aryl, cycloalkyl, heteroalkyl, heteroaryl, aminoalkyl, aminodialkyl, aminotrialkyl, aminoacyl, carbonyl, substituted or unsubstituted imine, sulfate, sulfonamide, phosphate, phosphoramide, hydrazide, hydroxamate, hydroxamic acid, heteroaryloxy, aminoaryl, aminoheteroaryl, thioalkyl, thioaryl or thioheteroaryl, which may optionally be further substituted.
The term “halogen” denotes fluorine, chlorine, bromine or iodine, preferably fluorine, chlorine or bromine.
The term “alkyl” used either alone or in compound words such as “optionally substituted alkyl”, “optionally substituted cycloalkyl”, “arylalkyl” or “heteroarylalkyl”, denotes straight chain, branched or cyclic alkyl, preferably C1-20 alkyl or cycloalkyl. Examples of straight chain and branched alkyl include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, tert-butyl, amyl, isoamyl, sec-amyl, 1,2-dimethylpropyl, 1,1-dimethylpropyl, hexyl, 4-methylpentyl, 1-methylpentyl, 2-methylpentyl, 3-methylpentyl, 1,1-dimethylbutyl, 2,2-dimethylbutyl, 3,3-dimethylbutyl, 2-dimethylbutyl, 1,3-dimethylbutyl, 1,2,2trimethylpropyl, 1,2-trimethylpropyl, heptyl, 5-methylhexyl, 1-methylhexyl, 2,2-dimethylpentyl, 3,3dimethylpentyl, 4,4-dimethylpentyl, 1,2-dimethylpentyl, 1,3-dimethylpentyl, 1,4-dimethylpentyl, 1,2,3trimethylbutyl, 1,1,2-trimethylbutyl, 1,1,3-trimethylbutyl, octyl, 6-methylheptyl, 1-methylheptyl, 1,1,3,3tetramethylbutyl, nonyl, 1-, 2-, 3-, 4-, 5-, 6- or 7methyloctyl, 1-, 2-, 3-, 4- or 5-ethylheptyl, 1-, 2- or 3propylhexyl, decyl, 1-, 2-, 3-, 4-, 5-, 6-, 7- or 8-methylnonyl, 1-, 2-, 3-, 4-, 5- or 6-ethyloctyl, 1-, 2-, 3 or 4-propylheptyl, undecyl 1-, 2-, 3-, 4-, 5-, 6-, 7-, 8 or 9-methyldecyl, 1-, 2-, 3-, 4-, 5-, 6- or 7-ethylnonyl, 1-, 2-, 3-, 4- or 5-propyloctyl, 1-, 2- or 3-butylheptyl, 1-pentylhexyl, dodecyl, 1-, 2-, 3-, 4-, 5-, 6-, 7-, 8-, 9- or 10-methylundecyl, 1-, 2-, 3-, 4-, 5-, 6-, 7- or 8-ethyldecyl, 1-, 2-, 3-, 4-, 5- or 6-propylnonyl, 1-, 2-, 3- or 4-butyloctyl, 1-2 pentylheptyl and the like. Examples of cyclic alkyl include mono- or polycyclic alkyl groups such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl and the like.
The term “alkylene” used either alone or in compound words such as “optionally substituted alkylenyl” denotes the same groups as “alkyl” defined above except that an additional hydrogen has been removed to form a divalent radical. It will be understood that the optional substituent may be attached to or form part of the alkylene chain.
The term “alkenyl” used either alone or in compound words such as “optionally substituted alkenyl” denotes groups formed from straight chain, branched or cyclic alkenes including ethylenically mono-, di- or polyunsaturated alkyl or cycloalkyl groups as defined above, preferably C2-6 alkenyl. Examples of alkenyl include vinyl, allyl, 1-methylvinyl, butenyl, iso-butenyl, 3-methyl-2butenyl, 1-pentenyl, cyclopentenyl, 1-methyl-cyclopentenyl, 1-hexenyl, 3-hexenyl, cyclohexenyl, 1-heptenyl, 3-heptenyl, 1-octenyl, cyclooctenyl, 1-nonenyl, 2-nonenyl, 3-nonenyl, 1 decenyl, 3-decenyl, 1,3-butadienyl, 1,4-pentadienyl, 1,3 cyclopentadienyl, 1,3-hexadienyl, 1,4-hexadienyl, 1,3cyclohexadienyl, 1,4-cyclohexadienyl, 1,3-cycloheptadienyl, 1,3,5-cycloheptatrienyl and 1,3,5,7-cyclooctatetraenyl.
The term “alkynyl” used either alone or in compound words, such as “optionally substituted alkynyl” denotes groups formed from straight chain, branched, or mono- or poly- or cyclic alkynes, preferably C 2-6 alkynyl.
Examples of alkynyl include ethynyl, 1-propynyl, 1- and 2butynyl, 2-methyl-2-propynyl, 2-pentynyl, 3-pentynyl, 4pentynyl, 2-hexynyl, 3-hexynyl, 4-hexynyl, 5-hexynyl, 10-undecynyl, 4-ethyl-1-octyn-3-yl, 7-dodecynyl, 9-dodecynyl, 10-dodecynyl, 3-methyl-1-dodecyn-3-yl, 2-tridecynyl, 11tridecynyl, 3-tetradecynyl, 7-hexadecynyl, 3-octadecynyl and the like.
The term “alkoxy” used either alone, or in compound words such as “optionally substituted alkoxy” denotes straight chain or branched alkoxy, preferably C1-7 alkoxy. Examples of alkoxy include methoxy, ethoxy, npropyloxy, isopropyloxy and the different butoxy isomers.
The term “aryloxy” used either alone or in compound words such as “optionally substituted aryloxy” denotes aromatic, heteroaromatic, arylalkoxy or heteroaryl alkoxy, preferably C6-13 aryloxy. Examples of aryloxy include phenoxy, benzyloxy, 1-napthyloxy, and 2-napthyloxy.
The term “acyl” used either alone or in compound words such as “optionally substituted acyl” or “heteroarylacyl” denotes carbamoyl, aliphatic acyl group and acyl group containing an aromatic ring, which is referred to as aromatic acyl or a heterocyclic ring which is referred to as heterocyclic acyl. Examples of acyl include carbamoyl; straight chain of branched alkanoyl such as formyl, acetyl, propanoyl, butanoyl, 2-methylpropanoyl, pentanoyl, 2,2-dimethylpropanoyl, hexanoyl, heptanoyl, octanoyl, nonanoyl, decanoyl, undecanoyl, dodecanoyl, tridecanyl, tetradecanoyl, pentadecanoyl, hexadecanoyl, heptadecanoyl, octadecanoyl, nonadecanoyl, and icosanoyl; alkoxycarbonyl such as methoxycarbonyl, ethoxycarbonyl, t butoxycarbonyl, t-pentyloxycarbonyl and heptyloxycarbonyl; cycloalkylcarbonyl such as cyclopropylcarbonyl cycle cyclopentylcarbonyl and cyclohexylcarbonyl; alkylsulfonyl such as methylsulfonyl and ethylsulfonyl; alkoxysulfonyl such as methoxysulfonyl and ethoxysulfonyl; aroyl such as benzoyl, toluoyl and naphthoyl; aralkanoyl such as phenylalkanoyl (e.g. phenylacetyl, phenylpropanoyl, phenylbutanoyl, phenylisobutyl, phenylpentanoyl and phenylhexanoyl) and naphthylalkanoyl (e.g. naphthylacetyl, naphthlpropanoyl and naphthylbutanoyl); aralkenoyl such as phenylalkenoyl (e.g. phenylpropenoyl, phenylbutenoyl, phenylmethacrylyl, phenylpentenoyl and phenylhexenoyl and naphthylalkenoy) (e.g. naphthylpropenoyl, napthylbutenoyl and naphthylpentenoyl); aralkoxycarbonyl such as phenylalkoxycarbonyl (e.g. benzyloxycarbonyl); aryloxycarbonyl such as phenoxycarbonyl and naphthyloxycarbonyl; aryloxyalkanoyl such as phenoxyacetyl and phenoxypropionyl; arylcarbamoyl such as phenylcarbamoyl; arylthiocarbamoyl such as phenylthiocarbamoyl; arylglyoxyloyl such as phenylglyoxyloyl and naphthylglyoxyloyl; arylsulfonyl such as phenylsulfonyl and naphthylsulfonyl; heterocycliccarbonyl; heterocyclicalkanoyl such as thienylacetyl, thienylpropanoyl, thienylbutanoyl, thienylpentanoyl, thienylhexanoyl, thiazolylacetyl, thiadiazolylacetyl and tetrazolylacetyl; heterocyclicalkenoyl such as heterocyclicpropenoyl, heterocyclicbutenoyl, heterocyclicpentenoyl and heterocyclichexenoyl; and heterocyclicglyoxyloyl such as thiazolyglyoxyloyl and thienyglyoxyloyl.
The term “aryl” used either alone or in compound words such as “optionally substituted are”, “arylalkyl” or“heteroaryl” denotes single, polynuclear, conjugated and fused residues of aromatic hydrocarbons or aromatic heterocyclic ring systems. Examples of aryl include phenyl, biphenyl, terphenyl, quaterphenyl, phenoxyphenyl, naphthyl, tetra anthracenyl, dihydroanthracenyl, benzanthracenyl, dibenzanthracenyl, phenanthrenyl, fluorenyl, pyrenyl, indenyl, azulenyl, chrysenyl, pyridyl, 4-phenylpyridyl, 3-phenylpyridyl, thienyl, furyl, pyrryl, pyrrolyl, furanyl, imadazolyl, pyrrolydinyl, pyridinyl, piperidinyl, indolyl, pyridazinyl, pyrazolyl, pyrazinyl, thiazolyl, pyrimidinyl, quinolinyl, isoquinolinyl, benzofuranyl, benzothienyl, purinyl, quinazolinyl, phenazinyl, acridinyl, benzoxazolyl, benzothiazolyl and the like. Preferably, the aromatic heterocyclic ring system contains 1 to 4 heteroatoms independently selected from N, O and S and containing up to 9 carbon atoms in the ring.
The term “heterocycle” used either alone or in compound words as “optionally substituted heterocycle” denotes monocyclic or polycyclic heterocycyl groups containing at least one heteroatom atom selected from nitrogen, sulphur and oxygen. Suitable heterocyclyl groups include N-containing heterocyclic groups, such as, unsaturated 3 to 6 membered heteromonocyclic groups containing 1 to 4 nitrogen atoms, for example, pyrrolyl, pyrrolinyl, imidazolyl, pyrazolyl, pyridyl, pyrazinyl, pyridazinyl, triazolyl or tetrazolyl; saturated to 3 to 6-membered heteromonocyclic groups containing 1 to 4 nitrogen atoms, such as, pyrrolidinyl, imidazolidinyl, piperidin or piperazinyl; unsaturated condensed heterocyclic groups containing 1 to 5 nitrogen atoms, such as, indolyl, isoindolyl, benzimidazoyl, quinolyl, isoquinolyl, indazolyl, benzotriazolyl or tetrazolopyridazinyl; unsaturated 3 to 6-membered heteromonocyclic group containing an oxygen atom, such as, pyranyl or furyl; unsaturated 3 to 6-membered heteromonocyclic group containing 1 to 2 sulphur atoms, such as, thienyl; unsaturated 3 to 6-membered heteromonocyclic group containing 1 to 2 oxygen atoms and 1 to 3 nitrogen atoms, such as, oxazolyl, isoxazolyl or oxadiazolyl; saturated 3 to 6-membered heteromonocyclic group containing 1 to 2 oxygen atoms and 1 to 3 nitrogen atoms, such as, morpholinyl; unsaturated condensed heterocyclic group containing 1 to 2 oxygen atoms and 1 to 3 nitrogen atoms, such as, benzoxazolyl or benzoxadiazolyl; unsaturated 3 to 6-membered heteromonocyclic group containing 1 to 2 sulphur atoms and 1 to 3 nitrogen atoms, such as, thiazolyl or thiadiazolyl; saturated 3 to 6-membered heteromonocyclic group containing 1 to 2 sulphur atoms and 1 to 3 nitrogen atoms, such as thiazolidinyl; and unsaturated condensed heterocyclic group containing 1 to 2 sulphur atoms and 1 to 3 nitrogen atoms, such as, benzothiazolyl or benzothiadiazolyl.
In a preferred embodiment, the invention relates to said first method wherein the compounds are synthesized.
In a preferred embodiment, the invention relates to said first method wherein the biological assays are selected from peptide ligand class of GPCRs.
In another aspect the invention provides a compound according to formula 1 in which at least one X is nitrogen, and said X is combined with the corresponding R 2 -R 5 to form a heterocycle. The synthesis of the heterocyclic components of the present invention is disclosed in WO 2004/022572.
In a preferred embodiment, the invention provides a compound according to formula 1 wherein X and R 2 combine to form a heterocycle.
In a preferred embodiment, the invention provides a compound according to formula 1 wherein the heterocycle is heteroaryl, including triazoles, benzimidazoles, benzimidazolone, benzimidazolothione, imidazole, hydantoine, thiohydantoine and purine.
DETAILED DESCRIPTION OF THE INVENTION
The embodiments of the invention will be described with reference to the following examples. Where appropriate, the following abbreviations are used.
Ac Acetyl
DTPM 5-Acyl-1,3-dimethylbarbiturate
Ph Phenyl
TBDMS t-Butyldimethylsilyl
TBDPS t-Butyldiphenylsilyl
Bn benzyl
Bz benzoyl
Me methyl
DCE 1,2-dichloroethane
DCM dichloromethane, methylene chloride
Tf trifluoromethanesulfonyl
Ts 4-methylphenylsulfonyl, p-toluenesulfonyl
DMF N,N-dimethylformamide
DMAP N,N-dimethylaminopyridine
α,α-DMT α,α-dimethoxytoluene, benzaldehyde dimethyl acetal
DMSO dimethylsulfoxide
DTT dithiothreitol
DMTST Dimethyl(methylthio)sulphoniumtrifluoro-methanesulphonate
TBAF tetra-n-butylammonium fluoride
Part A
Preparation of Building Blocks
In order to fully enable the invention, there is described below methods for the preparation of certain building blocks used in the preparation of the compounds of the invention. The building blocks described are suitable for both solution and solid phase synthesis of the compounds of the invention.
Example A: Synthesis of a 2,4 Dinitrogen Containing Galactopyranoside Building Block
Example B: Synthesis of a 3-nitrogen Containing Gulopyranoside Building Block
Example C: Synthesis of a 2,6-dinitrogen Substituted Glucopyranoside Building Block
Example D: Synthesis of a 2-nitrogen Containing Tallopyranoside Building Block
Example E: Synthesis to 3-nitrogen Containing Altropyranoside Building Block
Example F: Synthesis 2-nitrogen Containing Glucopyranoside Building Block
Example G: Synthesis of a 2-nitrogen Containing Allopyranoside Building Block
The Solid Phase Library Synthesis of Sugars is illustrated in Scheme 1.
The reaction conditions are as follows:
(A) 2P Compound Synthesis: R 1 =R 2 =OMe;
i) 2-naphthalene methanol, DMTST, DCM; TCA-Wang resin, BF 3 .Et 2 O, DCM; iii) NaOMe, methanol; iv a. KOtBu, DMF; b. Mel, DMF; v) HF ‘proton sponge’, AcOH, DMF, 65° C.; vi) a. KOtBu, DMF; b. Mel, DMF; vii) 1,4-dithio-DL-threitol, KOtBu, DMF; viii) HBTU, Fmoc-β-Ala-OH, DIPEA, DMF; ix) piperidine/DMF (¼); x) TFA, Et 3 SiH, DCM
(B) 3P Compound Synthesis: R 1 =methyl-2-naphthyl, R 2 =OMe;
i) 2-naphthalene methanol, DMTST, DCM; ii) TCA-Wang resin, BF 3 .Et 2 O, DCM; iii) NaOMe, methanol; iv) a. KOtBu, DMF; b, 2-bromomethyl-naphthalene, DMF; v) HF ‘proton sponge’, AcOH, DMF, 65° C.; vi) a. KOtBu, DMF; b. Mel, DMF; vii) 1,4-dithio-DL-threitol, KOtBu, DMF; viii) HBTU, Fmoc-β-Ala-OH, DIPEA, DMF; ix) piperidine/DMF (¼), x) TFA, Et 3 SiH, DCM
(C) 4P Compound Synthesis: R 1 =methyl-2-naphthyl, R 2 =4-chlorobenzyl
i) 2-napthalene methanol, DMTST, DCM; ii) TCA-Wang BF 3 .Et 2 O, DCM; iii) NaOMe, methanol; iv) a. KOtBu, DMF; b. 2-bromomethyl-naphthalene, DMF; v) HE ‘proton sponge’, AcOH, DMF, 65° C.; vi) a. KOtBu, DMF; b. 4-chlorobenzylbromide, DMF; vii) 1,4-dithio-DL-threitol, KOtBu, DMF; viii) HBTU, Fmoc-β-Ala-OH, DIPEA, DMF; ix) piperidine/DMF (¼); x) TFA, Et 3 SiH, DCM
The synthesis of the Allose 2,6N building block is illustrated in Scheme 2. The reaction conditions are as follows:
i) p-methoxybenzaldehyde dimethylacetal, camphorsulfonic acid, N,N-dimethylformamide (DMF); ii) Tf 2 O, pyridine, dichloromethane (DCM); iii) tetrabutylammonium benzoate, DMF, 55° C.; iv) BH 3 .THF, Bu 2 BOTf, DCM; v) methanesulfonylchloride, pyridine, DCM; vi) sodium azide, DMF, 85° C.; vii) sodium methanolate (NaOMe), methanol; viii) n-butanol, ethylene diamine, reflux; ix) DTPM reagent, methanol; x) benzoic anhydride, pyridine xi) trifluoroacetic acid, triethylsilane, DCM
Designing Libraries
The design of the libraries is based on the presentation of a positive charge and a crying number of aromatic substituents in different spatial arrangements on a monosaccharide scaffold. Starting with a positive charge and one aromatic displayed on the core scaffold, actives from this first library were elaborated on by further variation and addition of more aromatic substituents to quickly identify highly active molecules.
The first library of compounds comprises two pharmacophoric groups, known as a 2P library, in particular, one containing an aromatic and a positive charge. The library was designed such that each molecule presents two pharmacophoric groups in different relative orientation or presentation (e.g., distance, relative angle, i.e. relative position in, space is different).
Actives from this library were identified and SAR information from this library was used to design subsequent library of compounds wherein each compound may include three pharmacophoric groups, known as a 3P library. Subsequent libraries with four pharmacophoric groups are called 4P library, etc.
Members of significantly improved activity were identified out of the second library and were selected for further drug development.
The method of the invention includes real and virtual libraries.
Thus, the molecules according to formula 1 are well suited for generating iterative scanning libraries, starting from a selected number of pharmacophores (eg, two) in the first library and designing subsequent libraries with additional pharmacophores based on SAR information from the first library, thereby assisting in delineating pharmacophores.
The 2P and 3P library of compounds were synthesized according to the budding blocks as described in Examples A-G.
The 2P library (Table 1) was designed to scan molecular diversity for 3P molecules, comprising an aromatic and a positive charge.
The 2P library was screened for biological activity and the results are given in Table 1.
Similarly, the 3P library was designed to scan molecular diversity for 3P molecules. Design of 3P library resulted from SAR obtained from 2P library in Table 1.
The 3P library was screened for biological activity and the results are given in Table 2.
A visual analysis of the results according to Table 1 (2P library) and Table 2 (3P Library) indicates that:
1. 1, 2 allose substitution according to formula 0.3 (and Scaffold C/D) presents the most active arrangement of molecules in the library wherein Z is oxygen, R 1 is naphthyl and R 2 is propylamine or ethylamine.
These compounds represent most actives at low mM range, and are suitable candidates for further drug development.
2. R 1 as naphthyl is more active than the corresponding p-chlorobenzyl substituent.
3. 1, 2 allose according to formula 3 (Scaffold C/D) is more active than the corresponding 1, 2 glucose conformation (Scaffold A/B).
4. 1. 2 substitution according to formula 3 (Scaffold C/D) is more active then the corresponding 2, 6 substitution according the formula 4 (Scaffold G)
5. R 2 as propylamine and ethylamine are more active than methylamine wherein Z, R 1 and R 2 are as described above.
6. 2, 3 allose substitution according to formula 3 (Scaffold C/D) presents the more actives wherein R 2 is ethylamine, and R 3 is p-chlorobenzyl compared to corresponding R 2 as propylamine and ethylamine wherein R3 is p-chlorobenzyl substituent, and also wherein R 2 is methylamine, ethylamine or propylamine and R3 is naphthyl.
7. 2, 3 glucose substitution according to formula 3 (scaffold A/B) presents the more actives wherein R 2 propylamine and R 3 is naphthyl compared to corresponding R 2 as methylamine or ethylamine, and also wherein R 2 is methylamine, ethylamine or propylamine and R 3 is p-chlorobenzyl.
8. 2, 4 and 3, 4 substitutions according to formula 3 (Scaffold G) present the least actives.
Part B
Biological Assays
Example H: In Vitro Screening of Compounds Against Somatostatin Subtypes SSTR-1 to SSTR-5
General Method
Receptor membrane preparations containing the desired cloned receptor (for example cloned human somatostatin receptor subtype 5, SSTR5) and radiolabeled ligand were diluted at the concentration required for testing and according to the specific parameters associated with the selected receptor-ligand combination, including receptor B max , ligand K d and any other parameters necessary to optimize the experimental conditions. When tested for competition activity to the reference ligand, “compound” was mixed with membrane suspension and the radiolabeled reference ligand (with or without an excess of unlabeled ligand to the receptor for determination of non-specific binding) and incubated at the temperature required by internal standard operating procedures. Following incubation, the binding reaction was stopped by the addition of ice-cold washing buffer and filtered on appropriate filters, which are then counted. Data analysis and curve-fitting was performed with XLfit (IDBS).
Preparation of Compounds
10 mM solutions of test compounds in 100% DMSO were prepared, ˜160 μl was used for each dilution (20 μl/well in triplicate).
A 1.25 mM assay stock was prepared by making a 1:8 dilution of the 10 mM solution. To 30 μL of the 10 mM solution was added 210 μL milli-Q H 2 O. A 1:5 dilution series in milli-Q H 2 O was then prepared.
Final concentration
Final concentration
in SST4 assay
in SST5 assay
A.
240 μL of 1.25 mM
0.25 mM
0.125 mM
B.
48 μL A + 192 μL mQ
0.05 mM
0.025 mM
C.
24 μL B + 192 μL mQ
0.01 mM
0.005 mM
etc
Assays were performed in triplicate at each concentration within the 1:5 dilution series: 250 μM, 50 μM, 10 μM, 2 mM, 0.4 μM, 0.08 μM, 0.016 μM, 0.0032 μM, etc. (for SST4 assay and 125 μM, 10 μM, 2 μM, 1 μM, 0.5 μM, etc (for SST5 assay).
Fitter Plate Assay for SST5 Receptor
Human SST5 somatostatin receptor was transfected into HEK-293 EBNA cells. Membranes were suspended in assay buffer (50 mM Tris-HCl, 1 mM EGTA, 5 mM MgCl 2 , 10% sucrose, pH 7.5). The receptor concentration (B max ) was 0.57 pmol/mg protein K d for [ 125 I]SST-14 Binding 0.31 nM, volume 0.4 ml per vial (400 microassays/vial), and protein concentration 1.03 mg/ml.
After thawing the frozen receptor preparation rapidly, receptors were diluted with binding buffer, homogenized, and kept on ice.
1. Use Multiscreen glass fiber filter plates (Millipore, Cat No MAFCNOB10) precoated with 0.5% PEI for ˜2 hr at 4° C. Before use add 200 μl/well assay buffer and filter using Multiscreen Separation System. 2. Incubate 5.5 μg of membranes (40 μl of a 1:40 dilution), buffer and [ 125 I]SST-14 (4 nM, ˜80 000 cpm, 2000 Ci/mmol) in a total volume of 200 μl for 60 min at 25° C. Calculate IC50 for SST-14 (a truncated version of the natural ligand SST-28) (Auspep, Cat No 2076) and SST-28 (Auspep, Cat No 1638). Prepare serial dilutions (1:5) of compounds, as described above and instead of adding SST-14 in well, add 20 μl of compounds (Table 3). 3. Filter using Multiscreen Separation System with 5×0.2 ml ice-cold Assay buffer. 4. Remove the plastic underdrain and dry plate in oven for 1 hr at 40° C. 5. Seal tape to the bottom of the plate. 6. Add 50 μl/well scintillant (Supermix, Wallac, Cat No 1200-439). 7. Seal and count in the BJET, program 2.
TABLE 3
Compounds
Volume (ul)
TB
NSB
testing
Membranes (5.5 μg/well)
40
40
40
Radio-labeled label (~80 000
40
40
40
cpm, ~4 nM)
Unlabeled ligand
—
20
—
mQH 2 O
20
—
—
Compounds
20
Assay buffer
100
100
100
Total volume (μI)
200
200
200
TB: total binding
NSB: non-specific binding
Part C
General Experimental Methods
Example I: HPLC Method for Compounds in Tables 1 and 2
The HPLC separation of compounds in Tables 1 and 2 was conducted under Method A or Method B as shown below.
Method A
Column: Agent SB Zorbax C18 4.6×50 mm (5 μm, 80 À)
LC mobile phase:
5% aqueous MeCN/1 min
100% MeCN/7-12 min
Method B
Column: Agilent SB Zorbax C18 4.6×50 mm (5 μm, 80 À)
LC mobile phase:
5% aq MeCN/1 min
30% aq MeCN/3 min
40% aq MeCN/12 min
100% MeCN/13-15 min
Key to Building Blocks for Tables 1 and 2
Table 1: *% SST5 radio-ligand binding displaced at conc (μM) for 2P library of compounds
Table 2: *% SST5 radio-ligand binding displaced at conc (μM) for 3P library of compounds; R 4 =X30; compounds 60-63, 119 and 156-159 are comparative compounds from 2P library
“++”: % SST5 radio-ligand binding displaced at conc (μM) >60%
“+”: % SST5 radio-ligand binding displaced at conc (μM) 60>+>40%
“−”: % SST5 radio-ligand binding displaced at conc (μM) −<40%
Blank: not determined
RT: retention time/minutes
M+H: mass ion+1
TABLE 1
Biological activity of example 2P library
conc
conc
conc
Object ID
Scaffold
R1
R2
R3
R4
R5
500
250
50*
RT
M + H
1
E
—
X15
X2
X30
X24
3.24
449.58
2
A
X7
X20
X24
X30
X24
3.4
383.46
3
A
X7
X15
X24
X30
X24
3.42
397.48
4
E
—
X20
X2
X30
X24
3.49
435.55
5
A
X2
X20
X24
X30
X24
++
+
−
3.88
419.21
6
A
X2
X15
X24
X30
X24
++
+
−
3.83
433.23
7
E
—
X19
X24
X30
X3
−
−
−
3.42
405.12
8
E
—
X19
X24
X30
X2
++
+
−
3.81
421.17
9
E
—
X19
X3
X30
X24
−
−
−
3.62
405.12
10
E
—
X19
X2
X30
X24
−
−
−
4.03
421.17
11
A
X3
X19
X24
X30
X24
−
−
−
3.39
389.14
12
A
X2
X19
X24
X30
X24
−
−
−
4.08
405.19
13
B
X3
X19
X24
X30
X24
−
−
−
3.4
389.14
14
B
X2
X19
X24
X30
X24
−
−
−
3.88
405.19
15
E
—
X20
X24
X30
X3
−
−
−
3.25
419.13
16
E
—
X20
X24
X30
X2
+
−
−
3.59
435.19
17
E
—
X20
X3
X30
X24
−
−
−
3.68
419.13
18
E
—
X20
X2
X30
X24
−
−
−
4.06
435.19
19
A
X3
X20
X24
X30
X24
++
−
−
3.56
403.16
20
B
X3
X20
X24
X30
X24
+
−
−
3.37
403.16
21
B
X2
X20
X24
X30
X24
++
+
−
3.7
419.21
22
E
—
X15
X24
X30
X3
−
−
−
3.22
433.15
23
E
—
X15
X24
X30
X2
+
−
−
3.59
449.2
24
E
—
X15
X3
X30
X24
−
−
−
3.7
433.15
25
E
—
X15
X2
X30
X24
+
−
−
4.06
449.2
26
E
X3
X15
X24
X30
X24
++
−
−
3.57
417.17
27
B
X3
X15
X24
X30
X24
−
−
−
3.4
417.17
28
B
X2
X15
X24
X30
X24
++
−
−
3.68
433.23
29
F
—
X19
X24
X30
X3
−
−
−
3.55
405.12
30
F
—
X19
X24
X30
X2
+
−
−
3.84
421.17
31
F
—
X19
X3
X30
X24
+
−
−
3.75
405.12
32
F
—
X19
X2
X30
X24
−
−
−
4.05
421.17
33
C
X3
X19
X24
X30
X24
−
−
−
3.38
389.14
34
C
X2
X19
X24
X30
X24
−
−
−
3.72
405.19
35
D
X3
X19
X24
X30
X24
−
−
−
3.41
389.14
36
D
X2
X19
X24
X30
X24
+
−
−
3.77
405.19
37
F
—
X20
X3
X30
X24
−
−
−
3.76
419.13
38
C
X3
X20
X24
X30
X24
++
+
−
3.33
403.16
39
D
X3
X20
X24
X30
X24
++
−
−
3.44
403.16
40
D
X2
X20
X24
X30
X24
++
++
−
3.8
419.21
41
F
—
X15
X24
X30
X3
−
−
−
3.51
433.15
42
F
—
X15
X24
X30
X2
+
−
−
3.81
449.2
43
F
—
X15
X3
X30
X24
−
−
−
3.66
433.15
44
D
X3
X15
X24
X30
X24
++
−
−
3.51
417.17
45
D
X2
X15
X24
X30
X24
++
+
−
3.86
433.23
46
G
—
X24
X3
X19
X30
−
−
−
3.31
386.14
47
G
—
X19
X2
X24
X30
−
−
−
3.27
402.2
48
G
—
X19
X24
X8
X30
−
−
−
2.48
352.18
49
G
—
X2
X24
X19
X30
−
−
−
3.64
388.18
50
G
—
X8
X24
X19
X30
−
−
−
2.61
352.18
51
G
—
X24
X3
X20
X30
−
−
−
3.08
400.16
52
G
—
X2
X24
X20
X30
−
−
−
3.46
402.2
53
G
—
X8
X24
X20
X30
−
−
−
2.73
366.2
54
G
—
X24
X3
X15
X30
−
−
−
3.27
414.17
55
G
—
X2
X24
X15
X30
−
−
−
3.79
416.21
56
G
—
X8
X24
X15
X30
−
−
−
2.78
380.21
57
F
—
X20
X2
X30
X24
−
−
−
4.01
435.19
58
F
—
X15
X2
X30
X24
−
−
−
4.08
449.2
59
C
X2
X20
X24
X30
X24
++
++
+
3.74
419.21
TABLE 2 Biological activity of example 3P library Object conc conc conc conc conc conc conc conc conc ID Scaffold R1 R2 R3 R5 500 250 50 10 1.0 0.5 0.25 0.10 0.001* RT M + H 60 A X2 X20 X24 X24 ++ + − 3.88 419.21 61 B X2 X20 X24 X24 ++ + − 3.7 419.21 62 D X2 X20 X24 X24 ++ ++ − 3.8 419.21 63 C X2 X20 X24 X24 ++ ++ + 3.72 419.21 64 C and D X2 X20 X8 X24 ++ ++ ++ + − 4.98 65 C and D X2 X20 X8 X24 ++ 4.98 66 C and D X2 X20 X3 X24 ++ ++ ++ − − 5.25 67 C and D X2 X20 X3 X24 ++ 5.25 68 C and D X2 X20 X1 X24 ++ ++ ++ − − − 5.49 69 C and D X2 X20 X2 X24 ++ ++ ++ ++ + 5.23 70 C and D X2 X20 X3 X2 + − 5.85 71 C and D X2 X20 X3 X8 ++ − 5.61 72 C and D X2 X20 X3 X3 ++ − 5.51 73 C and D X2 X20 X2 X2 + − 5.95 74 C and D X2 X20 X2 X8 ++ − 5.45 75 C and D X2 X20 X2 X3 ++ − 6.46 76 C and D X2 X20 X8 X2 ++ − 5.7 77 C and D X2 X20 X8 X8 ++ − 5.01 78 C and D X2 X20 X8 X3 ++ + 5.37 79 B X2 X20 X2 X2 ++ − 10.31 80 A X2 X20 X2 X2 ++ − 10.88 81 B X2 X20 X2 X8 ++ − 8.02 82 A X2 X20 X2 X8 ++ + 8.68 83 B X2 X20 X2 X3 ++ − 9.39 84 A X2 X20 X2 X3 ++ − 10.24 85 D X2 X20 X2 X24 ++ ++ 50.92 86 C X2 X20 X2 X24 ++ ++ 54.37 87 A or B X2 X20 X8 X24 − − 3.78 495.59 88 A or B X2 X20 X8 X24 − − 3.86 495.59 89 A or B X2 X20 X3 X24 − − 3.95 530.03 90 A or B X2 X20 X3 X24 ++ + 3.97 530.03 91 A or B X2 X20 X1 X24 − − 4.5 571.69 92 A or B X2 X20 X2 X24 + − 4.33 545.65 93 A and B X2 X20 X24 X8 + − 4.13 495.59 94 A or B X2 X20 X24 X3 − − 4.33 530.03 95 A or B X2 X20 X24 X3 − − 4.33 530.03 96 A or B X2 X20 X24 X1 − − 4.77 571.69 97 A and B X2 X20 X24 X2 + − 4.52 545.65 98 A X2 X20 X2 X24 ++ + 5.45 545.65 99 A X2 X31 X2 X24 + − 5.07 559.67 100 A X2 X32 X2 X24 ++ + 5.05 559.67 101 A X2 X33 X2 X24 + − 4.79 557.66 102 A X2 X34 X2 X24 − − 6.24 613.77 103 A X2 X35 X2 X24 ++ + 5.85 585.71 104 A X2 X36 X2 X24 − − 6.33 599.74 105 A X2 X37 X2 X24 − − 6.72 599.74 106 A X2 X45 X2 X24 − − 4.96 573.7 107 A X2 X20 X46 X24 ++ ++ 4.22 530.03 108 A X2 X20 X47 X24 ++ + 4.87 564.48 109 A X2 X20 X48 X24 ++ − 4.98 530.03 110 A X2 X20 X49 X24 ++ ++ 4.43 546.64 111 A X2 X20 X50 X24 − − 5.44 552.66 112 A X2 X20 X51 X24 ++ + 3.78 546.64 113 A X2 X20 X52 X24 ++ ++ 5.71 564.48 114 A X2 X20 X9 X24 ++ ++ 5.89 545.65 115 A X2 X20 X53 X24 ++ + 5.8 564.48 116 A X2 X20 X54 X24 ++ + 4.43 546.64 117 A X2 X20 X55 X24 ++ ++ 5.71 564.48 118 A X2 X20 X56 X24 ++ ++ 6.9 587.68 119 A X2 X15 X24 X24 ++ + − 120 A and B X2 X15 X8 X24 ++ + 4.29/4.57 121 A and B X2 X15 X24 X1 + + 5.4 122 A and B X2 X15 X24 X2 ++ ++ 5.18 123 A and B X2 X15 X24 X8 − − 4.78 124 A and B X2 X15 X24 X3 + − 5.07 125 A and B X2 X15 X24 X4 + − 4.28 126 C and D X2 X15 X8 X24 ++ + + − − 4.97 127 C and D X2 X15 X3 X24 ++ ++ ++ − − 5.17 128 C and D X2 X15 X1 X24 ++ + ++ − − − 5.45 585.71 129 C and D X2 X15 X2 X24 ++ ++ − + − 5.18 559.67 130 A and B X2 X15 X4 X24 ++ 131 A and B X2 X15 X1 X24 ++ 132 A and B X2 X15 X2 X24 ++ 133 A and B X2 X15 X3 X24 ++ 134 A X2 X15 X3 X24 ++ ++ ++ ++ + 4.78 135 A X2 X15 X3 X2 ++ − 9.87 136 A X2 X15 X3 X8 ++ − 7.82 137 A X2 X15 X3 X3 ++ − 9.32 138 A X2 X38 X2 X24 − − 3.67 574.69 139 A X2 X39 X2 X24 + − 5.07 573.7 140 A X2 X40 X2 X24 ++ ++ 4.96 573.7 141 A X2 X41 X2 X24 − − 5.16 587.73 142 A X2 X53 X2 X24 ++ + 5.69/7.43 599.74 143 A X2 X42 X2 X24 − − 5.98 613.77 144 A X2 X15 X46 X24 ++ + 4.34 544.06 145 A X2 X15 X47 X24 ++ + 5.07 578.5 146 A X2 X15 X48 X24 ++ − 5.05 544.06 147 A X2 X15 X49 X24 ++ + 4.5 560.66 148 A X2 X15 X50 X24 − − 5.34 566.69 149 A X2 X15 X51 X24 + − 3.95 560.86 150 A X2 X15 X52 X24 ++ ++ 5.78 578.5 151 A X2 X15 X9 X24 ++ + 5.78 559.67 152 A X2 X15 X53 X24 ++ + 5.97 578.5 153 A X2 X15 X54 X24 ++ ++ 4.32 580.66 154 A X2 X15 X55 X24 ++ ++ 5.88 578.5 155 A X2 X15 X56 X24 ++ ++ 7.25 601.71 156 A X3 X19 X24 X24 − − − 3.39 389.14 157 B X3 X19 X24 X24 − − − 158 C X3 X19 X24 X24 − − − 3.38 389.14 159 D X3 X19 X24 X24 − − − 160 C and D X3 X19 X8 X24 − − − − − 4.8 161 C and D X3 X19 X3 X24 ++ − − − − 5.14 162 C and D X3 X19 X1 X24 + − − − − − 5.45 542.04 163 C and D X3 X19 X2 X24 ++ − − − − 5.2 164 C and D X3 X43 X24 X2 + − 3.45 165 C and D X3 X44 X24 X2 ++ − 4 166 A and B X3 X43 X24 X2 ++ − 3.59 167 A and B X3 X44 X24 X2 ++ ++ 3.97 168 A or B X3 X19 X8 X24 − − 169 A or B X3 X19 X8 X24 − − 170 A or B X3 X19 X3 X24 − − 171 A or B X3 X19 X3 X24 − − 172 A or B X3 X19 X1 X24 − − 173 A or B X3 X19 X1 X24 − − 174 A or B X3 X19 X2 X24 − − 175 A or B X3 X19 X2 X24 − − 176 A and B X3 X19 X24 X8 − − 4.88/5.61 465.95 177 A and B X3 X19 X24 X3 − − 6.06/6.52 500.39 178 A and B X3 X19 X24 X1 − − 9.09 542.04 179 A and B X3 X19 X24 X2 − − 7.43 516.01
Figure 1: Sidearms for Tables 1 and 2
Throughout the specification and the claims (if present), unless the context requires otherwise, the term “comprise”, or variations such as “comprises” or “comprising”, will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers.
Throughout the specification and claims (if present), unless the context requires otherwise, the term “substantially” or “about” will be understood to not be limited to the value for the range qualified by the terms.
It should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.
REFERENCES
[1] Patel, Y. C. (1999) Somatostatin and its receptor family. Front. Neuroendocr. 20, 157-198
[2] Csaba, Z. and Dournaud, P. (2001) Cellular biology of somatostatin receptors. Neuropeptides 35, 1-23
[3] T. Reisine, T. (1995) Somatostatin receptors: Am. J. Pysiol . ( Gastrointest. Liver Physiol. 32) 269, G813-G820
[4] Bauer, W. et al. (1982) SMS201-995: A very potent and selective octapeptide analogue of somatostatin with prolonged action. Life Sci. 31, 1133-1140
[5] Lamberts, S. W. J. et al. (1996) Drug therapy: Octreotide. N. Eng. J. Med. 334, 246-254
[6] Robinson, C. and Castaner, J. (1994) Lanreotide acetate. Drugs Future 19, 992-999
[7] Reisine, T. and Bell. G. I. (1995) Molecular biology of somatostatin receptors. Endocr. Rev. 16, 427-442
|
The invention provides a method of identifying biologically active compounds comprising: (a) designing a first library of compounds of formula (1) to scan molecular diversity wherein each compound of the library has at least two pharmacophoric groups R1 to R5 as defined below and wherein compound of the library has same number of pharmacophoric groups; (b) assaying the first library of compounds in one or more biological assay(s); and (c) designing a second library wherein each compound of the second library contains one or more additional pharmacophoric group with respect to the first library; such that the/each component of the first and second library is a compound of formula (1).
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/352,045, filed Jan. 25, 2002.
FIELD OF THE INVENTION
The present invention generally relates to power tools such as rotatable drills, power screwdrivers, and rotatable cutting devices. More specifically, the present invention relates to improvements in power tools and more particularly to the construction of a clutch mechanism and its coupling to a transmission.
BACKGROUND OF THE INVENTION
Modernly, manufacturers of power tools desire to reduce the cost of producing power tools by providing designs that provide the product with a high level of robustness while reducing complexity at the assembly level and minimizing components that do not add value to the product. Manufacturers are further challenged by the demand of modern consumers for tools that are relatively smaller in size, lighter in weight and more powerful.
Accordingly, it is highly desirable to eliminate threaded fasteners from the power tool, such as those that are typically employed to couple the transmission assembly to the clutch mechanism. The use of threaded fasteners in these situations necessitates the incorporation of bosses to the transmission assembly and the clutch mechanism that tend to enlarge the size of the tool and which add a degree of weight to the power tool. The fastening process itself tends to be relatively slow and errors in the process, such as over tightening, which can lead to the stripping of threads or cracking of the components, or under tightening, which can create an interference that prevents the components from operating properly, are possible. The use of torque controlled fastening equipment is known to alleviate such processing errors, but this equipment can be relatively expensive to purchase and operate.
It is also desirable to better integrate the clutch mechanism with the transmission assembly. Many of the known power tool designs employ a modular design that is based on a power tool having no torque controlled clutch. In cases where precise torque control was needed, a clutch module could be coupled to the output end of the base tool. While configuration in this manner effectively accommodated consumer demands for both the base and torque controlled models in an economical manner, the modular configuration tended to add considerable length and weight to the power tool.
SUMMARY OF THE INVENTION
In one preferred form, the present invention provides a coupling mechanism for coupling the components of a power tool, such as a transmission assembly and a clutch mechanism. The coupling mechanism includes a first structure, such as a gear case, having at least one fastening tab that defines a coupling recess. The coupling mechanism also includes a second structure, such as a clutch sleeve, having an aperture for receiving a part of the first structure, and at least one outboard tab for receiving the fastening tab or tabs. The outboard tab(s) include a pin aperture that is aligned to the coupling recess when the first and second structures are fitted together. A pin is placed into each pin aperture and an associated coupling recess and operates to lock the fastening tab within the outboard tab to thereby inhibit relative movement between the first and second structures.
In another preferred form, the present invention provides a power tool having an improved clutch mechanism for limiting the torsional output of a transmission assembly. The clutch mechanism includes a clutch member that is fixedly coupled to a portion of the transmission assembly, such as the ring gear of a planetary-type reduction gear set. The clutch member includes a contoured clutch face against which a rotation-inhibiting element is biased. The torsional output of the transmission assembly is limited by the force that is exerted by the rotation-inhibiting element onto the clutch face. When the torque that is exerted on the portion of the transmission assembly exceeds a predetermined magnitude, the clutch member, along with the portion of the transmission assembly, rotates relative to the rotation inhibiting element to thereby limit the torsional output of the power tool.
In yet another preferred form, the present invention provides an improved clutch mechanism. The clutch mechanism includes a unitarily formed clutch plate having an annular plate member and a plurality of legs that extend outwardly from the annular plate member toward a clutch member. The opposite end of the legs may be contoured to receive force-transmitting elements, such as bearing balls, which are employed to transmit a biasing force to the clutch member to bias the clutch member in a stationary condition. Alternatively, the opposite ends of the legs may be contoured to act as force transmitting elements.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional advantages and features of the present invention will become apparent from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a side view of a power tool constructed in accordance with the teaching of the present invention;
FIG. 2 is an exploded perspective view of a portion of the power tool of FIG. 1 ;
FIG. 3 is an enlarged view of a portion of FIG. 2 illustrating the transmission assembly and the clutch mechanism in greater detail;
FIG. 4 is an exploded perspective view of a portion of the power tool of FIG. 1 illustrating the construction of the gear case and the clutch sleeve;
FIG. 5 is a sectional view of a portion of the power tool of FIG. 1 taken along the longitudinal axis of the power tool and illustrating the construction of the transmission assembly;
FIG. 6 is a sectional view of a portion of the transmission assembly illustrating the second planetary gear set in the active position;
FIG. 7 is a perspective view of a portion of the transmission assembly illustrating the contour of the top and rear surfaces of the second reduction carrier;
FIG. 8 is a perspective view of a portion of the transmission assembly illustrating the third ring gear in greater detail;
FIG. 9 is a sectional view taken along the line 9 — 9 of FIG. 3 ;
FIG. 10 is a partial bottom view of a portion of the transmission assembly illustrating the speed selector mechanism in greater detail;
FIG. 11 is a sectional view of a portion of the power tool of FIG. 1 taken through the gear case and clutch sleeve and illustrating the method by which the transmission assembly and the clutch mechanism are coupled;
FIG. 12 is a side view of a the clutch plate;
FIG. 13 is an exploded side view in partial section illustrating the clutch plate and the balls;
FIG. 14 is a sectional view similar to that of FIG. 13 but illustrating an alternate embodiment of the clutch plate; and
FIG. 15 is a sectional view of a portion of the power tool of FIG. 1 taken along the longitudinal axis and illustrating the clutch mechanism in greater detail.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1 and 2 of the drawings, a power tool constructed in accordance with the teachings of the present invention is generally indicated by reference numeral 10 . As those skilled in the art will appreciate, the preferred embodiment of the present invention may be either a cord or cordless (battery operated) device, such as a portable screwdriver or drill. In the particular embodiment illustrated, the power tool 10 is a cordless drill having a housing 12 , a motor assembly 14 , a multi-speed transmission assembly 16 , a clutch mechanism 18 , an output spindle assembly 20 , a chuck 22 , a trigger assembly 24 and a battery pack 26 . Those skilled in the art will understand that several of the components of the power tool 10 , such as the chuck 22 , the trigger assembly 24 and the battery pack 26 , are conventional in nature and therefore need not be discussed in significant detail in the present application. Reference may be made to a variety of publications for a more complete understanding of the conventional features of the power tool 10 . One example of such publications is U.S. Pat. No. 5,897,454 issued Apr. 27, 1999, the disclosure of which is hereby incorporated by reference as if fully set forth herein.
The housing 12 includes a pair of mating handle shells 34 that cooperate to define a handle portion 36 and a drive train or body portion 38 . The trigger assembly 24 and the battery pack 26 are mechanically coupled to the handle portion 36 and electrically coupled to the motor assembly 14 in a conventional manner that is not specifically shown but which is readily the capabilities of one having an ordinary level of skill in the art. The body portion 38 includes a motor cavity 40 and a transmission cavity 42 . The motor assembly 14 is housed in the motor cavity 40 and includes a rotatable output shaft 44 , which extends into the transmission cavity 42 . A motor pinion 46 having a plurality of gear teeth 48 is coupled for rotation with the output shaft 44 . The trigger assembly and battery pack 26 cooperate to selectively provide electric power to the motor assembly 14 in a manner that is generally well known in the art so as to permit the user of the power tool 10 to control the speed and direction with which the output shaft 44 rotates.
The transmission assembly 16 is housed in the transmission cavity 42 and includes a speed selector mechanism 60 . The transmission assembly 16 receives a rotary input from the motor pinion 46 and converts that input to a relatively lower speed, higher torque output that is transmitted to the shaft 62 of the output spindle assembly 20 . The transmission assembly 16 includes a plurality of reduction elements that are selectively engaged by the speed selector mechanism 60 to provide a plurality of speed ratios. Each of the speed ratios multiplies the speed and torque of the drive input in a predetermined manner, permitting the output speed and torque of the transmission assembly 16 to be varied in a desired manner between a relatively low speed, high torque output and a relatively high speed, low torque output. Rotary power output from the transmission assembly 16 is transmitted to the output spindle assembly, to which the chuck 22 is coupled for rotation, to permit torque to be transmitted to a tool bit (not shown). The clutch mechanism 18 is coupled to the transmission assembly and is operable for limiting the magnitude of the torque associated with the output of the transmission assembly 16 to a predetermined, selectable torque limit.
Transmission Assembly
With additional reference to FIG. 3 , the transmission assembly 16 is illustrated to further include a gear case 100 that houses a three-stage, two-speed gear train 102 . With additional reference to FIG. 4 , the gear case 100 is shaped in a generally hollow cylindrical manner and includes a fastening tab 104 and a clip aperture 106 on each of its lateral sides, a pair of guide rails 108 and a guide tab 110 that is located on its top surface, and a central cavity 112 that extends longitudinally through the gear case 100 . Each fastening tab 104 terminates at its outward face at a coupling recess 114 that extends in a direction that is generally transverse to the central cavity 112 . The coupling recess 114 is preferably arcuately shaped, and in the particular embodiment illustrated, is illustrated to be generally U-shaped. Each clip aperture 106 extends through the wall 116 of the gear case 100 along the longitudinal axis 118 of the central cavity 112 and intersects the central cavity 112 . The guide rails 108 positioned rearwardly of the guide tab 110 and are spaced laterally apart from one another. The guide rails 108 and the guide tab 110 will be discussed in further detail, below.
The gear train 102 is illustrated to be a planetary type gear train, having a first planetary gear set 120 , a second planetary gear set 122 and a third planetary gear set 124 . In the example provided, each of the first, second and third gear sets 120 , 122 and 124 are operable in an active mode, wherein the gear set performs a speed reduction and torque multiplication operation, while the second planetary gear set 122 is also operable in an inactive mode, wherein it provides a rotary output having a speed and torque that is about equal to that which is input to it.
The first planetary gear set 120 includes first ring gear 130 , a first set of planet gears 132 and a first reduction carrier 134 . The first ring gear 130 is an annular structure, having a plurality of gear teeth 130 a that are formed about its interior diameter and a plurality of gear case engagement teeth 130 b that are formed onto its outer perimeter. With additional reference to FIG. 5 , the first ring gear 130 is disposed within the central cavity 112 of the gear case 100 such that the gear case engagement teeth 130 b engage mating teeth 130 c formed on the inner surface of the gear case 100 to inhibit relative rotation between the first ring gear 130 and the gear case 100 . As the gear case engagement teeth 130 b terminate prior to the rear face 130 d of the first ring gear 130 , forward movement of the first ring gear 130 is halted by interference between the mating teeth 130 c that are formed on the inner surface of the gear case 100 and the portion of the first ring gear 130 that is disposed rearwardly of the gear case engagement teeth 130 b.
The first reduction carrier 134 includes a body 134 a , which is formed in the shape of a flat cylinder and a plurality of cylindrical pins 134 b that extend from the rearward face of the body 134 a , and a plurality of 134 c
A plurality of gear teeth 134 c are formed into the outer perimeter of the body 134 a and are sized to engage the gear teeth 152 a of the second ring gear 152 . With reference to FIG. 7 , the profile of the gear teeth 134 c of the body 134 a is illustrated in greater detail. As shown, each tooth 134 c terminates at a gradual radius 190 at the forward face of the body 134 a but terminates abruptly at the rearward face of the body 134 a . A radius 192 is also formed on the valleys 194 between the gear teeth 134 c . The first set of planet gears 132 includes a plurality of planet gears 132 a , each of which being generally cylindrical in shape and having a plurality of gear teeth 132 b formed onto its outer perimeter and a pin aperture (not specifically shown) formed through its center. Each planet gear 132 a is rotatably supported on an associated one of the pins 132 b of the first reduction carrier 134 and is positioned to be in meshing engagement with the gear teeth of the first ring gear 130 . A first annular thrust washer 140 is fitted to the end of the gear case 100 proximate the motor assembly 14 and prevents the planet gears 132 from moving rearwardly and disengaging the pins 134 b of the first reduction carrier 134 . A raised portion 142 is formed onto the front and rear faces of each planet gear 132 to inhibit the gear teeth 132 b of the planet gears 132 from rubbing on the first reduction carrier 134 and the first thrust washer 140 . The teeth 46 a of the motor pinion 46 are also meshingly engaged with the teeth 132 b of the planet gears 132 and as such, the motor pinion 46 serves as the first sun gear for the first planetary gear set 120 .
The second planetary gear set 122 is disposed within the central cavity 112 forward of the first planetary gear set 120 and includes a second sun gear 150 , a second ring gear 152 , a second reduction carrier 154 and a second set of planet gears 156 . The second sun gear 150 is fixed for rotation with the first reduction carrier 134 and includes a plurality of gear teeth 150 a that extend forwardly from the flat, cylindrical portion of the first reduction carrier 134 .
The second ring gear 152 is an annular structure having a plurality of gear teeth 152 a formed about its interior diameter, an annular clip groove 158 formed into its outer perimeter and a plurality of gear case engagement teeth 160 that are formed onto its outer perimeter. The gear teeth 152 a may be heavily chamfered at the rear face 152 b of the second ring gear 152 but terminate abruptly its front face. More preferably, a heavy radius 170 is formed onto the rear face 152 b and the sides of each of the gear teeth 152 a as illustrated in FIG. 6 , with the heavy radius 170 being employed rather than the heavy chamfer as the heavy radius 170 on the gear teeth 152 a provides for better engagement between the second ring gear 152 and the second reduction carrier 154 , as will be described in more detail, below. In the example illustrated, the clip groove 158 is a rectangular slot having a pair of sidewalls 174 . The clip groove 158 will be discussed in further detail, below.
The second ring gear 152 is movably disposed within the central cavity 112 of the gear case 100 between a first position as shown in FIG. 6 , wherein the gear case engagement teeth 160 engage mating teeth 180 formed on the inner surface of the gear case 100 to inhibit relative rotation between the second ring gear 152 and the gear case 100 , and a second position as shown in FIG. 5 , wherein the gear case engagement teeth 160 are axially spaced apart from the mating teeth 180 to thereby permit relative rotation between the second ring gear 152 and the gear case 100 .
The second reduction carrier 154 includes a body 154 a , which is formed in the shape of a flat cylinder, and plurality of pins 154 b that extend from the rearward face of the body 154 a.
Referring back to FIGS. 3 and 5 , the second set of planet gears 156 is shown to include a plurality of planet gears 156 a , each of which being generally cylindrical in shape and having a plurality of gear teeth 156 b and a pin aperture (not specifically shown) in its center. Each planet gear 156 a is supported for rotation on an associated one of the pins 154 b of the second reduction carrier 154 and is positioned such that the gear teeth 156 b are in meshing engagement with gear teeth 152 a of the second ring gear 152 .
The third planetary gear set 124 is disposed on the side of the second planetary gear set 122 opposite the first planetary gear set 120 . Like the second planetary gear set 122 , the third planetary gear set 124 includes a third sun gear 200 , a third ring gear 202 , a third reduction carrier 204 and a third set of planet gears 206 . The third sun gear 200 is fixed for rotation with the body 154 a of the second reduction carrier 154 and includes a plurality of gear teeth 200 a that extend forwardly from the body 154 a . An annular second thrust washer 210 is disposed between the second ring gear 152 and the third ring gear 202 and operates to limit the forward movement of the second ring gear 152 and the rearward movement of the third ring gear 202 and the third set of planet gears 206 . The second thrust washer 210 , which includes an aperture 212 through which the third sun gear 200 extends, engages the inner surface of the gear case 100 .
The third ring gear 202 is an annular structure having a plurality of gear teeth 202 a formed about its interior diameter and an outer radial flange 220 that forms its outer perimeter. A clutch face 222 is formed into the forward surface of the outer radial flange 220 . In the particular embodiment illustrated, the clutch face 222 is shown to have an arcuate cross-sectional profile and is further defined by a plurality of peaks 224 and valleys 226 that are arranged relative to one another to form a series of ramps that are defined by an angle of about 18°. Those skilled in the art will understand, however, that clutch faces of other configurations, such as those having a sinusoidal shape, may also be employed. Those skilled in the art will also understand that while the clutch face 222 is shown to be unitarily formed with the third ring gear 202 , multi-component configurations may also be employed. Such multi-component configurations include, for example, an annular clutch face ring (not shown) having a rearward facing first side for engaging the third ring gear 202 and a forward facing second side that forms the clutch face 222 . Configuration in this latter manner may be advantageous, for example, when it is necessary for the clutch face 222 to have properties or characteristics (e.g., lubricity, hardness, toughness, surface finish) that are different from the properties or characteristics of the third ring gear 202 .
The third reduction carrier 204 includes a body 204 a , which is formed in the shape of a flat cylinder, and a plurality of cylindrical pins 204 b , which extend from the rearward face of the body 204 a , and a coupling portion 204 c that extends from the forward face of the body 204 a . Rotary power transmitted to the third reduction carrier 204 is transmitted through the coupling portion 204 c to a coupling member 230 that engages the shaft 62 of the output spindle assembly 20 . Those skilled in the art will understand that various other coupling devices and methods may be utilized to couple the third reduction carrier 204 to the output spindle assembly 20 , such as a direct coupling of the shaft 62 of the output spindle assembly 20 to the body 204 a of the third reduction carrier 204 .
The third set of planet gears 206 includes a plurality of planet gears 206 a , each of which being generally cylindrical in shape and having a plurality of gear teeth 206 b formed onto its outer perimeter and a pin aperture (not specifically shown) formed through its center. Each planet gear 206 a is rotatably supported on an associated one of the pins 204 b of the third reduction carrier 204 and is positioned to be in meshing engagement with the gear teeth 202 a of the third ring gear 202 .
The speed selector mechanism 60 is illustrated to include a slider body 240 and a clip structure 242 . The slider body 240 is an elongated structure that is configured to be housed between the handle shells 34 and selectively slid along the top of the gear case 100 . The slider body 240 includes an attachment groove 246 , which permits the clip structure 242 to be attached to the slider body 240 , and a selector tab 248 , which is configured to receive an input from the user of the power tool 10 to switch the second planetary gear set 122 between the active and inactive modes. With additional reference to FIGS. 9 and 10 , a slot 250 is formed into the underside of the slider body 240 and is sized to engage the guide tab 110 that extends from the top surface of the gear case 100 . The guide rails 108 are spaced laterally apart to receive the slider body 240 . The guide tab 110 and the guide rails 108 cooperate with the sides of the slot 250 and the sides of the attachment groove 246 , respectively, to guide the slider body 240 as the slider body 240 is moved in an axial direction along the top surface of the gear case 100 .
Returning to FIG. 3 , the clip structure 242 is a wire that is formed to include a circular body portion 256 and a pair of end tabs 258 that extend inwardly from the body portion 256 . The body portion 256 is fixedly coupled to an attachment tab 260 , which is illustrated to be a pair of trunnions that extend downwardly from the slider body 240 . The body portion 256 is sized to fit over the outer circumference of the gear case 100 and preferably includes a rotation-inhibiting element 262 to inhibit the clip structure 242 from rotating relative to the attachment tab 260 . In the embodiment provided, the rotation-inhibiting element 262 is illustrated to include a plurality of bends, such as M-, N-, S-, or Z-shaped bends, that are formed into the wire and which are molded into or abut the underside of the slider body 240 . Each of the end tabs 258 extends through an associated one of the clip apertures 106 in the sides of the gear case 100 and engages the annular clip groove 158 that is formed into the perimeter of the second ring gear 152 . The wire that forms the clip structure 242 is somewhat smaller in diameter than the width of the clip groove 158 .
Alternatively, the rotation-inhibiting element 262 may include a plurality of tabs that are formed from bends in the body portion 256 of the wire, wherein each tab is defined by a circumferentially extending segment that is offset radially outwardly from the remainder of the body portion 256 . Each of the tabs is configured to be received in a corresponding aperture formed into the slider body 240 such that the front and rear faces of each tab engage the sides of the apertures in the slider body 240 . The tabs, being confined within an associated aperture in the slider body 240 , inhibit relative movement between the slider body 240 and the body portion 256 of the clip structure 242 .
Sliding movement of the slider body 240 relative to the gear case 100 is operable for transmitting a force through the end tabs 258 of the clip structure 242 and to the second ring gear 152 which may be used to move the second ring gear 152 between the first and second positions. When the second ring gear 152 is positioned in the first position as illustrated in FIG. 6 , the engagement teeth 160 of the second ring gear 152 are engaged to the mating engagement teeth 180 of the gear case 100 and the gear teeth 152 a of the second ring gear 152 are engaged to only the gear teeth 156 b of the planet gears 156 a of the second planet gear set 156 , thereby permitting the second planetary gear set 122 to operate in the active mode. When the second ring gear 152 is positioned in the second position as illustrated in FIG. 5 , the engagement teeth 160 of the second ring gear 152 are not engaged to the mating engagement teeth 180 of the gear case 100 and the gear teeth 152 a of the second ring gear 152 are engaged to both the gear teeth 156 b of the planet gears 156 a of the second planet gear set 156 and the gear teeth 134 c of the first reduction carrier 134 , thereby permitting the second planetary gear set 122 to operate in the inactive mode.
Clutch Mechanism
In FIG. 3 , the clutch mechanism 18 is illustrated to include a clutch sleeve 300 , a clutch member 302 , a plurality of balls 304 , a clutch plate 306 , a spring 308 , an adjustment collar 310 , a detent mechanism 312 and a clutch cover 314 . With additional reference to FIG. 4 , the clutch sleeve 300 is illustrated to include a wall member 320 , which defines a hollow cavity or bore 322 that extends along the longitudinal axis of the clutch sleeve 300 , a base portion 324 and a nose portion 326 that extends forwardly from the base portion 324 . The rearward end of the bore 322 is sized to receive a forward portion of the gear case 100 , the third ring gear 202 and the third reduction carrier 204 , while the forward portion of the bore 322 is sized somewhat smaller so as to receive the coupling member 230 and the shaft 62 of the output spindle assembly 20 . The nose portion 326 , which is somewhat smaller in diameter than the base portion 324 , is generally cylindrical, having a helical thread form 330 that wraps around its perimeter.
The base portion 324 includes a pair of outboard tabs 334 , which are formed on the lateral sides of the base portion 324 , a plurality of leg apertures 336 , which extend generally perpendicular to the longitudinal axis of the bore 322 , and a detent aperture 338 for receiving the detent mechanism 312 . Each outboard tab 334 is configured to receive an associated one of the fastening tabs 104 and includes a pin aperture 340 . In the particular embodiment illustrated, each outboard tab 334 is defined by an outer lateral wall 342 , a lower wall 344 , and an upper wall 346 , through which the pin aperture 340 extends. With additional reference to FIG. 11 , a cylindrical locking pin 350 is fitted through the pin aperture 340 in each outboard tab 334 and the coupling recess 114 in the associated fastening tab 104 and thereby fixedly but removably couples the clutch sleeve 300 to the gear case 100 . The locking pins 350 are highly advantageous in that they eliminate the need for threaded fasteners, fastening tools and the use of bosses in the gear case 100 and the clutch sleeve 300 that are configured for receiving a conventional threaded fastener. The leg apertures 336 are circumferentially spaced about the nose portion 326 and extend through the base portion 324 and intersect the rearward portion of the bore 322 . The detent aperture 338 extends through the base portion 324 between the clutch cover 314 and the gear case 100 and is sized to receive a portion Of the detent mechanism 312 .
In FIGS. 3 , 12 and 13 , the clutch plate 306 is illustrated to be a unitarily formed structure that includes a washer-like annular plate member 360 and a plurality of leg members 362 that are coupled to and circumferentially spaced about the annular plate member 360 . The leg members 362 have a generally circular cross-section and extend generally perpendicularly from the plate member 360 . The end of the each leg member 362 opposite the plate member 360 terminates in a spherical recess 364 that is configured to receive one of the balls 304 , which are illustrated to be hardened bearing balls. The clutch plate 306 is disposed over the nose portion 326 of the clutch sleeve 300 and moved axially rearward to push the leg members 362 through the leg apertures 336 in the base portion 324 , as well as to bring each of the balls 304 into contact with the clutch face 222 and an associated one of the spherical recesses 364 .
In an alternate embodiment illustrated in FIG. 14 , the clutch plate 306 ′ is illustrated to be similar to the clutch plate 306 , except that the ends of the leg members 362 ′ opposite the annular plate member 360 terminate at a spherical protrusion 370 , rather than a spherical recess. Configuration in this manner is advantageous in that it eliminates the balls 304 from the clutch mechanism 18 .
Returning to FIG. 3 and with additional reference to FIG. 15 , the spring 308 is illustrated to be a conventional compression spring having ground ends. The spring 308 is disposed over the nose portion 326 of the clutch sleeve 300 between the plate member 360 of the clutch plate 306 and the adjustment collar 310 . The adjustment collar 310 is an annular structure that is illustrated to include an internal annular flange 380 , a threaded portion 382 and an engagement portion 384 . The internal annular flange 380 extends around the inner circumference of the adjustment collar 310 and sized somewhat smaller in diameter than the spring 308 but larger than the nose portion 326 of the clutch sleeve 300 . The threaded portion 382 intersects the internal annular flange 380 and is sized to threadably engage the thread form 330 that is formed on the outer diameter of the nose portion 326 . The engagement portion 384 is configured to permit the adjustment collar 310 to be rotatably coupled to the clutch cover 314 and well as to move axially within the clutch cover 314 . In the example provided, the engagement portion 384 includes a plurality of engagement teeth 384 a that are formed about the outer perimeter of the adjustment collar 310 . The engagement teeth 384 a will be described in further detail, below.
A wire clip 400 is coupled to the nose portion 326 to inhibit the removal of the adjustment collar 310 from the thread form 330 . The wire clip 400 is formed in U-shape, having a base 402 that is disposed between a pair of spaced apart legs 404 . Each of the legs 404 extends in a generally perpendicular direction away from the base 402 . With the clutch plate 306 and spring 308 fitted over the nose portion 326 and the adjustment collar 310 engaged to the thread form 330 , the wire clip 400 is fitted over the nose portion 326 generally perpendicular to the longitudinal axis of the clutch sleeve 300 such that legs 404 are engaged to leg apertures 408 in the clutch sleeve 300 and the base 402 is disposed in a shallow U-shaped recess 410 that is situated on the top surface of the nose portion 326 as best shown in FIG. 4 . Engagement of the wire clip 400 into the leg apertures 408 and recess 410 operatively locks the wire clip 400 to the nose portion 326 and thereby creates a positive stop that is configured to prevent the adjustment collar 310 from being threaded out of engagement with the thread form 330 that is formed onto the nose portion 326 .
The clutch cover 314 is constructed in the form of a hollow sleeve that shrouds the clutch plate 306 , the spring 308 , the nose portion 326 and the wire clip 400 . The clutch cover 314 extends forwardly of the base portion 324 and includes a gripping surface 420 that is formed on its outer perimeter. The gripping surface 420 is contoured to permit the user of the power tool 10 to rotate the clutch cover 314 about the longitudinal axis of the power tool 10 to adjust the setting of the clutch mechanism 18 as will be discussed in greater detail, below.
A plurality of mating engagement teeth 422 are formed onto the inner diameter of the clutch cover 314 which are sized to engage the engagement teeth 384 a of the adjustment collar 310 . The mating engagement teeth 422 are relatively longer than the engagement teeth 384 a and as such, permit the engagement teeth 384 a to axially slide along the mating engagement teeth 422 along the longitudinal axis of the power tool 10 when the clutch cover 314 is rotated.
In the example provided, the detent mechanism 312 is illustrated to include a detent spring 430 , a plunger 432 and a detent ring 434 . The detent spring 430 and plunger 432 are housed in the detent aperture 338 that is formed through the base portion 324 of the clutch sleeve 300 . The detent spring 430 , which is illustrated to be a conventional compression spring, abuts the gear case 100 on a first side and a flattened end of the plunger 432 on the opposite side, thereby biasing the plunger 432 in a direction outwardly from the base portion 324 . The plunger 432 includes a contact end 440 , which is defined by a spherical radius in the example illustrated, and which is biased forwardly by the detent spring 430 into contact with the detent ring 434 . In the particular embodiment provided, the detent ring 434 is integrally formed with the clutch cover 314 and includes a plurality of circumferentially spaced recesses or detents 442 that are sized to engage the contact end 440 of the plunger 432 . Each of the detents 442 is illustrated to be defined by a spherical radius that conforms to the contact end 440 . A setting indicator 450 ( FIG. 2 ) may be employed to indicate the position of the adjustment collar 310 relative to the clutch sleeve 300 . In the example provided, the setting indicator 450 includes an arrow 452 that is formed into the handle shells 34 and a scale 454 that is marked into the circumference of the clutch cover 314 .
Rotation of the clutch cover 314 relative to the clutch sleeve 300 causes the adjustment collar 310 to rotate in an equivalent manner to thereby alter the amount by which the spring 308 is compressed. Interaction between the contact end 440 of the plunger 432 and the detents 442 in the detent ring 434 provide the user of the power tool 10 with feedback as to the setting of the clutch mechanism 18 , as well as inhibit the clutch cover 314 from inadvertently rotating out of the position to which it has been set. The spring 308 exerts a compression force onto the annular flange 380 of the adjustment collar 310 and the plate member 360 of the clutch plate 306 , driving the leg members 362 of the clutch plate 306 rearwardly and biasing the balls 304 into engagement with the clutch face 222 . The balls 304 exert a counter torque onto the clutch face 222 that tends to inhibit rotation of the third ring gear 202 relative to the clutch sleeve 300 .
When the power tool 10 is operated and the torque that is exerted through the gear teeth 202 a of the third ring gear 202 exceeds the counter torque, the peaks 224 of the clutch face 222 ride over the balls 304 to enable the third ring gear 202 to rotate relative to the third reduction carrier 204 and greatly reduce the torque that is applied to the output spindle assembly 20 .
While the invention has been described in the specification and illustrated in the drawings with reference to a preferred embodiment, 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 as defined in the claims. 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 thereof. Therefore, it is intended that the invention not be limited to the particular embodiment illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the foregoing description.
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A hand-held power tool having a multi-speed transmission and a clutch. The multi-speed transmission and the clutch are coupled to one another via a set of interconnecting tabs that are slidingly engaged to one another and secured with pins to inhibit the withdrawal of the tabs from one another. The clutch may include a clutch member, a unitarily formed clutch plate and a plurality of engagement members. The clutch plate includes an annular plate member and a plurality of leg members that extend generally perpendicularly from the annular plate member and which bias the engagement members into engagement with the clutch member. The clutch member may be coupled to an element of the multi-speed transmission, such as to the ring gear of a planetary gear set, so as to reduce the overall size of the power tool.
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FIELD OF THE INVENTION
[0001] The invention refers to a (simple) cellulose sulphate based microencapsulation technology which has been applied to encapsulate bacterial or other microbial cells which produce and release digestive enzymes and thereby provides an acid resistant shelter for these microbial cells. Surprisingly, the resulting spheres were found to provide sufficient protection for encapsulated cells from treatment with aqueous acidic solutions. Thereby the cellulose sulphate microencapsulated cells, such as probiotics are now enabled to survive passage, for example, through the stomach after consumption by a human or animal with a higher survival rate than those not within a microcapsule. After passing the stomach, these cells are delivering products produced by them, e.g. enzymes or other nutrition factors. This technology therefore proves to be very useful in providing digestive or otherwise beneficial enzymes and/or of living microbial cells, into the lower gastrointestinal tract, where they could confer their health benefit to the host. Described is how cells are encapsulated with said material, and under which conditions the encapsulated cells survive the stomach passage and how the microbial cells or enzyme produced by said microbial cells can exit the microcapsules allowing the cells and/or the enzymes produced within the microcapsules to provide their health benefit. This technology will play an important role in the improvement of food, especially probiotic foods or the delivery of food additives to improve human and animal health and wherein these cells are still able to release their generated products e.g. enzymes and/or other nutritional factors into the surrounding environment after having been exposed to an acidic environment first.
BACKGROUND
Digestive Enzymes
[0002] Digestive enzymes are enzymes that break down polymeric macromolecules (such as contained in food) into their smaller building blocks (such as nutrients and waste products), in order to facilitate their absorption by the body. Digestive enzymes are found in the digestive tract of animals, which in the context of the present invention can be any, but preferably mammals, especially ruminants and other livestock, aquatic farmed animals such as fish and shrimp, pets and companion animals, avians and/or humans, where they aid in the digestion of food as well as inside the cells, especially in their lysosomes where they function to maintain cellular survival. Digestive enzymes are diverse and are found in the saliva secreted by the salivary glands, in the stomach secreted by cells lining the stomach, in the pancreatic juice secreted by pancreatic exocrine cells, and in the intestinal (small and large) secretions, or as part of the lining of the gastrointestinal tract. Digestive enzymes are classified based on their target substrates: Proteases and peptidases cleave proteins into their monomers, the amino acids; lipases split fat into three fatty acids and a glycerol molecule; carbohydrases cleave carbohydrates such as starch into sugars; nucleases split nucleic acids into nucleotides.
[0003] In the human digestive system, the main sites of digestion are the oral cavity, the stomach, and the small intestine. Digestive enzymes are secreted by different exocrine glands including: salivary glands, secretory cells in the stomach, secretory cells in the pancreas, secretory glands in the small intestine. The pancreas produces digestive enzymes, such as lipases, amylases and proteases that act in the small intestine. Known proteases are trypsin, chromotrypsin and carboxypeptidase.
[0004] The full benefit of food and nutritional supplements are only gained if the body has enough enzymes to properly digest the food and absorb the nutrients. Some digestive enzymes are found only in raw foods which are not routinely eaten and are not part of the usual diet most animal take in. Digestive enzymes produced by the animal's body, might become less abundant with the age of the animal; the older the animal, the less its body produces of them. A lack of digestive enzymes can contribute to a myriad of illnesses including arthritis, obesity, irritable bowel syndrome, heartburn, chronic fatigue syndrome and more. A lack of proteases can cause incomplete digestion that can lead to allergies and the formation of toxins.
[0005] It is commonly believed that taking supplements to increase levels of digestive enzymes would improve the body's ability to access and use food nutrients for energy, cell growth, and repair. By improving one's digestion supplements will often reduce gas and heartburn, and improve regularity. An estimated 15% of Americans suffer from arthritis, which is usually characterized with adjectives for inflammation such as; pain, swelling, stiffness, and redness. However, arthritis is not a single disorder, but the name of joint disease from a number of possible causes, such as genetics, infections, physical injury, allergies, stress, and faulty digestion. Clinical work at the Transformation Enzyme Corporation revealed that most arthritis sufferers respond well to treatment with protease and digestive enzyme supplements because arthritis is related to inflammation and digestion. Several studies have shown protease enzymes to be as effective as the drugs Methotrexate and Indomethacin for arthritis pain relief, but without the negative side-effects. By increasing support of the digestive and immune systems, inflammation is reduced.
[0006] A solution to health problems related to a lack of digestive enzymes is to take digestive enzyme supplements orally. Most digestive enzymes come in capsules which you can simply swallow. Capsules are made either of gelatin (called gel capsules) or vegetable cellulose blend (called veggie capsules). Most supplement companies have been moving toward veggie capsules over the past 10 years for all their encapsulated supplements. Most enzyme capsules can be opened and the powder poured out.
[0007] Simply swallowing additional amounts of digestive enzymes might not be the ideal solution, because the exposure to stomach acid when passing through the stomach might have a detrimental effect to the enzymes. Additional problems in providing enzymes as a food supplement are the taste of such enzymes, some of them cause a “burning sensation” in the mouth, and their sensitivity towards moisture. Non-encapsulated enzymes have been reported to lose their potency when they are exposed to normal air humidity, they therefore also cannot be taken as a drink or be taken as ingredient of a moist meal, unless added just before consumption.
[0008] The burning sensation is caused when proteases start to breakdown some of the dead layer or cells on the skin surface. These enzymes do remove damaged, infected, or dead cells. If proteases linger on the skin surface for a prolonged period, they may remove the dead cells exposing the healthy skin below. This can lead to irritation. Sometimes if enzymes are taken in a drink, which gets to the upper lip, proteases can linger and can cause a rash there.
[0009] Then there are also digestive enzymes that are sensitive to stomach acid. Pancreatic enzymes are not stable at wide ranges in pH or temperature and are destroyed by stomach acid. Thus, they need to be protected during passage through the stomach.
Probiotics
[0010] One of the fastest growing segments in both the human and animal health industries is the use of probiotic cells (probiotics). According to the currently adopted definition by FAO/WHO, probiotics are: “Live microorganisms which when administered in adequate amounts confer a health benefit on the host”. Lactic acid bacteria (LAB, Lb.) and bifido bacteria are the most common types of microbes used as probiotics; but certain yeasts and bacilli may also be helpful.
[0011] Probiotic microbial cells are sensitive to various environmental conditions such as pH, moisture, temperature, air and light. When these conditions are not properly controlled, the product's viability (often measured in colony forming units (cfu), or as metabolic activity rates (mar)), and therefore its efficacy, can be substantially reduced.
[0012] To be used as beneficial, potentially even therapeutic compounds in a diet, the probiotic microbial cells need to be protected a) during the manufacturing process, and b) during storage within the product and c) while passing through the digestive tract, especially the stomach. In dairy products such as yoghurts they have to survive mildly acidic conditions for an extended period of time. Probiotic survival in products is affected by a range of factors including pH, post-acidification (during storage) in fermented products, hydrogen peroxide production, oxygen toxicity (oxygen permeation through packaging), storage temperatures, stability in dried or frozen form, poor growth in milk, lack of proteases to break down milk protein to simpler nitrogenous substances and compatibility with traditional starter culture during fermentation. All these stresses result in death of a significant percentage of these cells. Therefore International Dairy Federation (IDF) suggests that a minimum of 10 7 probiotic microbial cells should be alive at the time of consumption per gram of the product, in order to achieve the acclaimed health benefits. It is believed however that this number can be decreased significantly when the major cause of cell death, i.e. the acidic degradation of the living cells in the stomach can be avoided by protecting the cells from such an acidic environment and thereby increasing the survival rate of cells in the stomach. A number of probiotic microbial cells are also able to produce digestive enzymes as well as when passing through the stomach and entering the intestine.
Microencapsulation
[0013] One solution to the problem of poor survival of probiotic microbial cells for example during storage in fermented dairy products or during exposure to stomach acid is microencapsulation. Encapsulation is the process of forming a continuous coating around an inner matrix that is wholly contained within the capsule wall as a core of encapsulated material. It must be distinguished from “immobilisation” which refers to the trapping of material within or throughout a matrix. In contrast to encapsulation, this is a random process resulting in undefined particle size where a percentage of immobilised elements will be exposed at the surface. Microencapsulation helps to separate a core material from its environment, thereby improving its stability and extending the core's shelf life. The structure formed by the microencapsulation agent around the core substance is known as the wall. The properties of the wall system are designed to protect the core and to potentially release it under specific conditions while allowing small molecules to pass in and out of the membrane. The capsules may range from submicron to several millimetres in size and can be of different shapes.
[0014] Several food grade biopolymers such as alginate, starch, xanthan gum, guar gum, locust bean gum and carrageenan gum as well as whey proteins have been tested as microencapsulation materials to protect the acid sensitive microbial cells with varying successes. For a recent review see Islam et al. “Microencapsulation of Live Probiotic Bacteria” J. Microbiol. Biotechnol. (2010), 20(10), 1367-1377. So far nobody reported on the use of a microencapsulation technology that allows digestive enzymes that are produced inside of microbial cells, to be released through the capsule wall.
Alginates
[0015] Alginates are natural anionic polysaccharides made up by D-mannuronic and L-guluronic acid residues joined linearly by 1-4 glycosidic linkages. Alginate is a natural product recovered from seaweed, which is considered to be non-toxic and alginate encapsulation is a widely used technology, due to its simple preparation and low price and good biocompatibility (the material does not affect the viability of most types of encapsulated cells). Alginate gels made from Ca 2+ alginate are stable in low pH. They swell in weakly basic solutions. When the pH is lowered below the pKa values of D-mannuronic and L-guluronic acid, though, alginate is converted to alginic acid with release of Ca 2+ and the formation of a more dense gel due to water loss.
[0016] An article by Kaila Kailasapathy (“Microencapsulation of Probiotic Bacteria: Technology and Potential Applications”, Curr. Issues Intest. Microbiol. (2002), 3, 39-48) provides a good overview of the different microencapsulation techniques that had been used up to that time.
[0017] It was reported that about 40% more lactobacilli survived freezing of ice milk when they were entrapped in calcium alginate than when they were not entrapped. An aqueous solution of alginate or carrageenan in vegetable oil containing Tween 80 (emulsifier) and sodium lauryl sulphate (surfactant) was used to encapsulate probiotic bacterial cells. The bacterial cells were mixed in a solution of alginate and dropped into oil to accomplish encapsulation. The emulsifier and surfactant were added to promote capsule formation.
[0018] Some of these micro-encapsulation laboratory procedures involve water-in-oil emulsion technology. This technique however may not be suitable for all food product applications because, firstly, the residual oil in the encapsulated material may be detrimental to texture and organoleptic characteristics, and may not be suitable for the development of low-fat dairy products. Secondly, the residual oil, emulsifier and surfactant in the encapsulated material can be toxic to live microbial cells and may interact with sensitive food components.
[0019] Also a modified alginate-starch encapsulation method has been described, wherein the prebiotic Hi-maize starch was incorporated during the calcium-alginate microencapsulation of probiotic cells. Cells encapsulated in presence of this starch had a prolonged shelf-life, compared to those encapsulated without the starch. Prebiotics are non-digestible food ingredients that stimulate the growth and/or activity of microbial cells in the digestive system which are beneficial to the health of the body. Typically, prebiotics are carbohydrates (such as oligosaccharides), but the definition may include non-carbohydrates, they are non digestible by the host organism (such as a mammal or human), but provide benefits to the microorganisms that can digest them. However, the encapsulated microbial cells did not show a significantly increased survival rate when subjected to low pH and high bile salt conditions during in vitro tests. They were exposed to conditions of pH 2, 3 or 4 for 3 hrs at 37° C. and samples were taken hourly. It turned out that Lactobacillus acidophilus is more sensitive than Bifidobacterium , but that the encapsulation did not protect the microbial cells from being degraded by aqueous acidic solutions (Sultana et al. “Encapsulation of probiotic microbial cells with alginate-starch and evaluation of survival in simulated gastrointestinal conditions and in yoghurt”, International Journal of Food Microbiology, (2000), 62(1-2), 47-55).
[0020] However, probiotics must not only be able to survive the manufacturing and storage conditions of food but must also eventually be fit to enter the gut. Therefore, they also have to survive gastric acidity, bile salts, enzymes, toxic metabolites, bacteriophages, antibiotics and anaerobic conditions, before they can exert their beneficial effect in the intestine.
[0021] Conventionally generated alginate capsules with diameters of 40-80 micrometer have been reported to confer only an insignificant protection of bifidobacteria when exposed to simulated gastric juice at pH 2.0 while larger alginate (1-3 mm) microspheres protected the encapsulated cells more substantially (Truelstrup-Hansen L, Allan-wojtas P M, Jin Y L, Paulson A T, “Survival of free and calcium-alginate microencapsulated Bifidobacterium spp. in simulated gastro-intestinal conditions.”, Food Microbiol. (2002), 19: 35-45.).
[0022] In 2009 Nazzaro et al. encapsulated L. acidophilus bacteria in alginate-inulin-xanthan gum and reported significantly enhanced cell viability after fermentation and storage (6×10 12 and 4×10 10 cells/ml versus 4×10 10 and 2×10 8 for free cells, respectively) as well as improved survival rates in simulated gastric acid (Nazzaro, F. et al., “Fermentative ability of alginate-prebiotic encapsulated Lactobacillus acidophilus and survival under simulated gastrointestinal conditions”, Journal of Functional Foods (2009), 1(3), 319-323).
[0023] Also lately, a novel microencapsulation method based on gelatin microspheres which are cross-linked with the non-cytotoxic genipin and coated with alginate cross-linked by Ca 2+ from external and internal sources, was described. The encapsulation in alginate-coated gelatin microspheres significantly (P<0.05) improved the survival of probiotic Bifidobacterium during exposure to adverse environmental conditions. Cell survival after exposure to simulated gastric juice, pH 2.0, for 5 min was only 2% and 1% of the initial populations for uncoated gelatin microspheres and free cells respectively. However, 54% and 20% of the initial populations survived when the bacteria were in alginate-coated microspheres produced by external and internal Ca 2+ -sources, respectively. After the initial losses (5 min) though, the populations of bifidobacteria declined at the same rate for all treatments over the 2 h incubation period. The decrease in the viable population by 3.45 log units for free B. adolescentis cells was similar to findings by others who observed reductions of about 3 log cfu ml for B. adolescentis exposed to Simulated gastric juice (SGJ, pH 2.0) for 2 to 3 h. (Annan N. T., Borza A. D. and Truelstrup Hansen L., “Encapsulation in alginate-coated gelatin microspheres improves survival of the probiotic Bifidobacterium adolescentis 15703T during exposure to simulated gastro-intestinal conditions”, Food Research international, (2008), 41(2), 184-193).
[0024] The time between start of their journey to the lower intestinal tract via the mouth, and release from the stomach has been reported to be about 90 min. Therefore, when Khater et al. compared the survival rates of 12 different probiotic strains encapsulated with alginate—encapsulation was performed according to a modified version of Sultana's protocol (as described above involving the Hi-maize starch)—under acidic stress, treatment times of 30, 60 and 90 mins in acidified medium were used (Khater & Ahmed, “Effect of Encapsulation on some Probiotic Criteria”, Journal of American Science, (2010), 6 (10), 810-819). Cellular stress begins in the stomach, which has a pH value as low as 1.5. In most in vitro assays however pH 3.0 is used to test acid resistance. The alginate encapsulated cells were therefore compared to non-encapsulated cells at a pH of 2 and a pH of 3. All non-encapsulated strains were strongly affected at pH 2.0, whereas alginate encapsulated bacteria survived a little bit longer in pH 2.0. The overall survival rates, however, were higher at pH 3.0 also for the encapsulated cells indicating that the effects of acidic stress cannot completely be prevented.
[0025] Furthermore, Khater et al. compared survival rates of these alginate encapsulated and non-encapsulated strains after exposure to different concentrations of bile salt, and also tested the effect of simulated gastric juice (SGJ at pH of 1.4) on viability of these bacteria. When the exposure times were increased to 24 hrs at pH 3.0 plus 12 hrs in a 0.3% concentrated oxgall solution, the results confirm that under these conditions alginate encapsulation increases the survival rate of probiotic bacteria in low pH followed by a treatment with bile salt. For one strain the survival rate after the 36 hrs treatment increased from 17% to 34% and for another strain from 37% to 50%. Survival rates between capsulated and non-encapsulated cells differed by only approximately 2% after an exposure of 3 hrs in the simulated gastric juice conditions though, a treatment apparently less detrimental for all cell strains, as survival rates even of non-encapsulated cells remained between 89% and 92% in this experiment.
[0026] However, in contrast, it has been reported that none of the free cells of Lactobacillus bulgaricus KFRI 673 survived a 60 min period in simulated gastric fluid (SGF) at pH 2.0, whereas the cells did survive a period of two hours in simulated intestinal fluid (SIF), suggesting that L. bulgaricus KFRI 673 is pH-sensitive and cannot survive in acidic pH conditions (reviewed by Islam, see above). Furthermore, Porubcan reported that about 99% of the viability of free cells is lost after they have been exposed to the stomach. His experiments show that exposure to simulated gastric acid at pH 1.6 for a period of 90 min dramatically reduces the viability of all cultures tested (U.S. Pat. No. 7,122,370, Example 1).
[0027] The U.S. Pat. No. 7,122,370 and U.S. Pat. No. 7,229,818 of Porubcan describe an acid induced encapsulation with alginate, which is resistant to low pH conditions. The formulation used includes a substantially water free mixture of probiotic cells with sodium or potassium alginate salts. The mixture has been formed and is maintained in an essentially water-free environment, by encoating the alginate/bacteria mix with an enteric coating, for example a capsule made of cellulose or gelatin. This “macro”-capsule is meant to protect the mixture of bacterial cells and alginate salts from becoming moist. Hence basically the solid cellulose capsule is providing an enteric coating protecting the two component mix until the capsule is dissolved in the stomach, where acid resistant microcapsules will then form, made of alginic acid and probiotic bacteria as soon as they get in contact with the acidic environment in the stomach. Due to the acid induced formation of the microcapsules, the probiotic bacterial cells seem to be protected from the gastric juice in the stomach while being encapsulated. Porubcan claims that cellulose as excipient, which is disclosed to encapsulate the mixture of alginate and cells and to provide a formulation that can easily be swallowed, is not protective with regards to the gastric acid in the stomach (http://www.survivalprobiotics.com/randy_commentary.html (last seen on 15 Nov. 2010):
[0028] “The probiotic bacteria are grown in the tanks in a broth medium for about 18 hours and then harvested by centrifuge and freeze-dried. The freeze-dried powders are filled into capsules along with food grade excipients such as cellulose. The big problem with this process is that it yields products with poor shelf-life (even when refrigerated) and poor survival in the stomach—all the CFU, literally 99.99%, get killed by stomach acid.”
[0029] While this system provides one solution to provide viable probiotics to customers, it is however not suitable for all uses as a food ingredient, as it is generating rather large capsules, which need to be swallowed intact, and may not be bitten open.
[0030] Already in 1995 a patent application was filed which discloses various methods of microencapsulation for lactobacilli and suggests to orally administer microencapsulated probiotic lactobacilli within pharmaceutically acceptable capsules, such as gelatine capsules, to prevent antibiotic associated diarrhoea—wherein the microencapsulation is described as a means to extend the bacterial shelf life, and to protect the bacteria from degradation while passing through the gut (U.S. Pat. No. 5,633,012). Described are microencapsulation systems using sodium alginate alone or alginate and poly L-lysine. One system is described wherein the bacteria are mixed with hydroxypropylmethylcellulose to be added into a solution of a mix of freely water permeable and partially water permeable acrylic methacrylic acid ester copolymers in acetone-isopropanol. The cellulose derivative serves as a carrier only, and is not part of the capsule. Two other microencapsulation processes described in here involve the use of polyvinylpyrrolidone or polyvinylpovidone.
[0031] The abandoned patent application US 2005/0266069 A1 by Simmons is another comprehensive source of information on the state of the art concerning the different methods of preparing stable probiotic microsphere compositions. Herein, a rather complex probiotic microsphere is described comprising a core of probiotic bacteria, a cellulosic excipient, a disintegrant and an additive, as well as an enteric coating resistant of gastric fluids. The enteric coating capable of being resistant to gastric fluids is comprised of a polymer or copolymer of acrylic acid and/or methacrylic acid and/or their esters, cellulose acetate phthalate, polyvinyl acetate phthatlate and shellac.
[0032] Concerning the methods of producing such capsules there are generally two different approaches. Simmons describes a technique involving the extrusion of polymer solutions, followed by spheronization which may comprise a series of non-continuous stages known as granulation (to form an extrudable paste), extrusion, spheronization and drying, followed by another step of coating said microspheres.
[0033] This rather complex production method is in contrast to the much simpler technique, which is employed for the generation of cellulose sulphate microencapsulated probiotics, according to the present invention. The latter simply involves two steps of dispersing the cells in the cellulose sulphate solution and introducing the mixture for example in form of droplets into a hardening solution, also referred to as precipitation bath. Basically preformed spherically droplets which are charged and therefore don't stick together fall into a hardening solution.
Cellulose Sulphate Microcapsules
[0034] In a different field, i.e. in the area of biomedicine and healthcare applications, living cells are encapsulated with the aim to inject them inside the body of a patient (i.e. implant them), where they are expected to deliver therapeutic biomolecules, substrates or enzymes which then pass through the membrane of the microcapsule, which protects them from being attacked by the body's immune system and localises them.
[0035] An alternative technology to the use of alginate described above, i.e. the forming of polyelectrolyte complex (PEC) microcapsules by oppositely charged polyions is a simple and effective method. The commonly employed polyelectrolyte capsule systems are sodium cellulose sulphate (herein referred to as NaCS)/poly[diallyl(dimethyl)ammonium chloride] (herein referred to as pDADMAC), chitosan/alginate, chitosan/xanthan, etc. pDADMAC is a quaternary ammonium homopolymer. The CAS name of pDADMAC is 2-Propen-1-aminium,N,N-dimethyl-N-Propenyl-,chloride homopolymer. It can be purchased at different molecular weights.
[0036] The NaCS/pDADMAC encapsulation system formed by dropping a solution of polyanion NaCS into a solution of polycation pDADMAC, has been systematically investigated and it captivates by its simplicity thereby decreasing the costs of the process and eliminating potential sources of contaminants. Molecules like nutrients and waste products can easily pass through the cellulose sulphate microcapsule pores, if the capsules have been made with comparatively small pDADMAC molecules. The material is biocompatible and long term survival could be documented for some cell types which were encapsulated with this system. It was characterized and optimized for biomedical purposes, and the microcapsules have subsequently been applied successfully, for example in the field of tumour therapy where the encapsulated living cells produce therapeutic compounds such as antibodies, which are released through the capsule pores within the patient's body (U.S. Pat. No. 6,540,995 to Gunzburg et al. and U.S. Pat. No. 6,426,088 to Piechaczyk et al.).
[0037] First experiments performed in house were showing that acidic protons H 3 O + would easily pass through the cellulose sulphate capsule walls. When CaCO 3 particles were encapsulated with sodium cellulose sulphate and small sized pDADMAC they completely dissolved when an aqueous acidic solution was added. The dissolving is happening in a time dependent manner. FIG. 2 is showing pictures of such capsules embedding CaCO 3 crystals which are dissolved slowly, at a pH below 6, in a time dependent manner. When reducing the pH further from pH 7.5 to pH 3 the CO 2 generated is forming bubbles within the capsules.
[0038] Therefore, it is surprising that NaCS/pDADMAC capsules are able to protect microbial cells from the effect of an acidic environment.
[0039] The idea to use this NaCS/pDADMAC system based encapsulation technology in order to protect the microbial cells from degradation through gastric juice in the stomach, and further while passing through the intestine was tested herein and, surprisingly, the microbial cells inside the macroporous capsules made of cellulose sulphate and pDADMAC ( FIG. 3 ) survived the acid treatment much longer than the non-encapsulated cells ( FIG. 4 ), despite of the capsules' rather large pore size (demonstrated in U.S. Pat. No. 6,540,995 and U.S. Pat. No. 6,426,088 to allow the release of macromolecules) and the teaching in the art that cellulose as excipient does not protect the cells from degradation through gastric juice in the stomach. Furthermore the cells remained viable and metabolically active. Most of the cells then still remained encapsulated while being treated with intestinal fluids, such as duodenal juice, hence the cells are enabled to pass through the digestive tract, for example, including the intestine, within the microcapsules and to thereby release the enzymes they produce, through the capsule pores into their surrounding environment. Depending on the microencapsulation conditions a release of microencapsulated microbial cells in the gut can be adjusted in order to improve the release of microbial cells from the microcapsules.
SUMMARY OF THE INVENTION
[0040] This invention is about the use of a specific microencapsulating material and methods to protect living microbial cells, which might be bacteria and other microorganism like fungi or yeast, in particular probiotic cells, which is a heterologous group consisting of special yeast, special fungis and special bacteria, from acidic degradation in acidic aqueous solution and further enable them to pass through the digestive tract, while remaining viable. It is also about the encapsulation of microbial cells which release enzymes, through the capsule pores into their surrounding environment, after having survived acidic gastric juice of animals, which might be vertebrates, but preferably avians and mammals, to gain the according health benefit. It is to be understood that the invention as described throughout the entire document can be applied to different other subgroups of animals as well. However, preferred animals are avians, especially avians which are useful for food production like geese, chicken, turkeys, fish, shrimp or mammals, like rodents, dogs or cats, but especially mammals which are useful for food production like ruminants (cattle, goats, sheep, bison, moose, elk, buffalo, deer) or pigs. Most preferred are however, humans in order to prevent or to treat gastrointestinal imbalances. Macroporous cellulose sulphate capsules containing microbial cells, such as microbial cells producing digestive enzymes and especially probiotics are provided which are resistant to a treatment with HCl acidified aqueous solution, especially with gastric acid or gastric fluid, for an extended time of at least 1 h and which are further resistant to treatment with intestinal fluids, such as simulated intestinal fluid (SIF) or duodenal juice, etc. The process to microencapsulate the microbial cells is surprisingly simple. The experimental data provided here reveal that the microencapsulation of microbial cells with sodium cellulose sulphate (NaCS) and poly[diallyl-dimethyl-ammonium chloride] (pDADMAC) resulted in macroporous microcapsules which protect the encapsulated microbial cells successfully from degradation in an acid environment, as well as in the rather basic environment of intestinal juices (pH is essentially around 8). Even after 90 mins of treatment with HCl at pH 2.0 the metabolic activity of the encapsulated microbial cells is still high compared to non-encapsulated cells. This is surprising because hydrogen ions (H 3 O + ) are expected to rapidly diffuse into the capsule due to the relatively large pore size (of about 80 kDA or higher), as has been shown in studies demonstrating that cellulose sulphate encapsulated cells do allow passage of substances as large as antibodies through their pores in the capsule wall. For some reason the encapsulation with sodium cellulose sulphate and pDADMAC resulting in macroporous capsule surfaces nevertheless provides a significant protection from degradation with acidic solutions. When treated with intestinal fluids such as duodenal juice the microcapsules still remain intact. The pore size is however large enough to allow the enzymes secreted by the microbial cells to pass through the capsule wall and be released, for example, into the digestive tract. This enables the passage of a high number of viable, metabolically active e.g. probiotic cells through the stomach into the intestine.
[0041] The cell microencapsulation technology, which is based on the use of sodium cellulose sulphate, which can be either homogenously or heterogenously sulphated cellulose, and pDADMAC has so far not been applied in order to protect the encapsulated bacteria or probiotics from acidic degradation, nor from degradation through extended periods of storage or both.
[0042] It is one embodiment of the invention to provide this technology for use in the food industry. Encapsulated microbial cells are especially useful to enhance weight gain in farm animals. Substitution e.g. of intrinsic microbial populations by microbial strains providing a more effective enzyme composition lead to an enhanced food utilisation. Therefore, the use of the technology and microcapsules as described above in the food industry is another embodiment of the invention.
[0043] By originating from a chemically defined starting material, surrounding the cells with such a cellulose based PEC capsule, which is not only of high mechanical strength and good biocompatibility, but also unaffected by acidic conditions, and able to respond to a change in the surrounding environment by releasing the cells and/or cell products from the capsules when passing through the intestine, a solution to the problem of the poor survival of the majority of cells, such as probiotics in dietary products and in orally administered food additives is achieved.
BRIEF DESCRIPTION OF THE FIGURES
[0044] FIG. 1 is representing the chemical structure of the polyelectrolytes used for encapsulation.
[0045] FIG. 1 a) is representing the chemical structure of sodium cellulose sulphate (NaCS).
[0046] FIG. 1 b ) is representing the chemical structure of the Poly[diallyl-dimethyl-ammonium chloride] (pDADMAC).
[0047] FIG. 2 is showing a series of pictures representing capsules made of cellulose sulphate and pDADMAC according to the invention, which contain CaCO 3 at different pH values. The first capsules are at a pH of 7.5 and contain CaCO 3 crystals. The last picture shows the capsules at a pH of 3, wherein the CaCO 3 crystals are dissolved and bubbles of CO 2 are visible inside the capsules. This demonstrates that acid (H 3 O + ) can freely enter the capsules and dissolve the CaCO3 crystals. Therefore, it is very surprising that the NaCS/pDADMAC capsules are able to protect microbial cells from the effect of an acidic environment.
[0048] FIG. 3 shows a light microscopic picture of NaCS/pDADMAC encapsulated Lactobacillus acidophilus cells.
[0049] FIG. 4 shows the survival of free (squares) versus NaCS/pDADMAC encapsulated (rhombes) Lactobacillus acidophilus in acidic conditions (HCl, pH2) for a period of up to 4 hours. The viability was determined by Alamar Blue® assay and measured in relative fluorescence units (RFU).
DETAILED DESCRIPTION OF THE INVENTION
[0050] The subject of the invention is encapsulated microbial cells, comprising capsules having a porous capsule wall, wherein the porous capsule wall comprises a complex formed from cellulose sulphate and poly[dimethyldiallyl-ammonium chloride], which are characterized as being resistant to treatment with acidic aqueous solution, especially bacterial cells that are sensitive to treatment with acidic aqueous solution, when not encapsulated. The cell microencapsulation technology used herein is based on the use of sodium cellulose sulphate which may be produced either by homogenously or heterogeneously sulphated cellulose. The pDADMAC used in the methods according to the invention is of a rather small molecular weight, as has been described by Dautzenberg et al. (1999b). (Dautzenberg H, Schuldt U, Grasnick G, Karle P, Müller P, Löhr M, Pelegrin M, Piechaczyk M, Rombs K V, Günzburg, W H, Salmons B, Saller R M.
[0051] “Development of cellulose sulfate-based polyelectrolyte complex microcapsules for medical applications”. Ann. N.Y. Acad. Sci. (1999), 875, 46-63). Here it was disclosed that the optimum mechanical strength of the capsule wall can be achieved with pDADMAC of about 20 kDa. The capsules produced that way are characterised as having pores large enough to allow passage of proteins or monoclonal antibodies, according to a size of at least 80 kDa or even up to 150 kDa. The dependency of pore size and the size of the pDADMAC used has been disclosed by Dautzenberg et al. (1999a) (“Size exclusion properties of polyelectrolyte complex microcapsules prepared from sodium cellulose sulphate and pDADMAC”, Journal of Membrane Science, (1999), 162(1-2), 165-171). It is clear that a lower molecular weight of the pDADMAC results in a lager pore size. It is preferred that the microcapsules having pore sizes large enough to allow the release of enzymes from microbial cells which are producing and excreting digestive enzymes.
[0052] In one embodiment of the invention the capsules are having the form of spheric microcapsules with a diameter of between 0.01 and 5 mm, preferably between 0.05 and 3 mm and most preferably between 0.01 and 1 mm. It is also preferred that the capsules have a porous capsule wall, which is permeable to said digestive enzymes. The microcapsules are characterized as to comprise surface pores which allow the enzymes to pass through. It is preferred that the surface pore size of the porous capsule wall is between 80 and 150 nm, to allow the enzymes to pass. It is especially preferred that the surface pores of the porous capsule wall have a molecular weight cut off (MWCO) between 50 and 200 kDa, preferably between 60-150 kDa and most preferably between 60 and 100 kDa.
[0053] Examples of the digestive enzymes and their sizes are proteases, such as Subtilisin from B. Subtilis , with a size of about 27 kDa, alpha-amylases of about 63 kDA, alpha-galactosidases of about 82 kDa, bromelain proteases of about 25 kDA, cellulases of about 32 kDa, glucoamylases of about 78 kDa, pectinases of about 35 kDa and lipases from Bacillus subtilis of about 20 kDa in size. The exact size might vary from organism to organism. Some of these enzymes also act as dimers. It is preferred that the cells are cells which are beneficial to an animal according to the present invention after consumption. It is preferred that the cells are selected from the group comprising yeasts such as Saccharomyces, Debaromyces, Candida, Pichia and Torulopsis , fungi such as Aspergillus, Rhizopus, Mucor , and Penicillium and Torulopsis and bacteria such as Bifidobacterium, Bacteroides, Clostridium, Fusobacterium, Melissococcus, Propionibacterium, Streptococcus, Enterococcus, Lactococcus, Staphylococcus, Peptostrepococcus, Bacillus, Pediococcus, Micrococcus, Leuconostoc, Weissella, Aerococcus, Oenococcus, Geobacillus and probacteria such as Lactobacillus . In the context of the present invention microbial cells might be selected from the groups comprising yeast, fungi and bacteria and/or probiotics or as a further embodiment of the present invention microbial cells might be combined from those groups. In the context of the present invention the term probiotics or probiotic cells is used interchangeably. It is preferred that these encapsulated microbial cells, especially those that secret digestive enzymes are selected from the group containing Saccharomyces, Bifidobacterium, Lactobacillus, Enterococcus, Streptococcus, Bacillus, Lactococcus, Leuconostoc, Pediococcus, Propionibacterium and Geobacillus.
[0054] More preferably the cells are selected from a group comprising Saccharomyces cereviseae, Bacillus coagulans, Bacillus licheniformis, Bacillus subtilis, Bifidobacterium angulatum, Bifidobacterium animalis, Bifidobacterium bifidum, Bifidobacterium breve, Bifidobacterium infantis, Bifidobacterium lactis, Bifidobacterium longum, Enterococcus faecium, Enterococcus faecalis, Lactobacillus acidophilus, Lactobacillus amylovorus, Lactobacillus alimentarius, Lactobacillus bulgaricus, Lactobacillus casei subsp. casei, Lactobacillus casei Shirota, Lactobacillus curvatus, Lactobacillus delbrueckii subsp. lactis, Lactobacillus fermentum, Lactobacillus farciminus, Lactobacillus gasseri, Lactobacillus helveticus, Lactobacillus johnsonii, Lactobacillus lacti, Lactobacillus paracasei, Lactobacillus pentosaceus, Lactobacillus plantarum, Lactobacillus reuteri, Lactobacillus rhamnosus ( Lactobacillus GG), Lactobacillus sake, Lactobacillus salivarius, Lactococcus lactis, Micrococcus varians, Pediococcus acidilactici, Pediococcus pentosaceus, Pediococcus acidilactici, Pediococcus halophilus, Streptococcus faecalis, Streptococcus thermophilus, Staphylococcus carnosus , and Staphylococcus xylosus.
[0055] It is especially preferred that the cells are probiotic cells. It is especially preferred that the probiotic cells are selected from the group comprising Lactobacillus acidophilus, Lactobacillus caseei, Lactobacillus delbrueckii subsp bulgaricus, Lactobacillus johnsonii, Lactococcus lactis subsp lactis, Lactococcus lactis subsp cremoris, Streptococcus thermophilus, Bifidobacterium bifidum, Bifidobacterium angulatum and Bifidobacterium longum . In one specific embodiment the cells are Lactobacillus acidophilus or Bacillus subtilis cells.
[0056] Encapsulated Lactobacillus acidophilus cells, comprising capsules having a porous capsule wall, wherein the porous capsule wall comprises a complex formed from either homogenously or heterogeneously sulphated cellulose sulphate and poly[dimethyldiallyl-ammonium chloride] thereby providing that these encapsulated cells are resistant to a treatment with acidic aqueous solution of a pH value of 2 for a time period of 2 to 4 hours are therefore a specific embodiment of the invention. It is a preferred embodiment wherein the cells are resistant for a time period of 2 hours.
[0057] It may be understood that the term “resistant” comprises a situation, wherein a majority of microbial cells is still viable after such treatment.
[0058] It is preferred that a majority of these cells is still viable after such a treatment with an acidic aqueous solution. It is especially preferred that the majority of cells is still metabolically active after such treatment and that the cells still produce and release enzymes. In this context the majority is understood to be at least 51% of the cells. It is preferred that 60% to 90% of the cells remain viable. It is even more preferred that 60% to 80% of the cells remain viable. It is an especially preferred embodiment wherein 60% of the cells remain viable after acidic treatment.
[0059] It is understood that at least more of the encapsulated cells are metabolically active after treatment with an acidic aqueous solution, than cells of the same type that were not encapsulated and treated under the same conditions.
[0060] It is a preferred embodiment wherein the time of treatment with acidic aqueous solution is between 0.5 and 2.5 hrs, preferably between 1 and 2 hrs, and most preferably 1.5 hrs. It is also a preferred embodiment of the present invention wherein the acidic aqueous solution has a pH range between 1.0 and 3.0, preferably between 1.5 and 2.5, most preferably is a pH of 2.0.
[0061] It is a preferred embodiment that the encapsulated cells according to the invention produce and release digestive enzymes, which are selected from the group comprising amylases, such as alpha-amylases, galactosidases, especially alpha-galactosidases, proteases, especially bromelain protease and subtilisin, cellulases, hemicellulases, pectinases and lipases. It is preferred that the enzymes are selected from the group containing the above. It is especially preferred that the encapsulated cells are selected from the group of Bifidobacterium, Lactobacillus, Enterococcus, Streptococcus, Bacillus, Lactococcus, Leuconostoc, Pediococcus, Propionibacterium and Geobacillus.
[0062] In a preferred embodiment of this invention the microbial cells are Bacillus subtilis cells and the secreted enzymes are proteases, especially subtilisin. Another embodiment of the invention related to encapsulated probiotic cells, comprises capsules having a porous capsule wall, wherein the porous capsule wall comprises a polyelectrolyte complex formed from the counter-charged polyelectrolytes cellulose sulphate and poly[dimethyldiallyl-ammonium chlorid], thereby providing that these encapsulated probiotic cells are resistant to treatment with acidic aqueous solution, and wherein the capsules are characterised as to release at least a part of the living probiotic cells upon treatment with intestinal fluids. The acidic aqueous solution may be gastric juice or gastric fluid. The treatment with intestinal fluid comprises passing through the intestine of an avian or of a mammal, including a human. Preferably the intestinal fluid comprises duodenal juice or fluid. It is a preferred embodiment that the encapsulated probiotic cells, comprising capsules as described above are characterised as surviving a treatment with simulated gastric fluid (SGF), and wherein a treatment with simulated duodenal fluid or simulated intestinal fluids (SIF) triggers or causes the release of at least a part of the probiotic cells out of the capsules.
[0063] Another embodiment of the present invention is to provide a food supplement comprising such encapsulated microbial cells, according to the different embodiments as described above, is also understood to be an embodiment of the invention. Furthermore a formulation, preferably a pharmaceutical formulation or pharmaceutical composition comprising encapsulated microbial cells, preferably probiotic bacterial cells, or encapsulated yeasts or encapsulated fungal cells, which are preferably probiotic fungal cells as described above is another embodiment of the invention. The encapsulated microbial cells may be used as a medicament or preventing agent. They may be used to treat or prevent diarrhea, including diarrhea caused by antibiotics and other forms of suffering from an unbalanced bacterial population in the intestine, be it in response to an antibiotic treatment or not.
[0064] The sodium cellulose sulphate used in the methods according to the invention was produced by the homogenously sulphating method starting with cellulose linters. However, it is also possible to use heterogenously sulphated cellulose, as also this material according to Dautzenberg et al. (1999b)(“Development of Cellulose Sulphate-based Polyelectrolyte Complex Microcapsules for Medical Applications”, Ann. N.Y. Acad. Sci., (1999), 875, 46-63.) results in the formation of capsules with large pores, of at least 80 kDa.
[0065] A food supplement comprising such encapsulated microbial cells or encapsulated probiotics is also understood to be an embodiment of the invention. Furthermore a formulation, preferably a pharmaceutical formulation comprising encapsulated bacterial cells or probiotics, as described above is another embodiment of the invention.
[0066] In WO/2006/095021 (US 20090011033) a method has been described, that describes the production of cellulose sulphate of sufficient quality. It is preferred that the cellulose sulphate used is of a molecular weight of between 100-500 kDa, preferably 200-400 kDa, and most preferably between 250-350 kDa. The experiments in the Example section of the present application were performed with NaCS material (09-Sul-592) provided by the Fraunhofer Institute of Applied Polymer Research (IAP) in Potsdam, Germany.
[0067] The preparation of cellulose sulphate capsules has been thoroughly described in DE 40 21 050 A1 of Dautzenberg. Also the synthesis of the cellulose sulphate has been described therein, methods for a comprehensive characterization of cellulose sulphate capsules have been extensively dealt with in H. Dautzenberg et al., Biomat. Art. Cells & Immob. Biotech., (1993), 21(3), 399-405. Other cellulose sulphate capsules have been described in GB 2 135 954. The properties of the cellulose capsules, i.e. the size, the pore size, wall thickness and mechanical properties depend upon several factors such as for example physical circumstances whereunder the capsules have been prepared, viscosity of precipitation bath, its ion strength, temperature, rapidity of addition of cell/cellulose sulphate suspension, constitution of cellulose sulphate, as well as other parameters described by the Dautzenberg group.
[0068] Generally, in order to form the capsules the sodium cellulose sulphate is brought in contact with an aqueous pDADMAC solution, which may be purchased e.g. from Aldrich Co., USA or Katpol Chemie to name a few. Alternatively, poly[dimethyldiallyl-ammonium chloride] (pDADMAC or also referred to as PDMDAAC) may be prepared via radical polymerization of dimethyl-diallyl-ammonium chloride, (according to the University of Potsdam, Department of Chemistry, Teltow, Germany). Mansfeld and Dautzenberg suggest to use a 1.2% (w/v) solution of PDMDAAC (pDADMAC) in destilled water. pDADMAC may be purchased in a variety of different sizes. Zhang et al. (Zhang, Yao and Guan, 2005 Preparation of macroporous sodium cellulose sulphate/poly(dimethyldiallylammonium chloride) capsules and their characteristics. Journal of Membrane Science. Volume 255, Issues 1-2, 2005, Pages 89-98) used a pDADMAC with a molecular weight of 200,000-350,000 Da, whereas Dautzenberg suggests a pDADMAC of a molecular weight of 10,000-30,000 Da.
[0069] In WO/2006/095021 (US 20090011033) a method has been described, that results in cellulose sulphate samples of sufficient quality. In this process a reaction mixture of n-propanol and sulphuric acid served as sulphating medium and agent.
[0070] Sodium cellulose sulphate ( FIG. 1 a ) serves as polyanion and poly[diallyldimethylammonium chloride] (pDADMAC) ( FIG. 1 b ) as polycation. The NaCS solution is used to build the capsule core and the pDADMAC solution as a precipitation bath delivering the second reaction component for PEC formation at the surface of the droplets, thus forming the capsules by covering the droplets with a solid membrane. A commercially available encapsulating machine may be used to form microcapsules, which in the context of the entire invention are also referred to as beads or microspheres. Such an encapsulator includes a perfussor drive which pushes a NaCS solution with defined velocity through a nozzle and thus generates a continuous liquid flow. The liquid flow is forced to oscillate by a pulsation unit, where the superimposed oscillation causes the break-off of the outlet liquid stream or jet into beads of equal volume. In order to improve the mono-dispersibility of the beads and at the same time to reduce coalescence, an electric field is provided under the nozzle outlet in such an encapsulator. Electrostatic charging in the free phase causes a repulsion of the individual beads, so that an aggregation of the individual beads up to entry into the complex-forming bath is substantially prevented.
[0071] The spheric beads formed in this manner are dropped into a complex-forming bath, within which at the outer membrane of the capsule is formed around the capsule by electrostatic interaction, for example between the NaCS and a pDADMAC solution. Under constant stirring, the capsules remain in this system until reaching a desired hardening degree in the corresponding container and are then available for further processing.
[0072] In lack of an encapsulator or other airjet droplet generator system, a syringe can be used with a 0.2 to 1.0 mm inner diameter needle possibly with a suitable syringe pump extrusion system. Alternatively the use of a pasteur pipette with e.g. an inner diameter of 1.5 mm also works to generate acid resistant capsules according to the present invention.
[0073] The resulting capsules have a pore size large enough to allow macromolecules up to 80 kDa or even up to 150 kDa, e.g. antibody proteins to pass. Capsules produced that way have been reported to have pore sizes large enough to release antibodies through these pores which are produced from hybridoma cells within these capsules. The cellulose sulphate encapsulation technology described by Dautzenberg et al. 1999b (“Development of Cellulose Sulphate-based Polyelectrolyte Complex Microcapsules for Medical Applications”) was employed to test whether in vivo production of a neutralising monoclonal antibody could protect mice against Fr-CasE retrovirus (Pelegrin et al., “Immunotherapy of Viral Disease by in Vivo Production of Therapeutic Monoclonal Antibodies”, Human Gene Therapy (2000), 11, 1407-1415). From these results it is clear that the capsules have pores large enough to allow a monoclonal antibody to pass through.
[0074] It is understood however that substances and methods of the invention are not limited to the use of the specific ingredients described herein; instead the invention comprises also the use of ingredients purchased from other sources or ingredients, produced by methods such as described above.
[0075] Before encapsulation the microbial cells are best grown to an OD 600 nm of 1 and harvested. However, other OD 600 are suitable as a starting point as well. Then they are encapsulated with cellulose sulphate and pDADMAC as follows:
[0076] Microbial cells are microencapsulated with NaCS according to the method of Dautzenberg et al. (“Preparation and Performance of Symplex Capsules”, Makromol. Chem., Suppl. 9, 203-210, 1985; “A new method for the encapsulation of mammalian cells”, Merten et al., Cytotechnology 7:121-120, 1991; “Development of Cellulose Sulphate-based Polyelectrolyte Complex Microcapsules for Medical Applications” Annals of the New York Academy of Sciences, 875 (Bioartificial Organs II: Technology, Medicine, and Materials), 46-63, 1999b). Briefly, NaCS serves as polyanion and builds the capsule core. Poly[diallyldimethyl-ammonium chloride] solution as polycation provides a precipitation bath delivering the second reaction component for the polyelectrolyte complex formation at the surface of the cellulose sulphate capsule core, thus forming microcapsules by covering the NaCS core droplets with a solid membrane.
[0077] The microbial cultures are grown up to an optical density indicating that they are in a fully viable state, for most of the microbial cells this might be best an optical density of 1. Then a portion, for example 50 ul, 100 ul, or 200 ul of the bacterial culture is mixed with about 20 times (100 ul are mixed with 2 ml) of that volume of sodium cellulose sulphate solution containing 1.8% sodium cellulose sulphate (09-5 ul-592, Fraunhofer Institute Golm, Germany) and 0.9% to 1% sodium chloride. Small amounts of that solution, for example droplets are then introduced into a bath of 1.3% 24 kDa (21-25 kDa average size) pDADMAC. This may be done with the use of a syringe and a needle, if no encapsulator is available or with the droplet generator system as described above. After a hardening time of 4 mins and several wash steps, the encapsulated cells are obtained from the bath and ready for use or storage.
[0078] These encapsulated cells may now additionally as a further embodiment of the invention be added to different types of food as food ingredients. Alternatively they may be consumed as a pharmaceutical composition, or pharmaceutical formulation. For example, they may be provided as (macro-)capsules with an enteric coating, which makes it suitable to swallow the right amounts of microcapsules to achieve the desired health benefit, such as in addition to supporting intestinal health and function, include (depending on the bacterial strain selected) repopulating the gut after antibiotic therapy, offsetting lactose intolerance, supporting the immune system and reducing cholesterol. Nutritional benefits include their role in enhancing the bio-availability of calcium, zinc, iron, manganese, copper and phosphorus and synthesis of vitamins. The therapeutic benefits of these microbial cells include antimicrobial activity, ability to assimilate cholesterol, improved lactose intolerance and anti-carcinogenic activity.
[0079] After encapsulation the encapsulated microbial cells might be further cultivated until the entire capsule volume is filled with microbial cells, which can be seen as a dense mass in the microscope. The more dense the capsules are filled with microbial cells, the more they are protected from the acidic environment and the more microbial cells survive the stomach passage or an incubation with acid aqueous solutions or gastric fluid.
[0080] It is therefore another embodiment of the invention to provide a method to protect cells from being degraded by treatment with an acidic aqueous solution, by encapsulation comprising a) suspending the living cells in an aqueous solution of a polyelectrolyte sodium cellulose sulphate, b) introducing the suspension in form of preformed particles into a precipitation bath containing an aqueous solution of the counter-charged polyelectrolyte poly[dimethyldiallyl-ammonium chloride], c) terminating the reaction in the bath after 1 to 60 mins, preferably 3-10 mins, more preferably 3-5 mins and most preferably after 4 mins, d) harvesting the encapsulated cells from the bath, e) optionally incubating the encapsulated cells in a medium or solution comprising further nutritional factors, f) optionally incubating the encapsulated cells until the capsules are filled entirely with cells, g) exposing the encapsulated cells to treatment with an acidic aqueous solution, which is known to degrade said cells, if they are not encapsulated, whereby the majority of encapsulated cells remains viable. In this context the majority is understood to be at least 51% of the cells, at least 60% or between 60 and 90% of the cells. In a preferred embodiment between 60% and 80% of the cells remain viable.
[0081] It is a preferred embodiment of the invention, wherein the method as claimed provides protection from acidic treatment with aqueous solution for a period of between 0.5 and 3 hours. In a preferred embodiment the period is between 1 and 2 hrs, and especially preferred is a period of 90 mins. Herein it is understood that protection is achieved if either a majority of cells is still viable or is still metabolically active or if more of the encapsulated cells remain viable when compared with unencapsulated cells which are treated under the same conditions. Metabolically active is understood as showing a reading on a UV-Vis spectrophotometer at 570 nm after incubation with resazurin which is reduced to fluorescent resorufin that is significantly different from the background or a negative control value.
[0082] Furthermore it is preferred that the acidic aqueous solution the cells are treated with is either gastric juice, gastric fluid or simulated gastric fluid or simulated gastric juice. The exposure to treatment with acidic solution may be an incubation in acidic aqueous solution, and it is a preferred embodiment wherein said treatment is performed under physiological conditions. Furthermore, it is preferred that the encapsulated cells are further resistant to being treated with intestinal fluids, such as simulated intestinal fluid, or duodenal juice.
[0083] The term “simulated gastric fluid” is understood to comprise different artificially prepared gastric fluids that have been disclosed in the literature. One of them is described here as an example: The simulated gastric fluid may for example be prepared on the basic gastric fluid and the pepsin. The basic gastric fluid has been prepared according to Clavel et al. (J Appl Microbiol. (2004), 97(1), 214-219) with some modifications. It contained 4.8 g of NaCl (POCH, Poland), 1.56 g of NaHCO 3 (POCH, Poland), 2.2 g of KCl (POCH, Poland), and 0.22 g of CaCl 2 (POCH, Poland) dissolved in 1 L of distilled water. After the autoclaving at 121° C./15 min, the pH of the basic gastric fluid was adjusted to 2.4±0.2 using 1 M HCl, and 2 mg of pepsin (Sigma Aldrich, USA) per 50 mL of the artificial gastric fluid was added.
[0084] The term “simulated intestinal fluid” is understood to comprise different artificially prepared intestinal or duodenal fluids that have been disclosed in the literature. One of them is described here as an example: The simulated duodenal fluid may be prepared on the basic duodenal fluid and an enzyme complex. The basic duodenal fluid may be prepared according to Marteau et al. (J Dairy Sci. 1997: 80(6), 1031-37) with some modifications. It contained 5.0 g of NaCl (POCH, Poland), 0.6 g of KCl (POCH, Poland), 0.03 g of CaCl 2 (POCH, Poland), and 17 g of bile salts (Merck, Germany) dissolved in 1 L of 1 mol/L NaHCO3 (POCH, Poland). After the autoclaving at 121° C./15 min, the pH of the basic juice was adjusted to 7.0±0.2 using 1 M NaOH, and an enzyme complex was added. The enzyme complex comprised of pancreatin enzymes: 20000 F.I.P. units of lipases, 16000 F.I.P. units of amylases, 1200 F.I.P. units of protease (=2 capsules of Kreon® 10000 (300 mg pancreatin enzymes) purchased from Solvay Pharmaceuticals, USA) were added per 50 mL of fluid.
[0085] It is another embodiment of the invention to provide a method of producing encapsulated microbial cells which generate and excrete digestive enzymes, with sodium cellulose sulphate and pDADMAC, resulting in microcapsules containing microbial cells, that are resistant to treatment with aqueous acidic solutions and that have a porous wall allowing the generated enzymes to pass through, comprising the following steps
[0000] i) suspending a culture of such microbial cells with a sodium cellulose sulphate solution, preferably containing 1.8% sodium cellulose sulphate and 0.9 to 1% sodium chloride,
ii) introducing the suspension in form of preformed particles into a precipitation bath preferably comprising 1.3% 24 kDa (20-25 kDa) pDADMAC, and harvesting microcapsules containing microbial cells from the bath. It is preferred that the reaction in the precipitation bath is terminated after 1-60 mins, preferably 1-10 mins, more preferably 3-5 mins, and most preferably after 4 mins for example by adding an excessive amount of washing solution.
[0086] A further embodiment of the invention comprises a method to prevent acidic degradation of probiotic microbial cells by encapsulation with sodium cellulose sulphate and pDADMAC, comprising the following steps suspending a culture of probiotic cells with a sodium cellulose sulphate solution containing 1.8% sodium cellulose sulphate and 0.9%-1% sodium chloride, introducing the suspension in form of preformed particles, for example by using a 5 ml syringe and a 23 G needle into a precipitation bath comprising 1.3% 24 kDa pDADMAC, wherein 24 kDa pDADMAC is to be understood as the average size, and harvesting microcapsules containing probiotic cells from the bath. It is a preferred embodiment wherein the reaction in the precipitation bath is terminated after 3-5 mins, preferably after 4 mins. 24 kDa pDADMAC from supplier Katpol Chemie is specified to embrace a range of 20-25 kDa.
[0087] For microencapsulation of L. acidophilus cells, the cells obtained from the culture may be mixed with NaCS as described and microcapsules may be produced manually with a syringe and a needle, as described in the example.
[0088] Further the invention provides for a method to introduce viable cells, which are sensitive to gastric acid if unencapsulated, into the intestine of animals, including humans, comprising administering encapsulated cells as have been described above.
[0089] It is also provided for a method to treat or prevent diarrhea, antibiotic caused diarrhea and other forms of suffering from an unbalanced bacterial population in the intestine by administering encapsulated cells according to the invention to mammals suffering or expected to suffer from said diarrhea, antibiotic caused diarrhea and other forms of suffering from an unbalanced bacterial population in the intestine.
[0090] The skilled reader will be aware that the cell density, as well as the concentrations of the NaCl may be varied. Also the forming of capsules is not limited to the exact hardening time of 240 s. Moreover, the NaCl solution may be replaced by a PBS solution or other buffer solutions.
[0091] The size of the capsules can be varied from 200-1200 um in diameter, if produced in an automated process involving an apparatus such as the encapsulator IE-50R and IEM-40 from EncapBioSystems, Switzerland, previously distributed by Inotech. It is a preferred embodiment of the invention wherein the capsule size is 200-700 um, and even more preferred wherein the capsule size is 200-500 um.
[0092] An alternative production method involves the use of Pasteur pipettes. When using pasteur pipettes for production of capsules manually the diameter of the microcapsules reached a size of 3,000-5,000 um.
[0093] A large sized capsule thereby clearly requires a different mode of uptake by an informed consumer, or patient, who is aware that he needs to swallow the dietary supplement without chewing it first, in order to allow full protection from stomach acid of the cells in the intact microcapsules. The size should otherwise not affect the survival times during processing and storage.
[0094] It is a preferred embodiment of the invention that the size of the capsules is between 500 and 700 um in diameter.
[0095] It is another preferred embodiment that the capsules have a diameter of at least 3,000 um when manually prepared, i.e. without an apparatus such as an encapsulator.
[0096] The so encapsulated cells may be used as additives to food, in cases where the encapsulated cells are meant to survive the stomach acid treatment. They may also be stored for prolonged periods of time at room temperature (RT).
[0097] A formulation, such as a pharmaceutical formulation comprising encapsulated microbial cells according to the method described above is another embodiment of the invention.
[0098] The application of these new substances and methods as described throughout, such as the encapsulated microbial cells resistant to acidic fluids, for the farming industry is also an embodiment of the invention. Due to similarities with the human digestion system the methods and substances of the invention can be used for delivery of beneficial probiotics to animals, especially humans in order to reduce gut associated problems by increasing feed digestion, nutrient absorption. In connection with farming purposes the delivery of beneficial probiotics can be used to increase meat production. It is to be understood that the invention as described throughout the entire document can be applied to different subgroups of animals like avians, especially avians which are useful for food production like geese, chicken, turkeys, fish, shrimp or of mammals which are useful for food production like ruminants (cattle, goats, sheep, bison, moose, elk, buffalo, deer).
[0099] Herein above is provided a method for preparing encapsulated microbial cells which produce and excrete digestive enzymes, wherein these capsules have a porous capsule wall, which is permeable to said digestive enzymes and are resistant to treatment with aqueous acidic solutions. That method comprises suspending the cells, which produce digestive enzymes, in an aqueous solution of polyelectrolyte, whereafter the suspension in the form of preformed particles, such as drops, is introduced into a precipitation bath containing an aqueous solution of a counter-charged polyelectrolyte.
EXAMPLES
[0100] In the following examples an Assay has been employed to measure the metabolic activity of cells, which is named AlamarBlue® assay. “AlamarBlue” is a registered trademark name by TREK Diagnostic Systems for an assay that is provided e.g. by Invitrogen or Promega. In the following the name AlamarBlue will be used to refer to an assay which uses the active ingredient natural reducing power of living cells to convert resazurin, a cell permeable compound that is blue in colour and virtually non-fluorescent. Upon entering metabolically active cells resazurin, the non-fluorescent indicator dye, is reduced to bright red-fluorescent resorufin. The amount of fluorescence produced is proportional to the number of living cells. 10 ul of AlamarBlue® was added into 100 ul of cell suspension and incubated for 2 hrs at 37° C. The fluorescence of the AlamarBlue® assay plate was read with a Tecan Infinite M200 reader. The fluorescence may be detected with any plate reader or fluorescence spectrophotometer using 560EX nm/590EM nm filter settings. Alternatively, the absorbance of AlamarBlue® can be read on a UV-Vis spectrophotometer at 570 nm.
[0101] The microbial cells and probiotics used for encapsulation were delivered freeze dried from the according supplier, and then cultivated in liquid medium. Samples of these cultures were kept frozen as glycerol stocks for use in separate experiments.
Example 1
Growing of Lactobacillus acidophilus to an OD of 1.0
[0102] A culture of Lactobacillus acidophilus was started with a 20 ul sample from the thawed bacteria stock by injecting it into 50 ml MRS (named by its inventors: de Man, Rogosa and Sharpe, developed in 1960; Preparation of 1 liter of MRS medium: 51 g MRS broth powder, 1 g Polysorbate 80, 0.5 g L-cysteine hydrochloride and 999 ml of H2O adjusted to pH of 6.2.) in a 50 ml EM flask. The stock had been kept at −80° C. and was purchased from DSM (catalogue number DSM 20079) (Moro) Hansen and Mocquot (ATCC 4356). The culture was incubated overnight shaking at 50 rpm and at 37° C. On Day 1 of the experiment, the optical density of the bacterial culture was determined at 600 nm on Tecan Infinite M200. Typically the optical density at 600 nm that gives a reading of 1 will correspond to the exponential phase of the bacterial growth. The cells were grown up to an OD 600 nm reading of 1, to ensure that cells were in the exponential phase before performing the stress tests (see Table 1).
[0000]
TABLE 1
Lactobacillus acidophilus culture profile growing overnight.
Growing
Time in
hrs
OD600
Day 0
4 pm
0
n.a.
Day 1
9 am
17
0.5805
Day 1
2 pm
22
1.0012
Example 2
Survival of Non-Encapsulated Lactobacillus acidophilus Cells in Hydrochloric Acid
[0103] A solution of 0.01M HCl in PBS (phosphate buffered saline) was prepared by adding 4.2 ml of 37% HCl to 500 ml PBS. The pH value was adjusted to 2.0 exactly by using 5M HCl.
[0104] 5 ul of the lactobacillus culture was added to 1 ml of hydrochloric acid in PBS (phosphate buffered saline salt solution) in a sterile Eppendorf tube in triplicate. As a control, 5 ul of the same Lactobacillus culture was added to 1 ml of PBS in a sterile Eppendorf tube in triplicate at 0 hr time point. The hydrochloric acid testing was carried out at different time points, i.e. after 1 hr, 1.5 hr and 2 hrs of exposure time.
[0105] At the various time points all the Eppendorf tubes were centrifuged down at speed of 3000×g for 1 min to remove hydrochloric acid. They were washed twice with MRS medium and 100 ul of MRS medium was added into the pellet. The pellet was resuspended therein and all was transferred into a 96 well plate.
[0106] An AlamarBlue assay, as described above, was carried out to determine the metabolic activities of the bacteria cells.
[0000]
TABLE 2
Viability of free Lactobacillus acidophilus determined as
AlamarBlue readings in RFU after different exposure times to HCl
Blank
Reading
0 h
1 h
1.5 h
2 h
3013
33073
26915
17932
3412
3023
32348
26695
23011
3362
3209
33877
11176
15657
4484
Mean
3082
33099
21595
18867
3753
Corrected
30018
18514
15785
671
Reading
Example 3
Encapsulation of Lactobacillus acidophilus Cells in NaCS and pDADMAC
[0107] 100 ul of the bacteria culture with an optical density of 1 were mixed with 2 ml of sodium cellulose sulphate solution containing 1.8% sodium cellulose sulphate (09-5 ul-592, provided by the Fraunhofer Institute) and 1% sodium chloride, and dropped into a 150 ml bath of 1.3% 24 kDa pDADMAC with the use of a 5 ml syringe and a 23 G needle.
[0108] The hardening time for the capsules in the pDADMAC bath was 4 mins. The capsules were then washed once for 8 min with 300 ml of 1×PBS, and once 4 mins with 300 ml of 1×PBS. These were followed by 3 washes with 30 ml 1× Phosphate Buffered Saline each and 3 washes with 30 ml MRS medium each. The capsules were then transferred to a 250 ml conical flask containing 100 ml of fresh MRS medium. These capsules were cultured at 37° C. incubator, with a speed of 50 rpm.
[0109] The AlamarBlue Assay described above was performed on the encapsulated lactobacillus cells. The assay was performed in triplicate on a Blank (100 ul LB medium+10 ul alamar-blue) and on the capsules (100 ul MRS medium+10 ul Alamar-Blue). The samples comprising the suspended cells and the indicator dye were incubated for 2 hrs in the plate at 37° C., and then measured.
[0000]
TABLE 3
Viability of encapsulated Lactobacillus acidophilus determined as
AlamarBlue readings in RFU at day 2 post encapsulation.
Blank
Reading
25726
24916
19246
Mean:
3432
23296
Corrected
19864
Reading:
Example 4
Survival of Encapsulated Lactobacillus Bacteria in Hydrochloric Acid
[0110] After having confirmed that the capsules are viable, hydrochloric acid testing was performed on the lactobacillus capsules. 1 capsule to 1 ml of hydrochloric acid in Phosphate Buffered Saline was placed in each well of a 24 well plate at different time points, at 4 hrs, 3 hrs, 2 hrs and 1 hr in triplicate. As a control to the experiment, 1 capsule was added to 1 ml Phosphate Buffered Saline at 0 h time point in triplicate.
[0111] At 0 h, the hydrochloric acid phosphate buffered saline solution was replaced with MRS medium. The capsules were washed twice with MRS media and then transferred 1 by 1 to a 96 well plate. 100 ul of fresh MRS medium and 10 ul alamar blue were added and incubated for 2 hrs. AlamarBlue assay plate was read on Tecan Infinite M200.
[0000]
TABLE 4
Viability of encapsulated lactobacilli determined
as AlamarBlue readings in RFU after
different exposure times to HCl
Blank
0 h
1 h
2 h
3 h
4 h
3298
25627
30832
16041
21733
24908
3429
24755
29182
18070
26421
19157
3491
26126
30969
18248
23770
19961
Mean
3406
25503
30328
17453
23975
21342
Blanked
22097
26922
14047
20569
17936
samples
[0112] A comparison of the AlamarBlue readings of lactobacillus free bacteria and encapsulated bacteria after HCl testing shows that after 2 hrs in HCl the viability of free bacteria dropped drastically indicating that free bacteria don't survive an exposure time of 2 hrs in HCl. The RFU readings of encapsulated bacteria however remain high even after 4 hrs of exposure to HCl indicating a higher viability and improved survival in capsules in HCl environment.
[0113] The metabolically active encapsulated lactobacillus strain remains highly viable beyond 4 hours in the environment of hydrochloric acid salt solution, pH 2.0 while the non encapsulated lactobacillus bacteria do not survive beyond 1.5 hours in a hydrochloric acid salt solution environment at pH 2 ( FIG. 4 ).
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A simple cellulose sulphate based microencapsulation technology has been applied to encapsulate bacterial or other microbial cells, which produce and release digestive enzymes and thereby provides an acid resistant shelter for these microbial cells. Surprisingly, the resulting spheres were found to provide sufficient protection for encapsulated cells from treatment with aqueous acidic solutions. Thereby the cellulose sulphate microencapsulated cells, such as probiotics are now enabled to survive passage, for example, through the stomach after consumption by a human or animal with a higher survival rate than those not within a microcapsule. After passing the stomach these cells are delivering products produced by them, e.g. enzymes or other nutrition factors. This technology therefore proves to be very useful in providing digestive or otherwise beneficial enzymes and/or of living microbial cells, into the lower gastrointestinal tract, where they could confer their health benefit to the host.
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TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
The present invention is generally directed to the field of electro-hydraulic actuators, and more particularly to a method and an apparatus utilizing a highly accurate electro-hydraulic actuator having a force generator to establish closed loop control.
BACKGROUND OF THE INVENTION
The inventor of the present invention has determined that there are numerous shortcomings with the methods and apparatus of the background art relating specifically to electro-hydraulic actuators.
Electro-hydraulic actuators that are required to maintain a high level of accuracy are typically controlled with servovalves and use position feedback to achieve closed loop control, e.g., with electrical devices. The position feedback may be accomplished by electrical devices such as LVDTs (Linear Variable Differential Transformer), RVDTs (Rotary Variable Differential Transformer), potentiometers, resolvers, Hall effect sensors, or piezo-resistive sensors.
However, there are applications where accurate electro-hydraulic actuators are required and electrical feedback is not available. In these situations, mechanical feedback must be used to maintain closed loop control. In a single-stage type, electro-hydraulic servovalve, a mechanical leaf spring or other spring force from the actuator is normally used to provide the mechanical feedback. As the size or the slew velocity of the actuator increases, the volumetric flow demand eventually exceeds the capacity of the servovalve, e.g., a jet-pipe, and a higher capacity flapper orifice design or a two-stage servovalve is typically required.
The present inventor has determined that it is extremely difficult to attempt to set a higher capacity two-stage servovalve with mechanical feedback from both the second stage as well as the actuator piston (first stage). In addition, the inventor of the present invention has determined that the accuracy of electro-hydraulic servovalves with mechanical feedback is typically limited to only eight percent or higher.
There are several examples of electro-hydraulic servovalves relating to the foregoing discussion of the background art. For example, U.S. Pat. No. 4,335,645 to Leonard, the entirety of which is hereby incorporated by reference, describes a direct drive, two-stage electro hydraulic servo valve incorporating hydro-mechanical position feedback.
However, the inventor of the present invention has determined that this type of complex electro-hydraulic servovalve is relatively expensive and difficult to utilize in practice. As aforementioned, attempting to set a higher capacity two-stage servovalve with mechanical feedback such as that described in the Leonard patent from both the first and second stage is extremely difficult. In the fluidic repeater described by Leonard, the second stage of the servo valve is hydraulically controlled by mechanical feedback from the position piston.
U.S. Pat. No. 4,4450,753 to Basrai et al., the entirety of which is herein incorporated by reference, describes an electro-hydraulic proportional actuator. However, this system requires electrical position feedback. Specifically, a pair of three way solenoid valves is used to position an actuator assembly having a double-acting, linear piston. An electronic control circuit using electrical position feedback nulls out the system and operates the solenoid valves to control fluid flow through the respective ports of the solenoid valves.
U.S. Pat. No. 4,807,517 to Daeschner, the entirety of which is hereby incorporated by reference, describes an electro-hydraulic proportional actuator including at least a piston, a valve for driving the piston into operating positions, a solenoid for producing a driving force for controlling the valve, and a plurality of springs for biasing the piston, solenoid and valve components. In this actuator, compression spring(s) are directly applied to the solenoid plunger and a sliding link rod to produce a force that counters the magnetic pull of the solenoid coil. When an electrical control signal is zero, the compression spring will force the solenoid plunger and the spool rod to the right (as seen and shown in FIG. 1 of Daeschner).
However, as aforementioned, it has been determined that the electro-hydraulic servovalves with mechanical feedback of the background art suffer from the above-described limitations, including being limited in their accuracy to eight percent or higher error rates.
SUMMARY OF THE PRESENT INVENTION
The present invention overcomes the shortcomings associated with the background art and achieves other advantages not realized by the background art. The present invention is intended to alleviate one or more of the following problems and shortcomings of the background art specifically identified by the inventor with respect to the background art.
The present invention, in part, is a recognition that it will be advantageous to implement a simplified and relatively easily controlled electro-hydraulic actuator utilizing mechanical servo position feedback.
The present invention, in part, is a recognition that an electro-hydraulic actuator using mechanical servo position feedback with a high level of accuracy has heretofore not been achieved by the background art.
The present invention, in part, provides an electro-hydraulic actuator comprising a single stage servomechanism; a current versus load generator, the current versus load generator capable of energizing the single stage servomechanism with an input force, the input force controlling the single stage servomechanism to regulate a regulated servo pressure controlled by the electro-hydraulic actuator.
The electro-hydraulic actuator may further comprise a mechanical feedback device producing a mechanical feedback force for offsetting the input force of the load generator, wherein the mechanical feedback force provides closed loop control of the electro-hydraulic actuator.
The present invention, also in part, provides methods of providing closed loop control for an electro-hydraulic actuator, said method comprising the steps of energizing a single stage servomechanism with a current versus load generator to produce an input force; and offsetting the input force of said load generator with a mechanical feedback force to achieve closed loop control of the actuator, e.g., through a roller assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinafter and the accompanying drawings that are given by way of illustration only, and thus do not limit the present invention.
FIG. 1 is a schematic view of an electro-hydraulic actuator utilizing mechanical servo position feedback according to an embodiment of the present invention; and
FIG. 2 is a schematic view of an electro-hydraulic actuator utilizing mechanical servo position feedback shown in operation with a high pressure compressor and pump according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail with reference to the accompanying drawings. FIG. 1 is a schematic view of an electro-hydraulic actuator utilizing mechanical servo position feedback according to an embodiment of the present invention. FIG. 2 is a schematic view of an electro-hydraulic actuator utilizing mechanical servo position feedback shown in operation with a high pressure compressor and pump according to an exemplary embodiment of the present invention.
For many years the Bendix Corporation designed and used computational hydromechanical feedback servomechanism(s) to provide accurate control of subsystems in large gas generator fuel controls. These mechanisms typically sense one or more pneumatic pressures, perform hydromechanical computations, and move an actuator piston to perform some desired function such as positioning a cam or valve in response. The present invention utilizes a similar concept to these types of servomechanisms of the background art. However, the input force that is normally provided by the pneumatic pressure(s) acting upon a bellows is created by a load generator in the present invention, e.g., similar to the magnetic coil of a solenoid or torque motor.
In FIG. 1 , an electro-hydraulic actuator 1 with a load generator 5 is shown. The load generator 5 includes a solenoid 10 that generates a solenoid force Fsol that serves as an input force to the electro-hydraulic actuator 1 . The solenoid force Fsol acts via the pivot 15 and the lever arm 16 to control the power piston 20 pressure Px via a control orifice 26 and a flapper valve assembly 27 . The power piston 20 is capable of reciprocating in a linear motion within a control cylinder 21 . The power piston 20 pressure Px is varied in proportion to the Fsol via the control orifice 26 .
An increase in power piston 20 pressure Px results in the power piston 20 moving away, e.g., to the left as seen in FIG. 1 and to the right in FIG. 2. A decrease in power piston 20 pressure Px results in a movement of the power piston 20 in the opposite direction, e.g., to the right as seen in FIG. 1 . As seen in FIG. 2 , one of skill in the art will appreciate that the power piston 20 is biased with a spring-biased, adjustable stop 30 in a preferred embodiment. The resulting or regulated servo pressure Pr occurs on the opposite side of the power piston 20 assembly and is further controlled with a servo pressure regulator 70 . In the example shown in FIG. 2 , a compressor discharge lockout valve 50 is operatively controlled by the regulated servo pressure via a second orifice 60 .
The power piston 20 includes a cam 22 having a cam surface 23 with a predetermined slope S. The cam 22 and cam surface 22 is engaged with a cam follower 25 and lever assembly 24 that provides mechanical feedback to the load generator 5 via a roller assembly 40 operatively connected via the cam follower 25 and lever assembly 24 . The cam follower 25 is arranged to follow the cam surface 22 throughout the power piston's 20 travel.
When the power piston 20 has moved to the desired linear position, e.g., the power piston 20 pressure Px and servo pressure Pr are at their desired values, the lever assembly transfers a mechanical feedback force via the roller assembly 40 that offsets or nullifies the initial load generator force Fsol. When the solenoid force Fsol, e.g., the input force, is nullified, the mechanical feedback via the roller assembly 40 is completed and thereby provides closed loop mechanical feedback to the electro-hydraulic actuator 1 . A trim spring 41 is provided that spring biases the mechanical feedback force of the roller assembly 40 in a preferred embodiment.
FIG. 2 is a schematic view of an electro-hydraulic actuator utilizing mechanical servo position feedback shown in operation with a high pressure compressor and pump according to an exemplary embodiment of the present invention. This actuator 1 was designed to meet specific requirements for an APU (Auxiliary Power Unit) engine application. In addition, one of skill in the art will appreciate that Po designates the pump pressure, Pr designates the servo pressure regulator pressure, Px designates the power piston 20 pressure, and Pcd is the compressor discharge pressure. In the load generator shown connected with a pivoted lever assembly, e.g., with a solenoid, Fsol is the solenoid force.
One of skill in the art will appreciate that a single shaft engine (gas turbine) normally drives a load via a reduction gearbox. This reduction gearbox may then be used to also drive engine accessories, e.g., such as fuel and oil pumps. A typical load is normally an electrical generator, mechanical pump or in some cases a second air compressor. However, a single shaft engine cannot normally accept any kind of load until it has started and accelerated to operating speed. Therefore, it is normally the case that all mechanical load should be removed from an operating gas turbine before it is shut down. For example, many aircraft APUs are single shaft designs with the aforementioned characteristics.
Alternatively, twin shaft gas turbines have the advantage that they can be started with a mechanical load applied. The compressor part of the engine or “Gas generator” is started and accelerated up to speed. The exhaust from the gas generator spins a power turbine driving the load. This type of small gas turbine is especially useful for starting larger engines and is known as a gas turbine starter (GTS) or jet fuel starter.
The power turbine in a twin shaft gas turbine must either drive a load or be connected to a mechanical governor so that the gas generator speed can be controlled to prevent the power turbine from over-speeding. GTS units do not always employ a governor, instead a speed sensing device shuts the GTS down when the load reaches a pre-determined speed. In addition, some GTS units are fitted with power turbine governing systems and can also drive loads such as AC generators and operate as APUs.
In the embodiment shown in FIG. 2 , a Start Check Valve (SCV) ensures that the actuator 1 will be fully extended during an engine start. After a start has been made and the APU accelerates to 100% speed, the SCV opens and the piston jumps out to a position determined by a machined cut in the piston that throttles servo supply pressure from which Px is derived. At approximately 60% engine speed, a sufficient level of Pcd has been typically been attained to open the Pcd Lockout Valve. The piston is then permitted to continue to travel to a position determined by the solenoid load cell. The restrictor in the piston and or the overboard drain, e.g., as shown in the exemplary embodiment, are necessary to produce the desired Px pressure to position the piston.
TABLE I and TABLE II include experimental values for a current versus load generator utilizing mechanical feedback as described hereinabove. As seen in TABLE I, the slope S of the cam surface can be represented in degrees, e.g., 14 degrees, and/or in terms of length versus current, e.g., inches of cam follower 25 travel along the cam surface per mA of solenoid current. This linear relationship between length and current permits accurate mechanical feedback in response to an input force from an electrical input device, e.g., a load generator with a solenoid. The mechanical feedback force provided by the spring-biased roller assembly 40 is accordingly proportional to the servoposition feedback, e.g., the servoposition or cam position obtained and related by the cam follower 25 and lever assembly. In TABLE II, the relationships between mA of solenoid current, Fsol and piston travel are shown.
One of skill in the art will also appreciate that mechanical feedback may be achieved by alternative sources not shown by the spring-biased, roller assembly of the preferred embodiments shown in the accompanying figures. For example, the present inventor has determined that it may be possible to also provide mechanical feedback by using a combination(s) of a hydraulically loaded piston or bellows assembly that receives a pressure signal that is biased as a function of the piston being positioned by the load solenoid. It may also possible to use a series of pivoted levers and springs manipulated by the piston to derive a position feedback signal.
TABLE I
Pivot to Solenoid
Ls = 1.0
Pivot to Trim Spring
Lts = 1.0
Pivot to Orifice
Lo = 1.5
Reference Spring Load
Fr = 10.0
Flapper Orifice Area
Ao = 0.00196 calculated
Flapper Orifice Diameter
Do = 0.05
Servo Pressure
Pr − Po = 150
Solenoid Force
Fsol = Column H calculated
Pivot to Roller
Lr = Column I calculated
Slope (inch per mA)
S = 0.0083 0.0082
Cam Follower Lever Ratio (Lcf/L)
Rcf = 1.36
Cam Follower Lever to Cam
Lcf = 0.952 calculated
Cam Follower to Roller
L1 = 0.7
Cam Slope in Degrees
Angle = 14
mA to Fs Multiplier
Rma = 0.015
TABLE II
Index Lr @
Piston
Index
Piston Travel
mA
Fsol
Lr
mA = 0
Travel
Travel
Required
0
0
−0.044
0
0
0.000
0.00
20
0.3
−0.014
0.03
0.164
0.000
0.00
40
0.6
0.016
0.06
0.327
0.142
0.14
60
0.9
0.046
0.09
0.491
0.305
0.30
80
1.2
0.076
0.12
0.655
0.469
0.47
100
1.5
0.106
0.15
0.818
0.633
0.63
120
1.8
0.136
0.18
0.982
0.796
0.80
140
2.1
0.166
0.21
1.145
0.96
0.96
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A method and apparatus for an electro-hydraulic actuator ( 1 ) having mechanical feedback provide closed loop control with a high degree of accuracy. The electro-hydraulic actuator ( 1 ) includes a current versus load generator ( 10 ), a single-stage servomechanism ( 20, 21, 22, 23 ), and a device ( 24, 25, 40, 41 ) for providing a mechanical feedback force for offsetting an input force (Fsol) of the current versus load generator ( 10 ).
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RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of co-pending U.S. Provisional Patent Application Ser. No. 62/013,690 filed on Jun. 18, 2014.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the construction of subterranean wells. More particularly, the present invention relates to methods and constructions for centering a casing within a well, particularly an oil or gas well.
[0003] A well is a subterranean boring from the Earth's surface that is designed to find and acquire liquids or gases. Wells for acquiring oil are termed “oil wells”. A well that is designed to produce mainly gas is called a “gas well”. Typically, wells are created by drilling a bore, typically 5 inches to 40 inches (12 cm to 1 meter) in diameter, into the earth with a drilling rig that rotates a drill string with an attached bit. After the hole is drilled, sections of steel pipe, commonly referred to as “casings” and which are slightly smaller in diameter than the borehole, are dropped “downhole” into the bore for obtaining the sought after liquid or gas.
[0004] The difference in diameter of the wellbore and the casing creates an annular space. When completing oil and gas wells, it is often important to seal the annular space with cement. This cement is pumped down into the annular space, often flushing out drilling mud. Once the annular space is filled with cement, the cement is allowed to harden to seal the well. To properly seal the well, the casing should be positioned so that it is in the middle or center of the annular space. The casing and cement provide structural integrity to the newly drilled wellbore and provide isolation of potentially dangerous high pressure zones. Thus, centralizing a casing inside the annular space is paramount and critical to achieve a reliable seal, and thus good zonal isolation. With the advent of deeper wells and horizontal drilling, centralizing the casing has become more important and more difficult to accomplish.
[0005] A traditional method to centralize a casing is to attach centralizers to the casing prior to its insertion into the annular space. Most traditional centralizers have tabs, wings or bows that exert force against the inside of the wellbore to keep the casing somewhat centralized. The centralizers are commonly secured at intervals along a casing string to radially offset the casing string from the wall of a borehole in which the casing string is positioned. Centralizers ideally center the casing string within the borehole to provide a generally continuous annulus between the casing string and the interior wall of the borehole. This positioning of the casing string within a borehole promotes uniform and continuous distribution of cement slurry around the casing string. Uniform cement slurry distribution results in a cement liner that reinforces the casing string, isolates the casing from corrosive formation fluids, prevents unwanted fluid flow between penetrated geologic formations, and provides axial strength.
[0006] A bow spring centralizer is the most common type of centralizer. It employs flexible bow springs to provide offset between the casing and wellbore sidewall. Bow spring centralizers typically include a pair of axially-spaced and generally aligned tubular collars that are coupled by multiple bow springs. The bow springs expand outwardly from the collars to engage the borehole sidewall to center a pipe received axially through the collars. Configured in this manner, the bow springs provide stand-off from the borehole, and flex inwardly as they encounter borehole obstructions, such as tight spots or protrusions into the borehole, as the casing string is installed into the borehole. Elasticity allows the bow springs to spring back to substantially their original shape after passing an obstruction to maintain the desired stand-off between the casing string and the borehole. Examples of such bow springs are disclosed in U.S. Pat. No. 4,545,436 and Great Britain Patent No. 2242457 which both disclose casing centralizers having a plurality of bow springs which are connected to first and second collars. The collars surround the well casing, and one or both of the collars slide longitudinally upon the pipe when the bow spring is deformed upon engaging the wellbore sidewall.
[0007] The use of bow spring centralizers presents a number of disadvantages and their installation is problematic. To achieve the desired centralization, bow centralizers are designed so that, prior to installation the bow springs extend beyond the inside diameter (“ID”) of the wellbore. The larger diameter of said bow springs requires them to be refracted from the force of pushing it down inside the casing or wellbore. This causes kinetic friction when slid down the hole (requiring running force) and also static friction when engaging restrictions or obstructions (requiring starting force). This friction is a primary reason that their use is discouraged. Further, the radial configuration of the bow springs causes the spring force of one bow spring to be counteracted by the bow springs on the opposite side of the casing. This results in a restoring force that diminishes as the casing approaches center, making better centralization require greater and greater spring forces. Furthermore, increased spring forces also increases running and starting resistance. Therefore, a balance is sought between the needed forces to centralize the casing and the increased resistance that these spring forces create.
[0008] An additional disadvantage of bow spring centralizers is that the bow springs obstruct the pumping of cement downhole. After being positioned downhole, the bow springs project radially outward from the casing like spokes to engage the wellbore's cylindrical wall. These bow springs can block the proper downward flow of the cement slurry or can create voids in the annular cement structure.
[0009] Various attempts have been made to develop centralizers that overcome some of these problems. U.S. Pat. No. 6,871,706 discloses a centralizer that requires the bending of a retaining portion of the collar material into a plurality of aligned openings, each to receive one end of each bow spring. This requires that the coupling operation be performed in a manufacturing facility using a press. The collars of the centralizer are cut with a large recess adjacent to each set of aligned openings to accommodate passage of a bow spring that is secured to the interior wall of the collar. Unfortunately, the recess substantially decreases the mechanical integrity of the collar due to the removal of a large portion of the collar wall to accommodate the bow springs.
[0010] U.S. Patent Publication 20120279725 and U.S. Pat. No. 7,857,063 describe centralizers that have a minimal radial expansion prior and during the casing's transportation downhole. Only after the casing is in place are the centralizer tabs expanded radially outward. This reduces the amount of friction that the casing string encounters as it is dropped downhole. Furthermore, the tabs extend laterally relative to the pipe's central axis in a manner that minimizes the obstruction to the flow of cement as it is poured downhole. Unfortunately, these centralizers are not suitable for traditional metal well casings that provide minimal radial expansion. Instead, the centralizers are useful only for centralizing tubular members capable of substantial expansion so as to force the centralizer tabs to engage the borehole wall.
[0011] Thus, there is a significant need for an improved casing centralizer that provides reduced friction as the centralizer is transported downhole.
[0012] There is a also a need for an improved casing centralizer that provides increased centralizing force for maintaining a casing in the center of a wellbore.
[0013] Still there is an additional need for an improved casing centralizer that provides minimal impedance to the flow of cement as cement is pumped downhole in the annular space between the casing string and the wellbore wall.
[0014] In addition, there is a need for an improved centralizer that provides reduced manufacturing and installation costs, and provides an improved ease of running the casing string downhole into the wellbore.
SUMMARY OF THE INVENTION
[0015] The present invention addresses the aforementioned disadvantages by providing an improved centralizer for centralizing a pipe downhole in a well. The term “pipe” is intended to be interpreted in the traditional sense as a cylindrical structure having an exterior wall and a central conduit. Furthermore, the term “pipe” is intended to include traditional well casings, casing strings, and casing couplers which connect casings to form a casing string. Moreover, the centralizer of the present invention may be integrated into the pipe so as to include the pipe's cylindrical exterior sidewall and central conduit which defines the pipe's longitudinal axis. Alternatively, the centralizer may include a structure for affixing the centralizer to a pipe, such as for affixing to a pipe immediately prior to the pipe being transported downhole into a well.
[0016] The centralizer of the present invention includes a pair of end collars. Each end collar is tubular and has a center hole for receiving a pipe. The end collars' tubular structure forms a longitudinal axis, and the end collars are positioned to receive a pipe coaxial to the longitudinal axis. The end collars are spaced longitudinally from one another and at least one end collar is capable of sliding telescopically and axially relative to the pipe. In alternative embodiments, both end collars are sized to freely rotate and slide longitudinally upon the pipe. Preferably, the end collars' inside diameter is only slightly larger than the outside diameter of the casing or pipe to be centralized, and it is permissible for one of the end collars to have an inside diameter substantially the same as the outside diameter of the pipe so as to form a press-fit engagement. Mechanical fasteners such as circular bands may be affixed to the exterior of the well pipe so as to prevent the centralizer from sliding from its desired location.
[0017] The centralizer further includes a plurality of longitudinally extending bow springs. The bow springs are elastic members which store mechanical energy so as to exert a resisting force when its shape is changed. Each bow spring has first and second ends wherein a bow spring's first end is affixed to a first end collar, and a bow spring's second end is affixed to a second end collar. The bow springs are arcuate so as to bow outwardly at their middle so as to form a radially extending arch capable of pushing against the inner wall of a wellbore. The bow springs are preferably positioned circumferentially and equally about the end collars so as to centralize a pipe within a wellbore and so as to form a substantially uniform annular space between the pipe and wellbore sidewall. Preferably, the bow springs are made of spring steel. As would be understood by those skilled in the art, radial compression of the bow springs causes the end collars to move longitudinally away from one another. When the source of the compression, such as the wellbore sidewall, is removed, the mechanical energy stored within the bow springs will cause the bow springs to expand radially, and cause the end collars to contract longitudinally.
[0018] The centralizer of the present invention also includes one or more center collars. Like the end collars, the center collar has a tubular structure having a center hole sized to slidably receive the pipe. The center collar is positioned coaxial to the pipe and intermediate to the first and second end collars. Preferably the center collar is capable of rotating about the pipe and sliding longitudinally relative to the pipe. However, where the end collars are capable of sliding longitudinally relative to the pipe, it is permissible for the centralizer's center collar to be affixed to the pipe.
[0019] The centralizer of the present invention includes a linkage assembly that forces the bow springs to move radially and in unison. The linkage assembly includes a plurality of linkage arms wherein each arm has a first end and a second end. Each linkage arm's first end attaches to a center collar and each linkage arm's second end attaches to a bow spring member so that the linkage arms extend radially like spokes from the exterior of the pipe to a bow spring. Each linkage arm extends radially and at least partially longitudinally so that when a bow spring is compressed, the linkage arms can be compressed as well while forcing the center collar to move longitudinally. Preferably, the linkage arms are formed of the same material, such as spring steel, that forms the collars and bow springs.
[0020] In a preferred embodiment, the linkage arms are constructed to bias outwardly in the manner of springs by storing mechanical energy to provide additional force causing the bow springs to be forced radially outward. In alternative embodiments, the leverage arms are affixed to the center collar and respective bow springs by hinges or the like so that the leverage arms do not store mechanical energy and do not function as springs. In either embodiment, spring or hinged, the compression of one or more bow springs radially inward causes the linkage assembly (comprised of the linkage arms) to force the center collars in the longitudinal direction. As would be understood by those skilled in the art, inward compression of a single bow spring causes the corresponding linkage arm to force the center collar in the longitudinal direction, which in turn causes the remaining linkage arms to force the remaining bow springs radially inward.
[0021] The centralizer may be constructed so that the bow springs curve outward so that their at-rest curvature would extend beyond the inside diameter of the intended wellbore so that the bow springs engage and are slightly compressed as the well pipe and centralizer are deposited downhole. However, to reduce running force (frictional resistance between the centralizer and wellbore) the centralizer may be constructed to force the bow springs radially inward to reduce the outer diameter of the bow springs, and to store mechanical energy in the bow springs. Various constructions may be employed. For example, the end collars may be forced longitudinally outward and locked in an extended position utilizing bolts or pins, or other projections, which extend outwardly from the well pipe. Longitudinal extension of the respective end collars causes the bow springs to compress radially inward, which in turn causes the center collar to move longitudinally from its at-rest position.
[0022] In alternative embodiments, the pipe may include locking rings which affix to the pipe for engaging both end collars so to maintain the end collars longitudinally apart. Still additional constructions can be developed by those skilled in the art so as to maintain the end collars in an extended position, with the bow springs compressed radially inward, while still enabling the end collars to extend still longitudinally further.
[0023] In additional embodiments, the centralizer includes spacers which affix to the exterior of the pipe for forcing the linkage arms and bow springs radially inward. In a first embodiment, a spacer is positioned between an end collar and center collar so as to move the center collar longitudinally from its at-rest position. The movement of the center collar causes the linkage arms to be forced radially inward, which in turn causes the bow springs to be forced radially inward. In still an alternative embodiment, the centralizer includes two sets of center collars, and two sets of linkage arms. As the bow springs are compressed, a first center collar moves longitudinally in a first direction, while the second collar moves longitudinally in an opposite direction. To radially retract the bow springs, a preferred centralizer includes a spacer which is positioned between the two center collars so as to move the center collars longitudinally away from one another, which in turn causes the linkage arms and bow springs to move radially inward into a compressed condition.
[0024] Preferably, for each of these embodiments, the bow springs have been forced radially inward to a diameter less than the diameter of the wellbore so as to reduce the running force of the well casing as it is deposited downhole. Advantageously, each of the bow springs have been compressed to store mechanical energy so as to exert an increased restoring force when compressed further by the wellbore diameter decreasing to smaller than the diameter of the centralizer bow springs.
[0025] In still additional embodiments, the end collars and one or more center collars are hinged so as to include at least a first hinge so as to allow the centralizer to open in a clamshell member so as to clamp upon a well pipe. Preferably, each collar includes two diametrically opposed hinges which can open and close by a longitudinally extending set pin. Advantageously, set pins can be removed from one side of the centralizer so as to allow the centralizer to open in a clamshell manner so as to affix to a pipe. Thereafter, the pins can be reinserted so as to affix the centralizer to a well pipe.
[0026] Advantageously, the centralizer has a minimal cross section prior to being transported downhole so as to reduce the friction that the casing encounters as it is transported downhole.
[0027] In addition, the centralizer's center collars and linkage assemblies cause all of the bow springs to act in unison. The collaboration of the bow spring motion creates a compounded spring force that improves centralization. Moreover, the centralizer with bow springs operating in unison prevents a single bow spring from bowing inwardly, without the remaining bow springs moving inward, which would decentralize the well casing.
[0028] Also advantageously, the angle, length, and position of the linkage arms can be varied to provide the bow springs with the desired radial force.
[0029] These and other more specific objects and advantages of the invention will be apparent to those skilled in the art from the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a perspective view of a centralizer including two center collars and hinged linkage arms;
[0031] FIG. 2 is a perspective view illustrating the centralizer shown in FIG. 1 wherein the bow springs have been forced radially inward and the center collars have been moved longitudinally outward;
[0032] FIG. 3 is a perspective view of a centralizer including a single center collar and wherein the end collars and center collar are hinged to allow the centralizer to open in a clamshell manner;
[0033] FIG. 4 is a perspective view illustrating the centralizer shown in FIG. 3 wherein the bow springs have been forced radially inward and the center collar has moved longitudinally upward;
[0034] FIG. 5 is a perspective view illustrating the centralizer shown in FIGS. 3 and 4 wherein a first set of locking pins has been removed so as to allow the centralizer to hinge open to accept the pipe;
[0035] FIG. 6 is a perspective cut-away view of a wellbore including a pipe casing and centralizers as illustrated in FIG. 1 ;
[0036] FIG. 7A is a perspective view illustrating a centralizer shown in FIG. 1 affixed to a well pipe prior to selection and insertion of a spacer;
[0037] FIG. 7B is a perspective view illustrating the centralizer and pipe casing of FIG. 7A wherein the centralizer includes a spacer for forcing center collars longitudinally apart;
[0038] FIG. 8A is a perspective view illustrating a centralizer and well casing including flexible straps for pulling center collars apart;
[0039] FIG. 8B is a perspective view illustrating a centralizer and well casing of FIG. 8A wherein the center collars have been forced longitudinally apart and locked in place utilizing flexible straps;
[0040] FIG. 9A is a perspective view of an additional embodiment of a centralizer wherein the linkage assemblies' linkage arms bias outwardly in the manner of leaf springs;
[0041] FIG. 9B is a perspective view illustrating the centralizer shown in FIG. 9A and illustrating the center collar's linkage arm providing additional force to move the bow springs radially outward;
[0042] FIG. 10A is a perspective view illustrating a centralizer and well casing prior to selection of a spacer in the form of a ring;
[0043] FIG. 10B is a perspective view illustrating the centralizer and well casing shown in FIG. 10A wherein a spacer of medium thickness has been selected;
[0044] FIG. 11A is a perspective view of a centralizer and well casing prior to affixing locking rings to a pipe to force the end collars longitudinally outward;
[0045] FIG. 11B is a perspective view illustrating the centralizer and well casing shown in FIG. 11A wherein the locking rings have been affixed to the well pipe in a manner that caused the end collars to be forced longitudinally apart, and caused the bow springs and linkage assemblies to be forced radially inward, and caused the center collars to move longitudinally apart;
[0046] FIG. 12A is a perspective view illustrating a centralizer and well casing prior to insertion of longitudinal spacers between center collars; and
[0047] FIG. 12B is a perspective view illustrating the centralizer and well casing shown in FIG. 12A wherein longitudinal spacers have been positioned between center collars so as to force the center collars longitudinally apart.
DETAILED DESCRIPTION OF THE INVENTION
[0048] While the present invention is susceptible of embodiment in various forms, as shown in the drawings, hereinafter will be described the presently preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the invention, and it is not intended to limit the invention to the specific embodiments illustrated.
[0049] With reference to FIGS. 1-12B , the present invention is a centralizer 1 for centralizing a pipe 3 , also referred to as a casing or well casing, within a wellbore 5 . The centralizer 1 includes two tubular end collars 9 , each having a center hole 11 sized to receive a pipe 3 . (See FIGS. 6-8 and 10 - 12 ). The end collars 9 are spaced longitudinally relative to one another and are positioned coaxial to the pipe 3 . At least one end collar 9 is capable of sliding longitudinally relative to the pipe 3 .
[0050] The end collars 9 are connected by a plurality of bow springs 17 . Each bow spring 17 includes a first end 19 affixed to a first end collar 9 and a second end 21 affixed to a second end collar 9 . The bow springs bow outwardly at their middle 23 so as to form a leaf spring type construction wherein radial inward compression of the bow spring's middle 23 causes the diameter of the bow springs, and in turn the centralizer, to reduce. This, in turn, causes the bow springs to extend longitudinally to force the end collars longitudinally away from each other. As illustrated in the figures, a preferred centralizer 1 has four bow springs 17 positioned equally circumferentially around the centralizer's central longitudinal axis so as to be positioned at 90° spacing to one another.
[0051] The centralizer 1 also includes at least one center collar 43 . The centralizer's center collar 43 is constructed in a similar manner as the end collar 9 so as to have a center hole 45 for coaxially receiving the pipe 3 . The center collar 43 is positioned and aligned so as to be intermediate the end collars 9 with the center collar's hole 45 coaxial to the end collars 9 .
[0052] Further, the centralizer includes a linkage assembly including linkage arms 31 which structurally connect the centralizer's center collar 43 to the bow springs 17 . Each linkage arm 31 has a first end 33 which affixes to the center collar 43 , and each linkage arm 31 includes a second end 35 which affixes to the bow spring 17 , preferably at approximately the bow spring's middle 23 . As illustrated in FIGS. 1-8B and 10 A- 12 B, the linkage arms 31 may be connected to the bow springs 17 and center collar 43 utilizing hinges 37 which allow the linkage arms to freely pivot where they connect to the bow spring and center collar. Alternatively, as illustrated in FIGS. 9A and 9B , the centralizer may be constructed so that the linkage arms 31 do not freely pivot where they connect to the bow spring and center collar. Instead, for this embodiment, the linkage arms 31 function as springs storing mechanical energy providing additional force against the bow spring's middle 23 .
[0053] Advantageously, the centralizer of the present invention can be constructed in a wide variety of manners. For example, as illustrated in FIGS. 3 , 4 , 9 A and 9 B, a preferred centralizer 1 includes only a single center collar 43 connected to the bow springs 17 by a single set of linkage arms 31 . Alternatively, as illustrated in FIGS. 1 , 2 , 6 - 8 B and 10 A- 12 B, the centralizer 1 may include two center collars 43 , and two sets of linkage arms 31 for connecting to the bow springs 17 . Preferably, the first and second sets of linkage arms are constructed to extend laterally, and longitudinally in opposite directions (not parallel), so that the center collars 43 move longitudinally in opposite directions when the bow springs 17 are compressed radially inward. (See FIGS. 6 , 7 B, 8 B and 10 B).
[0054] Preferably, the centralizer 1 is constructed so that the bow springs 17 relaxed state causes the bow springs' outer diameter 23 to be larger than the wellbore, diameter within which it is placed. However, to reduce the running force of the well casing as it is deposited downhole, it is preferred that the centralizer include one of various mechanisms for displacing the bow springs' radially inward so as to have a diameter smaller than the average diameter of the wellbore. In a first embodiment illustrated in FIGS. 7A , 7 B, 10 A, 10 B, 12 A and 12 B, the centralizer includes a spacer which forces the two center collars 43 axially apart, which in turn causes the linkage arms 31 to pull the bow springs 17 radially inward. For example, in a first embodiment illustrated in FIGS. 7A and 7B , the spacer may be an arcuate structure 51 abc having different sizes. A person using the centralizer downhole may select a smaller spacer 51 a wherein one wants to decrease the diameter of the bow springs slightly, but still maintain a substantially large diameter. Alternative spacers 51 b or 51 c could be selected to increase the longitudinal space 49 between the center collars 43 by selecting larger spacers such as 51 b or 51 c. For example, FIG. 7B illustrates the centralizer 1 of the present invention affixed to a pipe including an intermediate spacer 5 lb for longitudinally separating the center collars 43 . FIGS. 10A and 10B illustrate an alternative spacer 54 abc wherein the spacer is constructed in the form of a ring. A ring of desired thickness, such as a thin ring 54 a or a thick ring 54 c, is positioned between the center collars 43 prior to insertion of the pipe 3 . For example, FIG. 10B illustrates a centralizer and pipe assembly incorporating a spacer 54 b having a medium thickness which forces the bow springs radially inward a greater distance than the small spacer 54 a, but more than the larger spacer 54 c. As would be understood by those skilled in the art, the spacer can take various forms, such as simple longitudinal rods 53 , as illustrated in FIGS. 12A and 12B .
[0055] The bow springs may be forced radially inward utilizing still additional constructions. For example, FIGS. 8A and 8B illustrate a centralizer 1 including a plurality of flexible straps 55 and pins 57 which function as “tension members” so as to pull center collars 43 towards adjacent end collars 9 . In still alternative embodiments, the pipe may be constructed to include mechanical structures, such as projections, which lock the end collars into longitudinally extended positions so as to force the bow springs radially inward. The projections may be simple pins or bolts (not shown) affixed to the pipe's sidewall, which are positioned to maintain the end collars in an extended position. Alternatively, as illustrated in FIG. 11A and 11B , the pipe 3 may include fixed or adjustable ring-like structures 61 which affix to the pipe so as to maintain the end collars 9 in a longitudinally extended condition. Though not shown in the figures, the pipe may include projections, such as pins, bolts, or rings which engage both center collars, or a single center collar and end collar, so as to force the bow springs 17 radially inward.
[0056] In still additional embodiments of the invention illustrated in FIGS. 3-5 , the end collars 9 and center collar 43 include a hinge 13 to allow a centralizer to open in a clamshell member so as to receive a pipe, and thereafter be closed for affixing the centralizer 1 to a pipe 3 . In a preferred embodiment illustrated in FIGS. 3-5 , each end collar 9 and center collar 43 includes two diametrically opposed hinges which can open or close by removal of a longitudinally extending set pin 15 . Removing one side of the set pins 15 enables the centralizer 1 to open or close in a clamshell member. Meanwhile, removal of all set pins permits the centralizer 1 to be separated in half. Removal of either one side of the pins or both sides of the pins permits the centralizer to be affixed to a pipe. Thereafter, the pins 15 can be reinserted into the hinges 13 so as to affix the centralizer 1 to the pipe 3 .
[0057] While several particular forms of the invention have been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. Therefore, it is not intended that the invention be limited to the specific embodiments illustrated. I described my invention in such terms as to enable a person skilled in the art to understand the invention, recreate the invention and practice it, and having presently identified the presently preferred embodiments thereof,
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A centralizer for centralizing a pipe is provided which collaborates the spring force of its bow springs. The centralizer includes a pair of end collars, and at least one center collar. Each of the collars has a center hole for coaxially receiving a pipe. In addition, the centralizer includes a plurality of longitudinally extending and arcuate bow springs having ends which affix to the end collars. The centralizer includes linkage arms which connect the center collar to the bow springs. The linkage arms may provide additional outward spring force against the bow springs. Preferably, the centralizer includes a mechanism for forcing the bow springs radially inward from their at rest position.
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CLAIM OF PRIORITY
The present application claims priority from Japanese application JP 2006-239724 filed on Sep. 5, 2006, the content of which is hereby incorporated by reference into this application.
FIELD OF THE INVENTION
This invention relates to a shelf-like display machine and an image display method, for example, in which shelves or the like installed at stores such as retailers have an image display function.
BACKGROUND OF THE INVENTION
As have been already described in the non-patent document 1 below, there has been provided a proposal of method in which price tags at the shelves in a store such as a retailer shop are changed into electronic forms, prices and information on goods or the like are optionally changed over and they are displayed at the front ends of goods display shelves in a form of electronic paper.
SUMMARY OF THE INVENTION
However, the aforesaid prior art had a problem that it is hard to attain a correspondence between the display part and the goods under a certain arrangement of the goods because the display part with an electronic paper is arranged at a part of the shelf.
Additionally, it was necessary to prepare some special display substrates for changing all the lengths of the shelves into display segments and so their price was expensive. In addition, as shown in FIG. 32 , it was necessary to prepare some signal lines and wirings 902 for supplying a power supply up to display segments 901 and so it was necessary to perform a processing for shielding the wirings with opaque raw material and connecting the wirings whenever the shelves were required to be moved.
In view of the situation as above, this invention provides a shelf-like display machine and an image display method in which an optical path of a light source such as a projector for projecting an image is controlled to display some images at the ends of plural shelf plates.
(1) Plural images (either still images or animations) prepared in response to the number of stages of the shelves to be displayed are projected from the light source after each of the images is corrected in response to the optical path length ranging from the light source to the end of each of the shelves and then each of the images is guided to the end of each of the shelves with plural reflection members and the images are displayed at the aforesaid ends.
More practically, according to one aspect of the present invention, there is provided a shelf-like display machine comprising a light source for outputting an image; a first reflector member for reflecting the image projected from the light source; a first shelf plate and a second shelf plate in which light can be transmitted through their inner portions; a rear member supporting the first and second shelf plates in which light can be transmitted at their inner portions; a second reflection member for guiding the image reflected by the first reflector member and guided through the rear member to the first shelf plate; and a third reflector plate for guiding the image reflected by the first reflector member and guided through the rear plate to the second shelf plate; the image having a first image and a second image, the light source outputting the first image and the second image upon performing a correction processing in correspondence with an optical path length 1 ranging from the light source to the end of the first shelf plate and an optical path length 2 ranging from the light source to the end of the second shelf plate in such a way that the first image is displayed at the end of the first shelf plate opposite to the rear member and the second image is displayed at the end of the second shelf plate opposite to the rear member.
(2) Plural images (either still images or animations) prepared in response to the number of stages of the shelves to be displayed are projected from the light source and the optical path lengths ranging from the light source to the end of each of the shelves are substantially made equal to each other, and then each of the images is guided to the end of each of the shelves by plural reflector members to display the images at the end.
More practically, according to another aspect of the present invention, a shelf-like display machine includes a light source for outputting an image; a first reflector member for reflecting the image projected from the light source; a first shelf plate and a second shelf plate in which light can be transmitted through their inner portions; a rear member supporting the first and second shelf plates in which light can be transmitted at their inner portions; a second reflection member for guiding the image reflected by the first reflector member and guided through the rear member to the first shelf plate; and a third reflector plate for guiding the image reflected by the first reflector member and guided through the rear member to the second shelf plate; and the image has a first image and a second image; an optical path length 1 ranging from the light source to the end of the first shelf plate and an optical path length 2 ranging from the light source to the end of the second shelf plate become substantially the same to each other in such a way that the first image is displayed at the end of the first shelf plate opposite to the rear member and the second image is displayed at the end of the second shelf plate opposite to the rear member.
(3) The present invention provides a method in which when an image is displayed at plural screens arranged in spaced-apart relation, plural regions are extracted from the original image under a similar shape to that of the plurality of screens and while keeping positional relations of the plurality of screens; the plurality of regions are extracted while being scrolled at a predetermined speed in a direction connecting the plurality of regions; each of the regions is enlarged or reduced in such a way that a difference in the magnifying power may be corrected in reference to a difference in optical path length ranging from the light source to each of the screens so as to display the image to each of the screens.
More practically, the present invention provides an image display method for displaying an image on the spaced-apart first and second screens which includes the steps of extracting a first region of which shape is similar to that of the first screen and a second region of which shape is similar to that of the second screen from the image while keeping a positional relation between the first and second screens; extracting the first region and the second region from the image while scrolling them at a predetermined speed in a direction where the first region and the second region are connected, correcting a difference in magnifying power caused by different optical path lengths ranging from a light source for projecting the image to each of the screens and correcting to expand or reduce the first region and/or the second region; and projecting the first region to the first screen and the second region to the second screen.
It becomes possible to display easily images (information such as animations, still pictures, letters or the like) at the end of the shelf-like display machine without preparing any special display substrates and arranging a wiring for every shelf. Additionally, detailed information about goods, for example, can be effectively transmitted to the customers at a store selling goods.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A , 1 B, and 1 C are schematic views for showing one preferred embodiment of the present invention;
FIGS. 2A and 2B show a first image generation method of one preferred embodiment of the present invention;
FIG. 3 shows a second image generation method of one preferred embodiment of the present invention;
FIG. 4 shows a third image generation method of one preferred embodiment of the present invention;
FIG. 5 shows a fourth image generation method of one preferred embodiment of the present invention;
FIGS. 6A , 6 B, and 6 C show a fifth image generation method of one preferred embodiment of the present invention;
FIG. 7 is an illustrative view for showing a size inputting means of a shelf display machine;
FIGS. 8A , 8 B, and 8 C are illustrative views for showing a first image adjustment method;
FIG. 9 is an illustrative view for showing a second image adjustment method;
FIGS. 10A , 10 B, 10 C, 10 D, 10 E, and 10 F show some examples of a reflector member;
FIGS. 11A , 11 B, 11 C, and 11 D show some examples of a display end;
FIGS. 12A , 12 B, and 12 C show some examples of a mechanism for performing a fine adjustment of an optical reflection;
FIG. 13 is an illustrative view for showing a first structure for projecting an image to a location other than the end of a shelf of one preferred embodiment of the present invention;
FIG. 14 is an illustrative view for showing a second structure for projecting an image to a location other than the end of a shelf of one preferred embodiment of the present invention;
FIG. 15 is an illustrative view for showing a third structure for projecting an image to a location other than the end of a shelf of one preferred embodiment of the present invention;
FIG. 16 is an illustrative view for showing a first structure in which optical path lengths in one preferred embodiment are substantially the same to each other;
FIG. 17 is an illustrative view for showing a second structure in which optical path lengths in one preferred embodiment are substantially the same to each other;
FIG. 18 is an illustrative view for showing a third structure in which optical path lengths in one preferred embodiment are substantially the same to each other;
FIGS. 19A and 19B are illustrative views for showing a first structure for projecting an image to the side of a shelf of one preferred embodiment of the present invention;
FIGS. 20A , 20 B, and 20 C are illustrative views for showing a second structure for projecting an image to the side of a shelf of one preferred embodiment of the present invention;
FIGS. 21A , 21 B, 21 C, and 21 D show a first shelf-like display machine provided with a sensor of one preferred embodiment of the present invention;
FIGS. 22A , 22 B, and 22 C show a second shelf-like display machine provided with a sensor of one preferred embodiment of the present invention.
FIGS. 23A , 23 B, 23 C show a third shelf-like display machine provided with a sensor of one preferred embodiment of the present invention;
FIGS. 24A and 24B show a fourth shelf-like display machine provided with a sensor of one preferred embodiment of the present invention;
FIG. 25 shows examples of letters to be displayed at a display end;
FIG. 26 is an illustrative view for showing a first structure for displaying an image at the back of a shelf of one preferred embodiment of the present invention;
FIGS. 27A , 27 B, 27 C, and 27 D are illustrative views for showing a second structure for displaying an image at the back of a shelf of one preferred embodiment of the present invention;
FIGS. 28A and 28B are illustrative views for showing a third structure for displaying an image at the back of a shelf of one preferred embodiment of the present invention;
FIG. 29 is a view for showing a state in which display devices are arranged at the rear of a shelf to display images;
FIG. 30 is a view for showing a state in which a rear projector is arranged at the rear of each of the shelves to display an image;
FIGS. 31A and 31B show an example in which an image is displayed at the back of shelves of one preferred embodiment of the present invention; and
FIG. 32 is an illustrative view for showing the structure of the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
FIGS. 1A to 1C show a side elevational view and a front elevational view of shelves of one preferred embodiment and an example of display of images to be projected to a projector. As shown in the side elevational view of FIG. 1A and the front elevational view of FIG. 1B , light projected from the light source such as a projector 110 projecting an image is reflected upward through a reflector member such as a mirror 111 , the light passes through the rear member constituted by a member with hollow state or characteristic allowing light to be passed through it, the light is reflected again with mirrors 123 , 124 , and 125 arranged at the backs of the shelves 120 , 121 , and 122 having light transparent characteristic (using cavity and member through which light is transmitted, for example) and then the light is projected to the ends 126 , 127 , and 128 of the shelves. Screen raw material for collecting light or dispersing light is applied to the ends of the shelves to enable either letters or images projected by the projector to be projected to the ends. In addition, as described later, the image can be projected onto the ends also by constituting the shelf plates in such a way that when light transmitted at their inner portions to both front and rear of the shelves, the light shows total internal reflection there even if the screen raw material is not used. An image generating device such as a PC 130 or the like is connected to the projector 110 so as to output images including images 141 , 142 , and 143 to be displayed at each of the shelves as shown at 140 in FIG. 1C . In response to whether or not an up-and-down reversal function of the projector is used, it is set whether or not the up-and-down of the image to be sent to the projector is performed. FIG. 1C shows a reversed example. A method for generating an image for each of the shelves will be described later in reference to FIGS. 2 to 5 . The image generating device is connected to the network such as LAN, for example, and it is also applicable that the content of the outputted image is controlled from outside. In addition, arrangement of sensors 150 , 151 , 152 , and 153 also enables an approaching of a person near the shelf or a person's touch at the shelf to be detected and a displayed content to be dynamically changed.
(Image Generating Method)
Then, referring to FIGS. 2 to 5 , there will be described a method for generating an image for each of the shelves to be projected to the projector of the present invention. Although an example in which the number of shelves is three will be described as follows, the number of shelves can be calculated by a similar method whatever numbers may be applied. More practically, this method is carried out by inputting the design values such as shelf height or shelf width (Z 0 a , Z 0 b , Z 0 c , Z 1 a , Z 1 b , Z 1 c , Z 2 a , Z 2 b , and Z 2 c of 201 to 209 in FIG. 2A , for example) and calculating display rectangular areas at each of the shelves to be projected to the projector (H 0 L, H 0 R, V 0 t , V 0 b , H 1 L, H 1 R, V 1 t , H 2 L, H 2 R, V 2 t and V 2 b of 220 to 231 in FIG. 2B , for example).
In order to simplify the description, the optical paths are developed in a straight line as shown at 260 , 261 , and 262 in FIG. 3 and a method for calculating the display rectangular areas will be described as follows. In this case, Z 0 , Z 1 , and Z 2 of 240 to 242 in FIG. 3 can be attained in reference to their design values as follows.
Z 0=( Z 0 a+Z 0 b+Z 0 c )
Z 1=( Z 1 a+Z 1 b+Z 1 c ) Z 0
Z 2=( Z 2 a+Z 2 b+Z 2 c )( Z 0+ Z 1)
In addition, thicknesses Y 0 h , Y 1 h , and Y 2 h of each of the shelves from 250 to 252 and a width Xt ( 270 ) of each of the shelves are also design values.
Then, referring to FIG. 4 , the method for calculating the value in a horizontal direction will be described as follows. That is, drawing regions (H 0 L, H 1 L, H 2 L, H 2 R, H 1 R, H 0 R) of the images to be projected to the end of the shelf are calculated in reference to the design values such as each of the sizes of the shelf (Z 0 , Z 1 , Z 2 : height, Xt: width, θ: image angle ( 280 ) in a horizontal direction of the projector, H: a resolution in a horizontal direction of the projector). At first, when a length in a horizontal direction within the projection range X 0 ( 281 ) of the lower stage is included within a width Xt( 270 ) of the shelf, all the ranges that can be projected are used. At this time, since a relation of X 0 =2*Z 0 *tan θ is formulated, H 0 L=0, H 0 R=H can be attained. Next, since a length X 1 ( 282 ) in a horizontal direction within a projection range in the middle stage is (X 0 +2*Z 1 *tan θ) under application of 283 , it can be attained as H 1 L=H*(Z 1 *tan θ)/X 1 , H 1 R=H H*(Z 1 *tan θ)/X 1 , H 2 R=H H*(Z 1 +Z 2 )*tan θ)/X 1 . Further, since a length X 2 ( 285 ) in a horizontal direction within a projection range in the upper stage is (X 0 +2*(Z 1 +Z 2 )*tan θ) under application of 286 , it can be attained as H 2 L=H*(Z 1 +Z 2 )*tan θ)/X 1 , H 2 R=H H*(Z 1 +Z 2 )*tan θ)/X 1 , H 2 R=H H*(Z 1 +Z 2 )*tan θ)/X 1 .
Next, referring to FIG. 5 , there will be described a method for calculating values of the projector in its vertical direction. That is, drawing regions of image to be projected to the end of the shelf (V 0 t , V 0 b , V 1 t , V 1 b , V 2 t , V 2 b ) are calculated in reference to the design values of the shelf (Z 0 , Z 1 , Z 2 : height, Y 0 h , Y 1 h , Y 2 h : shelf thickness, p: image angle in a vertical direction and Ys( 330 ), Ym( 331 ) got by a mounting angle of the projector. In this case, to make the drawing easier to understand, the illustration is shown with the vertical direction of the optical path being compressed. A length Y 2 ( 310 ) in a vertical direction in a projection range at the upper stage is (Z 0 +Z 1 +Z 2 )/tan φ. A rate among the lengths Y 0 ( 311 ), Y 1 ( 312 ) and Y 2 ( 310 ) when the optical path to be projected to the end of each of the shelf plates is extended and the clearance lengths Yk 2 ( 313 ), Yk 1 ( 314 ), Yk 0 ( 315 ) becomes a rate in a vertical direction of the original image. Each of the distances Ya 1 ( 320 ), Yb 1 ( 321 ), Ya 0 ( 322 ) and Yb 0 ( 323 ) from the center of optical axis in this figure can be attained like Ya 1 =(Ym)*(Z 0 +Z 1 +Z 2 )/(Z 0 +Z 1 ), Yb 1 =(Ym+Y 1 h )*(Z 0 +Z 1 +Z 2 )/(Z 0 +Z 1 ), Ya 0 =(Ym+Y 1 h )*(Z 0 +Z 1 +Z 2 )/Z 0 , Yb 0 =(Ym+Y 1 h +Y 0 h )*(Z 0 +Z 1 +Z 2 )/Z 0 . In addition, since the relations of Y 2 =Y 2 h , Yk 2 =Ya 1 Ym, Y 1 =Yb 1 Ya 1 , Yk 1 =Ya 0 Yb 1 , Y 0 =Yb 0 Ya 0 are attained, and finally, vertical coordinate of the images to be displayed can be attained in reference to the design values, like V 2 b =V V*((Ys/Yt), V 2 t =V V*((Ys+Y 2 )/Yt), V 1 b =V V*((Ys+Y 2 +Yk 2 )/Yt), V 1 t =V V*((Ys+Y 2 +Yk 2 +Y 1 )/Yt), V 0 b =V V*((Ys+Y 2 +Yk 2 +Yk 1 )/Yt), V 0 t =V V*((Ys+Y 2 +Yk 2 +Y 1 +Yk 1 +Y 0 )/Yt.
Next, referring to FIGS. 6A to 6C , there will be described a method for calculating a clipping region in reference to the original image when images such as photographs and illustrations are displayed at a shelf. That is, the regions of original image to be clipped (V 0 c , Y 0 c , V 1 c , Y 1 c , V 2 c and Y 2 c from 401 to 406 in FIG. 6A ) are calculated in reference to the aforesaid design values of the shelf. In this case, each of the vertical and lateral resolutions of the original image (the number of pixels) shall be defined as Vi( 410 ) and Hi( 411 ), respectively. In this case, an aspect ratio displayed at the shelf is X 0 in FIG. 6C : (Y 0 h +Z 1 b +Y 1 h +Z 2 b +Y 2 h ). If it is assumed that a clipping is carried out in such a way that the former aspect ratio is coincided with an aspect ratio Hi: (Y 2 c Y 0 c +V 2 c ) clipped from the original image in FIG. 6A , it can be attained as a relation of (Y 2 c Y 0 c +V 2 c )/Hi=(Y 2 h +Z 2 b +Y 1 h +Z 1 b +Y 0 h )/X 0 . Since an aspect ratio of a lateral rectangle cut of the original image is equal to an aspect ratio displayed at each of the shelves, it can be attained as a relation of V 0 c /Hi=Y 2 h /X 0 , V 1 c /Hi=Y 1 h +Z 1 b +Y 0 h )/X 0 . In addition, since an aspect ratio of a rectangle enclosed by the two clipped rectangles is equal to an aspect ratio of clearance of the shelves, it can be attained as (Y 1 c Y 0 c V 0 c )/Hi=Z 2 b /X 0 , (Y 2 c Y 1 c V 1 c )/Hi=Z 1 b /X 0 . If the value of Y 0 c were determined in reference to the foregoing five equations, the remaining five variables Y 1 c , Y 2 c , V 0 c , V 1 c and V 2 c could be attained. In addition, increasing or decreasing the value of Y 0 c allows the image to be displayed while scrolling the image in a vertical direction.
Next, referring to FIG. 7 , an input screen 450 for the design values will be described as follows. This input screen can be set through PC outputting the images, for example.
Reference numeral 451 denotes a region for inputting the number of shelves and reference numerals 452 , 453 , and 454 denote a region for inputting a height from the lower stage, a region for inputting a shelf thickness and a region for inputting the deep size of a shelf, respectively, and each of them corresponds to Z 0 b , Y 0 h , and Z 0 c . Similarly, reference numerals 455 , 456 , and 457 correspond to Z 1 b , Y 1 h , and Z 1 c and reference numerals 458 , 459 , and 460 correspond to Z 2 b , Y 2 h , and Z 2 c . In this way, the design values are inputted, and the coordinate system for the image to be outputted is calculated with the PC 130 and projected to the projector 110 .
Next, referring to FIGS. 8A , 8 B, and 8 C, there will be described a method for fine adjusting a value of image area displayed at the projector calculated in reference to the design values with a graphical user interface. The screen calculated by the aforesaid method is displayed as shown in FIG. 8A under a state in which the display is connected to the PC 130 connected to a pointing device. Each of reference numerals 141 , 142 , and 143 in FIG. 8A denotes the image display region at each of the upper stage, middle stage and lower stage, and rectangles for rubber band indicated at 501 , 502 , and 503 are displayed at the right lower portion of each of the rectangles. A button for the pointing device is depressed ( 510 ) under a state in which cursors are present on these pointing devices and the cursor position ( 511 ) when the button is released is applied as a coordinate at the right lower portion of a new rectangle ( 512 ). In addition, as shown in FIG. 8C , when the button is depressed ( 520 ) under a state in which the cursor is present within the rectangles 141 , 142 , and 143 and also within the region other than the rectangles for the rubber bands, a difference between the horizontal direction and the vertical direction with respect to the coordinate ( 521 ) of the cursor when the button is depressed is added to the left upper coordinate and the right lower coordinate is applied as a coordinate for a new rectangle ( 522 ). These operations are carried out through a drug-and-drop action of the mouse, for example.
Next, referring to FIG. 9 , there will be described a fine adjustment for a clipping region. On the original image 540 are displayed clipping regions 430 , 431 , and 432 and the rectangles for a rubber band similar to that of FIG. 8 . When the rectangles 530 , 531 , and 532 for the rubber band are selected within the clipping region, a width of the clipping region in a vertical direction is adjusted and when other rectangles are selected, a position of the clipping region in a vertical direction is adjusted. Also in this case, these operations are carried out through a drug-and-drop with a mouse.
(Structure of Shelf-like Member)
Next, referring to FIGS. 10A to 10F , there will be described examples of a structure of the shelf-like member. Requirements necessary for the structure of the shelf-like member of the present invention consist in the fact that light projected from below is reflected at the back of the shelf by about 90° and then projected to the end of the shelf. In FIGS. 10A to 10F , each of the left sides corresponds to the front of the shelf where the image is displayed and each of the right sides corresponds to the back of the shelf where the light is reflected by about 90°. FIG. 10A shows an example in which a screen 602 having a function for dispersing or focusing light is attached to the front of a block 601 such as acryl resin or glass having a high transmittance of light and a mirror 603 is arranged at the back of the block in an inclined state. This structure is manufactured by the simplest manufacturing method. FIG. 10B shows an example in which an end 605 at the back of the block 604 is machined to show a slant surface in place of the mirror and a screen 606 is arranged at the front of the block under utilization of characteristic of total reflection of light at this surface. Since this structure does not show any displacement of the mirror, a re-adjustment by vibration or the like after its correct design is not necessary. FIG. 10C shows an example in which a mirror 608 is arranged at the back lower portion of a transparent or opaque top plate 606 , a rod-like raw material 608 such as acryl resin or glass with a high light transmittance is arranged at the lower portion of the front and a screen 609 is arranged. This structure enables utilization of expensive transparent raw material such as acryl resin or the like to be reduced. FIG. 10D shows an example in which a screen 611 with a frame is arranged at the lower portion of the front of the top plate 601 , and a rod-like raw material 612 of high light transmittance such as acryl resin or glass and the like machined to have a slanted state in respect to the shelf plate surface such as a triangular column or truncated trapezoid column, for example, is arranged at the lower portion of the back of the shelf. Light projected from below shows a total reflection at the slant surface of the acryl resin rod 612 and is projected to the screen 611 . This structure enables a strain of the reflector member to be reduced more as compared with that of a planer-like mirror. FIG. 10E shows an example in which a screen 614 with a frame is arranged at the lower portion of the front of the top plate 613 , and a mirror 615 is arranged at the lower portion of the back of the shelf. This structure does not require at all using an expensive transparent raw material such as acryl resin or the like. FIG. 10F shows an example in which a mirror 617 is arranged at the lower portion of the back of the top plate 616 , a frame 618 for assuring a strength is arranged at the lower portion of the side and a screen 619 with a frame is arranged at the lower portion of the front of the shelf. This structure enables light to be prevented from being leaked out of the side of the shelf plate.
Referring to FIGS. 11A to 11C , there will be described shapes of the shelf. As has been described up to now, it is also possible to apply a shape as follows, for example, in addition to a shelf of cubic-block shape. FIG. 11A shows an example in which an end 630 of the shelf where the image is displayed has a curved surface. When some letters are expressed to scroll at the end in a lateral direction, this structure can provide an effect that the letters are seen to flow in a cubic manner in a forward or rearward direction. FIG. 11B shows an example in which an end 631 is machined into a slant surface and its display area is made wide. This structure improves a visual recognition when the shelf is mounted at a level lower than a customer's point of view, for example. FIG. 11C shows an example in which a band-like screen raw material 632 is partially attached to a block-like transparent raw material 633 so as to project the image in a curved surface shape. This structure can provide an effect that as if the image is displayed in the air. FIG. 11D shows an example in which an incident part 634 for an image is a curved surface and a projecting surface 635 for the image is also a curved surface. This structure enables a strain of the image to be reduced when the image is displayed in a cubic form.
Next, referring to FIGS. 12A to 12C , there will be described a mechanism for use in performing a fine adjustment of reflection of light at the back of a shelf. In FIG. 12A , a shelf 650 is fixed under application of a hinge 652 capable of freely bending a mirror 651 arranged at the back of a shelf 650 . In addition, an angle of the mirror 651 can be adjusted by arranging a spacer 654 between the shelf 650 and a structure 653 supporting the shelf and moving the spacer in a forward or rearward direction. Next, in FIG. 12B , the shelf 655 is placed at the structure 656 for supporting the shelf and then a transparent raw material 657 of triangular column machined to form a slant surface, for example, is connected to the shelf 655 by a fixing tool 658 . The transparent raw material 657 can be turned freely and its reflecting angle can be adjusted. Next, in FIG. 12C , the shelf 659 of transparent raw material machined into a slant shape is placed at the structure 660 supporting the shelf in such a way that its back may be contacted with the ground surface of the structure, and a spacer 661 is arranged at the front of the shelf 659 . A reflecting angle at the back can be adjusted by moving up or down the height of the spacer 661 .
Second Embodiment
Next, there will be described a method for projecting an image to a place other than the end of the shelf-like member. At first, referring to FIG. 13 , there will be described a method for projecting an image to the upper surface of a shelf. FIG. 13 shows a side elevational view and a front elevational view of a shelf. The image projected by the projector 110 is reflected upward by a mirror 111 , passes through a shelf 670 of transparent raw material, is reflected downward by a mirror 671 mounted at the lower portion of the shelf and the image is projected to a screen 672 arranged at the upper portion of the shelf. Projection of the image onto the upper surface of the shelf through this method enables an image to be projected to goods placed on the shelf or the image to be displayed around the goods.
Next, referring to FIG. 14 , there will be described a method for projecting an image to the screen arranged at a shelf in a vertical orientation. The image projected by the projector 110 is reflected by the mirror 111 and the mirror 680 and projected to the screen 681 arranged at the upper surface of the shelf. Projection of an image to a vertical screen by this method enables an image of existing standard of 4:3, for example, to be displayed.
Next, referring to FIG. 15 , there will be described a method for projecting an image to a back between the shelves. A part of the image projected by the projector 110 is reflected by the mirror 111 as described above, reflected by the mirrors 690 and 691 and projected to the screens 692 and 693 at the ends of the shelf. A part of another image is projected to the screens 694 and 695 applied to the surface of a deep part between the shelves. At this time, since an incident angle to the screen 695 is shallow and a view angle from the projector in respect to a projecting area becomes narrow, a resolution of the image to be projected to the screen 695 is decreased. Since an effective resolution is smaller than that of the part projected to the end of a shelf, the resolution can be increased by machining the back 696 of the shelf into a slant surface or widening the depth size, adjusting both position and angle of the mirror 111 and making the incident angle to the screen 695 deeper.
Third Embodiment
Since optical path lengths from the projector to each of the screens are different from each other, the methods described above up to now correct the image projected from the projector so as to correct a difference in magnifying powers caused by the difference in optical path length and perform an output display. In turn, setting the optical path lengths ranging from the projector to each of the screens substantially equal to each other in this preferred embodiment eliminates an image correcting processing. In addition, the preferred embodiment has an effect that the focal point is strictly set for every image because the optical path lengths ranging from the projector to each of the screens are substantially set equal to each other. This situation will be described in detail as follows.
Referring now to FIG. 16 , there will be described a method for changing a depth of a shelf. Image projected from the projector 110 is projected to screens 701 , 702 and 703 at the ends of the shelves in the same manner as described above. The optical path lengths can be set substantially the same to each other by adjusting the depths 704 , 705 , and 706 in such a way that the distances at this time ranging from the projector 110 to the ends 701 , 702 , and 703 of the shelves may become constant.
Next, referring to FIG. 17 , there will be described a method for increasing the number of times of reflection and adjusting an optical path length. A part of the image projected from the projector 110 is reflected by mirrors 711 , 712 , 713 , and 714 and projected to a screen 715 at the end of a shelf. Similarly, another part of the image is reflected by mirrors 721 , 722 , 723 , and 724 and projected to a screen 725 at the end of a shelf. In regard to the upper-most shelf, the image may be projected to a screen 733 at the end of the shelf through twice reflection at the mirrors 731 and 732 in the same manner as described up to now. At this time, the optical path lengths can be set substantially the same to each other by adjusting distances between the mirrors 712 and 713 , and the mirrors 722 and 723 in such a way that the optical path lengths become constant with an optical path length ranging from the projector 110 to the screen 733 .
Referring to FIG. 18 , there will be described a method for aligning focal points by making a surface shape of each of the mirrors mounted at the backs of the shelves. That is, a correction is carried out by changing a curvature of the mirror in response to an optical path length for every shelf in such a way that a focal point is set to the end of each of the shelves. Its structure is similar to that shown in FIG. 1 ; in which when a mirror 740 at the upper-most shelf, for example, is set to have a flat surface, the focal point of the projector is aligned with the end of the upper-most shelf. Next, the surface shapes of mirrors 741 and 742 at other shelves are set to show curved surfaces curved in a vertical direction, thereby a displacement of focal points at the images projected at the end of each of the shelves can be corrected.
Fourth Embodiment
Next, there will be described a method for projecting an image also to the side of a shelf through machining of a shape of the shelf as shown in FIG. 19A . FIG. 19B is a view taken from above the shelf. Both ends of the back of the transparent raw material 750 of the shelf are cut into a triangle shape and each of the mirrors 751 , 752 , and 753 is arranged at the central part and both ends, respectively. The image reflected at the mirror 751 is projected to the front of the shelf and the image reflected by each of the mirrors 752 , 753 is projected to the side of the shelf.
Next, referring to FIGS. 20A to 20C , there will be described a method for projecting an image also to the side of the shelf. FIG. 20A is a view taken from above, FIG. 20B is a view taken from side and FIG. 20C is a view taken from front, respectively. A part of light 754 projected from below is reflected by the mirror 760 and projected directly to the front end of the shelf. Another part 755 is reflected by the mirror 761 , reflected by a surface 762 cut in a slant direction as viewed from above the lower portion, cut in a vertical direction as viewed from a horizontal direction, reflected in a slant upward direction by a surface 763 cut in a slant direction as viewed from the front both ends of the lower portion and projected to a side 764 of the shelf. Although the structure in respect to this method is complex, all the upper surfaces of the shelf can be utilized.
Fifth Embodiment
In order to perform an effective display of information, there will be described a method for detecting that a person approaches to the shelf or the goods are transferred. Referring to FIGS. 21A to 21D , there will be described a method detecting a state of the front of the shelf while a sensor is arranged at the back of the shelf. As shown in FIG. 21A , a bar-code reader 770 is arranged at the back of the shelf, and light of the bar-code reader passes through the inner portion of the shelf of raw material such as acryl resin or glass with a high transmittance. When a goods 771 attached with a bar-code is applied to the front of the shelf, the bar-code reader 770 reads the bar-code of the goods, sends the read value to the PC 130 in FIG. 1 and the related information can be displayed. With such an arrangement as above, a customer at a store applies the goods that the customer is interested in over the end of the shelf at its bar-code portion to allow the customer to review its related information. As shown in FIG. 21B , an infrared ray proximity sensor 772 , for example, is arranged at the back of the shelf, the sensor detects at 733 that a person approaches to the front of the shelf or applies his hand over the front, similarly the sensor transmits it to PC 130 in FIG. 1 and then the corresponded information is displayed. With such an arrangement as above, it becomes possible to perform a separate operation for displaying the letter information assuming that it is read when the proximity sensor is operated and for displaying an image with a better visibility from a far location when the proximity sensor is not operated, for example. In addition, it may also be applicable to change an image to be displayed and a position where the image is displayed in response to at which position in which shelf the sensor is detected. As shown in FIG. 21C , a camera 774 may be used to perform an image processing in place of the proximity sensor. FIG. 21D shows an example in which the camera is mounted below the transparent shelf to detect whether or not the goods are removed from the shelf. When it is detected that the goods are removed from the shelf, this system can be used in such a way that either message or information about the goods is displayed to the person coming to a store.
Next, referring to FIGS. 22A to 22C , there will be described a method in which the end of each of the shelves has a touch panel function. As shown in FIG. 22A , an infrared ray camera with an infrared ray projector is mounted near a location such as a side part of the projector 110 in FIG. 1 so as to attain the image at the end of the shelf in a direction opposite to the optical path facing from the projector to the end of the shelf. When the end of the shelf is touched by a customer, the image having a bright touched portion and remaining dark portions can be attained as shown in FIG. 22B , for example, and it is possible to detect which position in which shelf is touched by the customer. In addition, when an indoor area is fully filled with infrared rays, the image as shown in FIG. 22C cannot be attained unless the infrared ray projector is installed and also in this case, it is possible to detect which position in which shelf is touched by a customer. When it is detected through these methods that the left side in the upper stage is touched, for example, it becomes possible to replace the image displayed at the left side of the upper stage from PC and provide information suitable for a customer coming to a store.
Next, referring to FIGS. 23A to 23C , there will be described a method for managing respective goods through a movable bar-code reader. FIG. 23A is a side elevational view of a shelf, FIG. 23B is a rear view, and FIG. 23C shows an example of goods to which a bar-code is attached. The rear of the shelf is provided with a movable bar-code reader 790 , its position is controlled from PC 130 in FIG. 1 , and a bar code 792 of the goods 791 at this position is read and transmitted to PC 130 . An optical path 793 of light transmitted from the projector 110 , reflected by the mirror 111 and advanced upward is partitioned by either the transparent raw material or formed into a hollow state partitioned by the transparent raw material and then the bar code of the goods 791 can be read from the rear. With such an arrangement as above, since it is possible to check what type of goods are placed at which position in which shelf, information corresponding to the position and the goods can be displayed at the end of the shelf. In addition, information for guiding a customer coming to a store to teach the customer that the desired goods are placed at which position in which shelf can be displayed by displaying either the letters or images indicating a direction such as arrow marks at the end of the shelf. In addition, since the goods can be individually managed, a work such as an inventory can be simplified. Further, the bar code to be attached to the goods is printed at either a tape or seal-like raw material having a capacitor or RFID tag assembled therein, thereby it can be simultaneously utilized as one for preventing any gate-type theft.
Next, referring to FIGS. 24A and 24B , there will be described a method for displaying information about the goods or the like at the end of a shelf when the items such as goods placed on the shelf portion are removed by a customer coming to a store or the like. FIG. 24A shows a state before goods 800 are removed from the shelf, in which general information or information about entire goods, for example, is displayed at an end 801 of the shelf. A RFID tag reader 802 is arranged at the upper surface of a shelf and an RFID tag is attached to the goods 800 . FIG. 24B shows a state just after the goods 800 is removed and what type of goods is removed is detected with RFID tag reader 802 . Individual information about the removed goods is displayed at the surface 803 of a shelf to enable detailed information about the goods removed by a customer coming to a store to be displayed.
Next, referring to FIG. 25 , this figure shows an example of letters to be displayed at the end of a shelf. Reference numeral 810 denotes information such as prices of the goods placed on the shelf that corresponds to the conventional price tags. Reference numerals 811 and 812 denote displays about an advertisement of the goods concerned. Reference numerals 813 , 814 , and 815 denote displays about a store promotion that indicate the number of points, recruitment of members and thanks messages for customers coming to the store or the like. Reference numeral 816 denotes a display for use in visually guiding a traffic line for a customer coming to a store. Reference numeral 817 denotes a display indicating the position of goods. Reference numeral 818 denotes a display for use in guiding a customer coming to a store to an escaping path at the time of emergency. Reference numerals 819 , 820 , 821 , and 822 denote examples for displaying information attracting the interest of a customer coming to a store, for example, weather forecast, news, horoscope and music played in the store or the like.
Sixth Embodiment
Next, there will be described a method enabling a customer to see an image at the end of a back of a shelf, i.e. the image from the end of a shelf under application of characteristic of total reflection through the transparent raw material such as acryl resin or glass or the shelf enclosed by mirrors at its upper and lower sides, separate from the aforesaid method for displaying an image at the end of a front of a shelf in its dispersed or light collected state. FIG. 26 shows its configuration. Nothing is arranged at the front of the transparent raw material 830 such as an acrylic block, a screen raw material 831 is attached to the acrylic block at the back of a shelf and there is provided a mirror 832 reflecting the image from below to the screen raw material and projecting it.
FIGS. 27A to 27D show side elevational views of shelves to show a positional relation between the back screen and a position of point of view. As shown in FIG. 27A , when the point of view is sufficiently far from a shelf and placed at the same height of the shelf, an image of the back screen 840 can be seen as it is. As shown in FIG. 27B , looking at a point of view 841 near to some extent shows that light is totally reflected at the upper part and lower part of the shelf, a part of the light can be seen in a correct opposite state and another part of the light can be seen under its upside down state. As shown in FIG. 27C , looking at a point of view 842 sufficiently near the end of the shelf, light is reflected by plural times at the upper and lower sides of the shelf, it is possible to see an image where plural images at the screen 843 are repeated like a kaleidoscope, for example. As shown in FIG. 27D , even in the case that the point of view 844 is seen at the height different from the shelf, light is reversed at the upper and lower sides of the shelf and the image can be seen.
FIGS. 28A and 28B are views taken from above the shelf and show a positional relation between the back screen and the position of point of view. It is possible to see the image projected to the back screen in response to a reflecting characteristic inside the shelf as well as in the case that the point of view 850 is placed at the front of the shelf as shown in FIG. 28A and in the case that the shelf is seen from the slant point of view 851 in the same manner as that of the side.
FIG. 29 shows an example in which the effect described in reference to FIGS. 27 and 28 is embodied under application of a display device such as a liquid crystal display or a plasma display in place of projecting an image at the end of the shelf by the projector and the mirror. The back of the shelf is provided with a display 860 and its front is provided with a shelf plate 861 of transparent raw material such as acryl or glass.
FIG. 30 shows an example using a rear projection system in place of the aforesaid display device. The back of the shelf is provided with a screen raw material 870 and its front is provided with a shelf 871 of transparent raw material such as acryl. The image projected from a projector 872 is projected by the mirror 873 to the screen 870 .
Different images are displayed at the end of the shelf and the back of the shelf as shown in FIG. 31A under application of the methods in FIG. 29 and FIG. 30 described above, it is possible to see the image 880 displayed on the end of the shelf as if it is floated up as shown in FIG. 31B .
It can be utilized as a shelf-like display machine capable of effectively transmitting information on goods to a store visiting customer at the store selling goods.
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The prior art in this field had a display portion of electronic paper at a part of a shelf and showed a problem that the display portion and the goods were hardly co-related to each other in response to the arrangement of the goods. In view of the foregoing, plural images arranged in response to the number of stages of the shelves to be displayed are irradiated with a light source after each of the images is corrected in correspondence with the optical path length ranging from the light source to the end of each of the shelves, each of the images is guided to the end of each of the shelves by plural reflector members and then the images are displayed at the ends. In addition, each of the images is guided to the end of each of the shelves by plural reflector members and the images are displayed at the ends after plural images (either still images or animations) arranged in response to the number of stages of shelves to be displayed are irradiated by the light source and the optical path lengths ranging from the light source to the end of each of the shelves are set to be substantially the same to each other.
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FIELD OF THE INVENTION
This invention relates generally to the field of internal combustion engines and more particularly to the cooling systems used to control the heat generated by such combustion engines. Most particularly, this invention relates to thermostats used to control the flow of the coolant between an engine and a heat exchanger such as a radiator.
BACKGROUND OF THE INVENTION
Thermostats have been known and used extensively to control the circulation of coolant in internal combustion engines. In the past, the thermostats have taken the form of valves which are immersed in the coolant in, for example, a coolant conduit. Most commonly the valves include a valve member which spans the conduit and sits against a valve seat. Thus, in the closed position the valve substantially blocks the flow of coolant, for example, to the radiator, allowing the coolant to re-circulate past the engine and to heat up more quickly.
Typically such valves include a closed body containing a thermally expandible material such as wax. A piston is provided which is thrust outward upon the expansion of the wax due to higher coolant temperatures. The piston lifts the valve off the valve seat to allow the coolant to circulate past a heat exchanger, such as a radiator. This lowers the temperature of the coolant and removes heat from the engine. A spring is provided to urge the valve to a closed position so that in the resting or cooled state the valve is closed. Thus, when an engine is first started, the valve will be closed allowing the engine to attain its optimum running temperature more quickly.
Thermostats, to date, have been designed to permit the engine to operate over time at a constant optimum temperature. The thermostat accomplishes this by opening a valve in the cooling system when the engine temperature, and thus the liquid coolant temperature, rises. Opening the valve permits more flow to a heat exchanger such as a radiator, permitting more heat to be dissipated, which in turn can lower the engine temperature. As the engine temperature drops, and thus the coolant temperature drops, the valve closes, reducing the amount of heat dissipated and again maintaining an optimum operating temperature.
Such prior art thermostats are effective, simple and reliable, but suffer from several drawbacks. One is that the thermostat essentially requires the engine designer to set one optimum engine temperature. However, in practice, the engine operating temperature is known to affect engine performance. Specifically, a hotter running engine produces less in the way of emissions, by permitting more complete combustion which in turn improves fuel economy. A hotter running engine will deliver less power, while a cooler running engine delivers more power. Thus, any single optimum engine temperature is a compromise between power and emissions.
Another drawback is that thermostats are slow to respond. The coolant temperature change is fairly gradual and since the change in coolant temperature controls movement of the piston, the valve only opens slowly. Essentially the response of the thermostat lags the engine demand and thus acts as a dampened system. For example, it might take the thermostat 12 minutes to respond in winter when the engine start is very cold, and about 5 minutes in summer where the engine start temperature is warmer. Sharp changes in engine temperature which arise and then recede quickly are not well managed by the thermostat. However, such sharp changes may occur, for example during acceleration from a stop, when accelerating to pass, or when climbing a hill. Therefore there has been an effort to develop a thermostat which responds, on demand, rather than simply following coolant temperature. Of course, the thermostat still needs to reliably respond to coolant temperature changes in a manner which prevents overheating.
Various levers and actuators have been proposed to open and close valve elements on demand, but these suffer from various disadvantages. Firstly, they are relatively expensive. Secondly, they involve complex moving parts, which can fail over time. A failed system could lead to overheating and failure of the engine, which is unacceptable. Thus, electromechanical systems are inappropriate for the under the hood environment.
U.S. Pat. No. 4,890,790 and its related U.S. Pat. No. 4,961,530 disclose a better thermo-mechanical solution with a thermostat which is more responsive than one limited to responding to coolant temperature only. This patent teaches a first thermostat 40 located in the usual position within a coolant conduit and then a second thermostat like device 52 (called a thermal motor) located outside of the conduit and being insulated therefrom. The device 52 includes the same element as a thermostat as previously described, namely a closed body, a thermally expandible material within the body and a piston which can be extended in response to a temperature rise in the thermally expandible material. However, rather than the coolant temperature governing the degree of extension, the device 52 includes a small electrical heater within the closed body which can be used to heat the expandible material to in turn cause a piston to extend. The pistons of device 52 and the regular thermostat are made coaxial so that when the electrically controlled piston extends, the valve of the thermostat is lifted off the valve seat. The patents teach that in this way the valve can be opened in response to engine parameters such as load or the like measured by other sensors and the coolant allowed to circulate before the heat builds up in the engine. This ability to control the opening of the valve is said to virtually eliminate customer complaints of engine overheating and improves fuel economy and reduces emissions.
While a reasonable solution in some respects, this prior art device still suffers from numerous drawbacks and has not found widespread acceptance. For example, the thermal motor 52, although insulated from the coolant, projects, somewhat exposed, into the under the hood compartment. The air temperature of the under the hood environment can vary widely, depending upon outside temperature, and further can be quite hot when the engine reaches steady state operating temperatures, up to about 25% higher than the coolant temperature. Such a wide temperature range for the operating conditions of the thermally activated motor make it difficult to predict how much heat is needed from the electrical heater to cause the motor to move. Worse, the device 52 might be activated by the ambient temperature without even being controlled by the engine control system, which is unacceptable.
Further, connecting the piston of the device 52 to the thermostat piston coaxially magnifies the effect of the two thermally activated pistons systems since their movements are cumulative. This makes the valve opening and closing overly sensitive and difficult to reliably control. What is believed to happen in practice is that the valve will tend to open too much and then close too much and to essentially oscillate about the desired set point in an undampened manner. Such oscillation is hard on the components and renders the desired temperature less of the time, making the device less efficient rather than more efficient. What is needed therefore is a simple and reliable way of providing accurate temperature control for an internal combustion engine which responds both to the coolant temperature, which is responsive to engine load and which avoids these problems.
SUMMARY OF THE INVENTION
What is needed therefore is a controllable thermostat system which on the one hand is readily controlled by an engine control system to permit rapid response to short duration peak loads and yet which still responds in a safe and reliable way to changes in coolant temperature to prevent overheating. In this way, in the event the device ever fails, the thermostat portion will still be active to prevent engine overheating. Further the system should be made from inexpensive components which are reliable, safe and simple to install. The system should respond appropriately and not for example be susceptible to changes in operating environment causing the device to undesirably initiate, nor should the device be too sensitive and tend to overshoot in an undampened way any desired set point temperature. Further, the device should permit the engine temperature to be lowered on demand, to deliver more power, but also let the engine operate at high temperatures, to reduce emissions. The device should also respond rapidly to permit the engine temperature to be reduced, for example, within a time horizon of a real time loading event of an engine.
Therefore, according to a first aspect of the present invention there is provided, an apparatus for controlling a temperature of an engine by controlling a flow of a liquid engine coolant, the apparatus comprising:
a thermostat having a temperature responsive valve for substantially blocking and substantially unblocking the flow of said liquid coolant to a radiator, said thermostat having a first temperature activation range;
a thermally activated actuator operatively connected to said valve, said actuator having a second temperature activation range above said first temperature activation range; and
a source of electrothermal energy for activating said actuator to cause said temperature responsive valve to unblock the flow of said liquid coolant on demand.
According to a further aspect of the invention there is provided a method of controlling a temperature of an engine having a coolant circulation system comprising the steps of:
a) providing a thermally activated actuator;
b) providing a thermostat having a fixed thrust surface and an openable valve including by a valve body;
c) operatively connecting said thermally activated actuator to said valve body of said thermostat;
d) monitoring said engine to determine when to open said valve; and
e) opening said valve by activating said thermally activated actuator in response to said engine monitoring.
According to a further aspect of the invention there is provided an apparatus for controlling a temperature of an engine, said apparatus comprising:
a thermostat having a thermally controlled valve which opens to a first position in response to a coolant temperature, said first position corresponding to a first rate of coolant flow sufficient for maintaining an optimum engine temperature;
a thermally controlled actuator for opening said valve to a second position, said second position corresponding to a second rate of coolant flow sufficient to permit said engine to cool to a power delivering temperature below said optimum temperature; and
a heater associated with said actuator, said heater being initiated when additional power is required.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to drawings which depict, by way of example only, preferred embodiments of the invention and in which:
FIG. 1 is a front cross-sectional view of the present invention in place in a coolant conduit with the valve closed;
FIG. 2 is a side cross-sectional view of the invention of FIG. 1;
FIG. 3 is a top cross-section along lines A—A of FIG. 2;
FIG. 4 is a front cross-sectional view of the present invention in place in a coolant conduit with the valve open in a first mode;
FIG. 5 is a side cross-sectional view of the invention of FIG. 4;
FIG. 6 is a front cross-sectional view of the present invention in place in a coolant conduit with the valve open in a second mode; and
FIG. 7 is a side cross-sectional view of the invention of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An apparatus for controlling a temperature of an engine by controlling a flow of liquid engine coolant as illustrated generally as 10 in FIG. 1 . The apparatus includes an end cap 12 , and a main body 14 which defines a fluid conduit 16 . The main body 14 includes an attachment flange 18 having a pair of opposed fastener openings 20 for attaching the device 10 onto the cooling system of, for example, a vehicle. An O-ring 22 is provided to permit a liquid tight seal to be made between the part 10 and the remainder of the engine system. Although a particular configuration for end caps and main body is shown, it will be appreciated that various forms of fitting could be used without departing from the present invention.
Associated with the end cap 12 is an instrumentation package including a pair of electrical leads 24 which are connected to a fitting 26 external to the conduit 16 . A retaining ring 28 is associated with the instrumentation package 26 which includes an O-ring 30 to provide a liquid tight seal with respect to liquid in the conduit 16 . The retaining ring 28 is preferably formed with a sloped surface 32 for interfacing with the O-ring 30 .
Electrical leads 24 are most preferably connected to an electrical circuit controlled, for example, by an Engine Control Module (ECM). Typically an ECM will include a plurality of sensors which are used to sense various engine and vehicle parameters so the performance of the engine can be optimized. The present invention comprehends either using existing sensors, if appropriate and available, or using added sensors to provide the ECM with sufficient information to take advantage of the present invention as described herein.
Extending below the retaining ring 28 is a body 34 of the device which includes a closed portion 36 which forms a reservoir for a thermally expandable material (not shown), an extension 38 and a piston 40 . It will be noted that the reservoir 36 , extension 38 and piston 40 extend into the conduit 16 and in normal full coolant conditions would be surrounded by coolant fluid. The reservoir 36 , extension 38 and piston 40 may be considered to be an actuator, as explained below.
The top part 12 is secured to the main body 14 by being threaded for example, at 42 . Again, an O-ring 44 may be used to provide a secure liquid tight connection, between the top part 12 and main body 14 .
Also shown in FIG. 1 is a conventional thermostat 50 which includes a body 52 containing a thermally expandable material, a mounting bracket 54 , a valve 56 , a spring 58 extending between the mounting bracket 54 and the valve 56 , and a piston 60 . Also shown in FIG. 1 is a receptacle 80 into which piston 60 fits. The receptacle 80 is fixed in place and thus acts as a thrust surface for piston 60 . Also shown is a chamfered valve seat 82 against which the valve 56 seals. An important characteristic of the valve seat 82 is that the opening is sized and shaped so that the further displaced the valve 56 is from the valve seat 82 , the greater the flow of coolant to the heat exchanger, up to a maximum flow rate. The operation of these components is explained in more detail below.
Located in the middle of the conduit 16 is a connecting apparatus which includes a load transfer member 83 having a spring 84 extending between a ledge 86 shown in FIG. 1 and a ledge 88 shown in FIG. 2 . The member 83 operatively connects the actuator with the thermostat 50 . Again the operation of these elements will be described in more detail below.
Turning to FIG. 2, a cross-sectional view through the element 80 is now visible, showing that the element 80 extends outwardly from the side wall of the conduit 16 and thus permits the piston 60 of thermostat 50 to push there against as a thrust surface or point. Also shown is the support bracket 54 being lodged in downwardly dependent arms 90 fixed to main body 14 which locate the thermostat 50 in place. It is most preferred if the arms 90 are sized and shaped to fit into the coolant conduit located below main body 14 for ease of assembly. It will be noted that the conduit 16 includes a Y-connection 100 which will permit coolant to circulate to a radiator (not shown). Thus arrow 102 shows location of a radiator, and arrow 104 shows the inflow of coolant into conduit 16 from the engine (not shown). Arrow 105 shows the coolant not passing past valve 56 , which in this FIG. 2 is closed.
FIG. 3 shows a cross-sectional view from above of the elements of FIG. 2 along section line A—A. In particular, the main body 14 is shown forming a conduit 16 having a receptacle 80 for the piston 60 . Also shown is the load transfer member 83 extending on either side of the receptacle 80 . The load transfer member 83 is sized and shaped to be guided by an outer surface of the receptacle 80 . Other forms of load transfer member may be used, but reasonable results have been obtained with the form of member 83 as shown.
Returning to FIG. 2, also shown is an electrical heater 110 which extends downwardly into the closed portion 36 of body 34 . The electrical heater 110 is attached by means of insulated leads 112 which in turn form part of the instrumentation package 26 . It will be understood that other types of electrical connections can be made, provided that the ECM is operatively connected to the heater 110 .
FIG. 2 shows the position of the valve 56 when the coolant and engine are cold. In this circumstance, the valve 56 is tightly placed against the valve seat 82 blocking the flow of coolant from the engine to the radiator. This permits the coolant to recirculate past the engine allowing the engine to achieve its desired operating temperature more quickly (shown at 105 in FIG. 2 ).
Turning now to FIGS. 3 and 4, it can be seen that the valve 56 has moved off the valve seat 82 . At this time the temperature of the coolant has reached the activation temperature of the thermally expandable material in thermostat 50 causing it to expand and thereby causing the piston 60 to extend. Since the piston 60 abuts a thrust surface in the receptacle 80 , the extension of the piston 60 from the body 52 forces the valve 56 downwardly away from the valve seat 82 compressing the spring 58 . In this position the coolant can flow past the valve 56 and out into the radiator through the limb 100 of the conduit as shown by arrows C. It will be noted from FIG. 4 that although the valve 50 has opened, the load transferring member 83 has not moved and as a result a gap 120 exists between the load transfer member 83 and the valve 56 . In the event coolant temperature drops below the thermal activation point for the thermostat 50 , the spring 58 will cause the valve 56 to close onto the valve seat 82 , thereby reducing heat dissipation and preserving the engine temperature at the optimum set point temperature.
According to the present invention, it is preferred if the temperature activation range of the thermostat 50 is above the normal range for mass produced vehicles. Thus, where typically a thermostat will be set to begin to respond at a temperature of between 90° C. and 95° C., in the present invention the preferred activation temperature is between about 100° C. to 105° C. Most preferably the temperature activation range will begin at about 102° C. and be complete at about 10° C. higher at about 112° C. This temperature range is referred to as a first activation range. When the temperature of the coolant reaches 112° C. for example, the valve 56 will be displaced from the valve seat a distance D 1 . D 1 is defined as a distance which is enough to permit the engine to operate at the desired set point steady temperature. This amount of cooling can be achieved with coolant circulation flows of about 1 to 2 cubic meters per hour for a typical mid-sized car. Of course other types of cars or trucks will have different engine heat loads requiring different ranges of coolant flow. As explained in more detail below, the valve position for temperature maintenance at the optimum engine temperature is preferably not a fully open position of the valve 56 . Rather, the valve position at D 1 is such that enough coolant flow is allowed to achieve temperature maintenance. It will be further understood that an engine operating over a temperature range of 102° C. to 112° C. for a steady state temperature is running significantly hotter than a conventional system. This encourages more complete combustion, less emissions and a greater fuel economy. It is estimated that the fuel savings could be between one and two percent, or even higher depending upon the specifics of the engine.
FIG. 6 shows the configuration of the present invention when the piston 40 is extended. Piston 40 will be extended upon the engine control module sending a signal to the heater 110 causing the heater to rapidly heat up and in turn cause the thermally expandable material in the actuator to expand. As noted previously, this will occur as a result of particular conditions existing in the engine load, such as an acceleration or other circumstance which creates a need for more power, and hence more cooling. Heat from the heater 110 has the effect of pushing the piston 40 outwardly causing it to push load transferring member 83 downwardly. The load transferring member 83 transfers the load from the piston 40 to the shoulders of the thermostat 50 , causing the valve disk 56 to be displaced away from the valve seat 82 . Again, this permits the coolant to circulate past the thermostat 50 shown as arrows C and to the radiator through the leg 100 . As can be seen in FIGS. 6 and 7, the extension of the piston 40 compresses the spring 84 . Further, the extension of the piston 40 causes the piston 60 to move within the receptacle 80 creating a gap shown at 130 . Again, the valve 56 is displaced of the valve seat 82 but this time by a distance D 2 . According to the present invention D 2 is a distance sufficient to permit much greater flow of coolant past the valve than occurs at D 1 and is enough coolant flow to permit the engine temperature to be lowered, rather than held at a steady state, which is accomplished at position D 1 . Further, the lowering of the temperature is preferred to occur rapidly, within a time horizon of a loading event meaning that the coolant flow should be sufficient to achieve rapid cooling of the engine, if possible. Most preferable D 2 permits a coolant flow rate of about 8 to 12 cubic meters of flow per hour for a conventional mid sized car. As will be appreciated by those skilled in the art, other car types and other engine sizes may require more or less coolant flow. Thus D 2 will represent a further open position than D 1 . One method to achieve this according to the present invention is to cause the piston 40 to extend more or further when activated than the piston 60 extends when it is activated. However, other methods may also be used to achieve the same result of providing a greater cooling capacity by means of the actuator than the thermostat 50 .
Also according to the present invention the thermally expansible material responsible for extending piston 40 will be set to a different or second temperature activation range from the first temperature activation range responsible for extending piston 60 . Most preferably, the second temperature activation range will be significantly higher than the first temperature activation range of the main thermostat and may be, for example, about 25° C. higher. For example, thermally expansible material in the actuator responsible for extending piston 40 could be set to respond to about temperatures of 125° C. to 127° C. Since this second range is well above the first range, the piston 40 will never be caused to extend by reason of the coolant temperature alone. Quite simply, the operative range of the thermally expansive material in the actuator is above the actuation temperature range of the thermostat 50 . Thus, by normal operation the thermostat 50 will prevent the coolant from ever being able to get as high as the actuator initiation temperature. In this manner, the actuator is only activated as a result of electrical output from the electrical heater contained within the closed body 56 or by a direct command from the ECM.
It has been found that a rapid extension of the piston 40 can be achieved by choosing a heating element for heater 110 which heats to a temperature significantly higher still, for example to about 150° C. Also, it is preferred if the response is fast. This will permit the temperature of the thermally expansive material to reach expansion temperature much more rapidly. Of course, the temperature cannot be so high that it damages any of the components, especially the thermally expansive material. Thus, according to the present invention, a signal to heat the heater will quickly raise the temperature to cause the piston 40 to extend. A response time of under 10 seconds is preferred, and about 6 seconds has been achieved to date, but even better performance may be possible.
As will also be appreciated, as well as rapid heating of the thermally expansive material, rapid cooling of the engine is required if the needed power boost is to be delivered within the event time horizon. To this end the valve 56 must be able to be opened more, under the increased power situation, than in a steady state condition, to permit greater coolant flow.
Thus, another aspect of the present invention is that the movement range of the valve 56 from the thermostat 50 corresponds to flow rates of 1 to 2 m 3 per hour. However, because of the size and shape of the valve opening between valve 56 and valve seat 82 , the piston 40 opens the valve 56 more corresponding to a flow rate of about 10 m 3 per hour. In this way rapid cooling is provided, enough to lower the temperature of the coolant to well below normal operating temperatures, such as for example to about 70° C. to 80° C. Such a low engine temperature will increase power.
According to the present invention, the body 36 is located on the cold side of the valve 56 . The body 56 is completely surrounded by coolant which means that the temperature of the body 56 will be kept within the relatively small dynamic range of coolant temperatures. This means that the electrical energy required to heat the thermally expansible material in the body 36 will be restricted to a fairly narrow range thus permitting a more accurate and timely extension of the piston 40 . In other words, by providing the body 36 in the coolant, the coolant acts as a temperature buffer which in turn ensures that the piston 40 is more reliably and more quickly extendable by the electrical heater 110 .
For example, the body 38 will already be at the coolant temperature, because it is immersed therein. Thus, for steady state operation, the thermally expandible material will be essentially preheated to the running temperature of between 102° C. to 112° C. for example. In this way, there is a smaller thermal gap to overcome allowing more prompt heating, and extension of piston 40 . The initiation temperature of the material in body 38 can be any temperature, but is preferably a higher temperature and most preferably is a temperature which is higher enough to prevent unwanted extension of the piston by ambient conditions.
A further aspect of the present invention is that since it is surrounded by coolant, once the engine control module stops sending electrical energy to the heater, the coolant will have the effect of quickly cooling down the body 36 . The then occurring difference in coolant temperature and the temperature of the actuator will be large leading to more rapid cooling. Specifically, the actuator through piston 40 opens the valve 56 and permits the rapid cooling of the engine due to higher flow rates. This will lower the temperature of the engine and coolant to a lower temperature (which delivers a correspondingly higher power). Again, by way of example only, for a mid sized conventional car a preferred power delivering temperature is between 70 and 80 degrees C. and most preferably about 75 degrees C. Thus shortly after the heater in the actuator is initiated, the engine coolant temperature will also be about 75 degrees. Since the heater heats up to about 150 degrees as previously stated, the temperature difference is large between the thermally expansive material and the coolant (about 75 compared to between 140 and 150) and thus the thermally expansive material of the actuator is rapidly cooled by reason of the large temperature difference.
Quick cooling causes the piston 40 to retract relatively rapidly as well. This will permit the piston 60 to engage the receptacle 80 at the appropriate degree of openness for the valve 56 for that coolant temperature. In the example of a temperature of 75 degrees the valve 56 of thermostat 50 may be for example fully closed if the power delivering lower temperature occurred over a long enough period to permit the piston 60 to fully retract from its steady state position.
It will also be appreciated that the load transferring member 80 extends between the top piston 40 and the body of the thermostat 50 . Thus, as the top piston 40 extends the valve 56 is opened by movement of the body of the thermostat 50 . As the coolant temperature reduces as a result of the actuator opening the valve 56 , the thermostat 50 will react in a normal manner retracting the piston 60 . However, because the piston 60 is spaced from the thrust seat 80 by the load transfer member 83 , the position of the piston 60 will not influence the position of the valve 56 relative to the valve seat 82 . In this manner, the effect of the electronically controlled actuator valve opening is not cumulative, nor subtractive, of the effect of the coolant temperature thermostat valve opening. Rather the two effects are separate and independent. Thus, the temperature of the coolant can be set according to engine load since the valve can be opened immediately and by an appropriate signal from the ECM on demand.
It can now be appreciated that the valve 56 can be made to open enough to cause temperatures of coolant which are lower than the range of the normal operating temperatures set by a conventional thermostat. In circumstances where more power is required, it may be desirable to lower the temperature to a power delivering temperature. This can be accomplished simply by the engine control module energizing the electric heater in the actuator. In this case the valve can be opened to permit the temperature to be lowered and a burst of power to be delivered. Alternately, it is also known that a higher set point temperature permits the engine to operate with reduced emissions, at better fuel economy but with reduced power. This compromise has resulted in lower operating temperatures than might otherwise be desirable to reduce emissions. The actuator of the present invention permits engine operation at a higher running temperature for the purpose of reducing emissions, because any power loss can be compensated for on demand as explained above.
It will be appreciated by those skilled in the art that the foregoing description relates to preferred embodiments of the invention by way of example only. Various modifications and alterations of the invention have been suggested above and others will be apparent to those skilled in the art which still fall within the scope of the appended claims. For example, although the difference in initiation temperature between the upper and lower portions is preferred to be about 25°, any range of temperatures can be used provided that the actuator initiates at a temperature higher than the thermostat so that the actuator does not open the valve in an unintended fashion.
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An apparatus for controlling a temperature of an engine by controlling the flow of a liquid engine coolant to a radiator is disclosed. The apparatus includes a thermostat having a thermally responsive valve for substantially blocking or opening the flow of coolant to the radiator to maintain the engine at or about a preferred engine operating temperature. Also included is a thermally activated actuator for opening the valve in response to an engine condition such as load or a need for power. The actuator is activated at a temperature different than the thermostat. A source of electro thermal energy is provided to motivate the actuator so the valve may be opened on demand. In one aspect the invention provides a method of controlling the temperature of the engine by opening the valve in response to engine monitoring.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a golf club and, more particularly, to a structure of the clubhead designed to improve the hitting feel of the "irons".
2. Description of the Prior Art
One representative of the golf club of the prior art is disclosed in U.S. Pat. No. 3,995,865. The golf club disclosed is formed on its front side with a face providing a ball hitting surface and on its bottom with a flat sole. The construction of the golf club is completed by connecting a shaft to the neck or hosel.
In shorter irons such as Nos. 8 and 9 clubs, the conventional clubhead having the flat sole will make the golf player feel difficult to hit through the ball and is accordingly accompanied by the problem of the "poor through feel". With the shorter irons, specifically, the player will make a swing to hit down the ball with such a smaller radius of gyration as to spin the ball. With the flat sole described above, the resultant weak reaction of the ground would cause the swung clubhead to be dragged by the turf so that the hitting speed would drop. With longer irons such as Nos. 3 and 4 clubs, on the other hand, the player will make a swing to hit up the ball with such a larger radius of gyration as to hit it away. This "hitting up" swing will not need any strong reaction of the shorter irons from the ground but should make the clubface front impinge upon the ball. This makes it desirable to position the lower edge of the clubface as low as possible.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a set of golf clubs, of which the shorter irons are allowed to hit through the ball with less drag whereas the longer irons are allowed to position the lower edges of the clubfaces as low as possible to confront the ball accurately.
According to a major feature of the present invention, there is provided a set of golf clubs, of which the irons have their loft angles decreasing inversely proportionately to the lengths of shafts and their grounding edges formed on their soles such that they are swept back or regressed inversely proportionately to the lengths of the shafts.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will become apparent from the following description taken with reference to the accompanying drawings, in which:
FIGS. 1 and 2 show a first embodiment of the present invention, in which FIGS. 1(A) to 1(G) are sections showing Nos. 3 to 9 irons and FIGS. 2(A) and 2(B) are sections showing the used states of the Nos. 3 and 9 irons, respectively;
FIGS. 3(A) to 3(G) are sections showing Nos. 3 to 9 irons according to a second embodiment; and
FIG. 4 is a section showing a third embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described in the following in connection with its first embodiment with reference to FIGS. 1 and 2.
FIGS. 1(A) shows a No. 3 iron 2 which has a shaft 1 of a predetermined length. The iron 2 has its head 3 formed on its front side with a face 4 having a predetermined loft angle θ and on its bottom with a sole 5. On the back of the clubhead 3, there is formed a balancing recess 6 for adjusting the centroid (or center of mass) of the clubhead 3. At one side of the head 3, there is integrally formed a neck (or hosel) 7 to which is connected the clubshaft 1.
A grounding edge 8, at which the head 3 grounds at first when the No. 3 iron is swung, is formed in the shape of a ridge on the sole 5 of the head 3. The grounding edge 8 is located in the position of about 2/9 of a sole width W 1 from the (not-numbered) leading edge of the face 4, extending longitudinally on the sole 5.
In the head 3A of a No. 4 iron 2A equipped with a shaft 1A having predetermined length and loft angle θ 1 , as shown in FIG. 1(B), the grounding edge 8A is formed in the position of about 3/9 of the width W 2 of a sole 5A from the leading edge of a face 4A.
Likewise, in the heads 3B, 3C, 3D and 3E equipped with shafts 1B, 1C, 1D and 1E having predetermined lengths and loft angles θ 2 , θ 3 , θ 4 and θ 5 , as shown in FIGS. 1(C) to 1(F), respectively, the grounding edges 8B, 8C, 8D and 8E are formed in the respective positions of about 4/9, 5/9, 6/9 and 7/9 of the widths W 3 , W 4 , W 5 and W 6 of soles 5B, 5C, 5D and 5E.
In the head 3F of a No. 9 iron 2F equipped with a short shaft 1F having a loft angle θ 6 , as shown in FIG. 1(G), the grounding edge 8F is formed in the position of about 8/9 of the width W 7 of a sole 5F.
Thus, in case the No. 3 iron 2 having the long shaft 1 is swung, as shown in FIG. 2(A), i.e., in the case of a small angle of incidence α with respect to ground surface, the grounding edge 8 is located at a closer or leading side to the face 4 so that the swing can be made to hit the ball (not shown) away. Moreover, the face 4 has its lower edge positioned at a lower position so that it can confront the ball accurately when the iron 2 is swung to hit up the ball. In case, on the other hand, the No. 9 iron 2F having the short shaft 1F is swung, as shown in FIG. 2(B), i.e., in the case of a large angle of incidence β with respect to the ground surface, the grounding edge 8F is located at a farther or trailing side from the face 4F so that the swing can be made with less drag. With the grounding edge 8F being swept back, specifically, the reaction obtainable from the ground when the ball is hit down is so high that the head 3F can hit through the ball while receiving an upward reaction from the ground.
As described above, the grounding edge 8 of the No. 3 iron 2 having the longer shaft 1 is positioned closer to the face 4 so that the face 4 can have its lower edge displaced closer to the ground to confront the ball accurately. Thus, it is possible to provide the No. 3 iron 2 which can be easily swung to hit up the ball. On the other hand, the grounding edge 8F of the No. 9 iron 2F having the shorter shaft 1F is swept back apart from the face 4F so that the upward reaction obtainable when the ball is hit down is high. Thus, it is possible to provide the No. 9 iron 2F which can be swung to hit through the ball. In addition, the Nos. 4 to 8 irons 2A, 2B, 2C, 2D and 2E are also allowed to exhibit graduated performances between the Nos. 3 and 9 irons 2 and 2F.
FIG. 3 shows a second embodiment of the present invention, in which the same portions as those of the foregoing first embodiment are designated at the common reference characters while omitting their descriptions. As shown in FIG. 3(A), the grounding edge 8 of the No. 3 iron 2 having the long shaft 1 is located in the position of about 0.1 W 1 of the sole width W 1 from the leading edge of the face 4. Likewise, as shown in FIGS. 3(B) to 3(E), respectively, the grounding edges 8A, 8B, 8C, 8D and 8E of the Nos. 4 to 8 irons 2A, 2B, 2C, 2D and 2E are located in the respective positions of about 0.19 W 2 , 0.272 W 3 , 0.344 W 4 , 0.410 W 5 and 0.469 W 6 of the sole widths W 2 , W 3 , W 4 , W 5 and W 6 .
Moreover, the grounding edge 8F of the No. 9 iron 2F having the short shaft 1F is located in the position of about 0.522 W 7 of the sole width W 7 from leading edge of the face 8F.
Thus, the Nos. 3 to 9 irons 2, 2A, 2B, 2C, 2D, 2E and 2F have their respective grounding edges 8, 8A, 8B, 8C, 8D, 8E and 8F located in a geometric progression. With these locations, the No. 3 iron 2 having the longest shaft 1 has its grounding edge 8 displaced closer to the face 4 so that its face 4 can become liable to confront the ball accurately. On the other hand, the No. 9 iron 2F having the shortest shaft 1F has its grounding edge 8F swept back to hit through the ball.
Turning to FIG. 4 showing a third embodiment of the present invention, the golf club 2 is modified to establish no slope on the sole 5 at the back side of the grounding edge 8.
Incidentally, the present invention should not be limited to the embodiments thus far described but can be modified in various manners. For example, the grounding edges of the clubheads may be swept back by 1 mm. Moreover, the heads may be made of not only steel or wood but also an aluminum or titanium alloy. In the heads, still moreover, there may be combined face members and back members having larger specific gravities than those of the former.
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A set of golf clubs, has irons with their loft angles decreasing inversely proportionately to the lengths of shafts and their grounding edges formed on their soles such that they are swept back or regressed inversely proportionately to the lengths of the shafts. Thus, the longer irons for hitting up the ball are allowed to have their faces confront the ball accurately, and the shorter irons for hitting down the ball are allowed to have their faces hit it through.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to marine seismic surveying. In particular aspects, the invention relates to systems and methods for conducting a reflection seismic survey.
[0003] 2. Description of the Related Art
[0004] Seismic exploration is used to survey subterranean geological formations to determine the location of hydrocarbon formations within the earth. Reflection seismology is used to estimate the properties of the subsurface from reflected seismic waves. In reflection seismology, generated acoustic waves (i.e., shots) are propagated down through subterranean strata and reflect from acoustic impedance differences at the interfaces between various subterranean strata. Because many commercially viable hydrocarbon formations are located beneath bodies of water, marine seismic surveys have been developed. Marine seismic survey systems have been described in, for example, U.S. Pat. No. 6,026,059 issued to Starr.
[0005] The presence of background noise and multiple seismic signals tends to cover up the desired signals (traces) which reveal actual subsurface geological structure. As a result, it has become conventional to enhance the desired traces by collecting multiple signals having the same common mid-point (CMP). “Fold” quantifies the number of seismic traces that are recorded at a given CMP. Higher fold generally improves data quality as the traces are summed together such that the primary signal is enhanced by in-phase addition while ambient noise and interference are reduced. In 3-dimensional surveys, data is gathered by taking all seismic traces from an area around each CMP and assigning these traces to a “bin,” which is a discrete rectangular area of the surface area being surveyed. A 3-dimensional “image” of the subterranean structure can then be modeled from the bin data.
[0006] In a typical ocean bottom seismic survey system, a source vessel tows a source array through a body of water. The source array contains a number of seismic sources, such as air guns, which can create a seismic signal as known in the art. The source array produces seismic signals (shots) that are propagated down through the water and into the strata beneath the sea floor. As the seismic signals encounter the various subterranean strata, they are reflected back and are detected by one or more seismic receiver devices which record the signals and permit them to be analyzed. In an ocean bottom 3D seismic survey, it is typical to have a plurality of seismic recorders incorporated into an ocean bottom cable that is disposed in a linear fashion along the sea floor.
SUMMARY OF THE INVENTION
[0007] The present invention provides an ocean bottom seismic 3D survey system which includes a plurality of seismic signal receivers that are disposed in one or more linear arrays upon the sea floor. A source vessel tows a single or plurality of seismic source arrays in the water above the receivers. The source array is towed in a pattern of substantially parallel source lines that intersect the arrays of receivers. In preferred embodiments, the source lines are substantially perpendicular to the linear receiver arrays. Further, in preferred embodiments, the source lines of the pattern have variable, unequal lengths. At least one of the source lines has a first length, and at least one of another of the source lines has a second length that is less than the first length.
[0008] In a currently preferred embodiment, the invention features a survey pattern made up of a series of source lines having three unequal lengths: long, intermediate, and short. In a further aspect of the present invention, it is preferred that the source lines in the pattern occur in a particular sequence. A currently preferred sequence for the source lines is long-intermediate-short-intermediate. In a further currently preferred embodiment, the long source line is four units in length, the intermediate source line is three units in length, and the short source line is two units in length.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For detailed understanding of the invention, reference is made to the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings in which reference characters designate like or similar elements throughout the several figures of the drawings.
[0010] FIG. 1 illustrates an exemplary marine survey system.
[0011] FIG. 2 is a representation of an exemplary prior art survey source line pattern.
[0012] FIG. 3 illustrates the use of seismic sources and a receiver to image a relatively shallow target point.
[0013] FIG. 4 illustrates the use of seismic sources and a receiver to image a relatively deep target point.
[0014] FIG. 5 illustrates an exemplary survey source line pattern for a single swath of data acquisition in accordance with the present invention.
[0015] FIG. 6 depicts an exemplary cross-spread plot for a single fold of data.
[0016] FIG. 7 is a graph depicting the offset distribution of a single cross-spread.
[0017] FIG. 8 is a graph depicting traces obtained and the offset distances of those traces according to four different exemplary source line survey patterns.
[0018] FIG. 9 depicts the use of two swaths of the survey pattern depicted in FIG. 5 in a rollover used to image an adjacent target area.
[0019] FIG. 10 is a plan view of a larger target area made up of a number of overlapping survey patterns.
[0020] FIG. 11 is a plan view of an alternative survey pattern in accordance with the present invention.
[0021] FIG. 12 is a plan view of a further alternative survey pattern in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIG. 1 depicts an exemplary marine seismic survey system 10 which includes a source vessel 12 which is moving through a body of water 14 above a sea floor 16 . FIG. 1 depicts two subterranean strata 18 , 20 which underlie the sea floor 16 ; although those of skill in the art will recognize that typically there are a large number of such strata in any given instance. A seismic receiver cable 22 is disposed upon the sea floor 16 and, as shown in Prior Art FIG. 2 , includes a number of individual seismic receivers 24 , such as hydrophones, geophones, or similar devices of a type known in the art, for detecting a seismic signal and thereafter recording the signal or transmitting the signal to a distal storage device.
[0023] The source vessel 12 is towing a source array 26 in the water 14 . The source array 26 incorporates a number of seismic sources 28 . The seismic sources 28 are typically air guns of a type known in the art for producing a suitable acoustic signal which can propagate downwardly through the water 14 and into the strata 18 , 20 below. In FIG. 1 , there are nine seismic sources 28 . However, those of skill in the art will understand that this is merely by way of example, and that there may be more or fewer than nine.
[0024] As the source vessel 12 moves through the water 14 , the seismic source array 26 is repeatedly actuated to create a series of acoustic signals at known intervals that propagate downwardly and are partially reflected off of the strata 18 , 20 and the interfaces between the strata and are received at the receiver cable 22 . FIG. 2 is a plan view depicting an exemplary cross-spread survey pattern which might be used by the survey system 10 in order to obtain data relating to the strata 18 , 20 beneath the sea floor 16 . The dashed line 30 illustrates an exemplary path that the source vessel 12 could take above the seismic receiver cable 22 while activating the seismic sources 28 to produce seismic data relating to the formations below the sea floor 16 proximate the cable 22 . The path 30 includes a plurality of substantially parallel source lines 32 separated by turns 34 . It is noted that the source lines 32 are substantially equal in length. The source vessel 12 would travel in the direction indicated by the arrows 36 .
[0025] More frequent and shorter source line lengths are useful for obtaining good imaging of relatively shallow targets. FIG. 3 is a schematic drawing depicting the surveying of an exemplary relatively shallow target point T 1 , which is located at approximately 2000 feet below the sea floor 16 . Seismic rays 38 that originate from seismic source points S 1 and S 2 have short offset distances with respect to the receiver R and at least a portion of this seismic ray 38 will reflect back to the receiver R substantially along line 41 . Seismic rays 40 that originate from seismic source points S 3 and S 4 have longer offset distances, and, as a result, are likely to refract off the target point T 1 (as depicted by dashed line 42 ) rather than be reflected back to the receiver R. Therefore, the seismic rays 40 do not produce useable traces. The inventors have recognized, then, that for shallower targets, traces with longer offsets are less useful than those with shorter offsets and which are positioned substantially over the target point. Further, when using a longer source line length and a shallow target, most of the useful data is acquired when the seismic source points are located in relatively close proximity to a point directly above the target point T 1 .
[0026] FIG. 4 illustrates the instance of imaging a deeper target (T 2 ). Target point T 2 is at a deeper location, for example, 20,000 feet below the sea floor 16 ) than target point T 1 . Seismic rays 38 originating from seismic source points S 1 and S 2 will be largely reflected back to the receiver R 1 , R 2 , respectively. Because there is a more acute angle of approach to the deeper target point T 2 , a significant portion of seismic rays 40 originating from seismic source points S 3 and S 4 will also be reflected back toward receivers R 3 and R 4 along lines 41 . Therefore, there are more usable traces for deeper targets since traces with both short and long offsets provide useful data.
[0027] FIG. 5 illustrates an exemplary survey pattern 44 for a source vessel and towed source array conducted in accordance with the present invention. It will be understood by those of skill in the art that the pattern 44 depicted in FIG. 5 may represent a portion of a larger survey pattern having a larger number of source lines. FIG. 5 depicts a pair of substantially parallel receiver lines 46 and 48 . The receiver lines 46 , 48 are each made up of a plurality of individual seismic receivers 50 which are arranged in substantially linear arrays. In one embodiment of the present invention, the receivers 50 are autonomous receivers, often known as “nodal” receivers, of a type known in the art and which are operable to detect and record acoustic energy on-board. In another embodiment of the present invention, the seismic receivers 50 are receivers, of a type known in the art, that will detect acoustic energy and then transmit it to a distal, typically surface-based recorder via telemetry. The receiver lines 46 , 48 are preferably deployed along the sea floor 16 , as described earlier. Also, the receivers 50 are preferably spaced in a substantially equidistant manner from one another along each of the receiver lines 46 , 48 . The survey pattern 44 depicts the path to be taken by a source vessel towing an array of seismic sources, as previously described. The source vessel tows the seismic array in the direction of arrows 52 in a series of substantially parallel and linear source lines 53 which are connected by turns 54 , which are located at the linear ends of adjacent source lines 53 . FIG. 5 depicts an exemplary pattern 44 wherein the source lines 53 are oriented in a generally orthogonal, or perpendicular, manner to the orientation of the receiver lines 46 , 48 . However, it is also contemplated that the source lines 53 could be oriented to intersect the receiver lines 46 , 48 at a non-perpendicular angle, such as a 45 degree angle with respect to the direction of orientation of the receiver lines 46 , 48 . However, other angles of intersection (i.e., 30 degrees, 50 degrees, etc.) may also be used. A target zone 56 to be surveyed and imaged by the acquisition of seismic data by the survey pattern 44 is illustrated generally by boundary lines in FIG. 5 .
[0028] It can be seen from FIG. 5 that not all of the source lines 53 are of the same length. In accordance with the present invention, at least two of the source lines 53 are of different lengths. FIG. 5 depicts a currently preferred embodiment wherein the survey pattern 44 includes source lines 53 a that are of a first, longer length and source lines 53 b, which have a length that is shorter than the first length. Currently preferred embodiments also include source lines 53 c that are of an intermediate length that is greater than the length of the shorter source line 53 b, but shorter than the length of the longer source line 53 a. In further preferred embodiments of the present invention, the lengths of the different source lines 53 a, 53 b, 53 c are related as multiples of a particular unit length such that the long source line 53 a is four units in length, the short source line 53 b is two units in length, and the intermediate source line 53 c is three units in length. Using a unit length of 3,000 meters as an example, the long source lines 53 a would be 12,000 meters in length, the intermediate source lines 53 c would be 9,000 meters in length, and the short source lines 53 b would be 6,000 meters in length. It is noted that the source lines 53 a, 53 b, 53 c have been intentionally positioned so that the last shot point of any given source line 53 a, 53 b or 53 c is at the same cross-line position (i.e., perpendicular to the receiver lines 46 , 48 ) as the first shot point of the next source line 53 a, 53 b or 53 c to be recorded. This provides for a minimum distance traveled by the source vessel 12 between the end of any shot line and the beginning of the next shot line, resulting in maximum efficiency of recording operations.
[0029] In another aspect of the present invention, it is currently preferred that the length of the source lines are related to the interval between the receiver lines 46 , 48 . Interval 55 , depicted in FIG. 5 , is the distance between the two receiver lines 46 , 48 . In presently preferred embodiments, the length of the short source line 53 b is a certain minimum of an even multiple of the interval 55 . In a further preferred embodiment, the short source line is at least four times the length of the interval 55 . For example, if the interval 55 were 100 meters, the short source line 53 b would be 400 meters in length or more. Using source line lengths that are an even multiple of the number of receiver lines 46 , 48 , multiplied by the interval 55 between the receiver lines 46 , 48 ensures that the fold of coverage produced is consistent between adjacent swaths of coverage.
[0030] It is further currently preferred that the source lines 53 a, 53 b, 53 c occur in an order within the survey pattern which permits alternating coverage of opposite sides of a central target area by the intermediate source lines 53 c. In a currently preferred pattern 44 illustrated in FIG. 5 , a source vessel follows a path wherein it traverses a long source line 53 a followed by an intermediate length source line 53 b and then a short source line 53 b. Next, the vessel traverses an intermediate length source line 53 b, a long source line 53 a and an intermediate length source line 53 b, and then the pattern is repeated.
[0031] As the pattern 44 is traversed by a source vessel 12 , the seismic source array 26 is activated to create a series of acoustic energy shots in accordance with a predetermined scheme. This scheme may be based upon timed actuation of the seismic source array 26 , GPS-determined location of the vessel 12 , speed of the vessel 12 , or in accordance with other suitable actuation schemes known in the art. Reflected acoustic energy from the target zone 56 is then detected by the seismic receivers 50 of the receiver lines 46 , 48 .
[0032] FIG. 6 illustrates a graph that is representative of a single cross-spread fold of data between the seismic source line 32 / 53 and a single receiver line 22 or 46 . The area of common midpoint coverage is indicated by the square 60 . The square 60 is made up of a number of smaller squares, commonly known as bins, 62 , as is known in the art. The intersection 64 between the source and receiver lines 32 / 53 , 22 / 46 represents the location of the shortest offset distance between a seismic source 28 and receiver 24 . Therefore, bins 62 a in that area will be those with the shortest offset distance. On the other hand, those bins, such as 62 b, proximate the outer periphery of the square 60 will have the longest offset distances.
[0033] One consequence of a conventional cross-spread geometry for obtaining seismic data is that many more long offsets are recorded in each full fold bin as compared to short offsets. FIG. 7 depicts the offset distribution of a single cross-spread, by percentage, as taken along a long source line, such as source line 53 a. As can be seen, the majority of traces have an offset that is 4000 meters or more in length. The inventors have recognized that longer offsets, while useful in providing geological data relating to deeper and intermediate depth targets, are less effective in providing useful data for shallower targets.
[0034] FIG. 8 is a graph which illustrates the number of traces obtained and the offset distances of these traces according to four different exemplary survey patterns. The first survey pattern is depicted by the dashed line 66 is a pattern which employs a source line length of 12,000 meters. This pattern requires a time of 6.0 hours to complete surveying of a hypothetical target zone. The second survey pattern is depicted by the dashed and dotted line 68 in FIG. 8 . The second survey pattern utilizes a source line length of 9,000 meters. The second survey pattern 68 requires a survey time of 4.7 hours for the same target zone. The second pattern 68 requires a shorter survey time than the first survey pattern 66 , which is desirable. However, the second survey pattern 68 excludes traces having longer offset distances. There are no traces with offset distances longer than around 13,500 meters. As a result, imaging for some deeper targets is sacrificed.
[0035] A third exemplary survey pattern is depicted by the dotted line 70 in FIG. 8 . The third survey pattern uses a survey source line length of 6,000 meters. The third pattern requires a survey time of only 3.4 hours. However, the medium and long offset lengths are missing, with the longest offset lengths being slightly over 11,000 meters.
[0036] The fourth survey pattern is an exemplary survey pattern which is currently preferred in accordance with the present invention, and it is depicted by the solid line 44 in FIG. 8 . The survey pattern 44 is also depicted in FIG. 5 . The source line lengths in the fourth survey pattern 44 are in a sequence of 12,000 meters followed by a source line of 9,000 meters, then a source line of 6,000 meters, and then a source line of 9,000 meters. These sequences then repeat for the balance of the survey being conducted. This survey pattern requires a survey time of 4.7 hours to conduct. All of the patterns depicted in FIG. 8 provide a significant number of traces with a relatively short offset distance (i.e, less than 6,000 meters). The inventors consider the survey pattern 44 to be preferred since it provides a relatively short survey time (4.7 hours) while providing a mixture of traces having short and long offset lengths without excluding long offset length traces. In addition, the flatness of the curve for survey pattern 44 shows that a more even distribution of offset lengths (as among short, intermediate and long) is provided.
[0037] The order of the source lines in the preferred survey pattern 44 is advantageous since it provides relatively balanced lateral coverage of the survey area. Referring once again to FIG. 5 , it can be seen that an equivalent amount of intermediate source line offset length is provided on each lateral side portion 72 , 74 of the area defined between the receiver lines 46 , 48 and the outer boundaries of the target area 56 . There are portions of the source lines 53 and three turns 54 located in the lateral side portion 72 in FIG. 5 , and there are portions of source lines 53 and three turns 54 located in the opposite lateral side portion 74 . There is also substantially equivalent coverage of the target area 56 by longer offset distance traces on each of the distal lateral side portions 76 , 78 which lie outside of the target zone 56 . There are portions of source lines 53 a and 53 c in each of these side portions as well as three turns 54 in each.
[0038] Following the completion of the survey pattern 44 , the receiver lines 46 , 48 are relocated to a second, adjacent location on the ocean bottom 16 . Thereafter, the survey pattern 44 is conducted again in this adjacent location. FIG. 9 depicts an exemplary swath rolling technique wherein the receiver lines 46 , 48 are moved from their initial locations (designated by 46 , 48 in FIG. 9 ) to locations 46 a, 48 a, respectively, after the initial survey pattern 44 has been completed. After movement of the receiver lines 46 , 48 to the new locations 46 a, 48 a, a second survey pattern 44 a is then conducted. The new locations 46 a, 48 a are preferably based upon the interval distance 55 between the two receiver lines 46 , 48 . The distance that the receiver lines 46 , 48 are moved (the “rollover distance” 57 ) is preferably twice the interval distance 55 . For example, if the interval 55 is 100 meters, then the swath rolling distance 57 should be 200 meters. This results in a uniform layout of receiver lines.
[0039] The second survey pattern 44 a is preferably identical to the first survey pattern 44 . As can be seen from FIG. 9 , the second survey pattern 44 a overlaps and is interleaved with the first survey pattern 44 . The patterns 44 , 44 a are overlapping since the source lines 53 a, 53 b and 53 c of the second pattern 44 a extend onto and overlap the first pattern 44 . The patterns 44 , 44 a are also interleaved since the source lines 53 a, 53 b and 53 c of the second pattern 44 a are located laterally between the source lines 53 a, 53 b and 53 c of the first pattern. As a result, coverage is optimized.
[0040] As FIG. 10 illustrates, the survey pattern and swath rolling process is repeated with the receiver lines 46 , 48 being moved in both the cross-line direction 82 and in-line direction 80 . FIG. 10 depicts further subsequent locations 46 a, 48 a, 46 b, 48 b and 46 c, 48 c for the receiver lines 46 , 48 . Locations 46 a, 48 a and 46 b, 48 b are subsequent locations in the cross-line direction 82 while the locations 46 c, 48 c are exemplary subsequent locations in the in-line direction 80 . In FIG. 10 , a larger scale survey area is shown which is made up of a number of individual survey patterns 44 , 44 a, 44 b and 44 c which are double overlapped by virtue of being overlapping and interleaved. It will be appreciated that having a number of contiguous survey areas will result in imaging of a larger area.
[0041] FIGS. 11 and 12 depict two alternative survey patterns in accordance with the present invention. FIG. 11 illustrates an exemplary survey pattern 90 which includes first, long source lines 92 , intermediate length source lines 94 and short source lines 96 . In a preferred embodiment, the long source line 92 is three units in length, the intermediate length source line 94 is two units in length, and the short source line 96 is one unit in length. As an example, if the unit length is 2000 meters, the long source line 92 would be 6000 meters, the intermediate length source line 94 would be 4000 meters in length, and the short source line would be 2000 meters in length. A currently preferred order for the sequence of the source lines 92 , 94 , 96 in the survey pattern 90 is: a long source line 92 , intermediate length source line 94 , short source line 96 , and then an intermediate source line 94 . However, there are also other sequences for the source lines 92 , 94 , 96 which would also be effective and yield good imaging results. For example, the source lines could be sequenced as: long 92 , long 92 , intermediate 94 , short 96 , intermediate 94 , long 92 , long 92 , intermediate 94 , short 96 , intermediate 94 , and long 92 . In another example, the source lines could be sequenced as: long 92 , intermediate 94 , short 96 , short 96 , short 96 , intermediate 94 , and long 92 .
[0042] FIG. 12 illustrates a further exemplary survey pattern 100 in accordance with the present invention. The survey pattern 100 includes first, long source lines 102 , intermediate length source lines 104 , and short source lines 106 . In a currently preferred embodiment, the long source line 102 is eight units in length, the intermediate length source line 104 is five units in length, and the short source line 106 is two units in length. A currently preferred order for the sequence of the source lines 102 , 104 , 106 is: a long source line 102 , three short source lines 106 , and an intermediate length source line 104 . Thereafter, the sequence is repeated. There are other sequences for the source lines 102 , 104 and 106 which could also be used to yield good imaging results. For example, the source lines 102 , 104 , 106 could be sequenced as long 106 , intermediate 104 , short 102 , intermediate 104 , and long 102 .
[0043] Those of skill in the art will recognize that numerous modifications and changes may be made to the exemplary designs and embodiments described herein and that the invention is limited only by the claims that follow and any equivalents thereof.
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A method for acquiring three-dimensional seismic data for sub-surface geologic features wherein a seismic source array is moved along a survey pattern having a plurality of source lines of unequal lengths that are substantially parallel to each other and intersect a receiver line. The survey pattern can be repeated in an overlapping and interleaved fashion to survey a larger area.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates in general to the field of label removal methods and apparatus and in particular to methods and apparatus for cutting a slit in a pressure sensitive label attached to a slender glass vessel
[0003] 2. Description of the Prior Art
[0004] Various reasons exist to remove adhesively applied labels to glass vessels or vessels. One particular need is in the pharmacological field. Typically, pharmaceutical vessels or vessels comprise glass ampoules, syringes, and cartridges (needless syringes) that may, for example contain a single application of a medicine to be injected by a syringe into a patient. Again typically, but not necessarily, the ampoules, syringes or cartridges comprise a small diameter, slender vessel having a length relatively large as compared to the vessel diameter.
[0005] Such vessels are typically wrapped with a printed pressure sensitive label that is usually transparent and made from a plastic film. In most instances the label ends that are parallel to the axial axis of the vessel overlap each other by a relatively small amount, perhaps 10 to 20 percent of the vessel diameter. In one method to remove the pressure sensitive label, the initial step is to cut, actually slit, the label lengthwise, i.e. along the length of the vessel. The advent of a slit edge provides for a starting location to begin the process of removing the label
[0006] The type of slit to be cut can vary from one that simply cuts the label in a direction perpendicular to the surface of the vessel or one that provides a space between the slit ends along the periphery of the vessel's surface. The latter type is more preferred in that a discrete edge is made available that can be advantageously used in the process of label removal.
[0007] Therefore, what is needed are methods and apparatus for slitting a pressure sensitive label that is affixed to a slender glass vessel such that the label cab be more easily and efficiently removed. The present invention is directed to the process of making a spaced slit along the length of a pressure sensitive label attached to a slender glass vessel and accordingly achieves the aforesaid goal.
[0008] The above-stated objects as well as other objects which, although not specifically stated, but are intended to be included within the scope of the present invention, are accomplished by the present invention and will become apparent from the hereinafter set forth Detailed Description of the Invention, Drawings, and the Claims appended herewith.
SUMMARY OF THE INVENTION
[0009] The present invention accomplishes the above-stated objectives as well as others, as may be determined by a fair reading and interpretation of the entire specification herein, which comprises methods and apparatus for providing a slit in a pressure sensitive label in preparation for removal of the label from a slender glass vessel.
[0010] Typically, pharmaceutical vessels or vessels comprise glass ampoules, syringes, and cartridges (needle-less syringes) that include a pressure sensitive label attached to the vessel. Again typically, the longitudinal edges of the label overlap each other by a small amount. The present method utilizes a sharp instrument that transverses the overlapped area of the label to create a slit in the label. The sharp instrument is angled in two directions such that the slit originates at a top edge of the label and somewhat tangential to the surface of the vessel at the location of the slit. As the sharp instrument traverses downward along the length of the vessel, one cut edge of the label separates from the vessel leaving a small space between it and the vessel. The label is now in a position to be completely removed from the vessel by one or more known methods, such as being peeled from the vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Various other objects, advantages, and features of the invention will become apparent to those skilled in the art from the following discussion taken in conjunction with the following drawings, in which:
[0012] FIG. 1 is a schematic and exaggerated view of a prior art slender glass vessel having a pressure sensitive label attached thereto,
[0013] FIG. 2 is a top plan view of the prior art vessel of FIG. 1 illustrating the preferred locations to begin the slit in the label and the preferred direction of the slit,
[0014] FIG. 3 is a schematic, isometric view of an initial position of a sharp instrument relative to the overlapped portion of the label to be slit,
[0015] FIG. 4 is a top plan view of FIG. 3 illustrating the second angle of the sharp instrument in accordance with the inventive method; and
[0016] FIG. 5 is an isometric view of the slit created by the method of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention.
[0018] Reference is now made to the drawings, wherein like characteristics and features of the present invention shown in the various figures are designated by the same reference numerals.
[0019] Reference is now made to FIG. 1 which illustrates a typical prior art glass vessel 11 having a pressure sensitive label 12 attached to the vessel 11 . The label 12 can comprise a plastic film that is wrapped around the outer circumference of the vessel 11 . In most instances, the ends 13 (outer) and 14 (inner) of the label 12 that lie along the length of the vessel 11 overlap each other by a small amount 15 . There is no set amount of overlapping, but since the label 11 includes printing, the overlapped ends includes printing on only one of the overlapped ends 13 or 14 . But again, this is not a fixed variable. The overlap 15 can be appreciable or minimal. Indeed,.there may be no overlap such that a space exists between the ends 13 and 14 exposing a partial area of the outer circumference of the vessel 11 . For purposes of the description of the preferred embodiment of the present invention, it will be assumed that an overlap 15 in the fictitious and approximate amount of 10 to 20 percent of the circumference exists. Further, for similar purposes, it will be assumed that edge 13 is the outside edge and edge 14 is the inside edge. In a preferred embodiment, the point 22 represents the location that the slit is to begin. The dashed longitudinal line 16 represents the line along which the slit is to be made.
[0020] The position of the vessel 11 in FIG. 1 , that is up-right, is a preferred position to fixture the vessel in advance of the slitting operation; however a horizontal position of the vessel can also be used. Any commonly known fixture can be used for this purpose. For example, a base of the fixture can be provided with a blind opening having the diameter of the vessel. An upper part of the fixture can comprise a cap that is spring loaded so as to apply pressure to the top of the vessel 11 and capture it within the fixture. Another example of a known fixture can be similar to battery cradle in an electronic device where the battery lies in a semicircular groove that is spring loaded at one end. In this example, the vessel would be similarly cradled in a semicircular groove and held by a clamp to prevent rotation during the slitting process. Other fixturing methods can be readily envisioned by one of ordinary skill.
[0021] FIG. 2 illustrates an enlarged cross sectional view of the vessel 11 and the label 12 wrapped around the circumference of the vessel 11 . The overlap is seen as the area bounded by reference numeral 15 . For descriptive purposes, the slit 16 will be made along the line 17 . In this manner, the slit 17 will penetrate through the overlap 15 . Alternatively, the slit can be made at locations 17 A, 17 B, 17 C, or any other location across the label 12 . Or. slit 17 can be made in a direction 180 degrees opposite of the slit locations shown in FIG. 2 . The object being to provide a slit 16 across the overlapped ends 13 and 14 in a direction that ranges from being tangential to the circumference of the vessel 12 to an angle of approximately twenty degrees away from the tangential. In testing, it has been shown that a slit angled and separated from the opposite cut end 27 as stated provides sufficient separation of the cut end 26 so as to provide sufficient subsequent gripping of the cut end 26 to accomplish the subsequent label 11 removal. The invention is however not to be limited to the stated preferred embodiment. So long as some separation of cut end 26 occurs, the subsequent process of label removal can be adequately accomplished.
[0022] FIG. 3 schematically illustrates the initiation of the slit 16 along the line 17 using a sharp blade 21 . The initial point of contact of the blade 21 with the label 12 is at point 22 which is located at the top of the label 12 at the top of the slit line 16 as also seen in FIG. 1 . Thus, at the initiation of the slitting process, the top cutting edge 23 of blade 21 is positioned above the top edge 24 of label 12 with the top cutting edge 23 being positioned against the periphery or outer circumference of the vessel 11 . Such positioning results in the cutting edge 25 of blade 21 being angled downward and outward away from the circumference of the vessel 11 . Such positioning also results in the plane of the blade 21 being angled away from the line 17 of the slit 16 . It is this double angularity that results in the slit 16 being separated or the ends 26 and 27 being spaced apart as seen in FIG. 5 . The angularity of the cutting edge 25 of blade 21 is seen in FIG. 3 . The angularity of the plane of the blade 21 relative to the angle 17 of the slit 16 is seen in FIG. 4 .
[0023] With the blade 21 being maintained in the aforesaid position, the blade is brought downward in a straight line, along the length of slit line 16 . As the blade 21 so progresses, the cut end 26 of label 12 , together with a portion of the inner overlapped end of label 12 is gently but firmly directed outward away from the circumference or outer surface of vessel 11 (due to the above described double angle of blade 21 ) as schematically shown in cross section in FIG. 5 . When the blade 21 completely traverses the slit line 16 , the cut end 26 of label 12 is located away from the vessel 11 along the entire length of slit line 16 . It is now extremely more convenient to use the cut end 26 of label 12 to continue the label removal process
[0024] The above described slitting operation can be accomplished by hand using a fixture as above described to hold the vessel 11 . Or, the blade 21 can affixed to, for example a plate attached to a linear motion bearing such that it can be pivoted away from the vessel fixture to allow loading of a vessel and pivoted back toward the vessel in the preferred cutting position and then either mechanically or by hand drawn along the slit line 16 .
[0025] While the invention has been described, disclosed, illustrated and shown in certain terms or certain embodiments or modifications which it has assumed in practice, the scope of the invention is not intended to be nor should it be deemed to be limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
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A method for assisting in the removal of a pressure sensitive label from a slender glass vessel wherein said label is wrapped around the circumference of the vessel and extends along the length of the vessel includes positioning a planar cutting blade at two angles relative to the label, drawing the blade down along the length of the label, cutting the label into two opposite cut edges with one edge adhering to the vessel and the other cut edge being raised slightly away from the circumference of the vessel and forming a space between the two cut edges.
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BACKGROUND OF THE INVENTION
This invention relates to improvements in form structures for use in the making of columnar or the like concrete products and more particularly in those of the kind usable in centrifugal forming processes.
Previously known form structures of the kind described have generally comprised of a substantially cylindrical or frustoconical tubular form which has a single longitudinally extending gap formed in its wall with a pair of flanges formed along the opposite edges of such gap or alternatively is of the type axially split into two half secions with flanges formed along the oppsite longitudinal adges thereof. With such conventional forms, it has been common practice to clamp together the opposite flanges formed along the gap or split edges of the form by bolt means to hold the form in a closed cylindrical or frustoconical shape for placing concrete therein and, upon completion of the forming operation, to release the bolts in order to enable the form to be opened for removal of the formed product therefrom. Such bolting procedure required to assemble and disassemble the form, however, has been very difficult to automatize because of the wide variety in size and shape of forms used and actually been performed exclusively by manual labor, incurring inefficiency and high cost of production.
SUMMARY OF THE INVENTION
To overcome the previous difficulties described above, the present invention provides a novel form structure of the kind described which comprises a tubular frame adapted to be driven to rotate about its own axis, a resilient tubular casing having a longitudinally extending gap formed in its wall and having an outer diameter smaller than the inner diameter of said tubular frame so as to be arranged therein for axial movement relative thereto, and camming means associated with said tubular frame and casing so as to act upon said tubular casing circumferentially and radially thereof with axial movement of such tubular casing relative to said tubular frame to close said gap in said tubular casing while holding the latter in a position coaxial with said tubular frame.
The primary object of the invention is to eliminate the need for any clamping bolts such as required with conventional forms.
Another object of the invention is to enable the longitudinally extending gap in the wall of said tubular casing to be automatically closed as the casing is moved in an axial direction relative to said tubular frame while allowing the gap to open with axial movement of the casing in an opposite direction to facilitate separation and removal of a columnar concrete product formed therein.
A further object of the invention is to tightly seal the gap in the tubular casing as it is closed to prevent any loss of moisture contained in the concrete placed in the casing. To attain this object, a pair of radially outwardly extending ribs or flanges are formed on the tubular casing along the opposite edges of the gap in the wall thereof and a packing element is arranged between such flanges so as to be compressed with the aid of ridge formation on the inner wall surface of the tubular frame as the tubular casing is moved in an axial direction to close the gap in the wall thereof.
These and other objects, features and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an axial cross-sectional side view of one preferred embodiment of the invention, taken along the line I--I in FIG. 2 and showing the embodiment with a concrete pipe already formed therein and now being pushed out;
FIG. 2 is a transverse cross section of same taken along the line II--II in FIG. 1;
FIG. 3 is an enlarged fragmentary cross section taken along the line III--III in FIG. 1;
FIG. 4 is a fragmentary cross section taken along the line IV--IV in FIG. 3;
FIG. 5 is a transverse cross-sectional view of another embodiment of the present invention, taken along the line V--V in FIG. 6;
FIG. 6 is a fragmentary cross section taken along the line VI--VI in FIG. 5;
FIG. 7 is a fragmentary cross section taken along the line VII--VII in FIG. 5;
FIG. 8 is a fragmentary cross section taken along the line VIII--VIII in FIG. 5;
FIG. 9 is a fragmentary transverse cross-sectional view of a further embodiment of the invention, showing the tubular casing in open position; and
FIG. 10 is a fragmentary perspective view of same, showing the relationship between the ribs and guide projections formed on the tubular casing along the opposite edges of the gap therein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One preferred embodiment of the invention will now be described with reference to FIGS. 1 to 4, in which reference numeral 1 indicates an outer tubular casing or frame of the form structure illustrated; and 3, an inner tubular casing thereof.
The tubular frame 1 is formed of steel pipe with a plurality of steel rings or tires 2 integrally secured to the outer periphery thereof at axially spaced intervals in coaxial relation therewith and, as will readily be understood, is mounted on support rolls of an appropriate form rotating machine, not shown, through the intermediary of steel tires 2 to be driven to rotate about its own axis together with the inner, tubular casing 3 for centrifugal forming of columnar concrete products.
The tubular casing 3, serving as a form proper in which concrete is actually placed, is resilient in nature, being formed of steel plate, and has an inner peripheral wall surface substantially conforming to the profile of columnar concrete products to be formed therein. The casing 3 also has a gap 4 formed in the wall thereof which extends longitudinally over the whole length of the casing in parallel with the axis thereof. It is to be understood that the gap 4 remains open in the free state of the resilient tubular casing 3. Also, a pair of radially outwardly extending ribs or flanges 5 are formed on the tubular casing 3 along the opposite edges of the gap 4 to extend longitudinally of the casing over the whole length thereof. Further, a plurality of guide projections 6 are formed on the outside of each of ribs 5 on the tubular casing 3 at axially spaced intervals, each extending only a limited distance longitudinally of the casing 3. All of such guide projections 6 are arranged in paired cooperating relationship, each of such projections formed on one of the paired ribs being disposed circumferentially opposite to the corresponding one of guide projections 6 formed on the other rib 5.
As shown in FIGS. 3 and 4, each of the guide projections 6 has an outside guide face 60 which is inclined in an axial direction of the tubular casing 3 to approach the inside surface of the guide projection which is parallel to the axis of the casing. Thus, the guide projections 6 in each pair have respective outside surfaces 60 so inclined as to define a distance therebetween which increases from one end to the other of the paired projections.
Provided on the outer tubular casing or frame 1 are a plurality of cam blocks which are fixed as by welding to the inner wall surface of the frame 1 at axially spaced intervals in axially aligned relation with each other and each include a pair of opposite camming projections 7 extended radially inwardly of the frame 1 for cooperation with the corresponding one of the pairs of guide projections 6 formed on the inner, tubular casing 3. As clearly seen in FIG. 3, each of the paired camming projections 7 has a greater axial length than the guide projections 6 and has an inside face 70 inclined in an axial direction to closely conform to the inclined outside face 60 of the adjacent one of guide projections 6.
It is to be observed that, with axial movement of the resilient tubular casing 3 relative to the tubular frame 1, the camming projections 7 in each pair act upon the corresponding pair of guide projections 6 through the interengagement of inclined side faces 60 and 70 of the respective projections 6 and 7 to force the ribs 5 formed on the tubular casing 3 circumferentially toward each other against the resiliency thereof until the ribs 5 are placed in abutting engagement with each other to close the gap 4 in the wall of the tubular casing 3. Obviously, the gap 4 closed in this manner will become open again under the resiliency of the casing 3 when the latter is moved axially in the opposite direction.
Incidentally, the other tubular casing or frame 1 should be designed with an internal diameter which affords a radial distance between the walls of inner and outer tubular casings 3 and 1 sufficient to ensure smooth interengagement and relative sliding movement between the paired guide and camming projections 6 and 7 respectively provided on the inner and outer casings 3 and 1. Though each pair of camming projections 7 has been shown and described above as integrally formed on a block welded to the tubular frame 1, such projections may alternatively be formed separate and individually secured directly to the inner wall surface of the frame 1 as by welding.
Referring again to FIGS. 1, 3 and 4, the guide projections 6 formed on the resilient tubular casing 3 also have each a top guide surface 61 which is inclined downwardly to the left as viewed in FIGS. 1 and 3, that is, in the direction in which the outside guide face 60 is inclined to approach the inside surface of the guide projection 6. On the other hand, the channel-like cam blocks secured to the inner wall surface of tubular frame 1 and each forming a pair of camming projections 7 have each a radially inwardly directed bottom camming surface 71 defined between the pair of camming projections 7 and inclined downwardly to the left as viewed in FIGS. 1 and 3 so as to closely conform to the inclined top guide surfaces of the adjacent pair of guide projections 6. As will readily be understood, when the resilient tubular casing 3 is axially moved relative to the tubular frame 1 to close the gap 4, the inclined bottom surfaces 71 of the cam blocks are brought into sliding face-to-face contact with the inclined top surfaces 61 of the respective pairs of guide projections 6 to force the ribs 5, formed along the opposite edges of gap 4 and adjacent inner casing edges, radially inwardly through the intermediary of guide projections 6. Accordingly, any eccentricity or radial deflection of the gapped region of resilient tubular casing 3 such as may otherwise take place under centrifugal force when the tubular casing 3 rotates together with the tubular frame 1 can be effectively prevented.
Further, as seen in FIGS. 1 and 2, a plurality of radial lugs 12 are fixed to the outer wall surface of the tubular casing 3 in an angular position 180° spaced apart from the gap 4 at axially spaced intervals and are fitted into respective channel pieces 13, which are secured to the inner wall surface of tubular frame 1, for axial sliding movement relative thereto.
With the arrangement described above, it will readily be appreciated that the resilient tubular casing 3 as placed in proper engagement with the tubular frame 1 can be supported coaxially therein simply by driving the tubular casing 3 in an axial direction until the gap 4 is completely closed.
Further, in cases where the resilient tubular casing 3 has a relatively large circumferential length and its wall regions 90° apart from the gap 4 may possibly be deflected or bulged radially outwardly under centrifugal force during forming operation, an appropriate restraining arrangement can readily be provided, for example, as illustrated in FIG. 2, in which reference numeral 14 indicates radial lugs secured as by welding to the outside of the tubular casing 3 at axially spaced intervals at respective locations 90° apart from the gap 4 and each having an end face inclined to the axis of the casing. Reference numeral 15 indicates bearing blocks secured as by welding to the inside wall surface of the tubular frame 1 in an arrangement similar to that of radial lugs 14 on resilient tubular casing 3 and each having a similarly inclined bearing surface. As will readily be noted, the inclined surfaces of radial lugs 14 and bearing blocks 15 are brought into sliding engagement with each other and cooperate to hold the tubular casing 3 in a circular cross-sectional shape throughout the forming operation.
In use of the form structure described above, first the tubular casing 3 is axially moved to a set position within the tubular frame 1 and in this way the longitudinally extending gap 4 in the wall of resilient tubular casing 3 is tightly closed. Then, a cage of reinforcing steel tendons for a concrete pipe or column to be formed is properly arranged in the resilient casing 3 and concrete is placed therein. Subsequently, the form structure is driven to rotate as a whole about its own axis in order to consolidate the concrete under centrifugal force, and the concrete formed in the tubular casing 3 is steam-cured until it solidifies to an appropriate hardness for its separation and removal from the tubular form or casing 3. After such curing, the tubular casing 3 is forced to move axially backward from its set position and thus allowed to expand under its own resiliency to open the gap 4. In this manner, most of the formed surface of the concrete column is separated from the adjacent inner peripheral surface of tubular casing 3 practically in an automatic fashion and the concrete product can now be readily removed out of the form structure just by pushing same axially out of the resilient tubular casing 3 by an appropriate thrust machine, as indicated in FIG. 1 by the arrow a.
Another preferred embodiment of the present invention is illustrated in FIGS. 5 to 8, in which the same references have been used as in FIGS. 1 to 4 for similar parts.
Referring first to FIGS. 5 and 6, the resilient tubular casing 3 in this embodiment includes a pair of axially extending radial ribs 27 secured by welding to the outer wall surface of the casing 3 along the opposite edges of the gap 4 formed in the casing wall and a plurality of pairs of opposite guide projections or camming projection 18 arranged on the outside of said respective radial ribs 27 at axially spaced intervals. Guide projections 18 have each a planar guide face 180 (FIG. 7) inclined at an angle of approximately 30° to the medial plane of the resilient casing 3 and also inclined slightly downward, or radially in an axial direction thereof.
As shown in FIG. 5, a pair of nut blocks 19 are fitted in the outer casing 1 for each of the pairs of guide projections 18 formed on the inner, resilient casing 3 and are secured in place by welding. A pair of bolts 20 are threaded through the respective nut blocks and oppositely inclined to the medial plane of inner casing 3 so as to be brought into abutting engagement with the inclined guide surfaces 180 of the respective paired guide projections 18. Fixed to one of axially extending radial ribs 27 formed on the inner, resilient casing 3 (the right-hand side rib in FIG. 5) is a support plate 28 which extends in parallel with the form axis and to which a plurality of guide projections 29 are fixed at axially spaced intervals. As seen in FIG. 6, each of guide projections 29 has a top guide surface 290 inclined downward in an axial direction of the casing 3. A plurality of nut blocks 30 are fitted in the outer tubular casing or frame 1 one for each of the guide projections 29 and a bolt 31 is threaded through each of nut blocks 30 for abutting engagement with the inclined top surface 290 of the respective guide projection 29.
Further, a plurality of ribs 23 are welded to the outside of resilient tubular casing 3 at an angular position 180° apart from the gap 4 and are each formed with a groove extending parallel to the axis of the casing 3. On the other hand, a plurality of nut blocks 22 are secured to the tubular frame 1 at axially spaced locations opposite to the respective grooved ribs 23 on the inner casing 3. A bolt 21 is threaded through each of the nut blocks 22 to slidably fit in the groove in the respective rib 23. This arrangement, allows the resilient tubular casing 3 to move axially relative to the tubular frame 1. As will readily be understood, the gap 4 in the wall of the tubular casing 3 can be effectively closed or opened with axial movement thereof relative to the frame 1 as long as the threaded bolts 20, arranged on the frame 1 opposite to the respective guide projections 18 on the tubular casing 3, are held extended inwardly beyond the inner wall surface of the frame 1 to an appropriate extent. On this occasion, the bottom wall region of resilient tubular casing 3, which is substantially 180° apart from the gap 4, is only translated in parallel to the adjacent wall of frame 1, but the opposite wall edge portions of resilient tubular casing 3 extending longitudinally along the gap 4 are not only displaced circumferentially toward or away from each other but also displaced radially of the tubular casing 3 to effectively close or open the gap 4 because of the presence of threaded bolts 20 on the frame 1. It is to be noted in this connection that the radial displacement of one of the radial ribs 27 arranged along the opposite edges of gap 4 is aided by the guide action of the inclined top surfaces of guide projections 29, which are arranged on the support plate 28 secured to the radial rib 27 so as to be engaged by the respective threaded bolts 31 secured to the frame 1, thus making sure that the circumferentially opposite wall edge portions of tubular casing 3 are joined together accurately to complete a geometric circle.
Further, as shown in FIGS. 5 and 8, a plurality of radial projections 26 are arranged on the outer wall surface of tubular casing 3 intermediate the gap 4 and grooved ribs 23, for example, at locations 90° apart therefrom, and at appropriate axially spaced intervals. These projections 26 are each shaped in substantially the same manner as guide projections 29 and have each a guide face 260 inclined in an axial direction of the casing 3. On the other hand, nut blocks 25 are secured to the tubular frame 1 at respective locations opposite to the guide projections 26 on tubular casing 3 with bolts 24 threadably fitted through the respective blocks 25 for abutting engagement with the respective guide projections 26. This arrangement serves the purpose of imparting to the opposite 90° regions of the wall of resilient casing 3 a radial displacement proportional to the gap opening or closing movement of the opposite wall edge portions of casing 3 during axial movement thereof relative to tubular frame 1 thereby to maintain the inner, tubular casing 3 at all times in a circular cross-sectional shape with no distortion. Such arrangement also serves the purpose of preventing any radially outward deflection or bulging of the intermediate wall regions of tubular casing 3 which may otherwise take place under centrifugal force when the form structure is driven to rotate with concrete placed in the tubular casing 3 for centrifugal forming. Though, in FIG. 5, the guide projections 26 and abutting bolts 24 are shown provided in two sets on the opposite sides of the form structure at locations 90° apart from gap 4, it is to be understood that they may be provided in any larger number of sets depending upon the diametral size of the form structure.
FIGS. 9 and 10 illustrate a further embodiment of the invention which is basically the same in structure and function as the embodiment shown in FIGS. 5 to 8 except that it includes packing or seal means provided to prevent any moisture content of concrete placed therein from leaking out through the gap 4 in tubular casing 3 during centrifugal forming operation, in place of the arrangement including guide projections 29 and abutting bolts 31 in the embodiment of FIG. 5.
In FIGS. 9 and 10, in which the same references have been used as in FIGS. 5 to 8 for similar parts, reference numeral 270 indicates a pair of radial flanges secured to the outside of resilient tubular casing 3 along the opposite edges of the gap 4 formed therein and each taking the form of one of the legs of an angle bar 27, and 32 indicates a ridge secured to the inside of the outer casing or frame 1 and projecting radially inwardly therefrom into the space between the pair of radial flanges 270. Reference numeral 33 indicates a tubular packing element of rubber or the like elastic material arranged between the opposite radial flanges 270 and under the ridge 32 and extending longitudinally of the form structure over the entire length thereof. It is to be understood that the packing element 33 has such an outer diameter as to be sufficiently compressed around the periphery thereof. In other words, as the inner casing 3, initially assuming the state shown in FIG. 9 with its gap 4 kept open, in axially moved relative to tubular frame 1 to close the gap 4, the rubber packing 33 is radially compressed to extend wider under the combined action of the ridge 32 and flanges 270 against the adjacent wall edged portions of resilient tubular casing 3 to tightly seal the gap 4. Owing to this, any leakage through the closed gap of the moisture content of concrete subsequently placed in the resilient tubular casing 3 is effectively prevented during rotation of the form structure, enabling centrifugal forming operation with no danger of dehydration involved.
It will be apparent that, also with this embodiment, the gap 4 formed in the wall of resilient tubular casing 3 is effectively closed or opened with axial movement thereof relative to the tubular frame 1 under the control of paired guide projections 18 arranged on the pair of axially extending ribs 27, welded to the opposite side edges of gap 4, at appropriate axially spaced intervals and cooperating paired camming bolts 20 threadably fitted to the tubular frame 1.
While a few preferred embodiments of the invention have been shown and described, it will be apparent to close skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
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Labor-consuming bolting operation as required with conventional forms of the gapped or split type has been ingeniously expelled by the provision of a form structure comprised essentially of a rigid tubular frame, a resilient gapped tubular casing arranged therein as a form in which concrete is to be placed, and camming means arranged on the inside of the rigid frame and on the outside of the resilient casing and cooperable to act upon the resilient tubular casing radially and circumferentially thereof with axial movement of such resilient casing relative to the rigid frame so as to close the gap in the resilient casing while holding the latter in coaxial relation to the rigid frame, any loss of moisture content of concrete during centrifugal forming operation can be effectively prevented by arranging an appropriate packing element on the resilient casing along the gap therein.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a method and apparatus for delivering electrical energy produced by a defibrillator to a patient experiencing ventricular fibrillation (“VF”), and more particularly to a method and apparatus for controlling the delivery of electrical energy produced by an external defibrillator. The circuit of this invention allows for active and passive protection of the high energy delivery circuit in the event of a fault condition. The circuit also enables the patient to be protected from high voltage when the device is in standby or monitoring mode. The circuit provides a reliable and safe means of protecting the H-bridge from an over-current condition while increasing patient and operator safety. The circuit also has the advantage of being simple and inexpensive while maintaining a high degree of effectiveness.
2. Description of the Prior Art
Each day thousands of Americans are victims of cardiac emergencies. Cardiac emergencies typically strike without warning, oftentimes striking people with no history of heart disease. The most common cardiac emergency is sudden cardiac arrest (“SCA”). It is estimated that more than 1000 people per day are victims of SCA in the United States alone; this translates into one death every two minutes.
SCA occurs when the heart stops pumping blood. Usually SCA is due to abnormal electrical activity in the heart, resulting in an abnormal rhythm (arrhythmia). One such abnormal rhythm, VF, is caused by abnormal and very chaotic electrical activity in the heart. During VF the heart cannot pump blood effectively. VF may be treated by applying an electric shock to the patient's heart through the use of a defibrillator. The shock clears the heart of the abnormal electrical activity (in a process called “defibrillation”) by depolarizing a critical mass of myocardial cells to allow spontaneous organized depolarization to resume, thus restoring normal function. Because blood may no longer be pumping effectively during VF, the chances of surviving decrease with time after the onset of the emergency. Brain damage can occur after the brain is deprived of oxygen for four to six minutes.
External defibrillators send electrical pulses to the patient's heart through electrodes applied to the patient's torso. External defibrillators are typically located and used in hospital emergency rooms, operating rooms, and emergency medical vehicles. Of the wide variety of external defibrillators currently available, automatic and semi-automatic external defibrillators (AEDs) are becoming increasingly popular because they can be used by relatively inexperienced personnel. Such defibrillators can also be especially lightweight, compact, and portable.
AEDs must include circuitry capable of handling the high voltages and high currents associated with electrical defibrillation. In some instances, suitable components with the required electrical characteristics are not readily available, and the AED designer must instead rely on multiple component configurations where, functionally, a single component would suffice.
Additionally, AEDs require monitoring and control circuitry to protect the patient, as well as the AED circuitry itself, in the event of a fault condition. One common fault condition occurs as a result of variations in load impedances, such as those resulting from short circuits or open circuit conditions. The high voltages applied to patients may also create situations, such as arcing between electrodes or arcing between patient wires, that could also lead to failure of the therapy electronics if not properly protected. Such monitor and control circuitry is made increasingly complex by the multiple component configurations included in currently available AEDs.
One method employed by currently available defibrillators to solve this problem is by measuring patient impedance using a low-level signal prior to delivering a shock. The disadvantage of this method is that it relies heavily on the accuracy of the low-level signal measurement relative to the actual impedance (i.e., impedance detected during the high voltage pulse delivered during defibrillation). As will be appreciated by those of skill in the art, the low-level signal cannot predict all behaviors of the external circuit during defibrillation. An example of a condition that cannot be predicted is arcing.
Another method, employed by the ForeRunner® (manufactured by Heartstream, Inc., Seattle, Wash.), is to measure impedance during the initial portion of the waveform and to allow the circuit to continue if impedance is within tolerable limits. Toward that end a 20Ω resistor is placed in series for the first 100 μs that the voltage is delivered. During that time, the resistance across the electrodes is tested to ensure that the connection has not been shorted by monitoring the voltage across a 0.05Ω current sense resistor. Providing a resistance in series during the initial voltage delivery, ensures that the circuit will not be subjected to excessive current in the event that there is a short condition. However, if a fault occurs after the first 100 the circuit could be exposed to excessive currents.
What is needed, therefore, is an AED with a fault protection circuit that is capable of actively protecting the high voltage H-bridge. Protection of the H bridge can be accomplished by switching the bridge off during a fault condition, and/or passively protecting the high voltage bridge, e.g. by allowing the circuit to tolerate the fault condition. Further what is needed is a way to protect the H-bridge from valid load conditions while minimizing the exposure of the patient, or patient simulated load, to the energy stored in the AED. Finally what is needed is a way to protect the operator and/or patient in the event of a discharge to an abnormally high patient load.
SUMMARY OF THE INVENTION
In accordance with the present invention, an apparatus and method is provided for producing and controlling a high energy pulse for application to a patient experiencing VF. A storage circuit stores electrical energy and a steering circuit delivers the electrical energy from the storage circuit to the patient. A protection circuit is coupled with the storage circuit and with the steering circuit. The protection circuit selectively controls the delivery of the electrical energy from the storage circuit to the steering circuit. The protection circuit may include a disarm circuit that selectively shunts the electrical energy way from the steering circuit and patient. The protection circuit may include a limit circuit that limits the rate of delivery of the electrical energy from the storage circuit to the steering circuit. The rate at which electrical energy is delivered is measured and compared to a predetermined range of acceptable rates. If the rate falls within the acceptable range, then electrical energy continues to be delivered. If, however, the rate does not fall within the accepted range, the disarm circuit is enabled and the delivery of the electrical energy to the steering circuit is interrupted. Determination of whether the rate falls within a predetermined acceptable range occurs all the time, thus the disarm circuit can be enabled at any time the rate falls outside the accepted range. The limit circuit and disarm circuit together may limit a maximum voltage applied across the steering circuit when the delivery of electrical energy is interrupted.
This invention provides the advantage of limiting the exposure of the external circuit to high voltage/energy in the event of an over-current load condition. These advantages are achieved with the use of lower cost, readily available components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram depicting a defibrillator according to an embodiment of the present invention.
FIG. 2 is a functional block diagram depicting a high-voltage delivery circuit included in the defibrillator of FIG. 1 .
FIG. 3 is a schematic diagram depicting certain details of a first embodiment of the high-voltage delivery circuit of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Currently available external defibrillators provide either a monophasic or biphasic electrical pulse to a patient through electrodes applied to the chest. Monophasic defibrillators deliver an electrical pulse of current in one direction. Biphasic defibrillators deliver an electrical pulse of current first in one direction and then in the opposite direction. When delivered external to the patient, these electrical pulses are high energy (typically in the range of 30 J to 360 J). This invention may be employed by defibrillators that generate monophasic, biphasic or multiphasic waveforms. Additionally, this invention may be employed by defibrillators that allow the user to select the waveform type.
Defibrillators employing a monophasic waveform are well known in the art. While this invention may be used with a defibrillator employing a monophasic waveform, it is believed that the solution described herein is primarily beneficial for defibrillators that deliver biphasic or multiphasic waveforms.
An example of an AED employing a biphasic waveform is described in U.S. Pat. No. 5,607,454, entitled “Electrotherapy Method and Apparatus,” the disclosure of which is incorporated herein by reference. Such defibrillators employ a high voltage bridge circuit for steering the biphasic pulse applied to the patient. The energy delivered to the patient is first stored in an energy storage circuit such as a capacitor, with associated voltages commonly in the range of 1000-2500 V. Prior to delivery of the electrical energy to the patient, one or more of the components of the bridge circuit must withstand this voltage without significant leakage.
Should energy delivery via the bridge circuit be halted due to a fault condition, the corresponding currents and voltages handled by the bridge components are quite high. Given the components currently available to the AED designer, today's bridge circuits commonly include as many as eight to ten distinct switching elements. Correspondingly, the control circuitry associated with switching these elements is relatively complex. The circuit component numbers and complexity required by such AEDs can result in increased expense, potentially lowered reliability, and reduced portability.
In accordance with the present invention, embodiments of an external defibrillator are provided that have a high voltage bridge circuit using only five switching elements to steer the biphasic or multiphasic pulse. In an electrical path separate from the bridge circuit, a sixth switching element is provided for discharging/disarming the energy storage capacitor in the event of a fault. An additional switching element or elements can be provided for current initiation and commutation control. In the following description, certain specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be clear, however, to one skilled in the art, that the present invention can be practiced without these details. In other instances, well-known circuits have not been shown in detail in order to avoid unnecessarily obscuring the description of the various embodiments of the invention. Also not presented in any great detail are those well-known control signals and signal timing protocols associated with the internal operation of defibrillators.
FIG. 1 is a functional block diagram depicting a defibrillator or AED 10 having a high-voltage delivery circuit 12 in accordance with an embodiment of the present invention. The AED 10 includes a power supply 14 , which is powered by an energy source such as a removable battery 16 and provides power to other components of the AED. A microcontroller or processor 18 controls the operation of the various components of the AED 10 . The high-voltage delivery circuit 12 delivers a pulse of electrical energy to a patient via an electrode connector or interface 20 and electrodes 22 .
An electrocardiogram (ECG) circuit 24 acquires and processes the patient's ECG signals through the electrodes 22 and sends the signals to the processor 18 via a system gate array 26 . The system gate array 26 is preferably a custom application-specific integrated circuit (ASIC) integrating many of the defibrillator functions (including user interface control and many of the internal functions) and interfacing the processor 18 with other components of the AED 10 . Providing the separate system gate array or ASIC 26 allows the processor 18 to focus on other tasks. Of course, the functionality of the ASIC 26 could be included within the operations performed by the processor 18 , or could be replaced by discrete logic circuit components or a separately dedicated processor.
The AED 10 also includes a memory device 30 . As depicted in FIG. 1, memory device 30 is a removable PCMCIA card or magnetic tape. AED 10 also includes user interface components such as a microphone 32 , an audio speaker 34 , an LCD display panel 36 , and a set of push-button controls 38 . Those skilled in the art will understand that a number of other components are included within the AED 10 (e.g., a system monitor and associated status indicators), but are not shown in order to avoid unnecessarily obscuring the description of embodiments of the invention.
As shown in FIG. 2, the high-voltage delivery circuit 12 includes a number of functional circuit blocks which are both monitored and controlled by the ASIC 26 . A high-voltage charging circuit 40 , such as a flyback power supply, responds to one or more control signals issued by the ASIC 26 and generates electrical energy for provision to a capacitor 42 . By controlling the high voltage charger 40 , the ASIC can correct an over voltage condition as a result of measuring voltage on the capacitor 60 while it is charging.
The capacitor 42 , which could be an energy storage circuit (“ESC”), stores the electrical energy for delivery to the patient. The electrical energy is delivered to an energy transfer or steering circuit 46 (comprising four silicon controlled rectifier switches, SCR UL , SCR UR , SCR LL , and SCR LR ) through drive electronics 52 . The steering circuit 46 in turn delivers the electrical energy to the patient via the connector 20 and electrodes 22 (shown in FIG. 1 ).
The protection circuit 48 (shown in FIG. 3) functions to limit energy delivery from the ESC 42 to the steering circuit 46 (and hence to the patient) and to discharge or otherwise disarm the ESC 42 in the event of a fault condition. A monitor circuit 50 senses operations of both the protection circuit 48 and the steering circuit 46 and reports the results of such monitoring to the ASIC 26 . ASIC 26 provides instructions to the monitor circuit 50 which controls the disarm drive and IGBT drive of the circuit shown in FIG. 3 to prevent an over-current condition on the bridge. The above-described operations of the steering circuit 46 and the protection circuit 48 are controlled by a drive circuit 52 issuing a plurality of drive signals. Operation of the drive circuit 52 is, in turn, controlled by one or more control signals provided by the ASIC 26 and the microprocessor 18 .
FIG. 3 is a more detailed depiction of the invention shown in FIG. 2 .
An ESC 42 is provided which is a capacitor (or multiple capacitor unit) 60 . Suitable capacitance is approximately 100 μF; the ESC 42 is capable of regularly and reliably storing energy up to approximately 220 J (which corresponds to a voltage of approximately 2100 VDC). The capacitor 60 has a positive terminal or node 62 . The energy storage circuit provides energy to a steering circuit 46 which, in turn, controls the delivery of energy to a patient 104 . The steering circuit 46 enables the circuit to deliver either a biphasic or multiphasic energy pulse to the patient 104 .
The steering circuit 46 is configured as an “H-bridge”, with four switching elements. The steering circuit 46 includes an upper-left (UL) switching element, such as SCR UL 90 , and an upper-right (UR) switching element, such as SCR UR 92 . The anode of each of the SCRs 90 , 92 is connected to an upper node 76 , and the cathode of each of the SCRs is connected to a respective one of two patient terminals 96 (which, in turn, are coupled with the connector 20 and respective ones of the electrodes 22 of FIG. 1 ). The control terminal or gate of each of the SCRs 90 , 92 receives a respective UL or UR drive signal produced by the drive circuit 52 (shown in FIG. 2) to selectively switch the SCRs on. A patient 104 is represented by a resistor, shown in the electrical location of the patient during defibrillator operations.
The steering circuit 46 also includes a lower-left (LL) switching element, such as SCR LL 98 , and a lower-right (LR) switching element, such as a SCR LR 94 . The anode of the SCR LL 98 and the anode of the SCR LR 94 are each connected to a respective one of the patient terminals 96 . The cathode of the SCR LL 98 and the cathode of SCR LR 94 are each connected to a lower terminal or node 104 of the steering circuit 46 . The control terminal or gate of the SCR LL 98 receives an LL drive signal from the drive circuit 52 (shown in FIG. 2) to selectively switch the respective SCR on. The control terminal or gate of SCR LR 94 receives a LR drive signal from the drive circuit 52 to selectively switch the SCR on and off.
A high-voltage diode D 2 is connected in parallel to SCR UL 90 and SCR LL 98 at nodes 76 and 104 . Diode D 2 operates to snub inductance in the patient load when the bridge is turning off the current, for example during the commutation interval.
A sense resistor 106 is connected in series with the steering circuit 46 , between lower terminal 104 of the steering circuit 46 and the negative terminal of the energy steering circuit 42 at node 102 . A suitable resistance value for the sense resistor 106 is approximately 50 mΩ, and is preferably of the low-value precision resistor type commonly used as an electric shunt in ammeters. In a preferred embodiment, the monitor circuitry 50 (shown in FIG. 2) is an over-current/waveform abort control logic (OIWAL). If an over-current detection is “TRUE,” or the switch disarm signal is asserted, the OIWAL performs the necessary steps to shut down the patient load current and safely disarm the ESC 42 . Further details of how the drive is disarmed is discussed below.
Additionally, the information from the sense resistor 106 can be provided to the microprocessor 18 . The microprocessor can then perform time-integration calculations to obtain information concerning the voltage across the capacitor 60 during defibrillation energy delivery operations.
A limit circuit includes an inductor 64 is connected in series between the positive terminal of the energy storage circuit 42 at node 62 and resistor 68 . A suitable value for the inductor 64 is between 100 and 200 μH, preferably 150 μH. A high voltage diode D 1 is connected in parallel to the inductor 64 at nodes 62 and 80 . The inductor 64 controls the rate at which the current that is delivered to the steering circuit 46 by the ESC 42 can increase. The advantage of providing the inductor 64 in series with the ESC 42 is that by slowing the rate at which the current through the steering circuit 46 can ramp up, additional time is provided for the monitor circuit 50 to instruct a disarm circuit to disconnect the bridge in the event of an over-current situation. Further, the inductor 64 controls dl/dt such that a fixed current threshold can be used for over-current detection. The advantage of providing diode D 1 in parallel to the inductor 64 is that the diode functions to snub the inductor during current interruption.
The protection circuit 48 of FIG. 2 is shown in FIG. 3 as two distinct subcircuits—namely, a current limit resistor 68 and a disarm circuit 66 .
The current limit resistor 68 is connected in series between inductor 64 (which is connected to the positive terminal 62 of the capacitor 60 ) and the upper node 76 of the steering circuit 46 . The limit resistor 68 limits maximum current flow from the inductor 64 through the steering circuit; a suitable resistance value for the limit resistor 68 is between approximately 3-7Ω, more preferably 5Ω.
The disarm circuit 66 includes a disarm resistor 72 (with a suitable resistance value being between approximately 3-7Ω, more preferably 5Ω) and an SCR 74 . The disarm resistor 72 and SCR 74 are connected in series between the upper terminal 76 of the steering circuit 46 and the negative terminal 102 of the capacitor 60 , thereby providing an electrical path shunting the steering circuit. If a fault condition is detected (such as an over-current condition), the disarm SCR 74 is switched on and the energy stored in the capacitor 60 substantially dissipated in the disarm resistor 72 and the limit resistor 68 . The disarm SCR 74 is selectively switched on by a disarm drive signal provided by the drive circuitry 52 shown in FIG. 2 .
Another aspect of the invention is that it provides a mechanism to isolate the patient from the high voltages when the defibrillator is in monitoring mode, thus keeping current from leaking onto the patient 104 prior to delivery of the therapeutic energy pulse. Resistors 152 and 172 function to ground the patient and the ECG circuitry 24 , thus preventing current leakage during standby operations. Resistors 152 and 172 are selected to drain the upper SCR leakage currents when the ESC 42 is charging or charged in normal operation. IGBT 100 is left on (during the monitoring mode) to facilitate bleed off of the leakage through resistors 152 and 172 . The impedance of resistors 152 and 172 is selected so that under worst case operating conditions a minimal voltage is present at the isolation relay 200 contacts. A suitable value for resistors 152 and 172 is between approximately 5-10Ω, more preferably 9.4 kΩ.
An important aspect of this invention is that leakage resistors 152 and 172 are returned to the collector of IGBT 100 . This allows the resistors 152 , 172 to have a low resistance value without compromising commutation of the H-bridge. For example, if the resistors were returned to ground, the current flowing through the upper SCRs might exceed the hold current and the SCRs would stay on between phases. If the SCRs stayed on, a cross-conduction of the H-bridge would occur. These resistors also serve as a path to remove charge from a snubber network 150 during the commutation interval.
Additionally resistor R x and high voltage diode D 3 are provided in parallel to IGBT 100 collector-emitter at nodes 104 and 82 . Diode D 3 prevents a negative voltage across IGBT 100 during high impedance aborts. A high impedance abort occurs, for example, when the patient impedance at 104 is greater than 200Ω. Typically when patient impedance exceeds 200Ω the shock is aborted because it is not possible to complete the therapeutic shock without resulting in an over-voltage condition on the IGBT 100 during the commutation interval.
Resistor R x bleeds off IGBT collector-emitter capacitance during commutation interval. This results in a reduction or elimination of residual voltage at V A or V S prior to initiation of the next phase of the shock. Where V A is the voltage at the apex of the patient; V S is the voltage at the sternum of the patient.
The snubber network 150 has a capacitor 154 and a resistor 156 . The capacitor 154 and resistor 156 are connected in series. Capacitor 154 , resistor 156 and inductor 64 function to limit the rate of change of voltage across the SCR LL 98 when patient impedance is high. By controlling the rate of change of voltage (dV/dT), SCR LL 98 will not accidentally turn on when current is flowing from SCR UL 90 to SCR LR 94 during the first phase of the energy delivery, which might otherwise occur as a result of the voltage change at node 148 . Suitable values for capacitor 154 is from 0.007 to 0.03 μF, preferably 0.01 μF; suitable values for resistor 156 is from 25 to 100Ω, preferably 50Ω.
Isolation relay 200 , comprising switches 202 and 204 , is provided respectively between nodes 20 and 22 and patient 104 . The isolation relay 200 is used to prevent leakage, impedances or voltages from interfering with the ECG acquisition function during monitoring and charging activities.
Like resistor 152 , resistor 172 is provided on the other side of the H-bridge to isolate the patient 104 and the ECG circuitry 24 , thus preventing current leakage during standby operations.
The above-described control signals may be provided by any of a wide variety of suitable drive circuits known to those skilled in the art. For example, the control signals applied to the gates of the bridge SCR UL 90 , SCR UR 92 , SCR LR 94 , SCR LL 98 , may each be suitably provided by a corresponding pulse transformer. The secondary coil of each of the transformers may be tied directly to the corresponding SCR gate, with the SCRs designed so that, once triggered and conducting, they will tolerate the short-circuit on the gate-cathode junction that occurs with transformer saturation. Because of the more precise timing requirements for defibrillator disarm operations, the disarm SCR 74 may, for example, be suitably controlled by a logic-level MOSFET switching a bipolar pull-up transistor (not shown). A switching circuit is also provided, shown as IGBT 100 . The control signal applied to turn IGBT 100 on and off may, for example, be provided by bipolar pull-up and pull-down transistors (not shown), respectively, which may themselves be triggered by logic-level MOSFET devices (not shown).
The operation of the circuit structure shown in FIG. 3 will now be described. The capacitor 60 is charged by the charging circuitry 40 (shown in FIG. 2) to approximately 2000-2400 V, with the positive terminal 64 having a positive voltage relative to the negative terminal 102 . During monitoring operations, the capacitor 60 is fully charged, but no defibrillation energy is delivered to the patient pending completion of ECG monitoring by the ECG circuit 24 (shown in FIG. 1 ). During standby operation IGBT 100 is on. If the results of the ECG monitoring indicate that defibrillation energy should be delivered to the patient the isolation relay 200 is closed. After an appropriate settling time, SCR UL 90 and SCR LR 94 are turned on and conduction is initiated. During the first phase of the biphasic pulse delivery, current flows from the positive terminal 62 of the capacitor 60 through the inductor 64 , limit resistor 68 , SCR UL 90 , the patient, SCR LR 94 , IGBT 100 and the sense resistor 106 . When the microprocessor 18 has determined that phase 1 of the waveform is nearing completion, it signals the ASIC 26 to terminate phase 1 . Following a brief pause of approximately 400 μs, known as the commutation interval (or interphase delay), IGBT 100 is turned on and the approximately 10 μs later SCR UR 92 and SCR LL 98 are turned on, and electrical energy is further discharged through the patient in the second phase of the biphasic pulse applied to the patient. As will be appreciated by those of skill in the art, delivery of a multiphasic pulse would require these steps to be repeated until the desired number of phases had been achieved. Thus, no specific description of how to deliver a multiphasic pulse is provided.
SCRs of the type suitable for use in the steering circuit 46 and as the disarm SCR 74 are currently readily available. These SCRs can withstand the high voltage and currents occurring during defibrillation operations, and can also survive relatively intense transient effects, such as might occur due to a short circuit or when energy delivery operations are interrupted.
As is well known in the art, one disadvantage of SCRs is that, once turned on, they are not easily turned off absent a forced current commutation. Thus, the energy steering circuit 46 requires at least one switching element that can be turned off for purposes of current commutation and reversing polarity during biphasic energy delivery. Switching elements that can withstand the high voltages and currents that may occur during defibrillation operations are not readily or cost-effectively available. For example, readily available IGBTs can safely withstand a voltage of 1200 V applied across the collector and emitter. In the past IGBTs have been stacked in an effort to overcome limitations on voltage tolerances. However, this solution involves unnecessary complications to the bridge design. Those skilled in the art will appreciate that, if the above-described IGBT 100 were itself to “open” the steering circuit 46 to interrupt delivery of electrical energy from the capacitor 60 (when fully or near-fully charged), the voltage experienced by the IGBT 100 would significantly exceed the rated 1200 V limit thereby damaging the circuit.
In accordance with the embodiment of the invention depicted in FIG. 3, the IGBT 100 is protected from elevated voltages and currents. In the event of an over-current condition (caused, for example, by a short-circuit at the patient electrodes 22 ), the disarm SCR 74 is first switched on to begin discharging the capacitor 60 through the limit resistor 68 and the disarm resistor 72 . Because the resistors 68 and 72 form a voltage divider, the IGBT 100 can then be shut off at a lower collector-to-emitter voltage than would otherwise be the case. Thus, a single IGBT 100 may be employed, rather than the conventional multiple component approach found in current AED designs. Further, because the disarm circuit is external to the H-bridge, the ESC 42 can be safely disarmed without exposing the patient 104 to high voltages. In the event of a high impedance load fault, the microprocessor 18 can signal the OIWAL to protect the H-bridge and the patient load in a similar fashion. As will be appreciated by those of skill in the art a high impedance load fault can occur at several times during operation of the bridge. Initially, a high impedance load fault can occur during the initial voltage delivery (for example where the electrode pads are shorted out). Additionally, a high impedance load fault can occur at the end of phase one, where, for example, more than 1200 V remains on the capacitor. In either situation, the microprocessor signals the OIWAL to protect the patient and the H-bridge by aborting the shock. However, where the load fault is detected at the end of a phase, the result is that the shock delivered comprises only the phases delivered. Specifically, where the fault occurs at the end of phase one, the result is that a monophasic shock to the patient.
The embodiment of the present invention shown in FIG. 3 provides a relatively inexpensive and robust defibrillation energy delivery circuit. In contrast with currently available designs, the provision of the disarm circuit 66 allows a bridge circuit design comprised of four individual switching elements, which are readily available and low cost SCRs. In the event of a fault condition, such as an over-voltage condition, the energy stored in the capacitor 60 can be similarly discharged safely through the disarm circuit 48 .
In operation, the disarm circuit 66 is triggered in response to an over-current condition. Approximately 1 μs later, the IBGT 100 is turned off by OIWAL. In a preferred embodiment, the over-current trip point is set at approximately 80 Amps. At the maximum voltage of the capacitor the dl/dt of the inductor is approximately 14 A/μs. When the SCR is fired the resistors form a dividing network (with a ratio of approximately 2:1), where the top of the H-bridge is at the center point. When the IGBT 100 is turned off, the maximum voltage at the collector is V CAP /2. More importantly, as the IGBT 100 is turning off there is effectively a 5Ω snubber resitance across the collector-emitter junction. This provides a high degree of margin for RBSOA, which is the safe operating area of the IGBT 100 during turn-off.
Those skilled in the art will understand that certain of the circuits and components shown in FIGS. 1-3 have not been described in particular detail. In such case, the circuits and components are the type whose function and interconnection is well known in the art, and one skilled in the art would be able to use such circuits and components in the described combination to practice the present invention. The internal details of these particular circuits are not critical to the invention, and a detailed description of such internal circuit operation is therefore not required.
It will be appreciated that, while specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Those skilled in the art will appreciate that many of the advantages associated with the circuits described above in connection with FIG. 3 may be provided by other circuit configurations. Those skilled in the art will also understand that a number of suitable circuit components, other than those particular ones described above, can be adapted and combined in a variety of circuit topologies to implement a high voltage delivery circuit in accordance with the present invention. Accordingly, the invention is not limited by the disclosed embodiments, but instead the scope of the invention is determined by the following claims.
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An automatic external defibrillator is described that includes a high voltage delivery circuit for producing an electrical pulse to defibrillate a patient. In a preferred embodiment the electrical pulse is a biphasic or multiphasic electrical pulse. In one embodiment, the delivery circuit includes a high voltage capacitor coupled with a bridge circuit. The capacitor stores electrical energy for delivery to the patient, and the bridge circuit has four switching elements that are selectively switched to steer the current through the patient. A disarm circuit shunts the bridge circuit and operates to route energy away from the bridge circuit in the event a fault condition is detected, such as a short circuit at the patient electrodes. An example disarm circuit is a series-connected SCR and resistor. Also, a limiting circuit element (such as a resistor or an inductor) is provided in series with the capacitor. Together with the disarm circuit, the limiting circuit element reduces the voltage experienced by the bridge circuit switching elements when switched off in response to the detected fault condition. Consequently simpler, more robust, and less expensive high voltage delivery circuits are provided, as compared to conventional defibrillator circuit designs. A snubber circuit is also provided to prevent voltage from reaching the patient when the device is in standby mode.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a diesel engine, and more particularly, to a diesel engine capable of preventing a PM accumulation amount of a DPF from increasing excessively.
(2) Description of Related Art
As conventional diesel engines, there is a diesel engine including a DOC, a DPF, a PM accumulation amount estimating device of the DPF, a control unit, a DPF regenerating device, a DOC inlet temperature detector, an intake throttle device and an air intake amount detector (see Japanese Patent Application No. 2007-321705 (FIG. 1) for example).
The engine of this kind has a merit that even if the PM is accumulated on the DPF, DPF can be regenerated by the DPF regenerating device and the DPF can be reused.
However, the conventional diesel engine has such a problem that an intake throttling target value for regenerating the DPF to increase exhaust gas temperature to activation temperature of the DOC is only an air intake amount.
BRIEF SUMMARY OF THE INVENTION
Problem
There is concern that a PM accumulation amount of the DPF increases excessively.
According to the conventional diesel engine, since the intake throttling target value for regenerating the DPF is only the air intake amount, an intake throttling amount in air intake amount feedback control is limited, and in an operating state where a load is light and exhaust gas temperature is low, DOC inlet exhaust gas temperature does not rise up to DOC activation temperature, regeneration of the DPF is postponed for long periods, and there is concern that the PM accumulation amount of the DPF increases excessively. In this case, the DPF can not be used and exchange thereof is required in some cases.
It is an object of the present invention to provide a diesel engine capable of preventing a PM accumulation amount from increasing excessively.
Means for Solving the Problem
A matter to define the invention is as follows.
As illustrated in FIG. 1 , a diesel engine includes a DOC 1 , a DPF 2 , a PM accumulation amount estimating device 3 of the DPF 2 , a control unit 4 , a DPF regenerating device 5 , a DOC inlet exhaust gas temperature detector 6 , an intake throttle device 7 , an air intake amount detector 8 and a load detector 9 , when a PM accumulation estimate value of the DPF 2 reaches a predetermined value P and DOC inlet exhaust gas temperature reaches a predetermined value T0, DPF regenerating processing is started, unburned fuel is mixed into exhaust gas 10 in the DPF regenerating processing by the DPF regenerating device 5 under control of the control unit 4 as illustrated in FIG. 1 , temperature of exhaust gas 10 rises by catalytic combustion at the DOC 1 of the unburned fuel, PM accumulated on the DPF 2 is burned and removed and the DPF 2 is regenerated as shown in FIG. 2 , when the DOC inlet exhaust gas temperature does not reach the predetermined value T0, air intake amount feedback control is carried out by the control unit 4 , in the air intake amount feedback control, a target value of DPF regenerating intake throttling S 8 is set S 5 to a predetermined air intake amount V, and when the DOC inlet exhaust gas temperature reaches the predetermined value T0 by the DPF regenerating intake throttling S 8 , the DPF regenerating processing is started, and when the DPF regenerating processing is not started even when elapsed time reaches a predetermined value t after the air intake amount feedback control is started in a state where the DOC inlet exhaust gas temperature does not reach the predetermined value T0, the air intake amount feedback control is changed to exhaust gas temperature feedback control by the control unit 4 as shown in FIG. 2 , in the exhaust gas temperature feedback control, a target value of DPF regenerating intake throttling S 15 is changed to S 13 predetermined DOC inlet exhaust gas temperature T0 by the control unit 4 , when the DOC inlet exhaust gas temperature reaches the predetermined value T0 by the DPF regenerating intake throttling S 15 , the DPF regenerating processing is started, and when application of a load exceeding a predetermined amount is detected before the DOC inlet exhaust gas temperature reaches the predetermined value T0, the exhaust gas temperature feedback control is returned to the air intake amount feedback control by the control unit 4 as shown in FIG. 2 .
Effect of the Invention
It is possible to prevent a PM accumulation amount of a DPF from increasing excessively.
As illustrated in FIG. 2 , when the DPF regenerating processing is not started even when elapsed time reaches a predetermined value t after the air intake amount feedback control is started in a state where the DOC inlet exhaust gas temperature does not reach the predetermined value T0, the air intake amount feedback control is changed to exhaust gas temperature feedback control by the control unit 4 as illustrated in FIG. 2 . Therefore, limitation of the intake throttling of the air intake amount feedback control for regenerating the DPF is released, and air intake is further throttled. According to this, even in the operating state where a load is light and exhaust gas temperature is low, it is possible to raise DOC inlet exhaust gas temperature up to activation temperature of a DOC 1 in a short time, DPF regenerating processing is carried out early, and it is possible to prevent the PM accumulation amount of the DPF from increasing excessively.
Effects
Even if a load is applied, it is possible to stabilize rotation of an engine.
As illustrated in FIG. 2 , when application of a load exceeding a predetermined amount is detected before the DOC inlet exhaust gas temperature reaches the predetermined value T0, the exhaust gas temperature feedback control is returned to the air intake amount feedback control by the control unit 4 . Therefore, an air intake amount suitable for main injection which is increased by an applied load is secured, and it is possible to stabilize rotation of an engine.
It is possible to stabilize rotation of an engine.
As illustrated in FIG. 2 , in the exhaust gas temperature feedback control, before the DPF regenerating intake throttling S 15 in which the target value is set to a predetermined DOC inlet exhaust gas temperature T0, exhaust gas preliminary temperature rising processing S 14 is carried out by the control unit 4 , after-injection S 14 - 3 by the common rail device 11 is included in the exhaust gas preliminary temperature rising processing S 14 , and the after-injection S 14 - 3 is carried out at injection timing which is earlier than that of the post-injection S 3 . Therefore, it is possible to preliminary raise temperature of exhaust gas 10 before the DPF regenerating intake throttling S 15 by the after-injection S 14 - 3 , and it is possible to correspondingly make the intake throttling gentle and to correspondingly increase the air intake amount, and it is possible to stabilize the rotation of the engine by increase in output.
Effects
It is possible to swiftly start the DPF regenerating processing.
As illustrated in FIG. 2 , before the DPF regenerating intake throttling S 15 , after-injection S 14 - 3 preliminary raises temperature of exhaust gas 10 , temperature of the DOC 1 is brought close to activation temperature. Therefore, it is possible to swiftly start the DPF regenerating processing.
It is possible to swiftly start the DPF regenerating processing.
As illustrated in FIG. 2 , in the air intake amount feedback control, before the DPF regenerating intake throttling S 8 , the after-injection S 7 - 3 preliminary raises temperature of exhaust gas 10 and temperature of DOC 1 is brought close to activation temperature. Therefore, it is possible to swiftly start the DPF regenerating processing.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
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.
In the drawings:
FIG. 1 is a schematic diagram of a diesel engine according to an embodiment of the present invention;
FIG. 2 is a main flowchart of control of the engine shown in FIG. 1 ;
FIG. 3 is a sub-flowchart showing details of after-injection under air intake amount feedback control in FIG. 2 ; and
FIG. 4 is a sub-flowchart showing details of after-injection under exhaust gas temperature feedback control in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 to 4 are diagrams for describing a diesel engine according to an embodiment of the present invention. In this embodiment, a vertical type straight four-cylinder diesel engine will be described. This engine is used for an engine generator.
A general outline of this engine is as follows.
A cylinder head 13 is assembled into a cylinder block 12 , an engine cooling fan 14 is placed on a front portion of the cylinder block 12 , and a flywheel 15 is placed on a rear portion of the cylinder block 12 .
An intake manifold (not shown) is assembled into one of lateral sides of the cylinder head 13 , and an exhaust manifold 16 is assembled into the other lateral side.
A supercharger 17 is mounted on the exhaust manifold 16 , an exhaust path 18 extends from an exhaust turbine 17 a of the supercharger 17 , and an air suction path 38 extends from an air compressor 17 b of the supercharger 17 .
As shown in FIG. 1 , this engine includes a DOC 1 , a DPF 2 , a PM accumulation amount estimating device 3 of the DPF 2 , a control unit 4 , a DPF regenerating device 5 , a DOC inlet exhaust gas temperature detector 6 , an intake throttle device 7 , an air intake amount detector 8 and a load detector 9 .
As shown in FIG. 1 , the DOC 1 is placed on an upstream side in a DPF case 36 of an exhaust path 18 , and the DPF 2 is placed on a downstream side in the DPF case 36 .
The DOC 1 is an oxidation catalyst, and an oxidation catalyst component of the DOC 1 is supported by a honeycomb-shaped ceramic carrier. The DOC 1 is a flow-through monolith having cells 1 a , both ends of the cells 1 a are opened, and exhaust gas 10 passes through an inside of the cells 1 a.
The DPF 2 is a diesel particulate filter, an oxidation catalyst component of the DPF 2 is supported by a honeycomb-shaped ceramic carrier, the DPF 2 is a wall-flow monolith having adjacent cells 2 a and 2 a , ends of the cells 2 a and 2 a are alternately closed, exhaust gas 10 passes through a wall 2 b between the adjacent cells 2 a and 2 a , and PM included in the exhaust gas 10 becomes trapped. The PM is an abbreviation of particulate material.
The PM accumulation amount estimating device 3 of the DPF 2 is a computation unit of an engine ECU which is the control unit 4 . The PM accumulation amount estimating device 3 estimates a PM accumulation amount of the DPF 2 from map data which is previously obtained experimentally based on the engine target rotation number, the engine actual rotation number, DPF inlet exhaust gas temperature, DPF inlet exhaust gas pressure, exhaust gas differential pressure at an inlet and an outlet of the DPF 2 , DPF outlet exhaust gas temperature and fuel injection amount which are respectively detected by an engine target rotation number setting device 19 , an engine actual rotation number detector 20 , a DPF inlet exhaust gas temperature detector 21 , a DPF inlet exhaust gas pressure detector 22 , a differential pressure detector 23 and a DPF outlet exhaust gas temperature detector 37 .
The engine ECU is an engine electronic control unit and is a microcomputer.
As shown in FIG. 1 , the DPF regenerating device 5 includes the DOC 1 and a common rail device 11 .
The common rail device 11 includes injectors 24 , a common rail 25 , a fuel supply pump 26 and a fuel tank 27 . The injector 24 is mounted on the cylinder head 13 for each of the cylinders, and the injectors 24 are connected to the common rail 25 through high pressure pipes. Fuel 28 is supplied, under pressure, from the fuel tank 27 to the common rail 25 by the fuel supply pump 26 . A solenoid valve 24 a of the injector 24 is electrically connected to the control unit 4 , the solenoid valve 24 a is opened for predetermined time at predetermined timing, and a predetermined amount of fuel is injected at predetermined timing.
As shown in FIGS. 2 to 4 , as injections of the common rail device 11 , there are main injection which is injected near a top dead center of a compression stroke, after-injections S 7 - 3 and S 14 - 3 and a post-injection S 3 which are injected in an exhaust stroke. Injection timing of the after-injections S 7 - 3 and S 14 - 3 is earlier than the post-injection S- 3 . The main injection is injection for obtaining engine output. The after-injections S 7 - 3 and S 14 - 3 are injections for preliminary raising temperature of exhaust gas 10 before intake throttling S 8 and S 15 for regenerating the DPF. The post-injection S 3 is injection for mixing unburned fuel into exhaust gas 10 , for catalytic burning the fuel by the DOC 1 , for raising temperature of exhaust gas 10 , and for regenerating the DPF 2 .
As shown in FIG. 1 , injection timing and injection time of the injectors 24 are controlled by the control unit 4 based on the engine actual rotation number and a crank angle respectively detected by the engine actual rotation number detector 20 and a crank angle detector 29 , and phases of combustion cycles of the cylinders detected by a cylinder discriminating device 30 . The engine actual rotation number detector 20 and the crank angle detector 29 are pickup coils which face an outer periphery of a rotor plate 31 of the flywheel 15 . The engine actual rotation number detector 20 and the crank angle detector 29 detect the number of teeth which are provided in quantity on an outer periphery of the rotor plate 31 at constant intervals from one another. The cylinder discriminating device 30 is also a pickup coil which faces an outer periphery of a sensor plate 32 which is mounted on a camshaft. The cylinder discriminating device 30 discriminates phases of combustion cycles of the cylinders by detecting projections provided on the outer periphery of the sensor plate 32 . The cylinder discriminating device 30 and the pickup coils configuring the engine actual rotation number detector 20 and the crank angle detector 29 are electrically connected to the control unit 4 .
As the DPF regenerating device 5 , it is possible to use a combination of the DOC 1 and an exhaust gas pipe fuel injection device in addition to a combination of the DOC 1 and the common rail device 11 , and it is also possible to use an electric heater as the DPF regenerating device 5 .
As shown in FIGS. 1 and 2 , the intake throttle device 7 is an intake throttle valve. When DOC inlet exhaust gas temperature is less than activation temperature T0 of the DOC 1 , intake throttling S 8 and S 15 for gradually reducing an opening degree of the intake throttle valve is carried out by the control unit 4 , the air intake amount is reduced, and DOC inlet exhaust gas temperature rises.
The intake throttle device 7 is placed between the intake manifold and an intercooler 33 provided downstream of the air compressor 17 b of the supercharger 17 .
The air intake amount detector 8 is an air flow sensor, and is placed between an air cleaner 34 and the air compressor 17 b of the supercharger 17 . The intake throttle device 7 and the air intake amount detector 8 are electrically connected to the control unit 4 .
The load detector 9 is a computation processing unit of the engine ECU, and detects a load based on increase in an injection amount of the main injection.
When a mechanical cam-type fuel injection pump is used instead of the common rail device 11 , it is possible to use a rack position sensor which detects a fuel amount adjusting rack position of a fuel injection pump as the load detector 9 .
As shown in FIG. 2 , if the PM accumulation estimate value of the DPF 2 reaches a predetermined value P and the DOC inlet exhaust gas temperature reaches the predetermined value T0, the regenerating processing of the DPF 2 is started. As shown in FIG. 1 , in the DPF regenerating processing, unburned fuel is mixed into the exhaust gas 10 by the DPF regenerating device 5 under control of the control unit 4 , temperature of the exhaust gas 10 rises by catalytic combustion at the DOC 1 of the unburned fuel, PM accumulated on the DPF 2 is burned and removed, and the DPF 2 is regenerated.
As shown in FIG. 2 , when the DOC inlet exhaust gas temperature does not reach the predetermined value T0, the air intake amount feedback control is carried out by the control unit 4 . In the air intake amount feedback control, a target value of DPF regenerating intake throttling S 8 is set S 5 to a predetermined air intake amount V, and if the DOC inlet exhaust gas temperature reaches the predetermined value T0 by the DPF regenerating intake throttling S 8 , the DPF regenerating processing is started, and even if predetermined time value t is elapsed after the air intake amount feedback control is started in a state where the DOC inlet exhaust gas temperature does not reach the predetermined value T0, if the DPF regenerating processing is not started, the air intake amount feedback control is changed to exhaust gas temperature feedback control by the control unit 4 .
As shown in FIG. 2 , in the exhaust gas temperature feedback control, a target value of the DPF regenerating intake throttling S 15 is changed to predetermined DOC inlet exhaust gas temperature T0 S 13 by the control unit 4 , and if the DOC inlet exhaust gas temperature reaches the predetermined value T0 by the DPF regenerating intake throttling S 15 , the DPF regenerating processing is started, and if a load exceeding a predetermined amount is detected before the DOC inlet exhaust gas temperature reaches the predetermined value T0, the exhaust gas temperature feedback control is returned to the air intake amount feedback control by the control unit 4 .
As shown in FIGS. 2 and 4 , in the exhaust gas temperature feedback control, before the DPF regenerating intake throttling S 15 in which the target value is the predetermined DOC inlet exhaust gas temperature T0 is carried out, the exhaust gas preliminary temperature rising processing S 14 is carried out by the control unit 4 , the after-injection S 14 - 3 by the common rail device 11 is included in the exhaust gas preliminary temperature rising processing S 14 , and the after-injection S 14 - 3 is carried out at injection timing which is earlier than the post-injection S 3 .
As shown in FIGS. 2 and 3 , in the air intake amount feedback control, before the DPF regenerating intake throttling S 8 in which the target value is the predetermined air intake amount V is carried out, exhaust gas preliminary temperature rising processing S 7 is carried out by the control unit 4 , the after-injection S 7 - 3 by the common rail device 11 is included in the exhaust gas preliminary temperature rising processing S 7 , and the after-injection S 7 - 3 is carried out at injection timing which is earlier than the post-injection S- 3 .
A flow of processing carried out by the control unit 4 is as follows.
As shown in FIG. 2 , it is determined in step S 1 whether an accumulation estimate value of PM which is accumulated on the DPF 2 reaches a predetermined value P. The value P is a determination reference value of DPF regeneration. If the decision in step S 1 is NO, determination in step S 1 is repeated, and the decision becomes YES, the procedure is shifted to step S 2 .
It is determined in step S 2 whether the DOC inlet exhaust gas temperature reaches the value T0, and if the decision is YES, the procedure is shifted to step S 3 . The value T0 is activation temperature of the DOC 1 .
The post-injection is carried out in step S 3 , and it is determined in step S 4 whether a regeneration completion condition of the DPF 2 is satisfied. The regeneration completion condition is that accumulated time of a DPF inlet exhaust gas temperature more than a predetermined value reaches predetermined time. If the decision in step S 4 is YES, the DPF regenerating processing is completed. If the decision in step S 4 is NO, the procedure is returned to step S 3 .
If the decision in step S 2 is NO, the air intake amount feedback control of the intake throttling is carried out.
In the air intake amount feedback control, the intake throttling target value is set to the air intake amount V in step S 5 . The air intake amount V is such an air intake amount that even if a certain level of load is applied to the engine, the engine rotation can stably be maintained, and the intake throttling is more limited as compared with the exhaust gas temperature feedback control in which the exhaust gas temperature is used as a target value.
Time keeping is started in step S 6 . The time keeping is carried out by a time keeping unit 35 of the control unit 4 .
The exhaust gas preliminary temperature rising processing is carried out in step S 7 . Details of the exhaust gas preliminary temperature rising processing will be described later.
The DPF regenerating intake throttling is carried out in step S 8 , the intake throttle valve is gradually closed and an opening thereof degree becomes small.
It is determined in step S 9 whether the air intake amount reaches the target value V, and if the decision is YES, the procedure is shifted to step S 10 , and if decision is NO, the procedure is returned to step S 8 .
It is determined in step S 10 whether the DOC inlet exhaust gas temperature reaches the value T0. If the decision is YES, the procedure is shifted to step S 3 , and if the decision is NO, the procedure is shifted to step S 11 .
It is determined in step S 11 whether the counted elapsed time reaches a predetermined value t. The value t is set to such a time value that postponement of regeneration of the DPF 2 can not further be permitted. If the decision in step S 11 is YES, the time keeping is completed in step S 12 , and control of the intake throttling is switched to the exhaust gas temperature feedback control. If the decision in step S 11 is NO, the procedure is returned to step S 10 .
In the exhaust gas temperature feedback control, the target value of the DPF regenerating intake throttling S 15 is changed from the air intake amount V to the DOC inlet exhaust gas temperature T0 in step S 13 .
The exhaust gas preliminary temperature rising processing is carried out in step S 14 . Details of the exhaust gas preliminary temperature rising processing will be described later.
The DPF regenerating intake throttling is carried out in step S 15 , the intake throttle valve is gradually closed and its opening degree becomes small.
It is determined in step S 16 whether the DOC inlet exhaust gas temperature reaches the value T0. If the decision is YES, the procedure is shifted to step S 3 , and if the decision is NO, the procedure is shifted to step S 17 .
It is determined in step S 17 whether application of a load exceeding a predetermined amount is detected. If the decision is YES, the procedure is returned to step S 5 , and the exhaust gas temperature feedback control of the intake throttling is returned to the air intake amount feedback control.
Details of the exhaust gas preliminary temperature rising processing by the air intake amount feedback control are as follows.
As shown in FIG. 3 , in step S 7 where the exhaust gas preliminary temperature rising processing is carried out, intake throttling for after-injection is first carried out in step S 7 - 1 . The intake throttle target value for the after-injection is DOC exhaust gas inlet temperature T0′. The value T0′ is temperature of the exhaust gas 10 at which after-injection is burned, and is lower than the value T0 which is the DOC activation temperature.
It is determined in step S 7 - 2 whether the DOC inlet exhaust gas temperature reaches the target value T0′. If the decision is YES, procedure is shifted to step S 7 - 3 , and if the decision is NO, procedure is returned to step S 7 - 1 .
The after-injection is carried out in step S 7 - 3 .
It is determined in step S 7 - 4 whether the DOC inlet exhaust gas temperature reaches the value T0. If the decision is YES, the procedure is shifted to step S 7 - 8 , and if the decision is NO, the procedure is shifted to step S 7 - 5 .
In step S 7 - 8 , the after-injection is continued even after that, and the procedure is shifted to step S 3 .
It is determined in step S 7 - 5 whether an amount of after-injection reaches an upper limit. If the decision is YES, the procedure is shifted to step S 7 - 6 , and if the decision is NO, the procedure is shifted to step S 7 - 7 .
In step S 7 - 6 , the injection amount is fixed, the after-injection is continued even after that, and the procedure is shifted to step S 8 .
In step S 7 - 7 , the after-injection amount is increased and the procedure is returned to step S 7 - 3 .
The exhaust gas preliminary temperature rising processing in the exhaust gas temperature feedback control is the same as the exhaust gas preliminary temperature rising processing in the air intake amount feedback control, and details thereof are as follows.
As shown in FIG. 4 , in step S 14 where the exhaust gas preliminary temperature rising processing is carried out, intake throttling for after-injection is first carried out in step S 14 - 1 . The intake throttling target value for the after-injection is DOC exhaust gas inlet temperature T0′. The value T0′ is temperature of the exhaust gas 10 at which after-injection is burned, and is lower than the value T0 which is the DOC activation temperature.
It is determined in step S 14 - 2 whether the DOC inlet exhaust gas temperature reaches the target value T0′. If the decision is YES, the procedure is shifted to step S 14 - 3 , and if the decision is NO, the procedure is returned to step S 14 - 1 .
The after-injection is carried out in step S 14 - 3 .
It is determined in step S 14 - 4 whether the DOC inlet exhaust gas temperature reaches the value T0. If the decision is YES, the procedure is shifted to step S 14 - 8 , and if the decision is NO, the procedure is shifted to step S 14 - 5 .
In step S 14 - 8 , the after-injection is continued even after that, and procedure is shifted to step S 3 .
It is determined in step S 14 - 5 whether an amount of after-injection reaches an upper limit. If the decision is YES, procedure is shifted to step S 14 - 6 , and if the decision is NO, the procedure is shifted to step S 14 - 7 .
In step S 14 - 6 , the injection amount is fixed, the after-injection is continued even after that, and the procedure is shifted to step S 15 .
In step S 14 - 7 , the after-injection amount is increased and the procedure is returned to step S 14 - 3 .
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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The present invention provides a diesel engine capable of preventing a PM accumulation amount from increasing excessively. If DOC inlet exhaust gas temperature (“IEGT”) does not reach a predetermined value T0, a control unit carries out air intake amount feedback control (“AIAFC”), and a target value of intake throttling is set to a predetermined air intake amount. If the DPF regenerating processing is not started even if elapsed time reaches a predetermined value t after AIAFC is started in a state where the DOC IEGT does not reach the predetermined value T0, the control unit changes AIAFC to exhaust gas temperature feedback control (“EGTFC”). In EGTFC, the control unit changes a target value of intake throttling to a predetermined DOC IEGT T0. If application of a load exceeding a predetermined amount is detected before the DOC IEGT reaches the predetermined value T0, the control unit returns EGTFC to AIAFC.
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PRIORITY OF INVENTION
[0001] This application is a continuation of Ser. No. 11/853,606, filed on Sep. 11, 2007, and claims priority under 35 U.S.C. 119(e) from U.S. Provisional Patent Application No. 60/844,020 filed 12 Sep. 2006, and from U.S. Provisional Patent Application No. 60/905,365 filed 7 Mar. 2007.
BACKGROUND OF THE INVENTION
[0002] International Patent Application Publication Number WO 2004/046115 provides certain 4-oxoquinolone compounds that are useful as HIV integrase inhibitors. The compounds are reported to be useful as anti-HIV agents.
[0003] International Patent Application Publication Number WO 2005/113508 provides certain specific crystalline forms of one of these 4-oxoquinolone compounds, 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid. The specific crystalline forms are reported to have superior physical and chemical stability compared to other physical forms of the compound.
[0004] There is currently a need for improved methods for preparing the 4-oxoquinolone compounds reported in International Patent Application Publication Number WO 2004/046115 and in International Patent Application Publication Number WO 2005/113508. In particular, there is a need for new synthetic methods that are simpler or less expensive to carry out, that provide an increased yield, or that eliminate the use of toxic or costly reagents.
SUMMARY OF THE INVENTION
[0005] The present invention provides new synthetic processes and synthetic intermediates that are useful for preparing the 4-oxoquinolone compounds reported in International Patent Application Publication Number WO 2004/046115 and in International Patent Application Publication Number WO 2005/113508.
[0006] Accordingly, in one embodiment the invention provides a compound of formula 3:
[0000]
[0000] or a salt thereof.
[0007] In another embodiment the invention provides a compound of formula 5a:
[0000]
[0000] or a salt thereof.
[0008] In another embodiment the invention provides a method for preparing a compound of formula 3:
[0000]
[0000] or a salt thereof comprising converting a corresponding compound of formula 2:
[0000]
[0000] or a salt thereof to the compound of formula 3 or the salt thereof.
[0009] In another embodiment the invention provides a method for preparing a compound of formula 9:
[0000]
[0000] wherein R is C 1 -C 6 alkyl, comprising cyclizing a corresponding compound of formula 8:
[0000]
[0010] In another embodiment the invention provides a compound of formula 15:
[0000]
[0000] or a salt thereof.
[0011] In another embodiment the invention provides a compound of formula 15a:
[0000]
[0000] In another embodiment the invention provides a compound of formula 16:
[0000]
[0012] In another embodiment the invention provides a method for preparing a compound of formula 15:
[0000]
[0000] or a salt thereof comprising converting a corresponding compound of formula 14:
[0000]
[0000] to the compound of formula 15 or the salt thereof.
[0013] The invention also provides other synthetic processes and synthetic intermediates disclosed herein that are useful for preparing the 4-oxoquinone compounds.
DETAILED DESCRIPTION
[0014] The following definitions are used, unless otherwise described: halo is fluoro, chloro, bromo, or iodo. Alkyl denotes both straight and branched groups, but reference to an individual radical such as propyl embraces only the straight chain radical, a branched chain isomer such as isopropyl being specifically referred to.
[0015] It will be appreciated by those skilled in the art that a compound having a chiral center may exist in and be isolated in optically active and racemic forms. Some compounds may exhibit polymorphism. It is to be understood that the present invention encompasses processes for preparing any racemic, optically-active, polymorphic, tautomeric, or stereoisomeric form, or mixtures thereof, of a compound described herein, it being well known in the art how to prepare optically active forms (for example, by resolution of the racemic form by recrystallization techniques, by synthesis from optically-active starting materials, by chiral synthesis, or by chromatographic separation using a chiral stationary phase).
[0016] Specific and preferred values listed below for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents.
[0017] Specifically, C 1 -C 6 alkyl can be methyl, ethyl, propyl, isopropyl, butyl, iso-butyl, sec-butyl, pentyl, 3-pentyl, or hexyl.
[0018] A specific value for R a is methyl.
[0019] A specific value for R b is methyl.
[0020] A specific value for R c is 1-imidazolyl.
[0021] A specific value for R is ethyl.
[0022] In one embodiment, the invention provides a method for preparing a compound of formula 3:
[0000]
[0000] or a salt thereof comprising converting a corresponding compound of formula 2:
[0000]
[0000] or a salt thereof to the compound of formula 3 or the a salt thereof. As illustrated below, the reaction can conveniently be carried out by combining Compound 2 with a polar aprotic solvent (e.g., tetrahydrofuran) and cooling the mixture below room temperature (e.g., to about −20° C.).
[0000]
[0000] This mixture can be treated with a first organometallic reagent (e.g., a dialkylmagnesium, dialkylzinc, an alkylmagnesium halide, a trialkylaluminum, or a metal hydride reagent) to form a carboxylate salt. For example, the mixture can be treated with about 0.5 equivalents of dibutylmagnesium or butylethylmagnesium, or about one equivalent of butylethylmagnesium-butanol adduct, to afford Compound A. The resulting mixture can be combined with a second organometallic reagent (e.g., an alkyllithium or alkylmagnesium halide) to form an organometallic compound (Compound B1 or B2). Typically, this is performed at a reduced temperature to affect metal/halogen exchange. For example, the resulting mixture can be combined with about 1.2-2.2 equivalents of an alkyl lithium (e.g., about 1.8 equivalents n-butyllithium or tert-butyllithium) at about −50±50° C. to afford an organo-lithium compound (Compound B1). In one embodiment of the invention metal/halogen exchange reaction can be carried out at a temperature of about −20±20° C. The progress of the metal/halogen exchange reaction can be monitored by any suitable technique (e.g., by HPLC). Upon completion of the reaction, 3-chloro-2-fluorobenzaldehyde (about 1.3. equivalents) can be added. The progress of the addition reaction can be monitored by any suitable technique (e.g., by HPLC). Compound 3 can be isolated by any suitable technique (e.g., by chromatography or crystallization). This method avoids any contamination issues and the cost associated with the use of other reagents (e.g. transition metals such as palladium reagents).
[0023] In one embodiment of the invention the compound of formula 2 or a salt thereof is prepared by brominating 2,4-dimethoxybenzoic acid. The reaction can be carried out using standard bromination conditions.
[0024] In one embodiment of the invention a compound of formula 3 or a salt thereof is converted to a compound of formula 4:
[0000]
[0000] or a salt thereof. About 1 to 5 hydride equivalents of a silane reducing agent (e.g., phenyldimethylsilane, polymethylhydrosiloxane, or chlorodimethylsilane, or a trialkylsilane such as triethylsilane) are combined with a suitable acid (e.g., trifluoroacetic acid, triflic acid or acetic acid). The reaction can conveniently be carried out by using about 1.2 to 2.0 hydride equivalents of triethylsilane and about 5 to 10 equivalents of trifluoroacetic acid. To this mixture is added Compound 3 or a salt thereof. Compound 3 or a salt thereof can conveniently be added to the mixture at a reduced temperature, for example, about 0±10° C. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). Upon completion of the reaction, Compound 4 or a salt thereof can be isolated using any suitable technique (e.g., by chromatography or crystallization). Compound 4 or a salt thereof can also be prepared by adding trifluoroacetic acid to Compound 3 in a suitable solvent and then adding a silane reducing agent to provide Compound 4.
[0025] Alternatively, Compound 4 or a salt thereof can be prepared by forming a corresponding organometallic compound from Compound 2 and reacting the organometallic compound with Compound 11:
[0000]
[0000] wherein R y is a suitable leaving group (e.g., a triflate, mesylate, tosylate, or brosylate, etc.).
[0026] In another embodiment of the invention the compound of formula 4 or a salt thereof is converted to a compound of formula 5′:
[0000]
[0000] or a salt thereof, wherein R c is a leaving group. The carboxylic acid functional group of Compound 4 can be converted to an activated species, for example an acid chloride or an acyl imidazolide (Compound 5′) by treatment with a suitable reagent, such as, for example, thionyl chloride, oxalyl chloride, cyanuric chloride or 1,1′-carbonyldiimidazole in a suitable solvent (e.g., toluene or tetrahydrofuran). Any suitable leaving group R c can be incorporated into the molecule, provided the compound of formula 5′ can be subsequently converted to a compound of formula 6. The reaction can conveniently be carried out using about 1 equivalent of 1,1′-carbonyldiimidazole in tetrahydrofuran.
[0027] In another embodiment of the invention a compound of formula 5′ or a salt thereof can be converted to a compound of formula 6:
[0000]
[0000] or a salt thereof, wherein R is C 1 -C 6 alkyl. For example, a compound of formula 5′ can be combined with about 1 to 5 equivalents of a monoalkyl malonate salt and about 1 to 5 equivalents of a magnesium salt in a suitable solvent. Conveniently, a compound of formula 5′ can be combined with about 1.7 equivalents of potassium monoethyl malonate and about 1.5 equivalents of magnesium chloride. A suitable base, for example triethylamine or imidazole, can be added to the reaction. The reaction can conveniently be carried out at an elevated temperature (e.g., about 100±50° C.) and monitored for completion by any suitable technique (e.g., by HPLC). Upon completion of the reaction, Compound 6 can be isolated using any suitable technique (e.g., by chromatography or crystallization).
[0028] In another embodiment of the invention the compound of formula 6 or a salt thereof, can be converted to a corresponding compound of formula 7:
[0000]
[0000] wherein R a and R b are each independently C 1 -C 6 alkyl; and R is C 1 -C 6 alkyl. Compound 6 can be converted to an activated alkylidene analog, such as Compound 7, by treatment with a formate group donor such as a dimethylformamide dialkyl acetal (e.g., dimethylformamide dimethyl acetal) or a trialkylorthoformate. The reaction can be carried out at elevated temperature (e.g., about 100±50° C.). This reaction may be accelerated by the addition of an acid catalyst, such as, for example, an alkanoic acid, a benzoic acid, a sulfonic acid or a mineral acid. About 500 ppm to 1% acetic acid can conveniently be used. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). Compound 7 can be isolated or it can be used directly to prepare a compound of formula 8 as described below.
[0029] In another embodiment of the invention the compound of formula 7 can be converted to a corresponding compound of formula 8:
[0000]
[0000] wherein R is C 1 -C 6 alkyl. Compound 7 can be combined with (S)-2-amino-3-methyl-1-butanol (S-Valinol, about 1.1 equivalents) to provide compound 8. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). The compound of formula 8 can be isolated or used directly to prepare a compound of formula 9 as described below. In another embodiment, the invention provides a method for preparing a compound of formula 9:
[0000]
[0000] wherein R is C 1 -C 6 alkyl, comprising cyclizing a corresponding compound of formula 8:
[0000]
[0000] Compound 8 can be cyclized to provide Compound 9 by treatment with a silylating reagent (e.g., N,O-bis(trimethylsilyl)acetamide, N,O-bis(trimethylsilyl)trifluoroacetamide or hexamethyldisilazane). The reaction can be conducted in a polar aprotic solvent (e.g., dimethylformamide, dimethylacetamide, N-methylpyrrolidinone or acetonitrile). A salt (e.g., potassium chloride, lithium chloride, sodium chloride or magnesium chloride) can be added to accelerate the reaction. Typically, about 0.5 equivalents of a salt such as potassium chloride is added. The reaction may be conducted at elevated temperature (e.g., a temperature of about 100±20° C.) if necessary to obtain a convenient reaction time. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). During the workup, an acid can be used to hydrolyze any silyl ethers that form due to reaction of the silylating reagent with the alcohol moiety of compound 8. Typical acids include mineral acids, sulfonic acids, or alkanoic acids. One specific acid that can be used is aqueous hydrochloric acid. Upon completion of the hydrolysis, Compound 9 can be isolated by any suitable method (e.g., by chromatography or by crystallization). In the above conversion, the silating reagent transiently protects the alcohol and is subsequently removed. This eliminates the need for separate protection and deprotection steps, thereby increasing the efficiency of the conversion.
[0030] In another embodiment of the invention the compound of formula 9 is converted to a compound of formula 10:
[0000]
[0000] Compound 9 can be converted to Compound 10 by treatment with a suitable base (e.g., potassium hydroxide, sodium hydroxide or lithium hydroxide). For example, about 1.3 equivalents of potassium hydroxide can conveniently be used. This reaction may be conducted in any suitable solvent, such as, for example, tetrahydrofuran, methanol, ethanol or isopropanol, or a mixture thereof. The solvent can also include water. A mixture of isopropanol and water can conveniently be used. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). The initially formed carboxylate salt can be neutralized by treatment with an acid (e.g., hydrochloric acid or acetic acid). For example, about 1.5 equivalents of acetic acid can conveniently be used. Following neutralization, Compound 10 can be isolated using any suitable technique (e.g., by chromatography or crystallization).
[0031] In another embodiment of the invention the compound of formula 10 can be crystallized by adding a seed crystal to a solution that comprises the compound of formula 10. International Patent Application Publication Number WO 2005/113508 provides certain specific crystalline forms of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carb oxylic acid. The entire contents of International Patent Application Publication Number WO 2005/113508 is incorporated herein by reference (in particular, see pages 12-62 therein). The specific crystalline forms are identified therein as Crystal Form II and Crystal Form III. Crystal form II has an X-ray powder diffraction pattern having characteristic diffraction peaks at diffraction angles) 2θ(°) of 6.56, 13.20, 19.86, 20.84, 21.22, and 25.22 as measured by an X-ray powder diffractometer. Crystal form III has an X-ray powder diffraction pattern having characteristic diffraction peaks at diffraction angles 2θ(°) of 8.54, 14.02, 15.68, 17.06, 17.24, 24.16, and 25.74 as measured by an X-ray powder diffractometer. International Patent Application Publication Number WO 2005/113508 also describes how to prepare a crystalline form of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid that have an extrapolated onset temperature of about 162.1° C., as well as how to prepare a seed crystal having a purity of crystal of not less than about 70%. Accordingly, seed crystals of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid can optionally be prepared as described in International Patent Application Publication Number WO 2005/113508. Advantageously, the process illustrated in Scheme I below provides a crude mixture of Compound 10 that can be directly crystallized to provide Crystal Form III without additional purification (e.g. without the prior formation of another polymorph such as Crystal Form II, or without some other form of prior purification), see Example 6 below.
[0032] In cases where compounds identified herein are sufficiently basic or acidic to form stable acid or base salts, the invention also provides salts of such compounds. Such salts may be useful as intermediates, for example, for purifying such compounds. Examples of useful salts include organic acid addition salts formed with acids, for example, tosylate, methanesulfonate, acetate, citrate, malonate, tartarate, succinate, benzoate, ascorbate, α-ketoglutarate, and α-glycerophosphate. Suitable inorganic salts may also be formed, including hydrochloride, sulfate, nitrate, bicarbonate, and carbonate salts.
[0033] Salts may be obtained using standard procedures well known in the art, for example by reacting a sufficiently basic compound such as an amine with a suitable acid affording an anion. Alkali metal (for example, sodium, potassium, or lithium) or alkaline earth metal (for example calcium or magnesium) salts of carboxylic acids, for example, can also be made.
[0034] The invention will now be illustrated by the following non-limiting Examples. An integrase inhibitor of formula 10 can be prepared as illustrated in the following Scheme 1.
[0000]
Example 1
Preparation of Compound 3
[0035] Compound 2 (10 g) was combined with 192 mL of THF and cooled to −20° C. The mixture was treated successively with 21 mL of 1 M dibutylmagnesium solution in heptane and 19.2 mL of 2.5 M n-butyllithium solution in hexane while maintaining the temperature at −20° C. 3-Chloro-2-fluorobenzaldehyde (7.3 g) was added and the mixture allowed to warm to 0° C. After 2 hours at that temperature the reaction was quenched by the addition of 55 mL of 2 M hydrochloric acid. The phases were separated and the organic phase was extracted with 92 mL of ethyl acetate. The combined organic layers were washed with 92 mL of saturated aqueous sodium chloride. The organic phase was concentrated and the product precipitated by the addition of 200 mL heptane. The slurry was filtered and the product air dried to yield Compound 3: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.15 (br s, 1H), 7.81 (s, 1H), 7.42 (t, J=7.2 Hz, 1H), 7.26 (t, J=6.8 Hz, 1H), 7.15 (t, J=7.8 Hz, 1H), 6.77 (s, 1H), 6.09 (d, J=4.7 Hz, 1H), 5.90 (d, J=4.9 Hz, 1H), 3.84 (s, 3H), 3.80 (s, 3H).
[0036] Alternatively, Compound 3 can be prepared as follows.
[0037] Compound 2 (20 g) was combined with 300 mL of THF and cooled to −20° C. The mixture was treated successively with 75.93 g mL of butylethylmagnesium-butanol adduct (BEM-B) solution in heptane and 35.08 g of 28 wt % t-butyllithium solution in heptane while maintaining the temperature at −20° C. 3-Chloro-2-fluorobenzaldehyde (15.80 g) was added and the mixture allowed to warm to 0° C. After 2 hours at that temperature the reaction was quenched by the addition of 2M hydrochloric acid. The phases were separated and the organic phase was extracted with ethyl acetate. The organic phase was dried over sodium sulfate and the product was precipitated by the addition of MTBE. The slurry was filtered and the product air dried to yield Compound 3 (18.00 g; 69.1% yield): 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.15 (br s, 1H), 7.81 (s, 1H), 7.42 (t, J=7.2 Hz, 1H), 7.26 (t, J=6.8 Hz, 1H), 7.15 (t, J=7.8 Hz, 1H), 6.77 (s, 1H), 6.09 (d, J=4.7 Hz, 1H), 5.90 (d, J=4.9 Hz, 1H), 3.84 (s, 3H), 3.80 (s, 3H).
[0038] Compound 3 can also be prepared as illustrated in the following Scheme.
[0000]
[0039] Compound 14 (10 g) was combined with 28 mL of THF and 9 mL of bisdimethylaminoethyl ether before being cooled to 0° C. Isopropylmagnesium chloride (22.9 mL of a 2.07 M solution in THF) was added and the mixture was allowed to warm to room temperature overnight. Additional isopropylmagnesium chloride (5 mL) was added to improve conversion before 3-chloro-2-fluorobenzaldehyde (4.4 mL) was added. After stirring at ambient temperature for 2 hours 38.6 g of a 14 wt % THF solution of isopropylmagnesium chloride lithium chloride complex was added. After stirring overnight at ambient temperature CO 2 gas was bubbled into the reaction mixture. When conversion was complete the reaction was quenched to pH<3 with 2 M hydrochloric acid. The phases were separated and the organic phase was extracted with ethyl acetate. The combined organic layers were washed with saturated aqueous sodium chloride. The organic phase was concentrated and the product precipitated by the addition of MTBE. The slurry was filtered and the product air dried to yield Compound 3: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.15 (br s, 1H), 7.81 (s, 1H), 7.42 (t, J=7.2 Hz, 1H), 7.26 (t, J=6.8 Hz, 1H), 7.15 (t, J=7.8 Hz, 1H), 6.77 (s, 1H), 6.09 (d, J=4.7 Hz, 1H), 5.90 (d, J=4.9 Hz, 1H), 3.84 (s, 3H), 3.80 (s, 3H).
[0040] Compound 3 can also be prepared as illustrated in the following Scheme.
[0000]
Example 2
Preparation of Compound 4
[0041] Triethylsilane (6.83 g) was added to trifluoroacetic acid (33.13 g) that had been pre-cooled in an ice bath. Compound 3 (10 g) was added to the mixture keeping the temperature below 15° C. After stirring for 2 h MTBE was added to precipitate the product. The slurry was filtered and the product washed with additional MTBE. After drying, 9.12 g of Compound 4 was isolated: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.11 (br s, 1H), 7.47 (s, 1H), 7.42-7.38 (m, 1H), 7.14-7.08 (m, 2H), 6.67 (s, 1H), 3.87-3.84 (m, 8H).
[0042] Alternatively, Compound 4 can be prepared as follows.
[0043] Triethylsilane (7.50 g) was added to trifluoroacetic acid (49.02 g) that had been pre-cooled in an ice bath. Compound 3 (14.65 g) was added to the mixture keeping the temperature below 15° C. After stirring for 1 h a solution of 17.63 g sodium acetate in 147 mL methanol was added. The mixture was heated to reflux for 3 hours then cooled to 0° C. The slurry was filtered and the product washed with additional methanol. After drying 12.3 g of Compound 4 (89.7% yield) was isolated: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.11 (br s, 1H), 7.47 (s, 1H), 7.42-7.38 (m, 1H), 7.14-7.08 (m, 2H), 6.67 (s, 1H), 3.87-3.84 (m, 8H).
Example 3
Preparation of Compound 5a
[0044] Imidazole (0.42 g) and 1,1′-carbonyldiimidazole (5.49 g) were slurried in 30 mL of THF at ambient temperature. Compound 4 (10 g) was added in one portion and the mixture was stirred at ambient temperature until the reaction was complete by HPLC. The resulting slurry was filtered and the solids washed with MTBE. The solids were dried to yield Compound 5a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.99 (s, 1H), 7.52 (s, 1H), 7.41-7.38 (m, 1H), 7.30 (s, 1H), 7.12-7.08 (m, 2H), 7.04 (s, 1H), 6.81 (s, 1H), 3.91 (s, 2H), 3.90 (s, 3H), 3.79 (s, 3H).
Example 4
Preparation of Compound 6a
[0045] Imidazole (0.42 g) and 1,1′-carbonyldiimidazole (5.49 g) were slurried in 30 mL of THF at ambient temperature. Compound 5a (10 g) was added in one portion and the mixture was stirred at ambient temperature for 4 hours to form a slurry of compound 5a. In a separate flask, 8.91 g of potassium monoethyl malonate was slurried in 40 mL of THF. Magnesium chloride (4.40 g) was added and the resulting slurry was warmed to 55° C. for 90 minutes. The slurry of Compound 5a was transferred to the magnesium chloride/potassium monoethyl malonate mixture and stirred at 55° C. overnight. The mixture was then cooled to room temperature and quenched by the dropwise addition of 80 mL of 28 wt % aqueous H 3 PO 4 . The phases were separated and the organic phase was washed successively with aqueous NaHSO 4 , KHCO 3 and NaCl solutions. The organic phase was concentrated to an oil and then coevaporated with ethanol. The resulting solid was dissolved in 30 mL ethanol and 6 mL water. Compound 6a was crystallized by cooling. The solid was isolated by filtation and the product was washed with aqueous ethanol. After drying Compound 6a was obtained: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.51 (s, 1H), 7.42-7.38 (m, 1H), 7.12-7.10 (m, 2H), 6.70 (s, 1H), 4.06 (q, J=7.0 Hz, 2H), 3.89 (s, 8H), 3.81 (s, 2H), 1.15 (t, J=7.0 Hz, 3H).
[0046] Alternatively, Compound 6a can be prepared as follows.
[0047] Carbonyldiimidazole (10.99 g) was slurried in 60 mL of THF at ambient temperature. Compound 4 (20 g) was added in one portion and the mixture was stirred at ambient temperature for 30 min to form a slurry of compound 5a. In a separate flask 15.72 g of potassium monoethyl malonate was slurried in 100 mL of THF. Magnesium chloride (6.45 g) was added and the resulting slurry was warmed to 55° C. for 5 hours. The slurry of Compound 5a was transferred to the magnesium chloride/potassium monoethyl malonate mixture and stirred at 55° C. overnight. The mixture was then cooled to room temperature and quenched onto 120 mL of 28 wt % aqueous H 3 PO 4 . The phases were separated and the organic phase was washed successively with aqueous KHCO 3 and NaCl solutions. The organic phase was concentrated to an oil and then coevaporated with ethanol. The resulting solid was dissolved in 100 mL ethanol and 12 mL water. Compound 6a was crystallized by cooling. The solid was isolated by filtation and the product was washed with aqueous ethanol. After drying 21.74 g Compound 6a (89% yield) was obtained: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.51 (s, 1H), 7.42-7.38 (m, 1H), 7.12-7.10 (m, 2H), 6.70 (s, 1H), 4.06 (q, J=7.0 Hz, 2H), 3.89 (s, 8H), 3.81 (s, 2H), 1.15 (t, J=7.0 Hz, 3H).
Example 5
Preparation of Compound 9a
[0048] Compound 6a (20 g) was stirred with 6.6 g dimethylformamide dimethyl acetal, 66 g toluene and 0.08 g glacial acetic acid. The mixture was warmed to 90° C. for 4 hours. The mixture was then cooled to ambient temperature and 5.8 g (S)-2-amino-3-methyl-1-butanol was added. The mixture was stirred at ambient temperature for 1 hour before being concentrated to a thick oil. Dimethylformamide (36 g), potassium chloride (1.8 g) and bis(trimethylsilyl)acetamide (29.6 g) were added and the mixture was warmed to 90° C. for 1 h. The mixture was cooled to room temperature and diluted with 200 g dichloromethane. Dilute hydrochloride acid (44 g, about 1N) was added and the mixture stirred at ambient temperature for 20 min. The phases were separated and the organic phase was washed successively with water, aqueous sodium bicarbonate and water. The solvent was exchanged to acetonitrile and the volume was adjusted to 160 mL. The mixture was heated to clarity, cooled slightly, seeded and cooled to crystallize Compound 9a. The product was isolated by filtration and washed with additional cold acetonitrile. Vacuum drying afforded Compound 9a: 1 H NMR (DMSO-do, 400 MHz) δ 8.61 (s, 1H), 7.86 (s, 1H), 7.45 (t, J=7.4 Hz, 1H), 7.26 (s, 1H), 7.23-7.14 (m, 2H), 5.10 (br s, 1H), 4.62 (br s, 1H), 4.18 (q, J=7.0 Hz, 2H), 4.03 (s, 2H), 3.96 (s, 3H), 3.92-3.84 (m, 1H), 3.78-3.75 (m, 1H), 2.28 (br s, 1H), 1.24 (t, J=7.0 Hz, 3H), 1.12 (d, J=6.4 Hz, 3H), 0.72 (d, J=6.4 Hz, 3H).
[0049] Alternatively, Compound 9a can be prepared as follows.
[0050] Compound 6a (50 g) was stirred with 17.5 g dimethylformamide dimethyl acetal, 90 g DMF and 0.2 g glacial acetic acid. The mixture was warmed to 65° C. for 3 hours. The mixture was then cooled to ambient temperature and 14.5 g (S)-2-amino-3-methyl-1-butanol and 25 g toluene were added. The mixture was stirred at ambient temperature overnight before being concentrated by distillation. Potassium chloride (4.5 g) and bis(trimethylsilyl)acetamide (80.2 g) were added and the mixture was warmed to 90° C. for 2 h. The mixture was cooled to room temperature and diluted with 250 g dichloromethane. Dilute hydrochloride acid (110 g of ˜1N) was added and the mixture stirred at ambient temperature for 30 min. The phases were separated and the organic phase was washed successively with water, aqueous sodium bicarbonate and water. The solvent was exchanged to acetonitrile by distillation. The mixture was heated to clarity, cooled slightly, seeded and cooled to crystallize Compound 9a. The product was isolated by filtration and washed with additional cold acetonitrile. Vacuum drying afforded 48.7 g (81% yield) of Compound 9a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.61 (s, 1H), 7.86 (s, 1H), 7.45 (t, J=7.4 Hz, 1H), 7.26 (s, 1H), 7.23-7.14 (m, 2H), 5.10 (br s, 1H), 4.62 (br s, 1H), 4.18 (q, J=7.0 Hz, 2H), 4.03 (s, 2H), 3.96 (s, 3H), 3.92-3.84 (m, 1H), 3.78-3.75 (m, 1H), 2.28 (br s, 1H), 1.24 (t, J=7.0 Hz, 3H), 1.12 (d, J=6.4 Hz, 3H), 0.72 (d, J=6.4 Hz, 3H).
Example 6
Preparation of Compound 10
[0051] Compound 9a (6.02 g) was slurried in 36 mL isopropanol and 24 mL of water. Aqueous potassium hydroxide (2.04 g of 45 wt % solution) was added and the mixture warmed to 40° C. After 3 hours 1.13 g glacial acetic acid was added the mixture seeded with 10 mg of Compound 10. The mixture was cooled in an ice bath for 2 hours and the solid was isolated by filtration. The cake was washed with aqueous isopropanol and dried to give Compound 10: 1 H NMR (DMSO-d 6 , 400 MHz) δ 15.42 (s, 1H), 8.87 (s, 1H), 8.02 (s, 1H), 7.48-7.45 (m, 2H), 7.23 (t, J=6.8 Hz, 1H), 7.17 (t, J=7.8 Hz, 1H), 5.18 (br s, 1H), 4.86 (br s, 1H), 4.10 (s, 2H), 4.02 (s, 3H), 3.97-3.96 (m, 1H), 3.79-3.76 (m, 1H), 2.36 (br s, 1H), 1.14 (d, J=6.3 Hz, 3H), 0.71 (d, J=6.3 Hz, 3H).
Example 7
Preparation of Compound 13
[0052] The conversion of Compound 7a to Compound 9a described in Example 5 above produced a second product that was believed to result from the presence of (S)-2-amino-4-methyl-1-pentanol in the (S)-2-amino-3-methyl-1-butanol reagent. As illustrated below, an independent synthesis of Compound 13 was carried out to confirm the identity of the second product.
[0000]
[0053] Compound 13 was prepared from Compound 12 using a procedure analogous to the preparation of Compound 10 in Example 6 above. Following the workup described, the product was extracted into anisole. The desired product was isolated as a foam after removal of the solvent: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.80 (s, 1H), 8.02 (s, 1H), 7.48-7.44 (m, 2H), 7.23 (t, J=7.2 Hz, 1H), 7.16 (t, J=7.6 Hz, 1H), 5.19 (br s, 1H), 4.09 (s, 2H), 4.00 (s, 3H), 3.77 (br s, 2H), 1.94-1.87 (m, 1H), 1.82-1.75 (m, 1H), 1.43 (hept, J=6.4 Hz, 1H), 0.89 (d, J=6.4 Hz, 3H), 0.85 (d, J=6.8 Hz, 3H).
[0054] The intermediate Compound 12 was prepared as follows.
[0000] a. Compound 12 was prepared from Compound 6a using a procedure analogous to the preparation of Compound 9a, except (S)-(+)-2-amino-4-methyl-1-pentanol was used in place of (S)-2-amino-3-methyl-1-butanol. The desired product was isolated as a foam after concentrating the final acetonitrile solution to dryness: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.54 (s, 1H), 7.86 (s, 1H), 7.46-7.43 (m, 1H), 7.25 (s, 1H), 7.22-7.14 (m, 2H), 4.97 (br s, 1H), 4.20-4.16 (m, 2H), 4.03 (s, 2H), 3.95 (s, 3H), 3.73 (br s, 2H), 1.83-1.82 (m, 1H), 1.72-1.69 (m, 1H), 1.43 (hept, J=6.4 Hz, 1H), 1.24 (t, J=7.2 Hz, 3H), 0.88 (d, J=6.4 Hz, 3H), 0.84 (d, J=6.4 Hz, 3H).
[0055] Compound 13 is useful as an HIV integrase inhibitor as described in International Patent Application Publication Number WO 2004/046115. Accordingly, the invention also provides Compound 13 or a salt thereof, as well as methods for preparing Compound 13 or a salt thereof. The invention also provides a composition comprising Compound 10 or a salt thereof and Compound 13 or a salt thereof, as well as a compositions comprising Compound 9a or a salt thereof and Compound 12 or a salt thereof. Such compositions are useful for preparing integrase inhibitors described in International Patent Application Publication Number WO 2004/046115.
[0056] Alternatively, Compound 10 can be prepared from Compound 2 as described in the following illustrative Examples 8-12 that are based on 1 kg of starting material.
Example 8
Preparation of a Compound of Formula 3
[0057]
[0058] Compound 2 is combined with anhydrous tetrahydrofuran and warmed to form a solution or thin slurry. The mixture is cooled to −20 to −30° C. and butylethylmagnesium in heptane is added. In a separate reactor n-butyllithium in hexane is combined with cold (−20 to −30° C.) tetrahydrofuran. The compound 2/butylethylmangesium slurry is transferred to the n-butyllithium solution while keeping the mixture at −20 to −30° C. The lithium/halogen exchange reaction is monitored for completion by HPLC. Once complete, a solution of 3-chloro-2-fluorobenzaldehyde in tetrahydrofuran is added. After 1 hour the mixture is warmed to 0° C. and monitored by HPLC for reaction completion. Once complete, the reaction is quenched with aqueous hydrochloric acid to pH 1 to 3. The phases are separated and the aqueous phase is extracted twice with ethyl acetate. The combined organic phases are dried with sodium sulfate at 18 to 25° C. After removing the sodium sulfate by filtration the solvent is exchanged to MTBE and the resulting slurry cooled to 0° C. The product is isolated by filtration, washed with cold MTBE and dried at NMT 40° C. to yield Compound 3.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 2
261.07
1.00
1.00
THF
72.11
11.4
BuEtMg (15% w/w in heptane)
110.48
~1.8
0.55-0.6
n-BuLi (in hexane)
64.06
~1.9
1.8
Aldehyde
158.56
0.79
1.3
2M HCl
36.5
3.8
37% HCl
36.5
0.33
EtOAc
88.11
4.6
Na 2 SO 4
142.04
2
MTBE
88.15
9.5
1. Charge 1.00 kg Compound 2 and 8.7 kg THF to the reactor (1).
2. Heat the mixture to 45-50° C. to dissolve all solids or until a thin, uniform slurry is formed with no heavy solids resting on the bottom of the reactor.
3. Cool the contents of the reactor (1) to −20 to −30° C.
4. Charge BuEtMg (15% w/w in heptane) (˜1.8 kg; 0.6 eq.) to reactor (1) maintaining the temperature of the reaction mixture below −20° C. during the addition.
5. In a separate reactor (2) charge 2.6 kg THF and cool to −20 to −30° C.
6. To reactor (2) charge n-BuLi (in hexane) (1.9 kg, 1.8 eq.) maintaining the temperature below −20° C. during the addition.
7. Transfer the contents of reactor (1) to reactor (2) maintaining the temperature below −20° C. during the addition.
8. To reactor (3) charge 0.5 kg of THF and cool to −20 to −30° C.
9. Transfer contents of reactor (3) to reactor (1) then on to reactor (2) as a wash forward.
10. Approximately 15 minutes after the reactor contents have been combined, sample the reaction mixture and analyze by HPLC to determine completion of lithium/halogen exchange. (Typically there is 1-8% of Compound 2 remaining. If the amount of Compound 2 is greater than 8% sample the reaction again after at least 30 min. before charging additional n-BuLi).
11. In an appropriate container combine 0.79 kg of aldehyde and 0.79 kg THF.
12. Charge contents of the container to the reactor. Maintain the temperature of the reaction mixture below −20° C. during addition.
13. Agitate the reaction mixture at −20° C. for 1 h then warm to 0° C.
14. Quench the reaction mixture by adjusting the pH with 2 M HCl (−3.8 kg) to a pH of 1 to 3.
15. Separate the phases.
16. Extract the aqueous phase with 2.3 kg EtOAc.
17. Extract the aqueous phase with 2.3 kg EtOAc.
18. Discard the aqueous phase.
19. Combine organic phases and dry with 2 kg of Na 2 SO 4 for at least 1 h. The temperature of the organic phase should be 20-25° C. before Na 2 SO 4 addition.
20. Filter the slurry to remove Na 2 SO 4 .
21. Concentrate the combined organic phases by vacuum distillation to ˜1.5 L (should form a thick slurry).
22. Charge 2.8 kg methyl t-butyl ether (MTBE) to the slurry.
23. Concentrate the mixture to ˜1.5 L.
24. Charge 2.8 kg MTBE to the slurry.
25. Concentrate the mixture to ˜1.5 L.
26. Charge 1.9 kg MTBE to the slurry.
27. Cool the slurry to ˜0° C. and isolate Compound 3 by filtration.
28. Wash forward the distillation vessel with 1.9 kg MTBE pre-cooled to ˜0° C.
29. Deliquor the cake until a granular solid is obtained. The purity of Compound 3 can be improved if necessary by reslurry in 6 volumes of 85:15 toluene:HOAc.
30. Dry the wet cake under vacuum at <40° C.
Example 9
Preparation of a Compound of Formula 4
[0089]
[0090] Compound 3 is combined with trifluoroacetic acid and stirred to form a solution. The solution is cooled to −3 to 3° C. and triethylsilane is added while maintaining the temperature at NMT 15° C. The reaction is monitored for completion by HPLC. Once complete, MTBE is added to precipitate Compound 4 and the mixture is cooled to 0° C. The product is isolated by filtration, washed with MTBE and dried at NMT 60° C. to yield Compound 4.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 3
340.73
1.00
1.00
MTBE
88.15
5.6
TFA
114.02
1.7
5
Et 3 SiH
116.28
0.4
1.2
1. Dissolve 1.00 kg Compound 3 in 1.7 kg TFA.
2. Cool the reaction mixture to −3 to 3° C.
3. Charge 0.4 kg triethylsilane to the reaction mixture. Maintain the temperature of the reaction mixture less than 15° C. during this addition.
4. Sample the reaction mixture 30 minutes after the addition of the triethylsilane and analyze by HPLC to verify the complete conversion of Compound 3 to Compound 4.
5. Charge 4.0 kg MTBE to the reaction mixture maintaining the temperature of the mixture below 15° C. during addition.
6. Cool the mixture to 0° C. and agitate for at least 30 min.
7. Isolate Compound 4 by filtration and wash the reaction vessel forward with 1.6 kg MTBE.
8. Dry the Compound 4 obtained under vacuum at <60° C.
Note: The purity of Compound 4 may be improved by reslurry in 4 volumes of acetone. The slurry is warmed to 40° C. for 2 hours and cooled to 18 to 25° C. for 12 hours before filtration and washing with two 1 volume portions of acetone.
Example 10
Preparation of a Compound of Formula 6a
[0099]
[0100] Carbonyldiimidazole and imidazole are combined with anhydrous tetrahydrofuran. Compound 4 is added to this mixture to form Compound 5a and the reaction is monitored by HPLC. In a separate reactor potassium monoethylmalonate is combined with tetrahydrofuran before anhydrous magnesium chloride is added while maintaining the temperature NMT 30° C. The resulting slurry is warmed to 50° C. and held for at least two hours before the Compound 5a mixture is added. The reaction is monitored by HPLC. Once the formation of Compound 5a is complete, the mixture is cooled to 18 to 25° C. and added to aqueous phosphoric acid to quench. The organic phase is washed with aqueous sodium bisulfate, brine, potassium bicarbonate and brine solutions before being polish filtered. The solvent is exchanged for anhydrous ethanol. Water is added and the mixture is warmed to dissolve solids, cooled to about 40° C., seeded with Compound 6a and cooled to 0 to 5° C. The product is filtered, washed with cold aqueous ethanol and dried at NMT 40° C. to yield Compound 6a.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 4
324.73
1.000
1.00
THF
72.11
7.11
Imidazole
68.08
0.042
0.20
CDI
162.15
0.55
1.10
KEM
170.2
0.89
1.70
MgCl 2
95.21
0.44
1.50
H 3 PO 4 (85 wt %)
98.00
2.3
NaHSO 4
120.06
0.24
KHCO 3
100.12
0.50
NaCl
58.44
0.48
SDA 2B-2 EtOH (0.5% heptane)
46.07
~10 kg
Procedure:
[0000]
1. Charge 0.55 kg CDI and 0.042 kg imidazole to reactor 1.
2. Charge 2.67 kg THF to reactor 1 and agitate to form a slurry.
3. Charge 1.00 kg Compound 4 to reactor 1 in portions to moderate the CO 2 offgas. This addition is endothermic
4. Charge 0.89 kg KEM to reactor 2.
5. Charge 4.45 kg THF to reactor 2 and agitate to form a slurry.
6. Charge 0.44 kg MgCl 2 to reactor 2 (can be added in portions to moderate exotherm).
7. Warm the contents of reactor 2 to 50° C. and agitate at that temperature for at least two hours.
8. Transfer the contents of reactor 1 to reactor 2. Mixture will become thick temporarily if transferred very rapidly.
9. Agitate the contents of reactor 2 for at least 12 hours at 50° C.
10. Cool the slurry to ambient temperature.
11. Quench the reaction by transferring the reaction mixture onto 7.0 kg of 28 wt % aqueous H 3 PO 4 (2.3 kg 85 wt % H 3 PO 4 dissolved in 4.7 kg H 2 O). This addition is exothermic. Final pH of aqueous layer should be 1-2.
12. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaHSO 4 (0.24 kg of NaHSO 4 dissolved in 0.96 kg H 2 O). Final pH of aqueous layer should be 1-2.
13. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaCl (0.24 kg of NaCl dissolved in 0.96 kg H 2 O)
14. Wash the organic (top) phase with 5.0 kg of 10 wt % aqueous KHCO 3 (0.50 kg of KHCO 3 dissolved in 4.5 kg H 2 O). Final pH of aqueous layer should be 8-10.
15. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaCl (0.24 kg of NaCl dissolved in 0.96 kg H 2 O). Final pH of aqueous layer should be 7-9.
16. Concentrate the organic phase and exchange the solvent to EtOH.
17. Adjust the concentration to ˜3.5 L/kginput.
18. Charge 0.6 volumes of water.
19. Warm 70-80° C. to form a clear solution.
20. Cool to 40° C. and seed with 0.1 wt % Compound 6.
21. Cool slowly to 5° C.
22. Hold for at least 2 hours.
23. Filter and wash the cake with two 1.35 kg volume portions of 50:50 EtOH:H 2 O (1.2 kg EtOH combined with 1.5 kg H 2 O).
24. Dry the cake at less than 50° C.
Example 11
Preparation of a Compound of Formula 9a
[0125]
[0126] Compound 6a is combined with toluene, N,N-dimethylformamide dimethyl acetal and glacial acetic acid before being warmed to 100° C. The reaction is monitored by HPLC. Once the formation of Compound 7a is complete the mixture is cooled to 18 to 25° C. before (S)-(+)-valinol is added. The reaction is monitored by HPLC. Once the formation of Compound 8a is complete the mixture is concentrated. The residue is combined with dimethylformamide, potassium chloride and N,O-bistrimethylsilyl acetamide and warmed to 100° C. The reaction is monitored by HPLC. Once complete the mixture is cooled and dichloromethane is added. Aqueous hydrochloric acid is added to desilylate Compound 9a. This reaction is monitored by TLC. Once complete the organic phase is washed with water, aqueous sodium bicarbonate and water. The solvent is exchanged for acetonitrile and the mixture warmed. The mixture is seeded and cooled to crystallize Compound 9a. The product is filtered, washed with cold acetonitrile and dried at NMT 40° C. to yield Compound 9a.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 6a
394.82
1.00
1.00
Toluene
92.14
4.3
Glacial acetic acid
60.05
0.001
0.007
N,N-dimethylformamide dimethyl
119.16
0.33
1.1
acetal
(S)-(+)-Valinol
103.16
0.29
1.1
DMF
73.10
1.8
KCl
74.55
0.09
0.5
N,O-bis(trimethylsilyl)acetamide
203.43
1.13
2.2
1N HCl
36.5
2.0
DCM
84.93
10
Water
18.02
8
5% Aq. NaHCO 3
84.01
4
CAN
41.05
QS
Compound 9a seeds
475.94
0.005
1. Charge Reactor 1 with 1.00 kg Compound 6a.
2. Charge 0.33 kg N,N-dimethylformamide dimethyl acetal (1.1 eq), 0.001 kg glacial acetic acid and 3.3 kg toluene to Reactor 1.
3. Warm the mixture to ˜100° C. (note that some MeOH may distill during this operation).
4. After 1 h the reaction should be complete by HPLC (˜2% Compound 6a apparently remaining) 1 .
5. Cool the mixture in Reactor 1 to 18-25° C.
6. Charge 0.29 kg (S)-(+)-Valinol (1.1 eq) dissolved in 1.0 kg toluene to Reactor 1 and continue agitation at ambient temperature.
7. After 1 h the reaction should be complete by HPLC (<1% Compound 6a).
8. Concentrate the contents of Reactor 1 to ˜2 L/kg.
9. Charge 1.8 kg DMF, 0.09 kg potassium chloride (0.5 eq,) and 1.13 kg N,O-bistrimethylsilyl acetamide (2.2 eq.) to Reactor 1.
10. Warm the mixture in Reactor 1 to ˜100° C.
11. Reaction should be complete in ˜1 h (˜5% Compound 8a remaining).
12. Cool the contents of Reactor 1 to 18-25° C.
13. Charge 10 kg DCM to Reactor 1.
14. Charge 2.0 kg 1 N aqueous HCl to Reactor 1 over ˜15 min, maintaining the temperature of the mixture <35° C.
15. Agitate the mixture for at least 10 min to desilylate Compound 8a. Monitor the progress of desilylation by TLC. 2
16. Separate the phases.
17. Wash the organic phase with 4.0 kg water.
18. Wash the organic phase with 4.0 kg 5% aqueous sodium bicarbonate.
19. Wash the organic phase with 4.0 kg water.
20. Concentrate the organic phase by distillation to ˜1.5 L/kg Compound 6a.
21. Solvent exchange to ACN by distillation until a slurry is formed. Adjust the final volume to ˜8 L/kg Compound 6a.
22. Heat the mixture to reflux to redissolve the solid.
23. Cool the solution to 75° C. and charge Compound 9a seeds.
24. Cool the mixture to 0° C. over at least 2 h and hold at that temperature for at least 1 h.
25. Isolate Compound 9a by filtration and wash the wet cake with 1.6 kg cold ACN.
26. Dry the wet cake at <40° C. under vacuum.
Notes:
[0000]
1. The HPLC AN of remaining Compound 6a is exaggerated by a baseline artifact. The HPLC in step shows only 2% of Compound 6a relative to Compound 8a. Experiments demonstrated that adding more reagent and extending reaction time typically will not further reduce the observed level of Compound 6a.
2. TLC method:
Eluting solvent: 100% ethyl acetate, Silylated Compound 9a Rf: 0.85, Compound 9a Rf: 0.50.
Example 12
Preparation of a Compound of Formula 10
[0157]
[0158] Compound 9a is combined with aqueous isopropyl alcohol and warmed to 30 to 40° C. Aqueous potassium hydroxide is added and the reaction is monitored by HPLC. Once complete, glacial acetic acid is added and the mixture warmed to 60 to 70° C. The solution is hot filtered and cooled to 55 to 65° C. The solution is seeded (see International Patent Application Publication Number WO 2005/113508) and cooled to 0° C. The product is isolated by filtration, washed with cold aqueous isopropyl alcohol and dried at NMT 50° C. to yield Compound 10.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 9a
475.94
1.00
1.00
Isopropyl alcohol
60.10
4.7
Water
18.02
4.0
45% KOH
56.11
0.34
1.3
Glacial Acetic Acid
60.05
0.19
1.50
Compound 10 seeds
447.88
0.01
1. Charge 1.00 kg Compound 9a to Reactor 1.
2. Charge 4.7 kg isopropyl alcohol and 4.0 kg water to Reactor 1.
3. Charge 0.34 kg 45% aqueous KOH to Reactor 1.
4. Warm the mixture in Reactor 1 to 30-40° C.
5. When hydrolysis is complete add 0.19 kg of glacial acetic acid.
6. Warm the mixture to 60-70° C. and polish filter the solution to Reactor 2.
7. Cool the mixture in Reactor 2 to 55-65° C.
8. Seed with Compound 10 (see International Patent Application Publication Number WO 2005/113508) as a slurry in 0.28 volumes of 6:4 isopropyl alcohol:water.
9. Cool the mixture to 18-25° C. over at least 2 h and agitate to form a slurry.
10. Cool the mixture to 0° C. and agitate for at least 2 h.
11. Isolate Compound 10 by filtration and wash the cake with 3×1S cold isopropyl alcohol:water (6:4) solution.
12. Dry the isolated solids at <50° C. under vacuum.
Example 13
Preparation of Compound 15
[0171]
[0172] Bisdimethylaminoethyl ether (2.84 g) was dissolved in 42 mL THF and cooled in an ice bath. Isopropylmagnesium chloride (8.9 mL of a 2 M solution in THF) followed by Compound 14 (5 g dissolved in 5 mL THF) were added slowly sequentially. The mixture was allowed to warm to ambient temperature and stirred overnight. Next, 2.1 mL of 3-chloro-2-fluorobenzaldehyde was added. After stirring for ˜1 h, the mixture was quenched to pH ˜7 with 2N HCl. The product was extracted into ethyl acetate and the organic phase was dried over sodium sulfate. The solvent was exchange to heptane to precipitate the product and a mixture of heptanes:MTBE (4:1) was added to form a slurry. After filtration the solid was slurried in toluene, filtered and vacuum dried to yield compound 15: 1 H NMR (CD 3 CN, 400 MHz) δ 7.47 (s, 1H), 7.41-7.35 (m, 2H), 7.15 (t, J=7.4 Hz, 1H), 6.66 (s, 1H), 6.21 (br s, 1H), 3.90 (s, 3H), 3.87 (br s, 1H), 3.81 (s, 3H).
Example 14
Preparation of Compound 15a
[0173]
[0174] Compound 14 (5 g), isopropylmagnesium chloride (8.9 mL of 2M solution in THF) and THF (56 mL) were combined at ambient temperature and then warmed to 50° C. for ˜5 hours. After cooling to ambient temperature and stirring overnight, 2.1 mL of 3-chloro-2-fluorobenzaldehyde was added dropwise to form a slurry. After stirring overnight the solid was isolated by filtration and washing with MTBE to yield compound 15a.
Example 15
Preparation of Compound 16
[0175]
[0176] Triethylsilane (1.2 mL) was added to trifluoroacetic acid (2.3 mL) that had been pre-cooled in an ice bath. Compound 15 (1.466 g) was added to the mixture keeping the temperature below 5° C. After stirring for ˜2 h ice was added to quench the reaction. The product was extracted with DCM and the organic phase was washed with aq. NaHCO 3 . The organic phase was dried over Na 2 SO 4 and concentrated to dryness. The product was purified by silica gel column chromatography to provide 1.341 g of Compound 16: 1 H NMR (CDCl 3 , 400 MHz) δ 7.20 (t, J=7.0 Hz, 1H), 6.99-6.91 (m, 3H), 6.46 (s, 1H), 3.91 (s, 3H), 3.81 (s, 5H).
[0177] All publications, patents, and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.
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The invention provides synthetic processes and synthetic intermediates that can be used to prepare 4-oxoquinolone compounds having useful integrase inhibiting properties.
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TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates generally to virtual reality business systems and more particularly to delivering real time remote buying, selling, meeting, and interacting in a virtual reality environment.
BACKGROUND OF THE INVENTION
[0002] Shoppers' today buy primarily in person at retail outlets. Electronic shopping over the Internet is also available to consumers in its basic and still primitive form. Shopping at retail outlets require consumers to pay a premium price to support the retail infrastructure. Retail also restricts consumer choice and reach. Internet shopping, though increasing on an yearly basis still accounts for a minute fraction of total retail sales. This is due to both real and perceived security concerns, and also because of the inability of the current Internet shopping paradigm to offer a rich buying experience.
[0003] Amongst several more inhibitors to buy on the Internet, the aforementioned are the biggest roadblocks for the growth and evolution of electronic shopping. Even though increasing number of Internet storefronts are opening at regular intervals, an overwhelming majority of such electronic storefronts are yet to become profitable.
[0004] Additionally, many Internet shopping storefronts are shutting down further lowering consumer confidence in electronic shopping. Because of these concerns, a major portion of the industrial world population segment may never make an electronic purchase using the Internet.
[0005] Profit spurs growth, and growth spurs innovation. With retail profits at their historical lows, and with rising operational costs, innovation has come to a standstill in this once profitable sector. Expansion into newer markets is happening at a cautious pace. Dot Com ventures of yester years tried to fill this gap, but failed miserably. Consumer expectations of an alternative buying paradigm which is enjoyable and reliable like traditional shopping, but which also offers substantial lower prices and global reach are yet to be met.
[0006] Most traditional and Internet retailers typically lack in one or more of the following areas:
1. They do not maintain and continue to evolve personal consumer profile which are essential for customer centric selling approach. Customer preferences such as price sensitivity, brand affinity, choices and dislikes are not employed and made use of during the sales process. 2. They do not monitor individual consumer consumption, nor predict their needs. The concept of market of one still remains an elusive idea. At best, consumer consumption is calculated and predicted on the basis of local store sales or local geography. 3. Most Internet shopping ventures leave shoppers at the mercy of their navigation skills. Shoppers are left to fend for themselves should they have any questions or concerns during the shopping session. This style of buying and selling does not accommodate for product and services, presentation and their demonstration. 4. Both the conventional retail shopping and today's electronic shopping does not provide a means for group based remote shopping, whereby two or more buyers can shop together as a group from different locations.
SUMMARY OF THE INVENTION
[0011] The present invention provides a system and method for delivering real time remote buying, selling, meeting, and interacting in a virtual reality environment, embodying a wide array of virtual reality hardware; virtual reality client server based programming logic; and high speed internetworking. In all its embodiments, the present invention is designed to be used at virtual reality storefronts, homes, and offices over high capacity private networks, and also over the Internet; thus replicating and enhancing real life buying, selling, meeting and interacting in a virtual environment.
[0012] In one embodiment of the present invention, participants using virtual reality interacting system of the example types of business to business; business to consumers; consumers to consumers etc. interact with each other through the use of virtual reality headgear. All sounds and facial gestures of the parties involved are communicated by means of the virtual reality headgear. Facial gestures can be of example types smiling, frowning, stating, blushing, dozing etc.
[0013] In another embodiment, participants using virtual reality interacting system can smell the smells of virtual reality landscapes, merchandise, etc. by means of the virtual reality smells generator.
[0014] In another embodiment, the virtual reality interacting system includes a virtual reality navigator, which comprises of virtual reality navigation mechanism, virtual reality seating mechanism, virtual reality aisle walkway, sensors, virtual reality touch pads, and communication interfaces.
[0015] In another embodiment, the virtual reality interacting system includes high resolution video and audio equipment.
[0016] In another embodiment, a virtual reality interacting system includes a centralized master controller unit having CPU and allied computing resources of prior known art, and also having the central server based programming logic to control, coordinate, and monitor the seamless functioning of the many remote but similar virtual reality interacting systems.
[0017] Particular embodiments provide a means for navigation through the virtual reality paradigm. Sitting, standing, climbing, jogging, jumping, and walking through the virtual paradigm; merchandise demonstration; merchandise selection; services demonstration, services selection, etc are achieved by the combined use of the virtual reality headgear, virtual reality navigator, virtual reality aisle walker, and virtual reality sensors and touch pads
[0018] Particular embodiments provide a means for two or more buyers located at the same location, or at different locations to shop together as a group. A buyer can be shopping at any of the virtual reality storefronts, and subsequently his or her group member or members can join the shopping session from home or office by means of the Internet. Likewise a buyer can be shopping from a home or office over the Internet, and his or her group member or members can join the shopping session from any virtual reality storefront. Buyers can also shop together from different virtual reality storefronts.
[0019] Particular embodiments provides means for remote shoppers, remote sales consultants, real time inventory status, live and stored audio and video content, and client server based virtual reality programming logic to interact in real time to complete soft touch, high touch, and non-high touch products and services transactions.
[0020] Particular embodiments provide means for capturing, coordinating, synchronizing, and displaying all gestures and actions of buyers and their remote sales consultants in the display unit of the virtual reality headgear creating an illusion of continuous reality.
[0021] Particular embodiments provide means for maintaining past transaction history of buyers while also keeping a running preference of their profiles and to associate such preferences during the sales process in real time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] To provide a more complete understanding of the present invention and the features and advantages thereof, reference is made to the following description, taken in conjunction with the accompanying drawing, in which:
[0023] FIG. 1 illustrates an example virtual reality interacting system.
[0024] FIG. 2 illustrates an example demonstration center.
[0025] FIG. 3 illustrates an example central controller unit.
[0026] FIG. 4 illustrates an example of real time virtual reality interactive shopping from a plurality of remote locations connected by means of a private network and, or the Internet.
DESCRIPTION OF THE INVENTION
[0027] As used herein, the functional terminology of shoppers and buyers; sales consultants and merchandise demonstrators; virtual reality environment and virtual reality paradigm; transactions and interactions; and merchandise and equipment can be used interchangeably.
[0028] As described herewith, buyers are videotaped as they enter the virtual reality storefront. These images are then converted into digital images ready to interact in the virtual environment. With the exception of the face, the remainder of the buyer's torso along with all its adornments is represented virtually. This implies buyers are represented in the virtual environment with their real faces attached to their just videotaped body from shoulder down. Families and groups of shoppers are grouped together as a single shopping unit. Virtual reality interacting systems are strategically located all across the virtual reality storefront.
[0029] Buyers enter the virtual reality-shopping paradigm by wearing the virtual reality headgear. As they enter the virtual reality-shopping environment, their senses are transformed into a genie land with superb high quality real and imaginative landscapes, exotic smells and serene music imparting sensations and feelings to the buyer that they are amidst the virtual reality. The virtual reality interacting system combines the picture of all group members, and displays it in their headgear creating an illusion of entering together in the virtual reality paradigm. Family or group members can see each other in the virtual reality headgear and can talk amongst themselves. They can also see, hear, and interact with other shoppers shopping in the same virtual environments as they are. The group leader will have navigation control, while the rest of the group members can also share the navigation control.
[0030] Buyers who choose to shop from their home or office location using the Internet may have to upload their full size photograph during the initial registration process. If they have shopped before at a virtual reality storefront, they also have an option to use their existing video graphed images. Remote buyers also have to identify if there are any other shoppers along with them. Two or more buyers can shop as a group from remote locations. A buyer can be shopping at any of the virtual reality storefront, and their group members can join them over the Internet. Likewise a buyer having initiated the virtual reality shopping session over the Internet from home or office; her group member or members can join her from any of the virtual reality storefronts. Internet buyers are assumed to posses all or a subset of the virtual reality shopping equipment available at the virtual reality storefront. The virtual reality interacting system binds together local and remote shoppers in a single shopping unit and session and they interact with each other as if they are present at the same virtual reality storefront. This mimics real life interaction.
[0031] Sales consultants working from remote virtual reality office centers are assigned to specific customer units as they sign on to the virtual reality system. Merchandise display areas may have dedicated merchandise demonstrators. A sales consultant can also act as a merchandise demonstrator. The remote merchandise demonstrators are housed with the merchandise at remote physical locations. Strategically placed high resolution video cameras capture the sounds and actions of merchandise and merchandise demonstrators and subsequently the virtual reality interacting system superimposes in real time these high quality audio and video clips in the virtual reality paradigm for the shoppers to see and interact with. Shoppers can also interact with virtual merchandise in the virtual reality environment.
[0032] The virtual reality system will be capable of blocking all buyer conversations until after their introduction with the sales consultant, and the merchandise demonstrator. This closely replicates the real world shopping experience while also preserving buyers' privacy. Furthermore, during interaction with the sales consultant or the merchandise display representative, buyers will have the ability to confer in private.
[0033] As in real world retail shopping environment, shoppers can overhear other shopper's if they are in close proximity to them in the virtual environment. If the buyer is a repeat customer, the virtual reality system will attempt to assign the same sales consultant the shoppers have interacted previously. Based on their skills and ability in dealing with virtual customers, a sales consultant can be assigned to serve one or more customer units. Shoppers can also choose to shop and checkout merchandise and services without the aid of sales consultants or the merchandise demonstrators.
[0034] In the virtual environment, real and virtual merchandise can be displayed in well laid out real and virtual aisles. As buyers' enter the virtual shopping paradigm, professional greeter's or the virtual reality interacting system assigned sales consultant greets shoppers at the entry way of the virtual shopping paradigm, and the shopping session begins. The shopper and sales consultant interaction flows in a natural way as if they are present physically at the same location. The sales consultant interacts with the buyers using the similar virtual reality interacting system the shoppers are using.
[0035] The virtual reality interacting system provides a means for multiple sales consultants to interact with a shopper and his or her group members, if any.
[0036] Buyer profile and their past transaction history will be available to the sales consultant during the virtual shopping session. Upon determining what the shoppers are looking for, the virtual reality interacting system can assist the sales consultant to lead the buyers to the appropriate merchandise display area. Shoppers can themselves approach any merchandise display area that they may be interested in. The merchandise demonstrator demonstrates the merchandise and answers any questions that the buyers may have. The virtual reality system also provides the flexibility for the shoppers to roam around by themselves in the virtual aisles, and call the sales consultant when they are ready to make a purchase. As shoppers walk around the virtual aisles, they will have the ability to view and inspect any merchandise they like without any aid from the sales consultant and or the merchandise demonstrators By means sensors and virtual touch pads, shoppers can interact with the merchandise. For example, changing channels on a TV set that they may want to purchase. In this example case, the virtual touch pad can link buyer commands to the actual or virtual TV located in its actual existence or virtual existence in the remote merchandise display center.
[0037] During the virtual shopping session, the virtual reality system will provide the ability for the sales consultant to update shopper profile in real time based upon any new information the shoppers may provide. Once buyers make a decision to purchase an item, the sales consultant can lead shoppers to his or her virtual office. The sales consultant then sits down with the buyers in the virtual office and completes the transaction. On their end the buyers physically sit on their respective virtual reality seating mechanism while the virtual reality interacting system creates an illusion that the buyers are physically seated with the sales consultant at a remote location. During the sales or services transaction, the virtual reality interacting system can also suggest the sales consultant to recommend additional items the shoppers may likely purchase based upon their past transaction history, and future consumption trends.
[0038] The virtual reality interactional system described heretofore, describes an example shopping session between remote participants using the virtual reality interactional system. Said system can be used for participants of example type business to business users, business to consumers, and consumers to consumers from a variety of remote locations.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The detailed description of the present invention is described herewith in terms of real time remote shopping by means of example embodiments. Said invention can be used by participants of example type business to business users, business to consumers, and consumers to consumers from a variety of remote locations.
[0040] FIG. 1 illustrates an example virtual reality interacting system used for real time remote buying, selling, meeting and interacting in a virtual paradigm in real time. The key elements of virtual reality interacting system 1 are the virtual reality navigation unit 100 , and the virtual reality headgear 200 . Other component of the virtual reality interactive system 1 comprises of video equipment 10 and audio equipment 20 .
[0041] Said virtual reality navigation system 100 comprises of a CPU 101 ; an allied resources subsystem 102 of prior known art comprising of storage, memory etc; client side programming logic 103 ; wireless communication interfaces 120 , said interfaces comprising of wireless links and wireless network connections; and wireline communication interfaces 130 , said interfaces comprising of wireline links and wireline network connections. The virtual reality navigation system also comprises of a tightly coupled 110 assembly of virtual reality steering 140 ; virtual reality aisle walkway 150 ; virtual reality seating 160 ; virtual reality sensors 170 ; and virtual reality touch pads 180 .
[0042] Said virtual reality headgear 200 comprises of miniature cameras and audio system 210 ; sensors 220 ; vision unit 230 ; smells generator 240 ; and wireless communication links 250 . Said virtual reality headgear communicates with the virtual reality navigation system by wireless means 30 .
[0043] The virtual reality interacting system 1 by means of the virtual reality navigation system 100 captures, coordinates, synchronizes, and presents cohesive and rich three dimension visual views with full two way sound capabilities in the virtual reality headgear 200 , creating a continuous illusion of reality to perform interactive activities of the example type of real time remote buying and selling. Miniature cameras and audio system 210 embedded in the virtual reality headgear 200 captures all facial gestures and sounds of the shoppers. Said cameras and audio system can also capture external surrounding video and audio. Field of vision on the vision unit 230 represents the actual field of vision with full panoramic views as possible in real life vision.
[0044] Sensors 240 mounted on the virtual reality headgear 200 capture shopper head movements as they move their faces from side to side. Information 30 is exchanged between the virtual reality navigation system 100 and the virtual reality headgear 200 by means of wireless interfaces 120 , and 250 respectively.
[0045] Shopper communicates with each other, and with sales consultants using virtual reality interactive system 1 . The central controller unit 400 of FIG. 3 controls, coordinates, and presents the remote shoppers and their sales consultants' visual communication to each other on the vision unit 230 in the virtual reality headgear 200 .
[0046] FIG. 2 is an example illustration of demonstration center 300 comprising of merchandise 310 ; merchandise demonstration area 320 ; service demonstration area 330 ; video equipment 340 ; audio equipment 350 ; wireless communication interfaces 360 , said interfaces comprising of wireless links and wireless network connections; and wireline communication interfaces 370 , said interfaces comprising of wireline links and wireline network connections. During the example remote shopping session; products and services are demonstrated to remote shoppers in real time from the demonstration center 300 , and the audio and video of such demonstrations is superimposed in the virtual reality views of the vision unit 230 of the virtual reality headgear 200 by means of the central controller unit 400 of FIG. 3 .
[0047] The virtual reality system 1 also provides the flexibility for the shoppers to roam around by themselves in the virtual aisles, and call the sales consultant when they are ready to make a purchase. As shoppers walk around the virtual aisles, they will have the ability to view and inspect any merchandise 310 without any aid from the sales consultant and or the merchandise demonstrators in the demonstration center 300 .
[0048] FIG. 3 is an example illustration of the central controller unit 400 , which controls and coordinates the virtual reality interactive activities of example type shopping between remote shoppers, sales consultants and product demonstrators. Said shopping participants can be remotely present across a country, or across the world. The central controller unit 400 is the heart of the virtual reality interactive shopping and comprises of the key server programming logic 480 . Said logic can be centralized in a given geography or can be distributed across several central controller units 400 . The central controller unit 400 also comprises of wireless communication interfaces 410 , said interfaces comprising of wireless links and wireless network connections; wireline communication interfaces 420 , said interfaces comprising of wireline links and wireline network connections; CPU bank 430 ; allied subsystem resources of the type storage 440 and memory 450 ; virtual reality navigator system controller and synchronizer 460 ; and external applications interface 470 . Said external applications interface 470 comprising of standard APIs of the applications types of inventory management; customer relationship management; billing and invoice management, security management, order management; warehouse and shipping management; and customer assurance management etc. The navigator system controller and synchronizer 470 provides means for seamless orchestration of the virtual reality interactive sessions between all the participants of a virtual reality shopping session.
[0049] FIG. 4 is an example illustration of a plurality of virtual reality interacting systems 500 functioning over a high speed private network or the Internet 570 . In a virtual reality interacting system 500 there can be two or more virtual reality interactive systems 1 of FIG. 1 ; one or more demonstration center 300 of FIG. 2 ; and one or more central controller 400 unit of FIG. 3 . The example plural virtual reality interacting system 500 comprises of N virtual reality interacting systems 510 , 520 , 530 , and 540 respectively; one or more demonstration centers 550 one or more central controller units 560 ; connected over a high speed private network or the Internet 570 .
[0050] Said network can cover a defined geography and can also encompass the entire geography of planet earth. The virtual reality interacting systems 510 , 520 , 530 , and 540 can all be at one physical location or can be spread across several remote locations. Said locations can be of exclusive type of home locations, office locations, virtual reality storefront locations, or a combination thereof.
[0051] The present virtual reality invention along with all of its embodiments provides a means for delivering real time remote buying, selling, meeting and interacting in a virtual reality environment. One or more buyers when entering a virtual reality storefront or a virtual reality place of business are videotaped and audio taped using the strategically placed video equipment 10 , and audio equipment 20 of FIG. 1 . For purpose of illustration it is considered that a group of two shoppers enter a virtual reality storefront for the purpose of transacting business in a virtual environment with remote sales consultants and remote merchandise demonstrators. Furthermore, the group of two shoppers will be joined by a third shopper who is remote to the group's present virtual reality storefront physical location. The third member of the group can join the shopping session from a location of example type of a home location, an office location, or another virtual reality storefront location. The third shopper's physical location can be connected to the original shoppers' location by means of private network or the Internet. For purposes of clarity, the third shopper is to join the group from another remote virtual reality storefront. The remote shopper can already be shopping in the virtual paradigm or can join the group of two shoppers at a later time. As mentioned heretofore, for purpose of clarity and also to illustrate the powerful nature of interaction in a virtual paradigm closely mimicking real life shopping, the third shopper is to join the group at a later time after the first two shoppers had commenced their virtual reality shopping session. As the example two shoppers enter a virtual reality storefront they are video graphed and audio graphed.
[0052] The audio and the video graphs can also alert their remote sales consultant or consultants of their arrival, and can also act as bio-metric security signatures. Virtual reality interactive systems of FIG. 1 are strategically placed throughout the virtual reality storefront. A virtual reality storefront can be part of a traditional store or business or can be wholly of the type of a dedicated virtual reality storefront. A virtual reality storefront may have one or more virtual relating interacting systems of FIG. 1 . Access to the virtual reality interactive system is analogous to treadmill access of prior known art. The virtual reality aisle walker 150 of the virtual reality interactive systems is stationary. As the shoppers wear the virtual reality headgear 200 , the vision unit 240 transforms the shoppers' senses into a serene virtual reality paradigm enabling the shoppers to sense and feel that they are physically present in the depicted virtual reality environment. Said headgear 200 being lightweight and comfortably ventilated. The virtual reality paradigm can be of an example type of sea side open air antique shopping, thereby the smells generator 240 fragrances the shopper senses with fresh breeze of salty sea air. Shoppers can choose to enter the virtual reality paradigm in a sitting posture by physically sitting on the virtual reality seating 160 mechanism of the virtual reality interacting system 1 , or in a standing posture by standing on the aisle walker 150 of said virtual reality interacting system 1 . Shoppers can also choose to wear the extremities sensors 170 . The virtual reality steering mechanism 140 and the virtual reality touch pads 180 are at an arms length to the shoppers and can be auto adjusted based on their physique.
[0053] Buyers are videotaped as they enter the virtual reality interactive system 1 . The video is converted into virtual images ready to interact in the virtual environment. With the exception of a shopper's head, face and neck, the rest of the buyer's torso along with all its adornments is represented virtually. This implies that buyers are represented in the virtual environment with their real faces attached to their just videotaped digital images. In the viral reality environment described heretofore, the two shoppers can see each other and interact with each other as when outside of the virtual reality headgear 200 . At the entrance of the virtual reality paradigm, the shoppers are greeted with live or recorded professional greeter. The professional greeter can choose to shake hands with the shoppers, and the shoppers can respond to the greeter's handshake by means of the touch pads 180 which can take the shape of a human hand during handshake. The client programming logic 103 determines shopper moments by means of intelligent sensors 170 and touch pads 180 . The client programming logic 103 further synchronizes shopper facial and body moments by means of information exchange between the virtual reality headgear 200 and the virtual reality navigation system 100 employing the wireless communications interfaces 250 and 120 of said components.
[0054] Shoppers can see each other by means of the vision unit 230 and can also see other shoppers like themselves in the virtual reality paradigm they are present.
[0055] Communication between the shoppers is facilitated by means of the server programming logic 480 of central controller unit 400 of FIG. 3 , which in turns receives inputs from all the participating client programming logic systems 103 of FIG. 1 . Information exchange between the client programming logic 103 and server programming logic 480 can be facilitated by means of wireline and wireless communication interfaces 120 and 130 and 410 and 420 respectively. The navigator system controller and synchronizer 460 aids the server programming logic 480 in portraying seamless real life interactive behavior for the shoppers in the display vision units 230 .
[0056] The recorded or live professional greeters can enquire what the shoppers are seeking to buy, and can direct them in the appropriate merchandise location. The vision unit 230 portrays identical virtual reality environment for the two shoppers. Furthermore, the same environment is portrayed in the vision units 230 of the other shoppers who tend to be present at that time in the same virtual reality environment. The example shoppers walk in the direction shown by the professional greeter. Shoppers can also choose to ignore the professional greeter's advice and begin to walk in whichever direction they choose to, as in real life. As they begin to walk, the stationary virtual reality aisle walker 150 comes alive enabling the shoppers to move in any direction of their choice, the directions being depicted in the vision unit 230 of the virtual reality headgear 200 . The virtual reality aisle walker can be of example type of a belt and rotary ball bearings system. Movement sensors between the belt and the bearings capture the direction and speed of the walking shopper, and convey it to the client programming logic 103 of the virtual reality interacting system 1 . At all times, shoppers will have a clear view of how and where they are walking in the vision unit 230 ; furthermore they will have complete control to manipulate their walking behavior as they would in real life walking scenarios.
[0057] As the two example shoppers begin to move towards the merchandise 310 of FIG. 2 , they could see in their vision units 230 , their remote friend walking towards them in the virtual paradigm. When said group's third shopper singed on to the virtual reality paradigm from a remote virtual reality storefront, the virtual reality interacting system 1 of FIG. 1 prompted the remote shopper that her company has begun the virtual reality shopping session and are waiting her arrival. The server programming logic 480 of the central controller unit 400 of FIG. 3 with the aid of navigator system controller and synchronizer 460 coordinates the meeting of the three shoppers in the virtual paradigm. The remote shopper by means of the virtual reality aisle walker 150 walks towards the two shoppers with their images and location portrayed in the newcomer's vision unit 230 . Shoppers can exchange greeting handshake by means of the touch pads 180 . The shopping group then moves towards the demonstration center 300 of FIG. 2 to inspect and purchase the merchandise 310 . The server programming logic 480 of the central controller unit 400 superimposes the audio and video of the demonstration center 300 in the virtual paradigm facilitating for the remote shoppers to visit the demonstration center 300 remotely. Sales consultants by means of the virtual reality interacting system 1 can meet the shoppers in the virtual reality paradigm at the demonstration center 300 or at any time during the virtual reality shopping session. Shoppers can select the merchandise 310 from the demonstration center 300 . The merchandise 310 can be of physical merchandise or virtual merchandise. The sensors 170 and touch pad 180 enables the shoppers to interact with the remote physical and or virtual merchandise 310 at the demonstration center 300 .
[0058] Sales consultants and or the shoppers can request the remote merchandise demonstrators at the demonstration center 300 to demonstrate merchandise 310 and or services. Demonstrators demonstrate merchandise 310 and services, if any, by means of the virtual reality interacting system 1 of FIG. 1 from the remote demonstration center 300 . The video equipment 350 and audio equipment 360 captures the services and or the merchandise demonstration, and the demonstrated audio and video is furnished to the server programming logic 480 of FIG. 3 by means of communication interfaces 360 and 370 and 410 and 420 respectively. Said server programming logic 480 super imposes the merchandise and or service demonstration audio and video information in the vision unit 230 of the shoppers. Demonstrators can demonstrate the merchandise 310 or services in the merchandise demonstration area 320 and the service demonstration area 330 . Upon merchandise 310 selections, the sales consultant can invite the buyers to a virtual office in the virtual reality paradigm to complete the transaction. By means of the virtual reality seating 160 ; sensors 170 ; and touch pads 180 ; the shoppers and the sales consultants complete the business transactions. The server programming logic 480 with the aid of external applications interface 470 facilitates the completion of transaction and the delivery of merchandise 310 . The virtual reality steering 140 enables the shoppers to steer through the virtual aisles should the shoppers prefer to steer to the demonstration center instead of walking by means of the virtual reality aisle walkway 150 . Sensors 220 of the virtual reality headgear 200 capture and convey the head movements of shoppers to the client programming logic 103 . This information in turn is conveyed to the server programming logic 480 which by means of navigator system controller and synchronizer 460 facilities communication between the remotely located shoppers and their remote sales consultants and remote service and merchandise demonstrators. While particular embodiments are described and illustrated, the particular embodiments described and illustrated are only representative of the subject matter contemplated. The scope of the present invention encompasses embodiments that are or could become apparent to those skilled in the art, and the scope of the present invention is to be limited only by the appended claims. In the claims, reference to an element in the singular is not intended to mean one and only one, but rather one or more unless explicitly stated. The present invention encompasses all structural and functional equivalents to the elements of the embodiments described and illustrated that are known or later come to be known to those of ordinary skill in the art.
[0059] Moreover, it is not necessary for a device, method, or logic to address each and every problem sought to be solved by the present invention to be encompassed by the present claims. No element, component, or method step in the described and illustrated embodiments is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. sections 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”
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A virtual reality interactional system and a method of use in which remote shoppers, remote advisors, remote sales consultants, remote product display agents, real time inventory status, live and stored audio and video content, and client server based virtual programming logic interact in real time to complete soft touch, high touch, and non-high touch products and services transactions. The virtual reality interacting system encompasses a combination of virtual reality hardware, virtual reality programming logic and communication networks. It can be used at homes, offices, virtual reality storefronts, or a combination thereof using high capacity private networks and also the Internet. Business to business, business to consumer, and consumer to consumer interactive interactions can be seamlessly performed by means of the current invention.
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This application is a division of application Ser. No. 07/468,148, filed Jan. 22, 1990, abandoned.
SUMMARY
During the combustion of carbon-rich substances there is often abundant emission of carbon particles, (particulates), due to shortage of air in the mixture burnt or even to poor mixing.
According to the invention, particulates are removed by a system of conductors between which a high potential difference is established. When the carbon particles pass between these conductors they cause a discharge which renders them incandescent and they are burnt up.
DESCRIPTION
This invention concerns a device for stripping particulates from exhaust and flue gases. More precisely it concerns a system for eliminating or at least greatly decreasing the emission of particulates from diesel engine exhausts or from flue gases resulting from all those applications involving the burning of gas oil or heavier oils, even in mixes with aromatic fractions (heating plants, portable power generators, large power stations, etc.) or coal.
Although, for simplicity, reference is made principally to diesel engines in the remainder of the description, it is obvious that the points put forward and the conclusions reached refer to and hold good equally for the other applications.
Combustion of hydrocarbons, starting from molecules with about ten carbon atoms or simple aromatic molecules, gives rise not only to the usual products of combustion such as CO, CO 2 and H 2 O, but also to products such as unburnt organic compounds, soot and nitrogen oxides. The same holds good for the combustion of coal, at least as far as soot is concerned.
The composition of exhaust gas can vary considerably, depending on the quantity of air used for combustion. However, for a good process yield (e.g. to obtain sufficient power) the air-fuel ratio is fixed at around certain values which makes it difficult to avoid the emission of particulates.
The phenomenon is particularly evident to the observer in the case of automotive diesel engines, which are thus accused of causing heavy pollution and of seriously harming public health.
Generally speaking, these accusations are groundless. In fact, compared with gasoline engines, diesels emit from four to six times less carbon monoxide (which is a powerful poison since it blocks the blood-oxygen exchange), about half the amount of unburnt hydrocarbons (which are highly carcinorenic) and around half the nitrogen oxides (which are among those responsible for acid rain). However, diesel engines emit some forty times more carbon particles (which in the long term can cause bronchitis and other chest complaints), as well as sulphur oxides (also responsible for acid rain, but which could be eliminated if the diesel fuel were desulphurized, as is done with gasoline).
It should also be observed that soot adsorbs unburnt hydrocarbons and hence acts as a vector for these carcinogenic agents.
To sum up, there can be no doubt that the soot emitted by the combustion of gas oil, fuel oil and the like is extremely unpleasant and that such emissions should thus be eliminated or at least greatly reduced.
Some decrease in the particulates caused by the combustion or hydrocarbons can be achieved by adjusting the combustion by electronic means. However, this adjustment will only reduce the particulates by about 20%, which is not sufficient for a wide of applications. Many efforts have thus been made to resolve this problem.
Numerous patents (e.g. J63-232817, EP 283240 and 114696, U.S. Pat. Nos. 4,622,810; 4,604,868; and 4,571,938, etc.) use ceramic filters of various descriptions which mechanically trap the particulates and are periodically regenerated, for instance by combustion utilizing hot gases produced by a special burner or by a stream of preheated air. The filter is often also impregnated with a catalyst, usually platinum, to facilitate combustion.
In this manner the particulates is greatly reduced. However, the complexity of the solutions adopted to date, the cost and fragility of the ceramic filters, and the cost and deterioration of the catalysts (due to poisoning, for instance) have so far rendered the use of such filters uneconomic, especially for vehicles.
U.S. Pat. No. 4,741,746 suggests the use of an electrostatic precipitator with corona effect to precipitate the carbon particles from diwsel exhaust gases.
U.S. Pat. No. 4,587,808, also concerning diesel engines, provides for the use of a molecular dissociator which, with a charge of up to 150 kV, causes dissociation of the CO, CO 2 and NO x molecules and unburnt hydrocarbons into the constituent chemical elements, and the subsequent removal of the carbon particles thus produced, as well as of those already present in the exhaust gas, by means of an electrostatic separator and a cyclone.
At the 1987 Paris Meeting on Air Pollution Caused by Transport, it was reported, however, that when industrially-derived systems are installed in cars, their efficiency is dubious (as in the case of cyclones) or their size is excessive and their complexity prohibitive (electrostatic separators), (cf. Pollution Atmospherique, Special Number, December 1987, pp 268-285).
It is evident from the foregoing that in the case of applications of limited size (such as automotive diesel engines etc. or domestic heating plants) the technical and economic problems bound up with reduction of the particulate content of gases resulting from the combustion of hydrocarbons are far from being resolved.
The objective of this invention is to eliminate the drawbacks inherent in existing particulate stripping systems by providing a simple, inexpensive, compact device for the reduction of particulate emissions in gases resulting from the combustion of hydrocarbons.
According to this invention, a particulate removal device characterized by the combination of the following parts, is introduced into an exhaust pipe through which flow the products of combustion of hydrocarbons:
Two-pole high-voltage generator
Several conductors connected alternately to one or other of the poles
Means for introducing air into said pipe upstream of said conductors
Means for regulating said means for introducing air.
Said conductors each consists of a conductive metal grid inside said pipe set perpendicular to the general direction of flow of said exhaust gases.
The size of the grid (or the percentage ratio of the total cross-sectional area of the filaments forming the grid to the cross-section of the pipe) must be less than 50% and preferably less than 35%, but more than 10%/
These values are dictated by the need for a good balance between the necessity of not unduly obstructing the cross-section of the pipe, while having an adequate area covered by the electric discharge.
Alternatively, said conductors can consist of grids and/or plates, and/or wires, arranged to form flats or tubes parallel to the general direction of flow of said exhaust gases.
In this case the space occupied by said conductors, as defined above, can be less than 35% and more than 4%, while the grid and/or plates and/or wires can run parallel to the axis of said pipe for a length up to ten times the pipe diameter. In both these versions, said conductors can have points protruding at right angles from their surface.
The voltage supply to the conductors must be such as to provide an electric field between 50 and 98% of that which would cause a discharge in the gas at the operating temperature and under the relevant working conditions.
Said means for introducing air into said pipe consist of a valved conduit or line and a pipe.
Said means for controlling the means for introducing air consist of a probe which analyses the exhaust gas and transmits the results to a microprocessor which controls the pump and the valve for introducing the desired quantity of air into the pipe upstream of said conductors.
The present invention will now be described in greater detail by reference to the accompanying drawing which illustrates it purely by way of example, while in no way limiting the aims and scope of the invention:
FIG. 1 indicates the general schematic layout
FIG. 2 provides a sectional view of an embodiment in which the conductors are set parallel to the general direction of gas flow
FIG. 3 is a sectional perspective view of an embodiment in which the conductors are set perpendicular to the general direction of gas flow.
With reference to FIG. 1, a conduit is introduced into a pipe 1 carrying exhaust gas. Said conduit is complete with conductors (not shown) connected via cables 4 and 5 to voltage generator 3. A microprocessor 9 processes the signals concerning the composition of the gas analysed by probe 6 and controls valve 8 on line 7 connected to conduit 2, to admit into the latter the desired quantity of air, which is fed via pump 10.
In operation, probe 6 analyses the gas, especially as regards its CO, CO 2 and O 2 content. The signals are sent to the microprocessor 9 which--on the basis of pre-established programs and other information regarding specific fuel consumption--establishes the quantity of unburnt material and soot and hence the amount of air needed for their combustion and, consequently, controls pump 10 and valve 8.
At the same time, a high voltage is established between the conductors, through voltage generator 3.
When the gas flows between the electrodes, the soot contained therein lowers the dielectric constant of the system, causing a strong spark to be discharged onto the carbon particles, rendering them incandescent, so they are burnt up.
Enrichment of the gas with air and the high temperature attained permit most of the carbon particles to be burnt, while ensuring the production essentially of carbon dioxide. In this way, for example, the very low carbon monoxide content of diesel engine exhaust gases is maintained and, in some cases, even decreased.
Two embodiments of the invention are illustrated in FIGS. 2 and 3.
In FIG. 2, the conductors, in the form of flat plates 12, 12' and 13, are set parallel to the general direction of flow of the gas, from left to right; cables 4 and 5 respectively feed plates 12, 12' and 13, cable 5 passing through the wall of conduit 2 via insulated section 11. The plates can have protruding points 14 to assist the formation of electric discharges between the carbon particles and the plates themselves.
In FIG. 3, the conductors, in the form of circular grids 12, 12', 13 and 13', are set perpendicular to the general direction of gas flow, being fed via cables 4 and 5, while being kept insulated by insulators 11 which also permit the passage of cables 4 and 5 through the wall of conduit 2.
Of course, other shapes and arrangements of conductors 12 and 14 can be employed without any loss of the protection offered by the invention.
The present invention has been tested on the exhaust system of a diesel-electric set with a 3860 cc engine and a generator rated at 40 kV at 1500 rpm. The engine was run at 1400 rpm during the tests.
The conductors, in the form of a grid, as in FIG. 3, were set 3 cm apart. The diameter of the four pairs of conductors was 20% less than the internal diameter of the exhaust pipe. The voltage between the conductors of a pair of conductors ranged from 50 to 65 kV. The amount of space occupied transversely by each grid,
as defined above, amounted to 22% of the cross-sectional areas of the pipe.
The engine was run for one hour during each test and the particulate removal device was operated for fixed periods. At the same time, the exhaust gas was sampled and the sample was passed through a weighed filter. After the passage of one cubic meter of gas the filter, with its particulate load, was reweighed.
The average quantity of particulates contained in the exhaust gas which was not treated as per this invention was 17.2 mg/m 3 , the variability being between -3 and +4 mg/m 3 .
Insertion of the pairs of grids one by one resulted in a decrease in the particulate content of the treated gas, varying from about 15% (in the case of one pair of grids with voltage of 52 kV) to about 70% (with four pairs of grids and voltage of 60 kV).
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Device for reduction of exhaust gas particulates in an exhaust pipe, comprising in combination a two-pole high-voltage generator, and a plurality of conductors alternately connected to one or the other of the poles. The conductors constitute substantially the only obstruction to flow of exhaust gas through the pipe and occupy a total area which is less than 50% and more than 10% of the pipe cross section. Air is introduced into the pipe upstream of the conductors, and a probe analyzes the downstream gas and regulates the air introduction according to the detected composition.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 11/552,065, filed Oct. 23, 2006, which is incorporated herein by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to medical devices for monitoring analytes in a living body and delivering fluids thereto, such as monitoring glucose levels and delivering insulin to people with diabetes. More particularly, the invention relates to analyte monitoring and fluid delivery systems integrated into a flexible patch.
BACKGROUND OF THE INVENTION
[0003] In recent years, people with diabetes have typically measured their blood glucose level by lancing a finger tip or other body location to draw blood, applying the blood to a disposable test strip in a hand-held meter and allowing the meter and strip to perform an electrochemical test of the blood to determine the current glucose concentration. Such discrete, in vitro testing is typically conducted at least several times per day. Continuous in vivo glucose monitoring devices are currently being developed to replace in vitro devices. Some of these continuous systems employ a disposable, transcutaneous sensor that is inserted into the skin to measure glucose concentrations in interstitial fluid. A portion of the sensor protrudes from the skin and is coupled with a durable controller and transmitter unit that is attached to the skin with adhesive. A wireless handheld unit is used in combination with the skin-mounted transmitter and sensor to receive glucose readings periodically, such as once a minute. Every three, five or seven days, the disposable sensor is removed and replaced with a fresh sensor which is again coupled to the reusable controller and transmitter unit. With this arrangement, a person with diabetes may continuously monitor their glucose level with the handheld unit. Detailed descriptions of such a continuous glucose monitoring system and its use are provided in U.S. Pat. No. 6,175,752, issued to Abbott Diabetes Care, Inc., formerly known as TheraSense, Inc., on Jan. 16, 2001, which is incorporated by reference herein in its entirety.
[0004] Portable insulin pumps are widely available and are used by diabetic people to automatically deliver insulin over extended periods of time. Currently available insulin pumps employ a common pumping technology, the syringe pump. In a syringe pump, the plunger of the syringe is advanced by a lead screw that is turned by a precision stepper motor. As the plunger advances, fluid is forced out of the syringe, through a catheter to the patient. Insulin pumps need to be very precise to deliver the relatively small volume of insulin required by a typical diabetic (about 0.1 to about 1.0 cm 3 per day) in a nearly continuous manner. The delivery rate of an insulin pump can also be readily adjusted through a large range to accommodate changing insulin requirements of an individual (e.g., various basal rates and bolus doses) by adjusting the stepping rate of the motor. In addition to the renewable insulin reservoir, lead-screw and stepper motor, an insulin pump includes a battery, a controller and associated electronics, and typically a display and user controls. A typical insulin pump has a footprint about the size of a deck of cards and can be worn under clothing or attached with a belt clip. A disposable infusion set is coupled with the pump to deliver insulin to the person. The infusion set includes a cannula that is inserted through the skin, an adhesive mount to hold the cannula in place and a length of tubing to connect the cannula to the pump.
[0005] The continuous glucose monitoring and insulin delivery systems described above include various drawbacks. The rigid, flat mounting surfaces of the skin-mounted transmitters currently being developed can make them uncomfortable to wear. Additionally, since these transmitter units do not conform to the portion of the body they are mounted to, adherence to the skin and the locations on the body available for use can be limited. Currently available insulin pumps are complicated and expensive pieces of equipment costing thousands of dollars. The overall size and weight of the insulin pump and the long length of infusion set tubing can make currently available pumping systems cumbersome to use. Additionally, because of their cost, currently available insulin pumps have an intended period of use of up to two years, which necessitates routine maintenance of the device such as recharging the power supply and refilling with insulin.
[0006] Various attempts to significantly miniaturize and combine the monitoring and pumping systems described above while making them more reliable, less complex and less expensive have not been successful. Constraints which hinder such development efforts include the system requirements of sensors, insulin supplies and batteries which require periodic replacement, and the need to reduce risk of infection, increase user comfort and ease of use.
SUMMARY OF THE INVENTION
[0007] According to aspects of some embodiments of the present invention, an analyte monitoring and/or fluid delivery system is provided having components integrated into a flexible textile patch. The flexible patch may be configured to be worn on the skin of a person or animal. In one embodiment of the invention, a single, patch-mounted system monitors glucose levels of a diabetic person and may provide appropriate doses of insulin in response to the glucose measurements. According to other aspects of the invention, a hand-held user interface may be provided for wirelessly controlling the system and/or receiving information from it.
[0008] In some embodiments of the invention, conductive pathways are formed in the fabric of the patch. Components that may be integrated with the flexible patch include, but are not limited to: a power source, controller, transmitter, antenna, temperature and other sensors, fluid pump, infusion set, electrical pathways, switches, controls, electrodes, connectors, resistors and other circuit elements. Such components may be embedded, interwoven or coated on to the flexible patch instead of or in addition to surface mounting.
[0009] The flexible patch can be constructed of polyester, nylon, polyurethane, Lycra® or other synthetic or natural fibers. In one embodiment, the patch has elastomeric properties that come from properties of the fibers themselves, or from how the fibers are combined to form patch. The flexible patch may be woven, non-woven, knitted, spun or constructed of a textured film, preferably to form an electro-active fabric. Conductive aspects of the textile may come from fine metal wires, either in the yarn used to make the fabric of the patch or woven into the fabric alongside ordinary textile fibers. Alternatively, the electrical properties of patch 12 may come from inherently conductive polymers or nanocomposites deposited as coatings on the fabric's fibers.
[0010] According to aspects of some embodiments of the invention, the flexible patch may be soft, stretchable and breathable to increase patient comfort during use. The fabric of the flexible patch may be rolled, crumpled and folded without damaging its functionality. The flexible patch may also be constructed or coated to be flame resistant, water-resistant, or waterproof
[0011] According to aspects of some embodiments of the invention, portions of a flexible patch system or the entire system itself may be disposable, for instance after a predetermined period of use and/or after a particular consumable, such as an insulin supply, is exhausted. For example, just an analyte sensor, an infusion set and a mounting adhesive may be disposable, while the rest of the flexible patch system is reusable. In such an arrangement, an insulin or other fluid reservoir may be refillable, and/or may comprise a removable cartridge. A portion of electronic circuitry and/or fluid pump may also be removed and reused with a new flexible patch while the remainder of the used patch is discarded. Alternatively, a flexible patch monitoring and fluid delivery system may be constructed inexpensively enough, according to aspects of the present invention, so that the entire system can be disposed of and replaced periodically. Such arrangements would have the advantage of lowering the fixed and recurring costs associated with the use of a monitoring and/or fluid delivery system.
[0012] Various analytes may be monitored using aspects of the present invention. These analytes may include, but are not limited to, lactate, acetyl choline, amylase, bilirubin, cholesterol, chorionic gonadotropin, creatine kinase (e.g., CK-MB), creatine, DNA, fructosamine, glucose, glutamine, growth hormones, hematocrit, hemoglobin (e.g. HbAlc), hormones, ketones, lactate, oxygen, peroxide, prostate-specific antigen, prothrombin, RNA, thyroid stimulating hormone, and troponin, in samples of body fluid. Monitoring systems may also be configured to determine the concentration of drugs, such as, for example, antibiotics (e.g., gentamicin, vancomycin, and the like), digitoxin, digoxin, drugs of abuse, theophylline, warfarin and the like. Such analytes may be monitored in blood, interstitial fluid and other bodily fluids. Fluids that can be delivered include but are not limited to insulin and other medicines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Each of the figures diagrammatically illustrates aspects of the invention. Of these:
[0014] FIG. 1 is a plan view showing an exemplary embodiment of a flexible patch system constructed according to aspects of the present invention;
[0015] FIG. 2 is a side view of the system of FIG. 1 shown mounted on a patient P;
[0016] FIG. 3 is a perspective view illustrating the use of the system of FIG. 1 on a person.
[0017] Variation of the invention from that shown in the figures is contemplated.
DETAILED DESCRIPTION
[0018] The following description focuses on one variation of the present invention. The variation of the invention is to be taken as a non-limiting example. It is to be understood that the invention is not limited to particular variation(s) set forth and may, of course, vary. Changes may be made to the invention described and equivalents may be substituted (both presently known and future-developed) without departing from the true spirit and scope of the invention. In addition, modifications may be made to adapt a particular situation, material, composition of matter, process, process act(s) or step(s) to the objective(s), spirit or scope of the present invention.
[0019] FIG. 1 shows a top view of an exemplary embodiment of a combined fluid delivery and analyte monitoring system 10 constructed according to some aspects of the present invention, while FIG. 2 shows an elevational end view of system 10 mounted on the skin of patient P. Flexible fabric patch 12 forms the base of system 10 . Flexible patch 12 may be provided with an adhesive on a bottom surface to secure patch 12 to the skin of the patient during use. Various components may be attached to or integrated into flexible patch 12 , such as power source 14 , controller and transmitter module 16 , antenna 18 , temperature sensor 20 , fluid pump 22 and infusion set 24 . Electrical pathways 26 may be integrated into flexible patch 12 for interconnecting components of system 10 .
[0020] Flexible patch 12 may be provided with a thicker area 28 , generally towards its center, to afford sufficient support for mounting components. In one embodiment, central area 28 is about 1 mm thick. A peripheral area 30 of flexible patch 12 may be made thinner to promote attachment and adhesion to the skin, particularly as the skin moves and flexes.
[0021] Power source 14 may be one or more solar cells, disposable or rechargeable batteries or device, an electrochemical device generating power from an analyte of the patient, and/or other power source suitable for satisfying the power requirements of the components located on flexible patch 12 . Such power sources may be directly integrated into flexible patch 12 , or removably inserted into a holder attached to patch 12 . Power source 14 may itself be flexible by constructing a battery from one or more layers of paper or fabric. Such a paper or fabric battery can convert chemical energy directly into electricity by oxidizing metal on one side of the layer and allowing an oxide to be reduced on the other side when the battery is connected. The metal may be zinc, aluminum, nickel or other metals, the oxide can be manganese oxide, or other oxides, and the paper or fabric layer can contain an electrolyte. Such flexible batteries are currently being developed by companies such as Enfucell Ltd. of Espoo, Finland (www.enfucell.com). Flexible patch 12 itself may comprise one or more layers that can be used to form a flexible battery. Such an arrangement can reduce the need for electrical connectors for the battery, thereby contributing to making the overall system 10 smaller, softer, more conforming to the user and more comfortable to wear.
[0022] Circuitry for controller and transmitter 16 may be directly integrated into flexible patch 12 . Alternatively, controller and transmitter 16 can be constructed using traditional electronic component assembly techniques then physically and electronically attached to patch 12 . Such attachment of module 16 can be permanent or removable. Permanent attachment can be achieved by soldering electrical leads of module 16 to electrical leads on patch 12 . Removable attachment of module 16 can be achieved with a traditional electrical connector or with a snap type fitting 32 having electrical pathways interconnecting module 16 to patch 12 . Module 16 is preferably powered by power source 14 , but may include its own power source in addition to or instead of power source 14 .
[0023] Antenna 18 preferably is at least somewhat flexible to provide enhanced fit and comfort of patch 12 . Antenna 18 can be a separate element physically and electrically coupled with patch 12 , but preferably is formed by a conductive layer or layers of patch 12 . Antenna 18 is electrically connected to controller and transmitter module 16 to transmit radio frequency (RF) signals such as analyte readings therefrom to an external device, such as a handheld user interface. If module 16 is configured to receive information as well, antenna 18 can be arranged to both transmit and receive RF signals. An infrared (IR) transmitter or transceiver (not shown) can be utilized in addition to or instead of antenna 18 to wirelessly communicate information between system 10 and an external device. A transducer coil and/or cable connector (not shown) can also be provided for external communications, such as to a computer for running diagnostics, or uploading or downloading information.
[0024] Flexible patch 12 may be provided with one or more sensor sites 34 for receiving transcutaneous analyte sensors. Multiple sensors can be used simultaneously to provide redundant analyte readings. Alternatively, one sensor may be inserted at a time. After each sensor is used for a predetermined period, such as three, five or seven days each, it can be removed and a fresh sensor can be inserted at an unused sensor site. Preferably, once all of the sensor sites 34 of a particular patch 12 have been used, patch 12 is removed from the skin and a new patch 12 is applied to a different location on the user's skin. Alternatively, a portion of patch 12 can be reused with a new adhesive portion.
[0025] Transcutaneous analyte sensors can be inserted into the user's skin using an automatic introducer or inserter device, such as those described in U.S. patent application Ser. No. 10/703,214, published Jul. 8, 2004 under publication number 2004/0133164, now U.S. Pat. No. 7,381,184, incorporated herein by reference in its entirety. An inserted sensor can be electrically connected to controller and transmitter module 16 directly, with external conductors or through internal electrical pathways within flexible patch 12 . The sensors may include adhesive mounts, or some type of mounting feature such as one or more snaps, hooks, clamps, pins, clips or other means molded onto or attached to the patch to secure the sensor to flexible patch 12 or to the user's skin during use.
[0026] Monitoring and delivery system 10 can also include a temperature sensor 20 for sensing ambient temperature, skin surface temperature or sub-dermal temperature. Ideally, sub-dermal temperature is measured to more accurately calibrate the readings taken by the analyte sensors, since such readings are typically temperature sensitive. However, sub-dermal temperature measurement can be impractical, since this typically necessitates another puncture to the user's skin. Placing a temperature sensor below the surface of the skin can cause discomfort and increased chance of infection. Accordingly, temperature sensor 20 can be mounted to or integrated with the bottom surface of flexible patch 12 to measure the local surface temperature of the skin. From this temperature reading, the higher sub-dermal temperature may be estimated for the depth of penetration associated with sensor 20 . In one embodiment, temperature sensor 20 may be connected to controller and transmitter module 16 with internal electrical pathways within flexible patch 12 .
[0027] A fluid pump 22 , such as for delivering insulin or other medicine, can also be located on flexible patch 12 . In this exemplary embodiment, fluid pump 22 includes a removable fluid reservoir 36 . Reservoir 36 may be a disposable or refillable vial that is replaced by another vial when depleted. Reservoir 36 may be flexible so that it collapses like a balloon when its contents are emptied, or it may include a flexible diaphragm portion. Alternatively, reservoir 36 may be a rigid cylinder with a plunger 38 that forces fluid out when advanced into the reservoir 36 . Actuator 40 may be a stepper motor, a shape-memory alloy actuator or other suitable mechanism for advancing plunger 38 or otherwise moving fluid out of reservoir 36 . A shape-memory alloy actuator is preferred because of its small size, simplicity and reliability. It's low cost of manufacture also allows pump 22 to be disposable with patch 22 if desired. Details of such a shape-memory alloy driven pump are provided in U.S. patent application Ser. No. 10/683,659, published Jun. 17, 2004 under Publication No. 2004/0115067, now U.S. Pat. No. 6,916,159, incorporated herein by reference in its entirety. Reservoir 36 need not be removable from pump 22 and/or patch 12 , particularly if patch 12 is designed to be disposed of after the fluid is depleted.
[0028] Pump 22 preferably is powered by power source 14 , but may have its own power source. Internal conductive pathways 26 can be used to connect pump 22 with power source 14 and/or controller and transmitter module 16 . Pump 22 may be removably or fixedly attached to patch 12 . Pump 22 or a pump mounting base may be attached to patch 12 by sandwiching a portion of the patch material between the pump or base and a plate or washer(s) on the opposite side. Alternatively, pump 22 or a mounting base may be attached to patch 12 with an adhesive, fasteners or other suitable means.
[0029] In operation, pump 22 can receive control signals from controller and transmitter module 16 , causing actuator 40 to push fluid from reservoir 36 into tubing 42 of infusion set 24 , through cannula 44 and into the patient. Infusion set 24 may include an adhesive mount 46 for securing the distal end of infusion set 24 to patch 12 or directly to the patient's skin. The proximal end of infusion set 24 may be removably connected to an output port 48 of pump 22 . Multiple sites 50 may be provided in the thin region 30 of patch 12 for alternately placing infusion sets 24 . An automatic inserter or introducer may be used to insert cannula 44 of infusion set 24 into the patient. Preferably, a single puncture device can be used to insert cannulas 44 and the transcutaneous analyte sensors described above. After a predetermined period of use, typically 3 days, infusion set 24 can be removed by lifting adhesive mount 46 , removing cannula 44 from the patient and disconnecting tubing 42 from pump output port 48 . A fresh infusion set 24 may then be placed in another one of the sites 50 and connected to pump 22 . It may be advantageous to separate infusion set insertion sites 50 as far as possible from sensor insertion sites 34 as shown so that the local effect of the infusion of insulin or other fluid does not interfere with glucose monitoring or other analyte measurement. In one embodiment, infusion sites 50 are spaced about 1 inch apart.
[0030] In arranging system 10 components on flexible patch 12 , the longitudinal axis of components such as controller and transmitter module 16 , antenna 18 and pump 22 may be aligned with each other. This allows the overall system to be highly flexible in at least one direction. Since these components may be fairly long and rigid, the exemplary system 10 shown in FIG. 1 is more flexible along the y-axis shown than along the x-axis. With such an arrangement, patch 12 can more compliantly conform to curves of a patient's body when the y-axis is aligned with the direction of the sharpest curve at the application site of patch 12 . An example of such an alignment is shown in FIG. 3 , where patch 12 is attached to an upper arm of a patient P. As shown, the more compliant y-axis of flexible patch 12 is arranged horizontally to traverse the curve of the arm, while the less compliant x-axis is arranged vertically along the straighter, longitudinal axis of the arm. System 10 may be adhered to other suitable locations of the body, such as the torso, thigh or calf. In this exemplary embodiment, system 10 is about 4 inches long along the x-axis, about 3 inches long along the y-axis and has a maximum thickness of about 0.75 inches at pump 22 .
[0031] Flexible patch 12 itself can be constructed of polyester, nylon, polyurethane, Lycra® or other synthetic or natural fibers. Preferably, patch 12 has elastomeric properties that come from properties of the fibers themselves, or from how the fibers are combined to form patch 12 . Patch 12 can be woven, non-woven, knitted, spun or constructed of a textured film, preferably to form an electro-active fabric. Conductive aspects of the textile can come from fine metal wires, either in the yarn used to make the fabric of patch 12 or woven into the fabric alongside ordinary textile fibers. Alternatively, the electrical properties of patch 12 can come from inherently conductive polymers or nanocomposites deposited as coatings on the fabric's fibers.
[0032] As discussed above, various components of system 10 can be woven directly into the fabric of patch 12 , including, but not limited to, complex electronic pathways, circuits, controls, electrodes, temperature and other sensors, traces, connectors, resistors, antenna, batteries, switches and other components. Switches and other controls can be incorporated into flexible patch 12 by using a multilayered fabric. For example, three electro-active layers can be used. Two outer conductive layers can surround an inner resistive layer that separates the conductive layers until the layers are momentarily pressed together.
[0033] Using fabrics as discussed above, flexible patch 12 can be soft, stretchable and breathable to provide patient comfort during use. Existing fabrics can provide a high moisture vapor transmission rate (MVTR). Such fabrics can be rolled, crumpled and folded without damaging functionality. Patch 12 may also be constructed or coated to be flame resistant, waterproof or water-resistant if desired.
[0034] Further information on suitable fabrics, general construction and component integration methods for flexible patch 12 may be obtained from companies currently developing “smart fabrics” or “conductive textiles, such as Textronics (www.textronics.com), Konarka (www.konarka.com), Nanosonic (www.nanosonic.com), Eleksen (www. eleksen.com) and Eeonyx (www.eeonyx.com). For instance, Eeonyx has a proprietary process for coating textiles with inherently conductive polymers based on doped polypyrrole. The company polymerizes the materials in situ—or on the surface of the fabric itself—so the coating material fills interstices in the surface and forms a physical bond with the fibers. See also “Fabrics Get Smart”, by Joseph Ogando, Design News, May 15, 2006 (www.designnews.com/article/ca6330247.html), incorporated herein by reference in its entirety.
[0035] As for additional details pertinent to the present invention, materials and manufacturing techniques may be employed as within the level of those with skill in the relevant art. The same may hold true with respect to method-based aspects of the invention in terms of additional acts commonly or logically employed. Also, it is contemplated that any optional feature of the inventive variations described may be set forth and claimed independently, or in combination with any one or more of the features described herein. Likewise, reference to a singular item, includes the possibility that there are plural of the same items present. More specifically, as used herein and in the appended claims, the singular forms “a,” “and,” “said,” and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation. Unless defined otherwise herein, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The breadth of the present invention is not to be limited by the subject specification, but rather only by the plain meaning of the claim terms employed.
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A wearable, conductive textile patch is provided that may include any of a number of features for monitoring body analytes and/or delivering fluids to a body. In one embodiment of the invention, a single, patch-mounted system monitors glucose levels of a diabetic person and provides appropriate doses of insulin in response to the glucose measurements. A hand-held user interface can be provided for wirelessly controlling the system and/or receiving information from it. Conductive pathways can be formed in the fabric of the patch. Components that can be integrated into the flexible patch include a power source, controller, transmitter, antenna, temperature and other sensors, fluid pump, infusion set, electrical pathways, switches, controls, electrodes, connectors, resistors and other circuit elements. Such components can be embedded, interwoven or coated on to the flexible patch instead of or in addition to surface mounting. Methods associated with use of the flexible patch system are also covered.
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BACKGROUND OF THE INVENTION
The present invention relates to a stencil printing machine.
There has been known such a stencil sheet as is produced by bonding a resin film and a multi-porous substrate made of a multi-porous sheet with an adhesive.
This stencil sheet is prepared by perforating the film section by the use of a heat source such as a thermal head, and then is wrapped around a printing drum with the multi-porous substrate inside. Then, printing is done by passing ink through the stencil sheet to a printing paper.
In this type of printing using the above-described stencil printing machine, however, the multi-porous substrate itself has low perviousness to ink, resulting in ununiform ink transfer to a printing paper, that is, in an ununiformly printed image. This is because the multi-porous substrate produced of a multi-porous sheet has uneven density and thickness.
To make ink ununiformly transferred to paper look as if uniform, it is necessary to spread ink from the portion where ink has passed into the printing area of the paper, to the portion where no ink has been transferred. Thus spreading ink, however, will result in the presence of an excessive amount of ink within the printed area on the printing paper where ink passes through, and accordingly in ink offset and strike-through.
As a means for improving the ununiform ink condition on paper, there is used only a resin-film stencil for printing, that is, without using the multi-porous sheet substrate. In this case, the stencil sheet can not be conveyed in the machine, and is wrinkled in stencil preparation or when wrapped around the printing drum, and accordingly printed matter faithful to an original master copy is unobtainable. Such a technology has been disclosed in Japanese Patent Laid-Open No. Hei 5-220919.
The stencil sheet produced by bonding a conventional resin film and a porous substrate such as a porous sheet with an adhesive is generally of the order of 30 to 50 μm in thickness.
Therefore, for discharging the stencil sheet of this thickness by means of the stencil discharge section provided within the stencil printing machine, space as this thickness is needed. In this case, however, a limited quantity of discharged stencils is around 20 to 100, albeit it depends on the discharge system and capacity, and the discharge section is not capable of accommodating a large quantity of spent stencils.
Furthermore, the substrate such as the multi-porous sheet of the stencil sheet to be discharged to the stencil discharge section contains a large amount of ink; that is, ink is used wastefully.
By the way, the prior art technique for printing by the use of only a perforated resin-film stencil has been disclosed in Japanese Patents Laid-Open No. Hei 5-309932 and No. Hei 5-318900. According to the technique of Japanese Patent Laid-Open No. Hei 5-309932, a resin film and a substrate that have been separated are stripped off at the stencil discharge apparatus and received in a common receiving box. Therefore, the quantity of stencil paper discharged makes no difference from that of the stencil sheet made by bonding the prior art resin film and a multi-porous substrate of a multi-porous sheet with an adhesive.
According to the technique disclosed in Japanese Patent Laid-Open No. Hei 5-318900, the separated porous substrate is held inside the machine and accordingly the a space large enough to hold the porous substrate within the machine is required.
For printing by the use of a prior art stencil sheet made by bonding a resin film and a multi-porous substrate such as a multi-porous sheet with an adhesive, the stencil sheet is wrapped around the printing drum. At this time, if a perforated resin film which is on the outer side of the stencil sheet is impressed, ink passes through the perforated portion of the resin film, smearing the pressed member. Therefore, the stencil sheet, when wrapped around the printing drum, can not be impressed, and accordingly it is necessary to wrap the stencil sheet around the printing drum by using an impressing member with the printing paper inserted between the printing drum and the impressing member.
Furthermore, for fully impregnating a stencil sheet with ink from a multi-porous substrate such as a multi-porous sheet to a perforated resin film, a considerable pressure and/or impression time are required, resulting in excessive ink transfer to the printing paper used in wrapping the stencil sheet around the printing drum.
When printing is continuously performed immediately after the wrapping of the stencil sheet around the printing drum, the printing paper used in wrapping the stencil sheet is discharged onto a discharge tray, on which succeeding paper is stacked continuously. Since a large amount of ink remains on the paper used in wrapping, ink will transfer to the back side of the paper discharged thereon. The paper used in wrapping is a printed matter not faithful to the original master copy because of presence of such a defect as excessive strike-through. That is, the printing paper is used wastefully.
Furthermore, when the stencil sheet is wrapped around the printing drum with a decreased pressure and/or impression time required for wrapping around the printing drum, the first one to three printing sheets are not fully impregnated with ink, resulting in a failure in producing a printed matter faithful to an original master copy.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a stencil printing machine which is capable of smoothly conveying the stencil sheet, obtaining quality images, and remarkably increasing the discharged stencil sheet receiving capacity in a specific volume.
The stencil printing machine according to the first aspect of the present invention has a stencil perforating section for perforating a stencil sheet made by bonding a resin film and a substrate with an adhesive; a printing drum for printing by passing ink supplied to the inner peripheral surface, through the perforated section of the resin film remaining in the outer peripheral surface after the stencil sheet prepared at the stencil perforating section is wrapped around the outer peripheral surface of the printing drum with the resin film inside and then the substrate is removed from the stencil sheet that has been wrapped; a pressing member for pressing printing paper, against the printing drum; a separating means for separating and discharging the substrate from the stencil sheet wrapped around the printing drum, before starting printing; and a stencil discharge section for removing the resin film of the stencil sheet from the printing drum after completion of printing.
In the stencil printing machine according to the second aspect of the present invention, the separating means in the stencil printing machine of the first aspect has also a function to separate inked paper from the printing drum.
In the stencil printing machine according to the third aspect of the present invention, the substrate of the stencil sheet used in the stencil printing machine of the first aspect has a cut made along a direction intersecting with the direction of rotation of the printing drum and a plurality of holes formed at a specific spacing along the direction of rotation of the printing drum. The separating means stated above is a rotatable roller provided with a plurality of engaging members which engage with the holes of the substrate; the engaging member of the roller is engaged with the holes of the substrate of the stencil sheet wrapped around the outer peripheral surface of the printing drum, thereby rotating the roller to cur off the substrate at the cut from the resin film.
The stencil sheet according to the fourth aspect of the present invention is produced by separably bonding the resin film with an adhesive to an ink-receptive sheet as the substrate, said ink-receptive sheet being capable of being printed with said ink.
In the stencil sheet according to the fifth aspect of the present invention the adhesive stated above in the stencil sheet of the fourth aspect is a thermoplastic resin adhesive which is dissolved or swollen with a component in the printing ink.
The stencil sheet is wrapped around the printing drum with the perforated resin film inside and with the ink-receptive sheet outside. When wrapping the stencil sheet, a pressure is applied by the pressing member from the ink-receptive side, and thereafter the ink-receptive sheet of the stencil sheet is separated by the substrate separating part.
To this ink-receptive sheet thus separated, ink is transferred through the perforated portion of the resin film to print an image, thus making a test printing. It is, therefore, unnecessary to use a printing paper P for the purpose of test printing at the time of wrapping the stencil sheet on the printing drum. That is, an printed image has been formed on the ink-receptive sheet discharged out of the stencil printing machine, from which the fidelity of the perforated stencil sheet to the original master copy can be ascertained.
After the separation of the ink-receptive sheet, only the perforated resin film remains on the printing drum and is used for actual printing.
Therefore, since there is used no multi-porous substrate that formerly gave an adverse effect to printing, it is possible to obtain a printed matter which is faithful to the original copy.
After completion of printing, the stencil discharge section for removing the resin film from the printing section is required to receive only a very thin resin film, and consequently the discharge stencil sheet receiving capacity in a specific volume can be remarkably improved.
The above and other objects, aspects and advantages will become apparent to those skilled in the art by the preferred embodiment consistent with the principle of the invention, which will be discussed and illustrated in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a stencil printing machine of the present invention;
FIG. 2 is a view showing a fragmentary sectional view of the stencil printing machine of the present invention;
FIG. 3 is a view showing another example of a stencil sheet of the present invention;
FIG. 4 is a fragmental view of the stencil printing machine;
FIG. 5 is an enlarged view of FIG. 4; and
FIG. 6 is a comparison table for comparing the effect of the present embodiment with that of a prior art example.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinafter an embodiment of a stencil printing machine according to the present invention and a stencil sheet to be used in the same machine are explained.
FIG. 1 is a schematic view of the stencil printing machine of the present invention.
The stencil printing machine is provided with an original image reading section 5 including an image scanner 3, for reading an image of an original master copy to be printed; and a stencil perforating section 9 having a stencil perforating device 7 for duplicating an image by perforating a stencil sheet S in accordance with an original image data read by the original image reading section 5.
The stencil perforating device 7 adopts a perforating system using a thermal head or other to prepare the stencil sheet S. The shape of perforation is preferably independent by each dot, but each dot is unnecessarily fully independent. The stencil sheet is demanded to have a good printing resistance to withstand a tearing force during printing and can be smoothly conveyed to a stencil discharge section 27 described later.
It should be noticed that the stencil sheet S perforated to a normal image by a stencil perforating section 9 is sufficient. Also it should be noted that, in the present invention, the stencil sheet S rolled as illustrated is fed out successively and cut to a specific length after being perforated by the perforating device, but the stencil sheet S may be fed in a form of sheets which will be used one by one by each stencil preparation.
The stencil sheet S, after preparation, must be stably conveyed to a printing section 10. Since a perforated resin film S2 is integral with the ink-receptive sheet which is a substrate of the stencil sheet, the stencil sheet will never be wrinkled at the time of stencil perforation and wrapping around a printing drum 11.
The resin film S2 thus perforated by the stencil perforating section 9 is mounted, integrally with the ink-receptive sheet S1, around the outer peripheral surface of the printing drum 11 in the printing section 10. At this time, the stencil sheet S is wrapped with the resin film S2 on the printing drum 11 side. This wrapping is done by rotating the printing drum 11 in the direction of the arrow in the drawing with the leading edge of the stencil sheet S securely clamped with a clamper 11a.
The stencil sheet S, when wrapped, is simultaneously pressed against the printing drum 11 side by means of an impressing member 13, thus completing the installation of the stencil sheet on the printing drum 11. Thereafter the ink-receptive sheet S1 is separated from the resin film by the substrate separating section, and discharged out of the machine. For this substrate separating section, an existing separating pawl 21 is usable as the printing paper separating section as shown in FIG. 2. In the present embodiment, the ink-receptive sheet S1 is discharged out of the machine by this separating pawl, not by a special support separating section.
The printing drum 11 after the separation of the ink-receptive sheet Sl carries only the resin film S2 and is ready for printing on the printing paper P immediately by the use of the impressing member 13. At this time, no multi-porous substrate which will give an adverse effect to printing is in use, and the resin film S2 alone is present on the printing drum 11. It is, therefore, possible to obtain a printed matter faithful to the original master copy.
The printing paper P is fed out from the paper feed table 15. After being fed out one by one by means of the paper feed roller 17, the paper is fed in at a specific timing by the paper feed timing roller 19 between the printing drum 11 and the impressing member 13.
With the rotation of the printing drum 11, printing is done on the printing paper P, correspondingly to the image perforated on the stencil sheet S, with the pressure of the impressing member 13.
The printing paper P is separated from the printing drum 11 by means of a separating pawl 21 as a printing paper separating section, and conveyed by a belt conveyor system of a delivery apparatus 23 to be discharged out to a paper receiving tray 25.
In the case of a roll-type stencil sheet S, the ink-receptive sheet S1 should be designed to be easily separable; for example, there should be provided a separating portion in other than a perforable area, so that the ink-receptive sheet S1 can easily be separated thereat.
Furthermore, after the completion of printing, the resin film S2 of the stencil sheet S wrapped around the printing drum 11 is stripped from the printing drum 11 by means of the stencil discharge section 27 having the discharge pawl, discharge roller, etc. for discharging the stencil sheet S to be discharged into a stencil discharge box.
Since the ink-receptive sheet S1 is used as a substrate, a molten component resulting from the perforation of the resin film S2 at the perforating section 9 permeates to the interior of the ink-receptive sheet S1. Therefore, the stencil sheet S having a low adhesive power increases in the adhesive power at the perforated portion more than at the unperforated portion.
However, in the portion increased in the adhesive power by perforation, ink is permeated into the interior of the ink-receptive sheet S1 by the pressure of the impressing member 13, dissolving and/or swelling the molten component resulting from perforation, and therefore the adhesive power in the perforated portion decreases to facilitate the separation of the perforated resin film S2 from the ink-receptive sheet S1.
Forming a separating section 35 in a fixed position from the edge of the ink-receptive sheet S1 of the stencil sheet S is effective. This separating section 35 facilitates the separation of the ink-receptive sheet S1 from the resin film S2. As a method for providing this separating section 35, perforations are formed. The length of the perforations nearly agrees with the width of the clamper 11a as shown in FIG. 2. Also, the separating section 35 may have been fully cut. Furthermore, the ink-receptive sheet S1 may be a sheet similarly designed for easy separation.
The condition of a printed image on the paper evaluated by using an image analyzer on a whole solid-printed portion is shown in the table of FIG. 6.
As an example of comparison is used a conventional stencil sheet S produced by attaching the resin film S2 to the multi-porous sheet S1. Figures of high values used in the table indicate printed matter faithful to the original master copy; that is, figures of low values indicate printed matter of low fidelity to the original master copy.
In FIG. 1, a stencil discharge section 27 is disposed on the opposite side of the stencil perforating section 9; on the printing drum 11 only the perforated resin film S1 is present, and therefore only the extremely thin resin film S1 is received in the stencil discharge section.
Also shown in FIG. 6 is the quantity of discharged stencil papers received in the stencil discharge section 27, the holding capacity of which is 2.0 liters and is evaluated by a compression-type stencil discharge apparatus.
As an example of comparison is used a conventional stencil sheet S produced by attaching the resin film S2 to the multi-porous sheet S1. Figures of high values used in the table indicate a large discharge stencil holding capacity, while figures of low values indicate a small discharge stencil holding capacity.
By the way, in the present invention is used the ink-receptive sheet S1 as a substrate of the stencil sheet S. If an ink-unreceptive sheet is used, ink on the sheet that has been discharged out of the stencil printing machine will not permeate into the sheet but will remain on the sheet surface.
if the operator holds the discharged ink-unreceptive sheet by hand, his hands will be smeared with ink. The ink-receptive sheet is not limited and may be any type of sheet pervious to printing ink such as a quality printing paper or a synthetic resin sheet, cloth, and unwoven cloth which has been so processed as to be ink-receptive.
Furthermore, if a colored ink-receptive sheet is used, it can be realized from the printing paper P when discharged out of the machine, and also is usable as a tape sorter in order to sort the types of printing papers that have been stacked.
For the resin film S2 of the stencil sheet S of the present invention, a thermoplastic resin film perforated by a heat source like a thermal head, is used, for example, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyester, polystyrene, polyurethane, polycarbonate, acrylic resin, silicone resin, etc., of which particularly the poly-vinylidene chloride and polyester are desirable for use.
It is also possible to use a resin film which is perforable by dissolving by an ink jet system other than the heat source such as the thermal head.
For the adhesive for bonding the resin film S2 of the stencil sheet S of the present invention to the substrate for supporting the resin film S1, a thermoplastic adhesive is used.
For example, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyester, polystyrene, polyurethane, polycarbonate, acrylic resin, and silicone resin are usable. Of these, a material which is dissolved and/or swollen by a component of the printing ink used in the stencil printing machine must be selected.
When the ink-receptive sheet is separated by using an adhesive material, which is not dissolved and/or swollen with the component of ink, for bonding the resin film to the ink-receptive sheet, the adhesive power required for bonding the resin film of the stencil sheet S of the present invention to the substrate supporting the resin film must be so weak as to allow easy separation of the resin film from the substrate supporting the resin film.
Next, FIG. 3 shows another example of the stencil sheet of the present invention.
The stencil sheet S, as illustrated, is a continuous body having a plurality of perforations 30 at a specific spacing at both ends. And the ink-receptive sheet S1 is provided with perforations 31 at a specific spacing.
The printable area of the resin film S1 is to be a range L not extending to the perforations 30.
The stencil sheet S is received in a rolled state in the stencil perforating section 9, and is sent out to the printing drum 11 side while being perforated similarly to the above-described embodiment.
The stencil sheet S is discharged by the stencil printing machine partly shown in FIG. 4.
In the lower part of the printing drum 11 is provided a feed roller 32 near the separating pawl 21. This feed roller 32 has engaging pawls 32a which engage with the perforations 30 as shown in the enlarged view of FIG. 5. The engaging pawls 32a are arranged at the same spacing as the pitch of the perforations 30.
Therefore, the stencil sheet S after perforation is secured at the leading edge with the clamper 11a, and wrapped as far as the position shown in the drawing around the printing drum 11 with the rotation of the printing drum 11. Then, with the rotating drum 11 rotating, the feed roller 32 is turned in the direction of the arrow in the drawing, thereby separating the ink-receptive sheet S1 at the perforations 31 from the printing drum 11 and the resin film S2. Thus the stencil sheet S can easily be sent out and discharged.
According to the stencil printing machine of the present invention, the perforated resin film, which is integral with the ink-receptive sheet which is a substrate, can be conveyed with stability without wrinkling at the time of perforation and wrapping around the printing drum.
The ink-receptive sheet which is a substrate of the stencil sheet is separated from the resin film by means of the substrate separating section and discharged out of the stencil printing machine. Therefore, in the stencil discharge section for holding the resin film of the stencil sheet removed after printing from the printing section, only the resin film is discharged, thereby enabling to remarkably increase the capacity for holding discharged stencil papers in a specific volume.
Furthermore, as only the perforated resin film is wrapped around the printing drum and printed, printed matter faithful to the original copy are obtainable.
Furthermore, according to the stencil printing machine, since the constitution of an existing printing paper separating section is usable for separation and discharge of the printing paper, the substrate can be discharged out of the machine, thus enabling the simplification of the machine itself.
Furthermore, according to the stencil sheet of the present invention, the ink-receptive sheet which is a substrate is used and discharged out of the stencil printing machine, and therefore the fidelity of the perforated stencil sheet to the original copy can be ascertained. Consequently, no printing paper will be wasted by test printing.
Furthermore, according to the stencil sheet, since the ink-receptive sheet is used as the substrate, a component dissolved at the time of perforation of the resin film permeates into the interior of the ink-receptive sheet; however, because the component thus permeating is dissolved and/or swollen with a component in the ink, the perforated film can easily be separated from the ink-receptive sheet, thus enabling the provision of a highly reliable printing machine.
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A stencil printing machine is formed of a perforating section for perforating a stencil sheet produced by bonding a resin film to a substrate with an adhesive; a printing drum on the outer peripheral surface of which the stencil sheet perforated at the perforating section is wrapped with the resin film inside, and, after removal of a substrate from the stencil sheet thus wrapped, printing is done by passing ink supplied to an inner peripheral surface, through the perforated portion of the resin film remaining on the outer peripheral surface; an pressing member for pressing printing paper against the printing drum during printing; a separating device for separating and discharging the substrate from the stencil sheet wrapped around the printing drum, prior to starting printing; and a resin film removing section for removing the resin film of the stencil sheet from the printing drum after completion of printing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority of U.S. provisional application Ser. No. 60/307,224, filed Jul. 20, 2001.
SUMMARY OF THE INVENTION
[0002] The present invention is concerned with substituted imidazole of the general Formula I:
and pharmaceutically acceptable salts thereof which are antagonists and/or inverse agonists of the Cannabinoid-1 (CB1) receptor and are useful in the treatment, prevention and suppression of diseases mediated by the Cannabinoid-1 (CB1) receptor. The invention is concerned with the use of these novel compounds to selectively antagonize the Cannabinoid-1 (CB1) receptor. As such, compounds of the present invention are useful as psychotropic drugs in the treatment of psychosis, memory deficits, cognitive disorders, migraine, neuropathy, neuro-inflammatory disorders including multiple sclerosis and Guillain-Barre syndrome and the inflammatory sequelae of viral encephalitis, cerebral vascular accidents, and head trauma, anxiety disorders, stress, epilepsy, Parkinson's disease, and schizophrenia. The compounds are also useful for the treatment of substance abuse disorders, particularly to opiates, alcohol, and nicotine. The compounds are also useful for the treatment of obesity or eating disorders associated with excessive food intake and complications associated therewith.
[0003] The present invention is also concerned with treatment of these conditions, and the use of compounds of the present invention for manufacture of a medicament useful in treating these conditions.
[0004] The invention is also concerned with novel compounds of structural formula I.
[0005] The invention is also concerned with pharmaceutical formulations comprising one of the compounds as an active ingredient.
[0006] The invention is further concerned with processes for preparing the compounds of this invention.
BACKGROUND OF THE INVENTION
[0007] Marijuana ( Cannabis sativa L .) and its derivatives have been used for centuries for medicinal and recreational purposes. A major active ingredient in marijuana and hashish has been determined to be Δ 9 -tetrahydrocannabinol (Δ 9 -THC). Detailed research has revealed that the biological action of Δ 9 -THC and other members of the cannabinoid family occurs through two G-protein coupled receptors termed CB1 and CB2. The CB1 receptor is primarily found in the central and peripheral nervous systems and to a lesser extent in several peripheral organs. The CB2 receptor is found primarily in lymphoid tissues and cells. Three endogenous ligands for the cannabinoid receptors derived from arachidonic acid have been identified (anandamide, 2-arachidonoyl glycerol, and 2-arachidonyl glycerol ether). Each is an agonist with activities similar to Δ 9 -THC, including sedation, hypothermia, intestinal immobility, antinociception, analgesia, catalepsy, anti-emesis, and appetite stimulation.
[0008] The genes for the respective cannabinoid receptors have each been disrupted in mice. The CB1 −/− receptor knockout mice appeared normal and fertile. They were resistant to the effects of Δ 9 -THC and demonstrated a strong reduction in the reinforcing properties of morphine and the severity of withdrawal syndrome. They also demonstrated reduced motor activity and hypoalgesia. The CB2 −/− receptor knockout mice were also healthy and fertile. They were not resistant to the central nervous system mediated effects of administered Δ 9 -THC. There were some effects on immune cell activation, reinforcing the role for the CB2 receptor in immune system functions.
[0009] Excessive exposure to Δ 9 -THC can lead to overeating, psychosis, hypothermia, memory loss, and sedation. Specific synthetic ligands for the cannabinoid receptors have been developed and have aided in the characterization of the cannabinoid receptors: CP55,940 (J. Pharmacol. Exp. Ther. 1988, 247, 1046-1051); WIN55212-2 (J. Pharmacol. Exp. Ther. 1993, 264, 1352-1363); SR141716A (FEBS Lett. 1994, 350, 240-244; Life Sci. 1995, 56, 1941-1947); and SR144528 (J. Pharmacol. Exp. Ther. 1999, 288, 582-589). The pharmacology and therapeutic potential for cannabinoid receptor ligands has been reviewed (Exp. Opin. Ther. Patents 1998, 8, 301-313; Ann. Rep. Med. Chem., A. Doherty, Ed.; Academic Press, NY 1999, Vol. 34, 199-208; Exp. Opin. Ther. Patents 2000, 10, 1529-1538; Trends in Pharma. Sci. 2000, 21, 218-224). There is at least one CB1 modulator characterized as an inverse agonist or an antagonist, N-(1-piperidinyl)-5-(4-chlorophenyl)-1-(2,4-dichlorophenyl)-4-methylpyrazole-3-carboxamide (SR141716A), in clinical trials for treatment of eating disorders. There still remains a need for potent low molecular weight CB1 modulators that have pharmacokinetic and pharmacodynamic properties suitable for use as human pharmaceuticals.
[0010] U.S. Pat. No. 5,624,941 and U.S. Pat. No. 6,028,084, PCT Application Nos. WO98/43636 and WO98/43635, and EPO Application No. EP-658546 disclose substituted pyrazoles having activity against the cannabinoid receptors.
[0011] PCT Application Nos. WO98/31227 and WO98/41519 also disclose substituted pyrazoles having activity against the cannabinoid receptors.
[0012] PCT Application Nos. WO98/37061, WO00/ 10967, and WO0/10968 disclose diaryl ether sulfonamides having activity against the cannabinoid receptors.
[0013] PCT Application Nos. WO97/29079 and WO99/02499 disclose alkoxy-isoindolones and alkoxy-quinolones as having activity against the cannabinoid receptors.
[0014] U.S. Pat. No. 5,532,237 discloses N-benzoyl-indole derivatives having activity against the cannabinoid receptors.
[0015] U.S. Pat. No. 4,973,587, U.S. Pat. No. 5,013,837, U.S. Pat. No. 5,081,122, and U.S. Pat. No. 5,112,820, U.S. Pat. No. 5,292,736 disclose aminoalkylindole derivatives as having activity against the cannabinoid receptors.
[0016] The compounds of the present invention are modulators of the Cannabinoid-1 (CB1) receptor and are useful in the treatment, prevention and suppression of diseases mediated by the Cannabinoid-1 (CB1) receptor. The invention is concerned with the use of these novel compounds to selectively antagonize the Cannabinoid-1 (CB1) receptor. As such, compounds of the present invention are useful as psychotropic drugs in the treatment of psychosis, memory deficits, cognitive disorders, migraine, neuropathy, neuro-inflammatory disorders including multiple sclerosis and Guillain-Barre syndrome and the inflammatory sequelae of viral encephalitis, cerebral vascular accidents, and head trauma, anxiety disorders, stress, epilepsy, Parkinson's disease, and schizophrenia. The compounds are also useful for the treatment of substance abuse disorders, particularly to opiates, alcohol, and nicotine. The compounds are also useful for the treatment of eating disorders by inhibiting excessive food intake and the resulting obesity and complications associated therewith.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The compounds used in the methods of the present invention are represented by the compound of structural formula I:
or a pharmaceutically acceptable salt thereof, wherein;
R 1 is selected from:
(1) hydrogen, (2) C 1-10 alkyl, (3) C 2-10 alkenyl, (4) C 2-10 alkynyl, (5) cycloalkyl, (6) cycloalkyl-C 1-10 alkyl, (7) cycloheteroalkyl, (8) cycloheteroalkyl-C 1-10 alkyl, (9) aryl, (10) heteroaryl, (11) aryl-C 1-10 alkyl, and (12) heteroaryl-C 1-10 alkyl;
wherein alkyl, alkenyl, alkynyl, and cycloalkyl are optionally substituted with one to four substituents independently selected from R a , and aryl and heteroaryl are optionally substituted with one to four substituents independently selected from R b ;
R 2 is selected from:
(1) C 1-10 alkyl, (2) C 2-10 alkenyl, (3) C 2-10 alkynyl, (4) cycloalkyl, (5) cycloalkyl-C 1-10 alkyl, (6) cycloheteroalkyl, (7) cycloheteroalkyl-C 1-10 alkyl, (8) aryl, (9) heteroaryl, (10) aryl-C 1-10 alkyl, (11) heteroaryl-C 1-10 alkyl, (12) —OR d , (13) —NR d R e , and (14) —NR d S(O) m R e ;
wherein alkyl, alkenyl, alkynyl, and cycloalkyl are optionally substituted with one to four substituents independently selected from R a , and aryl, cycloheteroalkyl, and heteroaryl are optionally substituted with one to four substituents independently selected from R b ;
Ar 1 and Ar 2 are independently selected from phenyl, naphthyl, thienyl, furanyl, pyrrolyl, benzothienyl, benzofuranyl, indanyl, indenyl, indolyl, tetrahydronaphthyl, 2,3-dihydrobenzofuranyl, dihydrobenzopyranyl, and 1,4-benzodioxanyl, each optionally substituted with one or two groups independently selected from R c ; each R a is independently selected from:
(1) —OR d , (2) —NR d S(O) m R e , (3) —NO 2 , (4) halogen, (5) —S(O) m R d , (6) —SR d , (7) —S(O) 2 OR d , (8) —S(O) m NR d R e , (9) —NR d R e , (10) —O(CR f R g ) n NR d R e , (11) —C(O)R d , (12) —CO 2 R d , (13) —CO 2 (CR f R g ) n CONR d R e , (14) —OC(O)R d , (15) —CN, (16) —C(O)NR d R e , (17) —NR d C(O)R e , (18) —OC(O)NR d R e , (19) —NR d C(O)OR e , (20) —NR d C(O)NR d R e , (21) —CR d (N—OR e ), (22) CF 3 , (23) —OCF 3 , (24) C 3-8 cycloalkyl, and (25) cycloheteroalkyl;
each R b is independently selected from:
(1) R a , (2) C 1-10 alkyl, (3) C 2-10 alkenyl, (4) C 2-10 alkynyl, (5) aryl, and (6) aryl-C 1-10 alkyl;
wherein alkyl, alkenyl, alkynyl, and aryl are optionally substituted with one to four substituents selected from a group independently selected from R c ;
each R c is independently selected from:
(1) halogen, (2) amino, (3) carboxy, (4) C 1-4 alkyl, (5) C 1-4 alkoxy, (6) aryl, (7) aryl C 1-4 alkyl, (8) hydroxy, (9) CF 3 , (10) OC(O)C 1-4 alkyl, (11) OC(O)NR d R e , and (12) aryloxy;
R d and R e are independently selected from hydrogen, C 1-10 alkyl, unsubstituted or substituted with one to three substituents selected from R h , C 2-10 alkenyl; C 2-10 alkynyl; cycloalkyl, unsubstituted or substituted with one to three substituents selected from R h ; cycloalkyl-C 1-10 alkyl; cycloheteroalkyl, unsubstituted or substituted with one to three substituents selected from R h ; cycloheteroalkyl-C 1-10 alkyl; aryl, unsubstituted or substituted with one to three substituents selected from R h ; heteroaryl, unsubstituted or substituted with one to three substituents selected from R h ; aryl-C 1-10 alkyl; and heteroaryl-C 1-10 alkyl; or R d and R e together with the atom(s) to which they are attached form a heterocyclic ring of 4 to 7 members containing 0-2 additional heteroatoms independently selected from oxygen, sulfur and N—R d ; R f and R g are independently selected from hydrogen, C 1-10 alkyl, C 2-10 alkenyl, C 2-10 alkynyl; cycloalkyl; cycloalkyl-C 1-10 alkyl; cycloheteroalkyl; cycloheteroalkyl-C 1-10 alkyl; aryl; heteroaryl; aryl-C 1-10 alkyl; and heteroaryl-C 1-10 alkyl; or R f and R g together with the carbon to which they are attached form a ring of 5 to 7 members containing 0-2 heteroatoms independently selected from oxygen, sulfur and nitrogen; each R h is independently selected from:
(1) halogen, (2) amino, (3) carboxy, (4) C 1-4 alkyl, (5) C 1-4 alkoxy, (6) aryl, (7) aryl C 1-4 alkyl, (8) hydroxy, (9) CF 3 , (10) OC(O)C 1-4 alkyl, and (11) aryloxy;
m is selected from 1 and 2; and n is selected from 1, 2, and 3;
and pharmaceutically acceptable salts thereof.
[0111] “Alkyl”, as well as other groups having the prefix “alk”, such as alkoxy, alkanoyl, means carbon chains which may be linear or branched or combinations thereof. Examples of alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, sec- and tert-butyl, pentyl, hexyl, heptyl, octyl, nonyl, and the like.
[0112] “Alkenyl” means carbon chains which contain at least one carbon-carbon double bond, and which may be linear or branched or combinations thereof. Examples of alkenyl include vinyl, alkyl, isopropenyl, pentenyl, hexenyl, heptenyl, 1-propenyl, 2-butenyl, 2-methyl-2-butenyl, and the like.
[0113] “Alkynyl” means carbon chains which contain at least one carbon-carbon triple bond, and which may be linear or branched or combinations thereof. Examples of alkynyl include ethynyl, propargyl, 3-methyl-1-pentynyl, 2-heptynyl and the like.
[0114] “Cycloalkyl” means mono- or bicyclic or bridged saturated carbocyclic rings, each of which having from 3 to 10 carbon atoms. The term also includes monocyclic rings fused to an aryl group in which the point of attachment is on the non-aromatic portion. Examples of cycloalkyl include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, tetrahydronaphthyl, decahydronaphthyl, indanyl, and the like.
[0115] “Aryl” means mono- or bicyclic aromatic rings containing only carbon atoms. The term also includes aryl group fused to a monocyclic cycloalkyl or monocyclic cycloheteroalkyl group in which the point of attachment is on the aromatic portion. Examples of aryl include phenyl, naphthyl, indanyl, indenyl, tetrahydronaphthyl, 2,3-dihydrobenzofuranyl, dihydrobenzopyranyl, 1,4-benzodioxanyl, and the like.
[0116] “Heteroaryl” means a mono- or bicyclic aromatic ring containing at least one heteroatom selected from N, O and S, with each ring containing 5 to 6 atoms. Examples of heteroaryl include pyrrolyl, isoxazolyl, isothiazolyl, pyrazolyl, pyridyl, oxazolyl, oxadiazolyl, thiadiazolyl, thiazolyl, imidazolyl, triazolyl, tetrazolyl, furanyl, triazinyl, thienyl, pyrimidyl, pyridazinyl, pyrazinyl, benzoxazolyl, benzothiazolyl, benzimidazolyl, benzofuranyl, benzothiophenyl, furo(2,3-b)pyridyl, quinolyl, indolyl, isoquinolyl, and the like.
[0117] “Cycloheteroalkyl” means mono- or bicyclic or bridged saturated rings containing at least one heteroatom selected from N, S and O, each of said ring having from 3 to 10 atoms in which the point of attachment may be carbon or nitrogen. The term also includes monocyclic heterocycle fused to an aryl or heteroaryl group in which the point of attachment is on the non-aromatic portion. Examples of “cycloheteroalkyl” include pyrrolidinyl, piperidinyl, piperazinyl, imidazolidinyl, 2,3-dihydrofuro(2,3-b)pyridyl, benzoxazinyl, tetrahydrohydroquinolinyl, tetrahydroisoquinolinyl, dihydroindolyl, and the like. The term also includes partially unsaturated monocyclic rings that are not aromatic, such as 2- or 4-pyridones attached through the nitrogen or N-substituted-(1H,3H)-pyrimidine-2,4-diones (N-substituted uracils).
[0118] “Halogen” includes fluorine, chlorine, bromine and iodine.
[0119] When any variable (e.g., R 1 , R d , etc.) occurs more than one time in any constituent or in formula I, its definition on each occurrence is independent of its definition at every other occurrence. Also, combinations of substituents and/or variables are permissible only if such combinations result in stable compounds.
[0120] Under standard nomenclature used throughout this disclosure, the terminal portion of the designated side chain is described first, followed by the adjacent functionality toward the point of attachment. For example, a C 1-5 alkylcarbonylamino C 1-6 alkyl substituent is equivalent to
[0121] In choosing compounds of the present invention, one of ordinary skill in the art will recognize that the various substituents, i.e. R 1 , R 2 , etc., are to be chosen in conformity with well-known principles of chemical structure connectivity.
[0122] The term “substituted” shall be deemed to include multiple degrees of substitution by a named substitutent. Where multiple substituent moieties are disclosed or claimed, the substituted compound can be independently substituted by one or more of the disclosed or claimed substituent moieties, singly or plurally. By independently substituted, it is meant that the (two or more) substituents can be the same or different.
[0123] Compounds of Formula I may contain one or more asymmetric centers and can thus occur as racemates and racemic mixtures, single enantiomers, diastereomeric mixtures and individual diastereomers. The present invention is meant to comprehend all such isomeric forms of the compounds of Formula I.
[0124] Some of the compounds described herein contain olefinic double bonds, and unless specified otherwise, are meant to include both E and Z geometric isomers.
[0125] Some of the compounds described herein may exist with different points of attachment of hydrogen, referred to as tautomers. Such an example may be a ketone and its enol form known as keto-enol tautomers. The individual tautomers as well as mixture thereof are encompassed with compounds of Formula I.
[0126] Compounds of the Formula I may be separated into diastereoisomeric pairs of enantiomers by, for example, fractional crystallization from a suitable solvent, for example MeOH or ethyl acetate or a mixture thereof. The pair of enantiomers thus obtained may be separated into individual stereoisomers by conventional means, for example by the use of an optically active amine as a resolving agent or on a chiral HPLC column.
[0127] Alternatively, any enantiomer of a compound of the general Formula I or Ia may be obtained by stereospecific synthesis using optically pure starting materials or reagents of known configuration.
[0128] It is generally preferable to administer compounds of the present invention as enantiomerically pure formulations. Racemic mixtures can be separated into their individual enantiomers by any of a number of conventional methods. These include chiral chromatography, derivatization with a chiral auxillary followed by separation by chromatography or crystallization, and fractional crystallization of diastereomeric salts.
[0129] The term “pharmaceutically acceptable salts” refers to salts prepared from pharmaceutically acceptable non-toxic bases or acids including inorganic or organic bases and inorganic or organic acids. Salts derived from inorganic bases include aluminum, ammonium, calcium, copper, ferric, ferrous, lithium, magnesium, manganic salts, manganous, potassium, sodium, zinc, and the like. Particularly preferred are the ammonium, calcium, magnesium, potassium, and sodium salts. Salts derived from pharmaceutically acceptable organic non-toxic bases include salts of primary, secondary, and tertiary amines, substituted amines including naturally occurring substituted amines, cyclic amines, and basic ion exchange resins, such as arginine, betaine, caffeine, choline, N,N′-dibenzylethylenediamine, diethylamine, 2-diethylaminoethanol, 2-dimethylaminoethanol, ethanolamine, ethylenediamine, N-ethyl-morpholine, N-ethylpiperidine, glucamine, glucosamine, histidine, hydrabamine, isopropylamine, lysine, methylglucamine, morpholine, piperazine, piperidine, polyamine resins, procaine, purines, theobromine, triethylamine, trimethylamine, tripropylamine, tromethamine, and the like. The term “pharmaceutically acceptable salt” further includes all acceptable salts such as acetate, lactobionate, benzenesulfonate, laurate, benzoate, malate, bicarbonate, maleate, bisulfate, mandelate, bitartrate, mesylate, borate, methylbromide, bromide, methylnitrate, calcium edetate, methylsulfate, camsylate, mucate, carbonate, napsylate, chloride, nitrate, clavulanate, N-methylglucamine, citrate, ammonium salt, dihydrochloride, oleate, edetate, oxalate, edisylate, pamoate (embonate), estolate, palmitate, esylate, pantothenate, fumarate, phosphate/diphosphate, gluceptate, polygalacturonate, gluconate, salicylate, glutamate, stearate, glycollylarsanilate, sulfate, hexylresorcinate, subacetate, hydrabamine, succinate, hydrobromnide, tannate, hydrochloride, tartrate, hydroxynaphthoate, teoclate, iodide, tosylate, isothionate, triethiodide, lactate, panoate, valerate, and the like which can be used as a dosage form for modifying the solubility or hydrolysis characteristics or can be used in sustained release or pro-drug formulations.
[0130] It will be understood that, as used herein, references to the compounds of Formula I are meant to also include the pharmaceutically acceptable salts.
[0131] In one embodiment of the present invention, R 1 is selected from:
(1) hydrogen, (2) C 1-10 alkyl, (3) C 2-10 alkenyl, (4) C 2-10 alkynyl, (5) cycloalkyl, (6) cycloalkyl-C 1-10 alkyl, (7) aryl-C 1-10 alkyl, and (8) heteroaryl-C 1-10 alkyl;
wherein alkyl, alkenyl, alkynyl, and cycloalkyl are optionally substituted with one to four substituents independently selected from R a , and aryl and heteroaryl are optionally substituted with one to four substituents independently selected from R b .
[0140] In one class of this embodiment of the present invention, R 1 is selected from:
(1) hydrogen, and (2) C 1-10 alkyl.
[0143] In a subclass of this class of the present invention, R 1 is selected from:
(1) hydrogen, (2) methyl, and (3) ethyl.
[0147] In another subclass of this class of the present invention, R 1 is selected from:
(1) methyl, and (2) ethyl.
[0150] In still another subclass of the present invention, R 1 is methyl.
[0151] In another embodiment of the present invention, R 2 is selected from:
(1) C 1-10 alkyl, (2) C 2-10 alkenyl, (3) C 2-10 alkynyl, (4) cycloalkyl, (5) cycloalkyl-C 1-10 alkyl, (6) cycloheteroalkyl, (7) cycloheteroalkyl-C 1-10 alkyl, (8) aryl, (9) heteroaryl, (10) aryl-C 1-10 alkyl, (11) heteroaryl-C 1-10 alkyl, (12) —OR d , and (13) —NR d R e ,
wherein alkyl, alkenyl, alkynyl, and cycloalkyl are optionally substituted with one to four substituents independently selected from R a , and aryl, cycloheteroalkyl, and heteroaryl are optionally substituted with one to four substituents independently selected from R b .
[0165] In one class of this embodiment of the present invention, R 2 is selected from:
(1) —OR d , and (2) —NR d R e .
[0168] In one subclass of this class of the invention, R 2 is —NR d R e .
[0169] In one embodiment of the present invention, Ar 1 and Ar 2 are independently selected from phenyl, naphthyl, thienyl, each optionally substituted with one or two groups independently selected from R c ;
[0170] In one class of this embodiment of the present invention, Ar 1 and Ar 2 are phenyl, each optionally substituted with one or two groups independently selected from R c .
[0171] In a subclass of this class of the embodiment of the present invention, Ar 1 and Ar 2 are each independently selected from:
(1) phenyl, (2) 4-chlorophenyl, (3) 4-methylphenyl, and (4) 2,4-dichlorophenyl.
[0176] In another subclass of the present invention, Ar 1 is 4-chlorophenyl, and Ar 2 is 2,4-dichlorophenyl.
[0177] In one embodiment of the present invention, each R a is independently selected from:
(1) —OR d , (2) —NR d S(O) m R e , (3) —S(O) m R d , (4) —SR d , (5) —S(O) m NR d R e , (6) —NR d R e , (7) —O(CR f R g ) n NR d R e , (8) —CO 2 R d , (9) —CO 2 (CR f R g ) n CONR d R e , (10) —OC(O)R d , (11) —C(O)NR d R e , (12) —NR d C(O)R e , (13) —OC(O)NR d R e , (14) —NR d C(O)OR e , (15) —NR d C(O)NR d R e , (16) —CR d (N—OR e ), (17) —CF 3 , and (18) —OCF 3 .
[0196] In another embodiment of the present invention, each R b is independently selected from:
(1) R a , (2) halogen, (3) —CN, (4) C 1-10 alkyl, (5) C 2-10 alkenyl, (6) C 2-10 alkynyl, (7) aryl, and (8) aryl-C 1-10 alkyl;
wherein alkyl, alkenyl, alkynyl, and aryl are optionally substituted with one to four substituents selected from a group independently selected from R c ;
[0205] In one embodiment of the present invention, each R c is independently selected from:
(1) halogen, (2) —NR d R e , (3) C 1-4 alkyl, (4) C 1-4 alkoxy, (5) aryl C 1-4 alkyl, (6) hydroxy, (7) CF 3 , (8) —OCF 3 , (9) —CO 2 R d , (10) —C(O)NR d R e , and (11) —NR d C(O)R e .
[0217] In a class of the present invention, each R c is independently selected from:
(1) halogen, (2) C 1-4 alkyl, and (3) CF 3 .
[0221] In one subclass of this class of the present invention, each R c is independently selected from:
(1) chloro, (2) fluoro, (3) methyl, and (4) CF 3 .
[0226] In one embodiment of the present invention, R d and R e are independently selected from hydrogen, C 1-10 alkyl, cycloalkyl; cycloalkyl-C 1-10 alkyl; cycloheteroalkyl; cycloheteroalkyl-C 1-10 alkyl; aryl; heteroaryl; aryl-C 1-10 alkyl; and heteroaryl-C 1-10 alkyl; or R d and R e together with the atom(s) to which they are attached form a heterocyclic ring of 4 to 7 members containing 0-2 additional heteroatoms independently selected from oxygen, sulfur and N—R d .
[0227] In one class of this embodiment of the present invention, R d and R e are independently selected from hydrogen, C 1-10 alkyl; cycloalkyl; cycloalkyl-C 1-10 alkyl; cycloheteroalkyl; cycloheteroalkyl-C 1-10 alkyl; aryl; heteroaryl; aryl-C 1-10 alkyl; and heteroaryl-C 1-10 alkyl; or R d and R e together with the nitrogen to which they are attached form a heterocyclic ring of 4 to 7 members containing 0-1 additional heteroatoms independently selected from oxygen, sulfur and N—R d .
[0228] In a subclass of this class of the present invention, R d is selected from hydrogen, methyl, ethyl, n-propyl, isopropyl, butyl, t-butyl, n-hexyl, cyclohexyl, cycloheptyl, piperidinyl, morpholinyl, pyrrolidinyl, cycloheteroalkyl, phenyl and benzyl; R e is selected from hydrogen and methyl; or R d and R e together with the nitrogen to which they are attached form a piperidinyl, pyrrolidinyl, or morpholinyl ring.
[0229] In yet another subclass of this class of the present invention, R d is selected from hydrogen, methyl, ethyl, n-propyl, isopropyl, butyl, t-butyl, n-hexyl, cyclohexyl, cycloheptyl, piperidinyl, morpholinyl, pyrrolidinyl, cycloheteroalkyl, phenyl and benzyl; R e is selected from hydrogen and methyl; or R d and R e together with the nitrogen to which they are attached form a piperidinyl, pyrrolidinyl, or morpholinyl ring.
[0230] In another subclass of this class of the present invention, R d is selected from cyclohexyl, cycloheptyl, piperidinyl, morpholinyl, pyrrolidinyl, phenyl and benzyl;
R e is hydrogen; or R d and R e together with the nitrogen to which they are attached form a piperidinyl, or pyrrolidinyl ring.
[0232] In yet another subclass of the present invention, R d is selected from cyclohexyl and 1-piperidinyl; and R e is hydrogen.
[0233] In one embodiment of the present invention, R f and R g are independently selected from hydrogen, C 1-10 alkyl, cycloalkyl; cycloalkyl-C 1-10 alkyl; cycloheteroalkyl; cycloheteroalkyl-C 1-10 alkyl; aryl; heteroaryl; aryl-C 1-10 alkyl; and heteroaryl-C 1-10 alkyl; or
R f and R g together with the carbon to which they are attached form a ring of 5 to 7 members containing 0-2 heteroatoms independently selected from oxygen, sulfur and nitrogen.
[0235] In one embodiment of the present invention, each R h is independently selected from:
(1) halogen, (2) C 1-4 alkyl, (3) C 1-4 alkoxy, (4) aryl C 1-4 alkyl, (5) hydroxy, (6) CF 3 , (7) —OCF 3 , (8) —CO 2 R d , and (9) —C(O)NR d R e ;
[0245] In a class of the present invention, each R h is independently selected from:
(1) halogen, (2) C 1-4 alkyl, and (3) CF 3 .
[0249] In one subclass of this class of the present invention, each R h is independently selected from:
(1) chloro, (2) fluoro, (3) methyl, and (4) CF 3 .
[0254] Particular novel compounds which may be employed in the methods, uses and compositions of the present invention, include:
(1) benzyl 4,5-diphenyl-1-methylimidazole-2-carboxylate, (2) benzyl 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylate, (3) ethyl 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylate, (4) N-(piperidin-1-yl)-4,5-diphenyl-1-methylimidazole-2-carboxamide, (5) 2-(piperidin-1-ylcarbonyl)-4,5-diphenyl-1-methylimidazole, (6) N-(morpholin-4-yl)-4,5-diphenyl-1-methylimidazole-2-carboxamide, (7) N-phenyl-4,5-diphenyl-1-methylimidazole-2-carboxamide, (8) N-hexyl-4,5-diphenyl-1-methylimidazole-2-carboxamide, (9) N-cyclohexyl-4,5-diphenyl-1-methylimidazole-2-carboxamide, (10) N-(piperidin-1-yl)-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide, (11) 2-(piperidin-1-ylcarbonyl)-4,5-di-(4-methylphenyl)-1-methylimidazole, (12) N-(morpholin-4-yl)-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide, (13) 2-(pyrrolidin-1-ylcarbonyl)-4,5-di-(4-methylphenyl)-1-methylimidazole, (14) N-benzyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide, (15) N-phenyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide, (16) N-hexyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide, (17) N-t-butyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide, (18) N-cyclohexyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide, (19) N-propyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide, (20) N-methyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide, (21) benzyl 4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxylate, (22) N-(piperidin-1-yl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (23) 2-(piperidin-1-ylcarbonyl)-4,5-di-(4-chlorophenyl)-1-methylimidazole, (24) N-(morpholin-1-yl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (25) N-(hexyl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (26) N-(t-butyl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (27) N-(cyclohexyl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (28) N-hexyl-4,5-di-(4-chlorophenyl)imidazole-2-carboxamide, (29) N-cyclohexyl-4,5-di-(4-chlorophenyl)imidazole-2-carboxamide, (30) N-t-butyl-4,5-di-(4-chlorophenyl)imidazole-2-carboxamide, (31) benzyl 4,5-di-(4-chlorophenyl)-1-(2-(trimethylsilyl)ethoxymethyl)imidazole-2-carboxylate, (32) N-(piperidin-1-yl)-4,5-di-(4-chlorophenyl)imidazole-2-carboxamide, (33) N-(piperidin-1-yl)-4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide, (34) N-(cyclohexyl)-4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide, (35) N-(piperidin-1-yl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide, (36) N-(cyclohexyl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide, (37) N-(hexyl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide, (38) N-(t-butyl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide, (39) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (40) N-(piperidin-1-yl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (41) N-(cycloheptyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (42) N-(cyclopentyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (43) N-(morpholin-4-yl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (44) N-(phenyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (45) N-(piperidin-1-yl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxamide, (46) N-(cyclohexyl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxamide, (47) N-(hexyl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxamide, (48) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-ethylimidazole-2-carboxamide, (49) cyclohexyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate, (50) N-methyl-N-cyclohexyl-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate, (51) ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate, (52) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-ethylimidazole-2-carboxamide, (53) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-(1-methyl)ethyl-imidazole-2-carboxamide, (54) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-(1,1-dimethyl)ethyl-imidazole-2-carboxamide, (55) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-(2-dimethylamino)ethylimidazole-2-carboxamide, (56) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-butylimidazole-2-carboxamide, (57) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-(2-methoxy)ethylimidazole-2-carboxamide, (58) N-(piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-methyl-imidazole-2-carboxamide, (59) N-(pyrrolidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-methyl-imidazole-2-carboxamide, (60) N-(azepin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-methyl-imidazole-2-carboxamide, (61) N-(pentyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (62) N-(1-ethylpropyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (63) N-(1-methylethyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (64) N-(3-cyclohexenyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (65) N-(tetrahydropyran-4-yl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (66) N-(2,2-dimethyl-tetrahydropyran-4-yl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (67) N-((2-trans-hydroxymethyl)cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (68) N-((2-cis-hydroxymethyl)cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (69) N-((2-trans-hydroxy)cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (70) N-((2-cis-hydroxy)cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (71) N-((4-trans-hydroxy)cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (72) N-(4-methyl-cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide (Isomer A), (73) N-(4-methyl-cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide (Isomer B), (74) N-(1-fluoro-cyclohexen-4-yl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (75) N-(4,4-difluoro-cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (76) 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (77) N-(piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-ethyl-imidazole-2-carboxamide, (78) N-(piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-(1-methyl)ethyl-imidazole-2-carboxamide, (79) N-(piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-(1,1-dimethyl)ethyl-imidazole-2-carboxamide, (80) N-(piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-(2-dimethylamino)ethyl-imidazole-2-carboxamide, (81) N-(piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-propyl-imidazole-2-carboxamide, (82) N-(piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-butyl-imidazole-2-carboxamide, (83) N-(piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-(2-methoxy)ethyl-imidazole-2-carboxamide, (84) N-(cyclohexyl)-4-(2-chlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (85) N-(piperidin-1-yl)-4-(2-chlorophenyl)-5-(4-chlorophenyl)-1-methyl-imidazole-2-carboxamide,
and pharmaceutically acceptable salts thereof.
[0340] In one embodiment of the present invention, a compound selected from the following novel compounds is employed:
(1) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (2) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-ethylimidazole-2-carboxamide, (3) N-(piperidin-1-yl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (4) N-(cyclohexyl)-4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide, (5) N-(cycloheptyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (6) N-(piperidin-1-yl)-4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide, (7) N-(cyclopentyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide,
and pharmaceutically acceptable salts thereof.
[0348] In one class of this embodiment, a compound selected from the following novel compounds is employed;
(1) N-(cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (2) N-(piperidin-1-yl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide, (3) N-(cyclohexyl)-4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide,
and pharmaceutically acceptable salts thereof.
[0352] Compounds of this invention are modulators of the CB1 receptor and as such are useful for the prevention and treatment of disorders or diseases associated with the CB1 receptor. Accordingly, another aspect of the present invention provides a method for the treatment (including prevention, alleviation, amelioration or suppression) of diseases or disorders or symptoms mediated by CB1 receptor binding and subsequent cell activation, which comprises administering to a mammal an effective amount of a compound of Formula I. Such diseases, disorders, conditions or symptoms are, for example, psychosis, memory deficits, cognitive disorders, migraine, neuropathy, anxiety disorders, depression, stress, epilepsy, Parkinson's disease, schizophrenia, substance use disorders, particularly to opiates, alcohol, and nicotine, obesity, and eating disorders associated with excessive food intake and the resulting obesity and complications associated therewith.
[0353] The terms “administration of” and or “administering a” compound should be understood to mean providing a compound of the invention or a prodrug of a compound of the invention to the individual in need of treatment.
[0354] The administration of the compound of structural formula I in order to practice the present methods of therapy is carried out by administering an effective amount of the compound of structural formula I to the patient in need of such treatment or prophylaxis. The need for a prophylactic administration according to the methods of the present invention is determined via the use of well known risk factors. The effective amount of an individual compound is determined, in the final analysis, by the physician in charge of the case, but depends on factors such as the exact disease to be treated, the severity of the disease and other diseases or conditions from which the patient suffers, the chosen route of administration other drugs and treatments which the patient may concomitantly require, and other factors in the physician's judgment.
[0355] The utilities of the present compounds in these diseases or disorders may be demonstrated in animal disease models that have been reported in the literature. The following are examples of such animal disease models: a) suppression of food intake and resultant weight loss in rats (Life Sciences 1998, 63, 113-117); b) reduction of sweet food intake in marmosets (Behavioural Pharm. 1998, 9, 179-181); c) reduction of sucrose and ethanol intake in mice (Psychopharm. 1997, 132, 104-106); d) increased motor activity and place conditioning in rats (Psychopharm. 1998, 135, 324-332; Psychopharmacol 2000, 151: 25-30); e) spontaneous locomotor activity in mice (J. Pharm. Exp. Ther. 1996, 277, 586-594); f) reduction in opiate self-administration in mice (Sci. 1999, 283, 401-404);
[0356] The magnitude of prophylactic or therapeutic dose of a compound of Formula I will, of course, vary with the nature of the severity of the condition to be treated and with the particular compound of Formula I and its route of administration. It will also vary according to the age, weight and response of the individual patient. In general, the daily dose range lie within the range of from about 0.001 mg to about 100 mg per kg body weight of a mammal, preferably 0.01 mg to about 50 mg per kg, and most preferably 0.1 to 10 mg per kg, in single or divided doses. On the other hand, it may be necessary to use dosages outside these limits in some cases.
[0357] For use where a composition for intravenous administration is employed, a suitable dosage range is from about 0.001 mg to about 25 mg (preferably from 0.01 mg to about 1 mg) of a compound of Formula I per kg of body weight per day and for cytoprotective use from about 0.1 mg to about 100 mg (preferably from about 1 mg to about 100 mg and more preferably from about 1 mg to about 10 mg) of a compound of Formula I per kg of body weight per day.
[0358] In the case where an oral composition is employed, a suitable dosage range is, e.g. from about 0.01 mg to about 100 mg of a compound of Formula I per day, preferably from about 0.1 mg to about 10 mg per day. For oral administration, the compositions are preferably provided in the form of tablets containing from 0.01 to 1,000 mg, preferably 0.01, 0.05, 0.1, 0.5, 1.0, 2.5, 5.0, 10.0, 15.0, 20.0, 25.0, 30.0, 40.0, 50.0 or 1000.0 milligrams of the active ingredient for the symptomatic adjustment of the dosage to the patient to be treated.
[0359] For the treatment of diseases of the eye, ophthalmic preparations for ocular administration comprising 0.001-1% by weight solutions or suspensions of the compounds of Formula I in an acceptable ophthalmic formulation may be used.
[0360] Another aspect of the present invention provides pharmaceutical compositions which comprises a compound of Formula I and a pharmaceutically acceptable carrier. The term “composition”, as in pharmaceutical composition, is intended to encompass a product comprising the active ingredient(s), preferably present in pharmaceutically effective amounts, and the inert ingredient(s) (pharmaceutically acceptable excipients) that make up the carrier, as well as any product which results, directly or indirectly, from combination, complexation or aggregation of any two or more of the ingredients, or from dissociation of one or more of the ingredients, or from other types of reactions or interactions of one or more of the ingredients. Accordingly, the pharmaceutical compositions of the present invention encompass any composition made by admixing a compound of Formula I, additional active ingredient(s), and pharmaceutically acceptable excipients.
[0361] The term “pharmaceutically effective amount” of an active ingredient such as a compound of structural formula I, it is intended to encompass amounts of the ingredient that are therapeutically or prophylatically useful in treating or preventing disease, particularly diseases associated with modulation of the Cannabinoid 1 receptor.
[0362] Any suitable route of administration may be employed for providing a mammal, especially a human with an effective dosage of a compound of the present invention. For example, oral, rectal, topical, parenteral, ocular, pulmonary, nasal, and the like may be employed. Dosage forms include tablets, troches, dispersions, suspensions, solutions, capsules, creams, ointments, aerosols, suppositories and the like.
[0363] The pharmaceutical compositions of the present invention comprise a compound of Formula I as an active ingredient or a pharmaceutically acceptable salt thereof, and may also contain a pharmaceutically acceptable carrier and optionally other therapeutic ingredients. By “pharmaceutically acceptable” it is meant the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof. In particular, the term “pharmaceutically acceptable salts” refers to salts prepared from pharmaceutically acceptable non-toxic bases or acids including inorganic bases or acids and organic bases or acids.
[0364] The compositions include compositions suitable for oral, rectal, topical, parenteral (including subcutaneous, intramuscular, and intravenous), ocular (ophthalmic), pulmonary (aerosol inhalation), or nasal administration, although the most suitable route in any given case will depend on the nature and severity of the conditions being treated and on the nature of the active ingredient. They may be conveniently presented in unit dosage form and prepared by any of the methods well-known in the art of pharmacy.
[0365] For administration by inhalation, the compounds of the present invention are conveniently delivered in the form of an aerosol spray presentation from pressurized packs or nebulizers. The compounds may also be delivered as powders which may be formulated and the powder composition may be inhaled with the aid of an insufflation powder inhaler device. The preferred delivery systems for inhalation are metered dose inhalation (MDI) aerosol, which may be formulated as a suspension or solution of a compound of Formula I in suitable propellants, such as fluorocarbons or hydrocarbons and dry powder inhalation (DPI) aerosol, which may be formulated as a dry powder of a compound of Formula I with or without additional excipients.
[0366] Suitable topical formulations of a compound of formula I include transdermal devices, aerosols, creams, ointments, lotions, dusting powders, and the like. Topical preparations containing the active drug component can be admixed with a variety of carrier materials well known in the art such as, e.g., alcohols, aloe vera gel, allantoin, glycerine, vitamin A and E oils, mineral oil, PPG2 myristyl propionate, and the like. To be administered in the form of a transdermal delivery system, the dosage administration will, of course, be continuous rather than intermittent throughout the dosage regimen.
[0367] The compounds of the present invention can also be administered in the form of liposome delivery systems, such as small unilamellar vesicles, large unilamellar vesicles and multilamellar vesicles. Liposomes can be formed from a variety of phospholipids, such as cholesterol, sterylamine or phosphatidylcholines.
[0368] Compounds of the present invention may also be delivered by the use of monoclonal antibodies as individual carriers to which the compound molecules are coupled. The compounds of the present invention may also be coupled with soluble polymers as targetable drug carriers. Such polymers can include polyvinylpyrrolidone, pyran copolymer, polyhydroxypropylmethacrylamide phenol, polyhydroxyethylasparamidepheon, or polyethyleneoxidepolylysine substituted with palmitoyl residues. Furthermore, the compounds of the present invention may be coupled to a class of biodegradable polymers useful in achieving controlled release of a drug, for example, polylactic acid, polyepsilon caprolactone, polyhydroxybutyric acid, polyorthoesters, polyacetals, polydihydropyrans, polycyanoacrylates and cross-linked or amphipathic block copolymers of hydrogels.
[0369] Compounds of the present invention may also be delivered as a suppository employing bases such as cocoa butter, glycerinated gelatin, hydrogenated vegetable oils, mixtures of polyethylene glycols of various molecular weights and fatty acid esters of polyethylene glycol.
[0370] In practical use, the compounds of Formula I can be combined as the active ingredient in intimate admixture with a pharmaceutical carrier according to conventional pharmaceutical compounding techniques. The carrier may take a wide variety of forms depending on the form of preparation desired for administration, e.g., oral or parenteral (including intravenous). In preparing the compositions for oral dosage form, any of the usual pharmaceutical media may be employed, such as, for example, water, glycols, oils, alcohols, flavoring agents, preservatives, coloring agents and the like in the case of oral liquid preparations, such as, for example, suspensions, elixirs and solutions; or carriers such as starches, sugars, microcrystalline cellulose, diluents, granulating agents, lubricants, binders, disintegrating agents and the like in the case of oral solid preparations such as, for example, powders, capsules and tablets, with the solid oral preparations being preferred over the liquid preparations. Because of their ease of administration, tablets and capsules represent the most advantageous oral dosage unit form in which case solid pharmaceutical carriers are obviously employed. If desired, tablets may be coated by standard aqueous or nonaqueous techniques.
[0371] In addition to the common dosage forms set out above, the compounds of Formula I may also be administered by controlled release means and/or delivery devices such as those described in U.S. Pat. Nos. 3,845,770; 3,916,899; 3,536,809; 3,598,123; 3,630,200 and 4,008,719.
[0372] Pharmaceutical compositions of the present invention suitable for oral administration may be presented as discrete units such as capsules, cachets or tablets each containing a predetermined amount of the active ingredient, as a powder or granules or as a solution or a suspension in an aqueous liquid, a non-aqueous liquid, an oil-in-water emulsion or a water-in-oil liquid emulsion. Such compositions may be prepared by any of the methods of pharmacy but all methods include the step of bringing into association the active ingredient with the carrier which constitutes one or more necessary ingredients. In general, the compositions are prepared by uniformly and intimately admixing the active ingredient with liquid carriers or finely divided solid carriers or both, and then, if necessary, shaping the product into the desired presentation. For example, a tablet may be prepared by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine, the active ingredient in a free-flowing form such as powder or granules, optionally mixed with a binder, lubricant, inert diluent, surface active or dispersing agent. Molded tablets may be made by molding in a suitable machine, a mixture of the powdered compound moistened with an inert liquid diluent. Desirably, each tablet contains from 0.01 to 500 mg, particularly 0.01, 0.05, 0.1, 0.5, 1.0, 2.5, 3.0, 5.0, 6.0, 10.0, 15.0, 25.0, 50.0, 75, 100, 125, 150, 175, 180, 200, 225, and 500 milligrams of the active ingredient for the symptomatic adjustment of the dosage to the patient to be treated and each cachet or capsule contains from about 0.01 to 500 mg, particularly 0.01, 0.05, 0.1, 0.5, 1.0, 2.5, 3.0, 5.0, 6.0, 10.0, 15.0, 25.0, 50.0, 75, 100, 125, 150, 175, 180, 200, 225, and 500 milligrams of the active ingredient for the symptomatic adjustment of the dosage to the patient to be treated.
[0373] Exemplifying the invention is a pharmaceutical composition comprising any of the compounds described above and a pharmaceutically acceptable carrier. Also exemplifying the invention is a pharmaceutical composition made by combining any of the compounds described above and a pharmaceutically acceptable carrier. An illustration of the invention is a process for making a pharmaceutical composition comprising combining any of the compounds described above and a pharmaceutically acceptable carrier.
[0374] The dose may be administered in a single daily dose or the total daily dosage may be administered in divided doses of two, three or four times daily. Furthermore, based on the properties of the individual compound selected for administration, the dose may be administered less frequently, e.g., weekly, twice weekly, monthly, etc. The unit dosage will, of course, be correspondingly larger for the less frequent administration.
[0375] When administered via intranasal routes, transdermal routes, by rectal or vaginal suppositories, or through a continual intravenous solution, the dosage administration will, of course, be continuous rather than intermittent throughout the dosage regimen.
[0376] The following are examples of representative pharmaceutical dosage forms for the compounds of Formula I:
[0377] Injectable Suspension (I.M.) mg/mL
Compound of Formula I 10 Methylcellulose 5.0 Tween 80 0.5 Benzyl alcohol 9.0 Benzalkonium chloride 1.0 Water for injection to a total volume of 1 mL
[0378]
Tablet
mg/tablet
Compound of Formula I
25
Microcrystalline Cellulose
415
Povidone
14.0
Pregelatinized Starch
43.5
Magnesium Stearate
2.5
500
[0379]
Capsule
mg/capsule
Compound of Formula I
25
Lactose Powder
573.5
Magnesium Stearate
1.5
600
[0380]
Aerosol
Per canister
Compound of Formula I
24
mg
Lecithin, NF Liq. Conc.
1.2
mg
Trichlorofluoromethane, NF
4.025
g
Dichlorodifluoromethane, NF
12.15
g
[0381] Compounds of Formula I may be used in combination with other drugs that are used in the treatment/prevention/suppression or amelioration of the diseases or conditions for which compounds of Formula I are useful. Such other drugs may be administered, by a route and in an amount commonly used therefor, contemporaneously or sequentially with a compound of Formula I. When a compound of Formula I is used contemporaneously with one or more other drugs, a pharmaceutical composition containing such other drugs in addition to the compound of Formula I is preferred. Accordingly, the pharmaceutical compositions of the present invention include those that also contain one or more other active ingredients, in addition to a compound of Formula I. Examples of other active ingredients that may be combined with a compound of Formula I, either administered separately or in the same pharmaceutical compositions, include, but are not limited to:
[0382] It will be appreciated that for the treatment or prevention of eating disorders, including obesity, bulimia nervosa and compulsive eating disorders, a compound of the present invention may be used in conjunction with other anorectic agents.
[0383] The present invention also provides a method for the treatment or prevention of eating disorders, which method comprises administration to a patient in need of such treatment an amount of a compound of the present invention and an amount of an anorectic agent, such that together they give effective relief.
[0384] Suitable anoretic agents of use in combination with a compound of the present invention include, but are not limited to, aminorex, amphechloral, amphetamine, benzamphetamine, chlorphentemine, clobenzorex, cloforex, clominorex, clortermine, cyclexedrine, dexfenfluramine, dextroamphetamine, diethylpropion, diphemethoxidine, N-ethylamphetamine, fenbutrazate, fenfluramine, fenisorex, fenproporex, fludorex, fluminorex, furfurylmethylamphetamine, levamfetamine, levophacetoperane, mazindol, mefenorex, metamfepramone, methamphetamine, norpseudoephedrine, pentorex, phendimetrazine, phenmetrazine, phentermine, phenylpropanolamine, picilorex and sibutramine; and pharmaceutically acceptable salts thereof.
[0385] A particularly suitable class of anorectic agent are the halogenated amphetamine derivatives, including chlorphentermine, cloforex, clortermine, dexfenfluramine, fenfluramine, picilorex and sibutramine; and pharmaceutically acceptable salts thereof.
[0386] Particularly preferred halogenated amphetamine derivatives of use in combination with a compound of the present invention include: fenfluramine and dexfenfluramine, and pharmaceutically acceptable salts thereof.
[0387] It will be appreciated that for the treatment or prevention of obesity, the compounds of the present invention may also be used in combination with a selective serotonin reuptake inhibitor (SSRI).
[0388] The present invention also provides a method for the treatment or prevention of obesity, which method comprises administration to a patient in need of such treatment an amount of a compound of the present invention and an amount of an SSRI, such that together they give effective relief.
[0389] Suitable selective serotonin reuptake inhibitors of use in combination with a compound of the present invention include: fluoxetine, fluvoxamine, paroxetine and sertraline, and pharmaceutically acceptable salts thereof.
[0390] The present invention also provides a method for the treatment or prevention of obesity, which method comprises administration to a patient in need of such treatment an amount of a compound of the present invention and an amount of growth hormone secretagogues such as those disclosed and specifically described in U.S. Pat. No. 5,536,716; melanocortin agonists such as Melanotan II or those described in WO 99/64002 and WO 00/74679; β-3 agonists such as those disclosed and specifically described in patent publications WO94/18161, WO95/29159, WO97/46556, WO98/04526 and WO98/32753; 5HT-2 agonists; orexin antagonists; melanin concentrating hormone antagonists; galanin antagonists; CCK agonists; GLP-1 agonists; corticotropin-releasing hormone agonists; NPY-5 antagonists; and Y1 antagonists, such that together they give effective relief
[0391] As used herein “obesity” refers to a condition whereby a mammal has a Body Mass Index (BMI), which is calculated as weight per height squared (kg/m 2 ), of at least 25.9. Conventionally, those persons with normal weight, have a BMI of 19.9 to less than 25.9.
[0392] It will be appreciated that for the treatment or prevention of obesity, the compounds of the present invention may also be used in combination with histamine receptor-3 (H3) modulators, melanin concentrating hormone-1receptor (MCH1R) antagonists, melanin concentrating hormone-2 receptor (MCH2R) agonists and antagonists and/or phosphodiesterase-3B (PDE3B) inhibitors.
[0393] The obesity herein may be due to any cause, whether genetic or environmental. Examples of disorders that may result in obesity or be the cause of obesity include overeating and bulimia, polycystic ovarian disease, craniopharyngioma, the Prader-Willi Syndrome, Frohlich's syndrome, Type II diabetes, GH-deficient subjects, normal variant short stature, Turner's syndrome, and other pathological conditions showing reduced metabolic activity or a decrease in resting energy expenditure as a percentage of total fat-free mass, e.g., children with acute lymphoblastic leukemia.
[0394] “Treatment” (of obesity) refers to reducing the BMI of the mammal to less than about 25.9, and maintaining that weight for at least 6 months. The treatment suitably results in a reduction in food or calorie intake by the mammal.
[0395] “Prevention” (of obesity) refers to preventing obesity from occurring if the treatment is administered prior to the onset of the obese condition. Moreover, if treatment is commenced in already obese subjects, such treatment is expected to present, or to prevent the progression of, the medical sequelae of obesity, such as, e.g., arteriosclerosis, Type II diabetes, polycystic ovarian disease, cardiovascular diseases, osteoarthritis, dermatological disorders, hypertension, insulin resistance, hypercholesterolemia, hypertriglyceridemia, and cholelithiasis.
[0396] It will be appreciated that for the treatment or prevention of migraine, a compound of the present invention may be used in conjunction with other anti-migraine agents, such as ergotamines or 5-HT 1 agonists, especially sumatriptan, naratriptan, zolmatriptan or rizatriptan.
[0397] It will be appreciated that for the treatment of depression or anxiety, a compound of the present invention may be used in conjunction with other anti-depressant or anti-anxiety agents.
[0398] Suitable classes of anti-depressant agents include norepinephrine reuptake inhibitors, selective serotonin reuptake inhibitors (SSRIs), monoamine oxidase inhibitors (MAOIs), reversible inhibitors of monoamine oxidase (RIMAs), serotonin and noradrenaline reuptake inhibitors (SNRIs), corticotropin releasing factor (CRF) antagonists, (α-adrenoreceptor antagonists and atypical anti-depressants.
[0399] Suitable norepinephrine reuptake inhibitors include tertiary amine tricyclics and secondary amine tricyclics. Suitable examples of tertiary amine tricyclics include: amitriptyline, clomipramine, doxepin, imipramine and trimipramine, and pharmaceutically acceptable salts thereof. Suitable examples of secondary amine tricyclics include: amoxapine, desipramine, maprotiline, nortriptyline and protriptyline, and pharmaceutically acceptable salts thereof.
[0400] Suitable selective serotonin reuptake inhibitors include: fluoxetine, fluvoxamine, paroxetine and sertraline, and pharmaceutically acceptable salts thereof.
[0401] Suitable monoamine oxidase inhibitors include: isocarboxazid, phenelzine, tranylcypromine and selegiline, and pharmaceutically acceptable salts thereof.
[0402] Suitable reversible inhibitors of monoamine oxidase include: moclobemide, and pharmaceutically acceptable salts thereof.
[0403] Suitable serotonin and noradrenaline reuptake inhibitors of use in the present invention include: venlafaxine, and pharmaceutically acceptable salts thereof.
[0404] Suitable CRF antagonists include those compounds described in International Patent Specification Nos. WO 94/13643, WO 94/13644, WO 94/13661, WO 94/13676 and WO 94/13677.
[0405] Suitable atypical anti-depressants include: bupropion, lithium, nefazodone, trazodone and viloxazine, and pharmaceutically acceptable salts thereof.
[0406] Suitable classes of anti-anxiety agents include benzodiazepines and 5-HT 1A agonists or antagonists, especially 5-HT 1A partial agonists, and corticotropin releasing factor (CRF) antagonists.
[0407] Suitable benzodiazepines include: alprazolam, chlordiazepoxide, clonazepam, chlorazepate, diazepam, halazepam, lorazepam, oxazepam and prazepam, and pharmaceutically acceptable salts thereof.
[0408] Suitable 5-HT 1A receptor agonists or antagonists include, in particular, the 5-HT 1A receptor partial agonists buspirone, flesinoxan, gepirone and ipsapirone, and pharmaceutically acceptable salts thereof.
[0409] As used herein, the term “substance abuse disorders” includes substance dependence or abuse with or without physiological dependence. The substances associated with these disorders are: alcohol, amphetamines (or amphetamine-like substances), caffeine, cannabis, cocaine, hallucinogens, inhalants, nicotine, opioids, phencyclidine (or phencyclidine-like compounds), sedative-hypnotics or benzodiazepines, and other (or unknown) substances and combinations of all of the above.
[0410] In particular, the term “substance abuse disorders” includes drug withdrawal disorders such as alcohol withdrawal with or without perceptual disturbances; alcohol withdrawal delirium; amphetamine withdrawal; cocaine withdrawal; nicotine withdrawal; opioid withdrawal; sedative, hypnotic or anxiolytic withdrawal with or without perceptual disturbances; sedative, hypnotic or anxiolytic withdrawal delirium; and withdrawal symptoms due to other substances. It will be appreciated that reference to treatment of nicotine withdrawal includes the treatment of symptoms associated with smoking cessation.
[0411] Other “substance abuse disorders” include substance-induced anxiety disorder with onset during withdrawal; substance-induced mood disorder with onset during withdrawal; and substance-induced sleep disorder with onset during withdrawal.
[0412] It will be appreciated that a combination of a conventional antipsychotic drug with a CB1 receptor modulator may provide an enhanced effect in the treatment of mania. Such a combination would be expected to provide for a rapid onset of action to treat a manic episode thereby enabling prescription on an “as needed basis”. Furthermore, such a combination may enable a lower dose of the antipsychotic agent to be used without compromising the efficacy of the antipsychotic agent, thereby minimising the risk of adverse side-effects. A yet further advantage of such a combination is that, due to the action of the CB1 receptor modulator, adverse side-effects caused by the antipsychotic agent such as acute dystonias, dyskinesias, akathesia and tremor may be reduced or prevented.
[0413] Thus, according to a further aspect of the present invention there is provided the use of a CB1 receptor modulator and an antipsychotic agent for the manufacture of a medicament for the treatment or prevention of mania.
[0414] The present invention also provides a method for the treatment or prevention of mania, which method comprises administration to a patient in need of such treatment of an amount of a CB1 receptor modulator and an amount of an antipsychotic agent, such that together they give effective relief.
[0415] In a further aspect of the present invention, there is provided a pharmaceutical composition comprising a CB1 receptor modulator and an antipsychotic agent, together with at least one pharmaceutically acceptable carrier or excipient.
[0416] It will be appreciated that the CB1 receptor modulator and the antipsychotic agent may be present as a combined preparation for simultaneous, separate or sequential use for the treatment or prevention of mania. Such combined preparations may be, for example, in the form of a twin pack.
[0417] In a further or alternative aspect of the present invention, there is therefore provided a product comprising a CB1 receptor modulator and an antipsychotic agent as a combined preparation for simultaneous, separate or sequential use in the treatment or prevention of mania.
[0418] It will be appreciated that when using a combination of the present invention, the CB1 receptor modulator and the antipsychotic agent may be in the same pharmaceutically acceptable carrier and therefore administered simultaneously. They may be in separate pharmaceutical carriers such as conventional oral dosage forms which are taken simultaneously. The term “combination” also refers to the case where the compounds are provided in separate dosage forms and are administered sequentially. Therefore, by way of example, the antipsychotic agent may be administered as a tablet and then, within a reasonable period of time, the CB1 receptor modulator may be administered either as an oral dosage form such as a tablet or a fast-dissolving oral dosage form. By a “fast-dissolving oral formulation” is meant, an oral delivery form which when placed on the tongue of a patient, dissolves within about 10 seconds.
[0419] Included within the scope of the present invention is the use of CB1 receptor modulators in combination with an antipsychotic agent in the treatment or prevention of hypomania.
[0420] Suitable antipsychotic agents of use in combination with a CB1 receptor modulator include the phenothiazine, thioxanthene, heterocyclic dibenzazepine, butyrophenone, diphenylbutylpiperidine and indolone classes of antipsychotic agent. Suitable examples of phenothiazines include chlorpromazine, mesoridazine, thioridazine, acetophenazine, fluphenazine, perphenazine and trifluoperazine. Suitable examples of thioxanthenes include chlorprothixene and thiothixene. An example of a dibenzazepine is clozapine. An example of a butyrophenone is haloperidol. An example of a diphenylbutylpiperidine is pimozide. An example of an indolone is molindolone. Other antipsychotic agents include loxapine, sulpiride and risperidone. It will be appreciated that the antipsychotic agents when used in combination with a CB1 receptor modulator may be in the form of a pharmaceutically acceptable salt, for example, chlorpromazine hydrochloride, mesoridazine besylate, thioridazine hydrochloride, acetophenazine maleate, fluphenazine hydrochloride, flurphenazine enathate, fluphenazine decanoate, trifluoperazine hydrochloride, thiothixene hydrochloride, haloperidol decanoate, loxapine succinate and molindone hydrochloride. Perphenazine, chlorprothixene, clozapine, haloperidol, pimozide and risperidone are commonly used in a non-salt form.
[0421] It will be appreciated that a combination of a conventional antipsychotic drug with a CB1 receptor modulator may provide an enhanced effect in the treatment of schizophrenic disorders. Such a combination would be expected to provide for a rapid onset of action to treat schizophrenic symptoms thereby enabling prescription on an “as needed basis”. Furthermore, such a combination may enable a lower dose of the CNS agent to be used without compromising the efficacy of the antipsychotic agent, thereby minimising the risk of adverse side-effects. A yet further advantage of such a combination is that, due to the action of the CB1 receptor modulator, adverse side-effects caused by the antipsychotic agent such as acute dystonias, dyskinesias, akathesia and tremor may be reduced or prevented.
[0422] As used herein, the term “schizophrenic disorders” includes paranoid, disorganized, catatonic, undifferentiated and residual schizophrenia; schizophreniform disorder; schizoaffective disorder; delusional disorder; brief psychotic disorder; shared psychotic disorder; substance-induced psychotic disorder; and psychotic disorder not otherwise specified.
[0423] Other conditions commonly associated with schizophrenic disorders include self-injurious behavior (e.g. Lesch-Nyhan syndrome) and suicidal gestures.
[0424] Suitable antipsychotic agents of use in combination with a CB1 receptor modulator include the phenothiazine, thioxanthene, heterocyclic dibenzazepine, butyrophenone, diphenylbutylpiperidine and indolone classes of antipsychotic agent. Suitable examples of phenothiazines include chlorpromazine, mesoridazine, thioridazine, acetophenazine, fluphenazine, perphenazine and trifluoperazine. Suitable examples of thioxanthenes include chlorprothixene and thiothixene. Suitable examples of dibenzazepines include clozapine and olanzapine. An example of a butyrophenone is haloperidol. An example of a diphenylbutylpiperidine is pimozide. An example of an indolone is molindolone. Other antipsychotic agents include loxapine, sulpiride and risperidone. It will be appreciated that the antipsychotic agents when used in combination with a CB1 receptor modulator may be in the form of a pharmaceutically acceptable salt, for example, chlorpromazine hydrochloride, mesoridazine besylate, thioridazine hydrochloride, acetophenazine maleate, fluphenazine hydrochloride, flurphenazine enathate, fluphenazine decanoate, trifluoperazine hydrochloride, thiothixene hydrochloride, haloperidol decanoate, loxapine succinate and molindone hydrochloride. Perphenazine, chlorprothixene, clozapine, olanzapine, haloperidol, pimozide and risperidone are commonly used in a non-salt form.
[0425] Other classes of antipsychotic agent of use in combination with a CB1 receptor modulator include dopamine receptor antagonists, especially D2, D3 and D4 dopamine receptor antagonists, and muscarinic m1 receptor agonists. An example of a D3 dopamine receptor antagonist is the compound PNU-99194A. An example of a D4 dopamine receptor antagonist is PNU-101387. An example of a muscarinic m1 receptor agonist is xanomeline.
[0426] Another class of antipsychotic agent of use in combination with a CB1 receptor modulator is the 5-HT 2A receptor antagonists, examples of which include MDL100907 and fananserin. Also of use in combination with a CB1 receptor modulator are the serotonin dopamine antagonists (SDAs) which are believed to combine 5-HT 2A and dopamine receptor antagonist activity, examples of which include olanzapine and ziperasidone.
[0427] The method of treatment of this invention comprises a method of modulating the CB1 receptor and treating CB1 receptor mediated diseases by administering to a patient in need of such treatment a non-toxic therapeutically effective amount of a compound of this invention that selectively antagonizes the CB1 receptor in preference to the other CB or G-protein coupled receptors.
[0428] The term “therapeutically effective amount” means the amount the compound of structural formula I that will elicit the biological or medical response of a tissue, system, animal or human that is being sought by the researcher, veterinarian, medical doctor or other clinician.
[0429] The weight ratio of the compound of the Formula I to the second active ingredient may be varied and will depend upon the effective dose of each ingredient. Generally, an effective dose of each will be used. Thus, for example, when a compound of the Formula I is combined with a β-3 agonist the weight ratio of the compound of the Formula I to the β-3 agonist will generally range from about 1000:1 to about 1:1000, preferably about 200:1 to about 1:200. Combinations of a compound of the Formula I and other active ingredients will generally also be within the aforementioned range, but in each case, an effective dose of each active ingredient should be used.
[0430] Abbreviations used in the following Schemes and Examples:
4-DMAP: 4-dimethylaminopyridine Ac 2 O: acetic anhydride AcCN: acetonitrile Ag 2 O: silver(I) oxide AIBN: 2,2′-azobisisobutyronitrile BF 3 -Et 2 O: borontrifluoride etherate BH 3 -DMS: borane dimethylsulfide complex Bn: benzyl BOC: tert-butoxycarbonyl BOC-ON 2-(tert-butoxycarbonyloxyimino)-2-phenylacetonitrile BOP: benzotriazol-1-yloxy-tris(dimethylamino)-phosphonium hexafluorophosphate brine: saturated sodium chloride solution CBZ: benzyloxycarbonyl Cy 3 P: tricyclohexylphosphine DBU: 1,8-diazobicyclo[5.4.0]undec-7-ene DCC: dicyclohexylcarbodiimide DIBAL-H: diisobutylaluminum hydride DIPEA: N,N-diisopropylethylamine DME: 1,2-dimethoxyethane DMF: dimethylformamide DMPU: 1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)-pyrimidinone DMSO: dimethylsulfoxide EDC: 1-ethyl-3-(3-dimethylaminopropyl)-carbodiimide hydrochloride Et: ethyl Et 2 O: diethyl ether EtOAc: ethyl acetate EtOH: ethanol FMOC: 9-fluorenylmethoxylcarbonyl g or gm: gram h or hr: hours HATU: O-(7-azabenzotriazol-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate HBTU: O-(benzotriazol-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate HOAc: acetic acid HOAt: 1-hydroxy-7-azabenzotriazole HOBt: 1-hydroxybenzotriazole HPLC: high pressure liquid chromatography in vacuo: rotoevaporation KOAc: potassium acetate LDA: lithium diisopropylamide LiHMDS: lithium hexamethyldisilylamide mCPBA: meta-chloroperbenzoic acid Me: methyl MeI: methyl iodide MeOH: methanol mg: milligram MHz: megahertz min: minutes mL: milliliter mmol: millimole MPLC: medium pressure liquid chromatography MS or ms: mass spectrum MsCl: methanesulfonyl chloride NBS: N-bromosuccinimide n-Bu n-butyl NMO: 4-methyl-morpholine-N-oxide Pd 2 dba 3 : tris(dibenzylideneacetone)dipalladium(0) Ph: phenyl Ph 3 P: triphenylphosphine pTSA: para-toluenesulfonic acid PyBOP: (benzotriazol-1-yloxy)tripyrrolidinophosphonium hexafluorophosphate rt: room temperature TBAF: tetrabutylammonium fluoride TBSCl: tert-butyldimethylsilyl chloride t-Bu 3 P: tri-tert-butylphosphine TEA: triethylamine TFA: trifluoroacetic acid THF: THF TLC: thin layer chromatography TMSCHN 2 : trimethylsiliyldiazomethane TMSCl: trimethylsilyl chloride TMSI: trimethylsilyl iodide TPAP: tetrapropylammonium perruthenate TsCl: para-toluene sulfonyl chloride
[0504] Compounds of the present invention may be prepared by procedures illustrated in the accompanying schemes.
[0505] As outlined in Scheme 1, benzoin derivatives A are condensed with urea B in heated ethylene glycol to afford 2(3H)-imidazolone C . Typically, a mixture of the two regioisomers is obtained that may or may not be separated. Treatment of C with phosphorous oxychloride affords the 2-chloro-imidazoles D . Lithiation of D with n-butyllithium followed by acylation yields the imidazole-2-carboxylate E . The ester in E is hydrogenated (R 2 =benzyloxy) or hydrolyzed (R 2 =ethoxy or benzyloxy) to afford carboxylic acid F . Coupling with an amine derivative in the presence of a coupling agent yields the imidazole-2-carboxamides G . Alternatively, ester E may be heated neat with an amine to afford G directly. G may be obtained directly from D by lithiation with n-butyllithium followed by acylation with an isocyanate.
[0506] Alternatively, as shown in Scheme 2, benzil derivative A or benzoin derivative B are condensed with formamide and paraformaldehyde to afford diaryl-imidazole C . Treatment with base (e.g., sodium hydride) followed by treatment with an electrophile affords N-substituted imidazole D . Reaction with n-butyllithium followed by acylation yields imidazole-2-carboxylates E which may be treated as outlined in Scheme 1.
[0507] In Scheme 3, the diaryl imidazole A is treated with base (e.g., sodium hydride) followed by alkylation with a suitable protecting group (e.g. 2-trimethylsilyl-ethoxy-methyl chloride, SEM-Cl) to yield N-protected imidazoles B . Deprotonation with strong base (n-butyllithium) followed by treatment with an isocyanate derivative affords the protected 2-carboxamide C . Removal of the SEM-protecting group with TBAF yields the 4,5-diaryl-imidazole-2-carboxamide D which may be reacted with base and an electrophile (as in Scheme 2, B to C ).
[0508] Scheme 4 outlines the synthesis of acyloin derivatives that are useful in the preparation of compounds of the present invention. A single aryl aldehyde A (Ar 1 =Ar 2 ) or a mixture of aryl aldehydes (Ar 1 ≠Ar 2 ) is reacted with sodium cyanide in ethanol to yield benzoin derivative(s) B which may be used as starting materials as outlined in Schemes 1 or 2.
General Procedures.
[0509] The HPLC/MS analyses were preformed using a Micromass ZMD mass spectrometer coupled to an Agilent 1100 Series HPLC utilizing a YMC ODS-A 4.6×50 mm column eluting at 2.5 mL/min with a solvent gradient of 10 to 95% B over 4.5 min, then 0.5 min at 95% B: solvent A=0.06% TFA in water; solvent B=0.05% TFA in acetonitrile.
[0510] Proton NMR spectra were obtained with a 400 MHz Varian Spectrometer in CDCl 3 or CD 3 OD and chemical shifts are reported as δ using the deuterium of the solvent as standard and coupling constants are reported in hertz.
EXAMPLE 1
[0511]
Benzyl 4,5-diphenyl-1-methylimidazole-2-carboxylate
[0000] Step A: 4,5-Diphenyl-1-methyl-(1H),(3H)-imidazolin-2-one
[0512] A mixture of benzoin (9.5 g, 45 mmol), N-methylurea (10.0 g, 135 mmol) in ethylene glycol (50 mL) was heated to 180° C. for 1.5 hr. The reaction was allowed to cool and was aged for 16 hr before the precipitate was filtered. The solid was recrystallized from ethanol to afford a white solid. The above filtrate was diluted with water and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate and combined with the above mother liquor to give a crude solid after evaporation. Recrystallization from ethanol afforded a second crop of white solid title compound.
[0513] HPLC/MS: 251 (M+1), 292 (100%, M+1+41 (CH 3 CN)); R t =2.59 min
[0514] 1 HNMR (CD 3 OD): 3.10 (s, 3H), 7.19 (m, 4H), 7.35 (m, 2H), 7.46 (m, 4H).
[0000] Step B: 2-Chloro-4,5-diphenyl-1-methylimidazole
[0515] A mixture of 4,5-diphenyl-1-methyl-(1H),(3H)-imidazolin-2-one (3.0 g, 12 mmol) from Step A in phosphorous oxychloride (30 mL) was heated to 100° C. for 20 hr. Most of the phosphorous oxychloride was removed in vacuo and the residue was quenched into a mixture of ethyl acetate and saturated aqueous sodium bicarbonate. The layers were separated and the organic layer was washed with brine, dried over sodium sulfate and evaporated. The residue was purified by flash chromatography (2% methylene chloride in 20% ethyl acetate/hexanes) and then crystallized from ethyl acetate/hexanes to afford the title compound. A second crop of slightly impure title compound was obtained from the mother liquors.
[0516] HPLC/MS: 269 (M+1); R t =3.23 min; 1 HNMR (CDCl 3 ): 3.44 (s, 3H), 7.19 (m, 4H), 7.35 (m, 2H), 7.48 (m, 4H).
[0000] Step C: Benzyl 4,5-diphenyl-1-methylimidazole-2-carboxylate
[0517] A solution of 2-chloro-4,5-diphenyl-1-methylimidazole (1.46 g, 5.4 mmol) from Step B in tetrahydrofuran (THF) (20 mL) under nitrogen was cooled to −70° C. in a dry ice/acetone bath. n-Butyl lithium (1.6 N in hexanes, 10.2 mL, 16.3 mmol) was added via syringe. The reaction was allowed to warm to −20° C. for 2 hr. In a separate round-bottomed flask, a solution of benzyl chloroformate (CBZ-Cl) (4.3 mL, 16.3 mmol) in TBF (10 mL) was cooled to −20° C. The above imidazole reaction was added via a double-tipped needle to the solution of CBZ-Cl and after 20 min the reaction was allowed to warm to rt for 30 min. The reaction was then quenched into an aqueous sodium bicarbonate solution and was then extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate and evaporated. The residue was purified by flash chromatography (5% methylene chloride and 15% ethyl acetate in hexanes) to afford the title compound.
[0518] HPLC/MS: 369 (M+1); R t =3.60 min; 1HNMR (CDCl 3 ): 3.81 (s, 3H), 5.49 (s, 2H), 7.20 (m, 4H), 7.35 (m, 2H), 7.40 (m, 2H), 7.50 (m, 5H), 7.56 (m, 2H).
EXAMPLE 2
[0519]
Benzyl 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylate
[0000] Step A: 4,5-Di-(4-methylphenyl)-1-methyl-(1H),(3H)-imidazolin-2-one
[0520] Using essentially the same procedure as Example 1, Step A, 4,4′-dimethylbenzoin (10.8 g, 45 mmol) was converted to the title compound.
[0521] HPLC/MS: 320 (M+1+41 (CH 3 CN)); R t =3.07 min; 1 HNMR (CDCl 3 ): 2.29 (s, 3H), 2.43 (s, 3H), 3.15 (s, 3H), 7.03 (d, J=8.2 Hz, 2H), 7.12 (d, J=8.2 Hz, 2H), 7.25 (m, 4H).
[0000] Step B: 2-Chloro-4,5-di-(4-methylphenyl)-1-methylimidazole
[0522] Using essentially the same procedure as Example 1, Step B, 4,5-di-(4-methylphenyl)-1-methyl-(1H),(3H)-imidazolin-2-one (3.0 g, 10.8 mmol) from Step A was converted to the title compound.
[0523] HPLC/MS: 297 (M+1); R t =3.60 min; 1 HNMR (CDCl 3 ): 2.29 (s, 3H), 2.45 (s, 3H), 3.42 (s, 3H), 7.02 (d, J=8.2 Hz, 2H), 7.22 (d, J=6.3 Hz, 2H), 7.28 (d, J=6.3 Hz, 2H), 7.35 (d, J=8.2 Hz, 2H).
[0000] Step C: Benzyl 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylate
[0524] Using essentially the same procedure as Example 1, Step C, 2-chloro-4,5-di-(4-methylphenyl)-1-methylimidazoline (1.5 g, 5.1 mmol) from Step B was converted to the title compound.
[0525] HPLC/MS: 397 (M+1); R t =3.84 min; 1HNMR (CDCl 3 ): 2.29 (s, 3H), 2.44 (s, 3H), 3.78 (s, 3H), 5.48 (s, 2H), 7.03 (d, 2H), 7.19 (d, 2H), 7.28 (d, 2H), 7.35-7.42 (m, 5H), 7.54 (d, 2H).
EXAMPLE 3
[0526]
Ethyl 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylate
[0527] Using essentially the same procedure as Example 1, Step C, but using ethyl chloroformate, 2-chloro-4,5-di-(4-methylphenyl)-1-methylimidazoline (0.10 g, 0.33 mmol) from Example 2, Step B was converted to the title compound.
[0528] HPLC/MS: 335 (M+1); R t =3.31 min; 1 HNMR (CDCl 3 ): 1.56 (t, 3H), 2.31 (s, 3H), 2.47 (s, 3H), 3.88 (s, 3H), 4.58 (q, 2H), 7.09 (d, 2H), 7.21 (d, 2H), 7.33 (d, 2H), 7.48 (d, 2H).
EXAMPLE 4
[0529]
N-(Piperidin-1-yl)-4,5-diphenyl-1-methylimidazole-2-carboxamide and 2-(piperidin-1-ylcarbonyl)-4,5-diphenyl-1-methylimidazole
[0000] Step A: 4,5-Diphenyl-1-methylimidazole-2-carboxylic acid
[0530] To a suspension of benzyl 4,5-diphenyl-1-methylimidazole-2-carboxylate (0.43 g, 1.2 mmol) from Example 1, Step C in methanol (10 mL) was added 20% palladium on carbon (50% w/w water, 110 mg) and the mixture was hydrogenated on a Parr shaker at 40 psi for 1 hr. The reaction was filtered and the filtrate was evaporated to dryness to afford the title compound as a white solid. (Note: The title compound readily decarboxylates as the acid.) HPLC/MS: 279 (M+1); R t =2.05 min.
[0000] Step B: N-(Piperidin-1-yl)-4,5-diphenyl-1-methylimidazole-2-carboxamide and 2-(piperidin-1-ylcarbonyl)-4,5-diphenyl-1-methylimidazole
[0531] A mixture of 4,5-diphenyl-1-methylimidazole-2-carboxylic acid (50 mg, 0.18 mmol) from Step A, 1-aminopiperidine (0.052 mL, 0.36 mmol) (containing a small percent of piperidine as an impurity), PyBOP (NovaChem) (140 mg, 0.2 mmol) and N,N-diisopropyl-N-ethylamine (DIPEA) (0.065 mL, 0.2 mmol) in methylene chloride (2 mL) was stirred at rt for 20 hr. The reaction was diluted with water and extracted twice with methylene chloride. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified twice by prep TLC (1 mm, silica gel) eluting with 5% methylene chloride, 35% ethyl acetate in hexanes to afford the primary product N-(piperidin-1-yl)-4,5-diphenyl-1-methylimidazole-2-carboxamide and 2-(piperidin-1-ylcarbonyl)-4,5-diphenyl-1-methylimidazole as a byproduct. HPLC/MS: 361 (M+1); R t =2.64 min; 1 HNMR (CDCl 3 ): 1.4-1.7 (m, 2H), 1.92 (m, 4H), 2.96 (br s, 4H), 3.90 (s, 3H), 7.24 (m, 3H), 7.34 (m, 2H), 7.50 (m, 5H).
[0000] and
[0532] HPLC/MS: 346 (M+1); R t =2.80 min; 1 HNMR (CDCl 3 ): 1.75 (m, 6H), 3.64 (s, 3H), 3.78 (m, 2H), 4.03 (m, 2H), 7.21 (m, 3H), 7.38 (m, 2H), 7.49 (m, 5H).
EXAMPLE 5
[0533]
N-(Morpholin-4-yl)-4,5-diphenyl-1-methylimidazole-2-carboxamide
[0534] Using essentially the same procedure as Example 4, Step B, but using 4-aminomorpholine (0.025 mL), 4,5-diphenyl-1-methylimidazole-2-carboxylic acid (30 mg, 0.10 mmol) from Example 4, Step A was converted to the title compound.
[0535] HPLC/MS: 363 (M+1); R t =2.72 min.
EXAMPLE 6
[0536]
N-Phenyl-4,5-diphenyl-1-methylimidazole-2-carboxamide
[0537] Using essentially the same procedure as Example 4, Step B, but using aniline (0.025 mL), 4,5-diphenyl-1-methylimidazole-2-carboxylic acid (30 mg, 0.10 mmol) from Example 4, Step A was converted to the title compound.
[0538] HPLC/MS: 354 (M+1); R t =4.31 min.
EXAMPLE 7
N-Hexyl-4,5-diphenyl-1-methylimidazole-2-carboxamide
[0539] Using essentially the same procedure as Example 4, Step B, but using n-hexylamine (0.025 mL), 4,5-diphenyl-1-methylimidazole-2-carboxylic acid (30 mg, 0.10 mmol) from Example 4, Step A was converted to the title compound.
[0540] HPLC/MS: 362 (M+1); R t =4.24 min.
EXAMPLE 8
[0541]
N-Cyclohexyl-4,5-diphenyl-1-methylimidazole-2-carboxamide
[0542] Using essentially the same procedure as Example 4, Step B, but using cyclohexylamine (0.025 mL), 4,5-diphenyl-1-methylimidazole-2-carboxylic acid (30 mg, 0.10 mmol) from Example 4, Step A was converted to the title compound.
[0543] HPLC/MS: 360 (M+1); R t =3.95 min.
EXAMPLE 9
[0544]
N-(Piperidin-1-yl)-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide and 2-(piperidin-1-ylcarbonyl)-4,5-di-(4-methylphenyl)-1-methylimidazole
[0000] Step A: 4,5-Di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid
[0545] To a suspension of benzyl 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylate (0.35 g, 0.9 mmol) from Example 2, Step C in methanol (10 mL) was added 20% palladium on carbon (50% w/w water, 100 mg) and the mixture was hydrogenated at 40 psi for 1 hr. The reaction was filtered and the filtrate was evaporated to dryness to afford the title compound as a white solid. (Note: The title compound readily decarboxylates as the acid.)
[0546] HPLC/MS: 307 (M+1); R t =2.48 min.
[0000] Step B: N-(Piperidin-1-yl)-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide and 2-(piperidin-1-ylcarbonyl)-4,5-di-(4-methylphenyl)-1-methylimidazole
[0547] A mixture of 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid (25 mg, 0.08 mmol) from Step A, 1-aminopiperidine (0.020 mL, 0.16 mmol) (containing a small percent of piperidine as an impurity), PyBOP (NovaChem) (65 mg, 0.1 mmol) and DIPEA (0.025 mL, 0.1 mmol) in methylene chloride (1 mL) was stirred at rt for 20 hr. The reaction was diluted with water and extracted twice with methylene chloride. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified twice by prep TLC (1 mm, silica gel) eluting with 5% methylene chloride, 35% ethyl acetate in hexanes to afford the primary product N-(piperidin-1-yl)-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide (10 mg, 32%) and 2-(piperidin-1-ylcarbonyl)-4,5-di-(4-methylphenyl)-1-methylimidazole as a byproduct.
[0548] HPLC/MS: 389 (M+1); R t =3.04 min
[0000] and
[0549] HPLC/MS: 374 (M+1); R t =3.12 min
EXAMPLE 10
[0550]
N-(Morpholin-4-yl)-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide
[0551] Using essentially the same procedure as Example 9, Step B, but using 4-aminomorpholine (0.025 mL), 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid (25 mg, 0.08 mmol) from Example 9, Step A was converted to the title compound. HPLC/MS: 391 (M+1); R t =3.12 min.
EXAMPLE 11
[0552]
2-(Pyrrolidin-1-ylcarbonyl)-4,5-di-(4-methylphenyl)-1-methylimidazole
[0553] Using essentially the same procedure as Example 9, Step B, but using pyrrolidine (0.022 mL), 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid (25 mg, 0.08 mmol) from Example 9, Step A was converted to the title compound. HPLC/MS: 360 (M+1); R t =3.12 min.
EXAMPLE 12
[0554]
N-Benzyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide
[0555] Using essentially the same procedure as Example 9, Step B, but using benzylamine (0.022 mL), 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid (25 mg, 0.08 mmol) from Example 9, Step A was converted to the title compound. HPLC/MS: 396 (M+1); R t =4.13 min.
EXAMPLE 13
[0556]
N-Phenyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide
[0557] Using essentially the same procedure as Example 9, Step B, but using aniline (0.020 mL), 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid (25 mg, 0.08 mmol) from Example 9, Step A was converted to the title compound.
[0558] HPLC/MS: 382 (M+1); R t =4.43 min.
EXAMPLE 14
[0559]
N-Hexyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide
[0560] Using essentially the same procedure as Example 9, Step B, but using hexylamine (0.020 mL), 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid (25 mg, 0.08 mmol) from Example 9, Step A was converted to the title compound. HPLC/MS: 390 (M+1); R t =4.45 min.
EXAMPLE 15
[0561]
N-t-Butyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide
[0562] Using essentially the same procedure as Example 9, Step B, but using t-butylamine (0.022 mL), 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid (25 mg, 0.08 mmol) from Example 9, Step A was converted to the title compound. HPLC/MS: 362 (M+1); R t =3.92 min.
EXAMPLE 16
[0563]
N-Cyclohexyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide
[0564] Using essentially the same procedure as Example 9, Step B, but using cyclohexylamine (0.020 mL), 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid (25 mg, 0.08 mmol) from Example 9, Step A was converted to the title compound. HPLC/MS: 388 (M+1); R t =4.19 min.
EXAMPLE 17
[0565]
N-Propyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide
[0566] Using essentially the same procedure as Example 9, Step B, but using n-propylamine (0.015 mL), 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid (25 mg, 0.08 mmol) from Example 9, Step A was converted to the title compound. HPLC/MS: 348 (M+1); R t =3.76 min.
EXAMPLE 18
[0567]
N-Methyl-4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxamide
[0568] Using essentially the same procedure as Example 9, Step B, but using methylamine (0.20 mL of 2N methylamine in THF), 4,5-di-(4-methylphenyl)-1-methylimidazole-2-carboxylic acid (25 mg, 0.08 mmol) from Example 9, Step A was converted to the title compound. HPLC/MS: 320 (M+1); R t =3.28 min.
EXAMPLE 19
[0569]
Benzyl 4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxylate
[0000] Step A: 4,5-Di-(4-chlorophenyl)imidazole
[0570] A mixture of 4,4′-dichlorobenzil (3.0 gm, 10.8 mmol) and paraformaldehyde (2.0 gm, 67 mmol) in formamide (50 mL) was heated to 220° C. for 2.5 hr. The reaction was cooled, diluted with water, and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was crystallized from isopropyl acetate (or ethyl acetate) to provide the title compound as a white solid in 3 crops. HPLC/MS: 289 (M+1), 291 (M+3); R t =2.64 min.
[0000] Step B: 4,5-Di-(4-chlorophenyl)-1-methylimidazole
[0571] To a solution of 4,5-di-(4-chlorophenyl)imidazole (300 mg, 1.0 mmol) from Step A and methyl iodide (0.10 mL, 2.0 mmol) in DMF (5 mL) was added sodium hydride (80 mg 60% in mineral oil, 1.5 mmol) all at once at rt. After stirring for 1 hr, the reaction was quenched into water and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by flash chromatography (10% methylene chloride, 30% ethyl acetate in hexanes) to provide the title compound as a white solid.
[0572] HPLC/MS: 303 (M+1), 305 (M+3); R t =2.53 min; 1 HNMR (CDCl 3 ): 3.60 (s, 3H), 7.25 (d, J=8.5 Hz, 2H), 7.29 (d, J=8.5 Hz, 2H), 7.44 (d, J=8.5 Hz, 2H), 7.50 (d, J=8.5 Hz, 2H), 8.08 (br s, 1H).
[0000] Step C: Benzyl 4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxylate
[0573] To a solution of 4,5-di-(4-chlorophenyl)-1-methylimidazole (0.25 gm, 0.825 mmol) from Step B in THF (5 mL) cooled to −70° C. in a dry ice/acetone bath was added via syringe n-butyl lithium (1.6 N in hexanes, 0.62 mL, 1.0 mmol). The reaction was stirred at −70° C. for 30 min and then a solution of CBZ-Cl (0.42 mL, 1.65 mmol) in THF (2 mL) was added rapidly. The reaction was warmed to rt over 1 hr. The reaction was poured into an aq. sodium bicarbonate solution and then extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by flash chromatography (15% ethyl acetate in hexanes) to provide the title compound as a white solid. HPLC/MS: 437 (M+1), 439 (M+3); R t =4.37 min.
EXAMPLE 20
[0574]
N-(Piperidin-1-yl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide and 2-(piperidin-1-ylcarbonyl)-4,5-di-(4-chlorophenyl)-1-methylimidazole
[0000] Step A: 4,5-Di-(4-chlorophenyl)-1-methylimidazole-2-carboxylic acid
[0575] To a suspension of benzyl 4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxylate (185 mg, 0.42 mmol) from Example 19, Step C in methanol (20 mL) was added aq. 5N sodium hydroxide (0.25 mL, 1.27 mmol). The reaction was stirred at rt for 20 hr, concentrated in vacuo, acidified with 2N hydrochloric acid (0.50 mL), and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated to dryness to afford the crude title acid (150 mg) as a mixture with decarboxylated material. This material was used directly in Step B. HPLC/MS: 347 (M+1), 349 (M+3); R t =2.72 min.
[0000] Step B: N-(Piperidin-1-yl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide and 2-(piperidin-1-ylcarbonyl)-4,5-di-(4-chlorophenyl)-1-methylimidazole
[0576] A mixture of crude 4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxylic acid (45 mg, 0.13 mmol) from Step A (<50% pure due to decarboxylation), 1-aminopiperidine (0.050 mL, 0.33 mmol) (containing a small percent of piperidine as an impurity), Py-BOP (NovaChem) (110 mg, 0.16 mmol) and DIPEA (0.060 mL, 0.16 mmol) in methylene chloride (2 mL) was stirred at rt for 20 hr. The reaction was diluted with water and extracted twice with methylene chloride. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified twice by prep TLC (1 mm, silica gel) eluting with 40% ethyl acetate in hexanes to afford the primary product N-piperidin-1-yl-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide as the lower Rf product and 2-(piperidin-1-ylcarbonyl)-4,5-di-(4-chlorophenyl)-1-methylimidazole as a higher Rf byproduct along with recovered 4,5-di-(4-chlorophenyl)imidazole.
[0577] HPLC/MS: 429 (M+1), 431 (M+3); R t =3.55 min
[0000] and
[0578] HPLC/MS: 414 (M+1), 415 (M+3); R t =3.79 min
EXAMPLE 21
[0579]
N-(Morpholin-1-yl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0580] Using essentially the same procedure as Example 20, Step B, but using 4-aminomorpholine (0.020 mL, 0.12 mmol), 4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxylic acid (20 mg, 0.060 mmol) from Example 20, Step A was converted to the title compound. HPLC/MS: 431 (M+1), 433 (M+3); R t =3.55 min.
EXAMPLE 22
N-(Hexyl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0581] Using essentially the same procedure as Example 20, Step B, but using hexylamine (0.020 mL, 0.12 mmol), 4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxylic acid (20 mg, 0.060 mmol) from Example 20, Step A was converted to the title compound. HPLC/MS: 430 (M+1), 432 (M+3); R t =4.91 min.
EXAMPLE 23
[0582]
N-(t-Butyl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0583] Using essentially the same procedure as Example 20, Step B, but using t-butylamine (0.020 mL, 0.12 mmol), 4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxylic acid (20 mg, 0.060 mmol) from Example 20, Step A was converted to the title compound. HPLC/MS: 402 (M+1), 404 (M+3); R t =4.53 min.
EXAMPLE 24
[0584]
N-(Cyclohexyl)-4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0585] Using essentially the same procedure as Example 20, Step B, but using cyclohexylamine (0.020 mL, 0.12 mmol), 4,5-di-(4-chlorophenyl)-1-methylimidazole-2-carboxylic acid (20 mg, 0.060 mmol) from Example 20, Step A was converted to the title compound. HPLC/MS: 428 (M+1), 430 (M+3); R t =4.53 min.
EXAMPLE 25
[0586]
N-Hexyl-4,5-di-(4-chlorophenyl)imidazole-2-carboxamide
[0000] Step A: 4,5-Di-(4-chlorophenyl)-1-(2-(trimethylsilyl)ethoxymethyl)imidazole
[0587] To a solution of 4,5-di-(4-chlorophenyl)imidazole (500 mg, 1.7 mmol) from Example 20, Step A and 2-(trimethylsilyl)ethoxymethyl chloride (SEM-Cl) (0.46 mL, 2.6 mmol) in DMF (8 mL) at rt was added sodium hydride (60% in mineral oil) (135 mg, 3.4 mmol). The reaction was stirred for 20 min, poured into an aq. bicarbonate solution, and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by flash chromatography (25% ethyl acetate in hexanes) to afford the title compound as an oil. HPLC/MS: 419 (M+1), 421 (M+3); R t =3.60 min.
[0000] Step B: N-Hexyl-4,5-di-(4-chlorophenyl)-1-(2-(trimethylsilyl)ethoxymethyl)imidazole-2-carboxylate
[0588] A solution of 4,5-di-(4-chlorophenyl)-1-(2-(trimethylsilyl)ethoxymethyl)imidazole (40 mg, 0.10 mmol) from Step A in THF (1 mL) was cooled to −70° C. in a dry ice/acetone bath and n-butyl lithium (1.6M in hexanes, 0.075 mL, 0.12 mmol) was added. After 1 hr, hexyl isocyanate (0.030 mL, 0.20 mmol) was added and the reaction was warmed to rt for 1 hr. The reaction was quenched into an aq. sodium bicarbonate solution and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by prep TLC (1 mm, silica) (25% ethyl acetate in hexanes) to afford the title compound as an oil (12.5 mg, 24%) along with recovered starting material (23 mg, 57%). HPLC/MS: 546 (M+1), 548 (M+3); R t =3.89 min.
[0000] Step C: N-Hexyl-4,5-di-(4-chlorophenyl)imidazole-2-carboxylate
[0589] A solution of N-hexyl-4,5-di-(4-chlorophenyl)-1-(2-(trimethylsilyl)ethoxymethyl)imidazole-2-carboxylate (12.5 mg, 0.023 mmol) from Step B and tetrabutylammonium fluoride (TBAF) (1N in THF, 0.15 mL, 0.15 mmol) in THF (2 mL) was stirred at rt for 24 hr. Additional TBAF (0.10 mL) was added and the reaction was stirred another 72 hr. The volatiles were evaporated under nitrogen and the residue was purified by prep TLC (0.5 mm, silica) (15% ethyl acetate in hexanes) to afford the title compound. HPLC/MS: 416 (M+1), 418 (M+3); R t =2.64 min.
EXAMPLE 26
[0590]
N-Cyclohexyl-4,5-di-(4-chlorophenyl)imidazole-2-carboxamide
[0591] Using essentially the same procedure as Example 25, Step B-C, but using cyclohexyl isocyanate (0.027 mL, 0.21 mmol) in Step B, 4,5-di-(4-chlorophenyl)-1-(2-(trimethylsilyl)ethoxymethyl)imidazole (36 mg, 0.086 mmol) from Example 25, Step A was converted to the SEM intermediate and then to the title compound with TBAF. HPLC/MS: 414 (M+1), 416 (M+3); R t =3.55 min.
EXAMPLE 27
[0592]
N-t-Butyl-4,5-di-(4-chlorophenyl)imidazole-2-carboxamide
[0593] Using essentially the same procedure as Example 25, Step B-C, but using t-butyl isocyanate (0.016 mL, 0.14 mmol) in Step B, 4,5-di-(4-chlorophenyl)-1-(2-(trimethylsilyl)ethoxymethyl)imidazole (23 mg, 0.055 mmol) from Example 25, Step A was converted to the SEM intermediate and then to the title compound with TBAF. HPLC/MS: 388 (M+1), 390 (M+3); R t =2.45 min.
EXAMPLE 28
[0594]
Benzyl 4,5-di-(4-chlorophenyl)-1-(2-(trimethylsilyl)ethoxymethyl)imidazole-2-carboxylate
[0595] Using essentially the same procedure as Example 25, Step B, but using CBZ-Cl (0.030 mL, 1.2 mmol) in Step B, 4,5-di-(4-chlorophenyl)-1-(2-(trimethylsilyl)ethoxymethyl)imidazole (31 mg, 0.074 mmol) from Example 25, Step A was converted to the title compound. HPLC/MS: 553 (M+1), 555 (M+3); R t =5.2 min.
EXAMPLE 29
[0596]
N-(Piperidin-1-yl)-4,5-di-(4-chlorophenyl)imidazole-2-carboxamide
[0597] Using essentially the same procedure as Example 20, benzyl 4,5-di-(4-chlorophenyl)-1-(2-(trimethylsilyl)ethoxymethyl)imidazole (19 mg, 0.034 mmol) from Example 28, was converted to the SEM intermediate amide and then to the title compound with TBAF as in Example 25, Step C. HPLC/MS: 415 (M+1), 417 (M+3); R t =3.41 min.
EXAMPLE 30
[0598]
N-(Piperidin-1-yl)-4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide
[0000] Step A: (+/−)-2,2′,4,4′-Tetrachlorobenzoin
[0599] To a mixture of 2,4-dichlorobenzaldehyde (5.0 gm, 29 mmol) in ethanol (10 mL) was added a solution of sodium cyanide (500 mg, 10 mmol) in water (5 mL). The reaction was heated to reflux (100-110° C.) for 1 hr and was then cooled, diluted with water, and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by flash chromatography (10% methylene chloride, 10% ethyl acetate in hexanes) to afford the title compound as an oil. HPLC/MS: no parent ion, 372 (M+1−18 (H 2 O)+41 (CH 3 CN)), 374 (100%, M+3−18 (H 2 O)+41 (CH 3 CN)), 376 (M+5−18 (H 2 O)+41 (CH 3 CN)); R t =3.8 min
[0600] 1 HNMR (CDCl 3 ): 4.36 (d, 1H), 6.27 (d, 1H), 7.25 (s, 4H), 7.32 (br s, 1H), 7.41 (br s, 1H).
[0000] Step B: 4,5-Di-(2,4-dichlorophenyl)imidazole
[0601] A mixture of (+/−)-2,2′,4,4′-tetrachlorobenzoin (1.0 gm, 2.9 mmol) from Step A and paraformaldehyde (0.70 gm, 24 mmol) in formamide (20 mL) was heated to 200-210° C. for 3 hr. The reaction was cooled to rt, diluted with water, and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by flash chromatography, eluting first with 10% ethyl acetate in hexanes to afford 4,5-di-(2,4-dichlorophenyl)oxazole as a higher Rf byproduct and then with 75% ethyl acetate in hexanes to elute the title compound as an oil. HPLC/MS: 357 (M+1), 359 (100%, M+3), 361 (M+5); R t =2.72 min.
[0000] Step C: 4,5-Di-(2,4-dichlorophenyl)-1-methylimidazole
[0602] To a solution of 4,5-di-(2,4-dichlorophenyl)imidazole (230 mg, 0.65 mmol) from Step B and methyl iodide (0.062 mL, 1.0 mmol) in DMF (5 mL) was added sodium hydride (60% in mineral oil, 52 mg, 1.3 mmol). The reaction was stirred at rt for 3 hr and was then quenched with aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by flash chromatography (50% ethyl acetate in hexanes) to afford the title compound. HPLC/MS: 371 (M+1), 373 (100%, M+3), 375 (M+5); R t =2.85 min.
[0000] Step D: Ethyl 4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxylate
[0603] To a solution of 4,5-di-(2,4-dichlorophenyl)-1-methylimidazole (200 mg, 0.54 mmol) from Step C in THF (5 mL) cooled to −70° C. in a dry ice/acetone bath was added 1.6N n-butyl lithium in hexanes (0.40 mL, 0.65 mmol). The reaction was stirred for 1 hr and then ethyl chloroformate (0.10 mL, 1.1 mmol) was added via syringe. The reaction was allowed to warm to rt for 1 hr and was then quenched with aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by Prep TLC (2×1 mm, silica) (25% ethyl acetate in hexanes) to afford the title compound. HPLC/MS: 497 (M+1), 499 (100%, M+3), 501 (M+5); R t =3.95 min.
[0000] Step E: N-(Piperidin-1-yl)-4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide
[0604] A mixture of ethyl 4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxylate (20 mg, 0.045 mmol) from Step D in neat 1-aminopiperidine (1 mL) was heated at 90° C. for 72 hr. Most of the amine was evaporated under a stream of nitrogen and the residue was purified by Prep TLC (1 mm, silica) (25% ethyl acetate in hexanes to afford the title compound. HPLC/MS: 497 (M+1), 499 (100%, M+3), 501 (M+5); R t =3.95 min.
EXAMPLE 31
[0605]
N-(Cyclohexyl)-4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide
[0606] Using essentially the same procedure as Example 30, Step E, but using cyclohexylamine (1 mL), ethyl 4,5-di-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxylate (10 mg, 0.022 mmol) from Example 30, Step D was converted to the title compound. HPLC/MS: 496 (M+1), 498 (100%, M+3), 500 (M+5); R t =5.04 min.
EXAMPLE 32
N-(Piperidin-1-yl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide
[0000] Step A: (+/−)-4′-Chloro-2-hydroxy-2-(2,4-dichlorophenyl)acetophenone (Higher Rf Isomer) and (+/−)-2′,4′-dichloro-2-hydroxy-2-(4-chlorophenyl)acetophenone (Lower Rf Isomer)
[0607] To a mixture of 2,4-dichlorobenzaldehyde (5.3 gm, 30 mmol) and 4-chlorobenzaldehyde (10 gm, 70 mmol) in ethanol (30 mL) was added a solution of sodium cyanide (1.0 mg, 20 mmol) in water (10 mL). The reaction was heated to reflux (100-110° C.) for 5 hr and was then cooled, diluted with water, and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by flash chromatography (10% methylene chloride, 5-10% ethyl acetate in hexanes) to afford first recovered aldehydes and then the higher Rf isomeric trichloro product (contaminated with<10% of (+/−)-2,2′,4,4′-tetrachlorobenzoin having the same Rf). This was crystallized from ethyl acetate/hexanes to afford pure (+/−)-4′-chloro-2-hydroxy-2-(2,4-dichlorophenyl)acetophenone.
[0608] HPLC/MS: no parent ion; 297 (M+1−18 (H 2 O)), 299 (100%, M+3−18 (H 2 O)); 338 (100%, M+1−18 (H 2 O)+41 (CH 3 CN)), 340 (M+3−18 (H 2 O)+41 (CH 3 CN)); R t =3.6 min
[0609] 1 HNMR (CDCl 3 ): 4.45 (d, J=4 Hz, 1H), 6.28 (br d, 1H), 7.05 (d, J=8.4 Hz, 1H), 7.19 (dd, J=2.2 and 8.4 Hz, 1H), 7.41 (dt, J=2.5 and 8.5 Hz, 2H), 7.46 (d, J=2.2 Hz, 1H), 7.85 (dt, J=2.5 and 8.5 Hz).
[0610] Further elution (10% methylene chloride, 25% ethyl acetate in hexanes) gave a mixture of the lower Rf isomeric trichloro product and (+/−)-4,4′-dichlorobenzoin. This was crystallized from ethyl acetate/hexanes to afford pure (+/−)-4,4′-dichlorobenzoin (1.5 gm). The mother liquor was concentrated to give impure (+/−)-2′,4′-dichloro-2-hydroxy-2-(4-chlorophenyl)acetophenone as an oil.
[0611] HPLC/MS: no parent ion; R t =3.6 min
[0612] 1 HNMR (CDCl 3 ): 4.55 (br s, 1H), 5.81 (s, 1H), 7.26 (dt, J=2.5 and 8.5 Hz, 2H), 7.32 (dt, J=2.5 and 8.5 Hz, 2H), 7.39 (dd, J=2.0 and 8.4 Hz, 1H), 7.48 (d, J=2.0 Hz, 1H), 7.67 (d, J=8.4 Hz) and impurities.
[0000] Step B: 4-(4-Chlorophenyl)-5-(2,4-dichlorophenyl)imidazole
[0613] A mixture of (+/−)-4′-chloro-2-hydroxy-2-(2,4-dichlorophenyl)acetophenone (4.0 gm, 13 mmol) (higher Rf isomer from Step A) and paraformaldehyde (4.0 gm, 130 mmol) in formamide (60 mL) was heated to 200-210° C. for 3 hr. The reaction was cooled to rt, diluted with water, and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by flash chromatography, eluting first with 10% methylene chloride, 10% ethyl acetate in hexanes to afford a mixture of isomeric oxazoles as higher Rf byproducts (1.7 gm, 40%) (HPLC/MS: 324 (M+1), 326 (M+3); R t =4.3 min). Further elution with 50-100% ethyl acetate in hexanes gave the title imidazole product. This was crystallized from ethyl acetate/hexanes to afford the title compound as a white solid.
[0614] HPLC/MS: 323 (M+1), 325 (M+3); R t =2.6 min
[0615] Similar reaction of the impure lower Rf isomeric (+/−)-2′,4′-dichloro-2-hydroxy-2-(4-chlorophenyl)acetophenone afforded a mixture which could be separated by flash chromatography to give the same isomeric oxazoles, then additional title imidazole, and then (+/−)-4,5-(4-chlorophenyl)imidazole.
[0000] Step C: 4-(4-Chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole (Higher Rf Isomer) and 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole (Lower Rf Isomer)
[0616] To a solution of 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)imidazole (550 mg, 1.7 mmol) from Step B and methyl iodide (0.16 mL, 2.5 mmol) in DMF (10 mL) was added sodium hydride (60% in mineral oil, 140 mg, 3.4 mmol). The reaction was stirred at rt for 1 hr and was then quenched with aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by flash chromatography (50-75% ethyl acetate in hexanes) to afford the title higher Rf compound. HPLC/MS: 337 (M+1), 339 (M+3); R t =2.7 min.; 1 HNMR (CDCl 3 ): 3.48 (s, 3H), 7.22 (dt, J=2.0 and 8.6 Hz, 2H), 7.26 (d, J=8.2 Hz, 1H), 7.37 (dt, J=2.0 and 8.6 Hz, 2H), 7.38 (dd, J=2.2 and 8.2 Hz, 1H), 7.63 (d, J=2.2 Hz, 1H), 7.74 (s, 1H).
[0617] Further elution with 100% ethyl acetate afforded a mixture of isomers which were further separated by Prep TLC (3×1 mm, silica) (100% ethyl acetate) to give additional higher Rf isomer and pure lower Rf isomer.
[0618] HPLC/MS: 337 (M+1), 339 (M+3); R t =2.7 min; 1 HNMR (CDCl 3 ): 3.67 (s, 3H), 7.12 (dt, J=2.0 and 8.6 Hz, 2H), 7.20 (dd, J=2.0 and 8.2 Hz, 1H), 7.29 (d, J=8.2 Hz, 1H), 7.36 (dt, J=2.0 and 8.6 Hz, 2H), 7.37 (d, J=2.0 Hz, 1H), 7.78 (s, 1H).
[0000] Step D: Ethyl 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxylate
[0619] To a solution of 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole (100 mg, 0.30 mmol) from Step C in THF (4 mL) cooled to −70° C. in a dry ice/acetone bath was added 1.6N n-butyl lithium in hexanes (0.22 mL, 0.36 mmol). The reaction was stirred for 1 hr and then ethyl chloroformate (0.060 mL, 60 mmol) was added via syringe. The reaction was allowed to warm to rt for 1 hr and was then quenched with aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by Prep TLC (2×1 mm, silica) (25% ethyl acetate in hexanes) to afford the title compound. HPLC/MS: 409 (M+1), 411 (M+3); R t =4.19 min.
[0000] Step E: N-(Piperidin-1-yl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide
[0620] A mixture of ethyl 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxylate (50 mg, 0.125 mmol) from Step D in neat 1-aminopiperidine (1 mL) was heated at 90° C. for 72 hr. Most of the amine was evaporated under a stream of nitrogen and the residue was purified by Prep TLC (2×1 mm, silica) (40% ethyl acetate in hexanes to afford the title compound.
[0621] HPLC/MS: 463 (M+1), 465 (M+3); R t =3.81 min.
EXAMPLE 33
[0622]
N-(Cyclohexyl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide
[0623] To a solution of 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole (50 mg, 0.15 mmol) from Example 32, Step C in THF (3 mL) cooled to −70° C. in a dry ice/acetone bath was added 1.6N n-butyl lithium in hexanes (0.11 mL, 0.18 mmol). The reaction was stirred for 1 hr and then cyclohexyl isocyanate (0.040 mL, 30 mmol) was added via syringe. The reaction was allowed to warm to rt for 1 hr and was then quenched with aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by Prep TLC (1 mm, silica) (100% methylene chloride) to afford the title compound.
[0624] HPLC/MS: 462 (M+1), 464 (M+3); R t =5.17 min.; 1 HNMR (CDCl 3 ): 1.2-1.8 (4m, 6H), 1.85 (dt, 2H), 2.05 (m, 2H), 3.92 (s, 3H), 3.96 (m, 1H), 7.24 (d, J=8.2 Hz, 1H), 7.31 (br d, J=8.2 Hz, 2H), 7.44 (dd, J=2.0 and 8.2 Hz, 1H), 7.47 (br d, J=8.2 Hz, 2H), 7.68 (d, J=2.0 Hz, 1H), 7.88 and 8.33 (2 d, J=8.8 Hz, 1H). The isomeric assignment was confirmed by an NOe between the N-Me and 6-H of the 5-(2,4-dichlorophenyl) at δ=7.24.
EXAMPLE 34
[0625]
N-(Hexyl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide
[0626] Using essentially the same procedure as Example 33, but using n-hexyl isocyanate (0.040 mL, 0.30 mmol), 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole (50 mg, 0.15 mmol) from Example 32, Step C was converted to the title compound after purification twice by Prep TLC (25% ethyl acetate in hexanes).
[0627] HPLC/MS: 464 (M+1), 466 (M+3); R t =5.01 min.
EXAMPLE 35
[0628]
N-(t-Butyl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole-2-carboxamide
[0629] Using essentially the same procedure as Example 33, but using t-butyl isocyanate (0.040 mL, 0.30 mmol), 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methylimidazole (50 mg, 0.15 mmol) from Example 32, Step C was converted to the title compound after purification by Prep TLC (25% ethyl acetate in hexanes).
[0630] HPLC/MS: 436 (M+1), 438 (M+3); R t =4.83 min.
EXAMPLE 36
[0631]
N-(Cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0000] Method A
[0632] To a solution of 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole (50 mg, 0.15 mmol) from Example 32, Step C (lower Rf isomer) in THF (2.5 mL) cooled to −70° C. in a dry ice/acetone bath was added 1.6N n-butyl lithium in hexanes (0.120 mL, 0.18 mmol). The reaction was stirred for 1 hr and then cyclohexyl isocyanate (0.040 mL, 0.30 mmol) was added via syringe. The reaction was allowed to warm to rt for 1 hr and was then quenched with aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by Prep TLC (2×1 mm, silica) (25% ethyl acetate in hexanes) to afford the title compound. HPLC/MS: 462 (M+1), 464 (M+3); R t =4.80 min.; 1 HNMR (CDCl 3 ): 1.2-1.7 (4m, 6H), 1.80 (m, 2H), 2.02 (m, 2H), 3.93 (m, 1H), 4.03 (s, 3H), 7.13 (dt, J=2.0 and 8.4 Hz, 2H), 7.265 (dd, J=2.1 and 8.4 Hz, 1H), 7.35 (d, J=8.4 Hz, 1H), 7.37 (m, 1H), 7.39 (dt, J=2.0 and 8.4 Hz, 2H), 7.9 (v br s,, 1H). The isomeric assignment was confirmed by an NOe between the N-Me and the 2- and 6-H of the 5-(4-chlorophenyl) at δ=7.13.
[0000] Method B
[0000] Step A: Ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate
[0633] To a solution of 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole (72 mg, 0.21 mmol) from Example 32, Step C (lower Rf isomer) in THF (3 mL) cooled to −70° C. in a dry ice/acetone bath was added 1.6N n-butyl lithium in hexanes (0.160 mL, 0.26 mmol). The reaction was stirred for 1 hr and then ethyl chloroformate (0.045 mL, 42 mmol) was added via syringe. The reaction was allowed to warm to rt for 1 hr and was then quenched with aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by Prep TLC (2×1 mm, silica) (25% ethyl acetate in hexanes) to afford the title compound.
[0634] HPLC/MS: 409 (M+1), 411 (M+3); R t =3.92 min.
[0000] Step B: N-(Cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0635] A mixture of ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate (20 mg, 0.05 mmol) from Step A in neat cyclohexylamine (2 mL) was heated at 90° C. for 72 hr. Most of the amine was evaporated under a stream of nitrogen and the residue was purified by Prep TLC (1 mm, silica) (25% ethyl acetate in hexanes to afford the title compound.
[0636] HPLC/MS: 462 (M+1), 464 (M+3); R t =4.80 min.
EXAMPLE 37
[0637]
N-(Piperidin-1-yl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0638] Using essentially the same procedure as Example 36, Step B (Method B), but using neat 1-aminopiperidine (3 mL), ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate (30 mg, 0.073 mmol) was converted to the title compound after purification by Prep TLC (40% ethyl acetate in hexanes).
[0639] HPLC/MS: 463 (M+1), 465 (M+3); R t =3.63 min.
EXAMPLE 38
[0640]
N-(Cycloheptyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0641] Using essentially the same procedure as Example 36, Step B (Method B), but using neat cycloheptylamine (1.5 mL), ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate (30 mg, 0.073 mmol) was converted to the title compound after purification by Prep TLC (25% ethyl acetate in hexanes).
[0642] HPLC/MS: 476 (M+1), 478 (M+3); R t =4.96 min.
EXAMPLE 39
[0643]
N-(Cyclopentyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0644] Using essentially the same procedure as Example 36, Step B (Method B), but using neat cyclopentylamine (1.5 mL), ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate (30 mg, 0.073 mmol) was converted to the title compound after purification by Prep TLC (25% ethyl acetate in hexanes).
[0645] HPLC/MS: 448 (M+1), 450 (M+3); R t =4.61 min.
EXAMPLE 40
[0646]
N-(Morpholin-4-yl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0647] Using essentially the same procedure as Example 36, Step B (Method B), but using neat morpholine (1.5 mL), ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate (30 mg, 0.073 mmol) was converted to the title compound after purification by Prep TLC (60% ethyl acetate in hexanes).
[0648] HPLC/MS: 465 (M+1), 467 (M+3); R t =3.44 min.
EXAMPLE 41
[0649]
N-(Phenyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0650] Using essentially the same procedure as Example 36, Method A, but using phenyl isocyanate (0.023 mL, 0.21 mmol), 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole (35 mg, 0.10 mmol) was converted to the title compound after purification by Prep TLC (25% ethyl acetate in hexanes). HPLC/MS: 456 (M+1), 458 (M+3); R t =4.75 min.
EXAMPLE 42
[0651]
N-(Piperidin-1-yl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxamide
[0000] Step A: 4-(4-Chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole (Higher Rf Isomer) and 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-ethylimidazole (Lower Rf Isomer)
[0652] To a solution of 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)imidazole (400 mg, 1.24 mmol) from Example 32, Step B and ethyl iodide (0.200 mL, 2.5 mmol) in DMF (6 mL) was added sodium hydride (60% in mineral oil, 124 mg, 3.1 mmol). The reaction was stirred at rt for 1 hr and was then quenched with aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by flash chromatography (50-75% ethyl acetate in hexanes) to afford the title higher Rf compound. HPLC/MS: 351 (M+1), 353 (M+3); R t =2.9 min
[0653] Further elution with 100% ethyl acetate afforded a mixture of isomers which were further separated by Prep TLC (3×1 mm, silica) (100% ethyl acetate) to give additional higher Rf isomer (85 mg, 18%) and pure lower Rf isomer. HPLC/MS: 351 (M+1), 353 (M+3); R t =2.9 min.
[0000] Step B: Ethyl 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxylate
[0654] To a solution of 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole (230 mg, 0.66 mmol) from Step A (higher Rf isomer) in THF (4 mL) cooled to −70° C. in a dry ice/acetone bath was added 1.6N n-butyl lithium in hexanes (0.500 mL, 0.80 mmol). The reaction was stirred for 1 hr and then ethyl chloroformate (0.130 mL, 1.3 mmol) was added via syringe. The reaction was allowed to warm to rt for 1 hr and was then quenched with aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by Prep TLC (3×1 mm, silica) (25% ethyl acetate in hexanes) to afford the title compound.
[0655] HPLC/MS: 423 (M+1), 425 (M+3); R t =4.37 min.
[0000] Step C: N-(Piperidin-1-yl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxamide
[0656] A mixture of ethyl 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxylate (25 mg, 0.06 mmol) from Step B in neat 1-aminopiperidine (2 mL) was heated at 90° C. for 72 hr. Most of the amine was evaporated under a stream of nitrogen and the residue was purified by Prep TLC (1 mm, silica) (25% ethyl acetate in hexanes to afford the title compound. HPLC/MS: 477 (M+1), 479 (M+3); R t =4.03 min.
EXAMPLE 43
[0657]
N-(Cyclohexyl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxamide
[0658] Using essentially the same procedure as Example 42, Step C, but using neat cyclohexylamine (2 mL), ethyl 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxylate (30 mg, 0.073 mmol) from Example 42, Step B was converted to the title compound after purification by Prep TLC (25% ethyl acetate in hexanes). HPLC/MS: 476 (M+1), 478 (M+3); R t =5.04 min.
EXAMPLE 44
[0659]
N-(Hexyl)-4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxamide
[0660] Using essentially the same procedure as Example 42, Step C, but using neat hexylamine (2 mL), ethyl 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-ethylimidazole-2-carboxylate (25 mg, 0.060 mmol) from Example 42, Step B was converted to the title compound after purification by Prep TLC (25% ethyl acetate in hexanes). HPLC/MS: 478 (M+1), 480 (M+3); R t =5.23 min.
EXAMPLE 45
[0661]
N-(Cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-ethylimidazole-2-carboxamide
[0662] A solution of 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-ethylimidazole (43 mg, 0.12 mmol) from Example 41, Step A (lower Rf isomer) in THF (2 mL) cooled to −70° C. in a dry ice/acetone bath was added 1.6N n-butyl lithium in hexanes (0.092 mL, 0.15 mmol). The reaction was stirred for 1 hr and then cyclohexyl isocyanate (0.032 mL, 0.25 mmol) was added via syringe. The reaction was allowed to warm to rt for 1 hr and was then quenched with aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by Prep TLC (3×1 mm, silica) (25% ethyl acetate in hexanes) to afford the title compound. HPLC/MS: 476 (M+1), 478 (M+3); R t =4.99 min.
EXAMPLE 46
[0663]
Cyclohexyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate
[0664] To a solution of ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate (28 mg, 0.07 mmol) from Example 36, Step A (Method B) in cyclohexanol (2 mL) and methylene chloride (1 mL) was added a catalytic amount of sodium hydride (60% in mineral oil, <5 mg). The mixture was stirred at rt for 2 hr and then poured into aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by Prep TLC (3×1 mm, silica) (25% ethyl acetate in hexanes) to afford the title compound. HPLC/MS: 463 (M+1), 465 (M+3); R t =4.50 min.
EXAMPLE 47
[0665]
N-Methyl-N-cyclohexyl-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0666] To a solution of N-cyclohexyl-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide (15 mg, 0.033 mmol) from Example 36, (Method A) and methyl iodide (0.003 mL, 0.049 mmol) in DMF (2 mL) was added sodium hydride (60% in mineral oil, 2 mg, 0.049 mmol). The mixture was stirred at rt for 2 hr and then poured into aq. sodium bicarbonate and extracted twice with ethyl acetate. The organic layers were washed with brine, dried over sodium sulfate, and evaporated. The residue was purified by Prep TLC (0.5 mm, silica) (25% ethyl acetate in hexanes) to afford the title compound. HPLC/MS: 476 (M+1), 478 (M+3); R t =4.40 min.
EXAMPLE 48
[0667]
N-(Cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0000] Step A: 2-(4-Chlorophenyl)-1-(2,4-dichlorophenyl)ethanone
[0668] A 5 L round bottom flask equipped with an addition funnel, N 2 inlet, thermometer and a mechanical stirrer was charged with 387 mL of 1M sodium bis-trimethylsilylamide in TBF and cooled to −60° C. A solution of 230 g (1.35 mol) of 4-chlorophenylacetic acid in 300 mL of THF was added keeping the temperature below −40° C. After stirring the mixture for 90 min at −70° C., 264 g (1.29 mol) of methyl 2,4-dichlorobenzoate was added over 20 min. The solution was stirred for 40 min at −70° C., the cooling bath was removed and the mixture was allowed to warm to 0° C. Reaction was quenched by pouring into 4 L of 2N HCl and ice and extracted with ether. Each ether layer was washed with saturated NaHCO 3 , brine, dried with MgSO 4 and filtered through a 2″ plug of silica gel. The filtrate was concentrated to ca. 1 lit of a slushy liquid which was diluted with 1 L of hexane and cooled in a refrigerator. The solid formed was filtered, washed with hexane and dried. A second crop was isolated by concentrating the mother liquors. The two crops of crystals were combined. 1 H NMR: (500 MHz, CDCl 3 ): δ 4.21 (s, 2H), 7.2-7.5 (m, 7H).
[0000] Step B: 1-(4-Chlorophenyl)-2-(2,4-dichlorophenyl)ethane-1,2-dione
[0669] To a solution of 100 g (0.33 mol) of 2-(4-chlorophenyl)-1-(2,4-dichlorophenyl)ethanone in 1 L of DMSO, 75 g (0.42 mol) of NBS was added and the mixture was stirred over a weekend. The reaction was poured into 8 L of water and stirred for 30 min. The yellow solid formed was filtered and dried. This solid was purified by passing through a plug of 1 Kg of silica gel using hexane and 5% EtOAc-hexane to isolate the title compound. 1 H NMR: (500 MHz, CDCl 3 ): δ 7.4-8.0 (m, 7H).
[0000] Step C: 5-(4-Chlorophenyl)-4-(2,4-dichlorophenyl)-1-methyl-imidazole
[0670] A solution of 10 g (31.8 mmol) of 1-(4-chlorophenyl)-2-(2,4-dichlorophenyl)ethane-1,2-dione in 30 mL of acetic acid was treated with 15 g (223 mmol) of methylamine hydrochloride, 5 g (63.7 mmol) of NH 4 OAc and 7.8 mL (93.6 mmol) of aqueous formaldehyde (37%). The mixture was refluxed over night, cooled and quenched by adding aq. NaOH (final pH 8). The solution was extracted with EtOAc and each EtOAc layer was washed with brine, dried and concentrated. The residue was purified on a flash column with a gradient of 50-100% EtOAc-hexane followed by 5% MeOH-EtOAc to yield 4-(4-chlorophenyl)-5-(2,4-dichlorophenyl)-1-methyl-imidazole (higher Rf, 1 H NMR (500 MHz, CDCl 3 ) δ 3.47 (s, 3H), 7.22-7.24 (m, 2H), 7.26-7.28 (m, 1H), 7.36-7.39 (m, 3H), 7.64-7.65 (m, 2H)) and 3.5 g of 5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-methyl-imidazole (lower Rf, 1 H NMR (500 MHz, CDCl 3 ) for lower Rf: δ 3.66 (s, 3H), 7.12-7.14 (m, 2H), 7.19-7.23 (m, 1H), 7.26-7.29 (m, 1H), 7.35-7.38 (m, 3H), 7.64 (s, 1H).
[0000] Step D: N-(Cyclohexyl)-4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0671] A solution of 5.5 g (16.2 mmol) of 5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-methyl-imidazole in 70 mL of THF was cooled in a −78° C. bath and 15 mL of 1.6 M n-BuLi was slowly added. After stirring for 1 h, 5.2 mL (40.7 mmol) of cyclohexylisocyanate was added. The cooling bath was removed and the solution was stirred for 3 h. The reaction mixture was poured into a mixture of water/EtOAc. The layers were separated and the aqueous layer was extracted with EtOAc. The combined organic layer was washed with brine, dried and concentrated. The residue was purified on a flash column using a gradient of 2-10% EtOAc-hexane. The isolated product was crystallized from EtOAc-hexane (˜1:10) to obtain the title compound as a white solid with a melting point of 165° C. 1 H NMR (500 MHz, CDCl 3 ): δ 1.20-1.37 (m, 3H), 1.40-1.49 (m, 2H), 1.67-1.71 (m, 1H), 1.80-1.84 (m, 2H), 2.03-2.06 (m, 2H), 4.02 (s, 3H), 7.13-7.15 (m, 2H), 7.25-7.27 (m, 1H), 7.31-7.33 (m, 1H), 7.37-7.40 (m, 4H). LC-MS: R t =4.7 min. m/e=464.1 (M+1). Further elution allowed recovery of starting material.
[0672] The following compounds were synthesized by the procedure of example 48 by substituting an appropriate amine or amine hydrochloride for methylamine in step C.
retention Ex. time HPLC-mass No. Name Structure (min) spectrum m/e 49 N-(Cyclohexyl)- (2,4-dichlorophenyl)- 5-(4-chlorophenyl)-1- ethylimidazole-2- carboxamide 4.9 476.1 50 N-(Cyclohexyl)-4- (2,4-dichlorophenyl)- 5-(4-chlorophenyl)-1- (1-methyl)ethyl- imidazole-2- carboxamide 4.9 492.1 51 N-(Cyclohexyl)-4- (2,4-dichlorophenyl)- 5-(4-chlorophenyl)-1- (1,1-dimethyl)ethyl- imidazole-2- carboxamide 4.1 504.0 52 N-(Cyclohexyl)-4- (2,4-dichlorophenyl)- 5-(4-chlorophenyl)-1- (2- dimethylamino)ethyl- imidazole-2- carboxamide 3.4 521.0 53 N-(Cyclohexyl)-4- (2,4-dichlorophenyl)- 5-(4-chlorophenyl)-1- propylimidazole-2- carboximide 5.0 490.1 54 N-(Cyclohexyl)-4-(2,4-dichlorophenyl)- 5-(4-chlorophenyl)-1-butylimidazole-2- carboxamide 5.2 503.9 55 N-(Cyclohexyl)-4-(2,4-dichlorophenyl)- 5-(4-chlorophenyl)-1-(2- methoxy)ethylimidazole-2-carboxamide 4.7 505.9
EXAMPLE 56
[0673]
N-(Piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-methyl-imidazole-2carboxamide
[0000] Step A: Ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate
[0674] A solution of 1.1 g (3.25 mmol) of 5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-methyl-imidazole in 30 mL of dry THF was cooled in a −78° C. bath and 1.7 mL of 2.5 M n-BuLi in hexane was dropwise added. After stirring the solution for 1 h it was added with a canula to 0.623 mL of ethyl chloroformate in THF cooled in a −78° C. bath. The cold bath was removed and the reaction was stirred for 1 h then quenched with water. The mixture was extracted with EtOAc. The EtOAc layer was washed with brine, dried and concentrated. The residue was chromatographed using a gradient of 10-20% EtOAc-hexane to isolate the desired product. 1 H NMR (500 MHz, CDCl 3 ): δ 1.49 (t, 3H), 3.98 (s, 3H), 4.50 (q, 2H), 7.15-7.17 (m, 2H), 7.24-7.26 (m, 1H), 7.35-7.41 (m, 4H).
[0000] Step B: N-(Piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-methyl-imidazole-2-carboxamide
[0675] To a solution of 0.33 mL (3.05 mmol) of 1-aminopiperidine in 2 mL of dry toluene under N 2 , 1.5 mL (3.05 mmol) of 2M trimethylaluminum in hexane was added with cooling in ice bath. The cold bath was removed, reaction was stirred for 1 h and 0.5 g (1.22 mmol) of ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate in 3 mL of toluene, and 1.5 mL of CH 2 Cl 2 was added. The mixture was heated in a 60° C. bath for 2 h, cooled, quenched with water and the pH was adjusted to 5 with 1.2 N HCl. The solution was extracted with EtOAc twice. The combined EtOAc layer was washed with brine, dried and concentrated. The residue was purified by flash chromatography using 30% EtOAc/hexane as an eluant to isolate the title compound. 1 H NMR (500 MHz, CDCl 3 ): δ 1.47 (m, 2H), 1.77-1.82 (m, 4H), 2.89 (s, 4H), 4.00 (s, 3H), 7.11-7.14 (m, 2H), 7.23-7.26 (m, 1H), 7.28-7.30 (m, 1H), 7.36-7.39 (m, 3H), 8.15 (s, 1H). LC-MS: R t =3.6 min. m/e=465.1 (M+1).
[0676] The following compounds were prepared according to the procedure of example 56, by substituting an appropriate amine for 1-aminopiperidine in step B.
Ex. retention time HPLC-mass No. Name Structure (min) spectrum m/e 57 N-(Pyrrolidin-1- yl)-5-(4- chlorophenyl)-4- (2,4- dichlorophenyl)-1- methyl-imidazole- 2-carboxamide 3.1 451.1 58 N-(Azepin-1-yl)-5- (4-chlorophenyl)-4- (2,4- dichlorophenyl)-1- methyl-imidazole- 2-carboxamide 3.6 479.2 59 N-(Pentyl)-4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboximide 4.7 452.1 60 N-(1-Ethylpropyl)- 4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 4.64 452.1 61 N-(1-Methylethyl)- 4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 4.2 424.0 62 N-(3- Cyclohexenyl)-4- (2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 4.6 460.0 63 N- (Tetrahydropyran- 4-yl)-4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 3.9 465.8 64 N-(2,2-Dimethyl- tetrahydropyran-4- yl)-4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 4.2 493.8 65 N-((2-Trans- hydroxymethyl)cyclo- hexyl)-4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazoile-2- carboxamide 4.3 494.0 66 N-((2-Cis- hydroxymethyl)cyclo- hexyl)-4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 4.1 494.0 67 N-((2-Trans- hydroxy)cyclohexyl)- 4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 3.9 478.0 68 N-((2-Cis- hydroxy)cyclohexyl)- 4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 4.0 480.0 69 N-((4-Trans- hydroxy)cyclohexyl)- 4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 3.8 480.0 70 N(4-Methyl- cyclohexyl)-4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide (Isomer A) 4.96 476.0 71 N-(4-Methyl- cyclohexyl)-4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide (Isomer B) 4.99 478.0 72 N-(1-Fluoro- cyclohexen-4-yl)-4- (2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 4.53 480.0 73 N-(4,4-Difluoro- cyclohexyl)-4-(2,4- dichlorophenyl)-5- (4-chlorophenyl)-1- methylimidazole-2- carboxamide 4.48 500.0
EXAMPLE 74
[0677]
4-(2,4-Dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxamide
[0678] The title compound was prepared from ethyl 4-(2,4-dichlorophenyl)-5-(4-chlorophenyl)-1-methylimidazole-2-carboxylate and 2 M NH 3 in MeOH following the method of example 36, step B (method B). LC-MS: R t =3.6 min. m/e=379.9 (M+1).
EXAMPLE 75
[0679]
N-(Piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-imidazole-2-carboxamide
[0000] Step A 5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-{((2-trimethylsilyl)-ethoxy)methyl}-1H-imidazole
[0680] To a solution of 5-(4-chlorophenyl)-4-(2,4-dichlorophenyl-1H-imidazole (500 mg, 1.54 mmol) in 3 mL of DMF sodium hydride (59 mg, 1.54 mmol) was added in portions over a period of 15 minutes. The mixture was allowed to stir until H 2 evolution ceased and it was clear. To this solution 2-(trimethylsilyl)ethoxy methyl chloride was added. After stirring overnight, the reaction was quenched with water and extracted with EtOAc. The organic layer was washed with water (3×20 mL), brine (1×30 mL), dried with Na 2 SO 4 , filtered, and concentrated to dryness. The residue was purified on a silica gel column eluting with hexane and 20% EtOAc/hexane to give the title compound. 1 H NMR (500 MHz, CDCl 3 ): δ 0.004 (s, 9H), 0.84-0.88 (m, 2H), 3.42 (t, 2H), 5.05 (d, 1H), 5.16 (d, 1H), 7.26 (d, 2H), 7.35 (d, 1H), 7.40-7.42 (m, 3H), 7.62 (d, 1H), 7.80 (s, 1H).
[0000] Step B N-Piperidin-1-yl-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1(((2-trimethylsilyl)ethoxy)methyl)-1H-imidazole-2-carboxamide
[0681] The title compound was prepared from 5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-1-{((2-trimethylsilyl)ethoxy)methyl}-1H-imidazole as described in example 56, steps A and B. 1 H NMR (500 MHz, CDCl 3 ): δ −0.018 (s, 9H), 0.82-0.90 (m, 2H), 1.52 (m, 2H), 1.81-1.85 (m, 4H), 2.94 (s, 4H), 3.54-3.61 (m, 2H), 5.47 (d, 1H), 6.04 (d, 1H), 7.28 (d, 2H), 7.38-7.43 (m, 4H), 7.60 (d, 1H), 8.29 (s, 1H).
[0000] Step C N-(Piperidin-1-yl)-5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-imidazole-2-carboxamide
[0682] To a solution of 5-(4-chlorophenyl)-4-(2,4-dichlorophenyl)-N-piperidin-1-yl-1-{((2-trimethylsilyl)ethoxy)methyl}-1H-imidazole-2-carboxamide (180 mg, 0.310 mmol) in 2 mL dichloromethane was added boron trifluoride diethyl etherate (393 μL, 3.10 mmol). After stirring overnight, the reaction was quenched with aqueous K 2 CO 3 . The aqueous layer was extracted with EtOAc (3×10 mL). The combined organic extract was washed with brine, dried over Na 2 SO 4 , filtered, and concentrated. The residue was purified by preparative HPLC to isolate the title compound. 1 H NMR (500 MHz, CDCl 3 ): δ 1.54 (m, 2H), 1.78-1.83 (m, 4H), 3.12-3.14 (m, 4H), 7.30 (m, 1H), 7.32-7.33 (m, 7H), 7.52 (d, 1H). LC-MS: R t =3.4 min. m/e=450.9 (M+1).
[0683] The following analogs were prepared by the methods described in example 48 and/or example 56.
HPLC- mass Ex. retention time spectrum No. Name Structure (min) m/e 76 N-(Piperidin-1-yl)-5-(4- chlorophenyl)-4-(2,4- dichlorophenyl)-1-ethyl- imidazole-2-carboxamide 3.7 479.0 77 N-(Piperidin-1-yl)-5-(4- chlorophenyl)-4-(2,4- dichlorophenyl)-1-(1- methyl)ethyl-imidazole-2- carboxamide 3.8 493.1 78 N-(Piperidin-1-yl)-5-(4- chlorophenyl)-4-(2,4- dichlorophenyl)-1-(1,1- dimethyl)ethyl-imidazole- 2-carboxamide 3.4 505.1 79 N-(Piperidin-1-yl)-5-(4- chlorophenyl)-4-(2,4- dichlorophenyl)-1-(2- dimethylamino)ethyl- imidazole-2-carboxamide 2.9 522.0 80 N-(Piperidin-1-yl)-5-(4- chlorophenyl)-4-(2,4- dichlorophenyl)-1-propyl- imidazole-2-carboxamide 3.9 491.1 81 N-(Piperidin-1-yl)-5-(4- chlorophenyl)-4-(2,4- dichlorophenyl)-1-butyl- imidazole-2-carboxamide 4.1 506.9 82 N-(Piperidin-1-yl)-5-(4- chlorophenyl)-4-(2,4- dichlorophenyl)-1-(2- methoxy)ethyl-imidazole- 2-carboxamide 3.7 508.9 83 N-(Cyclohexyl)-4-(2- chlorophenyl)-5-(4- chlorophenyl)-1- methylimidazole-2- carboxamide 4.2 428.0 84 N-(Piperidin-1-yl)-4-(2- chlorophenyl)-5-(4- chlorophenyl)-1-methyl- imidazole-2-carboxamide 3.1 429.1
EXAMPLE 85
Cannabinoid Receptor-1 (CB1) Binding Assay
[0684] Binding affinity determination is based on recombinant human CB1 receptor expressed in Chinese Hamster Ovary (CHO) cells (Felder et al, Mol. Pharmacol. 48: 443450, 1995). Total assay volume is 250 μl (240 μl CB1 receptor membrane solution plus 5 μl test compound solution plus 5 μl [3H]CP-55940 solution). Final concentration of [3H]CP-55940 is 0.6 nM. Binding buffer contains 50 mM Tris-HCl, pH7.4, 2.5 mM EDTA, 5mM MgCl 2 , 0.5 mg/ml fatty acid free bovine serum albumin and protease inhibitors (Cat#P8340, from Sigma). To initiate the binding reaction, 5 μl of radioligand solution is added, the mixture is incubated with gentle shaking on a shaker for 1.5 hours at 30° C. The binding is terminated by using 96-well harvester and filtering through GF/C filter presoaked in 0.05% polyethylenimine. The bound radiolabel is quantitated using scintillation counter. Apparent binding affinities for various compounds are calculated from IC50 values (DeBlasi et al., Trends Pharmacol Sci 10: 227-229, 1989).
[0685] The binding assay for CB2 receptor is done similarly with recombinant human CB2 receptor expressed in CHO cells.
EXAMPLE 86
Cannabinoid Receptor-1 (CB1) Functional Activity Assay
[0686] The functional activation of CB1 receptor is based on recombinant human CB1 receptor expressed in CHO cells (Felder et al, Mol. Pharmacol. 48: 443-450, 1995). To determine the agonist activity or inverse agonist activity of any test compound, 50 ul of CB1-CHO cell suspension are mixed with test compound and 70 ul assay buffer containing 0.34 mM 3-isobutyl-1-methylxanthine and 5.1 uM of forskolin in 96-well plates. The assay buffer is comprised of Earle's Balanced Salt Solution supplemented with 5 mM MgCl 2 , 1 mM glutamine, 10 mM HEPES, and 1 mg/ml bovine serum albumin. The mixture is incubated at room temperature for 30 minutes, and terminated by adding 30 ul/well of 0.5M HCl. The total intracellular cAMP level is quantitated using the New England Nuclear Flashplate and cAMP radioimmunoassay kit.
[0687] To determine the antagonist activity of test compound, the reaction mixture also contains 0.5 nM of the agonist CP55940, and the reversal of the CP55940 effect is quantitated. Alternatively, a series of dose response curves for CP55940 is performed with increasing concentration of the test compound in each of the dose response curves.
[0688] The functional assay for the CB2 receptor is done similarly with recombinant human CB2 receptor expressed in CHO cells.
[0689] While the invention has been described and illustrated with reference to certain particular embodiments thereof, those skilled in the art will appreciate that various changes, modifications and substitutions can be made therein without departing from the spirit and scope of the invention. For example, effective dosages other than the particular dosages as set forth herein above may be applicable as a consequence of variations in the responsiveness of the mammal being treated for any of the indications for the compounds of the invention indicated above. Likewise, the specific pharmacological responses observed may vary according to and depending upon the particular active compound selected or whether there are present pharmaceutical carriers, as well as the type of formulation and mode of administration employed, and such expected variations or differences in the results are contemplated in accordance with the objects and practices of the present invention. It is intended, therefore, that the invention be defined by the scope of the claims which follow and that such claims be interpreted as broadly as is reasonable.
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The use of compounds of the present invention as antagonists and/or inverse agonists of the Cannabinoid-1 (CB1) receptor particularly in the treatment, prevention and suppression of diseases mediated by the Cannabinoid-1 (CB1) receptor. The invention is concerned with the use of these novel compounds to selectively antagonize the Cannabinoid-1 (CB1) receptor. As such, compounds of the present invention are useful as psychotropic drugs in the treatment of psychosis, memory deficits, cognitive disorders, migraine, neuropathy, neuro-inflammatory disorders including multiple sclerosis and Guillain-Barre syndrome and the inflammatory sequelae of viral encephalitis, cerebral vascular accidents, and head trauma, anxiety disorders, stress, epilepsy, Parkinson's disease, and schizophrenia. The compounds are also useful for the treatment of substance abuse disorders, particularly to opiates, alcohol, and nicotine. The compounds are also useful for the treatment of obesity or eating disorders associated with excessive food intake and complications associated therewith. Novel compounds of structural formula (I) are also claimed.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for protecting a computational device, in particular a cryptographic computational device, from DPA and DFA attacks according to preamble of claim 1 . Also disclosed is an improved computational device, being a smart card in particular, incorporating said protective mechanisms.
BACKGROUND OF THE INVENTION
[0002] Cryptographic computational devices have many applications both for the secure transmission of information and for the authentication and verification of the source of information. One application of a cryptographic computational device or system is a smart card, which contains valuable financial and personal data which intended to be kept secret via encryption. These devices, for reason of unauthorized access and/or unlawful benefit, are made object of attacks for extracting their encrypted confidential information, and as a consequence, the security level of said devices may be compromised. Once this event occurs, the attacker can access the otherwise restricted information and capabilities of the device and is then at liberty to engage in malicious activities including authorization of monetary transactions, impersonation of digital signatures and so on. With the global increase in the use of cryptographic computational devices such as chip-based cards or special ICs for electronic identification and authentication protocols, it has become necessary for cryptographic devices to be tamper-proof by advantageous incorporation of features resistive to aforementioned attacks that concede data security.
[0003] Not only for smart cards, also for other computational devices such as mobile phones, DPA and DFA attacks area a threat.
[0004] Cryptographic algorithms that normally go into the devices mentioned above are usually designed not to reveal their inputs and/or outputs. However, cryptographic keys and computational intermediates of these algorithms may be open to access by an attacker thus revealing the analyze intended and so compromising the security of the cryptographic device involved. Among classes of effective attacks known to be used with such intent, Differential Power Analysis (DPA) and Differential fault analysis (DFA) attacks are recognized as non-physical, non-invasive attacks which can be easily automated and can be mounted without knowing design of the target device. It would be therefore highly desirable to have mechanisms specifically resistive towards said attacks and yet be independent of the hardware involved.
[0005] Fundamentally, DPA is a class of attacks allowing extraction of encrypted information/cryptographic keys present on cryptographic devices such as smart cards by analyzing the power consumption of said devices and performing a statistical analysis on the measured data. This type of attack is based on the principle that as the cryptographic processor performs its cryptographic functions, such as encryption or signing, transistors comprising the processor switch on and off, which changes the amount of current drawn from the source supplying power to the processor. The attacker can correlate the current changes with data being processed and thus gain information on the crypto keys being used. In other words, a DPA attack is an exploit based on an analysis of the correlation between the electricity usage of a chip in a smart card and the encryption key it contains. As data is collected by monitoring the power emanations of the device under attack, physical access to the device being attacked is not necessary. In practice, small inductive probes or antennae placed adjacent to the device being attacked are sufficient for implementation of the attack.
[0006] DFA, on the other hand, is a type of side channel attack where the principle is to induce faults or unexpected environmental conditions into cryptographic implementations, so as to reveal their internal states. Using DFA attacks, secret keys for cryptographic algorithms can be determined by selectively introducing scattered computation errors in the processor. For example, high temperature, unsupported supply voltage or current, excessively high overclocking, strong electric or magnetic fields, ionizing radiation may be used to influence operation of the processor on-board the cryptographic device which then begins to output incorrect results due to physical data correction thus revealing that the processor is running and details of its internal data state. Effective countermeasures to DPA and/or DFA types of attacks are hence acutely required for security of any product which needs to protect cryptographic keys and other secret information from being leaked.
PRIOR ART
[0007] Attempts at addressing the needs mentioned hereinabove find mention in prior art. Many countermeasures have been proposed to defend cryptographic computational devices from DPA and/or DFA attacks. These are mostly based on vulnerability or error detection schemes or introduction of randomness, noise or continual modification of execution protocols. These countermeasures make the attack much more difficult by decreasing the amount of information obtained from each sampling of the power line signal. However, an attacker can overcome them by obtaining more samples of power line fluctuations and applying more sophisticated analytical techniques.
[0008] U.S. Pat. No. 7,430,293 B2 teaches architecture of cryptography processors used for cryptographic applications in which a plurality of calculating subunits and at least one arithmetic unit are subject to a single control unit which divides and schedules operations across the calculating subunits to result in a series of computational intermediates not necessarily obtained in a sequence to allow the attacker to readily arrive at the secret analyze. However, this system is not able to detect and provide countermeasures to DFA attacks.
[0009] EP1569118B1 discloses a method for safe calculation of a result in a microprocessor system where parallel computations are undertaken for arriving at the same computational result. Upon comparison, if results of the parallel computations are not identical, possibility of manipulation due to DFA is detected. This system is however vulnerable to DPA attacks.
[0010] Thus it may be seen that technologies comprising state of the art have critical shortcomings, requiring novel solutions for protection of (cryptographic) computational devices against all types of attacks, including DFA and DPA attacks, as recited hereinafter.
OBJECTIVES
[0011] The principal object of the present invention is to create a high level of security against DPA and/or DFA attacks on computational devices having multiple cores.
[0012] The above object is achieved by a method for detection and deployment of countermeasures against DPA/ DFA attacks on computational devices according to claim 1 . The random designation of the scheduler function to one of the plurality of cores leads to a randomness in execution flow. Therefore, the execution flow is capable to resist security threats initiated on the cryptographic device. The security threats are e.g. caused by non-invasive attacks based on differential power analysis or differential fault analysis.
[0013] Advantageous embodiments of the invention are specified in dependent claims.
[0014] According to an embodiment of the present invention, the execution flow comprises a plurality of operation cycles, and the random designation of the scheduler function is performed newly for each new operation cycle.
[0015] A business logic unit is according to one embodiment embodied to perform a cryptographic function such as a cryptographic algorithm.
[0016] Optionally, according to claim 3 , the group of business function related execution units comprise at least one each among: a business logic unit; and a redundant business logic unit causing the business logic unit to be executed at least twice as a measure for comparative verification of data integrity. According to this embodiment, in addition to randomization of claim 1 , redundancy is added to the execution flow, and the opportunity of data integrity check is created. Thus, according to the embodiment of claim 3 , the scheduler on the designated master core generates a both randomized and redundant and verifable execution flow having enhanced resistance against security threats.
[0017] The comparing of the results is, according to embodiments of the invention, performed at critical points in the execution flow, such as in cryptographic algorithms, at beginning/ end of rounds of a multi-round algorithm, before/after performing any security sensitive operation, before passing fo data on for further processing to a next execution unit, before forwarding of a result of an algorithm to an operating system, and the like.
[0018] Depending on a comparing result of comparing the computational results, one or more defense measures may be initiated, e.g. one or more of the per se known measures of claim 6 .
[0019] According to a further embodiment, a delay unit may be provided so as to impose, in addition, delay onto the execution flow. According to a further embodiment, a power consumption control unit is provided, performing pretentious execution of a cryptographic algorithm as a measure to generate a fictitious energy consumption signal. In particular, a thus achieved randomized execution and delay of the execution flow rendered by concerted execution of the security function related execution units and scheduler function related execution units causes the system to attain unpredictability and contain fictitious energy consumption signals as a countermeasure to allow check integrity of execution flow and to resist security threats.
[0020] The group of security function related execution units may further comprise a crypto unit controlling execution of the business logic unit, e.g. by performing a PIN check.
[0021] The group of scheduler function related execution units may further comprise a booting booting a secure operating system on the master core and/or an initialization unit initializating other cores, and may further comprise a separate boot up unit for initiating the initialization unit.
[0022] Referring back to claims 1 to 4 , it can be seen that the operation process/cycle is randomized via a specific scheduler due to which the execution units are allocated at random to the available processing cores. Delays may be introduced, again at random, between successive execution units so that security attacks based on chronometric prediction of execution sequences are avoided. Yet furthermore, selection of master core for initiation/boot sequence may also be randomized to make impossible any prediction of the processing sequence / queue, thereby not allowing for any planned security attacks. Overall, the orchestration of process execution scheme so enabled makes it unintelligible/to manifestation of conventionally known attack protocols and thus be a constitutive effective deterrent countermeasure itself against security threats.
[0023] These objects, together with other objects and advantages which will become subsequently apparent, reside in the detailed description set forth below in reference to the accompanying drawings and furthermore specifically outlined in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In the narration herein below, the present invention is explained in further detail based on exemplary embodiments and by reference to certain drawings, in which:
[0025] FIG. 1 is a schematic illustration to explain the execution scenario according to an embodiment of the present invention.
[0026] Table 1 lists the security attacks capable of being resisted by method of the present invention.
[0027] Attention of the reader is now requested to the detailed description to follow which narrates a preferred embodiment of the present invention and further indicates the various ways in which principles of the invention may be employed.
DETAILED DESCRIPTION
[0028] The present invention is directed towards creation of a high level of security against DPA and/or DFA attacks on cryptographic devices having multiple cores in a manner independent of external detectors or dedicated hardware sensors.
[0029] Reference is now made to a preferred but non-limiting embodiment of the present invention explained in reference to accompanying drawings.
[0030] FIG. 1 illustrates the high level hardware architecture proposed considering a multi core CPU having three cores Core 1, 2, 3. Here, the code and data sections are shared by the available cores and have access through a common system bus. Concept of the present invention is intended to be scalable for systems having more than one core where the business logic is broken down into multiple execution units which may then be scheduled for execution randomly and/or in parallel on different cores.
[0031] Conceptually, security in a cryptographic device depends on integrity of data and its execution. The present invention addresses these aspects by providing for distinct software checks that help to detect any instance of manipulation and/or security breach and accordingly cater appropriate countermeasures to avoid leakage of information.
[0032] According to one aspect of the present invention, integrity of data is checked by executing the same part of code reiteratively. Results from prior execution or from a standard library store are then compared to the latest computed result and deviations, if any, are assumed to be determinants of compromise in security of the device indicative of DFA attacks.
[0033] According to another aspect of the present invention, integrity of execution is checked by confirming the control flow. This is done by executing all the execution units involved in a particular scenario more than once. Any deviation, therefore is a determinant of security breach due to SPA/DPA attacks.
[0034] In the performance of execution integrity check as per one embodiment of the present invention, the execution units are categorized according to their function subscribed in the proposal scripted for execution of a particular business case scenario. The present invention assumes these units to be atomic in nature.
[0035] Accordingly, business logic units are a category of execution units representing the use scenario and, for execution of an actual business scenario, may be broken down into two or more independent execution subunits.
[0036] Redundant business logic units are the next category of execution units which are otherwise same as the business logic unit except that their role subscribed is to ensure the business logic units get scheduled at least twice for redundant execution as a measure to detect data security breaches.
[0037] Observe and check units are the next category of execution units which serve to observe the control flow and consistency of results between the business logic unit and redundant business logic units. At predetermined points the control flow or results are compared and inconsistency, if any, is understood as a security threat. These predetermined points could be—
1) within the cryptographic algorithm like DES, RSA, AES etc, 2) in case if algorithm comprises of multiple rounds then at the beginning and/or end of each round, 3) before and/or after performing any security sensitive operation like PIN comparison or MAC verification, 4) before the data is passed on for further processing to next block, etc.
[0042] Upon determination of checkpoints as provided above, the observe and check unit initiates an appropriate countermeasure which can comprise of one or more of the operations such as—
1) permanently or temporarily locking the device from further use; 2) deleting sensitive data in volatile and nonvolatile memory; 3) incrementing an error counter; 4) aborting the current operation by returning the possible erroneous response to hide the detection of the attack etc.
[0047] Scheduler units are the next category of execution units which schedule different execution units as per the scheduling algorithm subscribed. Optionally, the algorithm construct is made to randomize the scheduling process so that a new order of execution units is scripted every time and predicting the control flow even from intermediary information is not possible, thereby countering both DPA and DFA attacks.
[0048] Initialization units are the next category of execution units which perform the initial bring up of the system and may optionally comprise a boot up unit that initiates the scheduler unit.
[0049] Delay units are the next category of execution units which may be induced by the scheduler unit at random intervals as a default measure or alternatively, when no execution unit is free. Either way, the execution sequence is accordingly punctuated in a random manner which is impossible to predict and therefore, no knowledge can be had for aiding information acquisition by external attacks.
[0050] Power hog/power consumption units are the next category of execution units subject to being induced by the scheduler unit and whose operation is pretentious of executing complex algorithms like cryptography. The power signal generated is therefore a deliberate hoax for DPA attacks and therefore a security measure for the cryptographic device involved.
[0051] Crypto units are the next category of execution units for execution of the actual cryptographic algorithm.
Example 1
Execution Scenario
[0052] FIG. 1 shows a typical execution scenario according to one exemplary embodiment of the present invention where the cryptographic device comprises three processor cores, and business logic is broken into 2 execution units A and B. According to this proposal, for a duration of 5 execution units on 3 cores, a total of 15 execution units are executed in the composition:
1) 4 business related execution units (A, B, A′, B′) 2) 6 security related execution units (delay, power hog/power consumption, crypto) 3) 5 scheduler related execution units (init/scheduler, check)
[0056] One of the cores (Core # 1 for purpose of this example) shall act as the master and will have control during the initialization or power-on sequence and will after power-on on run a scheduler unit. The execution unit marked “init”, once executed on Core # 1 , shall boot the secure operating system on Core # 1 and initializes other cores. The scheduler execution unit marked “init” then identifies the execution units from the business logic (A, B) and then prepares the execution queues for the all the cores under framework of following rules:
a) There are at least two execution cycles for units A and B; b) Execution of units A and B is randomized; c) All units are executed on at least two different cores; d) To the extent the execution units are not sequential, their executions are optimized/parallelized as per processor core availability for best speed and unpredictability to external attacks; e) Gaps, if any, between two valid business logics are stuffed with random security related execution units wherein such stuffing is controlled by adding ‘critical section’ in the business logic to reduce any performance related overheads; f) Security related execution units to check consistency of execution flows and data results of the individual execution units is inserted whenever the results to be compared are available (As soon as A and A′ are available as shown in FIG. 1 ); and g) At end of the execution sequence described above the scheduler places itself in queue of one of the cores selected at random (Core # 3 as shown in FIG. 1 ) and marking that core as the master for scheduling the next business logic.
[0064] Optionally, the redundant execution units (A and A′ in FIG. 1 ) are compulsorily made to execute on different cores so that the core occupancy is kept maximally available for actual business logic units.
[0065] Redundant execution, in accordance with principles of the present invention explained above, ensures that the same execution unit is executed twice and results compared for integrity of data as well as execution flows. As the same execution unit is executed twice on different cores, security attacks manifested in resetting of counters using ultraviolet light or other means and/or skipping of execution logic is avoided.
[0066] Randomization, in accordance with principles of the present invention explained above, ensures that the execution units are executed at random and thereby insulating the system from security attacks that require establishment of an execution pattern evident from the power consumption signals, altering of voltage levels and preventing non-volatile memory writes.
[0067] Delayed/punctuated execution, in accordance with principles of the present invention explained above, ensures introduction of unpredictability into the execution sequence and therefore, protection against security violations that require monitoring of the power consumption footprints and other secondary data for manifesting the security breach.
[0068] To summarize, arrangement of redundant, randomized and punctuated execution of business logic on a multi-core system forms the inventive core of the present invention. Table 1 lists the attacks on security of a cryptographic device that can be prevented on implementation of the method provided for by the present invention.
[0069] An important feature of the present invention is that no hardware or other peripherals are involved for detection of the security threat. Entirely, the objects of detection and catering countermeasures are ably provided for on a software basis alone. Table 1 lists the attacks on security of a cryptographic device that can be prevented on implementation of the method provided for by the present invention.
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A method to protect computational, in particular cryptographic, devices having multi-core processors from DPA and DFA attacks is disclosed herein. The method implies: Defining a library of execution units functionally grouped into business function related units, security function related units and scheduler function related units; Designating at random one among the plurality of processing cores on the computational device to as a master core for execution of the scheduler function related execution units; and Causing, under control of the scheduler, execution of the library of execution units, so as to result in a randomized execution flow capable of resisting security threats initiated on the computational device.
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BACKGROUND OF THE INVENTION
This invention is directed to a synthetic multifilament yarn containing a novel finishing composition, and more specifically to a spin finish for multifilament yarn used in food packaging. Still more specifically, this invention is directed to a finishing composition comprising butyl stearate, sorbitan monooleate and polyoxyethylene (18-22) sorbitan monooleate, for multifilamentary yarns made from synthetic linear polymers including, for example, polyamides, polyesters, polyolefins, and other polymers useful in food packaging.
In the manufacture of yarn filaments including, for example, filaments made from linear polymers such as the polyesters and polyamides, the ultimate strength of the yarn can be substantially improved by subjecting the filaments to drawing techniques to increase their molecular orientation. Although the drawing operation may be conducted by various means, the common procedure comprises devices commonly known as feed and draw rolls for advancing the filaments. The filaments are stretched by running the rolls at differential speeds with the degree of drawing depending upon the ratio of the peripheral speeds of said rolls. In order to localize the point at which the stretching or drawing occurs, a draw point localizer is normally used. For example, a device may be placed between the feed and draw roll which is known as a draw pin around which the yarn is wrapped. This pin introduces a frictional drive on the moving filaments which causes drawing to take place in areas of the pin. It is well known that the drawing operation can be facilitated when the temperature of the yarn is elevated. The application of heat may be accomplished by various means, e.g., a hot plate placed between the feed and draw rolls.
One of the problems encountered during drawing, either at ambient or elevated temperatures is the frequent occurrence of filament breakage. Thus, during drawing, one or more of the individual filaments of the thread line may break and wrap around the draw rolls or the entire thread line may break which requires stoppage until adjustments can be made. One of the causes of filament breakage during the drawing process is the buildup of an extensive amount of tension on the yarn, which is due for the most part to the interfilamentary friction and yarn-to-metal friction. Excessive tensions resulting from the development of high frictions during the drawing can be reduced, however, by applying to the yarn various antifriction compositions. These compositions are generally applied via an aqueous medium prior to drawing. Although there are presently available various finishing compositions which may be used to reduce yarn tension buildup during drawing, there is a need for compositions capable of not only lowering the yarn to metal friction, but also consisting of ingredients suitable for use on yarn to be used in food packaging, where all ingredients must be approved by the Food and Drug Administration (FDA) for use as direct or indirect food additives.
SUMMARY OF THE INVENTION
In accordance with the present invention, I provide a spin finish composition for yarn used in food packaging, wherein all ingredients have been cleared by the FDA for general use as direct or indirect food additives. A further object of this invention is to provide a spin finish composition which is readily emulsifiable in water, has excellent stability to conventional yarn processing conditions, provides lubrication, static protection, and plasticity to the yarn for subsequent drawing and other high temperature processing.
The spin finish composition of the present invention consists essentially of about 45 to 55 weight percent of said composition of a compound selected from the group consisting of butyl stearate and coconut oil; about 14 to 22 weight percent of said composition of sorbitan monooleate; and about 27 to 37 weight percent of said composition of ethoxylated sorbitan monooleate, said ethoxylated sorbitan monooleate being ethoxylated with about 18 to 22 moles of ethylene oxide.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred spin finish composition of the present invention consists essentially of about 47 to 53 weight percent of said composition of a compound selected from the group consisting of butyl stearate and coconut oil; about 16 to 20 weight percent of said composition of sorbitan monooleate; and about 30 to 34 weight percent of said composition of ethoxylated sorbitan monooleate, said ethoxylated sorbitan monooleate being ethoxylated with about 20 mols of ethylene oxide.
In applying the finishing composition of this invention to the filaments, e.g., nylon, conventional methods may be employed. In general, good results are obtained in both hot and cold drawing operations when the finishing composition is applied in amounts ranging from about 0.2 to 1.5 percent and more preferably 0.8 to 1.0 percent by weight of the yarn. The finishing composition is desirably applied as an aqueous emulsion containing about 12 to 25 percent of the finishing composition. The finishing composition is applied to the yarn prior to drawing by conventional techniques which comprise, for example, bringing the yarn in contact with the composition while it moves during the course of production. The composition may be applied to the yarn by various methods and devices which may include use of a lubricating roll, wick, or having the yarn pass through a bath containing the finishing composition.
The following examples are provided to more fully illustrate the instant invention.
EXAMPLE 1
Table I shows the preferred finish composition of this invention.
TABLE I______________________________________Finish Composition Weight PercentButyl stearate 50Sorbitan monooleate 18Polyoxyethylene (20).sup.a sorbitan 32monooleate______________________________________ .sup.a The ethoxylated sorbitan monooleate was ethoxylated with about 20 moles of ethylene oxide.
It was found that the butyl stearate of this preferred finish composition can be replaced in full or in part with an equal weight of coconut oil, which is more resistant to high temperatures that may occur during processing of some yarns. However, the finish containing butyl stearate is generally preferred because of its better lubricating properties.
EXAMPLE 2
The following example demonstrates use of the preferred spin finish of the present invention.
A polycaprolactam yarn (200 denier-32 filament) was prepared by conventional spin-draw techniques. Immediately after spinning, the spin finish consisting of 50 parts by weight of butyl stearate, 18 parts by weight of sorbitan monooleate and 32 parts by weight of sorbitan monooleate reacted with 20 moles of ethylene oxide was applied to the yarn at the rate of 0.85 weight percent based on the weight of the yarn. The spin finish was applied to the yarn as 14 weight percent emulsion in water, by means of a conventional kiss roll applicator. Drawing performance, beaming, and weaving properties of the yarn were excellent.
After drawing, the yarn was tested for frictional and static properties. Yarn to metal friction was about 165 grams, based on the tension generated by passing the yarn over a 0.25 inch chrome plated stainless steel pin at 1,000 feet per minute, said pin having a RMS of 2.0-2.2. Static generation was 30 millivolts, based on static generated by passing the yarn over a 0.25 inch chrome plated stainless steel pin at 200 feet per minute, said pin having a RMS of 4.0-4.5.
Fabric was prepared by conventional means from yarn prepared in accordance with this example. This fabric was folded and placed over the bone of freshly cut meat, which was then covered with a conventional plastic wrapping. The folded fabric prevented the bone from cutting the plastic wrap.
EXAMPLE 3
Table II shows the criticality of the ingredients of the spin finish composition as well as the amounts of ingredients necessary in order to provide a stable emulsion. Note that only the finishes identified as B and C provide excellent emulsion stability after 48 hours. Varying the components or the weight ratio of components of the finish resulted in significant changes in emulsion stability.
TABLE II______________________________________Finish Compositions Composition in Weight PercentFinish Ingredients A B C D______________________________________Butyl stearate 50 45 50 50Sorbitan monooleate 25 20 18Polyoxyethylene (20)sorbitan monooleate 25 35 32 32Polyoxyethylene (20)sorbitan trioleate 18Emulsion stability*after 48 hours P E E F______________________________________ *Stability of 16 percent emulsion prepared at 55° C. E = Excellent - Translucent bluish-white, particle size less than 1 micron. No separation. F = Fair - Milky white, particle size up to 4 microns. Slight ring of oil separation on surface. P = Poor - Chalky white, particle size above 4 microns. Creaming on surface.
EXAMPLE 4
The spin finish compositions of Example 3 were used to prepare polycaproamide yarns as described in Example 2, and the resulting yarns were tested for frictional and static properties as described in Example 2. Table III shows criticality of the amounts and the presence of various components; note particularly the relatively low yarn to metal friction of Yarn C.
TABLE III______________________________________Finish and Fiber Process Data Composition in Weight PercentFinish Ingredients A B C D______________________________________Butyl stearate 50 45 50 50Sorbitan monooleate 25 20 18Polyoxyethylene (20)sorbitan monooleate 25 35 32 32Polyoxyethylene (20)sorbitan trioleate 18Fiber Process DataYarn to metal friction ofyarn, g. 188 196 165 170Static generation, millivolts 50 20 30 40______________________________________
Based on frictional properties and static properties shown in Table III, and the emulsion stability shown in Table II, Composition C is considered to be the preferred spin finish composition of the present invention.
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This invention relates to a yarn finishing composition and more specifically to a spin finish for multifilament yarns used in food packaging. The preferred finishing composition comprises butyl stearate, sorbitan monooleate and polyoxyethylene (20) sorbitan monooleate.
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FIELD OF THE INVENTION
[0001] The invention relates to navigation devices. The invention is particularly related to detecting defects in navigation data of the navigation devices.
BACKGROUND OF THE INVENTION
[0002] Navigation systems have been developed for assisting drivers to reach a desired destination. The user of such a system inputs the desired destination to the navigation device. As a response the system requests the current location coordinates of the navigation device from a positioning device, which is typically a GPS receiver. The navigation device then computes the route from the current location to the destination. The user of a navigation device is guided to the destination, for example, via the fastest route. The guiding procedure may include informing the user of the distance to the next turn or whether the next turn is to the right or left. During the guiding procedure the location of the user is monitored and, if necessary, a new route is computed. Computing a new route might be required for example if the user misses a turn and the directions are no longer valid.
[0003] Traditionally navigation devices comprise all the information and software required for computing the route even if the navigation device is, as in most cases, a cellular phone or a PDA device that has network connectivity means. This kind of implementation is known as on-board design. In off-board implementations the route is computed in a separate navigation server that sends the information back to the navigation device. Both of the implementations have their benefits and most likely a hybrid implementation with combination of on-board and off-board characteristics will be preferred in the future.
[0004] FIG. 1 presents an illustration of an off-board navigation system. In the navigation system of FIG. 1 an external server 15 includes all navigation data and computing means for providing guidance for the navigation device 14 . However, the navigation device 14 may just as well have all the information and software required for computing and providing the route information. In the example of FIG. 1 the navigation device 14 does not have a built-in positioning device but is connected wirelessly to a GPS receiver 13 that computes the exact location of the receiver 13 from the observations received from the GPS-satellites 10 , 11 and 12 . For understanding also the present invention better, it should be understood that navigation devices, particularly such mobile phones that are equipped with navigation software and positioning means, are capable of executing software applications. Thus, the navigation device has common means required for executing a program, such as a central processing unit and a memory. However, these are common features in present navigation and mobile devices and are not presented herein as they are well known to a person skilled in the art.
[0005] Inevitably, the navigation data has some defects especially when circumstances on a road have changed. A road may e.g. have been changed from a one-way road into a normal bi-directional road or if there used to be a “no right turn” sign in a junction that has been later removed. Updating navigation data is, therefore, not an easy task because one has to keep track of all changes happening on the road network. The changes may be permanent as well as temporary. A temporary change on the road network may be a road construction that will block a road for a while but will later be opened for traffic again. It is also possible that the navigation data was originally coded wrongly. A bi-directional road may have been marked as a one-way road in the navigation data or there may be a “no right turn” marked on the data in a place where there is not a corresponding sign on the road.
[0006] More advanced implementations of navigation devices can use additional information for routing purposes. The most beneficial types of additional information relate to road conditions. These include for example, traffic and weather information that might cause traffic jams or other delays in a journey. This kind of information changes rapidly. For example, a car crash on a highway might stop the traffic immediately causing a navigation fault, as the route must be changed if there is an alternative possibility.
[0007] These defects in the navigation data are difficult to notice or correct. They might have been erroneously input when coding the map into navigation data or they might result from unpredicted changes in the road network. In any event, due to their unexpected nature, these defects and errors in the navigation data tend to surface especially in such cases in which the user knows the fastest route himself and is directed via a longer one. The user finds these errors inconvenient and therefore, they also affect the usability of the navigation device.
PURPOSE OF THE INVENTION
[0008] The purpose of the invention is to provide a reliable procedure for detecting errors and defects in navigation data of navigation systems.
SUMMARY OF THE INVENTION
[0009] The invention discloses a method for detecting defects in navigation data. The invention further discloses a system and software for navigation devices with a navigation database.
[0010] It is assumed that the users of navigation devices will follow the computed route. The computed route may comprise the actual driving directions, speed limits and other restrictions that are significant in routing decisions and in estimating the advancing on the route. In the method according to the present invention, defects in the navigation data are detected by comparing the actual behavior of the user with the route that is assumed to be followed and suggested by the navigation software. The method further comprises the steps of detecting a difference between the actual behavior of the user and the assumed route and sending the detected difference to a receiving unit, which can be, for example, a navigation server or another navigation device. The difference can be a completely different route, different speed on the assumed route or the like. Furthermore, it is possible that the navigation device collects a plurality of defects before sending. For example, if the network is not available at the moment of the defect, the plurality of collected defects is sent when the network is available again. The navigation server then collects statistical information on such locations on the map where users repeatedly choose a different route from the Computed route and determines based on the statistics the possible defect in the navigation data. A threshold may be set e.g. for the number of times that users choose an alternate route. The threshold may as well be set to a certain percentage of the users driving another route. When the threshold is exceeded, the software concludes that there must be an error in the navigation data. The navigation data provider may also be informed of the possible defects. Depending on the nature of the noticed defect, he may then check whether the defect must be corrected and navigation data updated. The possible defect can be a major change in the road network that needs to be corrected in the navigation data or it can be a change in traffic or weather data that can be corrected automatically. For example, if a traffic jam has been reported but vehicle speeds are normal, there must be an error in traffic information and it can be corrected automatically or an automatic correction is suggested that needs to be verified by the service operator.
[0011] In a preferred embodiment of the error detecting method, comparing the actual route taken by the user with the computed route is done continuously as the user proceeds towards the destination. In another preferred embodiment, comparing the actual route taken by the user with the computed route is done after the guidance procedure.
[0012] The invention designed is particularly suitable for mobile phones that are equipped with navigation software and positioning means. Furthermore, the navigation device has common means required for executing a program, such as a central processing unit and a memory. However, these are common features in mobile devices and are not presented herein as they are well known to a person skilled in the art. The navigation device can also be some other kind of communications device enabled to communicate the computed route to the user. In such an example, there must be some data communications means available for the device and the navigation server to communicate.
[0013] In an embodiment of the invention the noticed differences are shared by using a peer to peer protocol. This type of sharing may be additional to using the server based implementation or independently. This information can be received from all users or from a group of predetermined users. The reliability of the received information can be improved by requiring several notifications. For example, if a traffic jam is reported, the navigation device waits for second notification as a confirmation to the first report. The user can define the number of required notifications.
[0014] The benefit of the invention is that it provides a simple and reliable error detecting procedure for navigation devices and systems. Defects in the navigation and additional data are perceived faster and easier than in prior art navigation systems. The invention further reduces the map provider's time-consuming task of searching for errors in the navigation data as well as the updating procedure of such data. Furthermore, a fast correction of the additional data will help the user in reaching the desired destination and also makes the traffic more fluent. A further benefit of the present invention is that while it facilitates the updating procedure, it also enables improving the quality of navigation data in navigation devices and systems. It is also a user-friendly method for detecting errors since it can be done in the background without the need for user interaction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are included to provide a further understanding of the invention and constitute a part of this specification, illustrate embodiments of prior art as well as the present invention. The figures, together with the description, help to explain the principles of the invention. In the drawings:
[0016] FIG. 1 is an illustration of an example embodiment of a prior art navigation system,
[0017] FIGS. 2 a and 2 b present an illustration of navigation data in weighted graph form,
[0018] FIGS. 3 a and 3 b present an illustration of a road network and the user's route, and
[0019] FIG. 4 is a flow chart of a method according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0021] To understand better the procedure for detecting defects in navigation data first one must know how the navigation material is organized. The navigation material comprises map information that is required for guiding the user of the device. The map material comprises geometry, topology, address and other information, such as traffic signs, that may be used during guidance. The actual road information is usually coded in the form of weighted graphs. The graph consists of vertices (or nodes) that are connected by lines called edges (or arcs). The vertices in the graph correspond to road junctions of a map and the connecting lines between the vertices respectively correspond to the roads. The connecting lines i.e. the edges are assigned a direction and a weight that may e.g. represent the complexity or the length of a road. FIGS. 2 a and 2 b provide an example of a directed graph corresponding to a road network. In addition to the above-mentioned information the navigation device may use additional information that is retrieved from the network, for example, traffic, weather information or other temporary information.
[0022] The user of the navigation device inputs the desired destination such as the location corresponding to vertex J 6 in FIGS. 2 a and b . As a response the system computes e.g. the shortest route from the user's current position to the desired destination and starts guiding the user to the destination. If the user is at junction J 1 , the device guides the user to take the shortest possible way via roads R 1 , R 5 , R 8 and R 11 . The user must drive via junction J 5 because road R 4 is a one-way road in the wrong direction. The navigation software computes the best route from the point of origin to the destination according to the predetermined rules, for example by minimizing the weight of the route. In this example ( FIG. 2 b ), the user could also be guided via roads R 1 , R 5 , R 7 and R 10 but this route would have much higher weight and it would, therefore, take longer than the route offered by the navigation device.
[0023] If the user/users of the navigation device choose another route than the one computed and suggested by the navigation software, the navigation device detects this difference by comparing the user's actual route with the computed route. It is assumed that the user of the device will follow the computed route. If the actual behavior of the user differs from the assumed route, the device sends the detected difference to the navigation server. This difference can be a completely different route or, for example, a difference in assumed speed of the navigation device. The navigation device may also inquire the user whether he wants to send the notification to the server but advantageously, the notification is sent without any interaction needed from the user. Based on the notifications on the differences between the actual routes and the computed routes, the navigation server collects information on the routes taken by the users and keeps track of the statistics on such locations where the actual route taken by the user differs from the suggested route. It is possible to monitor continuously whether the route taken by the users differs from the computed one. It is just as well possible for the navigation server to keep record of the users' routes and afterwards compare the actual route taken by the user with the given directions. For example, if the users repeatedly drive in the wrong direction on a road that is marked as a one-way road on the navigation data, the software may conclude that the marked road in fact is a two-way road. Similarly, the users may choose a different route e.g. if the road is blocked because of a temporary road construction or because of any other changes in the road network.
[0024] If, for example, a certain percentage of the users drive differently from the directions given by the navigation device, the navigation software may notify the navigation data provider of this event. The navigation data provider checks and approves the notification. He may send someone in person to check if the circumstances on the road have changed and if so, whether the changes are permanent or temporary (such as in case of a road construction). He may also conclude that the defect was in the navigation data in the first place and update the data based on his observations.
[0025] An example of the defect detecting procedure according to the present invention is disclosed in FIGS. 3 a and 3 b . When the user is on road R 9 in FIG. 3 a and enters road R 6 as his destination, the navigation software computes the optimum route to be via route R 5 and starts guiding the user to turn right at junction J 3 . However, if road R 5 has been blocked by e.g. a road construction ( FIG. 3 b ), the user must choose the route via roads R 7 , R 2 , R 8 and R 6 . As the user passes his guided turn at junction J 3 to road R 5 , the navigation device detects this discrepancy and sends the difference to the navigation server. An alternate route is then computed to the user driving already on road R 7 via roads R 2 and R 8 to the destination route R 6 . The navigation server collects information on all such events when a user chooses another route than the one suggested by the device itself. If a number of users choose this same alternate route, the navigation software concludes that there must be a defect in the navigation material and makes a further notification.
[0026] The defect detecting procedure is initiated automatically so that typically the user does not even notice it. In a method according to the invention the method is initiated by requesting and computing a route, step 40 . This is a common feature of navigation devices as their purpose is to guide a user of the device from the current location to a desired destination. After computing the route the navigation device starts guiding the user, step 41 . The computed route is assumed to be followed by the user. Thus, the user can start driving. When the guiding is started, the device monitors the location of the user and compares the actual route taken by the user with the computed route 42 . When the device detects a difference between the actual behavior of the user and the computed route 43 , it sends the difference to the navigation server 44 . The navigation server collects each detected difference 45 and sets a limit value for how many times the user's route differs from the computed route at the same location. When e.g. the users take a different route a certain number of times or a certain percentage of the users take a different route, then the navigation software concludes that there must be a defect in the navigation data at the location where these two routes differ. The software may also notify the navigation data provider who can update the data. If the navigation data has been already updated and the reporting user has an old version of the database, the service provider may send an update or a notification of an available update.
[0027] In a preferred embodiment the implementation comprises a mobile phone that is capable of executing a navigation software application. The navigation device has been connected to a GPS receiver with a wireless connection, such as Bluetooth, or has been built into the navigation device. The GPS system is mentioned because it is most commonly used, exact and because there are plenty of hardware implementations. However, for the error detecting procedure according to the present invention any kind of positioning system is acceptable. The navigation database is stored on a memory card. The navigation software is arranged to monitor or keep record of the routes chosen by the user and compare the routes with the navigation data in the device. The essential feature of the defect detecting procedure is the comparing of the actual route taken by the user with the given directions and determining, based on statistics, if there is a defect in the navigation data.
[0028] In an alternative preferred embodiment the implementation further comprises using the additional information regarding driving conditions on a route, such as traffic or weather information. Driving conditions data may and should be used in routing decisions in order to reach the best possible routing solution. This information changes rapidly and is subject to similar defects as described above. For example, when an traffic jamming accident occurs and it is not known in the additional information, firstly, it must be reported. When the speed limit and actual speed of the vehicle are known, it is easy to compute that the vehicle is not moving as expected. In this case, the navigation device sends a notification to the service provider providing the traffic information. In case of heavy traffic it is likely that there will be more than one report. When the number of reports fulfils a certain threshold in a predetermined time period, the additional information is changed. The change can be automatic or a notification to an operator who verifies the suggested change. Lastly, the change is reported to customers that are in the area, broadcasted to customers or dispatched in some other suitable way. Respectively, if a traffic jam is reported and the cars are moving considerably faster, the traffic information might be old and the reason for the jam no longer exists. Also in this case the noticed difference is sent to the service operator for further processing. Similar procedures can also be used for weather information, such as flooding, avalanches, wind or any other weather observations that might cause restrictions to roads, passes, bridges or the like.
[0029] In a further alternative embodiment a peer to peer protocol is used for sharing the information. In this embodiment the noticed defects are not sent to a server but shared directly to other users by sending the information directly to another navigation device. Respectively the updates are received directly from other navigation devices. This is particularly useful with the traffic conditions information sharing. In this case, if desired, the statistical analysis needs to be implemented in the navigation device. However, it is possible to use received information also without statistical analysis. Furthermore, it is possible to combine these methods of sending and receiving the information. Thus, the users can get the benefits by using both channels.
[0030] When using a navigation application according to the present invention, the defect detecting procedure can be totally independent and automatic and it does not require further interaction from the user of the navigation device. The user requests a route to be computed as usual. The navigation device acquires the position of the device and then computes the route. The device may then start a continuous error detecting procedure directly after computing the route. The server may collect only the locations on the map where the user takes another route than the one suggested by the device. The server may also collect information on the actual routes taken by the user and compare them with the navigation data later. After a certain threshold for the number of times that users choose an alternate route at the same location, the navigation data provider may be informed of the possible defect in the navigation data.
[0031] It is obvious to a person skilled in the art that with the advancement of technology, the basic idea of the invention may be implemented in various ways. The invention and its embodiments are thus not limited to the examples described above; instead they may vary within the scope of the claims.
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A navigation system using a mobile terminal ( 14 ), GPS receiver ( 13 ), navigation server ( 15 ) and navigation software, wherein the navigation software is arranged to detect defects in navigation or driving conditions data. Defects in the navigation or driving conditions data are detected by comparing the actual behavior of the user with the route computed and sug-gested by the navigation software. The difference be-tween the actual route taken by the user and the com-puted route is detected and sent to the navigation server ( 15 ). The navigation server ( 15 ) then collects statistical information on such locations on the map where users repeatedly choose a different route from the computed route and determines, based on the sta-tistics, the possible defect in the navigation or driving conditions data.
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[0001] The present invention relates to a material composed of composite particles of inorganic oxide, to a process for the preparation thereof and to the use thereof as electrode active material.
STATE OF THE ART
[0002] A lithium battery operates by reversible movement of lithium ions between a negative electrode and a positive electrode, through an electrolyte comprising a lithium salt in solution in a liquid solvent, polymer or gel.
[0003] The negative electrode is generally composed of a lithium sheet, a lithium alloy or a lithium-comprising intermetallic compound. The negative electrode can also be composed of a material capable of reversibly inserting lithium ions, such as, for example, graphite or an oxide, said insertion material being used alone or in the form of a composite material additionally comprising at least one binder and one agent which confers conduction of electrons, such as carbon.
[0004] Various complex oxides have been studied as active material for the positive electrode, acting as material for the reversible insertion of lithium ions. Mention may in particular be made of the compounds which have an olivine structure and which correspond to the formula LiMXO 4 , the compounds corresponding to the formula Li 2 MXO 4 in which M represents at least one transition metal and X represents an element chosen from S, P, Si, B and Ge (for example Li 2 FeSiO 4 ) and the compounds of the Nasicon type having a rhombohedral structure which correspond to the formula Li x M 2 (XO 4 ) 3 in which M represents at least one transition metal and X represents at least one element chosen from S, P, Si, B and Ge. These complex oxides are generally used in the form of nanometric or micrometric particles, optionally coated with carbon and/or bonded to one another via carbon bonds. The presence of the carbon improves the electrochemical performance, in particular when it is in the form of an adherent layer on the complex oxide.
[0005] Among these oxides, those in which M represents Fe, Mn or Co are advantageous, in particular because of some of their electrochemical properties and of their relatively low cost due to the high availability of the metals. However, they exhibit a few disadvantages. An oxide LiMXO 4 in which M is essentially Fe (in particular LiFePO 4 ) has a good electronic conductivity when it is in the form of particles coated with carbon and is used as electrode material. It can be easily obtained in the form of particles coated with an adherent layer of carbon but the energy density is low because of the relatively low voltage (of the order of 3.4 V vs Li/Li + ). The oxides LiMXO 4 in which M is essentially Mn and/or Co and/or Ni (in particular LiMnPO 4 , LiCoPO 4 and LiNiPO 4 ) have a markedly higher operating voltage (of the order of 4.1 V, 4.8 V and 5.1 V respectively) and consequently a high energy density but it is difficult to obtain them in the form of particles coated with an adherent layer of carbon and they have a relatively low electronic conductivity.
[0006] It was then envisaged to use particles having a core of an oxide LiMPO 4 and a coating of carbon, M representing Fe partially replaced by Mn. However, the presence of LiFePO 4 , which has a low potential (3.5 V), brings about a decrease in energy density with respect to the use of LiMnPO 4 alone. When the LiFePO 4 content is restricted to a value of less than 20% by weight, the voltage of the cathode is dominated by the LiMnPO 4 voltage (4.1 V), which limits the decrease in the energy density. A compound LiFe (1-x) Mn x PO 4 , which is a solid solution, gives acceptable results when x remains below 0.6, that is to say when the compound LiFePO 4 is predominant (Ref. Yamada, J. Power Sources, Volume 189, Issue 2, 15 Apr. 2009, pages 1154-1163). However, it is not possible to increase the contribution of Mn with respect to Fe.
SUMMARY
[0007] An object of the present invention is to provide an electrode material which has good performance when it is used as positive electrode active material in a lithium battery, in particular a high energy density and a good electronic and ionic conductivity.
[0008] The inventors have found that an adherent layer of carbon on a complex oxide can be easily obtained when the metal of the oxide exerts a catalytic effect on the reaction which results in the deposition of carbon. They have also found that, surprisingly, when a layer of an oxide of a metal is deposited at least on a portion of the surface of particles of a complex oxide having a high energy density, an adherent deposit of carbon is obtained without substantially reducing the operating potential, when said metal has a catalytic effect with regard to said reaction resulting in the deposition of carbon. This makes it possible to increase the electronic conductivity without reducing the energy density.
[0009] Consequently, according to one aspect of the present invention, a positive electrode material is provided which is composed of particles having a core of a complex oxide CO1, an at least partial coating of a complex oxide CO2 and an adherent surface deposit of carbon, said material being characterized in that the complex oxide CO1 is an oxide having a high energy density and the oxide CO2 is an oxide of a metal which has a catalytic effect on the reaction for the deposition of carbon, said oxide having a good electronic conductivity. The presence of the CO2 layer has the effect, on the one hand, of facilitating the deposition of an adherent layer of carbon on the surface of the oxide particles and, on the other hand, of improving the conductivity of the material when it is used as electrode material.
[0010] According to another aspect of the invention, a process is provided for the preparation of said electrode material.
[0011] Another aspect of the invention relates to a composite electrode, the active material of which is the material of the invention, and to a lithium battery, the positive electrode of which comprises said electrode material according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 represents the X-ray diffraction diagram of LiMnPO 4 prepared according to example 1.
[0013] FIG. 2 represents the X-ray diffraction diagram of LiMnPO 4 particles coated with LiFePO 4 prepared according to example 1.
[0014] FIGS. 3 , 4 and 5 relate to an electrochemical cell having an electrode, the active material of which is composed of LiMnPO 4 particles coated with LiFePO 4 and with a carbon layer deposited by pyrolysis of cellulose acetate, and they respectively represent:
the change in the potential P (in volts) as a function of time T (in hours), during operating at a C/24 rate ( FIG. 3 );
[0016] the percentage of capacity % C (curve represented by □□□) and the discharge/charge (D/C) ratio (curve represented by οοο), as a function of the number of cycles N ( FIG. 4 );
the Ragone diagram, that is to say the variation in the capacity C (in mAh/g) as a function of the discharge rate R ( FIG. 5 ).
[0018] FIGS. 6 , 7 and 8 relate to an electrochemical cell having an electrode, the active material of which is composed of LiMnPO 4 particles coated with LiFePO 4 and with a carbon layer deposited by pyrolysis of lactose, and they respectively represent:
the change in the potential P (in volts) as a function of time T (in hours), during operating at a C/24 rate ( FIG. 6 ); the percentage of capacity % C (curve represented by □□□) and the discharge/charge (D/C) ratio (curve represented by οοο), as a function of the number of cycles N ( FIG. 7 ); the Ragone diagram, that is to say the variation in the capacity C (in mAh/g) as a function of the discharge rate R ( FIG. 8 ).
[0022] FIG. 9 represents the X-ray diffraction diagram of a compound LiMn 0.67 Fe 0.33 PO 4 .
[0023] FIGS. 10 and 11 relate to an electrochemical cell having an electrode, the active material of which is composed of LiMn 0.67 Fe 0.33 PO 4 particles coated with a carbon layer deposited by pyrolysis of cellulose acetate, and they respectively represent:
the change in the potential as a function of time, during operation at a C/24 rate ( FIG. 10 ); the Ragone diagram, that is to say the variation of the capacity C (in mAh/g) as a function of the discharge rate R ( FIG. 11 ).
DETAILED DESCRIPTION OF THE INVENTION
[0026] A first subject matter of the invention is a positive electrode material composed of particles having a core of a complex oxide CO1, an at least partial coating of a complex oxide CO2 and an adherent surface deposit of carbon, said material being characterized in that:
the complex oxide CO1 has a potential of greater than 2.5 V and is chosen from the oxides of an alkali metal and of at least one element chosen from Mn, Co, Ge, Au, Ag and Cu, and the oxide CO2 is an oxide of an alkali metal and of at least one metal which has a catalytic effect on the reaction for the deposition of carbon and which is chosen from Fe, Mo, Ni, Pt and Pd.
[0029] The alkali metal A is chosen from Li, Na and K, Li being particularly preferred. Preferably, the alkali metal is the same in both oxides.
[0030] The oxide CO1 can be an oxide A z M 1 (1-a) M 2 a XO 4 in which M 1 represents at least one element chosen from Mn, Co, Cu and Ge, M 2 represents a transition metal other than Mn and Co, 0≦a≦0.5, 0≦z≦2 and X represents an element chosen from P, Si, V and Ti, in particular an oxide LiMnPO 4 in which Mn can be partially replaced by Co and/or Ni. The oxide LiMnPO 4 is particularly preferred.
[0031] The oxide CO2 can be an oxide A z M 3 (1-b) M 4 b X′O 4 or an oxide A x [M 3 (1-c) M 4 c ) 2 (X″O 4 ) 3 ] in which M 3 represents at least one element chosen from Fe, Mo, Pt and Pd, M 4 represents a transition metal other than M 3 , 0≦b≦0.5, 0≦c≦0.5, 0≦x≦3, 0≦z≦2, and X′ or X″ represents at least one element chosen from P, Si, S, V, Ti and Ge. In addition, the oxide CO2 can be an oxide LiFeBO 3 . The oxides LiFePO 4 , LiFeVO 4 , Li 2 FeSiO 4 , LiFeTiO 4 and Li 2 FeGeO 4 are particularly preferred as oxide CO2, more particularly LiFePO 4 . The material according to the invention is prepared from the precursors of its constituent elements. The preparation process comprises the following stages:
a) preparation of particles of oxide CO1 from its precursors; b) introducing the particles of oxide CO1 into a solution of precursors of the oxide CO2 and carrying out a heat treatment in order to bring about the reaction of the precursors of the oxide CO2; c) bringing the particles of oxide CO1 carrying a coating of oxide CO2 into contact with an organic precursor of carbon and carrying out a heat treatment so as to reduce the organic precursor to carbon.
[0035] An Li precursor is chosen from lithium oxide Li 2 O, lithium hydroxide, lithium carbonate Li 2 CO 3 , the neutral phosphate Li 3 PO 4 , the acid phosphate LiH 2 PO 4 , lithium orthosilicate, lithium metasilicate, lithium polysilicates, lithium sulfate, lithium oxalate and lithium acetate. Several precursors can be used simultaneously. The lithium precursor is preferably Li 2 CO 3 .
[0036] An iron precursor can be chosen from iron(III) oxide, magnetite Fe 3 O 4 , iron(III) phosphate, iron(III) nitrate, iron(III) sulfate, lithium iron hydroxyphosphate, iron(III) sulfate and iron(III) nitrate.
[0037] A manganese precursor can be chosen from manganese dioxide, manganese nitrate Mn(NO 3 ) 2 .4H 2 O and manganese sulfate MnSO 4 .H 2 O.
[0038] The Ni precursor can be chosen from the sulfate NiSO 4 .6H 2 O, the nitrate Ni(NO 3 ) 2 .6H 2 O, the acetate Ni(CH 3 COO) 2 .4H 2 O, nickel oxalate NiC 2 O 4 .2H 2 O and the phosphate Ni 3 (PO 4 ) 2 .7H 2 O.
[0039] The Co precursor can be chosen from the oxide Co 3 O 4 , the nitrate Co(NO 3 ) 2 .6H 2 O, the acetate Co(CH 3 COO) 2 .4H 2 O, the cobalt(II) sulfate, cobalt nitrate, cobalt oxalate CoC 2 O 4 .2H 2 O and the phosphate Co 3 (PO 4 ) 2 .
[0040] Divanadium pentoxide can be used as V precursor.
[0041] When X or X′ is P and when the Li or M precursor is not a phosphate, phosphoric acid H 3 PO 4 or di ammonium hydrogen phosphate (NH 4 ) 2 HPO 4 can be used as P precursor.
[0042] When X or X′ is S, the S precursor can be (NH 4 ) 2 SO 4 .
[0043] When X or X′ is Ge, the Ge precursor can be a tetraalkylammonium germanate.
[0044] In an advantageous embodiment, use is made of at least one compound among those mentioned above which is a precursor of several constituent elements of the oxide.
[0045] The preparation of the CO1 particles in stage a) can be carried out by the processes known in the prior art, consisting in at least partially dissolving the precursors in a carrier liquid, in applying a heat treatment in order to bring about the reaction of the precursors and to give rise to the precipitation of the oxide CO1, in allowing the reaction medium to cool, in recovering the particles, in washing them and in drying them. The temperature of the heat treatment is advantageously from 120° C. to 250° C. The drying temperature is advantageously between 80 and 140° C.
[0046] In stage b), the heat treatment is advantageously carried out at a temperature of between 120° C. and 250° C., and the recovery of the composite particles is carried out in a way analogous to that of stage a).
[0047] In stages a) and b), the carrier liquid for the precursors is advantageously water, preferably demineralized and degassed water.
[0048] Stage c) can be carried out in different ways.
[0049] According to a first embodiment, the deposition of carbon on the composite particles having a core of a complex oxide CO1 and a coating of complex oxide CO2 can be carried out by pyrolysis of an organic precursor. The organic precursor subjected to the pyrolysis can be chosen from hydrocarbons and their derivatives, particularly polycyclic aromatic entities, such as tar or pitch, perylene and its derivatives, polyhydric compounds, such as sugars and carbohydrates, their derivatives, and polymers. Mention may be made, as examples of polymers, of polyolefins, polybutadienes, polyvinyl alcohol, the condensation products of phenols, including those obtained from reaction with aldehydes, the polymers derived from furfuryl alcohol, the polymers derived from styrene, divinylbenzene, naphthalene, perylene, acrylonitrile and vinyl acetate, cellulose, starch and their esters and ethers, and their mixtures. When the precursor is soluble in water (for example, glucose, lactose and their derivatives), the pyrolysis can be carried out on the precursor in aqueous solution. The pyrolysis is generally carried out at temperatures between 100 and 1000° C.
[0050] According to a second embodiment, the deposition of carbon on the complex particles can be carried out by bringing said complex particles into contact with a compound which has one or more carbon-halogen bonds and reducing said compound, according to the reaction scheme CY—CY+2e − =>—C═C—+2Y − , in which Y represents a halogen or a pseudohalogen. This reaction can be carried out at low or moderate temperatures below 400° C. Pseudohalogen is understood to mean an organic or inorganic radical capable of existing in the form of a Y − ion and of forming the corresponding protonated compound HY. Mention may in particular be made, among halogens and pseudohalogens, of F, Cl, Br, I, CN, SCN, CNO, OH, N 3 , RCO 2 or RSO 3 , R representing H or an organic radical. The formation by reduction of CY bonds is preferably carried out in the presence of reducing elements, for example hydrogen, zinc, magnesium, Ti 3+ , Ti 2+ , SM 2+ , Cr 2+ or V 2+ ions, tetrakis(dialkylamino)-ethylenes or phosphines. Mention may be made, among compounds capable of generating carbon by reduction, of perhalocarbons, in particular in the form of polymers, such as hexachlorobutadiene and hexachlorocyclo-pentadiene.
[0051] According to a third embodiment, the deposition of carbon on the complex particles can be carried out by bringing said complex particles into contact with a compound which has one or more —CH—CY— bonds and eliminating the hydrogenated compound HY, Y being as defined above, by a low-temperature reaction according to the reaction scheme —CH—+B=>—C═C—+BHY. Mention may be made, as examples of compounds which can be used in this embodiment, of organic compounds comprising an equivalent number of hydrogen atoms and of Y groups, such as hydrohalocarbons, in particular the polymers, such as polyfluorides, polychlorides, polybromides, polyvinylidene acetates and carbohydrates. The dehydro(pseudo)halogenation can be obtained at low temperature, including ambient temperature, by the action of a base capable of reacting with the HY compound to form a salt. The base can be a tertiary base, chosen in particular from amines, amidines, guanidines or imidazoles, or an inorganic base, chosen from alkali hydroxides and organometallic compounds behaving as strong bases, such as AN(Si(CH 3 ) 3 ) 2 , LiN[CH(CH 3 ) 2 ] 2 and butyllithium.
[0052] A material according to the invention is of particular use as active material of the positive electrode of a lithium battery. The positive electrode is composed of a composite material deposited on a current collector. The current collector is a metal stable toward oxidation which can be aluminum, titanium or a stainless steel. The composite material comprises at least 60% by weight of material according to the invention, optionally a binder and/or an additive which confers electronic conduction. The binder can be a poly(vinylidene fluoride) or PVDF, a poly(vinylidene fluoride-co-hexafluoropropene) copolymer or PVDF-HFP, a poly(tetrafluoroethylene) or PTFE, a poly(ethylene-co-propylene-co-5-methylene-2-norbornene) (EPDM), or a poly(methyl methacrylate) or PMMA, and it represents at most 15% by weight of the composite material. The electronic conduction additive is advantageously chosen from carbon-based materials, in particular carbon blacks, acetylene blacks and graphites, and it represents at most 25% by weight of the composite material.
[0053] The electrode according to the invention can be used in a battery, the negative electrode of which is a sheet of lithium or of intermetallic lithium alloy, or a material capable of reversibly inserting lithium ions.
[0054] The electrolyte comprises at least one lithium salt in solution in a solvent which can be chosen from polar aprotic liquid solvents optionally gelled by addition of a polymer, and solvating polymers optionally plasticized by an aprotic liquid solvent. The lithium salt can be chosen from the salts conventionally used in ionic conduction materials for electrochemical devices operating by exchange of lithium ions. Mention may be made, by way of examples, of (CF 3 SO 2 ) 2 NLi (LiTFSI), (CF 3 SO 2 ) 2 CHLi, (CF 3 SO 2 ) 3 CLi, CF 3 SO 3 Li, LiClO 4 , LiPF 6 , LiBF 4 , LiAsF 6 , LiBOB, LiFSI or LiI.
[0055] The present invention is described below in more detail with the help of implementational examples, to which, however, it is not limited.
EXAMPLE 1
LiMnPO 4 Particles Coated with LiFePO 4
Preparation of LiMnPO 4 Particles
[0056] The following were prepared under a nitrogen atmosphere:
a solution A, by dissolution of 4.62 g of LiOH.H 2 O in 30 ml of demineralized and degassed water; a solution B, by dissolution of 9.27 g of Mn(NO 3 ) 2 .4H 2 O in 50 ml of demineralized and degassed water; a solution C, by dissolution of 4.0 g of an 85% aqueous H 3 PO 4 solution in 10 ml of demineralized and degassed water.
[0060] Solutions B and C were mixed and then solution A was gradually added thereto. It was found that the viscosity of the reaction medium increases as solution A is added, and the final pH measured is 6.6. In the reaction medium thus obtained, the Mn concentration is 0.4M and the Li/Mn/P ratio is 3/1/1.
[0061] The reaction medium was subsequently poured under a nitrogen atmosphere into a PTFE container incorporated in a pressurizable stainless steel chamber (Parr, volume of 325 ml) and the setup was placed in an oven at 220° C. for 7 hours and then cooled to ambient temperature. The precipitated powder was recovered by filtration, washed 3 times with 100 ml of distilled water and then dried in an oven at 90° C. under nitrogen for 12 h.
[0062] The entire process was repeated twice and 12 g of a compound in the form of a beige-colored powder were thus obtained. The X-ray diffraction diagram is represented in FIG. 1 . It shows that the compound is a single phase which exhibits an orthorhombic structure, the parameters of which are a=10.43100 Å; b=6.09470 Å; c=4.773660 Å.
[0000] Coating of the LiMnPO4 Particles with LiFePO 4
[0063] The following were prepared under a nitrogen atmosphere:
a solution D, by dissolution of 3.08 g of LiOH.H 2 O in 40 ml of demineralized and degassed water; a solution E, by dissolution of 10.0 g of FeSO 4 .7H 2 O and 4.75 g of (NH 4 ) 2 HPO 4 in 50 ml of demineralized and degassed water.
[0066] Solution D was gradually added to solution E. As above, the viscosity increases as solution D is added, and the final pH measured is 10.3. The Li/Fe/P ratio in the solution of LiFePO 4 precursors thus obtained is 2/1/1.
[0067] 10 g of LiMnPO 4 particles prepared according to the above procedure were introduced into this solution of precursors. The reaction medium thus obtained was poured under a nitrogen atmosphere into a PTFE container incorporated in a pressurizable stainless steel chamber (Parr, volume of 325 ml) and the setup was placed in an oven at 220° C. for 7 hours and then cooled to ambient temperature.
[0068] The compound which precipitated was recovered by filtration, washed 3 times with 100 ml of distilled water and then dried in an oven at 90° C. under nitrogen for 12 h.
[0069] 15.1 g of a compound in the form of a beige-colored powder were thus obtained. The X-ray diffraction diagram is represented in FIG. 2 . In this figure:
the peaks identified by the symbol ♦ correspond to the compound LiFePO 4 ; the peaks identified by the symbol □ correspond to the compound LiMnPO 4 .
[0072] It is thus apparent that the compound obtained comprises the LiFePO 4 phase and the LiMnPO 4 phase, which both have the olivine structure and the orthorhombic phase with different lattice parameters:
LiMnPO 4 a=10.43100, b=6.09470, c=4.73660 LiFePO 4 a=6.01890, b=10.34700, c=4.70390
Deposition of Carbon
[0075] The compound obtained in the preceding stage was introduced into a solution of cellulose acetate in an acetone/isopropanol (1/1) mixture, the acetate/[LiMnPO 4 ]LiFePO 4 ratio being 1/7, and then the reaction medium was subjected, under an inert atmosphere, to a heat treatment comprising a stage of 1 h at 400° C. followed by a stage of 3 h at 600° C. The final material was obtained in the form of a grayish-black powder.
Characterization
[0076] The electrochemical performance of the material obtained was determined in an electrochemical cell in which said material constitutes the cathode, the anode is of lithium metal and the electrolyte is a 1M solution of LiPF 6 in an EC/DEC 50/50 mixture, with a theoretical rate of C/24.
[0077] FIG. 3 represents the change in the potential as a function of time, during operation at a C/24 rate, which corresponds theoretically to a 48 h cycle. FIG. 3 shows a cycle time of 36 h, owing to the fact that not all the theoretical capacity is obtained. It also shows the presence of a first plateau at 3.5 V, corresponding to Fe, and a second plateau at 4.0 V, corresponding to Mn. In order to avoid degradation of the solvent of the electrolyte, the potential is maintained at 4.5 V instead of raising it further and thus the capacity of the first charge is limited to 94.9 mAh/g (instead of the theoretical value of 170 mAh/g), which is equivalent to a level x of lithium extracted from the material such as x=0.558.
[0078] FIG. 4 represents the percentage of capacity (left-hand ordinate) and the discharge/charge (D/C) ratio (right-hand ordinate), as a function of the number of cycles. During the cycles, charging is carried out at a C/4 rate and discharging is carried out at a 1 C rate. FIG. 4 shows that the reversible capacity is 99.5 mAh/g and that the efficiency (D/C ratio) remains substantially maintained at about 99%.
[0079] FIG. 5 represents the Ragone diagram of the material, that is to say the variation of the capacity as a function of the discharge rate. It shows that, at a rate of 10 C, the capacity delivered is 53 mAh/g.
EXAMPLE 2
LiMnPO 4 Particles Coated with LiFePO4
[0080] The procedure of example 1 was repeated for the preparation of the LiMnPO 4 particles coated with LiFePO4.
Deposition of Carbon
[0081] The LiMnPO 4 particles coated with LiFePO 4 were introduced into a solution of lactose in water, the lactose/[LiMnPO 4 ]LiFePO 4 ratio being 1/10, and then the reaction medium was subjected to a heat treatment under an inert atmosphere comprising a stage of 1 h at 400° C. followed by a stage of 3 h at 600° C. The final material was obtained in the form of a grayish-black powder.
Characterization
[0082] The electrochemical performance of the material obtained was determined in the same way as in example 1. FIG. 6 represents the change in the potential as a function of the time. It shows that the capacity of the first charge is 116 mAh/g, which is equivalent to a level of lithium extracted from the material x=0.682.
[0083] FIG. 7 represents the percentage of capacity (left-hand ordinate) and the discharge/charge (D/C) ratio (right-hand ordinate), as a function of the number of cycles. During the cycles, charging is carried out at a C/4 rate and discharging is carried out at a 1 C rate. FIG. 7 shows that the reversible capacity is 119.3 mAh/g and that the D/C ratio remains substantially constant.
[0084] FIG. 8 represents the Ragone diagram of the material, that is to say the variation of the capacity as a function of the discharge rate. It shows that, at a 10 C rate, the capacity delivered is 65.5 mAh/g.
COMPARATIVE EXAMPLE
LiMn 0.67 Fe 0.33 PO 4 Particles
[0085] By way of a comparison, particles of a phosphate LiMPO 4 , in which M represents Fe partially replaced by Mn, were prepared and a carbon coating was deposited on said particles by carbonization of a carbon-based precursor in the same way as in example 1.
Preparation of LiMn 0.67 Fe 0.33 PO 4 Particles
[0086] The following were prepared under a nitrogen atmosphere:
a solution A, by dissolution of 4.62 g of LiOH.H 2 O in 30 ml of demineralized and degassed water; a solution F, by dissolution of 3.33 g of FeSO 4 .7H 2 O, 4.02 g of MnSO 4 .H 2 O and 4.75 g of (NH 4 ) 2 HPO 4 in 50 ml of demineralized and degassed water.
[0089] Solution A was gradually added to solution F. It was found that the viscosity of the reaction medium increases as solution A is added, and the final pH measured is 10.7. In the reaction medium thus obtained, the Li/Mn/Fe/P ratio is 3/0.66/0.33/1.
[0090] The reaction medium was subsequently poured, under a nitrogen atmosphere, into a PTFE container incorporated in a pressurizable stainless steel chamber (Parr, volume of 325 ml), and the setup was placed in an oven at 220° C. for 7 hours and then cooled to ambient temperature. The precipitated powder was recovered by filtration, washed 3 times with 100 ml of distilled water and then dried in an oven at 90° C. under nitrogen for 12 h.
[0091] 6.2 g of a compound in the form of a powder having a light-gray color were thus obtained. The X-ray diffraction diagram is represented in FIG. 9 . It shows that the compound is a single phase which exhibits an orthorhombic structure.
Deposition of Carbon
[0092] The compound obtained in the preceding stage was introduced into a solution of cellulose acetate in an acetone/isopropanol (1:1) mixture, the acetate/LiMn 0.67 Fe 0.33 PO 4 ratio being 1/7, and then the reaction medium was subjected to a heat treatment under an inert atmosphere comprising a stage of 1 h at 400° C. followed by a stage of 3 h at 600° C. The final material was obtained in the form of a grayish-black powder.
Characterization
[0093] The electrochemical performance of the material obtained was determined in the same way as in example 1.
[0094] FIG. 10 represents the change in the potential as a function of the time. It shows that the capacity of the first charge is 54.5 mAh/g, which is equivalent to a level of lithium extracted from the material x=0.32. The reversible capacity is 55.7 mAh/g.
[0095] FIG. 11 represents the Ragone diagram of the material. It shows that, at a 10 C rate, the capacity delivered is 23.3 mAh/g.
[0096] It is thus apparent that, for materials having a similar global composition, the “particles comprising an LiMnPO 4 nucleus coated with LiFePO 4 ” form gives an electrochemical performance which is markedly superior to that of the “particles of a complex oxide LiFe 1-n Mn n PO 4 ” form, the particles carrying, in both cases, a carbon deposit.
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A positive electrode material, having particles having a complex oxide OC1 core, an at least partial complex oxide OC2 coating, and an adhesive carbon surface deposit. The material is characterized in that the complex oxide OC1 is an oxide having a high energy density and in that the oxide OC2 is an oxide of a metal having a catalytic effect on the reaction of the carbon deposit, the oxide having good electronic conductivity. The presence of the OC2 layer facilitates the deposit of a carbon adhesive layer at the surface of the oxide particles, and improves the conductivity of the material when the latter is used as an electrode material. The electrode material can particularly be used in the manufacture of a lithium battery.
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PRIORITY CLAIMED
This application is a Non-Provisional application including the subject matter and claiming the priority date under 35 U.S.C. §119(e) of Provisional Application Ser. No. 60/607,577, filed Sep. 8, 2004, the contents of which are meant to be incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to analog-to-digital converters and control structures and methods for an analog-to-digital converter.
2. Description of the Related Art
Analog-to-digital (ADC) converters are essential components in today's electronic circuits and systems. ADC converters transform analog signals to digital signals. Conventional delta sigma (ΔΣ) analog-to-digital converters offer high resolution and linearity, high integration, little differential non-linearity, and low cost. Their performance is not limited by mismatched components within the converter, and has low noise sensitivity. Most of the circuitry in delta sigma ADCs is digital; hence the performance of delta sigma ADCs does not drift with time and temperature.
Two basic principles govern the operation of conventional delta sigma ADCs: oversampling and noise shaping. The sampling frequency in a delta sigma ADC is typically chosen to be much larger than the input signal bandwidth. Oversampling spreads the quantization noise power over a bandwidth equal to the sampling frequency. A delta sigma ADC usually contains a delta sigma modulator, a lowpass filter, and a decimator filter. The delta sigma modulator applies a lowpass filter to the input analog signal and a high pass filter to the noise, hence placing most quantization noise energy above the input signal bandwidth. The lowpass filter follows the delta sigma modulator, attenuating out-of-band quantization noise. The decimator filter downsamples the sampled output digital signal to the Nyquist rate.
Since delta sigma ADCs typically operate at an oversampled rate much larger than the maximum input signal bandwidth, their circuitry is complex and their speed is low. Because of speed limitations, delta sigma ADCs perform best in high-resolution, very-low frequency applications.
In order to successfully extend the use of delta sigma ADCs to higher frequency applications, a parallel delta sigma ADC architecture has been proposed. U.S. Pat. No. 5,196,852 by Ian Galton and “ A Nyquist - Rate Delta - Sigma A/D Converter” IEEE Journal of Solid - State Circuits , Vol. 33, No. 1, pp. 45–52 describe parallel delta sigma ADC systems. The system described in U.S. Pat. No. 5,196,852 achieves an effective oversampling ratio of N*M, where N is the oversampling ratio of each delta sigma ADC and M is the number of parallel delta sigma ADC channels. The system described in “ A Nyquist - Rate Delta - Sigma A/D Converter ” achieves an effective oversampling ratio of M without oversampling in the individual delta sigma ADCs, where M is the number of parallel delta sigma ADC channels. However, with the circuits described in above works, the parallel delta sigma ADCs do not self-adapt. Hence, only a limited predetermined range of incoming signal frequencies can be processed.
A disclosed embodiment of the application addresses these and other issues by utilizing a parallel, adaptive delta sigma analog-to-digital converter.
SUMMARY OF THE INVENTION
Embodiments of the present invention are directed to an apparatus for adaptive analog-to-digital conversion. According to a first aspect of the present invention, an apparatus for adaptive analog-to-digital conversion comprises: a frequency modulator unit for changing an input analog signal into a modulated analog signal with a frequency spectrum in a bandwidth of interest; a parallel delta sigma conversion unit operatively connected to the frequency modulator unit, the parallel delta sigma conversion unit converting the modulated analog signal into a digital signal; and a controller operatively connected to the frequency modulator unit and the parallel delta sigma conversion unit, the controller adjusting at least one parameter relating to a frequency characteristic of the frequency modulator unit and/or the parallel delta sigma conversion unit.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects and advantages of the present invention will become apparent upon reading the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram of a parallel, adaptive delta sigma ADC according to an embodiment of the present invention;
FIG. 2A illustrates a frequency modulator unit included in a parallel, adaptive delta sigma ADC according to an embodiment of the present invention;
FIG. 2B illustrates aspects of the operation of a local oscillator and a mixer included in a frequency modulator unit according to an embodiment of the present invention;
FIG. 2C illustrates aspects of the operation of a tunable bandpass filter included in a frequency modulator unit according to an embodiment of the present invention;
FIG. 3 illustrates a delta sigma conversion unit included in a parallel, adaptive delta sigma ADC according to an embodiment of the present invention;
FIG. 4A illustrates a code generator that may be included in a delta sigma conversion unit of a parallel, adaptive delta sigma ADC according to an embodiment of the present invention;
FIG. 4B illustrates a code generator that may be included in a delta sigma conversion unit of a parallel, adaptive delta sigma ADC according to an embodiment of the present invention;
FIG. 4C illustrates a code generator that may be included in a delta sigma conversion unit of a parallel, adaptive delta sigma ADC according to an embodiment of the present invention;
FIG. 5 illustrates a control unit that may be included in a parallel, adaptive delta sigma ADC according to an embodiment of the present invention;
FIG. 6 illustrates aspects of the operation of a control unit that may be included in a parallel, adaptive delta sigma ADC according to an embodiment of the present invention;
FIG. 7 is a flow diagram illustrating operations performed by a frequency modulator unit according to an embodiment of the present invention;
FIG. 8 is a flow diagram illustrating operations performed by a delta sigma conversion unit according to an embodiment of the present invention;
FIG. 9A is a flow diagram illustrating aspects of an exemplary normal mode operation of a control unit included in a parallel, adaptive ADC according to an embodiment of the present invention;
FIG. 9B is a flow diagram illustrating aspects of an exemplary self calibration mode operation of a control unit included in a parallel, adaptive ADC according to an embodiment of the present invention;
FIG. 10 illustrates an exemplary Hadamard code generator included in a delta sigma conversion unit according to an embodiment of the present invention;
FIG. 11 illustrates a continuous time integrator circuit that may be included in a delta sigma ADC according to an embodiment of the present invention;
FIG. 12 illustrates a polarity reversal circuit that may be included in input and output multipliers of a delta sigma conversion unit according to an embodiment of the present invention;
FIG. 13A illustrates an exemplary set of Hadamard codes that may be produced by a Hadamard code generator, according to an embodiment of the present invention;
FIG. 13B illustrates an exemplary set of Hadamard input multiplier sequences that may be used by input multipliers in a delta sigma conversion unit, according to an embodiment of the present invention;
FIG. 13C illustrates an exemplary set of Hadamard output multiplier sequences that may be used by output multipliers in a delta sigma conversion unit, according to an embodiment of the present invention; and
FIG. 14A and FIG. 14B illustrate aspects of the operation for obtaining the output of a signal passed through Hadamard input multipliers and Hadamard output multipliers in a delta sigma conversion unit, according to a particular example of an embodiment of the present invention.
DETAILED DESCRIPTION
Aspects of the invention are more specifically set forth in the accompanying description with reference to the appended figures.
FIG. 1 is a block diagram of a parallel, adaptive delta sigma ADC according to an embodiment of the present invention. The parallel, adaptive delta sigma ADC 100 illustrated in FIG. 1 includes the following components: a frequency modulator unit 20 ; a delta sigma conversion unit 50 ; and a control unit 70 operatively connected as shown. An input analog signal 1 enters the parallel, adaptive delta sigma ADC 100 through frequency modulator unit 20 . Parallel, adaptive delta sigma ADC 100 converts input analog signal 1 to output digital signal 90 . Control unit 70 controls the operation of frequency modulator 20 and delta sigma conversion unit 50 . Delta sigma conversion unit 50 may also communicate with control unit 70 before outputting digital signal 90 . The parallel, adaptive delta sigma ADC 100 may be built for automatic, manual, or selectable automatic/manual control of output digital signal 90 . Operation of the parallel, adaptive delta sigma ADC 100 in FIG. 1 will become apparent from the following discussion.
FIG. 2A illustrates a frequency modulator unit 201 that may be included in a parallel, adaptive delta sigma ADC 100 according to an embodiment of the present invention. Frequency modulator unit 201 contains a tunable bandpass filter 140 operatively connected as shown. Frequency modulator unit 201 may also contain a local oscillator (LO) 110 and a mixer 120 operatively connected as shown. The LO 110 and mixer 120 are needed when input analog signal 1 lies outside the bandwidth accessible to delta sigma conversion unit 50 . For some embodiments, frequency modulator unit 201 may contain a chain of local oscillators 110 . Control unit 70 controls tunable bandpass filter 140 . Control unit 70 may also control local oscillator 110 .
Local oscillator 110 is a semiconductor device or an electronic circuit that generates one or more signals of constant frequency. The frequencies generated by local oscillator 110 are determined by parameters of electronic components inside local oscillator 110 as is known in the art. Mixer 120 is a semiconductor device or electronic circuit that multiplies two signals of different frequencies to obtain a signal of intermediate frequency. A frequency υ LO generated by local oscillator 110 is mixed by mixer 120 with all frequencies contained in input analog signal 1 , producing mixed analog signal 3 . Each frequency υ in present in input analog signal 1 is shifted to two frequencies υ LO −υ in and υ LO +υ in mixed analog signal 3 .
Local oscillator 110 is preferably tunable. This may be accomplished with, for example, a single tunable local oscillator 110 or a chain of tunable local oscillators 110 as is known in the art.
Tunable bandpass filter 140 is a semiconductor device or an electronic circuit that isolates and extracts independent communication channels from the frequency wideband of mixed analog signal 3 , and cuts off frequencies in the frequency wideband of mixed analog signal 3 that are either too high or too low. Tunable bandpass filter 140 may be a transmultiplexer; a spectral subband coder that divides an analog signal into frequency segments, or spectral terms, computed for non-overlapped successive blocks of input data; a collection of single-sideband narrowband filters which perform a complex heterodyne, hence basebanding a selected center frequency; a channelizer with suitable RF switches; an antialias filter; a band pass filter; a lowpass filter; or a bandpass and lowpass filter. The center frequency and/or bandwidth of tunable bandpass filter 140 can be changed manually or automatically, so that the passband of tunable bandpass filter 140 matches the bandwidth of interest of delta sigma conversion unit 50 , hence eliminating aliasing.
FIG. 2B illustrates aspects of the operation of a local oscillator 110 and a mixer 120 that may be included in a frequency modulator unit 201 according to an embodiment of the present invention. In case input analog signal 1 occupies a different frequency band than the frequency band parallel, adaptive delta sigma ADC 100 is designed for, the local oscillator 110 may be tuned such that the input signal is downshifted onto a desired bandwidth range.
In other words, the particular design values and construction of the parallel, adaptive delta sigma ADC 100 result in a device having a particular bandwidth range (bandwidth of interest). The local oscillator 10 may be used to shift the input signal onto the bandwidth range of the ADC 100 . For this purpose, local oscillator 10 may be tuned by control unit 70 to generate a signal of frequency υ LO which is mixed with all frequencies of input analog signal 1 in mixer 120 , producing mixed analog signal 3 . Each frequency υ in present in input analog signal 1 is shifted to two frequencies υ LO −υ in and υ LO +υ in in mixed analog signal 3 as illustrated in FIG. 2B . υ LO is chosen so that either υ LO −υ in or υ LO +υ in is located within the frequency band for which the parallel, adaptive delta sigma ADC 100 is designed.
FIG. 2C illustrates aspects of the operation of a tunable bandpass filter 140 included in a frequency modulator unit 201 according to an embodiment of the present invention. Tunable bandpass filter 140 divides the frequency wideband of mixed analog signal 3 into frequency segments 5 A, 5 B, . . . 5 Y, 5 Z. The number of frequency segments and the width of frequency segments may be tuned by control unit 70 . All frequency segments are then mapped to the lowest frequency segment 5 Z, avoiding aliasing of frequency segments.
FIG. 3 illustrates a delta sigma conversion unit 501 that may be included in a parallel, adaptive delta sigma ADC 100 according to an embodiment of the present invention. Delta sigma conversion unit 501 includes a code generator 150 , N number of delta sigma (ΔΣ) channels 155 1 , 155 2 , . . . 155 N connected in parallel, and an adder 260 operatively connected as shown. Each ΔΣ channel 155 i includes an input multiplier 160 i , a lowpass ΔΣ ADC 180 i , an adaptable digital correction filter 200 i , a programmable decimation filter 220 i , and an output multiplier 240 i , where subscript “i” has values from 1 to N.
A lowpass ΔΣ ADC 180 i is a delta sigma analog-to-digital converter and may be implemented using many possible converter types including low-order single-bit single-loop converter, high-order single-bit single-loop converter, single-bit multiloop (cascaded or MASH) converter and multi-bit (single-loop or multiloop) converter. All lowpass ΔΣ ADCs 180 i (for i from 1 to N) are preferably substantially identical. In one embodiment of the current invention, all lowpass ΔΣ ADC 180 i have the same order, number of bits, and signal delay.
Adaptable digital correction filters 200 i , programmable decimation filters 220 i , and output multipliers 240 i where subscript “i” has values from 1 to N, are conventional digital electronic devices. They can be implemented using a custom ASIC, an off the shelf FIR filter, a field programmable gate array, or a sufficiently fast microprocessor. The filter coefficients for the adaptable digital correction filters 200 i and the programmable decimation filters 220 i , may be stored in a register on the chip that holds the parallel, adaptive delta sigma ADC 100 , or in a separate memory off the chip, connected to a data bus. Adaptable digital correction filters 200 i , programmable decimation filters 220 i , and output multipliers 240 i , where subscript “i” has values from 1 to N, may also be combined into a single filter.
As will be further described below, adaptable digital correction filters 200 i and programmable decimation filters 220 i have programmable filter parameters such as length and bandwidth. Adaptable digital correction filters 200 i correct inaccuracies introduced by lowpass ΔΣ ADCs 180 i where subscript “i” has values from 1 to N, and may be implemented using known techniques.
Programmable decimation filters 220 i are used to down-sample signals and to eliminate out-of-band noise, and may be implemented using known techniques. Code generator 150 generates a set of codes. Input multipliers 160 i and output multipliers 240 i are standard multiplier circuits whose multiplication values are supplied by codes from the set of codes provided by code generator 150 . Adder 260 may be a simple adder circuit that adds its inputs bit-by-bit. Control unit 70 may control code generator 150 , adaptable digital correction filters 200 i , and programmable decimation filters 220 i .
A power splitter 159 simultaneously inputs one of the frequency segments produced by tunable bandpass filter 140 (signal 5 A) to all ΔΣ channels 155 1 , 155 2 , . . . 155 N . The set of codes generated by code generator 150 and applied by multipliers 160 i decomposes signal 5 A into orthonormal components. Along with other types of codes, a set of Hadamard codes or a set of Gold codes can be generated by code generator 150 for orthonormal decomposition of signal 5 A. Each input multiplier 160 i uses one and only one code from the set of codes generated by code generator 150 , to create a multiplication value for its frequency decomposing weighting function. Frequency decomposing weighting functions are orthonormal and channel specific. Inside channel i, signal 5 A is frequency-decomposed by input multiplier 160 i , passed through lowpass ΔΣ ADC 180 i , corrected by adaptable digital correction filter 200 i for inaccuracies gained from lowpass ΔΣ ADC 180 i , down-sampled by programmable decimation filter 220 i which also eliminates quantization noise, and multiplied by output multiplier 240 i which applies a time-shifted version of the frequency decomposing weighting function of input multiplier 160 i , that undoes the frequency decomposing action of input multiplier 160 i .
The outputs from all ΔΣ channels 155 are summed by adder 260 to obtain a digital signal 7 .
If signal 5 A has a frequency spectrum of X GHz, each lowpass ΔΣ ADC 180 i may be clocked at 2× GHz, which is the Nyquist rate of signal 5 A frequency spectrum. Each lowpass ΔΣ ADC 180 i is designed to have a band-pass response of X/N, hence the widest bandwidth signal the N-channel parallel, adaptive delta sigma ADC 100 can digitize is X GHz (N*X/N). The oversampling rate (OSR) of delta sigma conversion unit 501 for the entire frequency band of signal 5 A is 1, since each lowpass ΔΣ ADC 180 i is clocked at the Nyquist rate of signal 5 A frequency spectrum. However, within each ΔΣ channel 155 i the OSR ratio is N, calculated as the ratio of each lowpass ΔΣ ADC 180 i sampling frequency (2×) to the Nyquist frequency of the band-pass response of the channel (2*X/N). Therefore the parallel network of individual ΔΣ channels 155 i has N times larger OSR than a single lowpass ΔΣ ADC 180 i would exhibit.
FIG. 4A illustrates a code generator 150 A that may be included in a delta sigma conversion unit 501 of a parallel, adaptive delta sigma ADC 100 according to an embodiment of the present invention. Code generator 150 A is a code calculator that generates a set of codes in real-time, without any information except the desired length of the set of codes which is supplied by control unit 70 . Each code C i in the set of codes is sent to a pair of input multipliers 160 i and output multipliers 240 i . Input multipliers 160 i and output multipliers 240 i generate multiplication values from the code C i sent to them.
To account for processing times of the ΔΣ ADC 180 i , adaptable digital correction filter 200 i , and programmable decimation filter 220 i , the codes supplied to output multipliers 240 i are preferably time shifted or delayed relative to the input multipliers 160 i . This may be accomplished by, for example, a delay element (not shown), by the code calculator generator 150 A, or by the control unit 70 .
FIG. 4B illustrates a code generator 150 B that may be included in a delta sigma conversion unit 501 of a parallel, adaptive delta sigma ADC 100 according to an embodiment of the present invention. Code generator 150 B includes a memory 146 with registers or memory locations 148 1 , 148 2 , . . . 148 N that contain a set of codes. Code generator 150 B generates a set of output codes C 1 , C 2 . . . C N by direct read from memory registers or memory locations 148 1 , 148 2 , . . . 148 N . The code C i in each register 148 i is directly read into input multiplier 160 i and output multiplier 240 i . Input multipliers 160 i and output multipliers 240 i generate multiplication values from code C i .
FIG. 4C illustrates a code generator 150 C that may be included in a delta sigma conversion unit 501 of a parallel, adaptive delta sigma ADC 100 according to an embodiment of the present invention. Code generator 150 C includes a memory 147 with M sets of registers or memory locations. Each register set “j”, with “j” from 1 to M, contains N individual registers or memory locations 148 1j , 148 2j , . . . 148 Nj . Each register 148 ij stores an internal code H ij . There are N×M internal codes H ij as “i” runs from 1 to N and “j” runs from 1 to M. A switchable lookup table register 143 decides output codes C 1 , C 2 . . . C N by direct read from among all internal codes H ij . Output codes C 1 , C 2 . . . . C N are sent to all N ΔΣ channels 155 1 , 155 2 , . . . 155 N to input multiplier 160 i and output multiplier 240 i where subscript “i” has values from 1 to N. Input multipliers 160 i and output multipliers 240 i generate multiplication values from the code sent to them. Lookup table register 143 may store one lookup table or multiple lookup tables. An example of a lookup table is:
[ H 11 H 21 ⋯ ⋯ H N1 ⋯ ⋯ ⋯ ⋯ ⋯ ⋯ ⋯ ⋯ ⋯ ⋯ H 1 M H 2 M ⋯ ⋯ H NM ] .
This table would be read by direct memory read, switching between rows to select one row for output codes C 1 , C 2 . . . C N .
An example of a multiple lookup table is:
[
H
11
H
11
…
H
11
H
21
H
21
…
H
21
…
…
H
N1
H
N1
…
H
N1
H
12
H
12
…
H
12
H
22
H
22
…
H
22
…
…
H
N2
H
N2
…
H
N2
⋯
⋯
⋯
⋯
⋯
⋯
⋯
⋯
⋯
⋯
⋯
⋯
⋯
⋯
H
1
M
H
1
M
…
H
1
M
H
2
M
H
2
M
…
H
2
M
…
…
H
NM
H
NM
…
H
NM
]
FIG. 5 illustrates a control unit 700 that may be included in a parallel, adaptive delta sigma ADC 100 according to an embodiment of the present invention. Control unit 700 may include the following operational components: a mode control unit 305 ; a bandwidth control unit 300 ; a self calibration unit 320 ; and a DAC 340 . Bandwidth control unit 300 controls code generator 150 , programmable decimation filters 220 1 , . . . 220 N , tunable bandpass filter 140 , and tunable local oscillator 110 . Self calibration unit 320 controls adaptable digital correction filters 200 1 , . . . 200 N and DAC 340 , and communicates with bandwidth control unit 300 .
The parallel, adaptive delta sigma ADC 100 has two modes of operation: a normal operation mode and a self-calibration mode. Mode control unit 305 determines the operation mode of the parallel, adaptive delta sigma ADC 100 .
The parallel, adaptive delta sigma ADC 100 operates in normal operation mode most of the time. In normal operation mode, bandwidth control unit 300 determines the bandwidth of interest using internal algorithms or an external control signal manually or automatically commanded. Bandwidth control unit 300 calculates or looks up the proper code for code generator 150 , and calculates filter coefficients for programmable decimation filters 220 i , where “i” runs from 1 to N. Bandwidth control unit 300 also sets the center frequency and the bandwidth for tunable bandpass filter 140 and tunable local oscillator 110 . After sending commands to code generator 150 , programmable decimation filters 220 i , tunable bandpass filter 140 , and tunable local oscillator 110 , bandwidth control unit 300 remains idle until mode control unit 305 sends a command to change bandwidths again.
In self-calibration mode, self calibration unit 320 takes over bandwidth control unit 300 . Self calibration unit 320 sets filter coefficients for adaptable digital correction filters 200 i to zero, and then instructs bandwidth control unit 300 to set a predetermined calibration bandwidth. Self calibration unit 320 then creates a calibration signal using the built-in DAC 340 . The DAC 340 feeds the calibration signal to tunable bandpass filter 140 as an input. The calibration signal is processed by tunable bandpass filter 140 in the same manner as in normal mode operation. The digital output of the delta sigma conversion unit 501 is fed back to self calibration unit 320 . Self calibration unit 320 calculates a final set of adaptable digital correction filter 200 i coefficients for use when control unit 700 and parallel, adaptive delta sigma ADC 100 return to normal mode operation.
Mode control unit 305 may be a part of control unit 700 . In another embodiment of the invention, mode control unit 305 may be external to the parallel, adaptive delta sigma ADC 100 . The DAC 340 may be any conventional DAC. The DAC 340 function may also be generated by an alternate analog frequency synthesis technique. Mode control unit 305 , bandwidth control unit 300 , and self calibration unit 320 may be implemented using a single field programmable gate array; an ASIC; a microcontroller; a standard microprocessor; or a memory or set of memories.
FIG. 6 illustrates aspects of the operation of a control unit 700 that may be included in a parallel, adaptive delta sigma ADC 100 according to an embodiment of the present invention. Control unit 700 selects ( 902 ) the operation mode of the parallel, adaptive delta sigma ADC 100 .
If the selected operation mode is the normal operation mode ( 904 ), control unit 700 determines ( 905 ) the frequency or frequencies of interest for the parallel, adaptive delta sigma ADC 100 . Next, control unit 700 controls tunable local oscillator 110 by selecting ( 906 ) the frequency of tunable local oscillator 110 ; controls the tunable bandpass filter 140 by selecting the number of desired frequency segments ( 907 ), and/or the bandwidth of frequency segments ( 908 ), and/or the filter bandwidth ( 909 ); determines the length of code ( 910 ) and the type of code ( 911 ) for code generator 150 ; and controls programmable decimation filters 220 1 . . . 220 N by selecting the filters' function ( 912 ), cutoff frequency ( 913 ), and length ( 914 ). In one embodiment of the invention, code calculator generator 150 A directly calculates a code according to a selected code length ( 910 ). In other embodiments of the invention, code generators 150 B and/or 150 C choose an appropriate lookup table and/or lookup table read rate according to the selected code length ( 910 ) and the type of code ( 911 ).
If the selected operation mode is the self-calibration mode ( 903 ), control unit 700 determines a calibration signal ( 915 ) for an appropriate calibration bandwidth, and sends it to DAC 340 . Control unit 700 also controls the adaptable digital correction filters 200 1 , . . . 200 N by calculating ( 916 ) proper filter correction coefficients.
FIG. 7 is a flow diagram illustrating operations performed by a frequency modulator unit 201 according to an embodiment of the present invention. An analog signal 1 ( 481 ) is input into frequency modulator unit 201 . A test is performed ( 482 ) to determine whether input analog signal 1 lies outside the bandwidth accessible by delta sigma conversion unit 501 . If input analog signal 1 lies outside the bandwidth accessible by delta sigma conversion unit 501 , input analog signal 1 frequency is shifted to a frequency accessible to delta sigma conversion unit 501 , using ( 483 ) tunable local oscillator 110 whose frequency is controlled ( 906 ) by control unit 700 . Input analog signal 1 is then filtered ( 484 ) by tunable bandpass filter 140 that is controlled ( 1100 ) by control unit 700 . The output of frequency modulator unit 201 is analog input signal 5 A ( 615 ).
FIG. 8 is a flow diagram illustrating operations performed by a delta sigma conversion unit 501 according to an embodiment of the present invention. Delta sigma conversion unit 501 is designed to convert a bandwidth or set of separate bandwidths present in input analog signal 1 into a digital signal. Analog signal 5 A ( 615 ) output from frequency modulator unit 201 has a continuous low frequency band or an arbitrary set of bandwidths.
Power splitter 159 splits ( 620 ) analog signal 5 A into N identical signal channels. Each signal channel is passed to a ΔΣ channel 155 i , with subscript “i” having values from 1 to N. In each ΔΣ channel 155 i , input multiplier 160 i multiplies ( 830 ) the signal channel by a code from a code set ( 820 ) created by code generator 150 . Power splitter 159 and input multipliers 160 i break the band or bands of interest of analog signal 5 A into many continuous low frequency bands, by decomposing input analog signal 5 A into several subbands in which frequencies of interest are translated bit-by-bit to low frequency in each of the ΔΣ channels 155 i .
Control unit 700 sets ( 750 a ) the type and length of the code set that may be generated by real time calculation ( 824 ) in a code calculator generator 150 A, by direct read ( 822 ) from a memory 150 B containing a lookup table, or by direct read ( 826 ) from a memory with switchable output 150 C containing a group of code sets located in a memory lookup table. The generated code set is sent ( 820 ) to input multipliers 160 i and output multipliers 240 i .
The signal channel in each ΔΣ channel 155 i is then converted ( 832 ) to a digital signal channel by lowpass ΔΣ ADC 180 i . Errors introduced by lowpass ΔΣ ADCs 180 i are compensated ( 834 ) by the adaptable digital correction filters 200 i whose filter correction coefficients are set ( 750 b ) by control unit 700 . Quantization noise is removed ( 836 ) by programmable decimation filters 220 i whose decimation filter coefficients are set ( 750 c ) by control unit 700 .
The digital signal channel in each ΔΣ channel 155 i is demodulated ( 838 ) by output multiplier 240 i and is output from the ΔΣ channel 155 i . The output digital signal channels from all parallel ΔΣ channels 155 i for “i” from 1 to N are added ( 840 ) together by adder 260 . The output ( 842 ) of the adder is digital signal 7 .
For analog input signal 5 A to be accurately digitally reconstructed from the outputs of programmable decimation filters 220 i , the coefficients of programmable decimation filters 220 i are adapted ( 750 c ) by control unit 700 to the specific code ( 820 ) that was generated by code generator 150 . Hence, changing the code ( 820 ) generated by code generator 150 and the coefficients of programmable decimation filters 220 i with “i” from 1 to N, changes the band or bands in analog input signal 5 A that can be processed by delta sigma conversion unit 501 . Therefore, by changing the code generated by code generator 150 and the coefficients for programmable decimation filters 220 i , the parallel, adaptive delta sigma ADC 100 can change bandwidth and dynamic range. One set of codes and programmable decimation filters coefficients may create a wideband low dynamic range modulator, while another set of codes and programmable decimation filters coefficients may create a narrow band, high dynamic range modulator. The parallel ΔΣ channels 155 i may also be split into separate channel groups to create a modulator with separate pass-bands. In this case, separate bands of different bandwidth as well as continuous bands from analog signal 5 A can be processed by the parallel, adaptive delta sigma ADC 100 .
FIG. 9A is a flow diagram illustrating aspects of an exemplary normal operation mode of a control unit 700 included in a parallel, adaptive delta sigma ADC 100 according to an embodiment of the present invention. In a normal operation mode, bandwidth control unit 300 included in control unit 700 sets ( 1200 ) the tunable local oscillator 110 , the tunable bandpass filter 140 , the code generator 150 , and the programmable decimation filters 220 i to proper settings for a frequency band or bands of interest. The frequency band or bands of interest can be selected by bandwidth control unit 300 , or by an external command from an external signal. When signals of interest and consequently bands of interest are unknown, such as in passive listening of signals or in electronic signal warfare, bandwidth control unit 300 selects the frequency band or bands of interest using a self adaptive algorithm. When the input signals are known, such as in a RADAR signal emission, an external signal may direct the bandwidth control unit 300 to a specific frequency band with a desired dynamic range.
An exemplary self adaptive algorithm is presented in FIG. 9A . In one logic flow, the bandwidth control unit 300 sets ( 1202 ) all N parallel ΔΣ channels 155 i of delta sigma conversion unit 501 in use to form a wideband low dynamic range modulator to search for signals. Once a signal is detected ( 1204 ), bandwidth control unit 300 switches ( 1206 ) to a narrow band, high dynamic range configuration, to listen to the identified signal. This logic flow works well for large complex signals. A second logic flow may search for both large and small signals using ( 1208 ) half of the N parallel ΔΣ channels 155 i to form a wideband low dynamic range modulator to search for large signals, and half ( 1210 ) of the N parallel ΔΣ channels 155 i to form a narrow band, high dynamic range modulator to search for small signals. By slowly sweeping the center frequency of the high dynamic range band, bandwidth control unit 300 can locate ( 1212 ) small persistent signals. Once one or more signals of interest have been identified ( 1214 ), the bandwidth control unit 300 can allocate one or more parallel ΔΣ channels 155 i of the delta sigma conversion unit 501 to listen ( 1216 ) to the signals of interest, while using the remaining parallel ΔΣ channels 155 i to search ( 1218 ) for additional signals in other bands.
FIG. 9B is a flow diagram illustrating aspects of an exemplary self-calibration operation mode of a control unit 700 included in a parallel, adaptive delta sigma ADC 100 according to an embodiment of the present invention. In self-calibration mode, the small errors introduced by delta sigma modulators 180 i are quantified. Error quantification is important because it allows for error correction and compensation by adaptable digital correction filters 200 i . One exemplary implementation of error quantification and correction is shown in FIG. 9B , where a known signal is input into the delta sigma conversion unit 501 , and the output of the delta sigma conversion unit 501 is examined to determine introduced errors.
When control unit 700 decides that it is time for a self calibration cycle ( 1230 ) based on some external input or some internal routine, it activates ( 1232 ) the self calibration unit 320 , which instructs the bandwidth control unit 300 to switch ( 1234 ) to a predetermined calibration bandwidth. The bandwidth control unit 300 sets ( 1236 ) the code generator 150 , tunable bandpass filter 140 , and decimation filters 220 i , to the proper settings for the desired bandwidth. The self calibration unit 320 then activates the DAC 340 to produce ( 1238 ) a known calibration signal which is injected ( 1242 ) into the delta sigma conversion unit 501 . The coefficients on the digital correction filters 200 i are all set to zero ( 1240 ) so that no digital correction is performed. The uncorrected digital output signal 7 ( 1244 ) is fed back ( 1246 ) to the self-calibration unit and analyzed to determine what errors ( 1248 ) are introduced by the low pass ΔΣ ADCs 180 i . The self-calibration unit uses this signal to calculate ( 1250 ) a new set of coefficients ( 1254 ) for the adaptable digital correction filters 200 i with “i” from 1 to N.
Optionally, the calibration signal could be reinjected into delta sigma conversion unit 501 ( 1242 ) using the most recent set of adaptable digital correction filters 200 i coefficients. The output is re-measured to determine if errors are within tolerance ( 1249 ). Such errors are primarily nonlinearities and variations in gain from one ΔΣ channels 155 i to another. If the errors are within tolerance, the self calibration is completed ( 1252 ) and the latest found set of coefficients for adaptable digital correction filters 200 i with “i” from 1 to N, are stored to be used ( 1254 ) until the next self calibration cycle. Other variations on the self-calibration routine include calibrating each channel one at a time, and calibrating at various frequencies to eliminate frequency dependent errors.
FIG. 10 illustrates an example of code generator 150 (Hadamard code generator 1500 ) that may be included in a delta sigma conversion unit 501 according to an embodiment of the present invention. The orthogonal set of codes generated by a Hadamard code generator 1500 is used in a preferred embodiment of the current invention. A Hadamard code generator 1500 generates a Hadamard code from a conventional Hadamard matrix. The elements of a Hadamard matrix are 1s and −1s. The size of the Hadamard matrix used by Hadamard code generator 1500 is N×N, where N is the number of ΔΣ channels 155 in delta sigma conversion unit 50 . In order for the Hadamard matrix to exist, N can be a non-negative power of 2, or another number for which Hadamard matrices are known to exist. Such numbers may include all multiples of 4 smaller than 428. For N=1 the Hadamard matrix is H 1 =[1]. For N≧2, Hadamard matrix of order N, H N , is defined recursively as follows:
H N = [ H N / 2 H N / 2 H N / 2 - H N / 2 ] .
The N-by-N Hadamard matrix has the property that H N H N T =NI N where I N is the N-by-N identity matrix. The rows and columns of the Hadamard matrix are mutually orthogonal. The Hadamard codes 151 generated by Hadamard code generator 1500 are the individual rows of the N×N Hadamard matrix. The orthogonal set of codes 151 is sent to input multipliers 160 and to output multipliers 240 .
FIG. 11 illustrates a continuous time integrator circuit 400 that may be included in a ΔΣ ADC 180 i from a delta sigma conversion unit 501 , according to an embodiment of the present invention. An exemplary embodiment of this invention uses a continuous time 4 th order cascade of resonator filters that exhibits high stability. A building block of the filter is a continuous time integrator 400 illustrated in FIG. 8 . A transconductor stage charging a capacitor 440 implements the integrating function. A metal film resistor 420 is used in place of a transconductance element to improve and maintain the high degree of linearity required for high dynamic range performance of ΔΣ ADCs 180 . The schematic in FIG. 11 is a single ended design. A fully differential design such as that shown in FIG. 12 can also be used.
FIG. 12 illustrates a polarity reversal circuit 500 that may be included in input multipliers 160 i and output multipliers 240 i of a delta sigma conversion unit 501 according to an embodiment of the present invention. The polarity reversing circuit 500 reverses the differential input lines 520 and 521 to ΔΣ ADCs 180 at the appropriate times when the +/−1 Hadamard input multiplier sequences 152 and Hadamard output multiplier sequences 153 are applied to signal 5 A. An exemplary implementation of polarity reversal circuit 500 uses current steering bipolar switches 540 in emitter-follower unity gain buffers connected at the input of continuous time integrator circuit 400 of the first resonator in the continuous time 4 th order cascade of resonators filter in ΔΣ ADCs 180 . Bipolar transistors perform well as high-speed current switches and the negative feedback of the emitter-follower buffer configuration maintains circuit linearity. The input lines 560 and 561 labeled H+ and H− in the circuit diagram of FIG. 9 correspond to logical levels of 1 and −1 in a differential Hadamard input multiplier sequence 152 or Hadamard output multiplier sequence 153 . Polarity reversal circuit 500 is used to switch the inputs to the integrator 400 , between input value and inverted input value. Polarity reversal circuit 500 combines input multiplier 160 i with the input stage of its corresponding lowpass ΔΣ ADC 180 i . As a result, input multipliers 160 i do not add additional nonlinearities into the delta sigma conversion unit 501 .
FIGS. 13A , 13 B, 13 C, 14 A and 14 B illustrate a particular, non-limiting example of the invention. In this example, it is assumed that the bandwidth control unit 300 of control unit 700 has decided or has been instructed to form a single broadband modulator using four channels, that is N=4. The four channels cover the entire Nyquist band of the delta sigma conversion unit 501 . The signals at various points in the delta sigma conversion unit 501 are calculated to demonstrate the basic principle of delta sigma analog-to-digital conversion.
FIG. 13A illustrates an exemplary set of Hadamard codes 151 that may be produced by a Hadamard code generator 1500 for number N of ΔΣ channels 155 i in delta sigma conversion unit 501 with N=4, according to an embodiment of the present invention. Since H 1 =[1], it follows that
H 2 = [ H 1 H 1 H 1 - H 1 ] = [ 1 1 1 - 1 ]
and
H 4 = [ H 2 H 2 H 2 - H 2 ] = [ 1 1 1 1 1 - 1 1 - 1 1 1 - 1 - 1 1 - 1 - 1 1 ] .
The Hadamard codes 151 produced by Hadamard code generator 1500 for N=4 are the rows of Hadamard matrix H 4 . Hence the Hadamard codes 151 for N=4 are:
C1=[1 1 1 1] C 2=[1 −1 1 −1] C 3=[1 1 −1 −1] C 4=[1 −1 −1 1].
Hadamard input multiplier sequences 152 are generated from Hadamard codes C 1 , C 2 , C 3 and C 4 for input multipliers 160 . Similarly, Hadamard output multiplier sequences 153 are generated from Hadamard codes C 1 , C 2 , C 3 and C 4 for output multipliers 240 .
FIG. 13B illustrates an exemplary set of Hadamard input multiplier sequences 152 that may be used by input multipliers 160 in a delta sigma conversion unit 501 for number N of ΔΣ channels 155 i in delta sigma conversion unit 501 with N=4, according to an embodiment of the present invention. Hadamard input multiplier sequences 152 z i (n) are obtained from Hadamard codes 151 by the following formula:
z i ( n )= C i [n mod N]
where A mod B is the modulus function that returns the integer remainder value when A is divided by B, and i is the index for each ΔΣ channel 155 in delta sigma conversion unit 50 , i running from 1 to N. Other formulas for obtaining Hadamard input multiplier sequences 152 z i (n) are also possible and various lookup tables may also be used to supply the Hadamard code sequences as described in relation to FIGS. 4B and 4C . The first element in matrices C i has index 0, therefore C i elements have indices from 0 to N−1. When N=4 and signal samples n run from 0 to 15, Hadamard input multiplier sequences 152 for the second ΔΣ channel 155 , i=2, are:
z 2 (0)= C 2 [0 mod 4 ]=C 2 [0]=1 z 2 (4)= z 2 (8)= z 2 (12)= z 2 (0)=1 z 2 (1)= C 2 [1 mod 4 ]=C 2 [1]=−1 z 2 (5)= z 2 (9)= z 2 (13)= z 2 (1)=−1 z 2 (2)= C 2 [2 mod 4 ]=C 2 [2]=1 z 2 (6)= z 2 (10)= z 2 (14)= z 2 (2)=1 z 2 (3)= C 2 [3 mod 4 ]=C 2 [3]=−1 z 2 (7)= z 2 (11)= z 2 (15)= z 2 (3)=−1
Hadamard input multiplier sequences 152 for all N ΔΣ channels 155 when N=4 are shown in FIG. 13B . In each ΔΣ channel 155 i, sample n of signal 5 A is multiplied by z i (n).
FIG. 13C illustrates a set of exemplary Hadamard output multiplier sequences 153 that may be used by output multipliers 240 i in a delta sigma conversion unit 501 , for number N of ΔΣ channels 155 i in delta sigma conversion unit 50 with N=4, according to an embodiment of the present invention. The purpose of Hadamard output multiplier sequences 153 is to undo the frequency decomposing action of Hadamard input multiplier sequences 152 . Within each ΔΣ channel 155 , Hadamard output multiplier sequence 153 t i (n) is a delayed version of Hadamard input multiplier sequence 152 z i (n) to account for processing and signal delays between input multiplier 160 and output multiplier 240 . For the specific case of Hadamard input multiplier sequences 152 in FIG. 13B , a set of Hadamard output multiplier sequences 153 t i (n) that may be used by output multipliers 240 i can be obtained from Hadamard codes 151 by the following formula:
t i ( n )= C i [( n+ 1)mod N )]
When N=4 and signal samples n run from 0 to 15, Hadamard output multiplier sequences 153 for the second ΔΣ channel 155 , i=2, are:
t 2 (0)= C 2 [1 mod 4 ]=C 2 [1]=−1 t 2 (4)= t 2 (8)= t 2 (12)= t 2 (0)=−1 t 2 (1)= C 2 [2 mod 4 ]=C 2 [2]=1 t 2 (5)= t 2 (9)= t 2 (13)= t 2 (1)=1 t 2 (2)= C 2 [3 mod 4 ]=C 2 [3]=−1 t 2 (6)= t 2 (10)= t 2 (14)= t 2 (2)=−1 t 2 (3)= C 2 [4 mod 4 ]=C 2 [0]=1 t 2 (7)= t 2 (11)= t 2 (15)= t 2 (3)=1
Hadamard output multiplier sequences 153 for all ΔΣ channels 155 when N=4 are shown in FIG. 13C . In each ΔΣ channel 155 i, sample n of signal going into output multipliers 240 is multiplied by t i (n).
FIG. 14A illustrates aspects of the operation for obtaining the output of a signal passed through Hadamard input multipliers 160 i and Hadamard output multipliers 240 i in a delta sigma conversion unit 501 , according to a particular example of an embodiment of the present invention. For simplicity, the example uses a chain of Hadamard input multipliers 160 followed by Hadamard output multipliers 240 , without the lowpass ΔΣ ADCs 180 in the middle. The length of identical H(z) digital correction filters 200 is chosen to be 6. The 6 samples from a signal 5 A enter Hadamard input multipliers 160 S 0 =[x[0], x[1], x[2], x[3], x[4], x[5]]. Inside input multipliers 160 , signal S 0 is multiplied by corresponding Hadamard input multipliers sequences 152 labeled as C 1 set, C 2 set, C 3 set, C 4 set in FIG. 13B . Signals S 1 , S 2 , S 3 , S 4 for channels 1 , 2 , 3 and 4 respectively, are output from input multipliers 160 :
S 1 =[x[ 0 ]*z 1 (0), x[ 1 ]*z 1 (1), x[ 2 ]*z 1 (2), x[ 3 ]*z 1 (3), x[ 4 ]*z 1 (4), x[ 5 ]*z 1 (5)]=[ x[ 0 ],x[ 1 ],x[ 2 ],x[ 3 ],x[ 4 ],x[ 5]]; S 2 =[x[ 0 ]*z 2 (0), x[ 1 ]*z 2 (1), x[ 2 ]*z 2 (2), x[ 3 ]*z 2 (3), x[ 4 ]*z 2 (4), x[ 5 ]*z 2 (5)]=[ x[ 0 ],−x[ 1 ],x[ 2 ],−x[ 3 ],x[ 4 ],−x[ 5]];
and so on.
Signals S 1 , S 2 , S 3 and S 4 are sent to digital correction filters 200 or order 6 . Each order 6 digital correction filter 200 is represented by filter functions [h(0),h(1),h(2),h(3),h(4),h(5)]. Signals G 1 , G 2 , G 3 , and G 4 for channels 1 , 2 , 3 and 4 respectively, are output from digital correction filters 200 :
G 1 =h (0) x[ 0 ]+h (1) x[ 1 ]+h (2) x[ 2 ]+h (3) x[ 3 ]+h (4) x[ 4 ]+h (5) x[ 5]; G 2 =h (0) x[ 0 ]−h (1) x[ 1 ]+h (2) x[ 2 ]−h (3) x[ 3 ]+h (4) x[ 4 ]−h (5) x[ 5];
and so on.
Signals G 1 , G 2 , G 3 and G 4 are then input into Hadamard output multipliers 240 where they are each multiplied by the Hadamard output multiplier sequences 153 corresponding to the order of the last sample input into the system, x[5]. The Hadamard output multiplier sequences 153 corresponding to the order of the last sample input into the system are labeled t 1 (5) ,t 2 (5),t 3 (5),t 4 (5) in FIG. 5C . The output obtained from network adder 260 is sum G 1 t 1 (5)+G 2 t 2 (5)+G 3 t 3 (5)+G 4 t 4 (5). As seen in FIG. 14A , the output is 4h(2)x[2].
FIG. 14B illustrates aspects of the operation for obtaining the output of a signal passed through Hadamard input multipliers 160 i and Hadamard output multipliers 240 in a delta sigma conversion unit 501 , according to a particular example of an embodiment of the present invention. The algorithm presented in FIG. 14A is repeated in FIG. 14B for the next time instant when the input is S 0 =[x[1], x[2], x[3], x[4], x[5], x[6]]. Within each channel, signal S 0 is multiplied by corresponding Hadamard input multipliers sequences 152 labeled as D 1 set, D 2 set, D 3 set, D 4 set in FIG. 13B , sent to digital correction filters 200 , multiplied by the Hadamard output multiplier sequences 153 t 1 (6),t 2 (6),t 3 (6),t 4 (6) from FIG. 5C corresponding to the order of the last sample input into the system, x[6], and added back in network adder 260 . The result is 4h(2)x[3]. Therefore the output signal of network adder 260 is simply a delayed and scaled version of the input signal.
The parallel, adaptive delta sigma ADC 100 is compatible with high speed, BiCMOS mixed signal processes, SiGe processes, and monolithic integration, as well as ASIC implementation. The filtering operations inside parallel, adaptive ADC 100 are linear, and therefore can be interchanged and/or combined.
Although detailed embodiments and implementations of the present invention have been described above, it should be apparent that various modifications are possible without departing from the spirit and scope of the present invention.
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An apparatus performs adaptive analog-to-digital conversion. The apparatus according to one embodiment comprises a frequency modulator unit for changing an input analog signal into a modulated analog signal with a frequency spectrum in a bandwidth of interest, a parallel delta sigma conversion unit operatively connected to the frequency modulator unit, the parallel delta sigma conversion unit converting the modulated analog signal into a digital signal, and a controller operatively connected to the frequency modulator unit and the parallel delta sigma conversion unit, the controller adjusting at least one parameter relating to a frequency characteristic of the frequency modulator unit and/or the parallel delta sigma conversion unit.
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BACKGROUND
[0001] A fiber optic cable contains multiple, mutually-isolated, coated glass fibers. Sometimes the fibers in one cable are not identical in each of their diameters to the fibers in a second cable. Different optical fibers that meet different performance standards may not be identically manufactured which may result in slightly different optical fiber diameters. Different standard specifications for optical fibers are published by the International Telecommunication Union—Telecommunication Standardization Sector (ITU-T). These specifications vary from the ITU-T G.652 specification to the ITU-T G.657 specification, with some eighteen or more specifications or sub-specifications in between which may result in optical fiber diameter variations.
[0002] A mismatch in diameter between two optical fibers, for any reason, can result in significant insertion loss (signal loss) at a splice junction between the two optical fibers if their cross-sections at the splice junction do not optimally overlap. Even small variations in diameters on the order of 10% can be problematic. Consequently, when splicing optical fibers with different diameters, for example, by technicians working on a fiber optic cable installation at a construction site of a multi-dwelling unit (MDU), the technicians try to align the fibers optimally to mitigate insertion loss at the splice junction.
[0003] Different splicing techniques offer different alignment capabilities. For example, a fusion splicer can make use of photonics for alignment purposes, and thereby achieve a mode-field diameter alignment, a fiber-core alignment or a fiber cladding alignment, each of which probably provides a better overlap between the spliced optical fibers' cross sections as compared with the overlap achievable by a mechanical splicer. The mechanical splicer generally can not align two fibers as well as a fusion splicer because it is limited to geometrical/mechanical alignment constraints only.
[0004] But, a mechanical splicing technique has advantages; it is much less costly and easier to use than a fusion splicing technique. The latter requires a relatively expensive splicing instrument, access to electrical power which is sometimes not readily available during initial phases of building construction, more highly trained technicians, and more money for repairs if the fusion splicer is dropped or otherwise damaged during use. In a cable installation for a multi-dwelling unit (MDU) such as a large apartment building, the large number of required splices makes fusion splicing cost prohibitive. For that reason, and because of the other factors noted above, it would be preferable to use mechanical splicing, provided that misalignments resulting from mechanical splicing of optical fibers with unequal diameters could be mitigated.
[0005] There are different kinds of mechanical splicers, but a current widespread design uses a “V” groove as a channel to hold two optical fibers to be spliced together. The walls of the V groove are flat, and a cover pressing down on top of the open V channel presses against at least the larger of two unequally-diametered fibers. Because of geometry and gravitational force, the smaller diameter optical fiber is displaced downward in the direction of the bottom of the V channel, relative to the supported location of the larger diameter fiber. Thus, there is non-concentric overlap between the cross-sections of these two fibers at their splice junction, as a function of diameter difference. A portion of the cross-section of the smaller fiber hangs below the bottom of the cross-section of the larger fiber, or if the portable splicer is momentarily rotated by the technician on the job site for whatever reason, where either of the normally-up corners of the V-channel is momentarily located in a down position, a like portion of the cross-section of the smaller fiber could then protrude beyond the periphery of the larger fiber in the direction of that momentarily down corner.
[0006] Applicant provides an improvement to this V groove mechanical splice design by moving the cross-sections towards concentricity and thereby achieving increased cross sectional overlap and reduced insertion loss. Insertion loss has been reduced by as much as 0.1 dB-0.2 dB from use of Applicant's improvement, which shall be appreciated as being significant by those of skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is an exemplary end-view schematic diagram of a prior art V-groove mechanical splicer;
[0008] FIG. 2 is an exemplary end-view schematic diagram of apparatus configured in accordance with principles of the present invention;
[0009] FIG. 3 is an enlarged end view of a portion of FIG. 1 showing two optical fibers having dramatically different diameters for illustrative purposes;
[0010] FIG. 4 is an enlarged end view of a portion of FIG. 2 showing two optical fibers with diameters equal to those in FIG. 3 , for comparison purposes;
[0011] FIG. 5 is an exemplary schematic diagram depicting a longitudinal view of two optical fibers with unequal diameters as they might be supported by apparatus of FIG. 1 ; and,
[0012] FIG. 6 is an exemplary schematic diagram depicting a longitudinal view of the two optical fibers of FIG. 5 as they might be supported by apparatus of FIG. 2 ; and
[0013] FIG. 7 is an exemplary end view schematic diagram of an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0014] In this description, the same reference numeral in different Figs. refers to the same entity. Otherwise, reference numerals of each Fig. start with the same number as the number of that Fig. For example, FIG. 3 has numerals in the “300” category and FIG. 4 has numerals in the “400” category, etc.
[0015] In overview, a V-groove mechanical splicer for splicing optical fibers relies entirely on mechanical constraints to hold the optical fibers in place during the splicing operation. Before the actual splicing takes place, the coated optical fibers need to be properly stripped, cleaned and cleaved which is standard procedure. Cleaving is performed in an optical fiber cleaver, which cuts the ends of the optical fibers in a manner that provides flat and smooth end glass surfaces. These surfaces are either orthogonal to their respective longitudinal axes or are angled at other than 90 degrees to their respective longitudinal axes such as, e.g., 8 degrees, and perfectly mated to each other via alignment and/or keying techniques. An optical gel material that matches the optical properties of the glass of the fibers is used at the splice junction to reduce optical signal reflection and enhance optical transmission.
[0016] After preparation of the fibers as described above, embodiments of the present invention can be used. These embodiments include apparatus utilized by qualified technicians for splicing together two optical fibers of equal or unequal diameters. The apparatus has a closed splice-junction support channel. The closed channel is configured with three curved, concave surfaces which, if the optical fiber diameters are unequal, together hold or grip at least the larger of the two optical fibers therein. The three concave surfaces are utilized to increase overlap between cross-sections of the two optical fibers at their splice junction with concomitant reduction of insertion loss generated by the splice junction. This improved alignment between the two optical fibers at their splice junction results from usage of embodiments of the present invention to cause relative radial displacement of the two optical fibers in a direction towards a state of optical fiber concentricity or coaxiality. (If two optical fibers have equal diameters they would be likely to achieve actual concentricity or coaxiality when spliced together.)
[0017] This increase in overlap is measured with respect to results obtained from similar apparatus also having a closed splice junction support channel, but configured with three standard flat surfaces. The improved curvilinear, or arcuate, surfaces in embodiments of the present invention inherently and mechanically increase cross-sectional overlap and reduce signal loss at the splice interface as compared with results obtained from apparatus having optical fiber holding channels configured from flat surfaces.
[0018] The closed channel of a preferred embodiment of the present invention is configured from two curved restraining walls formed in the body of the mechanical splicer, and a curved cover (i.e., a curved ceiling). Instead of a curved cover, an arc formed within a portion of the cover (a “cover arc”) can be used. The cover is hinged from the body of the splicer and closes upon, or towards, the body of the splicer from which the two curved restraining walls are formed. The two curved restraining walls have substantially equal radii of curvature and meet together at one of their ends to form a linear channel. The channel's curvature, as viewed from inside the channel, is concave—the channel has concave walls for supporting two separate optical fibers therein. The channel is closed when either the curved cover or the cover arc, both also concave as viewed from inside the channel, and hinged at one end of the cover from the splicer body or chassis, is locked into its closed position. The cover or the cover arc has a radius of curvature that is equal to the radii of curvature of the walls. The cover or the cover arc is configured to firmly hold both inserted fibers having identical diameters, or the one of the two inserted fibers having the larger of the two unequal diameters, within concave constraints of both the channel and the cover or the cover arc when the cover is locked closed.
[0019] The radii of curvature of the walls and ceiling cover are equal to each other and are approximately two to three times the radius of curvature of the enveloped optical fibers, but these are not absolute limits and other radii of curvature of the walls and ceiling, larger or smaller, can be used. The body or chassis of the mechanical splicer of the preferred embodiments, including the walls and cover, is made from hard and inflexible material but not as hard as the glass which it envelopes. That material should be softer than the glass to avoid damaging the glass in the event that the glass happens to be larger than the space in the closed channel. For example, the body or chassis of embodiments of the present invention can be configured from metal such as aluminum and/or hard plastic.
[0020] FIG. 1 is an end view of prior art V-groove mechanical splicing apparatus 100 , showing various detail in schematic format. Body or chassis 101 has a V-groove or channel formed in it by flat side walls 102 and 103 which are shown on edge and which meet together at a line shown on end and representing channel bottom 109 . Cylindrically-shaped optical fiber 104 is shown on end as a circle resting in the V-groove. Another optical fiber to which optical fiber 104 shall be spliced also lies in the groove, hidden behind optical fiber 104 and is not shown in this Fig. The other optical fiber is also circular in cross-section and is equal in diameter to the diameter of optical fiber 104 . If the other optical fiber, not shown, were smaller in diameter than optical fiber 104 , a portion of it would have been visible below the bottom of optical fiber 104 . This shall be explained in detail in connection with FIGS. 3 and 4 .
[0021] Cover 105 is shown connected to body 101 by way of hinging mechanism 106 at the left hand side of the apparatus. Cover 105 has a flat inner surface 107 shown on edge in FIG. 1 . When cover 105 is rotated clockwise into a closed position via hinge 106 , flat surface 107 closes down upon optical glass fiber 104 . Cover 105 is held in place by way of hinge 106 at its left in cooperation with resilient clamping or locking means 108 shown at its right which can be made from metal such as spring steel.
[0022] In clamp 108 , control ends 112 and 113 are separated from each other by support brace 116 and can be squeezed together in directions 114 and 115 to open the mouth of the clamp. Depressions 111 a and 111 b , formed in the clamp, interlock with lip 110 a on the end of the top of cover 105 and lip 110 b on the end of the bottom of body 101 , respectively, when the control ends are released. The reverse procedure is performed to remove the clamp.
[0023] When cover 105 is locked closed, optical fiber 104 and the other optical fiber, not shown, are held in a closed, longitudinally-linear channel comprised of three flat walls 102 , 103 and 107 . Physical contact between the cylindrical surfaces of the two optical glass fibers and the three flat surfaces of the closed linear channel is made along three straight lines (not shown), each being parallel to the axes of rotation of the fibers, the lines being substantially equidistant from each other. The end view of that closed linear channel would appear as an equilateral triangle, or substantially close thereto. Apparatus designed in accordance with this principle of operation is commercially available. For example, 3M Company, Senko Co., Ltd and Corning Incorporated are three sources of commercially-available flat V groove alignment splicer models.
[0024] FIG. 2 is an exemplary end-view schematic diagram of apparatus 200 configured in accordance with principles of the present invention. Body or chassis 201 has a concave channel formed in it by curved side walls 202 and 203 having identical radii of curvature. The side walls are shown on edge and meet together at a line shown on end and representing channel bottom 208 . Cylindrically-shaped optical fiber 204 is shown on end as a circle resting in the concave channel. Another optical fiber to which optical fiber 204 shall be spliced also lies in the groove, hidden behind optical fiber 204 and is not shown in this Fig. The other optical fiber is also circular in cross-section and is equal in diameter to the diameter of optical fiber 204 . If the other optical fiber, not shown, were smaller in diameter than optical fiber 204 , a portion of it would have been visible below the bottom of optical fiber 204 . This shall be explained in detail in connection with FIGS. 3 and 4 .
[0025] Cover 205 is shown connected to body 201 by way of hinging mechanism 206 at the left hand side of the apparatus. Cover 205 has a curved inner surface or cover arc 207 having the same radius of curvature as those of side walls 202 and 203 , and is shown on edge in FIG. 2 . When cover 205 is rotated clockwise into a closed position via hinge 206 , curved surface 207 closes down upon optical glass fiber 204 . Cover 205 is held in place by way of hinge 206 at its left in cooperation with a clamping or locking means not shown in this Fig. to enhance clarity of presentation, but which is similar to clamping mechanism 108 shown in FIG. 1 . When cover 205 is locked closed, optical fiber 204 and the other optical fiber, not shown, are held in a closed, longitudinally-linear channel comprised of three concave walls 202 , 203 and 207 . Physical contact between the outer surfaces of the two optical glass fibers and the three curved surfaces of the closed linear channel is made along three straight lines (not shown), each being parallel to the axes of rotation of the Fibers. Because the radii of curvature of the two side walls and the radii of curvature of the cover arc are substantially the same, the lines of contact between the glass fibers and the curved walls are substantially equidistant from each other. The gap between the lower surface of cover 205 associated with cover arc 207 and the upper surface of body 201 can be larger or smaller than the gap shown; the actual gap distance is a function of diameter, or radius, of optical fiber 204 relative to radius of curvature of 202 , 203 and 207 .
[0026] The end view of that closed linear channel appears as three equal arc lengths of circular geometry. That end view would approach that of an equilateral triangle, having sixty degrees per angle, as the radius of curvature of each of those arcs was simultaneously increased, in a mathematical limit sense, to a distance of infinity. In a preferred embodiment, the radius of curvature of the three circular arcs is the same and fixed at approximately two to three times the radius of curvature of the encapsulated optical fiber, although larger and smaller radii of curvature can be used.
[0027] FIG. 3 is an enlarged end view 300 of a portion of FIG. 1 . However, instead of depicting two optical fibers having the same radius or diameter with one optical fiber hidden behind the other as presented in FIG. 1 , FIG. 3 shows two optical fibers 104 and 302 having dramatically different diameters. This diameter difference is greater than that which is expected to occur in actual practice, but is presented herein, along with FIG. 4 , to clearly illustrate the principle of operation of the present invention as well as the advantages of the present embodiment over the prior art embodiment.
[0028] FIG. 3 shows end views of flat surfaces 102 and 103 as depicted in FIG. 1 and also shows an end view of optical fiber 104 as it rests in the V groove upon side walls 102 and 103 . Cover 105 ( FIG. 1 ) is assumed to be in a closed position wherefore the end view of flat surface 107 is a straight and horizontal line, as shown, tangent to the top-most location of optical fiber 104 . Significantly, smaller-diameter optical fiber 301 , shown on end, is located in the V-groove and is partially visible. The cross-hatched area 302 represents the effective splice junction overlap between the two optical fibers. Although this may not be a realistic fiberoptic match-up, it can be seen that with the dramatically different diameters depicted, cross-hatched area 302 is less than half of the cross-sectional area of optical fiber 301 . In the mis-matched optical fiber circumstance shown, there would be substantial insertion loss at the splice junction of these two optical fibers.
[0029] FIG. 4 is an enlarged end view 400 of a portion of FIG. 2 showing two optical fibers with diameters equal to those of the optical fibers in FIG. 3 , for comparison purposes. FIG. 4 shows end views of curved surfaces 202 and 203 as depicted in FIG. 2 and also shows an end view of optical fiber 204 as it rests in the concave channel upon side walls 202 and 203 . Cover 205 ( FIG. 2 ) is assumed to be in a closed position wherefore the end view of curved surface 207 is a curved line, as shown, tangent to the top-most location of optical fiber 204 . The radii of curvature of surfaces 202 , 203 and 207 are all equal to each other and, in FIG. 4 , each is depicted as being three times the radius of curvature of optical fiber 204 . Although the radii of curvature are the same in a particular embodiment of the present invention, they need not be limited to a thrice constraint relative to the optical fiber being spliced, and the same larger, or smaller, radii of curvature for each of surfaces 202 , 203 and 207 can be used and are intended to be covered by the appended claims.
[0030] Smaller-diameter optical fiber 401 , shown on end and equal in diameter to optical fiber 301 of FIG. 3 , is resting in the concave channel formed by walls 202 and 203 and is, again, partially visible but, significantly, is less partially-visible than in FIG. 3 . The cross-hatched area 402 represents the effective splice junction overlap between the two optical fibers and this means that there is more overlap depicted in FIG. 4 than in FIG. 3 . It further appears that cross-hatched area 402 is more than half of the cross-sectional area of optical fiber 401 as compared with that of FIG. 3 which was less than half of the cross-sectional area of same-sized optical fiber 301 . It further appears that the cross-hatched area in FIG. 4 is approximately twice as large as that of FIG. 3 . Although there would still be some insertion loss at the splice junction of these two optical fibers in FIG. 4 , such loss would be much less than that depicted in FIG. 3 .
[0031] Thus, when any two optical fibers of different diameter are mechanically spliced in an embodiment of the present invention, there would always be less insertion loss at that splice junction as compared with the loss at a splice junction of those same two fibers as created by a prior art mechanical V-groove splicer.
[0032] FIG. 5 is an exemplary schematic diagram depicting a longitudinal view 500 of two optical fibers 104 and 501 with unequal diameters as they might be supported by apparatus of prior art FIG. 1 . These diameters are closer in size to each other than those shown in FIGS. 3 and 4 . The splice junction overlap is shown by dimension L 1 , and gel 502 is shown between the two optical fibers. The dimensions of gel thickness and optical fiber diameter are not necessarily in realistic proportions, but are depicted as such to enhance clarity of presentation.
[0033] FIG. 6 is an exemplary schematic diagram depicting a longitudinal view of the two optical fibers having the same size as those of FIG. 5 as they might be supported by apparatus of FIG. 2 . Optical fiber 204 has the same diameter as optical fiber 104 ; optical fiber 601 has the same diameter as optical fiber 501 ; gel 602 is used. The overlap is shown by dimension L 2 . L 2 is larger than L 1 . The dimensions of gel thickness and optical fiber diameter are again not necessarily in realistic proportions, but are depicted as such to enhance clarity of presentation.
[0034] In the preceding specification, various preferred embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow.
[0035] For example, FIG. 7 depicts an alternative embodiment 700 of the present invention. FIG. 7 is similar to FIG. 2 with the exception of the design of cover 702 . Splicer body 701 has equally curved walls 703 and 704 formed therein, similar to side walls 202 and 203 , respectively, in FIG. 2 . But, rather than having an inner surface 207 formed in cover 205 , that inner surface having the same radius of curvature (and virtually the same arc length) as those of side walls 202 and 203 as shown in FIG. 2 , FIG. 7 shows an extended curved ceiling 705 or a continuously curved inner cover ceiling 705 . That continuous curve runs from near the hinge at the left hand side of cover 702 to near the end of the cover at the right hand side of cover 702 . The curvature of the curved inner cover ceiling 705 is the same as the curvature of the arcs 703 and 704 .
[0036] The purpose of the alternative embodiment is to accommodate small variations in dimensions resulting from variations in the manufacturing process, when fabricating the embodiments of the present invention. The splicer body and cover can be stamped from aluminum, where the location and configuration of walls 202 / 203 or 703 / 704 in the body is precisely repeatable, but there could be some variation in cover/body alignment when the cover closes upon the splicer body. That is, the embodiment configured in accordance with FIG. 2 requires manufacturing techniques offering virtually perfect repeatability from manufactured unit to unit, in terms of all three of the splicer's arc and linear dimensions and in terms of hinge action. Without that level of repeatability, an end of arc 207 in cover 205 of FIG. 2 making unwanted contact with glass fiber 204 might cause an unwanted displacement of the glass fiber. The cover 205 must mate virtually perfectly and, if linearly offset relative to body 201 , the otherwise achievable optimum alignment cannot be achieved.
[0037] But, in the alternative embodiment, with a continuous arcuate inner cover ceiling 705 , similar slight displacements or similar slight variations in tolerance will be mitigated because the arc is continuous and without an end point in the vicinity of optical fiber 706 . If the cover is displaced slightly from optimum setting, the cover still presents virtually the same arc to the optical fiber that is encapsulated. Clamp 108 in FIG. 7 operates with respect to this embodiment as described above with respect to FIG. 1 . As with FIG. 2 , the gap between the lower surface 705 of cover 702 and the upper surface of body 701 can be larger or smaller than the gap shown; the actual gap distance is a function of diameter, or radius, of optical fiber 706 relative to radius of curvature of 703 , 704 and 705 .
[0038] The present invention is thus not to be interpreted as being limited to particular embodiments and the specification and drawings are to be regarded in an illustrative rather than restrictive sense.
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Apparatus and methodology for mechanically splicing two optical fibers of equal or different diameters. Instead of flat V-groove structure for holding the optical fibers to be spliced, embodiments of the present invention use a concave-walled channel to better align two optical fibers if they have different diameters. The cover holding the fibers in place in the concave channel is similarly curved. The improved alignment results in more area overlap between end surfaces of the two optical fibers to be spliced. This reduces insertion loss by 0.1 dB or better, at the splice junction and, therefore, improves light signal transmission. The radius of curvature of the concave structure can be approximately two to three times the radius of the optical fibers being spliced.
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Related Application
This application is a continuation-in-part of U.S. patent application Ser. No. 07/764,590, filed Sep. 24, 1991, entitled High Capacity, Low Profile Disk Drive System, which is incorporated herein by reference, now abandoned.
FIELD OF THE INVENTION
This application relates to disk drives generally, and particularly relates to docking modules for removable disk drives.
BACKGROUND OF THE INVENTION
Mass storage requirements for computers have matured substantially since the introduction of the personal computer. In the current computing environment, whether for large systems or personal computers, typical requirements for mass storage devices are in the hundreds of megabytes to several gigabytes. In conjunction with such mass storage requirements are the data security issues which require that these large mass storage devices be backed up in one way or another to ensure that there is minimal loss of data even in the event of a system failure.
There are several ways to achieve these goals. A conventional approach for the mass storage device is one or more fixed disk drives permanently mounted within a chassis. A typical approach for data backup is a tape drive providing archival storage. In some high end systems, such as file servers, it is known to provide mirrored drives, in which a two functionally identical drives are installed with one drive serving as the backup to the other drive. In many such systems, a tape backup is also provided to provide archival storage.
There are a number of difficulties with these approaches to mass storage and backup devices. One difficulty with permanently installed drives is that, in the event of a failure, the entire system must be taken down to replace the drive; even if the system includes mirrored drives, it is generally not recommended to disconnect a permanently installed drive while the system is powered up. Part of the problem relates to the fact that the drives are installed within the cabinet, and are not readily accessible without substantial disassembly of the system.
A second difficulty involves the availability of multiple drive bays for a system. In a conventional system, the number of drive bays available for mass storage devices can be fairly limited. While oversized cabinets have been built to accommodate the desire for multiple, large drives, the trend toward smaller, more compact systems is at odds with the desire for large storage capacities.
A third difficulty with permanently installed drives is that the capacity is limited to a specific number of megabytes. Even if a large capacity is initially provided, a truism in the industry is that capacity will eventually be reached.
A fourth difficulty relates to problems with conventional archival storage devices. Tape backups generally provide inexpensive but slow data storage, where data retrieval times are measured in minutes rather than milliseconds. While this delay is not necessarily bad in every instance, it is certainly undesirable in many applications. In addition, the accuracy of tape as a media is frequently in question.
Finally, a fifth difficulty relates to portability of the data. Permanently installed drives offer little portability, and a failure of another component in the system using exclusively permanently installed drives renders the entire system useless and the data inaccessible. While tape drives offer some solution to this problem, the effort in reinstalling a significant amount of software from tape onto a machine not the source of that data frequently makes the process so slow and inefficient as to be unworkable.
Removable media drives are known in the industry, and offer some limited success in overcoming a few of the foregoing limitations of conventional prior art systems. For example, SyQuest Technology offers cartridge drives in which the media can be removed from the remainder of the drive. While this approach does offer the ability to expand the capacity of a drive, the media in a SyQuest cartridge is readily exposed to the environment and can easily become contaminated from such exposure, rendering the cartridge useless. In addition, Bernoulli drives offer removable media, but suffer from slow access time and limited reliability. In addition, none of these devices can be readily hot swapped, and each of them has, historically, taken up at least a half-height drive bay for a single device. Importantly, the limited storage capacity of these devices makes them unsatisfactory as a primary drive or, in at least a number of cases, a backup device.
The assignee of the present invention has, in the past, offered a solution to some, but not all, of the foregoing limitations of the prior art. The aforementioned U.S. patent application Ser. No. 07/764,590, filed Sep. 24, 1991, discloses a removable disk drive of sufficient capacity to be installed as either a primary drive, a secondary drive, or a backup device. Moreover, the unit offers relatively fast access times, unlimited expansion of total capacity through the use of multiple cartridges, and shirt pocket portability. However, the device disclosed there did not include means for hot swapping of drives; that is, exchanging drives while the system is still operating without loss of data, and also provides only a single cartridge per half-height bay. In addition, while the docking module provided there operates well for many users, a method for simply ensuring that the drive is fully installed or disconnected is desirable.
As a result, there has been a need for a removable cartridge drive which improves upon the foregoing limitations of the prior art.
Summary of the Invention
The present invention substantially eliminates, or at the very least improves upon, each of the foregoing limitations of the prior art. The present invention is a docking module which cooperates with the disk drive disclosed in U.S. patent application Ser. No. 07/764,590, mentioned above, to provide a disk drive subsystem with hot swappability, multiple drives in a single half-height bay, and a means for positive insertion and removal of the drive.
In particular, the drive docking module of the present invention, in a first embodiment, provides a half-height structure having two drive bays, each capable of receiving a disk drive constructed in accordance with the '590 application noted above. In addition, a tri-state bus arrangement is provided so that either or both of the dual drives can be added to the system or removed from the system without requiring the rest of the system to be shut down.
Further, a positive insertion and removal structure is provided for ensuring that the drives are fully and correctly inserted and for simplifying the removal of a drive from the module. The insertion and removal structure cooperates with the electronics to assist in providing the hot swappability mentioned above, by causing power to the disconnected to the drive before the drive is actually disconnected from the backplane connector of the drive module.
In other embodiments of the present invention, various arrangements are shown in which a number of drives can be inserted into a docking module constructed in accordance with the present invention. In particular, these other arrangements allow for two such drives per half-height bay, but are several such bays high, allowing for as many as ten or more such disk drives within a single docking module. These configurations are particularly suited to RAID applications.
It is therefore one object of the present invention to provide a docking module which provides hot swappability of a disk drive within a computer system.
It is another object of the present invention to provide a docking module having the capacity for multiple thin disk drives within the space of a half-height bay.
It is a further object of the present invention to provide a docking module capable of supporting a plurality of disk drives at a density of at least two drives per half-height bay.
It is a still further object of the present invention to provide a means for positive insertion and removal of a disk drive from a bay within a docking module.
These and other objects of the present invention may be better appreciated by the following Detailed Description of the Invention, taken together with the attached Figures.
FIGURES
FIG. 1 shows in perspective view a two drive docking module in accordance with the present invention.
FIG. 2 shows in exploded perspective view the two drive docking module of FIG. 1.
FIGS. 3A and 3B show in top plan view the docking module of FIGS. 1 and 2, and in particular shows the relationship between the door and the slide in the open and closed positions, respectively.
FIG. 4 shows in cross-sectional side view the docking module of FIGS. 1-3 taken along line 4--4 of FIG. 3B.
FIG. 5 shows in detail view the relationship between the end of the slide, the disk drive and the optical switch.
FIGS. 6A-6F shows in schematic block diagram form the circuitry for providing hot swappability of the drive of FIG. 1.
FIGS. 7A-7B show an alternative embodiment of a docking module for use with five drives.
FIG. 8 shows an alternative embodiment of a docking module for use with ten drives.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2, a half-height docking module 10, designed to be installed within a housing such as a computer chassis or an external housing (not shown), includes a pair of doors 20A-B in a bezel 30. When either door 20 is opened a slot 40 suitable for receiving a disk drive 50 constructed in accordance with U.S. patent application Ser. No. 07,764,590, filed Sep. 24, 1991 and commonly assigned with the present application, is exposed. The drive 50 is inserted through the door into a pair of guides 60A and 60B, which are supported by a housing 70 enclosed at the top by a cover 72. The housing 70 supports, at the back thereof, a printed circuit board 80. The guides 60A-B extend from the door 20 to the printed circuit board 80, on which are connectors 90A-B designed to mate with a connector 92 on the abutting part of the drive 50 to provide power to the drive and communications between the PCB 80, a conventional host system (not shown) and the drive 50.
Each of the doors 20A-B connects to an associated slide 100 by means of a link 110, held in place by pins 112. The slide 100 in turn moves within a slot 120 in the left guide 60A. A tab 122, positioned slightly near but not quite at the end of the slide 100, extends out from the slide sufficiently to engage the drive 50 when the associated door 20 is opened, as will be appreciated in greater detail hereinafter. A lock 124 may be provided to engage a tab on the doors 20 to prevent unauthorized removal of the drives 50.
As best seen from FIG. 2, the printed circuit board 80 may be better appreciated. In addition to the connectors 90A-B, an optical switch 130 comprised of an LED/photosensor pair may be seen near the end each of the slides 100. When the door 20 is fully closed and a drive 50 is fully installed within the docking module 10, the back end 140 of the slide 100 will extend between the LED and its associate photosensor. As will be appreciated hereinafter in connection with FIGS. 5 and 6, the optical switch 130 is actuated by a slight forward movement of the slide 100 caused by the initial opening of the door, and before the tab 122 engages the drive 50 sufficiently to cause the connector on the back of the drive 50 to be disconnected from the connector 90 on the PCB 80. In this manner the drive 50 may be electrically disconnected from the host system bus prior to any physical disconnection.
Similarly, it will be appreciated that, when the drive 50 is inserted through the slot 40 and into the guides 60A-B, pushing on the door 20 gently forces the drive 50 into the connector 90 on the PCB 80. Momentarily after that connection is made, continued movement of the door 20 causes the end of the slide 100 to be inserted between the LED and photosensor of the optical switch 130. This, in turn, allows the host system to recognize the installation of the drive 50. It will be appreciated that, when the drive is fully installed in the preferred embodiment, the door closes and no components protrude beyond the doors.
Referring next to FIGS. 3A-B and 4, which show, respectively, the top plan view of the docking module 10 and a cross-sectional side view thereof taken along lines 4--4 in FIG. 3B, the arrangement of the drive 50 within the docking module 10 may be better appreciated. In particular, the upper door 20A is shown partially open with the associated slide 100 moved forward so that the tab 120 engages the associated drive 50 and causes it to be disconnected from the PCB 80 at connector 90. In contrast, lower door 20B is shown fully closed with its associated drive 50 fully installed and a connector 92 on the drive 50 mated with the connector 90, and its associated slide 100 fully extended into the opening in optical switch 130.
With particular reference to FIGS. 3A-B, the camming operation of the door 20 with the slide 100 may be better appreciated. The end of the door 20 to which the slide is connected may be seen to include a cam surface 102, where the pin 112 connects to one end of the link 110. A second pin 104 may be seen to connect the other end of the link 110 to the slide 100. A third pin 106 connects the end of the cam surface 102 to the bezel 30, so that rotation of the door 20 about the pin 106 causes the slide to be pushed back or pulled forward. A protrusion 108 on the back surface of door 20 provides pressure against the drive 50 to urge the drive into the connector 92.
By appropriate configuration of the cam surface 102, the protrusion 108 and the door 20, a significant mechanical advantage can be provided for urging the connector 92 on the disk drive 50 into a mating position with the connector 90 on the PCB 80. Likewise, the tab 122 on the end of the slide 100 cooperates with the door 20 and the cam surface 102 to provide a mechanical advantage in ejecting the drive from the connector 90.
In a presently preferred embodiment a mechanical advantage of approximately 10:1 is provided. This allows use of a connectors 90 and 92 with a relatively high retentive force while at the same time providing the user with relatively easy insertion and removal.
With reference next to FIG. 5, the cooperation of the slide 100 with the optical switch 130 and drive 50 may be better appreciated. In FIG. 5, slide 100 is shown with tab 122 juxtaposed against the back edge of drive 50 with connector 92 inserted into connector 90A, while slide end 140 has not yet engaged optical switch 130. The importance of this feature will be better appreciated in connection with FIG. 6, but it is important at this point to recognize that, on insertion of the drive, electrical contact is made at connector 90A, which supplies power and data signals to the drive 50, prior to actuation of optical switch 130. Similarly, on drive removal, optical switch 130 or its functional equivalent is disengaged before the drive is actually removed from the connector 90A.
Referring next to FIGS. 6A-6F, the operation of the PCB 80 may be better understood, including the capability in the present invention for adding and removing drives while the host system is operating, or what has been referred to herein as "hot swappability." This feature is particularly helpful in implementing RAID drive arrays. More particularly, FIG. 6A-6F shows in schematic block diagram form the circuitry implemented on PCB 80. While the circuitry shown in FIGS. 6A-6F is directed to disk drives using the AT or IDE interface, it will be appreciated by those skilled in the art that, given the teachings herein, other interfaces could readily be used. As will be appreciated in greater detail hereinafter, the basic function of the circuitry of FIG. 6A-6F is to isolate the IDE interface by means of a series of FET switch arrays when a drive is not fully installed in a slot with the door closed, although other means can be used to accomplish the necessary objectives, as will be discussed hereinafter.
The circuitry of FIGS. 6A-6F includes a bus connector 200 for connection to the IDE bus of the host system (not shown) in a conventional manner. In contrast, each of two disk drives connects to either connector 90A or 90B. For purposes of this discussion, connector 90A will be defined as the master connector, while connector 90B will be defined as the slave connector, as required by the CSEL signal 202A being tied low for the master and CSEL signal 202B tied high for the slave connector. In the typical embodiment the drive 50 inserted in each slot will sense the associated voltage and assume the appropriate role. Alternatively, the master/slave relationship can be defined in the drive itself, so that a drive is defined as a master or slave regardless of the slot into which it is inserted.
As discussed in connection with FIGS. 1 and 2, each slot has associated with it an optical switch 130. For purposes of simplicity, insertion of a drive 50 into the master slot will be explained; insertion of a drive into the slave slot involves identical components and operates in the same way.
The installation of a drive 50 involves cooperation between the mechanical components of the docking module and the circuitry of FIGS. 6A-6F. As a drive 50 is inserted by closing the door 20, the connector 92 on the back of the drive 50 makes connection with the associated connector 90A. This causes power to be applied, and the drive starts to spin up. As the door continues to close, the optical switch 130 opens and enables associated FET switch arrays 204 and 206 through a pair of buffers 208A-B. In the event the door is closed but no drive is installed, the optical switch 130 will not open because the ground path for the switch 130 is through the drive 50,
When FET switch arrays 204 and 206 close, the signals HD0 through HD15 are connected from the bus connector 200 to the drive connector 90A and thence to the drive 50. The FET switch arrays shown comprise eight switches each, and so eight HD signals are switched by each array, necessitating two switch arrays for a sixteen bit bus. However, it will apparent that different sizes of arrays may be used, and different bus widths may be accommodated as appropriate for the host system.
The data returning from the drive 50 to the host bus is buffered by means of a permanently enabled register, for example a 74HCT541DW. In this manner the outputs of the drive cannot corrupt the data on the host system bus. While such protection from data corruption may not be required in all instances, in some embodiments of the invention it is difficult to predict the initial state of many of the signals, and thus such protection is a good design practice. It will be appreciated, given the foregoing teachings, that the fundamental steps in installing a drive are first, the application of power; second, connection of the drive signals to the host bus; and third, the installation of the drive is sensed, to cause the tri-state buffers to connect the drive to the bus.
Once the drive is installed into the system, the system recognizes the drive in the conventional manner, with the exception that the device driver always assigns a drive letter to a slot, whether or not a disk is present. The device driver further provides a software interrupt looking for a drive to be installed in an empty slot. Once a drive is detected by the system, the software interrupt causes the device driver to do a Drive Inquiry command. The drive 50 responds with its configuration of heads, cylinders and sectors, which allows the IDE interface from the host to address it. The system then can automatically address the drive and its data without rebooting.
During operation, the drive 50 operates as a conventional drive. When the user desires to remove the drive, the door 20A is opened, causing the end 140 of the slide 120 to move out of the optical switch 130. This opens the FET switch arrays 204 and 206, disconnecting the drive 50 from the host system bus. The drive is then physically disconnected from the connector 90A, causing the drive to power down in a conventional manner.
Removal of the drive is essentially the reverse of installation. Opening the door causes the optical switch to open, which opens the FET switch arrays 204 and 206. The tab 122 then begins to pull the drive 50 out of the connector, and eventually disconnects power to the drive. At this point the bus is fully tristated, so that no data corruption occurs. Those skilled in the art will recognize that it is not necessary in all instances to provide tri-state buffers for the bus at the connector 200, although such a design is preferred in the exemplary embodiment described herein. In some instances it may be desirable to eliminate the FET switches and control the bus signals either directly from the drive or in another suitable manner.
Additionally, in some embodiments it may be preferable to provide a power-up delay between the time power is applied to the drive and the time the bus is enabled, to allow the drive to spin up and reach a stable state before the bus is enabled. In still other embodiments, it may be desirable to eliminate the optical switch 130. This can be accomplished in numerous ways, one of which is to use multi-sense pins on the connector 92. By using pins of three different lengths, with the power supply pins being longest, the bus pins being shorter, and the drive output pins the shortest, the power supply connection is made first, with the remaining connections being made at appropriate subsequent times.
Another alternative may include providing a data register into which data from a device driver may be written to the host system to allow additional control of docking module features. The register would typically be addressable at a free I/O location under the IDE (or alternative interface) address space, and could be configured to lock and unlock a solenoid to prevent or enable removal of the cartridge; provide LED status to indicate drive availability; enable or disable a Write Protect or Read Protect Bit, for security purposes; or enable a solenoid or other device for automated ejection of a drive 50. Other aspects which may be controlled by appropriate device drivers including Flush Write Cache, Spin Down, Tri-State Bus, and so on.
Referring next to FIGS. 7A-7B, an alternative embodiment to the design of FIGS. 1 and 2 may be better understood. FIG. 7A is a side elevational view of a docking module 300 capable of holding five drives 50; FIG. 7B is a front view of the same module; each has certain internal components shown for clarity.
Referring next to FIG. 8, a docking module 400 capable of holding ten removable disk drives 50 at a density of two drives per half-height bay is shown in side elevational view with certain elements revealed through the chassis.
Having fully described a preferred embodiment of the invention and various alternatives, those skilled in the art will recognize, given the teachings herein, that numerous alternatives and equivalents exist which do not depart from the invention. It is therefore intended that the invention not be limited by the foregoing description, but only by the appended claims.
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A docking module for removable disk drives provides, in one embodiment, space for two such disk drives within a standard half-height bay. The docking module provides cammed insertion and removal together with hot swappability of disk drives. The bay is provided within a housing member. A door is rotatably mounted on the housing member and configured to serve as a lever arm. An engagement portion for urging a disk drive into the bay protrudes from the door. A slide is mounted within the housing member and connected to the door such that rotation of the door causes the slide to move forward and back within the housing member. A tab on the inner end of the slide engages the disk drive to urge the disk drive out of the bay. Alternative embodiments provide ten or more disk drives at a density of two drives per half height bay.
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This application claims priority to PCT Application No. PCT/US2006/014939 filed Apr. 20, 2006, which claims the benefit of Provisional application Ser. No. 60/674,826 filed Apr. 26, 2005, all of which are incorporated herein in their entirety.
FIELD OF THE INVENTION
This invention relates to composite warp knitted and braided constructs, each comprising two types of yarns having significantly different absorption/biodegradation and strength retention profiles to produce warp-knitted meshes and braided sutures exhibiting bimodular changes in their properties when used as surgical implants.
BACKGROUND OF THE INVENTION
Blending of non-absorbable fibers having distinctly different individual physicochemical properties is a well-established practice in the textile industry and is directed toward achieving unique properties based on the constituent fibers in such blends. The most commonly acknowledged examples of these blends include combinations of (1) wool staple yarn and polyethylene terephthalate (PET) continuous multifilament yarn to produce textile fabrics which benefit from the insulating quality of wool and high tensile strength of the polyester; (2) cotton staple yarn and PET continuous multifilament yarn to produce water-absorbing, comfortable (due to cotton), strong (due to PET) fabrics; (3) nylon continuous multifilament yarn and cotton staple yarn to achieve strength and hydrophilicity; and (4) cotton staple yarn and polyurethane continuous monofilament yarn to yield water-absorbing, comfortable elastic fabrics. The concept of blending non-absorbable and absorbable fibers was addressed to a very limited extent in the prior art relative to combining polypropylene (PP) with an absorbable polyester fiber in a few fibrous constructs, such as hernial meshes, to permit tissue ingrowth in the PP component of these meshes and reducing long-term implant mass, as the absorbable fibers lose mass with time. However, the use of totally absorbable/biodegradable blends of two or more yarns to yield fibrous properties that combine those of the constituent yarns is heretofore unknown in the prior art. This provided the incentive to pursue this invention, which deals with totally absorbable/biodegradable composite yarns having at least two fibrous components and their conversion to medical devices, such as sutures and meshes, with modulated, integrated physicochemical and biological properties derived from the constituent yarns and which can be further modified to exhibit specific clinically desired properties.
A key feature of having an absorbable/biodegradable surgical implant comprising at least two differing fibrous components, which, in turn exhibit different absorption and strength retention profiles has been disclosed in the present parent application PCT Serial No. 2006014939. However, these applications did not describe any specifically new construct design of devices such as surgical sutures and hernial meshes, which are responsible for achieving novel clinical properties. Accordingly, this invention is directed to novel construct designs made of fully absorbable/biodegradable surgical sutures, especially those used in slow-healing tissues and surgical meshes such as those used in hernial repair and vaginal tissue reconstruction.
SUMMARY OF THE INVENTION
Generally, the present invention is directed to warp knitted composite meshes and braided composite sutures comprising slow-absorbable/biodegradable and fast-absorbable/biodegradable components, specially sized and constructed to produce surgical devices having unique properties.
One major aspect of this invention is directed to a warp-knitted composite mesh with a minimum area density of 50 g/m 2 , which includes (a) a slow absorbing/biodegradable multifilament yarn component having individual filament diameter of less than 20 micron; and (b) a fast-absorbing multifilament yarn component having individual filament diameter exceeding 20 micron, wherein the slow-absorbing/biodegradable multifilament component is a segmented copolymer made of molecular chains comprising at least 80 percent of l-lactide-based sequences and the fast-absorbing multifilament component is a segmented polyaxial copolymer made of molecular chains comprising at least 70 percent of glycolide-derived sequences, and wherein the slow-absorbing multifilament component is knitted in a 2-bar sand-fly net pattern and the fast-absorbing multifilament component is knitted in a standard 2-bar marquisette pattern, with all guide bars threaded 1-in and 1-out, using a warp knitting machine. Alternatively, the slow-absorbing multifilament component is knitted in 2-bar full tricot pattern and the fast-absorbing multifilament component yarn is knitted in a standard 2-bar marquisette pattern with all guide bars threaded 1-in and 1-out, using a warp knitting machine.
A clinically important aspect of this invention is the provision of a composite mesh having an area weight of about 130 g/m 2 and exhibiting a maximum burst force of at least 250 N and a maximum elongation of less than 10 percent under a 16 N force per cm of mesh width, and when incubated in buffered solution at pH 7.2 and 50° C. for about 2 weeks retains more than 20 percent of its maximum burst force and undergoes at least 12 percent elongation under a force of 16 N per cm of mesh width.
Alternatively, the slow-absorbing/biodegradable multifilament yarn component of the mesh comprises a poly-3-hydroxyalkanoate made of molecular chains consisting of at least 50 percent of 3-hydroxybutyric acid-derived sequences.
This invention also deals with a warp-knitted composite mesh with a minimum area density of 50 g/m 2 , comprising (a) a slow absorbing/biodegradable multifilament yarn component having individual filament diameter of less than 20 micron; and (b) a fast-absorbing multifilament yarn component having individual filament diameter exceeding 20 micron, wherein said mesh is coated with an absorbable polymer at a coating add-on of at least 0.1 percent based on the uncoated mesh weight. Optionally, the coating comprises a polyaxial copolyester made of molecular chains comprising about 95/5 ε-caprolactone-/glycolide-derived sequences, wherein the coating contains at least 1 bioactive agent selected from those groups known for their antineoplastic, anti-inflammatory, antimicrobial, anesthetic and cell growth-promoting activities.
Another major aspect of this invention deals with a braided composite suture comprising (a) a slow-absorbing/biodegradable multifilament yarn component having individual filament diameter of less than 20 micron, and capable of retaining at least 20 percent of its initial breaking strength when tested individually as a braid and incubated in a phosphate buffer at pH 7.2 and 50° C. for about 2 weeks; and (b) a fast-absorbing/biodegradable multifilament yarn component capable of retaining at least 20 percent of its initial breaking strength when tested individually as a braid and incubated in a phosphate buffer at pH 7.2 and 50° C. for about 1 day. In one embodiment the slow-absorbing/biodegradable and fast-absorbing/biodegradable multifilament components constitute the core and sheath of the braid, respectively. Alternatively, the slow-absorbing/biodegradable and fast-absorbing/biodegradable multifilament components constitute the sheath and core of the braid, respectively.
In terms of the chemical composition of the composite suture, in one embodiment the slow-absorbing/biodegradable multifilament component comprises a segmented copolymer made of the molecular chains consisting of at least 80 percent of l-lactide-derived sequences and the fast-absorbing/biodegradable multifilament component comprises a segmented polyaxial copolymer made of molecular chains consisting of at least 70 percent of glycolide-derived sequences. Alternatively, the slow absorbable/biodegradable multifilament component comprises silk, or a poly-3-hydroxyalkanoate made of a molecular chain consisting of at least 50 percent of 3-hydroxybutyric acid-derived sequences.
Additional aspects of this invention deal with a braided composite suture as described above coated with an absorbable polymer at a coating add-on of at least 0.1 percent based on the uncoated suture weight. Optionally, the coating comprises a polyaxial copolyester made of molecular chains comprising about 95/5 ε-caprolactone-/glycolide-derived sequences, wherein the coating contains at least one bioactive agent selected from those groups known for their antineoplastic, anti-inflammatory, antimicrobial, anesthetic and cell growth-promoting activities.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
During the first one to two days of introducing an implant in living tissue, an acute inflammation prevails at the implant site. This is manifested as redness, heat, swelling and pain. After about day three, any persistent local inflammatory response to the implant subsides. When a non-absorbable material is implanted, the acute inflammation persists for less than a week and the development of a fibrous connective tissue around the implant progresses for about a month, leading to a generally static, fibrous capsule. A long-term separation of the non-absorbable implant from surrounding tissues by the capsule can lead to complications. Depending on the type of implant site, these complications may (1) increase the risk of infection and (2) interfere with the integration of the implant components with surrounding tissue leading to mechanical instability, as in the case of hernial meshes. On the other hand, if the implant material biodegrades/absorbs over time, the inflammation can be restimulated, incrementally, during the implant residence time period at the site, a feature which can be most desirable in certain applications. These include surgical meshes used in hernial repair, where an incremental restimulation of inflammation can result in controlled and persistent collagen deposition and mechanical integration with the fibrous components of the mesh leading to critically needed mechanical stability. Obviously, one should not expect this to terminate after the first three or four weeks following implantation leading to catastrophic mechanical failure of the mesh. Additionally, the incremental restimulation of inflammation and controlled collagen deposition can be achieved through (1) movement of the mesh components and/or at the mesh-tissue interface; (2) providing continually increased porosity in the mesh to permit progressively increasing facile fibroblast migration; and (3) having structurally stable mesh construction that resists tear and unraveling under dynamic mechanical stresses. And, optimally, the mesh components should be designed to (1) exhibit at least two absorption/strength retention profiles, one that prevails during the first two to four weeks and a second which will be responsible for continued restimulation beyond four weeks; (2) display sufficient mechanical strength and stiffness in the first three to four weeks during which collagen is deposited and the mechanical load at the site commences to be shared between the mesh and surrounding tissue without experiencing premature deformation; (3) accommodate the biomechanical events associated with wound healing and tissue shrinkage, as well as incremental dynamic stresses due to regular motions of active patients, through an incremental increase in the engineering compliance of the mesh; and (4) have a carefully warp-knitted construction that accommodates mechanical changes at the implant site while resisting tearing and breaking/unraveling at the tissue-mesh interface and/or within the mesh construct itself.
In concert with the aforementioned discussion, the present invention addresses the requirements set forth for an optimal mesh. Similarly, it addresses the requirements of an optimum suture that is expected to provide an effective ligation for three to four weeks as well as up to a few months following implantation, as would be required for wound repairs of compromised and slow-healing tissues.
A key general aspect of this invention is directed to a warp-knitted composite mesh with minimum density of 50 g/m 2 to ensure having adequate mass and strength to allow anchoring to the natural tissue, using a suture and/or absorbable adhesive, without tearing, unraveling, and/or breaking immediately after placement and during the first few weeks of functional performance. This is to prevent mechanical failure at the tissue-mesh interface or within the mesh components. For anchoring the mesh to the biological site, an absorbable suture of choice will be expected to maintain a strength retention profile that parallels that of a long-lasting component of the composite mesh. Meanwhile, the composite mesh is expected to comprise (1) a slow-absorbing/biodegradable, multifilament yarn component having individual filament diameter of less than 20 micron and preferably less than 15 micron as the main, relatively more flexible matrix of the mesh, which retains a measurable breaking strength for at least six weeks and preferably for more than eight weeks; (2) a fast-absorbing/biodegradable, multifilament yarn component having individual filament diameter of more than 20 micron and preferably exceeding 25 micron, as the minor, relatively less flexible component of the mesh that will be responsible for providing adequate initial rigidity of the mesh, and facile anchoring to the surrounding tissues, while exhibiting a brief breaking strength profile of about two to four weeks—this is to allow the slow-absorbing flexible matrix to become progressively more extensible at about two to four weeks following implantation; and (3) a slow- and fast-absorbing multifilament components in specially designed warp-knitted construction to ensure their mechanical interdependence in terms of load-bearing contributions and ability to anchor to the surrounding tissue using an absorbable tissue adhesive, absorbable suture, or a combination, for example, of an absorbable cyanoacrylate-based adhesive and an absorbable suture—a useful illustration of such warp-knit construction entails knitting the slow-absorbing multifilament component in a 2-bar, sand-fly net pattern and the fast-absorbing component in a standard 2-bar marquisette pattern, with all guide bars threaded 1-in and 1-out in 18 gauge using preferably a Raschel or tricot knitting machine. An alternative composite mesh construction entails knitting the slow-absorbing component using a 2-bar full tricot pattern and the fast-absorbing component using a standard 2-bar marquisette pattern, with all guide bars threaded 1-in and 1-out in 18 gauge. The warp construction can be achieved using other patterns. To improve the initial burst strength of the composite mesh through minimizing the fiber-to-fiber friction coefficient and hence minimize the fraying of the mesh structure, a lubricant coating is applied to the mesh at a level of 0.1 to 10 percent based on the mesh uncoated weight. The absorbable coating can also be used as a carrier for the controlled release of one or more bioactive agents belonging to one or more group of drugs known for their antimicrobial, anti-adhesion, and growth-promoting agents. The ideal coating system can be a crystalline, easy-to-apply, lubricious polymeric system that provides surface lubricity and its composition can be controlled to assist in modulating the absorption/biodegradation profile of the fast-absorbing component at least in the first two weeks following implantation.
Although slow- and fast-absorbable/biodegradable components of the composite are, so far, described as multifilament yarns, which are warped independently, other alternative approaches can be used entailing (1) plying the fast- with the slow-absorbable/biodegradable yarns prior to warping; (2) using one or more additional yarns with a moderate or fast absorption/biodegradation profile; (3) using the fast-absorbing component as a single or two-ply monofilament; (4) using a yarn component based on an elastomeric polymer—this can be in the form of a fast-, moderate- or faster-absorbing monofilament, 2-ply monofilament or multifilament. The use of elastomeric components is expected to accommodate any transient change in stress at the application site at the initial period of implantation when inflammation-induced swelling is encountered. To further modulate the performance of the composite mesh, enzymatically biodegradable, multifilament yarn can be used as the slow-biodegrading component. Such yarns include those based on silk fibroin, poly-4-hydroxyalkanoate, casein, chitosan, soy protein, and similar naturally derived materials with or without chemical modification to modulate their biodegradation and breaking strength retention profiles.
Another key general aspect of this invention is directed to a braided suture comprising at least two absorbable/biodegradable monofilament and/or multifilament yarn components having a range of absorption/biodegradation and breaking strength retention profiles. The rationale for invoking such a diversity in the components constituting the composite braid is practically similar to that noted above for composite mesh, with the exception of the fact that in constructing the braid, there is an additional degree of freedom, namely, having a core and sheath as the basic structural components of the braid. Meanwhile, the braid construction may entail (1) using variable ratios of the core-to-sheath without encountering core popping; (2) having slow-absorbable/biodegradable, multifilament yarn as the core or sheath with the balance of braid consisting of a fast-absorbable/biodegradable multifilament yarn; (3) using elastomeric monofilament, plied monofilament or multifilament yarn as part of the braid construct and preferably in the core at variable levels to impart a controlled level of elasticity—this is to accommodate site swelling during the first few days following suture implantation. The composite suture can be coated to (1) improve its tie-down and handling properties; (2) possibly prolong the breaking strength retention profile; and (3) function as an absorbable carrier for the controlled release of one or more bioagent selected from the groups known for their antimicrobial, anti-adhesion, antithrombogenic, antiproliferative, antineoplastic, anti-inflammatory, and cell growth-promoting activities. The coating can also be used to allow the controlled and timely delivery of anesthetic agents to mediate pains following surgery. A useful feature of using a coating with an antineoplastic agent allows the use of the composite suture in cancer patients to minimize the likelihood of metastasis. Another useful feature is the use of the composite suture in anchoring synthetic vascular graft and perivascular wrap where (1) having two or more absorption/biodegradation profiles can allow accommodating physicomechanical changes at the suture line due to prevailing biological events; and (2) using antithrombogenic and/or antiproliferative agents can be beneficial in maintaining the long-term patency of the graft.
A clinically important aspect of this invention deals with bioactive meshes comprising a coating containing an antineoplastic, anti-inflammatory, and/or antiproliferative agent that allows the use of the composite mesh as vascular wrap in the management of vascular embolism.
Further illustrations of the present invention are provided by the following examples:
EXAMPLE 1
Preparation of Yarns I and II for Composite Mesh Construction
A segmented l-lactide copolymer (P1) prepared by the copolymerization of a mixture of an 88/12 (molar) l-lactide/trimethylene carbonate [following the general polymerization methods described in U.S. Pat. No. 6,342,065 (2002)] was melt-spun using a 20-hole die to produce multifilament Yarn I—this is used as the slow-absorbable/biodegradable component of certain composite meshes. The extruded multifilament yarn was further oriented using a one-stage drawing over a heated Godet at about 100-120° C. prior to its use for knitted mesh construction. Typical properties of Yarn I are shown below. For producing Yarn II, the fast-absorbing/biodegradable component of the composite mesh, a polyaxial, segmented glycolide copolymer (P2), made by ring-opening polymerization of a combination of an 88/7/5 (weight) glycolide/trimethylene carbonate/l-lactide [using the general polymerization method described in U.S. Pat. No. 7,129,319 (2006)] was melt-spun using a 10-hole die and oriented by in-line drawing. Typical properties of Yarn II and the form used in knitting are shown below.
Key properties of Yarns I and II:
Yarn I (2-ply natural yarn)
Fiber Count: 43 Denier Range: 80-100 g/9000 m Tenacity Range: 1.8 to 4.5 g/denier Ultimate Elongation: 20-30%
Yarn II (1-ply natural yarn)
Fiber Count: 10 Denier Range: 120-170 g/9000 m Tenacity Range: 3.5-5.5 g/denier Ultimate Elongation: 40-70%
EXAMPLE 2
General Method for Composite Mesh Construction
Compositions consisting of Yarns I and II which possess different degradation profiles (one relatively fast degrading and one slow degrading) were constructed using various knitting patterns to construct the desired warp-knitted meshes. Knit constructions were produced using a two-step process of warping yarn onto beams and constructing meshes using a typical Raschel or tricot knitting machine. Various knitting patterns and weight ratios of I to II can and were varied to modulate mechanical properties of the specific mesh. Knit constructions can be made from multifilament yarn, monofilament yarn, or combinations thereof. Knit mesh was heat set or annealed at 120° C. for 1 hour while under constant strain in the wale and course directions. Coating can be applied following annealing to modify the in vivo and/or in vitro characteristics.
EXAMPLE 3
Knitting Process of Mesh Pattern A
The knitting process utilized two warped beams of Yarn I, threaded on bars 1 and 2, and two warped beams of Yarn II threaded on bars 3 and 4. The knitting machine was equipped with 18-gauge needles. Yarn II was knitted in a 2-bar marquisette pattern and Yarn I was knitted in a 2-bar sand-fly net pattern with all guide bars for each pattern threaded 1-in and 1-out in 18 gauge.
Pattern A (28 courses per inch)
Bar 1—1-0/1-2/2-3/2-1//2× (1-in, 1-out)
Bar 2—2-3/2-1/1-0/1-2//2× (1-in, 1-out)
Bar 3—1-0/0-1//4× (1-in, 1-out)
Bar 4—0-0/3-3//4× (1-in, 1-out)
EXAMPLE 4
Knitting Process of Mesh Pattern-B
The knitting process utilized two warped beams of Yarn I threaded on bars 1 and 2 and two warped beams of Yarn II, threaded on bars 3 and 4. The knitting machine was equipped with 18-gauge needles. Yarn II was knitted in a 2-bar marquisette pattern and Yarn I was knitted in a 2-bar full tricot pattern with all guide bars for each pattern threaded 1-in and 1-out in 18 gauge.
Pattern B (19 courses per inch)
Bar 1—1-0/2-3//4× (1-in, 1-out)
Bar 2—2-3/1-0//4× (1-in, 1-out)
Bar 3—1-0/0-1//4× (1-in, 1-out)
Bar 4—0-0/3-3//4× (1-in, 1-out)
EXAMPLE 5
Characterization and In Vitro Evaluation of Typical Composite Meshes from Example 3
Testing Methods for Meshes from Example 3
Mechanical properties were characterized using the ball burst testing apparatus with physical characteristics based on the ASTM D3787-01 guideline for the fixture geometry (25.4 mm polished steel ball, 44.45 mm diameter inside opening). The mesh was clamped in the fixture without any applied tension and the ball was positioned in the center of the 44.45 mm diameter opening. The ball is then brought down to a position on the mesh such that a 0.1N force is applied. The test is initiated and the ball travels at 2.54 cm/min until failure characterized by the point of maximum load. For each test the following three characteristics were recorded with standard deviation values for n=4 sample sizes:
1) Maximum burst force obtained during the test (N) 2) The extension at the maximum load (mm) 3) The extension at 71N load (mm)
The extension at 71N is used to determine the 16N/cm elongation. The value of 71N is derived from the diameter of the opening (4.445 cm×16N/cm=71N). Initially the mesh has a 44.45 mm diameter and is all in one plane. As the test progresses the ball pushes the mesh downward and creates a cone like shape with the radius of the ball as the tip. Using CAD and curve fitting software a mathematical expression which relates the linear travel of the ball to the change in length of a line that passes under the center of the ball and up to the original 44.45 mm diameter (radial distension) was developed. From this information the percent elongation was determined
In vitro conditioned burst strength retention [BSR=(max. load at time point/initial max. load)*100] was conducted using a MTS MiniBionix Universal Tester (model 858) equipped with a burst test apparatus as detailed in ASTM D3787-01. Samples were tested initially, after in vitro conditioning using a 0.1M solution of buffered sodium phosphate at a 12.0 pH in 50 mL tubes for 10 days, and after conditioning using a 0.1M solution of buffered sodium phosphate at a 7.2 pH in 50 mL tubes for multiple time points of interest. Tubes were placed in racks and incubated at 50° C. under constant orbital-agitation. Samples were removed at predetermined time points for mechanical properties testing (n=3).
Physical Properties of a Typical Warp-Knit Composite Mesh from Example 3
TABLE I Pattern A Warp Knit Composite Mesh Physical Properties Knitting Area Weight Yarn II Content Pattern (g/m 2 ) (weight %) Pattern A 132 40
Mechanical Properties of Meshes from Example 3
TABLE II
Pattern-A Warp Knit Composite Mesh Initial Burst Properties
Elongation
Elongation
Elongation
Sample
Max. Burst
at Max
at 71 N
at 16 N/cm
Description
Force (N)
Force (mm)
Force (mm)
(%)
Pattern A
356
14.6
6.8
5.2
TABLE III
Properties of Pattern A Warp Knit Composite Mesh Following
Accelerated In Vitro Conditioning (12 pH, 50° C., 10 days)
Elongation
Elongation
Elongation
Sample
Max. Burst
at Max
at 71 N
at 16 N/cm
Description
Force (N)
Force (mm)
Force (mm)
(%)
Pattern A
194
21.5
15.8
25.6
TABLE IV
Properties of Pattern A Warp Knit Composite Mesh Due
to Accelerated In Vitro Aging (7.2 pH, 50° C.)
Elongation
Elongation
Max. Burst
at
Elongation at
at 16 N/cm
In Vitro
BSR
Force
Max Force
71 N Force
Force
Duration
(%)
(N)
(mm)
(mm)
(%)
0 days
—
352
14.29
6.52
4.76
3 days
106.3
374
14.71
6.84
5.28
7 days
44.9
158
14.24
7.92
7.14
11 days
59.1
208
18.89
13.13
18.38
14 days
55.7
196
19.63
14.31
21.46
18 days
52.6
185
17.98
13.20
18.56
21 days
55.4
195
18.44
13.21
18.59
35 days
51.4
181
17.88
13.54
19.43
56 days
36.9
130
16.37
14.01
20.66
EXAMPLE 6
Characterization and In Vitro Evaluation of Typical Composite Meshes from Example 4
Testing Methods for Meshes from Example 4
Mechanical properties testing was conducted using a MTS MiniBionix Universal Tester (model 858) equipped with a burst test apparatus as detailed in ASTM D3787-01. Samples were tested initially and after being conditioned using a 0.1M solution of buffered sodium phosphate at a 12.0 pH in 50 mL tubes for 10 days. Tubes were placed in racks and incubated at 50° C. under constant orbital-agitation. Samples were removed at predetermined time points for mechanical properties testing (n=3).
Physical Properties of a Typical Warp-Knit Composite Mesh from Example 4
TABLE V Pattern B Warp Knit Composite Mesh Tabulated Physical Properties Knitting Yarn B Content Pattern Area Weight (g/m 2 ) (weight %) Pattern B 135 31
Mesh Resultant Mechanical Properties from Example 4
TABLE VI
Pattern B Warp Knit Composite Mesh Initial Burst Properties
Elongation
Elongation
Elongation
Sample
Max. Burst
at Max
at 71 N
at 16 N/cm
Description
Force (N)
Force (mm)
Force (mm)
(%)
Pattern B
436
16.3
7.1
5.7
TABLE VII
Properties of Pattern B Warp Knit Composite Mesh Following
Accelerated In Vitro Conditioning (12 pH, 50° C., 10 days)
Elongation
Elongation
Elongation
Sample
Max. Burst
at Max
at 71 N
at 16 N/cm
Description
Force (N)
Force (mm)
Force (mm)
(%)
Pattern B
240
19.4
13.2
18.5
EXAMPLE 7
Preparation of Yarn III for Composite Braid Construction
The same polymer precursor, P2, described in Example 1 was used in preparing multifilament Yarn III. The polymer was melt-spun using a 20-hole die to produce multifilament Yarn III, which was further oriented using one-stage drawing over a heated Godet at about 100-120° C., prior to its use in braid construction.
EXAMPLE 8
Construction of Composite Braid SM1-1 Comprising a Yarn I-Core and Yarn III-Sheath
Braid SM1-1 was prepared using a 4-carrier core of Yarn I as single ply and 8-carrier Yarn III as 3-ply. The braid was hot-stretched to about 5-10 percent of its initial length using heated air at about 90° C. to tighten the braid construction. The strained braid was then annealed at 110° C. for 1 hour to yield a braided suture having about 110 ppi and a diameter of about 0.35 mm.
EXAMPLE 9
Construction of Composite Braid SM1-2 Comprising a Yarn III-Core and Yarn I-Sheath
Braid SM 1-2 was prepared using a 6-carrier core of Yarn III as single ply and 16-carrier sheath of Yarn I as single ply. The braid was hot stretched and annealed as described in Example 8 to yield a braided suture having about 50 ppi and a diameter of about 0.36.
EXAMPLE 10
In Vitro and In Vivo Evaluation of Braids SM1-1 and SM1-2 Suture Properties
The braids were sterilized with ethylene oxides and tested for their (1) initial physical properties; (2) accelerated in vitro breaking strength retention profile at pH 7.2 and 50° C.; and (3) in vivo breaking strength retention using a subcutaneous rat model. The results of the in vitro and in vivo evaluation are summarized in Table VIII.
TABLE VIII
In Vitro and In Vivo Properties of Composite Braids SMI-1 and SMI-2
Experiment
Braid SMI-1
Braid SMI-2
Physical Properties:
Diameter, mm
0.35
0.36
Initial Strength, Kpsi (N)
54.4 (36.1)
52.4 (36.7)
Elongation, %
45
41
Knot Max. Load, N
24.7
23.7
In vitro Breaking Strength Retention
(BSR) at pH 7.2/50° C. Percent at
Days 1, 2, and 3
85, 50, 24
81, 80, —
Weeks 1 and 2
21, 19
76, 76
In-Vivo BSR at Percent at
Weeks 2 and 3
43, 25
81, 77
Preferred embodiments of the invention have been described using specific terms and devices. The words and terms used are for illustrative purposes only. The words and terms are words and terms of description, rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill art without departing from the spirit or scope of the invention, which is set forth in the following claims. In addition it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Therefore, the spirit and scope of the appended claims should not be limited to descriptions and examples herein.
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Absorbable composite medical devices such as surgical meshes and braided sutures, which display two or more absorption/biodegradation and breaking strength retention profiles and exhibit unique properties in different clinical settings, are made using combinations of at least two types of yarns having distinctly different physicochemical and biological properties and incorporate in the subject construct special designs to provide a range of unique properties as clinically useful implants.
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This application is a divisional of application Ser. No. 192,348, filed May 10, 1988, now U.S. Pat. No. 4,925,381.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for press-molding a thermoplastic resin in which a plasticized resin is charged into a lower mold half of a mold in an open state, in a press-molding machine and the lower mold half is then clamped with an upper mold half to make compression molding.
An injection molding method is generally utilized for molding a product provided with a rib, a boss or an undercut portion, or a part having a thickened portion in a wide range. With this injection molding method, however, a material to be used as a molten resin injected into a closed mold cavity through a gate portion is limited to a resin having high fluidity, which gives little potential for using a resin having high molecular weight and high viscosity which have excellent physical properties. In addition, it is also difficult to mold a specific filler containing compound resin including various long fibers or metal powders and is also difficult to obtain a mold product which is thin. Moreover, in case of molding a product having a wide molding area, one molding cycle is protracted and the clamping force for clamping the molds is inevitably increased. These defects necessitate enlargement of the molding machine provided with multiple gates, thus requiring an increased cost for the equipment. The thus molded products are frequently flawed with a sink mark, warp or weld-mark, thus producing a problem in the quality of the product. In integral molding with a cloth having raised or soft foamed material, the application of high pressure in the injection molding operation may damage the characteristics of the products.
Conventional molding methods other than the injection molding method, such as vacuum and pressure molding method or a stamping molding method of a structual material also have a limitation in the shape of a product to be molded, which results in disadvantages of low productivity or high energy consumption.
These defects or disadvantages in the conventional molding methods are result from the fact that the plasticized resin is injected into the closed mold cavity through small nozzle means and, in order to obviate these defects, there is provided a compression molding method in which the plasticized resin is injected into the mold cavity formed by mold halves which are opened and the mold halves are then clamped under pressure. As a typical example of this method, "Resin Press-Molding Method Due to Direct Auto-charge of Resin" is disclosed in the Japanese Patent Post-Examination Publication No. 43012/83, which is generally called a stamping molding system mainly utilized for molding a large scale thin resin part for an automobile. According to this conventional method, the resin, plasticized and extruded by an extruder or extruding machine, has to be automatically measured so as to obtain an amount of plasticized resin corresponding in amount to one shot of the resin. The thus obtained resin is automatically charged into a lower mold of the press-molding machine while in an open state, and the molds are then clamped thereby spreading and press-molding the resin charged in the mold cavity. During this clamping operation, the molds are cooled and, after cooling, a molded product is taken out. In this operation, the measurement of the weight of the plasticized resin and the injection of the plasticized resin are performed by using an accumulating cylinder means and, accordingly, operations for stocking the melted and plasticized resin in the resin measuring chamber of the accumulating cylinder means and injecting the stocked resin into the mold cavity of the press molding machine have to be repeated intermittently to supply the resin into the lower mold. Accordingly, in this method, it is necessary to vary the stroke of the piston in the accumulating cylinder means every time so as to accord with the weight of the resin to be charged. These operations require much time for measuring and supplying the amount of resin for one charge and, hence, one molding cycle is protracted. The protracted molding cycle causes the resin in the mold to be cooled. Moreover, relatively complicated and large scale mechanisms such as hydraulic means for operating the piston of the accumulating cylinder means are required, and the cost of equipment therefore will be increased. In addition, many other movable members such as pivotable joint members are provided between the gate of the extruding machine and the accumulating cylinder means, so that there is a fear of leakage of the resin and a problem for the maintenance thereof.
SUMMARY OF THE INVENTION
An object of this invention is to substantially eliminate the defects or drawbacks encountered in the direct auto-charge type press-molding system for a thermoplastic resin of the type described above.
Another object of this invention is to provide a method of press-molding a thermoplastic resin capable of shortening the resin charging time into a mold cavity and making use of a thermoplastic resin with high viscosity.
A further object of this invention is to provide a machine for press-molding a thermoplastic resin including a mechanism for exactly measuring a resin amount to be charged into a mold cavity under the control of a microcomputer and further including a member constituting a resin passage which is flexible with no jointed or coupled portion and is heatable by a suitable heating element so as not to lower the temperature of the resin passing therethrough.
These and other objects can be achieved according to this invention, in one aspect, by providing a method of press-molding a plasticized resin extruded from a resin extruding machine and charged into a mold cavity of a mold of a press-molding machine comprising the steps of storing an amount of plasticized resin extruded from the extruding machine which exceeds that required for one resin charging shot into a mold cavity, supplying and measuring under a constant supplying pressure and under a regulated resin flow rate condition an amount of the stored resin required for one molding operation, charging the thus measured plasticized resin into the mold cavity by the predetermined amounts, and clamping the mold for carrying out a compression molding operation.
In another aspect of this invention, there is provided a machine for press-molding a plasticized resin extruded from a resin extruding machine and charged into a mold cavity of a mold of a press-molding machine comprising an accumulator operatively connected to an outlet port of the extruding machine for accumulating the plasticized resin in an amount exceeding that required for one resin charging shot into a mold cavity, a pneumatic piston-cylinder assembly for supplying the accumulated resin from the accumulator under a constant pressure, a volumetric flow meter for measuring an amount of the supplied resin required for one molding operation under a regulated resin flow rate condition, a nozzle member connected to the volumetric flow meter for charging the measured resin into the mold cavity, a controller for controlling the displacement and operation of the volumetric flow meter and the associated nozzle member for charging predetermined amount of the measured resin into the mold cavity, and a mechanism for clamping the molds after charging the resin into the mold cavity.
According to the press-molding method and press-molding machine for the plasticized resin having the specific characteristics of this invention described above, the plasticized resin stored in the accumulator is fed through the flexible resin passage hose by the cooperation of the pressure of the pneumatic piston-cylinder assembly and the sucking force of the gear pump, so that a resin with high viscosity can be easily fed with relatively low pressure applied to the flexible hose. Since the plasticized resin exceeding that required for one molding charge is stored in the accumulator and exactly measured by the gear pump, the repeated operation for accumulating the plasticized resin into the accumulator can be eliminated, thus saving the time required for stopping the operation of the gear pump and shortening the resin charging time. In addition, the plasticized resin is extruded into the accumulator during the mold clamping operation of the press-molding machine, thus preventing a temperature change of the plasticized resin to be charged. The displacement and the revolution number or rotational speed of the gear pump can be exactly controlled by a controller such as a microcomputer, thus exactly measuring the amount of the plasticized resin to be charged into the predetermined portions of the mold cavity.
The preferred embodiments of this invention will be further described in detail hereinbelow with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a plan view, partially in section, of a machine for press-molding a plasticized resin according to this invention; and
FIG. 2 is a brief side view of the machine viewed from the arrowed direction II--II shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, an extruding machine E for extruding a thermoplastic resin into a mold comprises an outer cylinder barrel 1, a hopper H through which the thermoplastic resin is fed into the cylinder barrel 1, and a screw unit 2 disposed in the barrel 1 to plasticize the thermoplastic resin and feed the same towards an extruding port formed at the front end of the extruding machine E. The extruding port is connected to an accumulator 3 for accumulating the plasticized resin from the extruding machine in an amount exceeding that required for one injection shot. A pneumatic cylinder assembly 7 is integrally connected to the rear end portion of the accumulator so that a piston member 8 slidably disposed in the accumulator 3 and a piston member 14 also slidably disposed in the pneumatic cylinder assembly 7 are operatively connected through a common piston rod 15. Air with a pressure P 2 regulated by a pressure adjusting means, not shown, is fed into a cylinder chamber defined in the rear portion of the pneumatic cylinder assembly 7 by the piston member 14. The piston member 14 is made of a magnetic material and the position of the piston member 14 in the cylinder assembly 7 is magnetically detected by, for example, a limit switch, not shown, located proximate to the cylinder assembly 7.
A flexible hose 4, as a resin passage, has one end connected to a front end port of the accumulator 3 and the other end connected to a gear pump 5, which is provided with a resin discharging nozzle 6 and is mounted on a table 12 movable in the X-axis direction. The gear pump 5 is operatively connected to a pulse motor 9 for driving the same, which is also mounted on the table 12. The gear pump 5 serves as a flow meter to measure and regulate the flow rate of the plasticized resin passing therethrough and, for this means, other rotary type pumps which function as a volumetric flow meter may be utilized in place of the gear pump. To the table 12 is operatively connected a nut, not shown, engaged with a screw member 17 which is driven by a pulse motor 16 so as to allow the table 12 to move in the X-axis direction along a guide located on a table 13 movable in the Y-axis direction. The tables 12 and 13 are referred to as X-axis and Y-axis tables 12 and 13, respectively, hereinafter for convenience sake. The Y-axis table 13 is movable in the Y-axis direction by a nut, not shown, engaged with a screw member 19 which is driven by a pulse motor 18. The operations of the pulse motors 9, 16, and 18 are controlled by microcomputer means, respectively, which are per se of a known type and briefly illustrated as C 1 , C 2 and C 3 .
The positions of the X-axis and Y-axis tables 12 and 13 are detected by position detectors and signals representing the positions thereof are transmitted from the detectors into a controller, not shown. The X-axis and Y-axis directional positions of the gear pump 5 are determined in accordance with these position signals and the revolution numbers of the pulse motors 16 and 18 and memorized in the controller. The gear pump 5 can thus be movable in the X- and Y-axes directions.
A press-molding machine 21 is located in an area wherein the gear pump 5 is freely movable. The press-molding machine 21 is provided with upper and lower mold halves 11 and 10 which are opened in a state shown in FIG. 2, in which the gear pump 5 is positioned between the upper and lower mold halves 11 and 10. When the gear pump 5 is retracted from this position, the upper mold half 11 is lowered by the action of a hydraulic means to forcibly contact or engage the lower mold half 10. As described before, the resin passage 4 connecting the accumulator 3 and the gear pump 5 is made of a flexible, heat-resisting and pressure-proof material, so that the movement of the gear pump 5 is freely performed. A preferred flexible hose 4 is made of a fluorine resin such as tetra-fluoroethylene polymer containing a metal wire and is reinforced by a reinforcing wire as a whole. A heating wire is further wound in spiral around the outer surface of the flexible tube 4 in a preferred embodiment of this invention for keeping constant the temperature of the plasticized resin passing therethrough.
The extruding and press-molding machines having constructions described hereinabove operate in the manner described hereunder.
The extruding machine E is first driven to extrude the plasticized resin into the accumulator 3 under the operation of the gear pump 5 being stopped. The piston member 14 is retracted and, when the predetermined amount of the plasticized resin corresponding to the amount exceeding that for one injection shot is stored in the accumulator 3, the limit switch detects the position of the piston member 14 and generates a signal to stop the operation of the extruding machine E. In this state, the gear pump 5 is moved to a predetermined position above the lower mold half 10 of the press-molding machine 21 being in an opened condition. Upon detecting the signal representing the fact that the predetermined amount of the plasticized resin is stored in the accumulator 3, the pulse motor 9 is driven to rotate the gear pump 5 to thereby measure the plasticized resin to be charged and charge the plasticized resin from the accumulator 3 through the hose 4 and through the nozzle 6 into the cavity 20 of the lower mold half 10. When the plasticized resin in the accumulator 3 is transferred by the operation of the gear pump 5, the piston member 8 advances by the pneumatic pressure P 2 (kg/cm 2 ) in the cylinder chamber of the cylinder assembly 7 and stops when the resin pressure P 1 (kg/cm 2 ) in the accumulator 3 and the pressure P 2 are balanced, whereby pressure on the suction side of the gear pump 5 is maintained constant. Accordingly, the flow amount of the plasticized resin to be charged by the gear pump 5 into the recess of the lower mold half 10 can be exactly controlled by the revolution number or rotational speed and the driving time of the pulse motor 9.
During the rotation of the gear pump 5, the pulse motors 16 and 18 are driven to move the gear pump 5 in the X- and Y-axes directions through the movements of the X-axis and Y-axis tables 12 and 13 to properly charge the plasticized resin in the cavity 20 of the lower mold half 10 in accordance with the moving locus of the gear pump 5. The resin charging mode can be optionally selected by controlling the rotational speed and the driving time of the pulse motors 16 and 18 so that, for example, much resin is charged for the formation of a thickened portion such as a boss or rib and less resin is charged for the formation of a thin portion. In actual operation, however, it is desirable to charge the plasticized resin to provide a thickness more than 5 mm for ensuring the temperature retaining characteristic of the resin. The moving speed of the gear pump 5 is based on the area to be molded, but is usually controlled in the range 5˜200 mm/sec.
After charging of the plasticized resin into the cavity 20 of the lower mold half 10 has been completed, the operation of the gear pump 5 is stopped and the gear pump 5 is then retracted to a position spaced from the mold clamping motion area of the press-molding machine 21. Upon the gear pump 5 being retracted, the upper mold half 11 is immediately lowered to forcibly press the stationary lower die to carry out the mold clamping operation. The plasticized resin charged into the mold cavity is distributed by the mold clamping force so as to fill the resin in the predetermined shape. After clamping and then cooling the mold, the upper mold half 11 is lifted upwardly to take out a molded product. The molding pressure imparted by the mold clamping force differs in various applications due to the viscosity or fluidability of the plasticized resin used and the shapes of projecting portions and corner portions of a product to be molded, but usually pressure of about 30 to 100 kg/cm 2 is available, which is less than one-third of the molding pressure required in the conventional injection molding method.
A time for filling the plasticized resin into the accumulator 3 can be set to a time required for the press-molding cycle, i.e., the waiting time of the gear pump 5 for the next charge of the plasticized resin in the lower mold half 10. In case these times are compared on the basis of the ratio of the operating capacities, according to an embodiment of this invention, an extruding machine having a resin extruding capacity ranging between one-sixth to one-third of the resin discharging capacity of a gear pump can be selectively used. For example, in case the plasticized resin in an amount of 500 g for one injection shot is charged into the mold for 5 seconds and the press-molding time is set to 30 seconds, the capacity for discharging a resin amount of 100 g/sec (360 kg/hr) is required for the gear pump 5, whereas an extruding machine having merely the extruding capacity of 16.7 g/sec (60 kg/hr) can be utilized. Accordingly, the extruding machine in this case can achieve the material balance in the plasticized resin feeding and charging operations with the treating capacity one-sixth of that of the gear pump 5, thus being advantageous in the installation of the equipment.
According to the method of this invention, a product was obtained in the following manner.
As a thermoplastic resin, a compound resin of polypropylene (melting point: 165° C., melt flow rate (230° C.): 6 g/10 min., density: 0.97 g/cm 3 ) was used to which talc of 10 weight % was added to obtain a product having an average thickness of 1.8 mm and a product weight of 195 g (molded area of about 1,000 cm 2 ). The molding operation was performed under resin charging temperature: 190° C.±3° C., temperature of mold: 30° C., mold clamping force: 70 ton (i.e., molding pressure: 70 kg/cm 2 ) and clamped mold holding time: 20 seconds. After 20 seconds, when the upper mold half was lifted, the temperature of the product was cooled to a temperature less than 50° C. and the product did not exhibit any change on standing. The resin charging time of this molding cycle was 3 seconds (charging amount of gear pump: 65 g/sec), and a total molding cycle was achieved in 28 seconds in consideration of another additional operation time. The thermoplastic resin utilized for this invention is not limited to that of the type described hereinbefore, and many other materials can be utilized such as crystalline polyolefin resin such as polypropylene, polyethylene, and ethylene-propylene copolymer, or polystyrene, polyamide, and ABS resin or compounds thereof. Furthermore, resin including talc, mica, glass fiber, synthetic resin or wood powder in addition to one of the resins described above may be utilized as a thermoplastic resin to be utilized for this invention. In a preferred embodiment, a hydraulically operative molding press is used as a molding press or press-molding machine.
According to this invention, as described hereinbefore, the thermoplastic resin press-molding method is of the direct-charge type in which the plasticized resin is directly charged into the mold cavity of the mold halves in an open state, so that the press-molding operation for obtaining a product having large size and relatively thin thickness can be performed at a molding speed remarkably higher than that in an injection molding method or vacuum forming method. Approximately 100% yield of the material can achieve an extremely high productivity, thus obtaining molded products with reduced cost in comparison with the conventional molding methods. In addition, various types of resins can be utilized, and, accordingly, an integral molding with other material such as surface decoration material made of such substances as polyvinyl chloride (PVC) leather or woven cloth with raising for the interior trim parts material for an automobile, for example, can be made.
Moreover, even in comparison with the conventional direct charge type molding method, according to this invention, the plasticized resin can be charged into the mold cavity through the accumulator and the flexible tube by the operation of the gear pump under the regulated flow rate of the resin, even with the high viscosity, to be charged for the resin charging time. A plasticized resin having a relatively low temperature can be utilized, and the cooling time for the charged resin can thus be shortened. The resin also can be charged into the mold cavity exactly in conformity with the shape of the mold, so that the resin is charged in a simple flow mode without substantially exhibiting the complicated orientation and the inner distortion of a product. This advantage can be improved by the fact that the mold clamping operation is done with relatively low molding pressure. The product molded in the manner thus described has a physical property substantially equally orientated in the vertical and lateral directions of the product and also has an excellent extension strength, impact-proof strength and stability in dimensions with no shrinkage and warp. The location of the flexible tube for passing the plasticized resin without using any coupling means can prevent the resin from leaking from coupled or jointed portions.
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A process is provided in which a plasticized resin is extruded from an extruding machine into an accumulator into which the resin is stored by an amount which exceeds the amount required for one resin molding operation. The stored resin, in operation, is fed through a flexible hose to a supply and measuring device, such as a gear pump, under controlled pressure conditions. The resin is measured by the supply and measuring device by regulating the flow rate of the resin and is then charged into the mold cavity in a measured amount. The clamping of the mold can be effected by a clamping force less than that required by a conventional press-molding machine.
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FIELD OF THE INVENTION
The present invention relates to a device for protection of occupants in a vehicle. More particularly, the present invention relates to such devices which are intended to be used in energy absorbing steering systems for motor vehicles. The invention also relates to a method for occupant protection in vehicles.
BACKGROUND OF THE INVENTION
In motor vehicles, it is a general goal to reduce the effects of a collision on the occupants of the vehicle as much as possible. In today's cars, three-point seatbelts are therefore normally employed to restrain the occupants of the vehicle. In a known manner, the seatbelts offer good protection and increased safety for the occupants should a collision take place.
Nowadays, there is also a desire to provide steering systems in vehicles which are energy-absorbing. The reason for this desire, which is dictated by legislation in certain countries, is that there is a need to offer some degree of protection to a driver who is not wearing a seatbelt when he is thrown towards the steering wheel in a collision.
It is previously known to design the steering system of the vehicle so that it absorbs energy when the driver of the car is thrown forwards and impacts the steering wheel during a collision. This can be achieved, for example, by designing the steering wheel with deformable and flexible spokes. This can also be achieved by arranging the steering shaft of the vehicle in a particularly designed energy absorbing steering column which is attached to the stress-bearing structure of the vehicle. In the event of a collision, when the steering wheel, and thus also the steering column, are influenced by a very large force as a result of the occupant being thrown forwards, this force will be transmitted from the steering wheel to the steering column. In this manner, the steering column will be displaced a certain distance relative to the vehicle structure. During this displacement, energy will be absorbed which, as a consequence, reduces the effects on the driver during the collision sequence.
Apparatus is disclosed in U.S. Pat. No. 4,978,138 for energy absorption in a steering system for vehicles. This apparatus is based on the principle that if the driver is not wearing his seatbelt, the steering system will absorb energy when the driver is thrown against the steering wheel during a possible collision. To achieve this, the arrangement includes a particular deformable and energy-absorbing bracket which is connected to the steering column. In order to determine whether the driver is wearing his seatbelt, a sensor is arranged on the seatbelt lock. This known arrangement also includes means for protecting the driver's knees, which means is activated irrespective of whether the driver is wearing his seatbelt or not. If the driver is wearing his seatbelt, the force from the knees will be absorbed by the knee protector as the steering wheel is displaced, whereby it is possible to prevent the upper body and head of the driver from impacting the steering wheel. The arrangement according to this patent, however, suffers from the disadvantage that the circumstances in which the driver can in fact impact the steering wheel during a collision even if he is wearing his seatbelt are not taken into account. This can occur, for example, when the driver has his seat in a well forward position or when the seatbelt is unusually slack.
SUMMARY OF THE INVENTION
In accordance with the present invention, these and other objects have now been realized by the invention of apparatus for protecting the occupant of a motor vehicle including a seatbelt for restraining the occupant and a stress-bearing structure, the apparatus comprising a steering shaft, a steering column supporting the steering shaft, the steering column displaceably mounted with respect to the stress-bearing structure, a first energy-absorbing unit for absorbing energy upon displacement of the steering column with respect to the stress-bearing structure by the occupant, a sensor for detecting a condition in which the occupant is restrained by the seatbelt, a second energy-absorbing unit for absorbing energy upon displacement of the steering column with respect to the stress-bearing structure by the occupant, and a locking member for permitting the absorption of energy by the second energy-absorbing unit by displacement of the steering column with respect to the stress-bearing structure by the occupant when the condition is detected by the sensor.
In accordance with one embodiment of the apparatus of the present invention, the locking member prevents absorption of energy by the second energy-absorbing unit by displacement of the steering column with respect to the stress-bearing structure by the occupant when the condition is not detected by the sensor.
In accordance with one embodiment of the apparatus of the present invention, the energy capable of being absorbed by the first energy-absorbing unit is less than the energy capable of being absorbed by the second energy-absorbing unit.
In accordance with another embodiment of the apparatus of the present invention, the second energy-absorbing unit comprises a first carriage fixedly mounted with respect to the steering column, a second carriage fixedly mounted with respect to the stress-bearing structure, the first and second carriages being displaceably mounted with respect to each other, and a second energy-absorbing element for absorption of the energy upon displacement of the first carriage with respect to the second carriage. In a preferred embodiment, the locking member comprises an electrically operated solenoid. Preferably, the electrically operated solenoid is mounted on one of the first and second carriages, the electrically operated solenoid including a piston, and wherein the other of the first and second carriages includes a recess cooperating with the piston. In accordance with a preferred embodiment, the electrically operated solenoid is mounted on the second carriage and the other of the first and second carriages comprises the first carriage.
In accordance with another embodiment of the apparatus of the present invention, the second energy-absorbing element comprises a strip including a first end and a second end, the first end of the strip being affixed to the first carriage and the second end of the strip being affixed to the second carriage.
In accordance with the present invention, these objects have also been overcome by the invention of a method for protecting the occupant of a motor vehicle including a seatbelt for restraining the occupant, a stress-bearing structure, a steering shaft, and a steering column supporting the steering shaft, the steering column being displaceably mounted with respect to the stress-bearing structure, the method comprising detecting a condition in which the occupant is restrained by the seatbelt, absorbing energy through a first energy-absorbing unit upon displacement of the steering column with respect to the stress-bearing structure by the occupant, and absorbing energy through a second energy-absorbing unit upon displacement of the steering column with respect to the stress-bearing structure when the condition is detected. In accordance with one embodiment, the method includes preventing absorption of the energy by the second energy-absorbing unit by displacement of the steering column with respect to the stress-bearing structure by the occupant when the condition is not detected.
In accordance with one embodiment of the method of the present invention, the energy capable of being absorbed by the first energy-absorbing unit is less than the energy capable of being absorbed by the second energy-absorbing unit. Preferably, the second energy-absorbing unit includes a locking member having a first actuated condition for preventing the absorption of energy by the second energy-absorbing unit, and a second non-actuated condition for permitting the absorption of energy by the second energy-absorbing unit, whereby the locking member is actuated when the condition is detected, the method including feeding a current to an electrically operated solenoid for actuating the locking member.
In accordance with another embodiment of the method of the present invention, a second carriage is affixed to the stress-bearing structure, and a first carriage is affixed to the steering column, the first and second carriages being displaceably affixed to each other, the absorbing of the energy through the second energy-absorbing unit comprising displacement of the first carriage with respect to the second carriage.
A primary object of the present invention is thus to solve the above-mentioned problems and to provide an improved device for energy absorption in a steering system for a motor vehicle which primarily provides optimal energy absorption irrespective of whether the seatbelt is being used by the driver.
The present invention is intended for use in vehicles having a steering column which supports a steering shaft and in which a force is normally exerted by the occupant against the steering column during a collision, whereby the steering column can thus be displaced with respect to the stress-bearing structure of the vehicle. The present invention comprises a first energy-absorbing unit for absorbing energy during such displacement. Furthermore, the present invention includes a sensor for detecting a condition which determines that the occupant is wearing his seatbelt. This invention is based on the principle that a second energy absorbing unit is arranged between the steering column and the vehicle's stress-bearing structure, and that the sensor is connected to a lock arrangement which, when said condition is detected, permits displacement of the second energy-absorbing unit with respect to the stress-bearing structure. During such displacement, energy is absorbed. In this manner, the energy-absorbing capability of the steering system can be varied depending on whether or not the driver is wearing his seatbelt. This provides increased safety for the driver in the event of a collision.
In a preferred embodiment, the second energy absorbing unit comprises a first carriage which is connected to the steering column and a second carriage which is connected to the stress-bearing structure of the vehicle. It further includes an energy-absorbing element for absorbing energy during displacement of the carriages with respect to each other. These two carriages can adopt two different conditions depending on whether or not the driver is wearing his seatbelt. Either the carriages are locked together with respect to each other, or they are disconnected so that they can be displaced relative to each other. In order to achieve this, the present invention comprises the above-mentioned lock arrangement which is controlled by a sensor which detects whether the seatbelt is being used. In this manner, a certain predetermined energy absorption in the steering column is attained when the driver is wearing his seatbelt, and another energy absorption is obtained when the driver is not wearing his seatbelt.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in the following detailed description in greater detail, with reference to a preferred embodiment and the attached drawings, in which:
FIG. 1 is a side, elevational, partly schematic view of a preferred embodiment of the present invention;
FIG. 2 is a top, perspective view of a portion of a first energy-absorbing unit according to the embodiment shown in FIG. 1;
FIG. 3 is a front, perspective view of a second energy-absorbing unit according to the present invention;
FIG. 4 is a side, elevational, schematic view of the present invention in a first condition; and
FIG. 5 is a side, elevational, schematic view of the present invention in a second condition.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the figures, in which like reference numerals refer to like elements thereof, FIG. 1 shows a somewhat simplified elevational view of apparatus according to the present invention. The apparatus is primarily intended to be employed in motor vehicles, for example in a car. The vehicle is, in a known manner, provided with a steering shaft 1 which, at its upper end, supports a steering wheel 2 . The lower end portion of the steering shaft 1 is connected to a steering mechanism (not shown) which, in a known manner, is intended for steering the wheels of the vehicle.
The steering shaft 1 is supported in a steering column 3 in a manner which is already known and which therefore will not be described in detail. For example, the steering column 3 can comprise means (not shown) for adjusting the rake and reach of the steering shaft 1 . Furthermore, the steering column 3 is substantially box-shaped with a substantially horizontal upper side and a somewhat angled lower side. The steering column 3 is arranged underneath the dashboard 4 of the vehicle, the contours of which are indicated by a broken line 5 . In addition, the shape and form of the steering column 3 are adapted, to the type of vehicle in which the present invention is employed.
The steering column 3 is designed so as to be able to absorb energy when influenced by the force which arises should the driver impact the steering wheel 2 during, for example, a collision. To this end, the sides of the steering column 3 are provided with elongated slots 6 , which are preferably four in number, whereby two of the slots are arranged on the side of the steering column 3 which is visible in FIG. 1 (and whereby the remaining slots are arranged on the opposite side of the steering column 3 and thus cannot be seen in FIG. 1 ). Two rods 7 extend through the steering column 3 and the slots 6 , which rods extend substantially perpendicular to the extension of the steering shaft 1 . The rods 7 are rotatably supported in brackets 8 , which are fixedly arranged on the outside of the steering column 3 .
With reference to FIG. 2, which is a perspective view from the front of the front end region of the steering column 3 , including one of the rods 7 , it is apparent that the rod 7 is provided with an energy-absorbing element which is preferably in the form of a wire 9 which can be unwound. One end of the wire 9 is fixed at an attachment point 10 on the short side 11 of the steering column 3 , while the rest of the wire 9 is wound about the rod 7 and is preferably also affixed thereto. The wire 9 is preferably a thick steel wire which is rolled out or unwound in the event that the steering column 3 attempts to be displaced in relation to the rod 7 . During such a displacement of the steering column 3 , the wire 9 offers a certain resistance, the amount of which is determined by the dimensions and material of the wire 9 , as well as its winding diameter. In this manner, the steering column 3 can absorb energy should a driver impact the steering wheel during a possible collision.
Each bracket 8 is provided with an attachment element in the form of a hook 12 . Referring once again to FIG. 1, it is apparent that each hook 12 has a region with a wedge-shaped cross section. Furthermore, each hook 12 is intended to be mounted in a corresponding wedge-shaped groove (not apparent from FIG. 1) in a first lower carriage 13 which constitutes a part of a further energy-absorbing arrangement. This carriage 13 is, in turn, displaceably arranged on the lower side of a second upper carriage 14 which is fixedly arranged on the lower side of the dashboard 4 . The arrangement with the two carriages, 13 and 14 , will now be described in detail with reference to FIG. 3 .
The lower carriage 13 is provided with a plurality of, preferably four, grooves or recesses 15 which serve as attachments for the above-mentioned hooks 12 (compare with FIGS. 1 and 2) which are arranged on the brackets 8 on the steering column 3 . When the complete device is in a mounted condition, the steering column 3 is thus fixedly arranged in relation to the lower carriage 13 by means of the brackets 8 and the hooks 12 . The upper carriage 14 is provided with holes or corresponding attachment means 16 intended for mounting to the dashboard which, in turn, is fixedly attached to the stress-bearing structure of the vehicle.
The lower carriage 13 is arranged with respect to the upper carriage 14 in such a manner that it can slide in the direction of its longitudinal extension which corresponds substantially to the longitudinal direction of the vehicle. For this purpose, the upper carriage 14 is provided with a suspension arrangement which is shown schematically in FIG. 3 in the form of a longitudinally extending guide 17 . Of course, more than one such guide 17 can be employed. Alternatively, the carriages can be suspended in a frame or a similar component so that the lower carriage can be displaced in its longitudinal direction. This displacement of the lower carriage 13 with respect to the upper carriage 14 occurs when certain predetermined operational conditions are present in accordance with that which is described in detail below.
An electrically-actuated solenoid 18 is arranged on the upper carriage 14 . The solenoid 18 is shown schematically in FIG. 3 and, in a known manner, comprises a displaceable piston 19 , the position of which is determined by providing a current from a source of power (not shown). In its non-influenced state, the piston 19 engages a corresponding hole or recess 20 in the lower carriage 13 . For this purpose, the piston is urged in the direction of the hole 20 by a spring 21 .
With the help of the solenoid 18 , the movement of the carriages, 13 and 14 , with respect to each other can be controlled. In the condition where no current is connected to the solenoid 18 , the piston 19 engages the hole 20 due to the influence of the spring 21 . This implies that the carriages, 13 and 14 , are locked with respect to each other. When a current is applied to the solenoid 18 , the piston 19 is withdrawn, whereby the force from the spring 21 is overcome. In this manner, the piston 19 is pulled out of engagement of the hole 20 , which now permits the lower carriage 13 to be displaced substantially horizontally with respect to the upper carriage 14 . In this condition, a second energy-absorbing element is also employed, this being in the form of a tongue or a strip 22 of metal. This strip 22 , which is also shown in FIG. 1, is attached at one end to the lower carriage 13 and at the other end to the upper carriage 14 . The strip 22 is somewhat curved and provides a predefined resistance, i.e. energy absorption, during displacement of the lower carriage 13 with respect to the upper carriage 14 .
The solenoid 18 is connected to a sensor arrangement, which is adapted to detect a condition which indicates whether or not the driver of the vehicle is wearing his seatbelt. For this purpose, the locking arrangement of the seatbelt is preferably provided with a switch 23 which is closed when the buckle of the seatbelt is locked. This indicates that the driver is wearing his seatbelt. The switch 23 is also connected to a source of energy which, in turn, is adapted to energize the solenoid 18 in the case where the seatbelt is being used. When the solenoid 18 is activated, its piston 19 is retracted from the hole 20 , which permits the above-mentioned displacement of the lower carriage 13 .
The present invention will now be described with reference to FIGS. 4 and 5 which, in a somewhat simplified manner, show its operation during a collision in which the steering wheel 2 , and thus also the steering column 3 , are influenced by a force F in a direction to the left in the drawings. FIG. 4 shows the condition which prevails when the seatbelt is not worn by the driver. This implies that the solenoid 18 is in its non-active position, whereby the piston 19 extends down into the hole 20 in the lower carriage 13 . Since the lower carriage 13 cannot then be displaced with respect to the upper carriage 14 , the steering column 3 will instead be displaced with respect to the lower carriage 13 , whereby the steering column 3 is displaced forwardly while the rods 7 are guided along the slots 6 . During this sequence of events, the energy absorbing wires 9 become unwound (compare with FIG. 2 ), which implies that the steering column 3 absorbs energy. This reduces the influences on the driver during an accident.
FIG. 5 shows the condition which prevails when the driver is wearing his seatbelt. In this situation, the solenoid 18 is actuated with the help of the above-mentioned sensor arrangement. This implies that the piston 19 is retracted so that it no longer projects into the hole 20 in the lower carriage 13 . In this manner, the lower carriage 13 becomes displaceable with respect to the upper carriage 14 . When the driver of the vehicle impacts the steering wheel 2 , the force F which thus arises will be transmitted to the lower carriage 13 (through the steering column 3 ), whereby the lower carriage 13 is displaced to the left in the drawing. During this sequence of events, energy will be absorbed by the energy-absorbing strip 22 which, during displacement of the lower carriage 13 , is extended and stretched out.
Preferably, the energy absorption capabilities of the wires 9 and the strip 22 are such that the strip 22 is more flexible than the wire 9 . In the case when the driver is wearing his seatbelt, this implies that the steering column 3 is not displaced with respect to the lower carriage 13 under the influence of the force F. This also implies that the system offers a lower resistance when a driver who is wearing his seatbelt impacts the steering wheel. This is because an amount of energy absorption during a collision is absorbed by the seatbelt itself.
By means of the present invention, two different types of energy absorption of the steering system are obtained. This is obtained automatically depending on whether or not the driver is wearing his seatbelt.
The present invention is not restricted to the above-described embodiments, but can be varied within the scope of the appended claims. For example, the size and choice of material for the steel wire 9 and the strip 22 can be varied depending on the desired energy absorption capability of the steering system. The energy absorption of the wire 9 and strip 22 is thus selected such that suitable energy absorption is obtained for the driver when driving without and with his seatbelt, respectively. The strip 22 can be made more flexible than the wire 9 , or vice versa. Furthermore, the wire 9 and the strip 22 can be replaced by other types of energy absorbing elements, for example ribbons, springs, material weakenings, etc. Instead of the steel wire 9 which is rolled about the rod 7 , other types of energy-absorbing elements can for example be arranged between the steering column 3 and respective brackets 8 for damping the force during displacement of the steering column 3 .
The two carriages can be locked with respect to each other either when the driver is wearing his seatbelt or when the driver is not wearing his seatbelt.
In accordance with one conceivable variation of the present invention, the function of the solenoid can also be controlled so that it is dependent on a weight sensor in the driver's seat which detects whether or not the occupant weighs more than a certain predetermined amount.
The two carriages, 13 and 14 , can be designed in different ways, for example in the form of box- or cassette-like elements which can be displaced substantially parallel with respect to each other. Nevertheless, it is a principle underlining the present invention that the two can be locked together with respect to each other depending on whether or not the driver is wearing his seatbelt.
The attachment of the steering column 3 can be achieved in various ways. For example, screws or similar attachment means can be used instead of the hooks 12 . Furthermore, the carriages, 13 and 14 , can be attached to the stress-bearing structure of the vehicle in a manner other than to the underside of the dashboard 4 . In addition, the slots 6 which are in the steering column 3 can for example be two in number instead of four as shown in the drawings.
The solenoid can be arranged such that its piston projects downwardly (see for example FIG. 4 ), upwardly, or to the side. For example, in accordance with a further variation, the solenoid can be arranged in the lower carriage, whereby its piston projects upwardly into a hole in the upper carriage.
Furthermore, more than one solenoid can be used as the locking means for the carriages.
The two carriages can be arranged as an upper and a lower carriage or, alternatively, as two carriages which are at least partially arranged side by side.
According to an alternative embodiment, the lower carriage 13 can be arranged directly against the underside of the dashboard. In such an arrangement, the solenoid and the one end of the strip 22 are also arranged on the underside of the dashboard.
Finally, it is to be appreciated that the invention can be employed in different types of vehicle, for example cars, trucks or buses.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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Apparatus and methods for protecting the occupant of a motor vehicle including a seat belt for restraining the occupant and a stress-bearing structure are disclosed. The apparatus includes a steering shaft, a steering column supporting the steering shaft, the steering column displaceably mounted with respect to the stress-bearing structure, a first energy absorber for absorbing energy upon displacement of the steering column with respect to the stress-bearing structure by the occupant, a sensor for detecting a condition in which the occupant is restrained by the seat belt, a second energy absorber for absorbing energy upon displacement of the steering column with respect to the stress-bearing structure by the occupant, and a lock for permitting absorption of energy by the second energy-absorbing unit by displacement of the steering column with respect to the stress-bearing structure by the occupant when the condition is detected by the sensor.
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BACKGROUND OF THE INVENTION
The present invention relates to portable restrooms. More specifically, the invention relates to portable restrooms with a multipurpose base design that can also be used as a fluid tank.
Many situations exist where portable restrooms are a beneficial and convenient fixture. For example, where special events are conducted and large amounts of people are temporarily going to be in certain locations, it is very beneficial to add a large number of portable restrooms which can be selectively placed at a location and then removed after the event. Additionally, in certain seasonal situations, it is beneficial to utilize portable restrooms which can then be used seasonally. For example, golf courses may typically include portable restrooms which can then be removed during the off seasons. Construction sites also provide another situation where portable restrooms are beneficial.
Portable restrooms can be classified in two categories: (1) flushing; and (2) non-flushing. Fresh Flushing portable restrooms require the addition of a fluid supply so that this flushing capability can be provided. In these situations, an additional fluid tank is added to the restroom as an external component. Also, pumps and fluid handling equipment are necessary to provide the flushing function. While very beneficial, the additional fluid tank is very cumbersome and subject to vandalism. Also, this additional component adds cost to the restroom. Further, this additional component extends from the basic structure of the restroom and makes transportation much more difficult.
In non-flushing models, no additional fluid is utilized. The restroom simply includes a waste holding tank which can be serviced as necessary.
As can be expected, portable restrooms are typically moved quite often. Also, these portable restrooms are typically placed directly on the ground and may often be slid around to appropriately position them. Consequently, a rugged support structure is required on the bottom portion of the portable restroom. This structure must be able to support the weight of the restroom while also withstanding wear caused by continuous movement and repositioning.
As is easily recognized, it is very undesirable to have the portable restrooms easily tip or fall over. As is well known, these portable restrooms are typically placed outdoors and must withstand high winds and other conditions. Consequently, it is beneficial to provide a considerable amount of weight in the bottom portion of the restroom in order to provide stability. This will help to keep the structure upright and avoid tipping.
SUMMARY OF THE INVENTION
In order to provide a portable restroom design which provides a great number of advantages and meets many of the above-referenced requirements, a multipurpose base assembly is used. This base assembly includes two basic components—a supporting structure and a tank/floor member. The supporting structure is preferably molded, blow molded, or twin sheet formed using material which is preferably greater than 0.2 inches in thickness. In one version, the supporting structure includes two separate molded runners which are arranged in a substantially parallel configuration beneath the tank member. Additionally, the tank member includes an internal chamber capable of maintaining liquids. This internal chamber can then be utilized to provide flushing fluid in a flushing restroom. Alternatively, if the flushing capability is not desired, the tank feature is not utilized and this simply provides a support floor for the restroom.
In order to maintain the flushing capability and not puncture the internal tank, the tank member is designed with a number of attachment flanges to accommodate fasteners. Utilizing these attachment flanges, fasteners can be inserted through attachment points without puncturing or interfering with the internal chamber. Consequently, the internal chamber is maintained and can easily contain a liquid.
In addition to the fluid tank capabilities, the base assembly allows the support structure to be separately molded, utilizing a heavier design. More specifically, the support structure, or runners, can be molded utilizing thicker walled design thus increasing the weight of these components. This provides the additional benefit of adding weight to the bottom portion of the restroom. Also, this thicker plastic increases the durability of the support structure, thus better accommodating the typical handling of the restroom. In one version, the support structure includes a pair of runners which are attached at an outer portion of the assembly. These runners easily withstand the sliding of the restroom. Additionally, the runners are easily replaced should they become overly work or damaged.
In addition to the heavier weights, the runners of the present invention are provided with an interlocking configuration so that the tank member and runners can be connected in a more robust manner. More specifically, the runners are provided with tabs extending from one side thereof. Also, the tank member is provided with a number of recesses or openings specifically designed to accommodate these interlocking tabs. When mated together, the runners and tank member provide a snap fit or interlocking configuration. The rigidity and stability of the overall unit is then enhanced by adding fasteners, such as lag bolts, which more permanently attach the runners to the tank member. This snap fit or interlocking connection provides multiple advantages. First off, the runner and tank member will be held together to accommodate the placement of further fasteners. Obviously, this makes the assembly process much smoother and more efficient. Additionally, this interlocking feature provides longitudinal strength to the connection. Oftentimes, the restroom is pushed along the ground perpendicular to the direction of the runners. By having an interlocking connection between the tank member and the runners, the strength of the connection is enhanced. More specifically, the longitudinal forces are distributed between the interlocking tab members, rather than being directed exclusively to the connectors. Consequently, a more structurally sound, robust, and efficient connection is achieved by having this interlocking feature.
Occasionally, it is necessary to lift the restroom and place it at appropriate locations. This is typically done by utilizing an overhead crane or boom of some type which has a cable attached to an upper portion thereof. When lifted, the weight of the restroom is then carried at those connection points. By having the runners snap fit into the base unit, the weight of the runners is more evenly distributed throughout various portions of the base unit, and not simply carried by the fasteners themselves. This provides additional load handling and load distribution when the restroom is handled in this fashion.
The tank member is also a molded unit which includes both the internal chamber for maintaining liquid, and all necessary structural supporting members so that it can also operate as a restroom floor. That is, the tank member is designed with appropriate support members so that the weight of users and additional components can be handled. Machined within the tank member are appropriate openings to provide for fluid handling. Specifically, a filling opening is provided which can easily accommodate a standard garden hose. Consequently, this aids in the ability to fill the base unit tank with flushing fluid as necessary. Additionally, appropriate connection ports and openings are provided to allow a pump to be attached thereto and pump hoses to be inserted.
In order to accommodate easy filling and pumping of the base unit tank, a fluid handling structure is configured for attachment to the rear of the portable restroom. This fluid handling structure includes a bezel for both filling and pumping of base unit tank. The hose is configured to extend through a filling opening in base tank, and into the fluid supply area. The bezel structure is attached thereto, such that the insertion of a hose (garden hose) into an opening in the bezel allows fluid to flow into base unit tank. However, when it is necessary to remove fluid, this bezel and hose structure also accommodates this operation. That is, a service wand is positioned directly over the opening in the bezel structure. By drawing a vacuum on the service wand, fluid is then drawn back through the hose and bezel, out of the base unit tank. The advantage of this filling and pumping mechanism is that a large hole does not need to be placed directly in the base unit tank. More specifically, it is not necessary for the service wand to be inserted into the tank, therefore a large opening is not necessary.
It is an object of the present invention to provide a restroom base that includes an integral tank which can be used to contain flushing fluid. By incorporating this tank into the base, the need for an additional external fluid tank is eliminated.
It is an object of the present invention to provide a base assembly having all necessary structural support capabilities to allow proper operation of the restroom. Additionally, it is an object to have a base assembly which includes an integral fluid tank for maintaining flushing liquid therein.
It is a further object of the present invention to provide a base assembly which has additional mass and weight which can be placed in a lower portion thereof. This provides the additional advantage of overall stability for the portable restroom.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the present invention can be seen by referring to the following detailed description, and the drawings in which:
FIG. 1 is a perspective view of a portable restroom which includes the base assembly of the present invention;
FIG. 2 is an exploded view of the components making up the base assembly;
FIG. 3 is a perspective view of the base assembly;
FIGS. 4 and 5 are cross sectional drawings showing the snap fit relationship between the runners and the tank member;
FIGS. 6 and 7 are cross sectional drawings showing the complete base assembly; and
FIG. 8 is a cross sectional drawing of the vacuum bezel and fill structure used in the base tank.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown a base assembly 10 for use in a portable restroom. As expected, this base assembly is situated on the bottom of the restroom and support all other necessary components 18 . Those additional components 18 include a waste tank 12 , enclosure walls 14 , an enclosure roof 16 , and an enclosure door (not shown). As shown in FIG. 2, base assembly 10 is comprised of a tank member 20 and a support structure 30 . Support structure 30 consists of a first runner 32 and a second runner 34 . Tank member 20 is supported by first runner 32 and second runner 34 and spans the distance there between. As more fully described below, tank member 20 includes a number of recesses and grooves on the bottom side thereof to receive both first runner 32 and second runner 34 .
As can be seen in FIGS. 2 and 3, tank member 20 includes a planer upper surface 22 covering a portion thereof. Tank member 20 also includes a recess 24 in the back portion thereof. As expected, the waste tank 12 is typically positioned in the back portion of the portable restroom. Consequently, recess 24 is configured to accommodate waste tank 12 . Referring to FIG. 7, which is a cross sectional diagram showing tank member 20 and first runner 32 . As can be seen, recess 24 is situated in a back portion 26 of tank member 20 .
Referring now to FIGS. 4 through 6, the interrelationship between first runner 32 , second runner 34 , and tank member 20 can be more fully seen. First runner 32 and second runner 34 are specifically designed to have inward mating tabs 36 and 37 on an inner side thereof. Inward mating tabs 36 and 37 are specifically designed to mate with adjoining contours in tank member 20 . Additionally, a first outer tab or outer rib 38 is designed into first runner 32 , and second outer tab or outer rib 39 is designed into second runner 34 . Again, outer tabs 38 and 39 are specifically configured to mate with adjoining surfaces in tank member 20 . Inward tabs 36 and 37 can be configured in a number of maimers. However, it is important that inward tabs 36 and 37 have at least one horizontal or horizontally extending portion 40 . These horizontal portions 40 extend from the main inner surface 42 of first runner 32 and second runner 34 . Similarly, outer tab 38 includes at least one vertically extending portion 44 . Vertically extending portions 44 are specifically designed and intended to mate with corresponding elements 46 of tank member 20 . Once assembled, vertical member 44 and tank element 46 are juxtaposed in relation to one another.
Outer tabs 38 and 39 , and inner tabs 36 and 37 are specifically configured and designed to provide for the snap fit attachment of first runner 32 and second runner 34 . When assembled, these members are pressed in place and will stay attached until a predetermined amount of force is used to disassemble them. To further enhance attachment, a fastener 50 is used to connect first runner 32 and second runner 34 to tank member 20 . Fastener 50 is typically a lag screw, however various types of fasteners, such as rivets, can be used.
By providing this snap fit connection between tank member 20 and first runner 32 , multiple advantages are achieved. For example, assembly is simplified because the runners are held in place while fastener 50 is attached. Also, it is not uncommon for portable restroom 18 to be lifted at various times. By having first runner 32 and second runner 34 snap fit to tank member 20 , the weight of first runner 32 and second runner 34 is evenly carried by multiple points in the assembly. If a snap fit connection was not used, all of the weight would simply be carried by the fastener, thus creating excessive strain thereon. This is especially beneficial as first runner 32 and second runner 34 are designed to be somewhat heavy, thus providing stabilization of restroom 18 .
Referring again to FIG. 2, it can be seen that first runner 32 also includes a first recessed notch 70 on an inner portion thereof. This notch essentially consists of a cutout portion or notch in inward mating tab 36 . Similarly, second runner 34 includes a second notch 72 on an inner portion thereof. First notch 70 and second notch 72 are designed to provide drainage for any fluid that may enter the recess formed between tabs 36 and 38 .
As previously mentioned, it is not uncommon for restroom 10 to be moved and/or slid during use. If the restroom is slid along the axial direction of first runner 32 and second runner 34 , forces will be naturally encountered by the various components of restroom 10 . First notch and second notch 72 provide structure which can help handle these forces. Also, the pair of outer ribs 38 and 39 wrap around either side of the restroom to help deal with these forces. Specifically, a front portion 84 of outer rib 38 wraps around the front side of tank member 20 . Similarly, a rear portion 86 of outer rib 38 wraps around the rear of tank member 20 . Outer rib 39 of runner 34 has a similar front portion 88 and rear portion 90 . If these structures were not present, this sliding force would be presented as a sheer force on connectors 50 .
As previously mentioned, tank member 20 is provided with an internal chamber 28 which is specifically designed to function as a fluid tank. By utilizing this component as a fluid tank, a potentially cumbersome external component is eliminated. Again, all portable restrooms do not include a flushing capability. When this flushing feature is desired, an external fluid tank has typically been installed. By having internal chamber 28 function as an integrated fluid tank, the often cumbersome external fluid tank is eliminated. Additionally, by integrating the fluid tank into tank member 20 , additional stabilization capabilities are achieved. That is, the inclusion of fluid in the base unit adds additional weight to a lower portion of restroom 18 , thus providing further stability and potentially avoiding tipping.
As is expected, tank member 20 can be reconfigured in any number of different manners. Naturally, it is necessary to provide stability for tank member 20 as this also doubles as a restroom floor. Consequently, necessary load members must be included to support the weight of restroom users.
In order to accommodate fasteners 50 , certain attachment features must be incorporated within the design of tank member 20 . Naturally, care must be taken to insure that fasteners 50 do not puncture or in any way enter internal chamber 28 . Referring again to FIGS. 5 and 6, it can be seen where tank member 20 includes attachment flanges 58 to accommodate this attachment. These attachment flanges are adapted to accommodate fasteners 50 passing there through, without interfering with internal chamber 28 . As previously mentioned, a snap fit design is specifically used to further enhance attachment of first runner 32 and second runner 34 to tank member 20 . This also helps to reduce the number of fasteners required in the assembly. Thus, fewer fasteners can be used in the overall design. This further helps by minimizing the need for special structures to accommodate fastening.
In order to accommodate operation as a flushing restroom, tank member 20 is provided with a filling hole 60 , as seen in FIG. 2 . Filling hole 60 is designed to accommodate a standard garden hose, or another fill hose to allow filling internal chamber 28 with fluid. Additionally, pump out structure 62 allows a vacuum wand to be placed against a fill port fitting, allowing fluid to be drawn from this tank.
Referring now specifically to FIG. 8, there is shown a cross sectional diagram illustrating a filling structure 100 used in cooperation with the base tank 20 of the present invention. Generally speaking, filling structure 100 includes a bezel 102 structure which is positioned on an outer surface of a restroom wall 104 . Specifically, this filling structure 100 is situated on a rear panel or rear wall 104 of the restroom, thus is not easily seen by the customer. Attached to bezel 102 is a filling hose 110 which extends through filling hole 60 and into the interior 28 of tank member 20 . This structure allows for easy filling and draining of fluid from tank member 20 , should that be necessary.
The fill opening 112 of bezel 102 is specifically configured to allow a typical garden hose to be inserted there through. This accommodates easy filling of the base tank without the need for additional tools and/or adapters. Also, bezel 102 includes a flat sealing surface 114 which is configured to cooperate with a service wand 120 , thus allowing the tank to be easily emptied. Service wand 120 is traditionally attached to a pump or vacuum mechanism, which is typically carried by a service vehicle. The operator can easily press service wand 120 against sealing structure 114 , and operate the vacuum pump. By doing this, water is drawn from internal chamber 28 of tank member 20 . After this water has been removed, the restroom can be easily moved or repositioned as necessary.
As can be appreciated, the specific configuration of tank member 20 may vary depending upon several factors. More specifically, if a different support structure is used, related changes must be made in tank member 20 . For example, the support structure could easily be configured as a web or grid of support points (as opposed to first runner 32 and second runner 34 ). As can be easily appreciated, tank member 20 could appropriately be reconfigured to cooperate with this modified support structure. Despite this modification of elements, the integral tank can still be incorporated into this tank member design. As previously mentioned, having an integral tank member provides the distinct advantage of eliminating a separate tank.
Those skilled in the art will further appreciate that the present invention may be embodied in other specific forms without departing from the spirit or central attributes thereof. In that the foregoing description of the present invention discloses only exemplary embodiments thereof, it is to be understood that other variations are contemplated as being within the scope of the present invention. Accordingly, the present invention is not limited in the particular embodiments which have been described in detail therein. Rather, reference should be made to the appended claims as indicative of the scope and content of the present invention.
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In order to provide additional flexibility in a portable restroom, a base assembly is specifically designed to include an internal tank capable of maintaining and carrying flushing fluid. Thus, when a flushing restroom is desired, an additional tank is not needed. In order to convert to a flushing model, the base assembly is simply filled with appropriate liquid, and a pump is added. In addition to providing additional capabilities, the additional fluid in the base unit provides for more weight, thus increasing the stability. Also, the base assembly has a support structure which can be snap fit to the tank member. By allowing the snap fitting feature, the support structure can be designed very rugged, however will very easily and completely attach to the tank member.
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BACKGROUND OF INVENTION
1. Field of Invention
The present invention relates to a method and an apparatus for joining separated blocks of dough, and for supplying a continuous sheet of dough formed from the joined dough blocks. In particular, the present invention relates to a method and apparatus for joining a first kneaded dough block to a subsequently-provided kneaded dough block such that the gel structures of the dough blocks are integrally joined to form a continuous dough sheet on a production line.
2. Prior Art
In a conventional apparatus, a plurality of dough sheets are formed by pressing individual kneaded dough blocks, and then portions of each dough sheet are cut away to produce, for example, bread products. Each dough sheet has a volume corresponding to the volume of the kneaded dough block from which it was formed. The entire dough sheet is used in one production lot, or each part of the dough sheet is used in a production lot. When one dough sheet is used in a production lot, production time is lost between the adjacent dough sheets when they are fed by a conveyor. Also, fragments which remain after portions of the dough sheet are cut away are not used during production.
In a conventional apparatus, if necessary, adjacent dough sheets are joined to each other by a manual operation. That is, a rear end of a dough sheet is piled on a front end of a subsequently-formed dough sheet, and then the piled ends are manually pressed such that they adhere to each other. There is no apparatus to perform this sheet joining operation. Thus, the operation must be manually performed whenever a gap appears between sequentially-formed dough sheets, so that a significant amount of manual labor is needed to perform the joining operation. In bread production lines, unmanned production is usually performed to make bread from dough sheets that have the same conditions in their degree of composition and kneading, because technology to make a thin dough sheet has been improved and is now broadly used. However, when many kinds of breads that have several shapes and additional ingredients, such as fillings, are made on the same production line, much manual work is needed to join sequentially-formed dough sheets.
A gel structure is formed in a dough mass during a mixing operation. When the dough mass is cut to form individual dough blocks, the gel structure of each dough block is separated from the dough mass and from all previously-formed dough blocks. Thus, in order to join two separated dough blocks, it is necessary to join their gel structures. Currently, there is no apparatus for automatically joining the gel structures of two dough blocks.
SUMMARY OF INVENTION
An object of the present invention is to overcome the disadvantages of the prior art.
In accordance with the present invention, a method and apparatus are provided for automatically joining a first dough block to a subsequently-formed dough block, so that a very long and continuous dough sheet is automatically made, and so that unmanned production over a 24 hour period is achieved.
The present invention allows gel structures of dough blocks to be automatically joined to each other. This invention also allows several kinds of breads to be produced during a non-stop production process. In a conventional apparatus there are many production lots corresponding to the mixing operations of the dough. This invention allows a continuous dough sheet corresponding to one production lot to be made. Thus, this invention allows segmentation of douch sheets to be minimized. Also, this invention minimizes the time between the processing of subsequently-formed dough sheets.
One object of the present invention is to provide a method and apparatus for joining dough blocks to each other. The apparatus comprises horizontally and oppositely-positioned pairs of rollers provided in a plurality of tiers. The rollers are arranged such that the distances between the roller pairs in the upper tiers are sequentially greater than the distances between the roller pairs in the lower tiers, thereby forming a “V” shaped space for receiving the dough blocks. Each pair of rollers is rotated in an opposite direction such that a surface of each roller facing the “V” shaped space pushes the dough blocks downward. In addition, the distances between the roller pairs are alternately increased and decreased, thereby causing a pressure applied to the dough blocks by the rollers to alternately increase and decrease to produce a vibrations in the dough blocks as the dough blocks are impelled downward. The resulting thixotropic effect in the dough produced by these vibrations accelerates the growth of gluten and the joining of gel structures of the dough blocks, and a continuous belt-like dough sheet is thereby formed.
The method uses horizontally and oppositely positioned pairs of rollers provided in a plurality of tiers. The rollers are arranged such that the distances between the roller pairs of the upper tiers are sequentially greater than the distances between the roller pairs of the lower tiers, thereby forming a “V” shaped space for receiving the dough blocks. The method includes rotating the rollers of each pair in opposite directions while alternately increasing and decreasing the distances between the rollers of each pair such that a pressure applied by the rollers to the dough blocks is alternately increased and decreased, thereby impelling the dough blocks downward. The resulting vibrations in the dough produced by this pressing and releasing action accelerates the growth of gluten and the joining of gel structures of the dough blocks, and a continuous belt-like dough sheet is thereby formed from the dough blocks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a bread production apparatus that includes a first embodiment of an apparatus for joining dough blocks according to the present invention.
FIG. 2 is an enlarged schematic side view of the apparatus shown in FIG. 1 .
FIG. 3 is a schematic side view for explaining operation steps of the apparatus shown in FIG. 2 .
FIG. 4 is a schematic side view for explaining operation steps of the apparatus shown in FIG. 2 .
FIG. 5 is a schematic side view of a second embodiment of the apparatus for joining dough blocks according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a bread-making apparatus that includes an apparatus 1 for joining dough blocks in accordance with a first embodiment of the present invention. A bowl 2 mixes and kneads materials to make a dough mass 4 . The dough mass 4 is supplied from the bowl 2 onto a conveyor or a dough feeder 3 . The dough feeder 3 feeds the dough mass 4 to a set of rotatable cutter blades 5 , which separates dough blocks 6 from the dough mass 4 . The dough blocks 6 are then supplied to the joining apparatus 1 in response to signals from a sensor 21 (shown in FIG. 2 and discussed below). The joining apparatus 1 joins dough blocks to each other to provide a continuous belt-like dough sheet 7 which is deposited from a lower opening of the joining apparatus 1 onto a first conveyor 8 . The dough sheet is continuous (i.e., not separated by gaps). The first conveyor 8 feeds the dough sheet 7 to a dough-extending apparatus 9 . The extending apparatus 9 presses and extends the dough sheet 7 to make a pressed dough sheet 10 having a predetermined thickness and width required for making desired bread products. The dough-extending apparatus 9 feeds the pressed dough sheet 10 to a second conveyor 11 . A depositing apparatus 12 is located above the second conveyor 11 so as to supply a filling, such as jam or meat, onto the pressed dough sheet 10 . A cutting apparatus 13 is positioned over the second conveyor 11 . The cutting apparatus 13 moves vertically to cut the pressed dough sheet 10 into pieces 14 , each piece 14 having a desired length and width. Also, the cutting apparatus 13 may provide desired shapes to the pieces 14 . Then resulting dough pieces 14 are continuously output from the cutting apparatus 13 .
FIG. 2 is an enlarged view of a part of the bread-making apparatus shown in FIG. 1. A hopper 22 is positioned at the forward end of the dough feeder 3 .
The rotatable cutter blades 5 are positioned at a bottom opening of the hopper 22 . The joining apparatus 1 is located under the opening of the hopper 22 and the rotatable cutter blades 5 . A sensor 21 is positioned near an upper opening of the joining apparatus 1 , and senses whether an amount of dough in the joining apparatus 1 decreases to such an extent that the upper surface of the dough is below a predetermined level in the joining apparatus 1 . When the sensor 21 senses the surface of the dough in the joining apparatus 1 is below a predetermined level, it outputs a signal. In response to this signal, the dough feeder 3 is driven to feed the dough mass 4 into the hopper 22 . Simultaneously, the dough cutter blades 5 are rotated. When the dough mass 4 is supplied from the dough feeder 3 to the hopper 22 , a dough block 6 is cut from the dough mass 4 by the blades 5 , which are located at the bottom opening of the hopper 22 , thereby causing the dough block 6 to have a predetermined volume. The cut dough block 6 drops into the upper opening of the joining apparatus 1 . As a result, the amount of dough in the joining apparatus 1 is increased such that an upper surface of the dough is above the predetermined level.
The joining apparatus 1 includes a first roller group 20 including rollers 23 , 24 , 25 and 26 , and a second roller group 20 ′ including rollers 23 ′, 24 ′, 25 ′ and 26 ′. In the embodiment shown in FIG. 2, each roller of the first and second groups 20 and 20 ′ is cylindrical, and is shown in end-view in FIG. 2 . The rollers 23 - 26 are parallel and aligned in a first row, and the rollers 23 ′- 26 ′ are also parallel and aligned in a second row. The first and second rows of rollers are arranged to form a “V” shaped space for receiving the dough blocks 6 cut by the blades 5 . Each roller of the first group is arranged opposite to a corresponding roller of the second group in a horizontal plane or tier. For example, rollers 23 and 23 ′ are arranged in an uppermost tier and are separated by a first horizontal gap forming the upper opening of the joining apparatus 1 . Likewise, rollers 26 and 26 ′ are arranged in a lowermost tier and are separated by a second horizontal gap forming the lower opening of the joining apparatus 1 . The first horizontal gap is greater than the second horizontal gap. The remaining opposing roller pairs (that is, 24 and 24 ′, and 25 and 25 ′) in the respective intermediate tiers are spaced apart to form the “V” shaped space. In addition, the rollers of the first group 20 are rotated in an opposite direction from the rollers of the second group 20 ′ by a suitable driving means (not shown) such that the dough blocks therebetween are pushed downward. For example, as indicated in FIG. 2, the rollers of the first group 20 are rotated clockwise, while the corresponding rollers of the second group are rotated counter-clockwise. In addition to rotating, each roller reciprocally swings or linearly moves toward and away from its opposing roller. Thus, the rollers in an opposite roller pair are alternately moved toward and away from each other in a horizontal plane, so that the gaps between them are repeatedly increased and decreased. When the opposing rollers move toward each other, pressure on the dough therebetween is increased. When the opposing rollers move away from each other, the pressure is decreased. The rate of movement of the opposing rollers is selected such that the repeated increase and decrease in pressure applied to the dough produces vibrations which create a thixotropic effect in the dough. As a result, the gluten in the dough increases and the gel structures of the dough blocks are joined to each other.
The circumferential speeds of the lower rollers of the groups are lower than those of the upper rollers of the groups. However, the circumferential speeds of all of the rollers may be the same. Also, the speeds of the rollers of one group may differ from those of the rollers of the other group.
FIG. 3 shows the joining apparatus 1 , in which the circumferential speeds of the lower rollers of the groups are lower than those of the upper rollers. For example, the speeds of the rollers 25 , 25 ′, and 26 , 26 ′ are lower than those of the rollers 23 , 23 ′ and 24 , 24 ′. Parts of the surfaces of each dough block 6 that contact the upper rollers 23 , 23 ′, and 24 , 24 ′ are drawn downward as the rollers rotate. Then, these parts and/or other parts of the surface of each dough block 6 that contact the lower rollers 25 , 25 ′, and 26 , 26 ′ are drawn to the lower opening of the joining apparatus 1 . Thus, the parts of the dough block 6 that contact the upper rollers flow faster than those that contact the lower rollers.
However, parts of each dough block 6 located in the middle of the “V” shaped space between the opposite roller pairs (that is, parts which do not contact any roller) flow faster than the parts that contact the rollers. This occurs because the pressure applied by the opposing roller pairs to each dough block 6 when the opposing rollers approach each other forces the dough blocks downward toward the lower opening, rather than the dough blocks being drawn by the rotations of the rollers 23 , 23 ′, 24 , 24 ′, 25 , 25 ′, 26 , and 26 ′. Thus, as shown in FIG. 3, parts of each dough block 6 that do not contact the rollers and that are generally positioned at the middle between each opposing roller pairs flow faster than those that contact the rollers.
In detail, a lower surface of a dough block 6 is generally flat (horizontal) when the dough block is supplied from the hopper 22 onto the top surface of a previously-supplied dough block located in the joining apparatus 1 . As the dough block is drawn downward into the joining apparatus 1 , the lower surface of the dough block 6 that contacts the upper surface of the previously-supplied dough block descends at a higher rate at the mid-point between the opposing roller pairs such that the dough block becomes V-shaped. This V-shaped layer is gradually elongated as the dough block 6 descends further into the joining apparatus 1 , so that the surface areas of adjacent dough blocks that contact each other are increased. Then, the layer extends longitudinally. Simultaneously, the roller pairs move toward and away from each other to press the dough block and release the pressure from the dough block, so that the contacted surfaces are vibrated by the motions of the rollers. As a result, the adhesion between the contacted surfaces of the adjacent dough blocks is increased. Also, the receding and approaching movements of the rollers function as a tapping motion on the dough blocks, resulting in generating a thixotropic effect. Thus, the flowage of the dough is increased and the joining of the gluten in the dough is accelerated. Finally, the joining apparatus 1 supplies a continuous and belt-like dough sheet 7 through the lower opening onto the first conveyor 8 .
FIG. 4 shows the joining apparatus 1 , in which the circumferential speeds of the rollers of one group differ from those of the rollers of the other group. That is, the circumferential speeds of the rollers 23 , 24 , 25 , and 26 of the group 20 are faster than those of the rollers 23 ′, 24 ′, 25 ′, and 26 ′ of the group 20 ′. As a result, as shown in this figure, the parts of each dough block 6 that contact the rollers 23 , 24 , 25 , and 26 are drawn down faster by these rollers than the parts of each dough block 6 that contact the rollers 23 ′, 24 ′, 25 ′, and 26 ′. Thus, each separated dough block 6 is modified to form long continuous dough layers. The movements of the rollers toward and away from each other increases adhesion between the dough layers. Then, the joining apparatus 1 supplies a continuous and belt-like dough sheet 7 to the first conveyor 8 .
FIG. 5 shows another embodiment, namely, 1 ′, of the joining apparatus 1 as in FIG. 1 . It includes a group 50 of rollers 51 , 52 , 53 , and 54 and the group 20 ′ of the rollers 23 ′, 24 ′, 25 ′, and 26 ′. The cross-sectional shape of each roller of the group 50 is hexagonal. These hexagonal rollers impel the dough with a stronger force than the cylindrical rollers, so that each separated dough block 6 is modified more effectively into long continuous dough layers along the longitudinal direction of the flow of the dough. The long continuous dough layers extending in the longitudinal direction of flow of the dough have large contact surfaces. Thus, the resulting thixotropic effect unites the gel structures of the dough layers.
Polygonal rollers may be used for the sectional shape of the rollers. Also, polygonal rollers may be used for the upper rollers of the joining apparatus 1 in FIG. 1, so that the same effects as is the case as in FIG. 4 can be generated.
In the above embodiments, either or both of the group 20 ′ of the rollers 23 ′, 24 ′, 25 ′, and 26 ′ and the group 20 of the rollers 23 , 24 , 25 , and 26 or either or both of the group 20 ′ of the rollers 23 ′, 24 ′, 25 ′, and 26 ′ and the group 50 of rollers 51 , 52 , 53 , and 54 is/are reciprocally swung or linearly and reciprocally moved. However, this invention is not limited to these configurations. For example, the distances between the opposite roller pairs may be changed so that their pressing movements are sequentially generated between them from above downwards. Also, the distances between the opposite roller pairs may be alternately changed in the vertical direction such that the pressing movements between the opposite roller pairs are alternately effected in the vertical direction.
By this invention gel structures in respective dough blocks are joined to each other by repeatedly providing pressing and vibrating operations to the dough blocks, so that the dough blocks are deformed and piled upon each other to form layers. Thus, a continuous belt-like dough web is formed.
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An apparatus for joining dough blocks to form a continuous dough sheet. The dough blocks are cut from a dough mass and drop into a space between first and second groups of rollers. The first and second groups of rollers include horizontally-paired rollers arranged in tiers and forming a substantially V-shaped space for receiving the dough blocks, with the uppermost pair of rollers being separated by a first horizontal gap which is wider than a second horizontal gap separating the lowermost pair of rollers. The first group of rollers are rotated in a direction (e.g., clockwise) which is opposite to that of the second group of rollers. In addition, the first group of rollers is alternately moved toward and away from the second group of rollers, thereby applying vibrations to the dough blocks. The combined rotation and vibrations of the rollers impels the dough blocks downward toward the second gap between the lowermost pair of rollers and increases gluten growth and a joining of the gel structures to produce a continuous dough sheet.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The following application is a continuation-in-part of U.S. patent application Ser. No. 09/903,737 filed Jul. 7, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates to hole diggers. In particular, the invention describes a post hole digger that makes uniform diameter holes.
BACKGROUND OF THE INVENTION
[0003] To utilize the post hole diggers generally in use, the hole digger is thrust into the ground and the handles are pulled apart to close the blades and scoop out the dirt. As the hole becomes deeper, the upper portion of the hole becomes progressively wider and larger in diameter. A three-foot deep hole made with a traditional hole digger with a closed blade having an+ approximate diameter only five inches must be opened up ten to eleven inches at the top. The hole created will be tapered which creates a lack of ground support when concrete or similar fill material is used to keep a post or pole in position. The instant invention enables the digging of post holes of essentially uniform diameter from ground surface level to the bottom of the hole.
SUMMARY OF THE INVENTION
[0004] The present invention is able to dig a hole without appreciably enlarging the upper section of the hole. The present device is comprised of a pair of handles, two metal scoops and a hinge bracket. In an alternative embodiment, the device may comprise two unitary pieces incorporating the handle and scoop into one unit with the unitary pieces joined by a hinge bracket. In another embodiment, each scoop is contiguous with a hinge bracket section, forming one piece. The hinge bracket is designed to limit the movement from the elongated handles and to translate the movement to the scoops. In the most preferred embodiment, the handles slightly cross in front of each other while in the open scoop position and open to form two parallel straight lines when the scoops are closed.
[0005] In a preferred embodiment, the scoops are joined together to provide strength and limitation of movement. The digging scoops can be joined together by a bolt or, in a preferred embodiment, one of the scoops may have a fixed protrusion fitted into a slot formed in the second scoop to allow a sliding movement of the first scoop providing a more secure hold on dirt, soil or gravel when the scoops are closed. The hinge bracket is positioned near the midpoint of the pair of handles or, alternatively, between the midpoint of the handles and the top of the digging scoops. The bracket hinge limits the movement of the handles and translates the handle movement to the digging scoops.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1A shows a side view of an embodiment of the post hole digger in which a bolt holds the scoops together.
[0007] [0007]FIG. 1B shows a side view of a preferred embodiment of the post hole digger.
[0008] [0008]FIG. 2 shows a top cross section of the hinge bracket.
[0009] [0009]FIG. 3A shows the scoops in a preferred embodiment slidably attached using a bolt-slot sliding union.
[0010] [0010]FIG. 3B depicts a pair of unattached scoops.
[0011] [0011]FIGS. 4A and 4B show side views of alternative embodiments of the post hole digger where each scoop is contiguous with a hinge bracket section, forming one piece.
[0012] [0012]FIG. 4C shows a front view of the alternative embodiment shown in FIG. 4B, illustrating the location of the handles at the open position of the scoops.
[0013] [0013]FIG. 5 shows a front view of an embodiment of the groundbreaking edge of the digging scoop.
[0014] [0014]FIGS. 6A and 6B show the post hole digger of the instant invention and a prior art post hole digger, respectively, in operation digging a hole.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The preferred embodiment of the present invention will now be described with reference to accompanying drawings. It will nevertheless be understood that no limitations of the scope of the invention is thereby intended, such alterations as scale of the parts, materials used, position of the hinge bracket, color or weight which would fall within the spirit and the scope of the invention described herein.
[0016] [0016]FIG. 1A shows a side view of one embodiment of the post hole digger 14 . The post hole digger 14 is comprised of two handles 8 approximately four to six feet long with a diameter of approximately one inch. Blades 12 a and 13 a of scoop 28 are fixedly attached at one end of one of each handle 8 . The handles 8 are joined by a hinge bracket 9 attached to the two handles. The hinge bracket 9 has a pin 7 that rotates to translate the motion applied to the handles 8 into movement of the scoops 28 allowing the opening and closing of the scoops 28 . In a preferred embodiment, the hinge bracket is located at a midpoint on the handles with the midpoint defined as the point midway between the top 29 of scoop 28 and the top of the handles. In an alternative preferred embodiment, the hinge bracket 9 may be located between the midpoint and the top of the scoops. In the embodiment shown in FIG. 1A, the scoops are securely joined together by a bolt 29 . In the present invention it is not necessary to have the scoop joined but it is a preferred embodiment to provide strength and restrain movement. It should be recognized that the handle/scoop component can be fabricated into a single unitary part, such as by forging, with two such unitary parts joined using hinge bracket 9 and the scoop attachment bolt 29 noted supra.
[0017] [0017]FIG. 1B shows an alternative preferred embodiment of the post hole digger 14 . As in FIG. 1A the device has a pair of handles 8 , two digging scoops 12 and 13 and a hinge bracket 9 . The location and function of the hinge bracket 9 is as in FIG. 1A. At the end of each handle 8 a scoop blade 12 or 13 is fixedly secured. In the upper portion of scoop 12 is fixed protrusion 11 . The upper portion of opposite scoop blade 13 has a slot 10 that slides forward and backward on the fixed protrusion 11 . In one embodiment, protrusion 11 may be a bolt. The top or head of the protrusion may be wider then slot 10 to ensure the protrusion will be confined within the slot 10 . The efficiency and closing power of the movement of scoop blades 12 and 13 is enhanced by the sliding of scoop 12 into and away from scoop 13 .
[0018] [0018]FIG. 2 shows a cross sectional view of the hinge bracket 9 and the handles 8 of the post hole digger. The handles 8 are securely attached to the hinge bracket by a screw 18 that passes through the hinge bracket 9 and attaches hinge bracket 9 to the handle 8 . In the preferred embodiment, shown in FIG. 7, the screw extends into handle 8 approximately one-half the diameter of handle 8 . It is recognized that other attachment methods are possible such as a nut and bolt combination, adhesive or rivets. The hinge bracket 9 has a rotatable attachment 17 joining the two halves of the hinge bracket 9 between the handles 8 . The rotatable attachment 17 rotates to translate the motion applied to the handles to the opening and closing of the scoops for the removal of dirt from the hole. This allows for the digging of a hole of essentially uniform diameter in which the width or diameter of the hole is only slightly larger than the distance between scoop blades 12 and 13 in the open position without appreciably enlarging the upper portion of the hole. The hinge bracket 9 is preferably made of hardened steel and the handles 8 of wood. It is recognized that other durable materials can be used to fabricate hinge bracket 9 , such as aluminum, plastics, and other suitable materials known in the art. Suitable metals, fiberglass, plastic and plastic coated materials can be used to fabricate handles 8 .
[0019] [0019]FIG. 3A shows an enlarged side view of the scoops. In FIG. 3A, arrow 15 depicts the direction in which scoop blade 13 slides on protrusion 11 which projects through slot 10 . Scoop blades 12 and 13 are able to slide into or away from each other. The scoops of the post hole digger can be made of any material that is suitable for outdoor use and digging. Preferably the material will be durable, generally non-corroding and substantially lightweight. Some of the materials that may be used include, but are not limited to aluminum, hardened steel and others. In a preferred embodiment, the scoop blades will be made of hardened steel. The material composing the scoop blades can be varied accordingly to the type of soil being dug such as a loose sandy soil or a hard-packed clay soil. The scoops can be attached to the handle by pressure insertion or by a bolt or a screw or by other methods well known in the art.
[0020] [0020]FIG. 3B depicts the scoops in an alternative embodiment in which both scoops are identical. One side of the upper portion scoop blade 6 a defines a hole 16 through which protrusion 11 passes. (See FIG. 3A). The opposite side of the upper portion of scoop blade 6 a defines a slot 10 that will allow for the sliding movement. Once the hole 16 and the slot 10 from each pair of scoop blades 6 a are aligned, the protrusion 11 is passed through both holes 16 and is secured. In one embodiment, protrusion 11 is a bolt. In a variation, protrusion 11 may be two bolts used to connect the pair of scoops 6 a together. In either variation, the top or head of the protrusion is wider than the width of the slot 10 allowing for stable sliding movement and stronger closing power. The head of the protrusion 11 is defined as part or all of that portion of the protrusion that extends through slot 10 . FIG. 3B also depicts a receiving section 32 formed to receive handle 8 . Persons of ordinary skill in the art will recognize that other methods exist to movably attach scoops 6 a to handles 8 such as rods with internal or external threading to receive bolts, nuts or rivets and threaded receiving section 32 adapted to receive a handle with a compatibly threaded end.
[0021] [0021]FIGS. 4A and 4B show side views of alternative embodiments of the post hole digger where each scoop is contiguous with a hinge bracket section, together forming one piece. In FIG. 4A an alternative embodiment of the post hole digger 14 has each scoop 30 and 32 contiguous with a hinge bracket section 37 and 38 , respectively, each forming one piece with scoop blade 30 and 32 respectively. It should be recognized that the handle/scoop component can be fabricated into a single unitary part with each unitary part joined to form post hole digger 14 . As in FIG. 1A, the device has a pair of handles 8 , two digging scoops 30 and 32 and a hinge bracket formed by sections 37 and 38 . In this view the sections 37 and 38 of the hinge bracket keep the scoops section 30 and 32 in an angle. It should be appreciated that hinge sections 37 and 38 may be attached in an approximately straight line perpendicularly transversing the handles 8 at the top of the hinge similar to the embodiment of FIG. 1B. The trimming at the sides of the hinge bracket allows for more power or force to be applied to the scoops. The scoop 30 is elongated in the upper section to join a section from the hinge bracket section 37 to form one contiguous piece. Similarly, hinge section 38 is joined with scoop 32 to form one contiguous piece. In a preferred embodiment, hinge bolt 7 is located 20-21 inches from the scoop tip 40 . In a more preferred embodiment hinge bolt 7 is 10-18 inches from the scoop tip 40 . In a most preferred embodiment, hinge bolt 7 is 12-14 inches from the scoop tip 40 . However, any suitable distance between the hinge bolt 7 and scoop tip 40 will allow the hinge bracket to translate the movement of handles 8 to the scoop blades 30 and 32 enabling the scoops to close. It should be understood that the hole digger is still functional if the bracket is located at the midpoint as in FIG. 1A or as low as approximately 16 inches above the scoop tip. At the end of each handle 8 , a scoop blade 30 or 32 is fixedly secured with a screw 39 . It can be appreciated that other means available to someone of ordinary skill in the art could be used to secure the handle to the scoop blade, such as adhesive, bolts, threaded connections or pressure fitting. In the upper portion of scoop 32 is a fixed bolt 11 as in FIG. 1B. The upper portion of opposite scoop blade 30 has a slot 10 that slides forward and backward on the fixed bolt 11 as in FIG. 1B. The efficiency and closing power of the movement of scoop blades 30 and 32 is enhanced by the sliding of scoop 30 into and away from the fixed scoop 32 . It should be understood that the hole digger also functions if the scoops are joined by a bolt 29 as in FIG. 1A or are not joined except by the hinge bracket sections.
[0022] [0022]FIG. 4B illustrates a most preferred embodiment of the post hole digger 14 where each scoop 42 and 43 is contiguous with a hinge bracket section 40 or 41 , forming one piece. The post hole digger 14 shown in FIG. 4B is similar to the post hole digger 14 shown in FIG. 4A except for the cutout region 44 present in 4 A and the angled handles 8 shown in FIG. 4B. The contiguous region from scoop 42 to hinge section 40 forms a solid panel 45 that defines slot 10 . The arrangement of scoop 43 and hinge section 41 are the same as that of scoop 42 and hinge section 40 . The solid panel 45 adds strength and leverage to the design. In the most preferred embodiment depicted in FIG. 4B, solid panel 45 measures approximately 4 inches from hinge bolt 7 to sliding bolt 11 . However, persons skilled in the art will understand that the use of shorter and longer solid panels will allow the attached hinge bracket sections 40 and 41 to translate the movement of the handles scoops 42 and 43 enabling the scoops to close. It also should be understood that the hole digger is still functional if the bracket is located as in FIB. 1 A or as in FIG. 4A. In this most preferred embodiment, the handles 8 cross in front of each other when the scoops of the digger are in the open position. FIG. 4C illustrates a front view of this most preferred alternate embodiment. It can be appreciated in FIG. 4C that the handles, when in the crossed position, allow for a space to be present at the top of the handles. The operator of the hole digger moves the handles away from each other to close the scoops and remove the dirt from the hole.
[0023] [0023]FIG. 5 shows an enlarged front view of an alternative embodiment of scoop blade 35 . The figure depicts the ground braking edge or blade of the scoop with teeth 33 . The teeth 33 at the tip have a slight bend towards the opposite scoop. The bend of the teeth has an angle 34 in the range of 0° to 28° degrees. In the most preferred embodiment, the bend angle 34 is between 18° to 22° degrees. The teeth 33 with the slight angle 34 at the edge contribute to closing of the scoops with less force, making removal of dirt from the hole less tiring when digging in certain soils. The teeth 33 can be present or absent from the digging blades in any of the embodiments presented in this application.
[0024] [0024]FIGS. 6A and 6B depict the one embodiment of post hole digger of the instant invention and a prior art post hole digger, respectively, in operation. In FIG. 6A, it can be appreciated that the hole 19 dug by the post hole digger 14 of the present invention is relatively uniform in diameter from top to bottom. In comparison, the hole dug by the prior art post hole digger 27 is wider at the ground surface than at the bottom. The prior art post hole digger 27 has two scoop blades 26 and 24 and a bolt 25 joining both scoop blades. Both of the scoops are fixed in position by the bolt 25 whereas in the present invention post hole digger 14 has a fixed scoop 43 and a sliding moving scoop 42 . It can be appreciated that each of the scoops is contiguous with a hinge bracket section 40 or 41 , forming one piece. The hinge bracket limits the movement of the handles 8 . The hinge bracket has a pin 7 that rotates to translate the minimum motion applied to the handles 8 into movement of the scoops 42 and 43 allowing the opening and closing of the scoops 42 and 43 . In this figure the scoops 42 and 43 are closed, showing the uncrossing of the handles 8 . Line 21 illustrates the width of the open handles. In contrast, with the prior art post hole digger 27 , as the hole 20 becomes deeper, the movement of the handles 23 becomes wider and more extreme creating a tapered hole rather the more uniform hole 19 fashioned by post hole digger 14 of the instant invention. The teeth 33 can also be observed in the close position of the scoops, allowing for a better grasp of dirt with a minimum of force in some soils. Persons skilled in the art will realize that in all embodiments described herein, longer handles and suitably placed hinge brackets or hinge sections will enable the digging of deeper holes with approximately uniform diameter.
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The present invention relates to post hole diggers. In particular, the present invention describes a post hole digger that constructs uniform diameter holes. The post hole digger of the present invention is comprised of a pair of handles, digging scoops and a hinge bracket. The hinge bracket translates the movement of the handles into movement of the scoops. The hinge bracket restricts the movement of the handles as digging occurs, allowing for the construction of a relatively straight-sided post hole, essentially removes the tapering of a hole as the hole becomes deeper.
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FIELD OF THE INVENTION
The present invention relates generally to speech communication systems and more specifically to coding techniques for speech compression.
BACKGROUND OF THE INVENTION
Efficient communication of speech information often involves the coding of speech signals for transmission over a channel or network ("channel"). Speech coding systems include coding processes which convert speech signals into codewords for transmission over the channel and decoding processes which reconstruct speech from received code words. These coding and decoding processes provide data compression and expansion useful tier communication of speech signals over channels of limited bandwidth.
In analysis-by-synthesis speech coding systems, such as code-excited linear predictive (CELP) speech coding known in the art, a speech signal for coding is first divided into contiguous time segments of fixed duration referred to as subframes. Each subframe is typically 2.5 to 7.5 milliseconds (ms) in duration. Most of the speech information of each subframe is coded as a set of parameters characterizing the speech signal within the subframe. Several contiguous coded subframes (usually 4 or 6) are collected together in groups referred to as frames. These frames of coded speech are communicated via a channel to a receiver. The receiver may, e.g., synthesize audible speech from the received frame information.
A goal of most speech coding systems is to provide faithful reproduction of original speech sounds such as, e.g., voiced speech, produced when the vocal cords are tensed and vibrating quasi-periodically. In the time domain, a voiced speech signal usually appears as a succession of similar but slowly evolving waveforms referred to as pitch-cycles. A pitch-cycle waveform is generally characterized by a major transient surrounded by a succession of lower amplitude vibrations. A single one of these pitch-cycle waveforms has a duration referred to as a pitch-period.
Because of the nature of the voiced speech signal pitch-cycle, speech coding systems which operate on a subframe basis aim to accurately represent widely disparate signal features within a subframe. How these speech signal features are treated by a speech coding system significantly affects system performance.
SUMMARY OF THE INVENTION
The present invention provides a speech coding method and apparatus which selectively applies speech coding techniques to time segments of speech information signals, such as, e.g., pitch-cycle waveforms. A speech information signal comprising N signal segments is coded with a first speech coder to provide a first coded representation for each of the N signal segments. A second speech information signal reflecting speech information not coded by the first coder is determined for each of one or more of the N signal segments. In addition to coding the N first speech information signal segments with the first speech coder, M of the second speech information signals are coded with a second speech coder, where 1≦M≦N-1. The selective coding of M of the second speech information signals is done responsive a coding criterion. By selective use of the second speech coder, the number of bits needed to represent speech information may be reduced, or alternatively, better performance may be obtained without an increase in bit rate. The first and second speech coders may be any of those known in the art.
Illustrative embodiments of the present invention provide improved CELP speech coding systems. Such improved CELP systems are adapted to provide for subframes of 2.5 ms in duration. These subframes serve as the segments referenced above. Given their short duration, many subframes of a speech information signal will not contain a major signal transient. The illustrative embodiments provide coding for all subframes with the first speech coder. For those subframes without a major transient, such coding may be all that is required to satisfy an applicable coding criterion, such as a threshold signal energy For those segments which include a major transient, additional coding may be employed to meet the applicable criterion. In this way, speech information signal coding is tailored on a subframe basis to meet coding requirements as needed.
In a first illustrative embodiment of the present invention, the selection of second speech information signals for coding with a second speech coder is based upon the coding criterion. In a second illustrative embodiment, the coding of second speech information signals involves coding several trial combinations of second speech information signals and selecting one of the combinations based on a coding criterion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 presents a first illustrative embodiment of the present invention.
FIG. 2 presents three contiguous frames of a speech information signal x(i).
FIG. 3 presents an illustrative bit format for one frame of coded speech information.
FIG. 4 presents an illustrative embodiment of a receiver for use with the illustrative embodiment of FIG. 1.
FIG. 5 presents a second illustrative embodiment of the present invention.
FIG. 6 presents a speech coding subsystem, comprising adaptive and fixed codebooks, for use with the illustrative embodiment of FIG. 5.
FIG. 7 presents an illustration of certain quantities relating to the number of subframes coded in accordance with the principles of the present invention
DETAILED DESCRIPTION
A. Introduction to the Illustrative Embodiments
For clarity of explanation, the illustrative embodiments of the present invention are presented as comprising, among other things, individual functional blocks. The functions these blocks represent may be provided through the use of either shared or dedicated hardware, including, but not limited to, hardware capable of executing software. Illustrative embodiments may comprise digital signal processor (DSP) hardware, such as the AT&T DSP16 or DSP32C, and software performing the operations discussed below. Very large scale integration (VLSI) hardware embodiments of the present invention, as well as hybrid DSP/VLSI embodiments, may also be provided.
The illustrative embodiments of the present invention provide an improvement to conventional CELP speech coding. Because the embodiments are directed to an improvement of CELP, those aspects of the embodiments ordinarily found in conventional CELP will not be discussed in great detail. For a discussion of conventional CELP and related topics, see commonly assigned U.S. patent application Ser. No. 07/782,686, which is hereby incorporated by reference as if set forth fully herein. In light of this incorporated disclosure and the discussion to follow, it will be apparent to those of ordinary skill in the art that the present invention is applicable to various other speech coding systems, not merely analysis-by-synthesis coding systems generally, or CELP coders specifically.
The illustrative embodiments of the present invention concern selective application of two speech coders. The first speech coder comprises a long term predictor (LTP) (either alone or in combination with a linear predictive filter (LPF)). The second comprises a fixed stochastic codebook (FSCB) and search mechanism. As in conventional CELP, the embodiments code subframes of a speech information signal. These subframes are packaged together in conventional fashion as a frame of coded speech information and communicated to a receiver. Each frame is 20 ms in duration and comprises eight 2.5 ms subframes of speech information.
The illustrative embodiments provide coding for voiced speech signals. Coding for other types of speech signals, e.g., silence and unvoiced speech, may be provided by conventional coding techniques known in the art. Switching between such coding techniques and embodiments of the present invention may also be accomplished by conventional techniques known in the art. See, e.g., commonly assigned U.S. Pat. No. 5,007,093, which is hereby incorporated by reference as if fully set forth herein. For the sake of the clarity of explanation of the present invention, these well understood techniques will not be presented further.
Communication channels for use with embodiments of the present invention may comprise, e.g., a telecommunications network, such as a telephone network or radio link, or a storage medium, such as a semiconductor memory, magnetic disk or tape memory, or CD-ROM (combinations of a network and a storage medium may also be provided). Within the context of the present invention, a receiver is any device which receives coded speech signals over the communications channel. So, e.g., a receiver may comprise a CD-ROM reader, a dish or tape drive, a cellular or conventional telephone, a radio receiver, etc. Thus, the communication of signals via the channel may comprise, e.g., signal transmission over a network or link, signal storage in a storage medium, or both.
B. A First Illustrative Embodiment
A first illustrative embodiment of the present invention is presented in FIG. 1. As shown in the Figure, a sampled speech information signal, s(i), (where i is the sample index) is provided to a linear predictive filter 20 and a linear predictive analyzer 10. Signal s(i) may be provided, e.g., by conventional analog-to-digital conversion of an analog speech signal. Linear predictive analyzer (LPA) 10 computes linear prediction coefficients in the conventional fashion well known in the art based on the signal s(i). The coefficients are determined and quantized by LPA 10 to be valid at frame boundaries, as in conventional CELP. Coefficient values, α r , valid at the center of subframes within the boundaries are determined by conventional interpolation of quantized frame boundary coefficient data by LPA 10. The coefficients, α r , valid at subframe centers are output to buffer 27 and LPF 20. Coefficients valid at frame boundaries, α r F , are additionally output to channel interface 55. Values of a r valid at the center of subframes are used by LPF 20 and, via buffer 27, adaptive codebook and search (ACB&S) 30 and FSCB search 40, in the conventional manner.
Signal x(i)--the first speech information signal of the illustrative embodiment--is foraged in the conventional manner by LPF 20 based on coefficients provided by LPA 10. Two subframes of signal x(i) are provided by LPF 20, one subframe (i.e., 20 samples) at a time, by the filtering of successive samples of LPF 20 input signal s(i) as follows: ##EQU1## where linear prediction coefficients α r are valid at the center of the subframe in question. Since R is usually about 10 samples (for an 8 kHz sampling rate), the signal x(i) retains the long-term periodicity of the original signal, s(i). ACB&S 30, discussed below, is provided to remove this redundancy.
Subframes of signal x(i) are output from LPF 20 and are provided to subframe analyzer 25 and buffer 29. Analyzer 25 and buffer 29 each store pairs of subframes of the information signal x(i) provided by LPF 20. In accordance with the present invention, subframe analyzer 25 determines, for each pair of subframes it has stored, which subframe should be coded with use of the first coder only (i.e., the ACB&S 30), and which should be coded with use of both the first and second coders (i.e., the ACB&S 30 and the FSCB system 40, 45). This determination is based on the speech information signal energy of each subframe of the pair. The subframe which exhibits the greater signal energy is chosen by analyzer 25 for coding with use of both the first and second speech coders. The other subframe--the one with less signal energy--is coded with use of the first speech coder, but not the second. Subframe energy is determined by analyzer 25 in conventional fashion: ##EQU2## where L is the number of samples in a subframe (e.g., L=20 samples).
Subframe energy is determined by analyzer 25 for each subflame of a subframe pair prior to coding either of the two subframes. Once the determination of subframe energy has been made, the subframes of the pair in question may be coded in turn. Copies of these subframes are stored in buffer 29, as discussed above, for the purpose of coding by the embodiment. Linear prediction coefficients from analyzer 10 needed for coding these buffered subframes are stored in buffer 27.
Buffers 27, 29 do not acid coding delay to the system. This is because ordinary linear prediction analyzers and filters, e.g., LPA 10 and LPF 20, must themselves collect and store speech information signal values in order to determine linear prediction coefficients and filtered speech information. In one conventional form of linear prediction analysis, the LPA 10 stores one-half frame of speech information signal samples on each side of a frame boundary at which linear prediction coefficients are to be computed. Therefore, prior to determining linear prediction coefficients valid at the center of the first subframe of a given frame, the conventional LPA 10 introduces a delay of one and one-half frames. Since samples (e.g., whole subframes) of speech information signals must be stored for the computation of these linear prediction coefficients, the storage of subframes in buffer 27 may be implemented as a block transfer of information which can occur without sample delay. Thus, no delay need be introduced by virtue buffer 27, 29 storage.
Analyzer 25 controls the coding of the pair subframes stored in buffer 29 by the generation of an enable signal, ε, which it provides to the coders. Once ε is appropriately asserted, the subframes of a buffered subframe pair are coded, one at a time, by application of the first coder--the ACB&S 30.
The ACB&S 30 of the illustrative embodiment comprises a conventional CELP adaptive codebook and search mechanism which determines a gain λ(i) and a delay d(i) (although indexed by i, values for d(i) and λ(i) are constant for all samples within a subframe). ACB&S 30 will be enabled to operate when ε takes on a value other than 00 (see discussion of ε below). Computed values for delay and gain for each coded subframe are provided by ACB&S 30 to channel interface 55 as shown in FIG. 1. A subframe of a residual speech information signal, r(i), --the second speech information signal of the embodiment--is determined as follows:
r(i)=x(i)-λ(i)x(i-d(i)), (3)
where the x(i-d(i)) are samples of a speech information signal synthesized (or reconstructed) in earlier subframes. To facilitate implementation of (3), ACB&S 30 provides the quantity λ(i)x(i-d(i)) to subtraction circuit 35. Signal r(i) is the speech information signal remaining alter λ(i)x(i-d(i)) is subtracted from x(i) by circuit 35; r(i) reflects speech information not coded by the first speech coder. Signal r(i) may then coded with a FSCB mechanism 40 under the control of subframe analyzer 25 by enable signal, ε.
The enable signal, ε, is provided by analyzer 25 to the fixed stochastic codebook (FSCB) search mechanism 40 to control application of the FSCB to the subframe of a pair of subframes determined to contain the greater energy. The enable signal, ε, may be implemented with two bits. So, e.g., when the bits forming ε are 01, the FSCB system 40, 45 codes the first (or earlier) subframe of a subframe pair. When the bits forming ε are 10, the FSCB system 40, 45 codes the second subframe of the pair (ε equalling 00 indicates a wait or idle state for both coders commensurate with speech information signal buffering).
When the enable signal is asserted (as either a 01 or 10), the FSCB search mechanism 40 operates to determine a vector from the FSCB 45 and a scaling factor, μ(i), which in combination most closely match the signal r(i) associated with the subframe to be coded. The FSCB 45 and search mechanism 40 are conventional in the art except for the control provided by the analyzer 25. FSCB mechanism 40 provides as output to channel interface 55 an index indicating the determined FSCB vector, I FC , and an associated scaling factor, μ(i). When the enable signal from analyzer 25 is not asserted (i.e., ε is 00), the FSCB mechanism 40 sits idle.
Analyzer 25 also provides to channel interface 55 a single bit for each pair of subframes processed by the embodiment of FIG. 1. This bit, referred to as the subframe selection bit, ξ, reflects the asserted value of ε supplied to FSCB 40. When ε is set to 01, the subframe selection bit ξ is set to 0. When ε is set to 10, ξ is set to 1. Channel interface 55 requires a subframe selection bit ξ for each pair of coded subframes to provide an indication of which subframes has been coded with both coders and which has not.
Once coding of the two subframes of a subframe pair is complete, coding is halted until analyzer 25 has determined how to code the next successive pair of subframes. Analyzer 25 halts coding by providing ε equal to 00. First and second coders operate responsive to the asserted ε signal and then check ε when done. If ε equals 00, they halt; otherwise they proceed to code the next pair of subframes as described above.
FIG. 2 is provided to facilitate an understanding of how the analyzer 25 and the buffers 27 and 29 operate over time with the other components of the illustrative embodiment of FIG. 1. FIG. 2 presents contiguous frames of the speech information signal x(i). These frames are provided to analyzer 25 for energy determinations (actual sample values for signal x(i) are not shown for the sake of clarity). As shown in the Figure, each of the frames, F-1, F, and F+1, comprises eight subframes, labeled a through h. Since each frame comprises 160 samples (or 20 ms of speech information at 8 kHz sampling rate), each of the labeled subframes comprises 20 samples (or 2.5 ms of speech information). Consecutive pairs of subframes within each frame are numbered 1 through 4.
Assume that a signal, s(i), has been provided to LPA 10 and LPF 20 of FIG. 1 as is conventional in CELP coders. As a result, LPA 10 has determined LP coefficients valid at the frame boundaries between frames F-1 and F, (i.e., a r F-1 ), and F and F+1 (i.e., a r F ). These coefficients are used in a conventional interpolation process by LPA 10 to provide subframe coefficients as discussed above. These subframe coefficients are used by LPF 20 in conventional fashion to filter subframes of signal s(i).
At the outset, two subframes of signal s(i) are filtered by LPF 20 to yield the first pair subframes of signal x(i) in frame F: subframes a and b (i.e., frame F, pair 1). Analyzer 25 and buffer 29 receive and store subframes a and b of frame F. The enable signal bits provided by analyzer 25 are set to 00, reflecting an idle state of the coding system. Analyzer 25 determines which of subframes a and b contains the greater amount of energy as discussed above. Responsive to this determination, analyzer 25 controls the coding of subframes a and b by the first and second coders. As part of this control process, analyzer 25 provides an enable signal, ε, indicating which of the two subframes is to be coded with both coders.
Once the enable signal is provided, coding occurs as described above. Analyzer 25 can then reset enable signal to 00. Analyzer 25 and buffer 29 proceed to store the next contiguous pair of subframes--frame F, subframe pair 2, comprising subframes c and d. Control of the coding of subframes c and d responsive to this determination is thereafter effected by analyzer 25.
The determination of subframe energy and control of coders is repeated for each consecutive pair of subframes in the speech information signal. So, for example, after coding subframes c and d, the embodiment of FIG. 1 proceeds to code subframes e and f (i.e., pair 3), and subframes g and h (i.e., pair 4) of frame F. As a result of coding only one subframe of each consecutive subframe pair with the second coder, the second coder has been used to code only 4 of the 8 subframes in frame F. At this point, LPA 10 computes additional frame boundary linear prediction coefficients (e.g., coefficients valid at the right boundary of frame F+1, a r F +1) and the whole process repeats itself, from one frame to the next, for as long as there are signal subframes to code.
FIG. 7 presents an illustration of certain quantities relating to the number of subframes coded in accordance with the principles of the present invention. FIG. 7 depicts an illustrative frame of 8 subframes, such as frame F of FIG. 2. Each subframe is coded with use of a first speech coder while only one subframe from each of the 4 pairs of subframes is coded with use of both the first and second speech coders. The letter "F" indicates a subflame coded with use of the first speech coder only while the letter "B" indicates a subframe coded with use of both speech coders. In this example, there are N=8 subframes of the frame F which are to be coded. There are P=4 subframes coded with use of the first speech coder (and not the second). There are M=4 subframes coded with use of both speech coders. Said alternatively, there are L=8 subflames coded with use of the first coder (whether with or without the second coder), and K=4 subframes coded with use of the second speech coder (whether with or without the first coder).
Over the course of coding eight subframes of a frame of speech, information representative of each coded speech subframe is collected by channel interface 55 for transmission to a receiver over a channel 56. The receiver uses this information in the reconstruction of speech. This information comprises ACB&S parameters λ(i) and d(i), the FSCB index, I FC , and scaling factor, μ(i) (for the appropriate higher energy subframes), and the linear prediction coefficients a r , valid at the later of the two frame boundaries associated with the coded frame, e.g. a r F . This information further comprises a set of subframe selection bits, ξ, identifying which subframe in each successive pair of coded subframes has been coded with use of both coders. Channel interface 55 buffers all information it receives during the coding of a frame and maps (or assembles) the buffered information into a format suitable for communication over channel 56.
FIG. 3 presents an illustrative format of a frame of coded speech information as assembled by interface 55. This format comprises 158 bits which ,are partitioned among various quantities needed by a receiver to reconstruct a frame of speech. These quantities include ACB&S 30 information (i.e., delay and gain) for all eight subframes of the frame, and FSCB system 40, 45 information (i.e., codebook index and gain) for four of the eight subframes.
As shown in the Figure, linear prediction coefficients, a r , 1≦r≦10, are represented by a field of 30 bits. These 30 bits are used to represent the coefficients in the conventional fashion well known in the art.
Also represented is ACB&S delay and gain information for each of the eight subframes of a coded frame. Each subframe's ACB&S delay, d(i), is represented by a 7 bit field. Each subframe's ACB&S gain, λ(i), is represented by a 4 bit field. Therefore, a total of 88 bits (i.e., 8 subframes×(7 bits+4 bits)) are used to represent coded speech information provided by the first coder--the ACB&S 30.
As an alternative to coding each delay of a frame with 7 bits, either the fourth or the fifth subframe delay of may be coded with 7 bits and the other seven subframe delays may be coded differentially, using 2 bits per subframe differential delay value. This practice saves a total of 35 bits, reducing the number of bits required to code a frame from 158 to 123.
As a further alternative to coding multiple delay values (whether differential or otherwise) for each frame, the present invention may be combined with the generalized analysis-by-synthesis techniques disclosed in U.S. patent application Ser. No. 07/782,686 and incorporated by reference above. By virtue of combining the present invention with the techniques of the referenced application, delay information need be sent only once for each coded frame. Thus, e.g., only seven bits need be used to represent delay for the entire frame. This provides a savings of an additional 1.4 bits. To combine tile techniques of the referenced application with those of the present invention, the embodiments presented in FIGS. 3 and 5 of the referenced application may each be modified to buffer signal x(i) and parameters M and a n while subframe analysis is performed in accordance with the first illustrative embodiment of tile present invention. Alternatively, embodiments presented in FIGS. 3 and 5 may each be used as coding subsystems in accordance with the second illustrative embodiment of the present invention (see below).
FIG. 3 further shows a 4 bit subframe selection field which contains a subframe selection bit, ξ, for each of four contiguous pairs of subframes coded. Each of these four bits represents one of the four subframe pairs. As stated above, a zero-valued selection bit indicates the first (i.e., the earlier) of two subframes of a subframe pair has been coded with use of both coders, while a one-valued selection bit indicates the second (i.e., the later) of two such subframes has been so coded.
After the four bits designated for subframe selection, the channel format includes a field for the representation of FSCB system 40, 45 information. The bits of this field are divided among the four subframes identified by the subframe selection bit field. For each such identified subframe, a FSCB index, I FC (6 bits), and a FSCB scaling factor, μ(i) (3 bits), are communicated. Thus, the field comprises 36 bits (4 subframes×(3 bits+6 bits)).
A frame of coded speech information in the format described above is communicated over communication channel 56 to a receiver. The receiver reconstructs or synthesizes a frame of speech information from the coded frame. An illustrative embodiment of a receiver tier synthesizing speech information according to the present invention is presented in FIG. 4.
As a general matter, the receiver of FIG. 4 performs the inverse of the coding process discussed above. Successive frames of coded speech information transmitted by channel interface 55 are received by receiver channel interface 58. Interface 58 unpacks the bits of a received coded frame format and provides appropriate information and signals to other elements of the receiver.
Assume that a frame of coded speech information has been received by channel interface 58 and that this frame represents frame F presented in FIG. 2. Responsive to receipt of this coded frame, channel interface extracts linear prediction coefficients, a r F , from the received frame. Recall that these coefficients are valid at the latest frame boundary (,that is, the frame boundary which lies at the end of frame F). These coefficients are used, together with the set of previously received and stored linear prediction coefficients valid at previous frame boundary (the frame boundary which lies at the end of frame F-1, a r F-1 ), to provide a set of coefficients valid at the center of each subframe of speech within frame F. These sets of coefficients are provided with conventional linear prediction coefficient interpolation well known in the art. Naturally, the set of linear prediction coefficients received by interface 58, ahd r F , will be buffered for use in a subsequent interpolation process. This subsequent interpolation process will be performed in response to the receipt on the next frame of coded speech information, frame F+1. The process of buffering and interpolation is repeated tier each frame of coded speech received by interface 58.
After interpolating linear prediction coefficients, the receiver proceeds to synthesize the subframes of coded speech. Interface 58 extracts from the received frame the subframe selection bit ξ associated with the first pair of coded subframes, a and b, of frame F. The interface 58 examines ξ to determine whether the synthesis of the first subframe of speech information (i.e., subframe a of frame F) requires application of the FSCB 70. If so, interface 58 provides a logically true subframe selection control signal, γ, to switches 60 and 80 of the receiver. Signal γ asserted as true causes the switches 60, 80 to be in a closed state effectively coupling the FSCB 70 into the synthesis process for subframe a. If no application of FSCB 70 is required for subframe a, interface 58 provides a logically false γ to switches 60 and 80, causing switches 60 and 80 to open, effectively decoupling the FSCB 70 from the synthesis process.
After determining the appropriate subframe selection control signal γ, interface 58 may extract and output to switch 60 the fixed codebook index, I FC , associated with the subframe of the first subframe pair which has been coded with use of the FSCB system 40, 45. Also, interface 58 may extract and provide to multiplier circuit 75 the FSCB gain, μ(i), for that subframe.
Assuming that subframe a is the subframe of the first pair coded with both coders, signal γ will be true and switches 60 and 80 will be closed. Index, I FC , and gain, μ(i), provided will be used by FSCB 70 and multiplier 80, respectively, to provide a synthesized excitation signal, e(i), in the conventional fashion. This excitation signal, e(i), is the contribution of the FSCB system 70, 75 to a synthesized speech information signal or subframe a. The excitation signal e(i) is provided to summing circuit 100 for addition to the adaptive codebook contribution to the synthesized speech information signal for that subframe.
This adaptive codebook contribution is provided based on the extracted adaptive codebook delay and gain information, d(i) and λ(i), respectively, associated with subframe a of coded speech. The adaptive codebook contribution is determined in the conventional fashion, with the delay, d(i), serving to identify a previously synthesized frame of speech information, and the gain λ(i) acting as a multiplicative factor.
Synthesis of speech for subframe a is completed by an inverse LPF 110 based on linear prediction coefficients provided by interface 58. These coefficients are valid at the center of subframe a.
Since subframe a of the first pair of subframes was coded with use of both coders, it follows that subframe b was coded without the FSCB system 40, 45. Therefore, to proceed with the synthesis of speech for subframe b, interface 58 must apply a logically false subframe selection control signal γ to switches 60 and 80. By doing this, interface 58 causes FSCB system 70, 75 to play no part in the synthesis of speech for this subframe. Speech associated with subframe b is therefore synthesized with use of the adaptive codebook 90 and gain multiplication circuit 95, along with the inverse LPF 110. As a result of switch 80 being open, excitation signal e(i) is zero valued.
Consecutive pairs of coded subframes of speech are handled in the same manner as subframes a and b. Of course, other subframe pairs may have been coded differently (that is, with the first of the two subframes coded without the FSCB system 40, 45). In such a circumstance, the procedures discussed above for subframes a and b would be reversed.
C. A Second Illustrative Embodiment
A second illustrative embodiment of the present invention is presented in FIG. 5. Like the first embodiment described above, this embodiment may employ the channel fore, at presented in FIG. 3 and may communicate with the receiver presented in FIG. 4. Unlike the first embodiment, however, this embodiment does not decide prior to the coding process which subframe of a subframe pair will be coded with use of one coder and which will be coded with use of both coders. Rather, for a given pair of subframes, this illustrative embodiment provides coded alternatives: (i) a first alternative where the first subframe of a pair is coded with both coders, but the second is coded without the second coder; and (if) a second alternative where the first subframe is coded without the second coder, and the second subframe is coded with both coders. The second embodiment then chooses the alternative which results in lower coding error. The parameters (i.e., the coded representation) of the chosen alternative are then provided to a channel interface for communication to a receiver.
As shown in FIG. 5, a linear predictive filter 20 and a linear predictive analyzer 10 receive a sampled speech information signal, s(i). Analyzer 10 and filter 20 are the same devices described above with reference to the first illustrative embodiment. As with the first embodiment, LPA 10 computes linear prediction coefficients, a r F , valid at frame boundaries, based on signal s(i). Values for a r valid at the center of subframes within the boundaries ,are determined by conventional interpolation of frame boundary coefficients by LPA 10. The coefficients, at, valid at subframe centers are output to LPF 20, LPF -1 S 120(LPF -1 S 120 will be discussed below in connection with the choice of coded alternatives), ACB&S 30, and FSCB search 40. Coefficients, a r F , valid at frame boundaries are additionally output to selector 130. Subframes of speech information signal x(i) are formed in the conventional manner by LPF 20, as described above for the first illustrative embodiment.
Like the first embodiment, the second embodiment operates on pairs of subframes. In this case, each pair of subframes of x(i) is provided by LPF 20, in parallel, to two coding subsystems 115, 116.
Each coding subsystem 115, 116 operates to code the subframes of a subframe pair in a similar manner. As shown in FIG. 6, the subsystems 115, 116 comprise the same coders (an adaptive codebook ACB&S 31, 32 and a FSCB system 40, 45). The difference between these subsystems 115, 116 concerns the way their the coders are applied to the subframes of a given subframe pair. Subsystem 115 codes the first subframe of a subframe pair with use of both coders, and the second subframe without the second coder; subsystem 116 codes the first subframe of the same pair without the second coder, and the second subframe with both coders. Control of subframe coding by the second coder for subsystems 115, 116 is effected by FSCB control 37, 38, respectively, which sets ε such that the appropriate subframe within a pair is always coded for the subsystem 115, 116.
Thus, subsystems 115, 116 provide alternative coded representations of a given subframe pair from which one must be chosen. These alternative representations are provided by coding subsystems 115, 116 to selector 130 as ACB&S delay and gain information, d(i) and λ (i), respectively; and FSCB system index and gain information, I FC and μ(i), respectively. The choice between two coded representations of a subframe pair is based on the amount of coding error introduced by each representation. The amount of coding error introduced by each representation is evaluated by selector 130, in combination with LPF -1 S 120 and subtraction circuits 125.
Referring again to FIG. 5, each coding subsystem 115, 116 provides an estimated speech information signal, x(i), which is equal to the speech information signal which would be synthesized by a receiver if it were to receive that subsystem's coded representation of the original speech information signal x(i). The estimated speech information signal x(i) from each subsystem 115, 116 may therefore be compared to original speech information signal x(i) to determine a measure of error introduced by the coded representation.
A measure of coding error is provided by forming a difference, δ, between a perceptually weighted original speech information signal, x(i), and a perceptually weighted estimated speech information signal x(i) from each coding subsystem, for a pair of subframes. Perceptual weighting is provided by LPF -1 S 120 which operate according to the following expression: ##EQU3## where linear prediction coefficients a r are valid at the center of the subframe in question, R is the number of coefficients, and γ is a perceptual weighting factor (illustratively set to 0.8). Difference signals, δ(i), are formed by subtraction circuits 125 and represent coding error over a pair of subframes.
The difference signals, δ(i), are provided to selector 130 for comparison. The selector squares these difference signals, δ(i) 2 , to determine error signal energy. These error signal energies are compared to determine which is smaller. The coding subsystem responsible for introducing the smaller error, as represented by the smaller error signal energy, δ(i) 2 , is the one chosen to provide the coded representation of the pair of subframes.
As discussed above, both coding subsystems 115, 116 provide their coded representations of a subframe pair to selector 130. Once selector 130 has determined which subsystem 115, 116 will introduce the smaller error by its coded representation, it provides that representation to a channel interface 55 Channel interface 55 is the same as that discussed above with reference to the first illustrative embodiment. Interface 55 packs bits in a format for transmission to a receiver in the fashion discussed above with reference to FIG. 3.
In addition to the coded representation of a subframe pair, selector 130 provides linear prediction coefficients a F r and a subframe select bit, ξ, to the interface 55 The linear prediction coefficients a F r are the same as those discussed above with reference to the first embodiment. They are valid at the end of the frame containing the coded subframe pair in question. The subframe select bit, ξ, is defined as discussed above with reference to the first illustrative embodiment. Values for the bit are determined based on the particular coding subsystem 115, 116 chosen by selector 130. When coder 115 has been chosen to provide the coded representation for the pair of subframes (i.e., when tile first subframe of a pair has been coded with both coders of subsystem 115), ξ is set equal to 0. When coder 116 has been chosen to provide the coded representation of the pair of subframes (i.e., when the second subframe of a pair has been coded with both coders of subsystem 116), ξ is set equal to 1.
After choosing a coded representation for a pair of subframes of the speech information signal, x(i ), and prior to the coding of the next pair of subframes in a frame of speech information, selector 130 updates the contents of certain memories of the embodiment. It does this by providing an update signal, υ, to the adaptive codebooks and searches, 31, 32, and FSCB searches 40 of subsystems 115, 116. Signal υ is also provided to those LPF -1 120 which provide perceptual weighting to the estimated speech information signals, x(i), output by tile subsystems 115, 116. The update signal, υ, causes the contents of tile adaptive codebook 32, m 1 , associated with tile subsystem which provided the chosen representation to overwrite the contents of the adaptive codebook 32 of the other subsystem 116, 115. Furthermore, it causes the signal memories of the adaptive codebook search 31, FSCB search 40, and LPF -1 120(m 2 , m 3 , m 4 , respectively) which are associated with the chosen representation to overwrite the signal memories of the other adaptive codebook search 31, FSCB search 40 and LPF -1 120 (linear filters operate by summing weighted past values of either or both input and output signals; it is the memory holding these past values--the signal memory--which is overwritten by this process; conventional adaptive codebook search 31 and FSCB search 40 of subsystems 115, 116 also contain inverse LPF filters which are used to assess codebook vector errors (see U.S. patent application Ser. No. 07/782,686, incorporated by reference above)). Illustratively, υ takes on the same values as subframe selection signal, ξ. As such, responsive to receiving υ, the memories of the system have the information needed (m 1 , m 2 , m 3 , m 4 ) to effect tile correct memory update. After completion of this update process, the coding of tile next pair of subframes in a frame of a speech information signal may occur.
The teachings of the present invention may be applied to still further illustrative embodiments. For example, an embodiment may be provided which comprises a first and a second speech coder and which codes a speech information signal segment using either or both of the speech coders. If these are N signal segments for coding by this embodiment, then tile first coder is applied in the coding of L such segments, and the second coder is applied in the coding of M such segments, where L+M≧N+1. In this embodiment, each of the N segments is coded with use of at least one of the two coders.
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A speech coding method and apparatus which selectively applies speech coding techniques to time segments of speech information signals, such as, e.g., pitch cycle waveforms is disclosed. A speech information signal comprising N signal segments is coded with a first speech coder to provide a first coded representation for each of the N signal segments. A second speech information signal reflecting speech information not coded by the first coder is determined for each of one or more of the N signal segments. In addition to coding the N first speech information signal segments with the first speech coder, M of the second speech information signals are coded with a second speech coder, where 1≦M≦N-1. The selective coding of M of the second speech information signals is done responsive a coding criterion. By selective use of the second speech coder, the number of bits needed to represent speech information may be reduced, or alternatively, better performance may be obtained without an increase in bit rate. The first and second speech coders may be any of those known in the art.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/663,234, filed Jun. 22, 2012, which is incorporated in its entirety herein for all purposes.
BACKGROUND OF THE INVENTION
[0002] High performance down-converting phosphor technologies will play a prominent role in the next generation of visible light emission, including high efficiency solid-state white lighting (SSWL). In addition, such technologies are also applicable to near infrared (NIR) and infrared (IR) light emitting technologies. Down-conversion from ultraviolet (UV) or blue light emitting semiconductor light emitting diodes (LEDs) into blue, red and green wavelengths offers a fast, efficient and cost-effective path for delivering commercially attractive white light sources. Unfortunately, existing rare-earth activated phosphors or halophosphates, which are currently the primary source for solid-state down-conversion, were originally developed for use in fluorescent lamps and cathode ray tubes (CRTs), and therefore have a number of critical shortfalls when it comes to the unique requirements of SSWL. As such, while some SSWL systems are available, poor power efficiency (<20 light lumens/watt (lm/W)), poor color rendering (Color Rendering Index (CRI)<75) and extremely high costs (>$200/kilolumen (klm)) limit this technology to niche markets such as flashlights and walkway lighting.
[0003] Furthermore, LEDs often suffer from reduced performance as a result of internal reflection of photons at the chip/coating interface. Typically, LEDs are encapsulated or coated in a polymeric material (which may comprise phosphors) to provide stability to the light-emitting chip. Currently these coatings are made by using an inorganic or organic coating that has a very different refractive index than the base material (i.e., the chip), which results in a detrimental optical effect due to the refractive index mismatch at the interface between the two materials. In addition, the temperature of the LED can reach in excess of 100° C. To allow for the expansion and contraction that can accompany this temperature rise, a compliant polymeric layer (e.g., silicone) is often placed in contact with the chip. In order to provide additional stability to the LED, this compliant layer is often further coated with a hard shell polymer.
[0004] The resulting LED structure suffers loss of light at the chip/compliant polymer interface due to the lower refractive index of the polymer coating in relation to the LED. However, if the refractive index of the compliant layer is increased, even greater loss will occur due at the high refractive index/low refractive index interface between the compliant polymer and the hard shell polymer due to internal reflection.
[0005] There are several critical factors which result in poor power efficiencies when using traditional inorganic phosphors for SSWL. These include: total internal reflection at the LED-chip and phosphor layer interface resulting in poor light extraction from the LED into the phosphor layer; poor extraction efficiency from the phosphor layer into the surroundings due to scattering of the light generated by the phosphor particles as well as parasitic absorption by the LED chip, metal contacts and housing; broad phosphor emission in the red wavelength range resulting in unused photons emitted into the near-IR; and poor down-conversion efficiency of the phosphors themselves when excited in the blue wavelength range (this is a combination of absorption and emission efficiency). While efficiencies improve with UV excitation, additional loss due to larger Stokes-shifted emission and lower efficiencies of LEDs in the UV versus the blue wavelength range makes this a less appealing solution overall.
[0006] As a result, poor efficiency drives a high effective ownership cost. The cost is also significantly impacted from the laborious manufacturing and assembly process to construct such devices, for example the heterogeneous integration of the phosphor-layer onto the LED-chip during packaging (DOE and Optoelectronics Industry Development Association “Light emitting diodes (LEDs) for general illumination,” Technology Roadmap (2002)). Historically, blue LEDs have been used in conjunction with various band edge filters and phosphors to generate white light. However, many of the current filters allow photon emission from the blue end of the spectrum, thus limiting the quality of the white LED. The performance of the devices also suffer from poor color rendering due to a limited number of available phosphor colors and color combinations that can be simultaneously excited in the blue. There is a need therefore for efficient nanocomposite filters that can be tailored to filter out specific photon emissions in the visible (especially the blue end), ultraviolet and near infrared spectra.
[0007] While some development of organic phosphors has been made for SSWL, organic materials have several insurmountable drawbacks that make them unlikely to be a viable solution for high-efficiency SSWL. These include: rapid photodegradation leading to poor lifetime, especially in the presence of blue and near-UV light; low absorption efficiency; optical scattering, poor refractive index matching at the chip-interface, narrow and non-overlapping absorption spectra for different color phosphors making it difficult or impossible to simultaneously excite multiple colors; and broad emission spectra. There exists a need therefore for polymeric layers that aid production of high quality, high intensity, white light. Surprisingly, the present invention meets this and other needs.
BRIEF SUMMARY OF THE INVENTION
[0008] In some embodiments, the present invention provides a quantum dot binding-ligand having a siloxane polymer including a plurality of monomer repeat units. The quantum dot binding-ligand also includes a plurality of amine or carboxy binding groups each covalently attached to one of the monomer repeat units, thereby forming a first population of monomer repeat units. The quantum dot binding-ligand also includes a plurality of solubilizing groups each covalently attached to one of the monomer repeat units, thereby forming a second population of monomer repeat units.
[0009] In some embodiments, the quantum dot binding ligand has the structure of formula I:
[0000]
[0000] wherein each R 1 can independently be C 1-20 alkyl, C 1-20 heteroalkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or aryl, each optionally substituted with one or more —Si(R 1a ) 3 groups; each R 1a can independently be C 1-6 alkyl, cycloalkyl or aryl; each L can independently be C 3-8 alkylene, C 3-8 heteroalkylene, C 3-8 alkylene-O—C 2-8 alkylene, C 3-8 alkylene-(C(O)NH—C 2-8 alkylene) q , C 3-8 heteroalkylene-(C(O)NH—C 2-8 alkylene) q , or C 3-8 alkylene-O—C 1-8 alkylene-(C(O)NH—C 2-8 alkylene) q ; each R 2 can independently be NR 2a R 2b or C(O)OH; each of R 2a and R 2b can independently be H or C 1-6 alkyl; each R 3 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or aryl; each R 4 can independently be C 8-20 alkyl, C 8-20 heteroalkyl, cycloalkyl or aryl, each optionally substituted with one or more —Si(R 1a ) 3 groups; each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, -L-(R 2 ) q , cycloalkyl or aryl; subscript m is an integer from 5 to 50; subscript n is an integer from 0 to 50; and subscript q is an integer from 1 to 10, wherein when subscript n is 0, then R 1 can be C 8-20 alkyl, C 8-20 heteroalkyl, C 8-20 alkenyl, C 8-20 alkynyl, cycloalkyl or aryl, each optionally substituted with one or more —Si(R 1a ) 3 groups.
[0010] In some embodiments, the present invention provides a method of making a quantum dot binding-ligand of formula Ib:
[0000]
[0000] The method of making the quantum dot binding-ligand of formula I includes forming a reaction mixture having water and a compound of formula II:
[0000]
[0000] to afford a compound of formula III:
[0000]
[0000] The method also includes forming a reaction mixture of (R 5 ) 3 SiOM and the compound of formula III, to afford a compound of formula IV:
[0000]
[0000] The method also includes forming a reaction mixture of the compound of formula IV, a catalyst, and CH 2 ═CH(CH 2 ) p NR 2a R 2b , thereby forming the compound of formula I. For formulas Ib, II, III and IV, each R 1 can independently be C 8-20 alkyl, C 8-20 alkenyl, C 8-20 alkynyl, cycloalkyl or aryl; each R 2a and R 2b can independently be H or C 1-6 alkyl; each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, C 3-8 alkyl-NR 2a R 2b , cycloalkyl or aryl; subscript m can be an integer from 5 to 50; M can be hydrogen or a cation; and subscript p can be an integer of from 1 to 6.
[0011] In some embodiments, the present invention provides a composition of a quantum dot binding-ligand of the present invention, and a first population of light emitting quantum dots (QDs).
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.
[0013] FIG. 1 shows the synthesis of one type of quantum dot binding-ligand of the present invention by partial hydrosilylation of a commercially available siloxane with an alkene, followed by hydrosilylation of the remaining silane groups with an alkene-amine.
[0014] FIG. 2 shows the synthesis of another type of quantum dot binding-ligand of the present invention by condensation of a long-chain alkyl functionalized dichlorosilane (RSi(Cl) 2 H) with water, followed by end-capping the terminal chloro groups of the siloxane polymer, and then hydrosilylation of the silane groups with a suitable alkeneamine
[0015] FIG. 3 shows the synthesis of another type of quantum dot binding-ligand of the present invention prepared by separating any bis-substituted chlorosilane (1a) prepared in the first step, followed by conversion to a silanol (1b), and then reaction with the siloxane polymer (2) to form the end-capped siloxane polymer (3a). The remaining silane groups are reacted with a suitable alkene and Karstedt's catalyst to prepare the final product (4a), having two additional alkyl-amine groups and four additional long-chain alkyl groups compared to the product of the scheme in FIG. 2 .
[0016] FIG. 4 shows the Laser HALT data for PSAW-1:1 versus epoxy silicone hybrid (ESH) quantum dot compositions, demonstrating improved lifetime for the PSAW-1:1-QD compositions for both red (R) and green (G) light.
[0017] FIG. 5 shows the synthesis of a silyl-modified binding ligand by hydrosilylation of a siloxane polymer with the trialkylsilyl-modified alkene, following by hydrosilylation with an alkene-amine to afford the trialkylsilyl-modified siloxane polymer.
[0018] FIG. 6 shows the synthesis of a siloxane homopolymer having both the carboxylic acid binding group and the long-alkyl solubilizing group on a single monomer. First, trichlorosilane is modified with a long-chain alkyl via a Grignard reaction. The product is then polymerized under condensation conditions to afford a polysilane, which is then modified with the carboxylic acid binding group via hydrosilylation with Karstedt's catalyst.
[0019] FIG. 7 shows an alternative synthesis to the compound shown in FIG. 7 . After modifying the trichlorosilane with the alkyl solubilizing group, the silyl group is reacted with a precursor to the bis-carboxylic acid binding group under hydrosilylation conditions using Karstedt's catalyst. The resulting dichlorosilane is polymerized under condensation conditions to form the product homopolymer.
[0020] FIG. 8 shows the synthesis of a siloxane copolymer with a bis-amine binding group on one monomer and an alkyl solubilizing group on the second monomer. The siloxane polymer is prepared starting with a polysilane that is partially modified with a long-chain alkene via hydrosilylation. The remaining silyl groups are reacted with a precursor to the bis-amine binding group (allyl dimethyl succinate), again via hydrosilylation with Karstedt's catalyst. The dimethyl succinate is then converted to an amine by reaction with 1,2-diaminoethane to afford the product ligand.
[0021] FIG. 9 shows the synthesis of a siloxane homopolymer having both the bis-amine binding group and the long-alkyl solubilizing group on a single monomer. The synthesis follows that described above for FIG. 8 , with the additional step of converting the dimethyl succinate to an amine by reaction with 1,2-diaminoethane.
DETAILED DESCRIPTION OF THE INVENTION
I. General
[0022] The present invention provides siloxane amine waxes (SAW) for binding to quantum dots. The ligands provide greater stability for the quantum dots due to a plurality of amine or carboxy binding groups.
II. Definitions
[0023] “Siloxane polymer” or “polysiloxanes” refers to a polymer having a monomer repeat unit of the formula: —Si(R 2 )O—. The R groups of the siloxane polymer can be the same or different, and can be any suitable group, including, but not limited to, hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl and heteroaryl. When both R groups are other than hydrogen, the siloxane polymer can be referred to as a “silicone.” The siloxane polymers can be linear, branched or cyclic. The siloxane polymer can include a single type of monomer repeat unit, forming a homopolymer. Alternatively, the siloxane polymer can include two or more types of monomer repeat units to form a copolymer that can be a random copolymer or a block copolymer.
[0024] “Solubilizing group” refers to a substantially non-polar group that has a low solubility in water and high solubility in organic solvents such as hexane, pentane, toluene, benzene, diethylether, acetone, ethyl acetate, dichloromethane (methylene chloride), chloroform, dimethylformamide, and N-methylpyrrolidinone. Representative solubilizing groups include long-chain alkyl, long-chain heteroalkyl, long-chain alkenyl, long-chain alkynyl, cycloalkyl and aryl.
[0025] “Amine binding group” refers to an amine having the formula —NR 2 . The R groups attached to the nitrogen atom can be any suitable group, including hydrogen and alkyl. Moreover, the R groups can be the same or different.
[0026] “Carboxy binding group” refers to a carboxylic acid group: C(O)OH.
[0027] “Alkyl” refers to a straight or branched, saturated, aliphatic radical having the number of carbon atoms indicated. Alkyl can include any number of carbons, such as C 1-2 , C 1-3 , C 1-4 , C 1-5 , C 1-6 , C 1-7 , C 1-8 , C 1-9 , C 1-10 , C 1-12 , C 1-14 , C 1-16 , C 1-18 , C 1-20 , C 8-20 , C 12-20 , C 14-20 , C 16-20 , and C 18-20 . For example, C 1-6 alkyl includes, but is not limited to, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec_butyl, tert-butyl, pentyl, isopentyl, hexyl, etc. Other alkyl groups include octane, nonane, decane, undecane, dodecane, tridecane, tetradecane, pentadecane, hexadecane, heptadecane, octadecane, nonadecane, and icosane. Alkyl groups can be substituted or unsubstituted.
[0028] “Long-chain alkyl groups” are alkyl groups, as defined above, having at least 8 carbon chain atoms. Long-chain alkyl groups can include any number of carbons, such as C 8-20 , C 12-20 , C 14-20 , C 16-20 , or C 18-20 . Representative groups include, but are not limited to, octane, nonane, decane, undecane, dodecane, tridecane, tetradecane, pentadecane, hexadecane, heptadecane, octadecane, nonadecane, and icosane. Long-chain alkyl groups can also be substituted with silane groups.
[0029] “Alkylene” refers to a straight or branched, saturated, aliphatic radical having the number of carbon atoms indicated, and linking at least two other groups. The alkylene can link to 2, 3, 4, or more groups, and be divalent, trivalent, tetravalent, or multi-valent. The groups linked to the alkylene can be linked to the same atom or different atoms of the alkylene group. For instance, a straight chain alkylene can be the bivalent radical of —(CH 2 ) n —, where n is 1, 2, 3, 4, 5 or 6. Representative alkylene groups include, but are not limited to, methylene, ethylene, propylene, isopropylene, butylene, isobutylene, sec-butylene, pentylene and hexylene. Alkylene groups can be substituted or unsubstituted.
[0030] “Alkylamine binding group” refers to an amine linked to an alkyl, as described above, and generally having the formula —C 1-20 alkyl-NR 2 . The alkyl moiety of the alkylamine binding group is linked to the siloxane polymer of the present invention. Any suitable alkyl chain is useful. The R groups attached to the nitrogen atom can be any suitable group, including hydrogen and alkyl. Moreover, the R groups can be the same or different.
[0031] “Heteroalkyl” refers to an alkyl group of any suitable length and having from 1 to 5 heteroatoms such as N, O and S. Additional heteroatoms can also be useful, including, but not limited to, B, Al, Si and P. The heteroatoms can also be oxidized, such as, but not limited to, —S(O)— and —S(O) 2 —. For example, heteroalkyl can include ethers (ethyleneoxy and poly(ethyleneoxy)), thioethers and alkyl-amines. The heteroatom portion of the heteroalkyl can replace a hydrogen of the alkyl group to form a hydroxy, thio or amino group. Alternatively, the heteroatom portion can be the connecting atom, or be inserted between two carbon atoms.
[0032] “Long-chain heteroalkyl groups” are heteroalkyl groups, as defined above, having at least 8 chain atoms. Long-chain heteroalkyl groups can include any number of chain atoms, such as C 8-20 , C 12-20 , C 14-20 , C 16-20 , or C 18-20 .
[0033] “Heteroalkylene” refers to a heteroalkyl group, as defined above, linking at least two other groups. The two moieties linked to the heteroalkylene can be linked to the same atom or different atoms of the heteroalkylene.
[0034] “Alkenyl” refers to a straight chain or branched hydrocarbon having at least 2 carbon atoms and at least one double bond. Alkenyl can include any number of carbons, such as C 2 , C 2-3 , C 2-4 , C 2-5 , C 2-6 , C 2-7 , C 2-8 , C 2-9 , C 2-10 , C 2-12 , C 2-14 , C 2-16 , C 2-18 , C 2-20 , C 8-20 , C 12-20 , C 14-20 , C 16-20 , and C 18-20 . Alkenyl groups can have any suitable number of double bonds, including, but not limited to, 1, 2, 3, 4, 5 or more. Examples of alkenyl groups include, but are not limited to, vinyl (ethenyl), propenyl, isopropenyl, 1-butenyl, 2-butenyl, isobutenyl, butadienyl, 1-pentenyl, 2-pentenyl, isopentenyl, 1,3-pentadienyl, 1,4-pentadienyl, 1-hexenyl, 2-hexenyl, 3-hexenyl, 1,3-hexadienyl, 1,4-hexadienyl, 1,5-hexadienyl, 2,4-hexadienyl, or 1,3,5-hexatrienyl. Alkenyl groups can be substituted or unsubstituted.
[0035] “Long-chain alkenyl groups” are alkenyl groups, as defined above, having at least 8 carbon chain atoms. Long-chain alkenyl groups can include any number of carbons, such as C 8-20 , C 12-20 , C 14-20 , C 16-20 , or C 18-20 . Representative groups include, but are not limited to, octene, nonene, decene, undecene, dodecene, tridecene, tetradecene, pentadecene, hexadecene, heptadecene, octadecene, nonadecene, and icosene. The long-chain alkenyl groups can have one or more alkene groups.
[0036] “Alkynyl” refers to either a straight chain or branched hydrocarbon having at least 2 carbon atoms and at least one triple bond. Alkynyl can include any number of carbons, such as C 2 , C 2-3 , C 2-4 , C 2-5 , C 2-6 , C 2-7 , C 2-8 , C 2-9 , C 2-10 , C 2-12 , C 2-14 , C 2-16 , C 2-18 , C 2-20 , C 8-20 , C 12-20 , C 14-20 , C 16-20 , and C 18-20 . Examples of alkynyl groups include, but are not limited to, acetylenyl, propynyl, 1-butyryl, 2-butyryl, isobutynyl, sec-butyryl, butadiynyl, 1-pentynyl, 2-pentynyl, isopentynyl, 1,3-pentadiynyl, 1,4-pentadiynyl, 1-hexynyl, 2-hexynyl, 3-hexynyl, 1,3-hexadiynyl, 1,4-hexadiynyl, 1,5-hexadiynyl, 2,4-hexadiynyl, or 1,3,5-hexatriynyl. Alkynyl groups can be substituted or unsubstituted.
[0037] “Long-chain alkynyl groups” are alkynyl groups, as defined above, having at least 8 carbon chain atoms. Long-chain alkynyl groups can include any number of carbons, such as C 8-20 , C 12-20 , C 14-20 , C 16-20 , or C 18-20 . Representative groups include, but are not limited to, octyne, nonyne, decyne, undecyne, dodecyne, tridecyne, tetradecyne, pentadecyne, hexadecyne, heptadecyne, octadecyne, nonadecyne, and icosyne. The long-chain alkynyl groups can have one or more alkyne groups.
[0038] “Cycloalkyl” refers to a saturated or partially unsaturated, monocyclic, fused bicyclic or bridged polycyclic ring assembly containing from 3 to 12 ring atoms, or the number of atoms indicated. Cycloalkyl can include any number of carbons, such as C 3-6 , C 4-6 , C 5-6 , C 3-8 , C 4-8 , C 5-8 , C 6-8 , C 3-9 , C 3-10 , C 3-11 , C 3-12 , C 6-10 , or C 6-12 Saturated monocyclic cycloalkyl rings include, for example, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and cyclooctyl. Saturated bicyclic and polycyclic cycloalkyl rings include, for example, norbornane, [2.2.2]bicyclooctane, decahydronaphthalene and adamantane. Cycloalkyl groups can also be partially unsaturated, having one or more double or triple bonds in the ring. Representative cycloalkyl groups that are partially unsaturated include, but are not limited to, cyclobutene, cyclopentene, cyclohexene, cyclohexadiene (1,3- and 1,4-isomers), cycloheptene, cycloheptadiene, cyclooctene, cyclooctadiene (1,3-, 1,4- and 1,5-isomers), norbornene, and norbornadiene. When cycloalkyl is a saturated monocyclic C 3-8 cycloalkyl, exemplary groups include, but are not limited to cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and cyclooctyl. When cycloalkyl is a saturated monocyclic C 3-6 cycloalkyl, exemplary groups include, but are not limited to cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl. Cycloalkyl groups can be substituted or unsubstituted.
[0039] “Alkyl-cycloalkyl” refers to a radical having an alkyl component and a cycloalkyl component, where the alkyl component links the cycloalkyl component to the point of attachment. The alkyl component is as defined above, except that the alkyl component is at least divalent, an alkylene, to link to the cycloalkyl component and to the point of attachment. In some instances, the alkyl component can be absent. The alkyl component can include any number of carbons, such as C 1-6 , C 1-2 , C 1-3 , C 1-4 , C 1-5 , C 2-3 , C 2-4 , C 2-5 , C 2-6 , C 3-4 , C 3-5 , C 3-6 , C 4-5 , C 4-6 and C 5-6 . The cycloalkyl component is as defined within. Exemplary alkyl-cycloalkyl groups include, but are not limited to, methyl-cyclopropyl, methyl-cyclobutyl, methyl-cyclopentyl and methyl-cyclohexyl.
[0040] “Aryl” refers to an aromatic ring system having any suitable number of ring atoms and any suitable number of rings. Aryl groups can include any suitable number of ring atoms, such as, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 or 16 ring atoms, as well as from 6 to 10, 6 to 12, or 6 to 14 ring members. Aryl groups can be monocyclic, fused to form bicyclic or tricyclic groups, or linked by a bond to form a biaryl group. Representative aryl groups include phenyl, naphthyl and biphenyl. Other aryl groups include benzyl, having a methylene linking group. Some aryl groups have from 6 to 12 ring members, such as phenyl, naphthyl or biphenyl. Other aryl groups have from 6 to 10 ring members, such as phenyl or naphthyl. Some other aryl groups have 6 ring members, such as phenyl. Aryl groups can be substituted or unsubstituted.
[0041] “Alkyl-aryl” refers to a radical having an alkyl component and an aryl component, where the alkyl component links the aryl component to the point of attachment. The alkyl component is as defined above, except that the alkyl component is at least divalent, an alkylene, to link to the aryl component and to the point of attachment. The alkyl component can include any number of carbons, such as C 0-6 , C 1-2 , C 1-3 , C 1-4 , C 1-5 , C 1-6 , C 2-3 , C 2-4 , C 2-5 , C 2-6 , C 3-4 , C 3-5 , C 3-6 , C 4-5 , C 4-6 and C 5-6 . In some instances, the alkyl component can be absent. The aryl component is as defined above. Examples of alkyl-aryl groups include, but are not limited to, benzyl and ethyl-benzene. Alkyl-aryl groups can be substituted or unsubstituted.
[0042] “Silane” or “silyl” refers to a silicon atom having several substituents, and generally having the formula —SiR 3 . The R groups attached to the silicon atom can be any suitable group, including, but not limited to, hydrogen, halogen and alkyl. Moreover, the R groups can be the same or different.
[0043] “Forming a reaction mixture” refers to combining at least two components in a container under conditions suitable for the components to react with one another and form a third component.
[0044] “Catalyst” refers to a transition metal catalyst capable of performing a hydrosilylation reaction. Representative catalysts include palladium and platinum catalysts such as Karstedt's catalyst. Other catalysts are useful in the present invention.
[0045] “Cation” refers to metal and non-metal ions having at least a 1+ charge. Metals useful as the metal cation in the present invention include the alkali metals, alkali earth metals, transition metals and post-transition metals. Alkali metals include Li, Na, K, Rb and Cs. Non-metal cations can be formed from a variety of groups including quaternary nitrogen groups such as ammonium ions, R 4 N + , wherein the R groups can be the same or different, and can be any suitable group, including, but not limited to, hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl and heteroaryl.
[0046] “Quantum dot” or “nanocrystal” refers to nanostructures that are substantially monocrystalline. A nanocrystal has at least one region or characteristic dimension with a dimension of less than about 500 nm, and down to on the order of less than about 1 nm. As used herein, when referring to any numerical value, “about” means a value of ±10% of the stated value (e.g. about 100 nm encompasses a range of sizes from 90 nm to 110 nm, inclusive). The terms “nanocrystal,” “quantum dot,” “nanodot,” and “dot,” are readily understood by the ordinarily skilled artisan to represent like structures and are used herein interchangeably. The present invention also encompasses the use of polycrystalline or amorphous nanocrystals.
III. Quantum Dot Binding-Ligands
[0047] The present invention provides a siloxane amine wax (SAW) for binding to quantum dots (QDs) and related materials. The SAW materials of the present invention contain a waxy component (long-chain alkyl) and a plurality of amine or carboxy groups capable of binding to QDs, improving stability of the resulting ligand-QD complex.
[0048] In some embodiments, the present invention provides a quantum dot binding-ligand having a siloxane polymer including a plurality of monomer repeat units. The quantum dot binding-ligand also includes a plurality of amine or carboxy binding groups each covalently attached to one of the monomer repeat units, thereby forming a first population of monomer repeat units. The quantum dot binding-ligand also includes a plurality of solubilizing groups each covalently attached to one of the monomer repeat units, thereby forming a second population of monomer repeat units.
[0049] In some embodiments, the present invention provides a quantum dot binding-ligand having a siloxane polymer including a plurality of monomer repeat units. The quantum dot binding-ligand also includes a plurality of alkylamine binding groups each covalently attached to one of the monomer repeat units, thereby forming a first population of monomer repeat units. The quantum dot binding-ligand also includes a plurality of solubilizing or hydrophobic groups each covalently attached to one of the monomer repeat units, thereby forming a second population of monomer repeat units.
[0050] The siloxane polymer can be any siloxane polymer having a waxy component and a binding component. The waxy component can be any solubilizing or hydrophobic group. In some embodiments, the solubilizing or hydrophobic group can be a long-chain alkyl group, a long-chain alkenyl group, a long-chain alkynyl group, a cycloalkyl or an aryl.
[0051] In some embodiments, the solubilizing group or waxy component can be a long-chain alkyl. In some embodiments, each long-chain alkyl group can be octane, nonane, decane, undecane, dodecane, tridecane, tetradecane, pentadecane, hexadecane, heptadecane, octadecane, nonadecane, or icosane. In some embodiments, each long-chain alkyl group can be hexadecane, heptadecane, octadecane, nonadecane, or icosane. In some embodiments, each long-chain alkyl group can be hexadecane, octadecane, or icosane. In some embodiments, each long-chain alkyl group can be octadecane. The long-chain alkyl group can be linear or branched, and optionally substituted.
[0052] The siloxane polymer can have any suitable number of monomer repeat units. For example, the siloxane polymer can include from 5 to 100 monomer repeat units. Alternatively, the siloxane polymer can include about 5, 10, 15, 20, 25, 30, 40, 50, 60, 70, 80, 90 or 100 monomer repeat units. In some embodiments, the siloxane polymer can include from about 5 to about 50, or about 10 to about 50, or about 10 to about 25 monomer repeat units.
[0053] When there are at least two types of monomer repeat units, one type of monomer repeat can be present in a greater amount relative to the other types of monomer repeat units. Alternatively, the different types of monomer repeat units can be present in about the same amount. In some embodiments, the first population of monomer repeat units is about the same number as the second population of monomer repeat units.
[0054] Each monomer repeat unit can be the same or different. In some embodiments, there are at least two types of monomer repeat units in the siloxane polymer. In some embodiments, the siloxane polymer includes at least two types of monomer repeat units where a first type includes to the long-chain alkyl group and a second type includes to the alkylamine binding group. Other types of monomer repeat units can also be present. The siloxane polymer of the present invention can include 1, 2, 3, 4 or more different kinds of monomer repeat units. In some embodiments, the siloxane polymers of the present invention have a single type of monomer repeat unit. In other embodiments, the siloxane polymers of the present invention have two different types of monomer repeat units.
[0055] In some embodiments, each monomer repeat unit is covalently linked to both the amine or carboxy binding group and the long-chain alkyl group, such that the first and second populations of monomer repeat units are the same.
[0056] In some embodiments, each monomer repeat unit is covalently linked to both the alkylamine binding group and the long-chain alkyl group, such that the first and second populations of monomer repeat units are the same.
[0057] In some embodiments, the quantum dot binding ligand has the structure of formula I:
[0000]
[0000] wherein each R 1 can independently be C 1-20 alkyl, C 1-20 heteroalkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or aryl, each optionally substituted with one or more —Si(R 1a ) 3 groups; each R 1a can independently be C 1-6 alkyl, cycloalkyl or aryl; each L can independently be C 3-8 alkylene, C 3-8 heteroalkylene, C 3-8 alkylene-O—C 2-8 alkylene, C 3-8 alkylene-(C(O)NH—C 2-8 alkylene) q , C 3-8 heteroalkylene-(C(O)NH—C 2-8 alkylene) q , or C 3-8 alkylene-O—C 1-8 alkylene-(C(O)NH—C 2-8 alkylene) q ; each R 2 can independently be NR 2a R 2b or C(O)OH; each of R 2a and R 2b ) can independently be H or C 1-6 alkyl; each R 3 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or aryl; each R 4 can independently be C 8-20 alkyl, C 8-20 heteroalkyl, cycloalkyl or aryl, each optionally substituted with one or more —Si(R 1a ) 3 groups; each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, -L-(R 2 ) q , cycloalkyl or aryl; subscript m is an integer from 5 to 50; subscript n is an integer from 0 to 50; and subscript q is an integer from 1 to 10, wherein when subscript n is 0, then R 1 can be C 8-20 alkyl, C 8-20 heteroalkyl, C 8-20 alkenyl, C 8-20 alkynyl, cycloalkyl or aryl, each optionally substituted with one or more —Si(R 1a ) 3 groups.
[0058] In some embodiments, wherein each R 1 can independently be C 1-20 alkyl, C 1-20 heteroalkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or ary; each R 1a can independently be C 1-6 alkyl, cycloalkyl or aryl; each L can independently be C 3-8 alkylene; each R 2 can independently be NR 2a R 2b or C(O)OH; each of R 2a and R 2b can independently be H or C 1-6 alkyl; each R 3 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or aryl; each R 4 can independently be C 8-20 alkyl, C 8-20 heteroalkyl, cycloalkyl or aryl; each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, -L-(R 2 ) q , cycloalkyl or aryl; subscript m is an integer from 5 to 50; subscript n is an integer from 0 to 50; and subscript q is an integer from 1 to 10, wherein when subscript n is 0, then R 1 can be C 8-20 alkyl, C 8-20 heteroalkyl, C 8-20 alkenyl, C 8-20 alkynyl, cycloalkyl or aryl.
[0059] Radical L can be any suitable linker to link the binding group R 2 to the siloxane polymer. In some embodiments, each L can independently be C 3-8 alkylene, C 3-8 alkylene-O—C 2-8 alkylene, C 3-8 alkylene-(C(O)NH—C 2-8 alkylene) 2 , or C 3-8 alkylene-O—C 1-8 alkylene-(C(O)NH—C 2-8 alkylene) 3 . In other embodiments, each L can independently be C 3-8 alkylene. In some other embodiments, each L can independently be propylene, butylene, pentylene, n-propylene-O-i-propylene, and pentylene-(C(O)NH-ethylene) 2 . In still other embodiments, each L can independent by propylene, butylene or pentylene.
[0060] The binding group, R 2 , can be any suitable amine or carboxylic acid. For example, R 2 can be a primary amine where both of R 2a and R 2b are H. Alternatively, R 2 can be a secondary amine where one of R 2a and R 2b is H and the other is C 1-6 alkyl. Representative secondary amines include, but are not limited to, those where R 2a is methyl, ethyl, propyl, isopropyl, butyl, etc. Tertiary amines, where each of R 2a and R 2b is C 1-6 alkyl, are also useful as the binding group R 2 . In those cases, the R 2a and R 2b can be the same or different. Representative tertiary amines include, but are not limited to —N(Me) 2 , —N(Et) 2 , —N(Pr) 2 , —N(Me)(Et), —N(Me)(Pr), —N(Et)(Pr), among others.
[0061] In some embodiments, each -L-(R 2 ) q group can independently be C 3-8 alkylene-(R 2 ) 1-3 , C 3-8 heteroalkylene-R 2 , or C 3-8 alkylene-(C(O)NH—C 2-8 alkylene-R 2 ) 2 . In other embodiments, each L-(R 2 ) q group can independently be C 3-8 alkylene-C(O)OH, C 3-8 alkylene-(C(O)OH) 2 , C 3-8 alkylene-O—C 2-8 alkylene-(C(O)OH) 3 , C 3-8 alkylene-NR 2a R 2b , or C 3-8 alkylene-(C(O)NH—C 2-8 alkylene-NR 2a R 2b ) 2 . In some other embodiments, each L-(R 2 ) q group can independently be C 3-8 alkylene-C(O)OH, C 3-8 alkylene-(C(O)OH) 2 , or C 3-8 alkylene-NR 2a R 2b . In some other embodiments, each L-(R 2 ) q group can independently be:
[0000]
[0000] In still other embodiments, each L-(R 2 ) q group can independently be:
[0000]
[0062] One of radicals R 1 and R 4 can be the solubilizing ligand. When subscript n is 0, R 1 can be the solubilizing ligand. When subscript n is greater than 1, either of R 1 and R 4 can be the solubilizing ligand. Any suitable solubilizing ligand can be used in the present invention. In some embodiments, at least one of R 1 and R 4 can be C 8-20 alkyl or C 8-20 heteroalkyl, wherein each alkyl group is optionally substituted with one —Si(R 1a ) 3 group. In other embodiments, at least one of R 1 and R 4 can be C 8-20 alkyl or C 8-20 heteroalkyl. In some other embodiments, at least one of R 1 and R 4 can be C 16 alkyl, C 18 alkyl, C 20 alkyl, or —(CH 2 ) 2 —(OCH 2 CH 2 ) 3 —OCH 3 , wherein each alkyl group is optionally substituted with one —Si(R 1a ) 3 group. In still other embodiments, at least one of R 1 and R 4 can be C 16 alkyl, C 18 alkyl, C 20 alkyl, or —(CH 2 ) 2 —(OCH 2 CH 2 ) 3 —OCH 3 .
[0063] When the alkyl group of R 1 or R 4 is substituted with the —Si(R 1a ) 3 group, the substitution can be at any point on the alkyl group, including the terminal carbon, or any other carbon in the alkyl chain. The alkyl group can be branched or unbranched. The R 1a group can be any suitable group that promotes solubilization of the siloxane polymer. For example, each R 1a can independently be C 1-6 alkyl, cycloalkyl or aryl. Each R 1a can be the same or different. In some embodiments, each R 1a can independently be C 1-6 alkyl. The alkyl groups of R 1a can be branched or unbranched. Representative alkyl groups of R 1a include, but are not limited to, methyl, ethyl, propyl, etc. In some embodiments, each R 1a can be ethyl.
[0064] Radical R 3 can be any suitable group. In some embodiments, each R 3 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or aryl. In other embodiments, each R 3 can independently be C 1-20 alkyl. In some other embodiments, each R 3 can independently be C 1-6 alkyl. In still other embodiments, each R 3 can independently be C 1-3 alkyl. In yet other embodiments, each R 3 can independently be methyl, ethyl or propyl. In still yet other embodiments, each R 3 can be methyl.
[0065] R 5 can be any suitable group. In some embodiments, each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, -L-(R 2 ) q , cycloalkyl or aryl. In other embodiments, each R 5 can independently be C 1-20 alkyl. In some other embodiments, each R 5 can independently be C 1-6 alkyl. In still other embodiments, each R 5 can independently be C 1-3 alkyl. In yet other embodiments, each R 5 can independently be methyl, ethyl or propyl. In still yet other embodiments, each R 5 can be methyl.
[0066] Alternatively, R 5 can be an amine or carboxy binding group, or a solubilizing group. In some embodiments, at least one R 5 can be -L-(R 2 ) q , as defined above. In other embodiments, at least one R 5 can be C 8-20 alkyl. In some other embodiments, at least one R 5 can be C 12-20 alkyl. In still other embodiments, at least one R 5 can be octadecane.
[0067] When the quantum dot binding-ligands of the present invention have two types of monomer repeat units, such that subscript n is not 0, the structure can be the structure of formula I, wherein each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or aryl; subscript m can be an integer from 5 to 50; and subscript n can be an integer from 1 to 50. In some embodiments, R 1 can independently be C 1-3 alkyl. In some embodiments, the alkyl groups of R 4 can be C 8-20 , C 12-20 , C 14-20 , C 16-20 , or C 18-20 .
[0068] Any suitable number of subscripts m and n can be present in the quantum dot binding-ligands of the present invention. For example, the number of subscripts m and n can be from about 1 to about 100, or from about 5 to about 100, or from about 5 to about 50, or from about 10 to about 50, or from about 10 to about 25. Alternatively, the number of subscripts m and n can be about 5, 10, 15, 20, 25, 30, 40, 50, 60, 70, 80, 90 or about 100.
[0069] Any suitable ratio of subscripts m and n can be present in the quantum dot binding-ligands of the present invention. For example, the ratio of subscript m to n can be from about 10:1, 5:1, 2.5:1 2:1, 1:1, 1:2, 1:2.5, 1:5 or about 1:10. In some embodiments, the ratio of subscript m to subscript n is about 2:1. In some embodiments, the ratio of subscript m to subscript n is about 1:1. In some embodiments, the ratio of subscript m to subscript n is about 1:2.
[0070] In some embodiments, R 1 and R 3 can each independently be C 1-3 alkyl; each R 1a can independently be C 1-6 alkyl; each R 4 can independently be C 8-20 alkyl or C 8-20 heteroalkyl, wherein the alkyl group can optionally be substituted with one —Si(R 1a ) 3 group; each R 5 can independently be C 1-3 alkyl; and subscript q can be an integer from 1 to 3.
[0071] In some embodiments, subscript n is other than 0. In other embodiments, the quantum dot binding ligand can have the following structure:
[0000]
[0000] wherein subscripts m and n are each an integer from 10 to 14. In some embodiments, the quantum dot binding ligand can have any of the following structures:
[0000]
[0000] wherein each R 1a can independently be C 1-6 alkyl, and subscripts m and n can each be an integer from 10 to 14.
[0072] In some embodiments, the quantum dot binding ligand can have any of the following structures:
[0000]
[0000] wherein each R 1a can independently be C 1-6 alkyl, and subscripts m and n can each be an integer from 10 to 14.
[0073] In some embodiments, subscript n is 0. In other embodiments, each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or aryl; subscript m can be an integer from 5 to 50; and subscript n can be 0. In some other embodiments, each R 1 can independently be C 8-20 alkyl or C 8-20 heteroalkyl, wherein the alkyl group can optionally be substituted with one —Si(R 1a ) 3 group; each R 1a can independently be C 1-6 alkyl; each R 5 can independently be C 1-3 alkyl; and subscript q can be an integer from 1 to 3. In still other embodiments, each R 1 can independently be C 8-20 alkyl or C 8-20 heteroalkyl; each R 1a can independently be C 1-6 alkyl; each R 5 can independently be C 1-3 alkyl; and subscript q can be an integer from 1 to 3.
[0074] In some embodiments, the quantum dot binding ligand has the structure:
[0000]
[0000] In other embodiments, R 1 can be C 8-20 alkyl. In some other embodiments, the quantum dot binding ligand can have any of the following structures:
[0000]
[0000] wherein subscript m is an integer from 5 to 50.
[0075] In other embodiments, R 1 can be C 8-20 alkyl. In some other embodiments, the quantum dot binding ligand can have any of the following structures:
[0000]
[0000] wherein subscript m is an integer from 5 to 50.
[0076] In some embodiments, the quantum dot binding ligand has the structure of formula Ia:
[0000]
[0000] wherein each R 1 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or ary, wherein the alkyl group is optionally substituted with one —Si(R 1a ) 3 group 1; each R 2 can independently be C 3-8 alkyl-NR 2a R 2b ; each of R 2a and R 2b can independently be H or C 1-6 alkyl; each R 3 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or aryl; each R 4 can independently be C 8-20 alkyl; each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, C 3-8 alkyl-NR 2a R 2b , cycloalkyl or aryl; subscript m can be an integer from 5 to 50; and subscript n can be an integer from 0 to 50; wherein when subscript n is 0, then R 1 can be C 8-20 alkyl, C 8-20 alkenyl, C 8-20 alkynyl, cycloalkyl or aryl. In some embodiments, the alkyl groups of R 1 or R 4 can be C 8-20 , C 12-20 , C 14-20 , C 16-20 , or C 18-20 .
[0077] Radical R 5 can be any suitable group. In some embodiments, each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, C 3-8 alkyl-NR 2a R 2b , cycloalkyl or aryl. In some embodiments, each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, cycloalkyl or aryl. In some embodiments, each R 5 can be C 1-20 alkyl. In some embodiments, each R 5 can be C 8-20 alkyl. In some embodiments, each R 5 can be octadecane. In some embodiments, each R 5 can be C 1-3 alkyl. In some embodiments, each R 5 can independently be methyl, ethyl or propyl. In some embodiments, each R 5 can be aryl. In some embodiments, each R 5 can be phenyl. In some embodiments, R 5 can be C 3-8 alkyl-NR 2a R 2b . In some embodiments, R 5 can be C 3 alkyl-NR 2a R 2b . In some embodiments, each R 5 can independently be octadecane or C 3 alkyl-NR 2a R 2b .
[0078] In some embodiments, the quantum dot binding-ligand can have the following structure:
[0000]
[0079] In some embodiments, the quantum dot binding-ligand of the present invention has the following structure:
[0000]
[0000] wherein subscripts m and n are each an integer from 10 to 14.
[0080] When the quantum dot binding-ligands of the present invention have a single type of monomer repeat unit, such that subscript n is 0, the structure can be the structure of formula I, wherein each R 1 can independently be C 8-20 alkyl, C 8-20 alkenyl, C 8-20 alkynyl, cycloalkyl or aryl. In some embodiments, each R 1 can independently be C 8-20 alkyl; subscript m can be an integer from 5 to 50; and subscript n can be 0. In some embodiments, the quantum dot binding-ligand of formula I can have the following structure:
[0000]
[0081] In some embodiments, the quantum dot binding-ligand of formula I can have the following structure:
[0000]
[0000] wherein R 1 can be C 8-20 alkyl; and subscript p can be an integer from 1 to 6. In some embodiments, subscript p can be 1, 2, 3, 4, 5, or 6. In some embodiments, subscript p can be 1.
[0082] In some embodiments, the quantum dot binding-ligand of formula I can have the following structure:
[0000]
[0000] wherein subscript m can an integer from 6 to 8.
[0083] In some embodiments, each R 5 can independently be C 8-20 alkyl, C 8-20 alkenyl, C 8-20 alkynyl, C 3-8 alkyl-NR 2a R 2b , cycloalkyl or aryl. In some embodiments, each R 5 can independently be C 8-20 alkyl or C 3-8 alkyl-NR 2a R 2b . In some embodiments, the quantum dot binding-ligand can have the structure:
[0000]
IV. Methods of Making Quantum Dot Binding-Ligands
[0084] The quantum dot binding-ligands of the present invention can be prepared by any suitable means known to one of skill in the art. For example, a commercially available siloxane polymer can be hydrosilylated with an alkene and an alkene-amino in sequential steps (as shown in FIG. 1 ) to form the quantum dot binding-ligand of formula I where subscript n is not 0. Alternatively, a siloxane polymer can be prepared by condensation of a long-chain alkyl functionalized dichlorosilane (RSi(Cl) 2 H) with water, followed by end-capping the terminal chloro groups of the polymer, and then hydrosilylation of the silane groups with a suitable alkeneamine ( FIG. 2 ). FIG. 3 shows yet another method for preparing the quantum dot binding-ligands of the present invention. Following the method described in FIG. 2 , any bis-substituted chlorosilane (1a) prepared in the first step is separated, converted to a silanol (1b), and then reacted with the siloxane polymer (2) to form the end-capped siloxane polymer (3a). The remaining silane groups are reacted with a suitable alkene and Karstedt's catalyst to prepare the final product (4a), having two additional alkyl-amine groups and four additional long-chain alkyl groups compared to the product of the scheme in FIG. 2 . Other methods of making the quantum dot binding ligands of the present invention are described in the remaining figures.
[0085] In some embodiments, the present invention provides a method of making a quantum dot binding-ligand of formula Ib:
[0000]
[0000] The method of making the quantum dot binding-ligand of formula I includes forming a reaction mixture having water and a compound of formula II:
[0000]
[0000] to afford a compound of formula III:
[0000]
[0000] The method also includes forming a reaction mixture of (R 5 ) 3 SiOM and the compound of formula III, to afford a compound of formula IV:
[0000]
[0000] The method also includes forming a reaction mixture of the compound of formula IV, a catalyst, and CH 2 ═CH(CH 2 ) p NR 2a R 2b , thereby forming the compound of formula I. For formulas Ib, II, III and IV, each R 1 can independently be C 8-20 alkyl, C 8-20 alkenyl, C 8-20 alkynyl, cycloalkyl or aryl; each of R 2a and R 2b can independently be H or C 1-6 alkyl; each R 5 can independently be C 1-20 alkyl, C 2-20 alkenyl, C 2-20 alkynyl, C 3-8 alkyl-NR 2a R 2b , cycloalkyl or aryl; subscript m can be an integer from 5 to 50; M can be hydrogen or a cation; and subscript p can be an integer of from 1 to 6.
[0086] In some embodiments, the alkyl group of R 1 can be C 12-20 , C 14-20 , C 16-20 , or C 18-20 . In some embodiments, the alkyl group of R 1 can be C 18 , octadecane.
[0087] Any suitable amount of water is useful in the methods of the present invention. For example, water can be present in an amount from about 0.01 to about 1.0 molar equivalents, or from about 0.1 to less than 1.0 equivalents, or from about 0.25 to about 0.75 equivalents, or from about 0.5 to about 0.75 equivalents. Water can also be present in an amount of about 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9 or about 1.0 molar equivalents. In some embodiments, the water can be present in step (a) in an amount of less than about 1.0 eq. to the compound of formula II. In some embodiments, the water can be present in step (a) in an amount of from about 0.1 to about 0.75 eq. to the compound of formula II. In some embodiments, the water can be present in step (a) in an amount of from about 0.5 to about 0.75 eq. to the compound of formula II.
[0088] Any suitable nucleophile can be used to end-cap the terminal chloro groups of formula III. In some embodiments, the nucleophile can be (R 5 ) 3 SiOM, where each R 5 is as described above and M can be hydrogen or a cation. Any suitable cation is useful for the nucleophile, including metal and non-metal cations. In some embodiments, M can be a metal cation such as Na + or K + .
[0089] The catalyst of step (b) can be any catalyst suitable for performing a hydrosilylation reaction. For example, the catalyst can be a transition metal catalyst such as Karstedt's catalyst, a platinum based catalyst. In some embodiments, the catalyst can be Karstedt's catalyst.
V. Compositions
[0090] The quantum dot binding-ligands of the present invention can be complexed to a quantum dot (QD). In some embodiments, the present invention provides a composition of a quantum dot binding-ligand of the present invention, and a first population of light emitting quantum dots (QDs).
[0091] In some embodiments, the quantum dot binding-ligand can have the structure of formula I, as described above. In some embodiments, the quantum dot binding-ligand can have the structure:
[0000]
[0000] wherein subscripts m and n are each an integer from 10 to 14. In some embodiments, the quantum dot binding-ligand can have the structure of formula Ib, as described above. In some embodiments, the quantum dot binding-ligand can have the structure:
[0000]
[0000] wherein subscript m is an integer from 6 to 8.
Quantum Dots
[0092] Typically, the region of characteristic dimension will be along the smallest axis of the structure. The QDs can be substantially homogenous in material properties, or in certain embodiments, can be heterogeneous. The optical properties of QDs can be determined by their particle size, chemical or surface composition; and/or by suitable optical testing available in the art. The ability to tailor the nanocrystal size in the range between about 1 nm and about 15 nm enables photoemission coverage in the entire optical spectrum to offer great versatility in color rendering. Particle encapsulation offers robustness against chemical and UV deteriorating agents.
[0093] Additional exemplary nanostructures include, but are not limited to, nanowires, nanorods, nanotubes, branched nanostructures, nanotetrapods, tripods, bipods, nanoparticles, and similar structures having at least one region or characteristic dimension (optionally each of the three dimensions) with a dimension of less than about 500 nm, e.g., less than about 200 nm, less than about 100 nm, less than about 50 nm, or even less than about 20 nm or less than about 10 nm. Typically, the region or characteristic dimension will be along the smallest axis of the structure. Nanostructures can be, e.g., substantially crystalline, substantially monocrystalline, polycrystalline, amorphous, or a combination thereof.
[0094] QDs (or other nanostructures) for use in the present invention can be produced using any method known to those skilled in the art. For example, suitable QDs and methods for forming suitable QDs include those disclosed in: U.S. Pat. No. 6,225,198, U.S. Pat. No. 6,207,229, U.S. Pat. No. 6,322,901, U.S. Pat. No. 6,872,249, U.S. Pat. No. 6,949,206, U.S. Pat. No. 7,572,393, U.S. Pat. No. 7,267,865, U.S. Pat. No. 7,374,807, US Patent Publication No. 2008/0118755, filed Dec. 9, 2005, and U.S. Pat. No. 6,861,155, each of which is incorporated by reference herein in its entirety.
[0095] The QDs (or other nanostructures) for use in the present invention can be produced from any suitable material, suitably an inorganic material, and more suitably an inorganic conductive or semiconductive material. Suitable semiconductor materials include any type of semiconductor, including group II-VI, group III-V, group IV-VI and group IV semiconductors. Suitable semiconductor materials include, but are not limited to, Si, Ge, Sn, Se, Te, B, C (including diamond), P, BN, BP, BAs, AlN, AlP, AlAs, AlSb, GaN, GaP, GaAs, GaSb, InN, InP, InAs, InSb, AlN, AlP, AlAs, AlSb, GaN, GaP, GaAs, GaSb, ZnO, ZnS, ZnSe, ZnTe, CdS, CdSe, CdSeZn, CdTe, HgS, HgSe, HgTe, BeS, BeSe, BeTe, MgS, MgSe, GeS, GeSe, GeTe, SnS, SnSe, SnTe, PbO, PbS, PbSe, PbTe, CuF, CuCl, CuBr, CuI, Si 3 N 4 , Ge 3 N 4 , Al 2 O 3 , (Al, Ga, In) 2 (S, Se, Te) 3 , Al 2 CO 3 , and appropriate combinations of two or more such semiconductors.
[0096] In some embodiments, the semiconductor nanocrystals or other nanostructures can also include a dopant, such as a p-type dopant or an n-type dopant. The nanocrystals (or other nanostructures) useful in the present invention can also include II-VI or III-V semiconductors. Examples of II-VI or III-V semiconductor nanocrystals and nanostructures include any combination of an element from Group II, such as Zn, Cd and Hg, with any element from Group VI, such as S, Se, Te, Po, of the Periodic Table; and any combination of an element from Group III, such as B, Al, Ga, In, and Tl, with any element from Group V, such as N, P, As, Sb and Bi, of the Periodic Table. Other suitable inorganic nanostructures include metal nanostructures. Suitable metals include, but are not limited to, Ru, Pd, Pt, Ni, W, Ta, Co, Mo, Ir, Re, Rh, Hf, Nb, Au, Ag, Ti, Sn, Zn, Fe, FePt, and the like.
[0097] While any method known to the ordinarily skilled artisan can be used to create nanocrystal phosphors, suitably, a solution-phase colloidal method for controlled growth of inorganic nanomaterial phosphors is used. See Alivisatos, A. P., “Semiconductor clusters, nanocrystals, and quantum dots,” Science 271:933 (1996); X. Peng, M. Schlamp, A. Kadavanich, A. P. Alivisatos, “Epitaxial growth of highly luminescent CdSe/CdS Core/Shell nanocrystals with photostability and electronic accessibility,” J. Am. Chem. Soc. 30:7019-7029 (1997); and C. B. Murray, D. J. Norris, M. G. Bawendi, “Synthesis and characterization of nearly monodisperse CdE (E=sulfur, selenium, tellurium) semiconductor nanocrystallites,” J. Am. Chem. Soc. 115:8706 (1993), the disclosures of which are incorporated by reference herein in their entireties. This manufacturing process technology leverages low cost processability without the need for clean rooms and expensive manufacturing equipment. In these methods, metal precursors that undergo pyrolysis at high temperature are rapidly injected into a hot solution of organic surfactant molecules. These precursors break apart at elevated temperatures and react to nucleate nanocrystals. After this initial nucleation phase, a growth phase begins by the addition of monomers to the growing crystal. The result is freestanding crystalline nanoparticles in solution that have an organic surfactant molecule coating their surface.
[0098] Utilizing this approach, synthesis occurs as an initial nucleation event that takes place over seconds, followed by crystal growth at elevated temperature for several minutes. Parameters such as the temperature, types of surfactants present, precursor materials, and ratios of surfactants to monomers can be modified so as to change the nature and progress of the reaction. The temperature controls the structural phase of the nucleation event, rate of decomposition of precursors, and rate of growth. The organic surfactant molecules mediate both solubility and control of the nanocrystal shape. The ratio of surfactants to monomer, surfactants to each other, monomers to each other, and the individual concentrations of monomers strongly influence the kinetics of growth.
[0099] In semiconductor nanocrystals, photo-induced emission arises from the band edge states of the nanocrystal. The band-edge emission from luminescent nanocrystals competes with radiative and non-radiative decay channels originating from surface electronic states. X. Peng, et al., J. Am. Chem. Soc. 30:7019-7029 (1997). As a result, the presence of surface defects such as dangling bonds provide non-radiative recombination centers and contribute to lowered emission efficiency. An efficient and permanent method to passivate and remove the surface trap states is to epitaxially grow an inorganic shell material on the surface of the nanocrystal. X. Peng, et al., J. Am. Chem. Soc. 30:7019-7029 (1997). The shell material can be chosen such that the electronic levels are type I with respect to the core material (e.g., with a larger bandgap to provide a potential step localizing the electron and hole to the core). As a result, the probability of non-radiative recombination can be reduced.
[0100] Core-shell structures are obtained by adding organometallic precursors containing the shell materials to a reaction mixture containing the core nanocrystal. In this case, rather than a nucleation-event followed by growth, the cores act as the nuclei, and the shells grow from their surface. The temperature of the reaction is kept low to favor the addition of shell material monomers to the core surface, while preventing independent nucleation of nanocrystals of the shell materials. Surfactants in the reaction mixture are present to direct the controlled growth of shell material and ensure solubility. A uniform and epitaxially grown shell is obtained when there is a low lattice mismatch between the two materials.
[0101] Exemplary materials for preparing core-shell luminescent nanocrystals include, but are not limited to, Si, Ge, Sn, Se, Te, B, C (including diamond), P, Co, Au, BN, BP, BAs, AlN, AlP, AlAs, AlSb, GaN, GaP, GaAs, GaSb, InN, InP, InAs, InSb, AlN, AlP, AlAs, AlSb, GaN, GaP, GaAs, GaSb, ZnO, ZnS, ZnSe, ZnTe, CdS, CdSe, CdSeZn, CdTe, HgS, HgSe, HgTe, BeS, BeSe, BeTe, MgS, MgSe, GeS, GeSe, GeTe, SnS, SnSe, SnTe, PbO, PbS, PbSe, PbTe, CuF, CuCl, CuBr, CuI, Si 3 N 4 , Ge 3 N 4 , Al 2 O 3 , (Al, Ga, In) 2 (S, Se, Te) 3 , Al 2 CO 3 , and appropriate combinations of two or more such materials. Exemplary core-shell luminescent nanocrystals for use in the practice of the present invention include, but are not limited to, (represented as Core/Shell), CdSe/ZnS, InP/ZnS, PbSe/PbS, CdSe/CdS, CdTe/CdS, CdTe/ZnS, as well as others.
[0102] In some embodiments, CdSe is used as the nanocrystal material, due to the relative maturity of the synthesis of this material. Due to the use of a generic surface chemistry, it is also possible to substitute non-cadmium-containing nanocrystals. Exemplary luminescent nanocrystal materials include CdSe or ZnS, including core/shell luminescent nanocrystals comprising CdSe/CdS/ZnS, CdSe/ZnS, CdSeZn/CdS/ZnS, CdSeZn/ZnS, InP/ZnS, PbSe/PbS, CdSe/CdS, CdTe/CdS or CdTe/ZnS. Most preferably, the quantum dots of the present invention can include core-shell QDs having a core including CdSe and at least one encapsulating shell layer including CdS or ZnS. In other embodiments, InP is used as the nanocrystal material.
[0103] In some embodiments, the light emitting quantum dots can be CdSe or CdTe and quantum-dot binding ligand can include an amine binding group. In other embodiments, the light emitting quantum dots can be CdSe or CdTe and R 2 can be NR 2a R 2b . In some other embodiments, the light emitting quantum dots can be InP and quantum-dot binding ligand can include a carboxy binding group. In still other embodiments, the light emitting quantum dots can be InP and R 2 can be C(O)OH.
[0104] The luminescent nanocrystals can be made from a material impervious to oxygen, thereby simplifying oxygen barrier requirements and photostabilization of the QDs in the QD phosphor material. In some embodiments, the luminescent nanocrystals can be coated with one or more quantum dot binding-ligand of the present invention and dispersed in an organic polymeric matrix having one or more matrix materials, as discussed in more detail below. The luminescent nanocrystals can be further coated with one or more inorganic layers having one or more material such as a silicon oxide, an aluminum oxide, or a titanium oxide (e.g., SiO 2 , Si 2 O 3 , TiO 2 , or Al 2 O 3 ), to hermetically seal the QDs.
Matrix Materials
[0105] Generally, the polymeric ligand is bound to a surface of the nanostructure. Not all of the ligand material in the composition need be bound to the nanostructure, however. The polymeric ligand can be provided in excess, such that some molecules of the ligand are bound to a surface of the nanostructure and other molecules of the ligand are not bound to the surface of the nanostructure.
[0106] The phosphor material of the present invention further comprises a matrix material in which the QDs are embedded or otherwise disposed. The matrix material can be any suitable host matrix material capable of housing the QDs. Suitable matrix materials will be chemically and optically compatible with back-lighting unit (BLU) components, including the QDs and any surrounding packaging materials or layers. Suitable matrix materials include non-yellowing optical materials which are transparent to both the primary and secondary light, thereby allowing for both primary and secondary light to transmit through the matrix material. In preferred embodiments, the matrix material completely surrounds the QDs and provides a protective barrier which prevents deterioration of the QDs caused by environmental conditions such as oxygen, moisture, and temperature. The matrix material can be flexible in applications where a flexible or moldable QD film is desired. Alternatively, the matrix material can include a high-strength, non-flexible material.
[0107] Preferred matrix materials will have low oxygen and moisture permeability, exhibit high photo- and chemical-stability, exhibit favorable refractive indices, and adhere to the barrier or other layers adjacent the QD phosphor material, thus providing an air-tight seal to protect the QDs. Preferred matrix materials will be curable with UV or thermal curing methods to facilitate roll-to-roll processing. Thermal curing is most preferred.
[0108] Suitable matrix materials for use in QD phosphor material of the present invention include polymers and organic and inorganic oxides. Suitable polymers for use in the matrixes of the present invention include any polymer known to the ordinarily skilled artisan that can be used for such a purpose. In suitable embodiments, the polymer will be substantially translucent or substantially transparent. Suitable matrix materials include, but are not limited to, epoxies, acrylates, norbornene, polyethylene, poly(vinyl butyral):poly(vinyl acetate), polyurea, polyurethanes; silicones and silicone derivatives including, but not limited to, amino silicone (AMS), polyphenylmethylsiloxane, polyphenylalkylsiloxane, polydiphenylsiloxane, polydialkylsiloxane, silsesquioxanes, fluorinated silicones, and vinyl and hydride substituted silicones; acrylic polymers and copolymers formed from monomers including, but not limited to, methylmethacrylate, butylmethacrylate, and laurylmethacrylate; styrene-based polymers such as polystyrene, amino polystyrene (APS), and poly(acrylonitrile ethylene styrene) (AES); polymers that are crosslinked with bifunctional monomers, such as divinylbenzene; cross-linkers suitable for cross-linking ligand materials, epoxides which combine with ligand amines (e.g., APS or PEI ligand amines) to form epoxy, and the like.
[0109] The QDs used the present invention can be embedded in a polymeric matrix (or other matrix material) using any suitable method, for example, mixing the nanocrystals in a polymer and casting a film, mixing the nanocrystals with monomers and polymerizing them together, mixing the nanocrystals in a sol-gel to form an oxide, or any other method known to those skilled in the art. As used herein, the term “embedded” is used to indicate that the luminescent nanocrystals are enclosed or encased within the polymer that makes up the majority component of the matrix. It should be noted that luminescent nanocrystals are suitably uniformly distributed throughout the matrix, though in further embodiments they can be distributed according to an application-specific uniformity distribution function.
[0110] The composition optionally includes a plurality or population of the nanostructures, e.g., with bound ligand. The composition optionally includes a solvent, in which the nanostructure(s) and ligand can be dispersed. As noted, the nanostructures and ligand can be incorporated into a matrix to form a polymer layer or nanocomposite (e.g., a silicone matrix formed from the ligand). Thus, the composition can also include a crosslinker and/or an initiator. Suitable crosslinkers include organic or polymeric compounds with two or more functional groups (e.g., two, three, or four) that can react with amine groups (or other groups on the ligand) to form covalent bonds. Such functional groups include, but are not limited to, isocyanate, epoxide (also called epoxy), succinic anhydride or other anhydride or acid anhydride, and methyl ester groups, e.g., on a silicone, hydrocarbon, or other molecule. In one class of embodiments, the crosslinker is an epoxy crosslinker, e.g., an epoxycyclohexyl or epoxypropyl crosslinker (e.g., compounds A-C or D-G in Table 1, respectively). The reactive groups on the crosslinker can be pendant and/or terminal (e.g., compounds B and D or compounds A, C, and E-G in Table 1, respectively). The crosslinker is optionally an epoxy silicone crosslinker, which can be, e.g., linear or branched. In certain embodiments, the crosslinker is a linear epoxycyclohexyl silicone or a linear epoxypropyl (glycidyl) silicone. A number of exemplary crosslinkers are listed in Table 1. Suitable crosslinkers are commercially available. For example, compounds H-K are available from Aldrich and compounds A-G are available from Gelest, Inc., e.g., with a formula weight of about 900-1100 for compound A as product no. DMS-EC13, with a formula weight of about 18,000 and a molar percentage of 3-4% for m for compound B as product no. ECMS-327, with a formula weight of about 8000, m≈6, and n≈100 for compound D as product no. EMS-622, and as product no. DMS-E09 for compound E.
[0000]
TABLE 1
Exemplary crosslinkers.
A
where n is a positive integer
B
where m and n are positive integers
C
D
where m and n are positive integers (e.g., m ≈ 6 and n ≈ 100)
E
F
where Ph represents a phenyl group
G
where Ph represents a phenyl group
H
1,4-butanediol diglycidyl ether
I
trimethylolpropane triglycidyl ether
J
4,4′-methylenebis(N,N-diglycidylaniline)
K
bisphenol A diglycidyl ether
L
M
1,6-diisocyanate
N
where n is a positive integer
O
where n is a positive integer and where Me represents a methyl group
[0111] The quantum dot compositions and films prepared using the quantum dot binding-ligands of the present invention are useful in a variety of light emitting devices, quantum dot lighting devices and quantum dot-based backlighting units. Representative devices are well known to those of skill in the art and can be found, for example, in US Publication Nos. 2010/0167011 and 2012/0113672, and U.S. Pat. Nos. 7,750,235 and 8,053,972.
[0112] The quantum dot compositions of the present invention can be used to form a lighting device such as a backlighting unit (BLU). A typical BLU can include a QD film sandwiched between two barrier layers. QD films of the present invention can include a single quantum dot and a single quantum-dot binding-ligand, or a plurality of quantum dots and a plurality of quantum-dot binding-ligands. For example, a QD film of the present invention can include a cadmium quantum dot, such as CdS, CdTe, CdSe, CdSe/CdS, CdTe/CdS, CdTe/ZnS, CdSe/CdS/ZnS, CdSe/ZnS, CdSeZn/CdS/ZnS, or CdSeZn/ZnS, and a quantum-dot binding ligand having amine binding groups. The QD films of the present invention can include an InP quantum dot, such as InP or InP/ZnS, and a quantum-dot binding ligand having carboxy binding groups.
[0113] In some embodiments, the QD films of the present invention include both cadmium and indium containing quantum dots. When both cadmium and indium containing quantum dots are present, the QD film can include a first film containing the cadmium quantum dots and a second film containing the indium quantum dots. These films can then be stacked one on top of another to form a layered film. In some embodiments, a barrier film or other type of film can be stacked in between each of the cadmium and indium films. In other embodiments, the cadmium and indium quantum dots are mixed together in a single QD film with their respective quantum-dot binding-ligands.
[0114] Mixed QD films, with either a single layer or multi-layer film, have the advantage of reducing the amount of cadmium in the system. For example, the cadmium can be reduced below 300 ppm, 200, 100, 75, 50 or 25 ppm. In some embodiments, the QD film contains less than about 100 ppm cadmium. In other embodiments, the QD film contains less than about 50 ppm.
VI. Examples
General Methods
[0115] All manipulations were performed under a dry, oxygen-free, nitrogen atmosphere using standard Schlenk technique. Allylamine, 1-octadecene, polysilane (1) and Karstedt's Catalyst were handled inside the glove box. Dry toluene, allylamine (98%) and 1-octadecene (>95% by GC) were obtained from Sigma-Aldrich. Allylamine was distilled from CaCl 2 and stored under nitrogen before use while 1-octadecene was used without further purification. Karstedt's catalyst, 2.1 to 2.4 wt % in xylenes was obtained from Gelest and used without further purification. A 100× dilution of Karstedt's catalyst was produced by dissolving 0.10 mL of stock solution into 10 mL of toluene. (The stock solution contains 0.113 moles of platinum per mL and the 100× dilution contains 0.00113 mmoles platinum per mL solution.) The polysilane (1) or “polyMethylHydrosiloxanes, Trimethylsilyl terminated” with Mw of 1400-1800 and viscosity 15-29 Cs (PN: HMS-991) was also obtained from Gelest. The silane was purified by vacuum overnight to P<50 mtorr and then handled inside the glove box. NMR chemical shift data were recorded with a Bruker FT NMR at 400 MHz for proton or 100 MHz for 13 C{ 1 H} and are listed in ppm. IR analysis was obtained on a Nicolet 7200 FTIR equipped with an attenuated total reflectance (ATR) sampling accessory.
[0116] Water will react in the second step of the synthesis with primary amine (amine is 4× equivalents to silane in this step) to produce hydroxide ions and quaternary amine. Then at reaction temperature, hydroxide ions will catalyze re-distribution of the silicone backbone and cause the Mn (number average molecular weight) of the polymer to increase substantially. A little water will cause the Mn to increase slightly while a lot of water will cause the reaction solution to gell. Even a little Mn increase could reduce the ability of the ligand to bind nanocrystals and less efficient nanocrystal binding will reduce the stability nanocrystal/ligand complex.
Example 1
Preparation of Polymeric Silicone Amine Wax (PSAW-1:1)
[0117] This example provides a method for making polymeric silicone amine wax (PSAW) with a 1:1 ratio of alkyl amine (aminopropyl) to long-chain alkyl (octadecyl).
[0000]
[0118] The apparatus was set up with a 250 mL, 3-neck RBF equipped with nitrogen inlet adapter (Teflon valve/stopper), thermocouple positioned to measure reaction solution temperature directly (with temperature controller) and short path distillation head with receiver. Additionally the distillation head was attached to a bubbler containing a one-way valve. The apparatus was configured so that upon attachment of a Schlenk line to the hose adapter, nitrogen gas could be passed into the reaction flask, across the surface of the reaction solution and out the bubbler attached to the distillation head. Also, the one way valve on the bubbler allowed vacuum to be applied to the whole apparatus, from the bubbler to the hose adapter.
[0119] After attachment to the Schlenk line, silane polymer HMS-991 (10 g, 10.2 mL, 6.25 mmoles of polymer strands with 150 mmoles of silane) was added followed by 1-octadecene (18.9 g, 24.0 mL, 75 mmoles) by syringe. The reaction apparatus was placed under vacuum until a pressure of less than 100 mtorr was reached and back flushed with nitrogen 3 times. Vacuum was applied with the valve between the distillation head and bubbler open. Then toluene (50 mL) was added, nitrogen gas flow was adjusted to slowly pass through the apparatus and out the bubbler. Also coolant was circulated through the distillation head condenser and the reaction solution temperature was set to 120 C. Distillation was continued until about half the toluene was collected or about 25 mL. Then the reaction solution was cooled to 60 C and the distillation head was replaced by a nitrogen filled reflux condenser connected to the Schlenk line. The reaction solution was heated to 100 C and Karstedt's catalyst (3.32 mL of a 100× dilution of stock solution with 0.731 mg and 0.00375 mmoles platinum or enough for 20,000 turnovers) was added by syringe. Then the reaction solution was heated at 100 C with stirring overnight. After heating the slightly amber reaction solution was sampled and the volatiles removed for NMR and IR analysis. Analysis by proton NMR indicated that the olefin had been consumed and the silane peak had been reduced in size by 50%. The next step in the synthesis was performed without isolation of intermediate 2. However, polysilane silicone wax 2 was isolated and characterized. 1 H NMR (toluene-d 8 , δ): 0.1 to 0.4 (broad m, 90H, SiCH 3 ), 0.7 to 1.0 (broad m, 60H, SiCH 2 (CH 2 ) 16 CH 3 ), 1.2 to 1.7 (broad m, 192H, SiCH 2 (CH 2 ) 16 CH 3 ), 5.0 to 5.2 (broad m, 12H, SiH). IR (cm −1 , diamond): 2957 sh, 2917 s, 2850 s (sp 3 C—H), 2168 sh, 2158 m (Si—H), 1466 (sp 3 C—H), 1258 s (Si—CH 3 ), 1086 sh, 1033 s (Si—O—Si) and 765 s (Si—CH 3 ).
[0120] Analysis of Starting Material Polysilane Silicone (Gelest PN:HMS-991) (1):
[0121] 1 H NMR (neat with coaxial insert using benzene-d 6 , δ): 0.72 to 0.96 (m, 90H, CH 3 ), 5.40 (s, 24H, silane). 13 C{ 1 H} (neat with coaxial insert using benzene-d 6 , δ): 1.6 to 2.7 (m, CH 3 ). IR (cm −1 , diamond): 2966 w (sp 3 C—H), 2160 m (Si—H), 1259 m (sp 3 C—H), 1034 s (Si—O—Si), 833 s (Si—H) and 752 s (Si—CH 3 ).
[0122] The reaction solution was then cooled to 60 C and allylamine (17.1 g, 22.5 mL, 300 mmoles) was added by syringe which instantly produced a colorless solution. Immediately following allylamine, Karstedt's catalyst (0.66 mL, 14.6 mg and 0.075 mmoles of platinum or enough for 1000 turnovers) was added by syringe. The reaction solution temperature was then set to 80 C and the solution heated for 2 h. A sample was prepared for analysis by vacuum transfer of volatiles. Proton NMR indicated a significant reduction of the Si—H peak with lumpy resonances integrating to about 0.25 of the analysis of intermediate 2. Therefore, since other peaks obscure integration in the Si—H region, FTIR analysis was used to provide an accurate determination. FTIR determined almost complete disappearance of the Si—H peak.
[0123] Following consumption of the silane, the reaction solution was cooled to room temperature for removal of volatiles by vacuum transfer. For this step the reflux condenser and thermocouple were replaced by stoppers and the reaction flask connected to a supplemental trap cooled by dry ice/ethanol. The product was dried on that vacuum system for a couple of hours then the solids were broken by spatula before drying under vacuum at room temperature overnight. In the morning the product was divided up further with a spatula and the reaction flask was placed directly on the Schlenk line until a pressure of <50 mtorr was reached for 30 minutes. The product PSAW-1:1, a waxy semi-crystalline white solid (27.9 g, 5.26 mmoles or 84.2% yield) was stored in the glove box. 1 H NMR (toluene-d 8 , δ): 0.2 to 0.5 (broad m, 90H, SiCH 3 ), 0.6 to 1.0 (broad m, 84H, SiCH 2 CH 2 CH 2 NH 2 , SiCH 2 (CH 2 ) 16 CH 3 ), 1.2 to 1.7 (broad m, 216H, SiCH 2 CH 2 CH 2 NH 2 , SiCH 2 (CH 2 ) 16 CH 3 ), 2.5 to 2.8 (broad m, 24H, SiCH 2 CH 2 CH 2 NH 2 ) 3.4 to 3.6 (broad m, 24H, SiCH 2 CH 2 CH 2 NH 2 ). IR (cm −1 , diamond): 2958 sh, 2916 s, 2849 s (sp 3 C—H), 1467 w (sp 3 C—H), 1257 m (Si—CH 3 ), 1074 sh, 1015 (Si—O—Si) and 784 sh, 767 s (Si—CH 3 ).
[0124] Determination of Ratio of Alkyl Amine to Long-Chain Alkyl.
[0125] The amine to C18 ratio was determined by the stoichiometry of the two sequential reactions in the synthesis. For example in PSAW-1:1, the first hydroslation with 1-octadecene was driven to completion. The stoichiometry (i.e. 1-octadecene added) determined that half the siloxy repeat units (or initial Si—H bonds) are attached to octadecenyl groups. Even though the second hydrosilation uses 4 times the amount of allylamine compared to the number of Si—H bonds that remain, only one quarter that amounts reacts with the polymer leaving three quarters in the reaction solution. Once the remaining Si—H bonds were reacted with allylamine, the left-over allylamine was removed by precipitation into methanol. The excess allylamine is soluble in methanol and was washed away from the product in the work up.
Example 2
Preparation of Polymeric Silicone Amine Wax (PSAW-1:2)
[0126] This example provides a method for making polymeric silicone amine wax (PSAW) with a 1:2 ratio of alkyl amine (aminopropyl) to long-chain alkyl (octadecyl), using the procedure described above in Example 1. For example, silane polymer HMS-991 (10 g, 10.2 mL, 6.25 mmoles of polymer strands with 150 mmoles of silane) used 1-octadecene (25.3 g, 32.0 mL, 100 mmoles) and allylamine (11.4 g, 15.0 mL, 200 mmoles). Karstedt's catalyst was also scaled accordingly, using platinum for 20,000 turnovers in the first step (0.0050 mmoles) and then 1000 turnovers in the second step (0.050 mmoles). (302-071)
[0127] Analysis of Polymeric Silicone Amine Wax PSAW-1:2.
[0128] 1 H NMR (toluene-d 8 , δ): 0.2 to 0.5 (broad m, 90H, SiCH 3 ), 0.6 to 1.0 (broad m, 96H, SiCH 2 CH 2 CH 2 NH 2 , SiCH 2 (CH 2 ) 16 CH 3 ), 1.1 to 1.7 (broad m, 528H, SiCH 2 CH 2 CH 2 NH 2 , SiCH 2 (CH 2 ) 16 CH 3 ), 2.5 to 2.8 (broad m, 16H, SiCH 2 CH 2 CH 2 NH 2 ) 3.4 to 3.7 (broad m, 16H, SiCH 2 CH 2 CH 2 NH 2 ). IR (cm −1 , diamond): 2958 sh, 2916 s, 2849 s (sp 3 C—H), 1467 w (sp 3 C—H), 1257 m (Si—CH 3 ), 1074 sh, 1015 (Si—O—Si) and 784 sh, 767 s (Si—CH 3 ).
Example 3
Preparation of Polymeric Silicone Amine Wax (PSAW-2:1)
[0129] This example provides a method for making polymeric silicone amine wax (PSAW) with a 2:1 ratio of alkyl amine (aminopropyl) to long-chain alkyl (octadecyl), using the procedure described above in Example 1. For example, silane polymer HMS-991 (10 g, 10.2 mL, 6.25 mmoles of polymer strands with 150 mmoles of silane) used 1-octadecene (12.6 g, 16.0 mL, 50 mmoles) and allylamine (22.8 g, 30.0 mL, 400 mmoles). Karstedt's catalyst was also scaled accordingly, using platinum for 20,000 turnovers in the first step (0.0025 mmoles) and then 1000 turnovers in the second step (0.10 mmoles). (302-075)
[0130] Analysis of Polymeric Silicone Amine Wax PSAW-2:1. 1 H NMR (toluene-d 8 , δ): 0.2 to 0.6 (broad m, 90H, SiCH 3 ), 0.6 to 1.0 (broad m, 72H, SiCH 2 CH 2 CH 2 NH 2 , SiCH 2 (CH 2 ) 16 CH 3 ), 1.0 to 1.8 (broad m, 288H, SiCH 2 CH 2 CH 2 NH 2 , SiCH 2 (CH 2 ) 16 CH 3 ), 2.5 to 2.9 (broad m, 32H, SiCH 2 CH 2 CH 2 NH 2 ) 3.3 to 3.7 (broad m, 16H, SiCH 2 CH 2 CH 2 NH 2 ). IR (cm −1 , diamond): 2958 sh, 2916 s, 2849 s (sp 3 C—H), 1467 w (sp 3 C—H), 1257 m (Si—CH 3 ), 1074 sh, 1015 (Si—O—Si) and 784 sh, 767 s (Si—CH 3 ).
Example 4
Preparation of Oligomeric Silicone Amine Wax (OSAW)
[0131] This examples describes the preparation of oligomeric silicone amine wax (OSAW) having both the long-chain alkyl group and the alkyl-amine group on each monomer unit.
[0000]
Synthesis of Octadecyl Dichloro Silane (1)
[0132] The apparatus, a 2 L 3-neck RBF, was equipped with nitrogen inlet adapter (Teflon valve/stopper), thermocouple positioned to measure reaction solution temperature directly (with temperature controller) and 500 mL addition funnel. The addition funnel was placed on the center neck to allow the drops of Grignard reagent into the most efficiently mixed portion of the reaction solution. Toluene (370 mL) was added to the reaction flask after measurement of solution volume in the addition funnel, followed by trichlorosilane (100 g, 74.4 mL, 738 mmoles) from a syringe directly into the reaction solution. Octadecylmagnesium chloride in THF (369 mL of a 0.50 M solution or 185 mmoles) was transferred into the addition funnel. The Grignard reagent addition was started and the reaction solution temperature was allowed to warm with the slightly exothermic reaction. Upon completion of the addition the reaction solution was cloudy grey with microscopic salts but upon warming to 60 C the reaction solution became white as macroscopic crystals appeared in solution. The volatiles were removed by vacuum transfer using a dry ice/ethanol cooled receiver overnight. The resulting white slurry was extracted with hexane (1×80 mL, 2×20 mL) and transferred through a filer tip cannula equipped with Fisherbrand P8 (particle retention 20-25 um) into a separate flask. The filtrate was clear and colorless. The volatiles were removed to a pressure of <100 mtorr which produced a viscous colorless oil. The oil was distilled trap-to-trap using an inverted ‘U’ shaped connector between the pot and receiver with the receiver cooled with dry ice/ethanol bath. To remove the product from the higher boiling bis-addition by-product a pot temperature of 300 C (thermocouple between the heating mantle and flask) was used with a pressure of less than 100 mtorr. During the distillation the inverted ‘U’ tube was also heated with a heat gun to drive over the distillate. The product is a clear colorless oil. This synthesis produced 48.6 g, 155 mmoles and 84.0% yield. 1 H NMR (toluene-d 8 , δ): 0.77 (t, 2H, Si—CH 2 ), 0.89 (t, 3H, octadecyl CH 3 ), 1.1-1.4 (m, 32H, CH 2 ), 5.30 (s, 1H, Si—H). IR (cm −1 , diamond): 2919 s, 2852 s (sp 3 C—H), 2203 m (Si—H), 1466 m (sp 3 C—H) and 553, 501 m (symm and asymm Si—Cl).
[0133] Please note: The trap contents (or trapped reaction volatiles) from the reaction solution contain excess trichlorosilane because a three fold excess was used in the reaction. The thawed trap material should be slowly added to water (to produce silicates and hydrochloric acid) or a solution of alcohol and quartenary amine (to produce alkoxy silicone and ammonium hydrochloride) to decompose the chlorosilane before pouring the solution into the waste.
Synthesis of Oligomeric Silane (3)
[0134] A 1 L, 3 neck RBF was equipped with a nitrogen inlet adapter (Teflon valve/stopper), thermocouple positioned to measure the reaction solution temperature directly (with temperature controller) and another inlet adapter attached to an oil filled bubbler. The apparatus was configured so nitrogen gas could be passed into the flask, across the surface of the reaction solution and out through the bubbler. Then toluene (300 mL) was added followed by octadecyl dichloro silane (1) (60 g, 192 mmoles) by syringe. Then water (2.59 g, 2.59 mL, 144 mmoles) was added to a 50 mL Schlenk flask and dissolved in THF (15 mL) before being pulled into a syringe. The reaction solution was stirred rapidly and nitrogen was flowing across the reaction surface as the solution of water/THF was added drop-wise to the center of the reaction vortex over 20 minutes. The reaction solution temperature did not increase significantly during water/THF addition. Then the reaction solution was stirred at RT for 15 minutes before being heated to 60 C for 5 minutes.
[0135] Oligo dichlorosilane (2) has been formed at this point, and while not isolated, was characterized as follows: 1 H NMR (toluene-d 8 , δ): 0.7 to 1.0 (broad m, 35H, SiCH 2 (CH 2 ) 16 CH 3 ), 1.2 to 1.7 (broad m, 224H, SiCH 2 (CH 2 ) 16 CH 3 ), 5.0 to 5.2 (broad m, 7H, SiH). IR (cm −1 , diamond): 2916 s, 2849 s (sp 3 C—H), 2163 m (Si—H), 1466 (sp 3 C—H), 1079 m, 1030 sh (Si—O—Si) and 464 m (Si—Cl).
[0136] After 5 minutes at about 60 C the sodium trimethylsilanolate solution was added (48.0 mL of a 1.0 M solution or 48.0 mmoles) by syringe. After another 5 minutes at about 60 C, triethyl amine (29.1 g, 40.4 mL, 288 mmoles) was added quickly by syringe into the center of the reaction solution vortex which turned the clear reaction solution opaque white. Then the reaction solution was stirred at 60 C for another 10 minutes before being allowed to cool toward RT. The volatiles were removed by vacuum transfer using a dry ice/ethanol cooled receiver (overnight) which produced a white paste. The product was isolated by extraction with hexane (1×80 mL and 2×40 mL) and each extract was transferred by cannula using a filter tip cannula equipped with Fisherbrand P8 filter paper (particle retention 20-25 um) into a separate Schlenk flask. The volatiles were removed from the clear colorless filtrate by vacuum transfer to produce a white solid. After preliminary vacuum, the solids were broken up before final vacuum to a pressure of <50 mtorr. The product, a white powder, weighed 50.7 g. The formula weight was determined by using end group analysis with proton NMR by comparing the integration of octadecyl methylenes against the silicon methyl groups. It was determined that n=7.2 repeat units so the formula weight was calculated to be 2312 so 50.7 g was 21.9 mmoles with reaction yield of 82.1%. 1 H NMR (toluene-d 8 , δ): 0.1 to 0.3 (broad m, 18H, SiCH 3 ), 0.7 to 1.0 (broad m, 35H, SiCH 2 (CH 2 ) 16 CH 3 ), 1.2 to 1.7 (broad m, 224H, SiCH 2 (CH 2 ) 16 CH 3 ), 5.0 to 5.2 (broad m, 7H, Si—H). IR (cm −1 , diamond): 2917 s, 2848 s (sp 3 C—H), 2161 m (Si—H), 1468 m (sp 3 C—H), 1075 m (Si—O—Si).
Synthesis of Oligomeric Silicone Amine Wax or OSAW (4)
[0137] A 250 mL, 3-neck RBF equipped with a nitrogen inlet adapter (Teflon valve/stopper), reflux condenser and suba seal was placed under vacuum to <200 mtorr and back flushed with nitrogen. Then oilgo silane (3) (10 g, 3.36 mmoles of polymer strands, n=9.4 formula weight of 2974 but containing 33.5 mmoles of silane) was added from a vial through the ‘suba seal’ orifice and the orifice fitted with a thermocouple positioned to measure the reaction solution temperature directly (with temperature controller). Toluene (6 mL) was added and the reaction solution was heated to 60 C. Allylamine (7.65 g, 10.0 mL, 134 mmoles) was added by syringe followed by a Karstedt's Catalyst (0.296 mL, 0.0335 mmoles platinum or enough for 1000 turnovers) which heated the solution slightly. Then the reaction solution was heated at 65 C for 2 days. Following sample analysis by FTIR that revealed a small Si—H peak at 2160 cm −1 , a little more allylamine (1.52 g, 2 mL, 26.7 mmoles) was added and the reaction solution was heated at 65 C for another day. Sample analysis by FTIR did not show an Si—H peak so the reaction solution was allowed cooled toward RT. Toluene (2 mL) was added as the reaction solution was cooling to RT to prevent solidification. Then the reaction solution was added drop-wise over 10 minutes to a separate Schlenk flask containing methanol (100 mL). Methanol precipitated the product as a white solid. The supernatant was removed by a filter tip cannula equipped with Fishebrand P8 filter paper (particle retention 20-25 um) and the precipitate was rinsed with methanol 2×100 mL before placing the product under vacuum to a pressure of <100 mtorr. The product (with n=9.4 and formula weight of 3510) is a white somewhat granular powder (8.97 g, 3.02 mmoles, 89.8% yield). 1 H NMR (toluene-d 8 , δ): 0.2 to 0.4 (broad m, 18H, SiCH 3 ), 0.7 to 1.0 (broad m, 49H, SiCH 2 CH 2 CH 2 NH 2 and SiCH 2 (CH 2 ) 16 CH 3 ), 1.2 to 1.8 (broad m, 126H, SiCH 2 (CH 2 ) 16 CH 3 and SiCH 2 CH 2 CH 2 NH 2 ), 2.6 to 2.9 (broad m, 14H, SiCH 2 CH 2 CH 2 NH 2 ), 3.6 to 3.7 (broad m, 14H, CH 2 NH 2 ). IR (cm −1 , diamond): 2917 s, 2849 s (sp 3 C—H), 1467 m (sp 3 C—H), 1066 s, 1036 s (Si—O—Si).
Example 5
Compositions of Quantum Dots with PSAW-1:1
[0138] Ligand exchange was accomplished by dissolving nanocrystals/quantum dots in hexane or toluene, adding an amino functional silicone, heating at 50° to 60° C. for 16 to 36 h, and removing the volatiles by vacuum transfer. (In general, ligand exchange is typically accomplished at 50° to 130° C. for 2 to 72 h.) The quantum yield and other parameters were maintained, and the nanocrystals were left in silicone as a clear oil.
[0139] In the glove box CdSe/CdS/ZnS nanocrystals (NCs), dissolved in toluene from the shell synthesis, were washed by precipitation with 2 volumes of ethanol, mixing by vortex mixer followed by centrifugation for 10 minutes. The supernatant was decanted and the NCs were dissolved in the same volume of toluene as the NC shell solution. Then the optical density (OD) was determined by dissolving a small amount of NC/ligand/toluene solution in toluene, measuring the OD at 460 nm then extrapolating back to the OD of the stock solution. The amount of PSAW used in the exchange was based upon the concentration of NCs dissolved in PSAW, as if the PSAW was the solvent. A NC concentration of between 25 and 400 was the normal range. Then the amount of toluene was calculated to produce a solution of 6 OD. The amount of toluene above the amount that was solubilizing the NCs was used to dissolve PSAW in a flask and was heated to 100 C. Then the solution of NCs/ligand/toluene was added drop-wise over 15 to 30 minutes followed by heating the exchange solution for 2 h at 100 C. The volatiles were removed by vacuum transfer to a pressure of less than 100 mtorr. The NCs/ligand is now a waxy solid that was dissolved into Part B epoxy (Locktite CL30) by THINKY mixer and then to produce a epoxy mixture capable of thermal cure mixed into Part A. The amount of Part A to B used was 2:1 weight ratio.
[0140] For example: NCs in shell growth solution (15 mL) were precipitated by combination with ethanol (30 mL), mixed and centrifuged for 10 minutes. The supernatant was decanted and the pellet was dissolved in toluene (15 mL). The optical density (OD) was measured by dissolution of a 0.1 mL sample into 4.0 mL toluene and the absorbance measured at 460 nm. An absorbance of 0.236 calculated an OD of 9.68. A portion of the washed NCs in toluene (6.2 mL) was to be used for ligand exchange with 0.60 g of PSAW to make 100 OD in PSAW. The total volume of toluene to be used was 10 mL and the exchange OD was projected occur at OD 6.0. Then to a flask was added PSAW (0.60 g) and toluene (3.8 mL) and the solution was heated to 100 C. The washed NCs in toluene (6.2 mL) were added drop-wise over 20 minutes and the solution was heated at 100 C for 120 minutes longer. Following ligand exchange the solution was cooled to room temperature and the volatiles removed by vacuum transfer to a pressure of less that 100 mtorr. The amount of NCs/ligand to be used in the formulation depends upon a number of other factors such as film thickness and desired white point and will not be described.
Example 6
Preparation of PSCAW
[0141]
[0142] General Methods. All manipulations were performed under a dry, oxygen-free, nitrogen atmosphere using standard Schlenk technique. Dry, deoxygenated toluene, methanol, 4-pentenoic acid, and 1-octadecene (>95% by GC) were purchased from Aldrich and used without further purification. Karstedt's catalyst, 2.1 to 2.4 wt % in xylenes was obtained from Gelest, used without further purification, stored and handled inside the glove box. A 100× dilution of Karstedt's catalyst was produced by dissolving 0.10 mL of stock solution into 10 mL of toluene. (The stock solution contains 0.113 moles of platinum per mL so the 100× dilution contains 0.00113 mmoles platinum per mL solution.) The polysilane HMS-991 (1) was purchased from Gelest. The silane was purified by vacuum overnight to P<50 mtorr at room temperature (RT) and then handled inside the glove box. NMR chemical shift data were recorded with a Bruker FT NMR at 400 MHz for proton or 100 MHz for 13 C{ 1 H} and are listed in ppm. IR analysis was obtained on a Nicolet 7200 FTIR equipped with an attenuated total reflectance (ATR) sampling accessory.
[0143] Synthesis of Polymeric Silicone Carboxylic Acid Wax (3). The apparatus was set up with a 100 mL, 3-neck RBF equipped with nitrogen inlet adapter (Teflon valve/stopper), thermocouple positioned to measure reaction solution temperature directly (with temperature controller) and short path distillation head with receiver. Additionally the distillation head was attached to a bubbler containing a one-way valve. The apparatus was configured so that upon attachment of a Schlenk line to the hose adapter, nitrogen gas could be passed into the reaction flask, across the surface of the reaction solution and out the bubbler attached to the distillation head. Also, the one way valve on the bubbler allowed vacuum to be applied to the whole apparatus, from the bubbler to the hose adapter.
[0144] After attachment to the Schlenk line, polysilane 1 (7.00 g, 4.38 mmoles of polymer strands with 100 mmoles of silane) was added followed by 1-octadecene (13.0 g, 16.0 mL, 50.0 mmoles) by syringe. The reaction apparatus was placed under vacuum until a pressure of less than 100 mtorr was reached and back flushed with nitrogen once. This vacuum step was preformed with the valve between the distillation head and bubbler open. Then toluene (30 mL) was added, nitrogen gas flow was adjusted to slowly pass through the apparatus and out the bubbler. Also coolant was circulated through the distillation head condense and the reaction solution temperature was set to 120° C. Distillation was continued until about half the toluene was collected or about 15 mL. Then toluene (15 mL) was added, the reaction solution was cooled to 60° C. and the distillation head was replaced by a nitrogen filled reflux condenser connected to the Schlenk line. The reaction solution was heated to 60° C. and Karstedt's catalyst (2.2 mL of a 100× dilution of stock solution with 2.50×10 −3 mmoles platinum or enough for 20,000 turnovers) was added by syringe. The reaction was exothermic and reached 130 C, and after the temperature dropped was heated at 90° C. for 3 h then the reaction solution was sampled and the volatiles removed for analysis. Analysis by FTIR and proton NMR indicated that the olefin had been consumed and the silane peak had been reduced in size by around 50%. The next step in the synthesis was performed without isolation of intermediate 2. IR (cm −1 , diamond): 2957 sh, 2916 s, 2850 s (sp3 C—H), 2160 m (Si—H).
[0145] The reaction solution was then cooled to 60° C. and 4-pentenoic acid (10.0 g, 10.19 mL, 100 mmoles) was added by syringe. The reaction experienced an exotherm, self heating to above 140° C., upon which the reaction mixture gelled and bumped gelled product into the condenser. The gelled product would slowly dissolve into toluene over a few days. IR (cm −1 , diamond): 3600 to 2300 broad (carboxylic acid OH), 2956 sh, 2916 s, 2849 s (sp2 C—H), 1709 s (carboxylic acid C═O), 1077 sh, 1015 s (Si—O—Si).
Example 7
Preparation of PS2CAW
[0146]
[0147] General Methods.
[0148] All manipulations were performed under a dry, oxygen-free, nitrogen atmosphere using standard Schlenk technique. Dry, deoxygenated toluene, methanol and 1-octadecene (>95% by GC) were purchased from Aldrich and used without further purification. Allyl succinic anhydride was purchased from TCI America and distilled before use. Karstedt's catalyst, 2.1 to 2.4 wt % in xylenes was obtained from Gelest, used without further purification, stored and handled inside the glove box. A 100× dilution of Karstedt's catalyst was produced by dissolving 0.10 mL of stock solution into 10 mL of toluene. (The stock solution contains 0.113 moles of platinum per mL.) The polysilane (1) or “polyMethylHydrosiloxanes, Trimethylsilyl terminated” with n of about 6 was purchased as a special order from Genesee Polymers Corp in Burton, Mich. The silane was purified by vacuum overnight to P<50 mtorr at room temperature (RT) and then handled inside the glove box. NMR chemical shift data were recorded with a Bruker FT NMR at 400 MHz for proton or 100 MHz for 13 C{ 1 H} and are listed in ppm. IR analysis was obtained on a Nicolet 7200 FTIR equipped with an attenuated total reflectance (ATR) sampling accessory. The polysilane silicone (1) was characterized as follows: 1 H NMR (toluene-d 8 , δ): 0.16 (m, 36H, SiMe), 4.93 (m, 6H, Si—H); IR (cm −1 , diamond): 2961 w (sp3 C—H), 2161 m (Si—H), 1257 m (sp3 C—H), 1039 s (Si—O—Si).
Synthesis of Polymeric Silicone Carboxylic Acid Wax (4)
[0149] The apparatus was set up with a 50 mL, 3-neck RBF equipped with nitrogen inlet adapter (Teflon valve/stopper), thermocouple positioned to measure reaction solution temperature directly (with temperature controller) and short path distillation head with receiver. Additionally the distillation head was attached to a bubbler containing a one-way valve. The apparatus was configured so that upon attachment of a Schlenk line to the hose adapter, nitrogen gas could be passed into the reaction flask, across the surface of the reaction solution and out the bubbler attached to the distillation head. Also, the one way valve on the bubbler allowed vacuum to be applied to the whole apparatus, from the bubbler to the hose adapter.
[0150] After attachment to the Schlenk line, polysilane 1 (5.00 g, 9.56 mmoles of polymer strands with 57.4 mmoles of silane) was added followed by 1-octadecene (7.42 g, 9.17 mL, 28.7 mmoles) by syringe. The reaction apparatus was placed under vacuum until a pressure of less than 100 mtorr was reached and back flushed with nitrogen once. This vacuum step was preformed with the valve between the distillation head and bubbler open. Then toluene (15 mL) was added, nitrogen gas flow was adjusted to slowly pass through the apparatus and out the bubbler. Also coolant was circulated through the distillation head condenser, the receiver was cooled with dry ice/ethanol and the reaction solution temperature was set to 120 C. Distillation was continued until about half the toluene was collected or about 12 to 13 mL. Then toluene (15 mL) was added, the reaction solution was cooled to 60 C and the distillation head was replaced by a nitrogen filled reflux condenser connected to the Schlenk line. The reaction solution was heated to 60 C and Karstedt's catalyst (1.27 mL of a 100× dilution of stock solution with 1.43×10 −3 mmoles platinum or enough for 20,000 turnovers) was added by syringe. The reaction exothermed to 130 C and after the temperature dropped was heated at 90 C for 3 h. then the reaction solution was sampled and the volatiles removed for analysis. Analysis by FTIR and proton NMR indicated that the olefin had been consumed and the silane peak had been reduced in size by around 50%. The next step in the synthesis was performed without isolation of intermediate 2.
[0151] The reaction solution was then cooled to 60 C and allyl succinic anhydride (4.02 g, 3.43 mL, 28.7 mmoles) was added by syringe. Immediately following allyl succinic anhydride, Karstedt's catalyst (2.54 mL of a 100× dilution of the stock solution or 2.86×10 −3 mmoles of platinum, enough for 10,000 turnovers) was added by syringe. The solution temperature was then set to 110 C and the solution heated overnight. A sample was prepared for analysis by addition of a 0.3 mL sample drop-wise to a rapidly stirring solution of 2 mL methanol. Following precipitation the supernatant was decanted and the white waxy sample washed with methanol (2 mL) before being prepared for analysis by removal of the volatiles by vacuum transfer. Proton NMR indicated a significant reduction of the Si—H peak with lumpy resonances integrating to about 0.25 of the analysis of intermediate 2. Therefore, since other peaks obscure integration in the Si—H region due to a small amount of double bond migration, FTIR analysis was used to provide an accurate determination. FTIR determined almost complete disappearance of the Si—H peak. However the reaction solution was heated at 120 C overnight once again to insure that the reaction had been driven to completion. Subsequent sample preparation and analysis determined that the reaction was complete.
[0152] Following consumption of the silane, toluene (2 mL) was added and the reaction solution was cooled to room temperature. The reaction solution was transferred into methanol (280 mL) dropwise by cannula in a 500 mL Schlenk flask which formed a white precipitate. Stirring was ceased after 5 minutes and the precipitate allowed to settle. Then the supernatant was removed by filter tip cannula equipped with Fisherbrand P8 filter paper (particle retention 20-25 um) and the precipitate washed with methanol (40 mL). Although the anhydride product 3 was not hydrolyzed to succinic acid in the next step, analysis of polymeric silicone anhydride wax 3 was available in the analytical section. 1 H NMR (toluene-d 8 , δ): 0.15 to 0.40 (m, 36H, SiMe), 0.55 to 0.95 (m, 21H, SiCH 2 CH 2 , (CH 2 ) 16 CH 3 ), 1.25 to 1.75 (m, 114H, SiCH 2 (CH 2 ) 16 CH 3 , SiCH 2 CH 2 CH 2 CH), 1.8 to 2.8 (m, 9H, CH 2 CH(CO 2 H)CH 2 CO 2 H). IR (cm −1 , diamond): 2958 sh, 2917 s, 2849 s (sp3 C—H), 1863 m, 1782 s (anhydride symm & asymm), 1257 m (sp3 C—H), 1062 sh, 1021 s (Si—O—Si).
[0153] Water (16 mL, 888 mmoles) was added to the reaction flask and a thin wire thermocouple was positioned between the flask and heating mantle to roughly measure the reaction solution temperature. The reaction solution was heated at 130 C under nitrogen overnight which produced a goopy white opaque solution. After volatiles were removed using a dry ice/ethanol cooled supplementary trap the volatiles were broken up before ultimate volatiles removal by vacuum on the Schlenk line until a pressure of <50 mtorr was reached for 30 minutes. The product, a semi-crystalline white solid (9.79 g, 5.75 mmoles or 60.2% yield) was stored in the glove box. 1 H NMR (CDCl 3 , δ): −0.05 to 0.15 (m, 36H, SiMe), 0.35 to 0.60 (m, 12H, SiCH 2 CH 2 ), 0.86 (t, 9H, (CH 2 ) 16 CH 3 ), 1.15 to 1.80 (m, 108H, SiCH 2 (CH 2 ) 16 CH 3 , SiCH 2 CH 2 CH 2 CH), 2.20 to 3.10 (m, 9H, CH 2 CH(CO 2 H)CH 2 CO 2 H). IR (cm −1 , diamond): 3600 to 2300 broad (carboxylic acid OH), 2958 sh, 2921 s, 2849 s (sp2 C—H), 1707 s (carboxylic acid C═O), 1257 m (sp3 C—H), 1074 sh, 1021 s (Si—O—Si).
Example 8
Preparation of OSCAW
[0154]
[0155] General Methods.
[0156] All manipulations were performed under a dry, oxygen-free, nitrogen atmosphere using standard Schlenk technique. The reagents octadecyl magnesium chloride (0.5 M in tetrahydrofuran or THF), trichlorosilane, sodium trimethylsilanolate (1.0 M in THF) and triethylamine were obtained from Sigma-Aldrich and stored in the glove box before being used without further purification. The solvents THF, toluene and hexanes were purchased dry and deoxygenated from Fisher Chemical, used without further purification and handled by Schlenk technique. The 4-pentenoic acid was obtained from Sigma-Aldrich and stored in the glove box before being used without further purification. Karstedt's catalyst, 2.1 to 2.4 wt % in xylenes was obtained from Gelest and used without further purification. (The stock solution contains 0.113 moles of platinum per mL.) NMR chemical shift data were recorded with a Bruker FT NMR at 400 MHz for 1 H and are listed in ppm. IR analysis was obtained on a Nicolet 7200 FTIR equipped with an attenuated total reflectance (ATR) sampling accessory.
Synthesis of Oligomeric Silane
[0157]
Synthesis of Octadecyl Dichloro Silane (1)
[0158] The apparatus, a 2 L 3-neck RBF, was equipped with nitrogen inlet adapter (Teflon valve/stopper), thermocouple positioned to measure reaction solution temperature directly (with temperature controller) and 500 mL addition funnel. The addition funnel was placed on the center neck to allow the drops of Grignard reagent into the most efficiently mixed portion of the reaction solution. Toluene (370 mL) was added to the reaction flask after measurement of solution volume in the addition funnel, followed by trichlorosilane (100 g, 74.4 mL, 738 mmoles) from a syringe directly into the reaction solution. Octadecylmagnesium chloride in THF (369 mL of a 0.50 M solution or 185 mmoles) was transferred into the addition funnel. The Grignard reagent addition was started and the reaction solution temperature was allowed to warm with the slightly exothermic reaction. Upon completion of the addition the reaction solution was cloudy grey with microscopic salts but upon warming to 60 C the reaction solution became white as macroscopic crystals appeared in solution. The volatiles were removed by vacuum transfer using a dry ice/ethanol cooled receiver overnight. The resulting white slurry was extracted with hexane (1×80 mL, 2×20 mL) and transferred through a filer tip cannula equipped with Fisherbrand P8 (particle retention 20-25 um) into a separate flask. The filtrate was clear and colorless. The volatiles were removed to a pressure of <100 mtorr which produced a viscous colorless oil. The oil was distilled trap-to-trap using an inverted ‘U’ shaped connector between the pot and receiver with the receiver cooled with dry ice/ethanol bath. To remove the product from the higher boiling bis-addition by-product a pot temperature of 300 C (thermocouple between the heating mantle and flask) was used with a pressure of less than 100 mtorr. During the distillation the inverted ‘U’ tube was also heated with a heat gun to drive over the distillate. The product is a clear colorless oil. This synthesis produced 48.6 g, 155 mmoles and 84.0% yield. 1 H NMR (toluene-d 8 , δ): 0.77 (t, 2H, Si—CH 2 ), 0.89 (t, 3H, octadecyl CH 3 ), 1.1-1.4 (m, 32H, CH 2 ), 5.30 (s, 1H, Si—H). IR (cm −1 , diamond): 2921 s, 2852 s (sp 3 C—H), 2205 m (Si—H), 1466 m (sp 3 C—H) and 553, 501 m (symm and asymm Si—Cl).
[0159] Please note: The trap contents (or trapped reaction volatiles) from the reaction solution contain excess trichlorosilane because a three fold excess was used in the reaction. The thawed trap material should be slowly added to water (to produce silicates and hydrochloric acid) or a solution of alcohol and quartenary amine (to produce alkoxy silicone and ammonium hydrochloride) to decompose the chlorosilane before pouring the solution into the waste.
Synthesis of Oligomeric Silane (3)
[0160] A 1 L, 3 neck RBF was equipped with a nitrogen inlet adapter (Teflon valve/stopper), thermocouple positioned to measure the reaction solution temperature directly (with temperature controller) and another inlet adapter attached to an oil filled bubbler. The apparatus was configured so nitrogen gas could be passed into the flask, across the surface of the reaction solution and out through the bubbler. Then toluene (300 mL) was added followed by octadecyl dichloro silane (1) (60 g, 192 mmoles) by syringe. Then water (2.59 g, 2.59 mL, 144 mmoles) was added to a 50 mL Schlenk flask and dissolved in THF (15 mL) before being pulled into a syringe. The reaction solution was stirred rapidly and nitrogen was flowing across the reaction surface as the solution of water/THF was added drop-wise to the center of the reaction vortex over 20 minutes. The reaction solution temperature did not increase significantly during water/THF addition. Then the reaction solution was stirred at RT for 15 minutes before being heated to 60 C for 5 minutes.
[0161] Oligo dichlorosilane (2, n=7) has been formed at this point but was not isolated in this procedure. However, analysis for this species is included (vide infra) 1 H NMR (toluene-d 8 , δ): 0.7 to 1.0 (broad m, 35H, SiCH 2 (CH 2 ) 16 CH 3 ), 1.2 to 1.7 (broad m, 224H, SiCH 2 (CH 2 ) 16 CH 3 ), 5.0 to 5.2 (broad m, 7H, SiH). IR (cm −1 , diamond): 2916 s, 2849 s (sp 3 C—H), 2163 m (Si—H), 1466 (sp 3 C—H), 1079 m, 1030 sh (Si—O—Si) and 464 m (Si—Cl).
[0162] After 5 minutes at about 60 C the sodium trimethylsilanolate solution (48.0 mL of a 1.0 M solution or 48.0 mmoles) was added by syringe. After another 5 minutes at about 60 C, triethyl amine (29.1 g, 40.4 mL, 288 mmoles) was added quickly by syringe into the center of the reaction solution vortex which turned the clear reaction solution opaque white. Then the reaction solution was stirred at 60 C for another 10 minutes before being allowed to cool toward RT. The volatiles were removed by vacuum transfer using a dry ice/ethanol cooled receiver (overnight) which produced a white paste. The product was isolated by extraction with hexane (1×80 mL and 2×40 mL) and each extract was transferred by cannula using a filter tip cannula equipped with Fisherbrand P8 filter paper (particle retention 20-25 um) into a separate Schlenk flask. The volatiles were removed from the clear colorless filtrate by vacuum transfer to produce a white solid. After preliminary vacuum, the solids were broken up before final vacuum to a pressure of <50 mtorr. The product, a white powder, weighed 50.7 g. The formula weight was determined by using end group analysis with proton NMR by comparing the integration of octadecyl methylenes against the silicon methyl groups. It was determined that n=7.2 repeat units so the formula weight was calculated to be 2312 so 50.7 g was 21.9 mmoles with reaction yield of 82.1%. 1 H NMR (toluene-d 8 , δ): 0.1 to 0.3 (broad m, 18H, SiCH 3 ), 0.6 to 0.9 (broad m, 35H, SiCH 2 (CH 2 ) 16 CH 3 ), 1.2 to 1.7 (broad m, 224H, SiCH 2 (CH 2 ) 16 CH 3 ), 4.8 to 5.0 (broad m, 7H, Si—H). IR (cm −1 , diamond): 2956 sh, 2917 s, 2848 s (sp 3 C—H), 2161 m (Si—H), 1468 m (sp 3 C—H), 1065 m, 1075 sh (Si—O—Si).
Synthesis of Oligomeric Silicone Carboxylic Acid Wax or OSCAW
[0163] A 100 mL 3-neck RBF was set up on the Schlenk line with a reflux condenser, thermocouple positioned to measure the reaction solution temperature connected to a temperature controller and nitrogen inlet adapter. After vacuum and back flush with nitrogen 3 times, polysilane 3 was added (5 g, 16.7 mmoles estimated by using a polymer repeat unit fwt of 298.51) from a vial after storage and weighing in the glove box. Then reaction flask was vac again once to less than 100 mtorr and back flushed with nitrogen gas. Toluene (2 mL) and 4-pentanoic acid (2.77 g, 2.93 mL, 27.7 mmoles) were added and the reaction solution was heated to 60 C. Karstedt's catalyst (0.739 ml or 8.35×10 −4 mmoles of a 100× dilution of the stock solution or enough for 20,000 turnovers) was added and the solution was heated at 60 C for a couple of hours. Then the temperature was increased by 20 C incrementally and the reaction solution was heated at 120 C overnight. Following sample analysis by FTIR and 1 H NMR, indicating the silane had been consumed, toluene (2 mL) was added before the reaction solution was cooled to room temperature to prevent solidification. Then the reaction solution was added dropwise to a separate RBF containing MeOH (45 mL) to precipitate the product. (Please note that 4-pentanoic acid is soluble in MeOH.) The supernatant was removed by a filter tip cannula equipped with Fisherbrand filter paper (particle retention 20-25 um) and the precipitate rinsed with MeOH (10 mL). The volatiles were removed and the solids broken up to facilitate drying before final vacuum to p<50 mtorr to leave a slightly off white powder, 4.17 g, 1.37 mmoles, 63.7% yield (based upon a silane with n=7.2). 1 H NMR (toluene-d 8 , δ): 0.25 to 0.50 (broad m, 18H, SiMe), 0.70 to 1.20 (broad m, 49H, SiCH 2 CH 2 CH 2 CH 2 CO 2 H and SiCH 2 (CH 2 ) 16 CH 3 ), 1.20 to 1.75 (broad m, 252H, SiCH 2 (CH 2 ) 16 CH 3 , SiCH 2 CH 2 CH 2 CH 2 CO 2 H and SiCH 2 CH 2 CH 2 CH 2 CO 2 H), 2.2 to 2.7 (broad m, 14H, SiCH 2 CH 2 CH 2 CO 2 H) and 13.5 to 15.5 (broad m, 14H, CH 2 CO 2 H). IR (cm −1 , diamond): 2500 to 3500 (broad CO 2 H), 2917 s, 2849 s (sp 3 C—H), 1711 m (C═O), 1467 s (sp 3 C—H), 1077 s, 1036 sh (Si—O—Si).
Example 9
Preparation of OS2CAW
[0164] The Oligomeric Silicone Di-Carboxylic Acid Wax (OS2CAW) was prepared by two methods.
[0165] General Methods.
[0166] All manipulations were performed under a dry, oxygen-free, nitrogen atmosphere using standard Schlenk technique. The solvents toluene and methanol were purchased from Fisher already deoxygenated and dry in 1 L containers and used without further purification. Dimethoxyethane (DME) was purchased from Aldrich already dry and deoxygenated in 1 L containers also and used without further purification. Allyl succinic anhydride was purchased from TCI America and distilled before use. Platinum (II) acetylacetonate [Pt(acac)2] was purchased from Strem Chemical and used without further purification. In the glove box 50 mg of Pt(acac) 2 was dissolved in 10 mL of DME to produce a solution containing 1.27×10 −2 mmoles Pt/mL solution. Speier's catalyst, hexachloro platinic acid hydrate was purchased from Aldrich and used without further purification. (To make a stock solution 55 mg was dissolved in 10.0 mL of DME producing 1.34×10 −2 mmoles Pt/mL catalyst solution.). NMR chemical shift data were recorded with a Bruker FT NMR at 400 MHz for 1 H and are listed in ppm. IR analysis was obtained on a Nicolet 7200 FTIR equipped with an attenuated total reflectance (ATR) sampling accessory.
[0167] The octadecyl dichloro silane (1) is characterized as follows: 1 H NMR (toluene-d 8 , δ): 0.77 (t, 2H, Si—CH 2 ), 0.89 (t, 3H, octadecyl CH 3 ), 1.1-1.4 (m, 32H, CH 2 ), 5.30 (s, 1H, Si—H); IR (cm −1 , diamond): 2919 s, 2852 s (sp 3 C—H), 2203 m (Si—H), 1466 m (sp 3 C—H) and 553, 501 m (symm and asymm Si—Cl).
Method 1
[0168]
Synthesis of Allyl Succinic Acid
[0169] Water (321 g, 321 mL, 1.78 moles) was placed in a 1 L, 3-neck RBF and briefly uacuumed to remove oxygen. Then allyl succinic anhydride (50 g, 42.7 mL, 357 mmoles) was added and the reaction solution heated to 110 C overnight. The reaction solution was then cooled to room temperature and the volatiles removed from a sample to prepare for FTIR analysis. After confirming the anhydride had been converted to carboxylic acid, the volatiles were removed by vacuum transfer while stirring the reaction solution at 30 C. The reaction flask temperature was maintained with a temperature controller while being monitored using a thin wire thermocouple placed between the heating mantle and reaction flask. As the product began to solidify, the solids were broken up to facilitate drying. After the majority of the water had been removed, the flask was connected directly to the Schlenk line to achieve a pressure <20 mtorr overnight. The product is a white solid (55.6 g, 352 mmoles, 98.5% yield). 1 H NMR (DMSO-d 6 , δ): 2.07 to 2.35 and 2.42 to 2.52 (m, 4H, CH 2 ═CHCH 2 CH(CO 2 H)CH 2 CO 2 H), 2.66 to 2.74 (m, 1H, CH 2 CH(CO 2 H)CH 2 ), 5.00 to 5.09 (m, 2H, CH 2 ═CHCH 2 ) 5.6 to 5.78 (m, 1H, CH 2 ═CHCH 2 CH). IR (cm −1 , diamond): 2300 to 3700 (broad CO 2 H), 3029 w (sp2 C—H), 2978 w, 2921 w (sp3 C—H), 1689 s (C═O).
Synthesis of Oligomeric Silicone Di-Carboxylic Acid Wax or OS2CAW
[0170] To a 250 mL, 4-neck RBF in the glove box was added oilgomeric silane (34.2 g, 114 mmoles estimated of silane repeat units by using a fwt of 298.51; from Example 8) and allyl succinic acid (19 g, 120 mmoles) as dry powders. Before removal from the glove box the flask was equipped with a nitrogen inlet adapter and three Suba-seal stoppers. Upon attachment to the Schlenk line, the flask was equipped with a reflux condenser and thermocouple positioned to measure the reaction solution temperature directly. Also a heating mantle and temperature controller was connected to the thermocouple. Then DME (20 mL) was added which formed a slurry. While the mixture was being heated to 80 C the slurry transformed to a solution at about 60 C and was mixing easily at 80 C. However the reaction solution was turbid and separated into two phases when the stirring was ceased. Then the catalyst solution (0.189 mL of Pt(acac) 2 /DME, or 2.40×10 −3 mmoles or enough for 50,000 turnovers) was added to the reaction solution and after about 15 minutes the temperature was set to 100 C to gently reflux overnight.
[0171] After being heated at for about 16 h the reaction solution was homogenous. To prevent solidification during sample withdrawal, about 0.3 ml of toluene was pulled into the syringe before the 0.3 mL sample was withdrawn. Vacuum transfer of the volatiles produced a waxy solid. FTIR analysis determined that the silane had been consumed which was confirmed by 1 H NMR. Then the reaction solution was diluted with 20 mL DME before cooling to room temperature to prevent solidification. The reaction solution was transferred drop-wise into MeOH (300 mL) in a 1 L Schlenk flask which precipitated the product. After stirring for 10 minutes the supernatant was removed by filter tip cannula equipped with Fisherbrand P8 filter paper (20-25 um particle retention). The volatiles were removed from the product to p<100 mtorr before water (540 mL, 30 moles) was added to the reaction flask to hydrolyze the product to back to succinic acid. Then the reaction flask was fitted with a reflux condenser and heated at 100 C using a temperature controller with thermocouple between flask and heating mantle. The reaction solution was heated overnight under nitrogen.
[0172] After confirmation by FTIR of conversion to acid the product was isolated by removal of volatiles using a supplementary trap cooled with dry ice. As the water was removed the solids were broken up to facilitate drying. Eventually product was vacuumed to p<20 mtorr overnight. The product was a white powder 37.3 g, 119 mmoles, 73.6% yield with n=6.5 repeat units for the oligomer. 1 H NMR (toluene-d 8 , δ): 0.2 to 0.5 (broad m, 18H, SiCH 3 ), 0.7 to 1.1 (broad m, 49H, SiCH 2 CH 2 CH 2 and SiCH 2 (CH 2 ) 16 CH 3 ), 1.2 to 1.8 (broad m, 126H, SiCH 2 (CH 2 ) 16 CH 3 and SiCH 2 CH 2 CH 2 CHCO 2 H), 2.2 to 2.7 (broad m, 21H, SiCH 2 CH 2 CH 2 CH(CO 2 H)CH 2 CO 2 H) and 13.5 to 15.5 (broad m, 14H, CO 2 H). IR (cm −1 , diamond): 2500 to 3500 (broad CO 2 H), 2958 sh, 2916 s, 2849 s (sp 3 C—H), 1711 m (C═O), 1467 s (sp 3 C—H), 1066 s, 1020 sh (Si—O—Si).
Method 2
[0173]
Synthesis of Succinic Anhydride Wax (2)
[0174] To a 100 mL, 4-neck RBF equipped with a nitrogen inlet adapter and thermocouple with temperature controller was added dichlorosilane 1 (10.0 g, 31.9 mmoles) and allyl succinic anhydride (4.48 g, 3.82 mL, 31.9 mmoles) which formed a turbid solution. The turbid solution separated into 2 phases when the stirring was ceased. The reaction solution was heated to 80 C and the Speir's catalyst (0.955 mL, 1.28×10-4 mmoles platinum of a 100× dilution of the stock solution or enough for 250,000 turnovers) was added all at once in a stream. No exothermic reaction was observed but the reaction solution was heated overnight at 80 C. After about 16 h at 80 C the reaction solution was clear light yellow and remained in one phase when the stirring was ceased. A sample 0.2 mL was withdrawn into a long 18 Ga needle using a syringe containing 0.3 mL of toluene to prevent solidification of the sample in the needle. The volatiles were removed and the sample analyzed by FTIR and 1H NMR and determined the reaction was complete. This product was not isolated but taken to the next reaction directly. Analysis for the succinic anhydride wax 2 is provided. 1 H NMR (CDCl 3 , δ): 0.55 to 0.95 (m, 7H, CH 3 (CH 2 ) 16 CH 2 SiCH 2 CH 2 ), 1.05 to 1.50 (m, 36H, CH 3 (CH 2 ) 16 CH 2 SiCH 2 CH 2 CH 2 CH), 1.70 to 2.00 (m, 3H, CH 2 Si(CH 2 ) 3 CH(CO 2 H)CH 2 CO 2 H). IR (cm −1 , diamond): 2958 sh, 2915 s, 28449 s (sp3 C—H), 1856 m, 1774 s (symm and asymm anhydride C═O), 522 s, 472 m (Si—Cl).
Synthesis of Oligomeric Silicone Succinic Anhydride Wax (3)
[0175] Toluene (25 mL) was added to the reaction flask and the reaction solution cooled to RT. Water (0.287 g, 16.0 mmoles) was weighed on an analytical balance and then dissolved in DME (2 mL) in the glove box before being withdrawn into a syringe. The reaction apparatus was modified under positive nitrogen pressure, by connection of a nitrogen filled bubbler to the standard taper that was on the opposite side from the nitrogen inlet adapter of the reaction flask. The nitrogen gas was adjusted to gently flow across the reaction solution and out the bubbler by slightly increasing nitrogen pressure above atmospheric pressure. The stopper in the center of the flask was changed for a suba seal and the water/DME filled syringe was positioned on the center opening so the water solution could be dropped directly into the vortex of the reaction solution. Then the water/DME solution was added drop-wise while stirring to reaction solution over 20 minutes. The reaction solution was stirred at RT for 15 more minutes before sodium trimethyl silenolate (16.0 mL, 16 mmoles) was added in a stream all at once. Again the reaction solution was stirred for 15 minutes at RT then heated to 60 C for 5 minutes before cooling to RT. The thermocouple and bubbler were replaced with stoppers and the volatiles were removed by vacuum transfer using a supplementary trap cooled with dry ice/ethanol overnight. After about 16 h under vacuum the reaction flask was connected directly to the vacuum line until a pressure of less than 500 mtorr was attained. FTIR and 1 H NMR analysis show the Si—Cl bonds have been hydrolyzed to Si—O—Si bonds. Also the product had between 6 and 8 repeat units by end group analysis. The product was not isolated but was taken directly to the next step without purification. 3 (n=7): 1 H NMR (toluene-d 8 , δ): 0.05 to 0.15 (m, 18H, SiMe), 0.40 to 0.65 (m, 28H, CH 2 CH 2 SiCH 2 CH 2 ), 0.86 (t, 21H, CH 3 CH 2 ), 1.15 to 1.95 m, 252H, CH 3 (CH 2 ) 16 CH 2 SiCH 2 CH 2 CH 2 CH), 2.4 to 3.2 (m, 21H, CH 2 Si(CH 2 ) 3 CH(CO 2 H)CH 2 CO 2 H); IR (cm −1 , diamond): 2858 sh, 2917 s, 2849 s (sp 3 C—H), 1862 m, 1781 s symm & asymm anhydride), 1466 m (sp 3 C—H), 1066 s, 1010 sh (Si—O—Si).
Synthesis of Oligomeric Silicone Di-Carboxylic Acid Wax or OS2CAW (4)
[0176] The reaction flask was equipped with a thermocouple positioned to measure the temperature of the reaction solution and water (25 mL, 1.39 moles) was added for the hydrolysis reaction. The reaction solution was heated to 60 C for 2 h. Then the volatiles were removed from a reaction sample which produced a white powder that was insoluble in toluene, chloroform and DMSO. FTIR analysis indicated that the reaction was finished and that the anhydride had been converted to acid. Then the thermocouple was replaced with a stopper before the volatiles were removed by vacuum transfer using a supplementary trap cooled with dry ice/ethanol overnight. After being subjected to vacuum for about 16 h most of the water had been removed so the large chunks of solids were broken up before the product vacuumed on the Schlenk line to a pressure of less than 50 mtorr overnight. The product (n=7) is a white solid 9.93 g, 3.89 mmoles or 97.7% yield. IR (cm −1 , diamond): 2500 to 3500 broad (carboxylic acid OH), 2958 sh, 2916 s, 2849 s (sp3 C—H), 1704 s (carboxylic acid C═O), 1077 sh, 1009 s (Si—O—Si).
Example 10
Preparation of EO-PS2CAW
[0177]
[0178] General Methods.
[0179] All manipulations were performed under a dry, oxygen-free, nitrogen atmosphere using standard Schlenk technique. Dry, deoxygenated toluene was purchased from Fisher and used without further purification. Dry, deoxygenated dimethoxyethane (DME) was purchased from Aldrich and used without further purification. Allyloxy(triethylene oxide), methyl ether, 95% (Mn=3) was purchased from Gelest and used without further purification. Karstedt's catalyst, 2.1 to 2.4 wt % in xylenes was obtained from Gelest, used without further purification, stored and handled inside the glove box. A 100× dilution of Karstedt's catalyst was produced by dissolving 0.10 mL of stock solution into 10 mL of toluene. (The stock solution contains 0.113 moles of platinum per mL.) The polysilane (1) or “polyMethylHydrosiloxanes, Trimethylsilyl terminated” with Mn of about 6 was purchased as a special order from Genesee Polymers Corp in Burton, Mich. The silane was purified by vacuum overnight to P<50 mtorr and then handled inside the glove box. NMR chemical shift data were recorded with a Bruker FT NMR at 400 MHz for proton or 100 MHz for 13 C{ 1 H} and are listed in ppm. IR analysis was obtained on a Nicolet 7200 FTIR equipped with an attenuated total reflectance (ATR) sampling accessory. Polysilane silicone (GP-1015 with n=6)) (1) is characterized as follows: 1 H NMR (toluene-d 8 , δ): 0.16 (m, 36H, SiMe), 4.93 (m, 6H, Si—H); IR (cm −1 , diamond): 2961 w (sp3 C—H), 2161 m (Si—H), 1257 m (sp2 C—H), 1039 s (Si—O—Si).
Synthesis of Polymeric Silicone Amine Wax (4)
[0180] A 500 mL, 4-neck RBF was equipped with a nitrogen inlet adapter, distillation head with receiver and thermocouple was attached to the Schlenk line. Additionally the distillation head was attached to a bubbler containing a one-way valve. The apparatus was configured so that upon attachment of a Schlenk line to the hose adapter, nitrogen gas could be passed into the reaction flask, across the surface of the reaction solution and out the bubbler attached to the distillation head. Also, the one way valve on the bubbler allowed vacuum to be applied to the whole apparatus, from the bubbler to the hose adapter. The thermocouple was attached to a heating mantle with temperature controller to maintain the desired reaction solution temperature. The apparatus was placed under vacuum to a pressure of less than 100 mtorr before being back flushed with nitrogen. This vacuum step was preformed with the valve between the distillation head and bubbler open.
[0181] Then polysilane 1 (34.2 g, 65.3 mmoles of polymer strands with n=6) was added followed by allyloxy(triethylene oxide), methyl ether (40 g, 196 mmoles) along with toluene (160 mL). The receiver was cooled in a dry ice/ethanol bath and the reaction flask was heated to 130 C while nitrogen was passed across the surface of the reaction solution from the inlet adapter and out through the distillation head and bubbler. After collection of about 150 mL of distillate the reaction solution was sampled for analysis. The volatiles were removed from the sample for analysis by 1H NMR in toluene-D8. (To determine the relative amounts of reactants, the OMe peak at 3.1 pm was set to integrate at 9 which was measured against the Si—H peak at 4.9 ppm. Unfortunately the Si—H peak splits one of the protons of that terminal allyl multiplet and can not be integrated directly. The two terminal allyl protons are well separated and along with the other allyl proton can be used to determine the amount of allyloxy(triethylene oxide) in the reaction mixture. The multiplet from non-overlapped terminal allyl proton at 5.2 ppm was averaged with the other non-overlapped allyl proton multiplet at 5.7 ppm to determine the integration for terminal one allyl proton. Then the silane was the difference between the allyl proton and silane combined with the other terminal allyl proton. The analysis demonstrated that the stoichiometry of the poly silane and allyloxy(triethylene oxide) was close enough to continue to the hydrosilation reaction.
[0182] After heating the reaction solution to 60 C Karstedt's catalyst (1.72 mL of a 100× dilution of the stock solution with 1.94×10 −3 mmoles platinum or enough for 100,000 turnovers) was added to the reaction solution. The solution temperature mildly exothermed and was then heated at 100 C overnight. Analysis of reaction solution sample determined the reaction was 90% complete so another aliquot of Karstedt's catalyst (0.86 mL, 9.72×10 −4 moles of platinum a 100× dilution or enough for 200,000 turnovers) was added and the reaction solution heated overnight at 100 C. Analysis after volatiles removal the reaction was complete as determined by consumption of allyl.
[0183] A 12.9 mL portion of the reaction solution (12.0 g or 10.5 mmoles of polysilane 2) was used in the next reaction. In the glove box allyl succinic acid (5 g, 31.6 mmoles) was added to a 100 mL 3-neck RBF equipped with thermocouple and nitrogen adapter. Then on the Schlenk line polysilane 2 was added by syringe and the reaction solution was heated to 80 C before Karstedt's Catalyst (0.316 mL, 3.57×10 −6 mmoles platinum from a 10,000× dilution or enough for 1,000,000 turnovers was added. The reaction solution slightly exothermed and then the temperature was set to 100 C overnight. Since analysis determined the reaction was still incomplete, the reaction solution temperature was reduced to 80 C and DME (3.0 mL) was added to allow the reaction solution to stir efficiently. Then Karstedt's Catalyst (1.27 mL, 1.43×10 −4 moles platinum of the 1000× dilution or enough for 20,000 turnovers) was added and the reaction solution heated at 100 C overnight. After sample preparation analysis determined the silane had been consumed but the succinic acid had been partially converted to anhydride, i.e. it was a mixture of 3a and 3b. 1 H NMR (toluene-d 8 , δ): 0.05 to 0.25 (m, 36H, SiMe), 0.50 to 0.70 (m, 6H, SiCH 2 CH 2 ), 1.50 to 1.70 (m, 6H, SiCH 2 CH 2 CH 2 O), 3.10 (s, 9H, OCH 3 ), 3.25 to 3.65 (m, 42H, CH 2 CH 2 CH 2 OCH 2 CH 2 O) n , 4.80 to 4.90 (m, 3H, SiH). IR (cm −1 , diamond): 2958 w, 2921 sh, 2870 m (sp3 C—H), 2151 m, (Si—H), 1258 m (sp3 C—H), 1089 s, 1029 s (Si—O—Si).
[0184] The product was dissolved in toluene (20 mL), DME (20 mL) and water (142 mL, 142 g, 7.9 moles) and heated at 100 C for 2 h. Then the volatiles are removed by vacuum transfer using a supplementary trap cooled with dry ice/ethanol overnight. To facilitate drying the product, a clear almost colorless oil was slowly stirred, while placed under vacuum while directly attached to a high vacuum line overnight. The product was maintained under vacuum until a pressure of <20 mtorr had been attained overnight. 1 H NMR (CDCl 3 , δ): 0.05 to 0.60 (m, 36H, SiMe), 0.60 to 0.85 (m, 12H, SiCH 2 CH 2 ), 1.40 to 1.90 (m, 18H, SiCH 2 CH 2 CH 2 O, SiCH 2 CH 2 CH 2 CH), 2.15 to 2.85 (m, 9H, CH 2 CH(CO 2 H)CH 2 CO 2 H), 3.15 to 3.75 (m, 51H, CH 2 (OCH 2 CH 2 )OCH 3 ) 9 to 11 (broad m, 6H, CO 2 H). IR (cm −1 , diamond): 2958 sh, 2929 sh, 2874 m (sp3 C—H), 1709 s, (carboxylic acid C═O), 1858 m, (sp3 C—H), 1082 s, 1019 s (Si—O—Si).
Example 11
Preparation of PSAW-Si(R) 3
[0185]
[0186] The preparation of PSAW-Si(R) 3 is described in FIG. 5 , and follows the procedure for preparation of PSAW described in Example 1 using triethyl(octadec-1-en-9-yl)silane in place of octadecene.
Example 12
Preparation of PS2AW
[0187]
[0188] The preparation of polymeric silicone di-amine (PS2AW) follows the synthesis of PS2CAW above in Example 7, using allyl dimethyl succinate to modify the siloxane (see FIG. 8 ). Allyl dimethyl maleate and allyl dimethyl itaconate can also be used. After conjugation to the siloxane polymer via hydrosilylation using a catalyst such as Karstedt's catalyst, Speier's catalyst or Pt(acac) 2 , the esters can be reacted with 1,2-diaminoethane to form the desired product.
Example 13
Preparation of OS2AW
[0189]
[0190] The preparation of oligomeric silicone di-amine (OS2AW) follows the procedure described above in Example 9, using allyl dimethyl succinate to modify the siloxane (see FIG. 7 ). After conjugation to the siloxane polymer via hydrosilylation using a catalyst such as Karstedt's catalyst, Speier's catalyst or Pt(acac) 2 , the esters can be reacted with 1,2-diaminoethane to form the desired product.
Example 14
Preparation of PS3CAW
[0191]
[0192] The preparation of polymeric silicone tricarboxylic acid (PS3CAW) is described below and follows the procedure above in Example 7. The commercially available starting material is triethyl citrate from Aldrich. The alcohol group can be converted to a tosylate leaving group by p-toluene sulfonyl chloride using known methods. Then the tosyl leaving group can be displaced with the allyl alkoxide to form a terminal olefin as shown below.
[0000]
[0193] The allyl modified tris-ester can then be reacted with the siloxane polymer 2 from Example 7 via hydrosiliylation with a suitable catalyst such as Karstedt's catalyst, Speier's catalyst or Pt(acac) 2 , to form the siloxane monomer. The final polymer can then be prepared by saponification of the esters, such as via lipase enzyme.
Example 15
Preparation of OS3CAW
[0194] The preparation of oligomeric silicone tricarboxylic acid (OS3CAW) is described below.
[0195] The commercially available starting material is triethyl citrate from Aldrich. The alcohol functionality is converted to a tosylate leaving group by p-toluene sulfonyl chloride. Then the tosyl leaving group can be displaced with the allyl alkoxide to form a terminal olefin as shown below.
[0000]
[0196] The allyl modified tris-ester can then be reacted with diethoxyoctadecylsilane via hydrosiliylation with a suitable catalyst such as Karstedt's catalyst, Speier's catalyst or Pt(acac) 2 , to form the siloxane monomer:
[0000]
[0197] The final polymer can then be prepared by condensation of the siloxane monomer to form the polymer and then saponification of the esters, such as via lipase enzyme:
[0000]
Example 16
Laser HALT Accelerated Lifetime Test
[0198] Nanocrystal compositions with PSAW-1:1 were prepared as described above.
Preparation of Comparative Nanocrystal/Silicone Composition
[0199] Another exemplary composite was produced, this one having CdSe/CdS/ZnS nanocrystals in a matrix formed from pendant amine functional silicones. Separate batches of red and green CdSe/CdS/ZnS nanocrystals dissolved in toluene (two batches with different sizes and emission peaks for each color) were exchanged with amino silicone (50:50 mixture of degassed AMS-242 and AMS-233, Gelest, Inc.) at 50° C. for about 66 h. Nanocrystal concentration was between about 3 and 50 OD in toluene, with the amino silicone at 0.01-0.1 ml per ml toluene. The solutions were then cooled to 30° C. and the volatiles removed to p<60 mtorr for about 90 min. Samples were dissolved in toluene at 25 mg (nanocrystals plus amino silicone)/mL. The OD/g (at 1 cm path length) was determined for each batch of red and green nanocrystals at 460 nm using a UV-Vis instrument. The neat solution was calculated by assuming the density of neat nanocrystals in aminosilicone was 1 (i.e., multiplied by 40), to ensure the ODs measured were close to the projected values. Then nanocrystals from the two batches of red and two of green nanocrystals in amino silicone were combined, along with additional amino silicone. The amount of red nanocrystals added from the two red batches was adjusted to obtain a final OD of about 10, and the amount of green nanocrystals added from the two green batches was adjusted to obtain a final OD of about 30. In this example, 6.8 mL of each batch of green nanocrystals and 2.5 mL of each batch of red nanocrystals were combined, along with an additional 11.49 g of the amino silicone (again a 50:50 mixture of degassed AMS-242 and AMS-233). An equal volume of toluene (30 mL) was also added. Ligand exchange was performed on the mixture at 60° C. for 16 h. After heating the mixture was cooled to 30° C. and the volatiles removed to p<35 mtorr for 2 h. After volatiles removal the product was an orange paste.
Preparation of Matrix
[0200] 0.5 g of the QD/aminosilicone or QD/PSAW composition was then added to 9.5 g of uncured Loctite E-30cl epoxy in a 10 ml plastic cup. The cup was then placed in a a planetary mixer (THINKY ARV-310) and run for 4 minutes at 2000 rpm until homogeneous. The cup was then brought into a glove box. The contents were poured onto a 50 um thick polyester film (3M, Ultrabarrier). A second piece of film was placed on top of the epoxy pool and then the stack was passed through a set of precision rolls to squeeze it down so that the epoxy/quantum dot layer was 100 um in thickness. The stack was then placed in a 100 C oven for 15 min to cure the epoxy.
[0201] Laser Procedure.
[0202] From the film cast above, a 20 mm diameter is cut using a steel punch. The sample is then clamped between two sapphire plates and mounted into the beam path. The sapphires are coupled to a heating element and maintained at a temperature of 60+/−5° C. The blue laser (450 nm) is attenuated to 60 W/cm2 and has a spot size of approximately 1 mm. A shutter is opened and the beam passes through the film sample. The resulting emission spectra are collected continuously using a spectrophotometer (Ocean Optics, Inc.) with a fiber optic probe. FIG. 4 plots the red and green emission from the film sample as a function of time. Table 2 summarizes the emission data for the films.
[0000]
TABLE 2
Laser HALT Lifetime Study Data
85%
50%
85%
50%
Lifetime/POR
Lifetime/POR
Lifetime
Lifetime
Temp.
Flux
Standard
Standard
(hrs)
(hrs)
Sample
(° C.)
(W/cm 2 )
Green
Red
Green
Red
Green
Red
Green
Red
ESH
57
60
1.0
1.0
1.0
1.0
1.2
1.8
5.0
6.8
standard
PSAW-1:1
62
60
5.9
5.6
3.6
3.2
7.1
10.2
17.9
21.6
[0203] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, one of skill in the art will appreciate that certain changes and modifications may be practiced within the scope of the appended claims. In addition, each reference provided herein is incorporated by reference in its entirety to the same extent as if each reference was individually incorporated by reference. Where a conflict exists between the instant application and a reference provided herein, the instant application shall dominate.
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Siloxane polymer ligands for binding to quantum dots are provided. The polymers include a multiplicity of amine or carboxy binding ligands in combination with long-alkyl chains providing improved stability for the ligated quantum dots. The ligands and coated nanostructures of the present invention are useful for close packed nanostructure compositions, which can have improved quantum confinement and/or reduced cross-talk between nano structures.
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ORIGIN OF THE INVENTION
This invention was made by an employee of the United States Government and may be used by or for the Government without the payment of any royalties thereon or therefor.
TECHNICAL FIELD
The present invention relates to coupled cavity traveling wave tubes (CCTWT's) and more particularly to an improved technique of providing velocity tapering and hence improving efficiency.
BACKGROUND ART
It is known that all types of traveling wave tubes (TWT's) tend to lose the desired synchronization between the electron beam and the interacting electromagnetic wave as the electron beam progresses along the slow wave structure (SWS). Such loss of beam-wave synchronization occurs at the expense of beam kinetic power and results in the loss of the desired traveling wave interaction, thereby limiting the attainable efficiencies.
Various methods have been proposed to delay the loss of synchronism and thereby enhance the efficiency of TWT's. One class of methods involves so-called velocity tapering, i.e., a gradual reduction in the SWS wave velocity near the output end of the TWT. With this approach the wave velocity and beam velocity decrease together, loss of synchronism is delayed, and TWT efficiency is thereby increased. In current practice the required velocity reduction is accomplished by a reduction in the periodic length of the SWS. This approach to TWT efficiency enhancement is discussed, for example, in the journal article "Improvement of Traveling Wave Tube Efficiency Through Period Tapering", N. H. Pond and R. J. Twiggs, IEEE Transactions on Electron Devices, Vol. ED-13, 1966, pp. 956-961.
Certain adverse effects limit the usefulness of period tapering as applied to cavity coupled traveling wave tubes. A large amount of period tapering may result in undesired oscillations in the CCTWT, as is discussed in more detail in the aforesaid Pond and Twiggs journal article. Furthermore, the reduction in periodic length provided by period tapering leads to an increase in Joule heating losses and a decrease in interaction impedance. Reference is made to "Calculation of Coupled-Cavity TWT Performance", J. R. M. Vaughn, IEEE Transactions on Electron Devices, Vol ED-22, 1975, pp. 880-890 for a further discussion of these effects.
A further approach to velocity tapering in TWT's having a coupled cavity slow wave structure is disclosed in U.S. Pat. No. 3,846,664 (King et al). In this patent the speed of travel of the applied r.f. wave is slowed so as to be substantially in step with the decreasing velocity of the electron beam by varying, in accordance with a predetermined tapering law, the resonant frequency of the coupling elements, i.e., slots, which couple the adjacent cavities of the slow wave structure. The main purpose of this approach is to provide frequency dependent velocity reduction so that higher frequencies have less velocity than lower frequencies with the result that the bandwidth is increased, i.e., the upper cut-off frequency remains the same and the lower cut-off frequency is reduced. A further patent of interest is U.S. Pat. No. 3,274,428 (Harris) which discloses a traveling wave tube having a band pass slow wave structure whose frequency characteristic varies along the length thereof, in order to inhibit oscillation. To accomplish this, the sizes of coupling apertures in partitions disposed transverse to the beam path are varied between maximum nearer the electron gun to a minimum nearer the collector electrode.
SUMMARY OF THE INVENTION
In accordance with the invention, a coupled cavity traveling wave tube includes a slow wave structure which provides velocity tapering that affords synchronization between the electron beam and the SWS wave so as to enhance the efficiency of the traveling wave tube. The velocity taper is achieved by a slow wave structure wherein the resonant frequencies of the individual resonant cavities is reduced as a function of the distance from the electron gun, this being done while maintaining the period of the slow wave structure unchanged and the bandwidth of the slow wave structure substantially unchanged. This graduated change in the resonant frequencies of the cavities can, for example, be accomplished by increasing the radius of the individual cavities as a function of distance from the electron gun. Other techniques of achieving the same result include decreasing the gap length and increasing the ferrule radius and various techniques can be used in different combinations.
As is explained in more detail hereinbelow, the coupled cavity traveling wave tube embodying the invention provides substantial advantages over the prior art. For example, coupled cavity traveling wave tubes which provide period tapering suffer disadvantages having to do with the rapid decrease in interaction impedance and increase in r.f. skin effect losses per cavity with decreasing circuit wave velocity. In contrast with the technique of the invention, this decrease in interaction impedance and increase in r.f. losses is reduced or eliminated. Moreover, in contrast to traveling wave tubes of the type disclosed in the King et al patent, the difference between the upper and lower cut-off frequencies remains about the same for the traveling wave tube of the invention so that, as stated above, the bandwidth remains substantially the same. As was discussed previously, in the traveling wave tube of the King et al patent, the bandwidth is increased, with the upper cut-off frequency remaining the same and lower cut-off frequency being reduced.
Other features and advantages of the invention will be set forth in or apparent from the detailed description of the preferred embodiments found hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a conventional CCTWT employing period tapering;
FIG. 2 is a schematic diagram similar to that of FIG. 2 incorporating phase delay tapering in accordance with the invention;
FIG. 3 is a diagram of a typical velocity profile;
FIGS. 4(a) and 4(b) are transverse and longitudinal sections, with portions broken away, showing the geometry of a typical CCTWT and illustrating the parameters which can be varied;
FIG. 5 is a longitudinal section of a portion of a CCTWT incorporating velocity tapering technique of the invention; and
FIG. 6 is a series of beta-omega curves used in explaining the differences between the invention and the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a conventional traveling wave tube (TWT), generally denoted 10, includes a vacuum envelope 12 which is preferably metallic. The TWT 10 also comprises an electron gun having a heater 18 energized by a suitable source indicated at 19, a cathode 20 heated by heater 18 to provide electrons, and an accelerating electrode 22 having an aperture therein through which electrons are transmitted from the cathode 20 so as to form a beam 24 of electrons. The cathode 20 is maintained at a suitable negative potential with respect to the accelerating electrode 22 by a suitable voltage source connected thereto and indicated at 32.
The electron beam 24 passes through a slow wave structure (SWS) 26 depicted schematically in FIG. 1 by a meandering line formed by generally rectangular turns. The SWS 26 is of the coupled cavity type whose basic geometry is shown in FIGS. 4(a) and 4(b) discussed below. The SWS 26 may be interrupted by a sever 28 which absorbs backward wave power traveling along the SWS 26 in order to insure stability. The rectangular turns in the schematic depiction of the SWS 26 are shown as being gradually more closely spaced near the output end of the SWS 26, so as to indicate that the gradual reduction in circuit periodic length associated with the "period tapering" technique discussed above. The electron beam 24, after passing through the SWS 26, is collected by a conventional collector electrode 54.
An input coupler 42 is connected to receive the high frequency input signal to be amplified and provides appropriate impedance matching and coupling of input signal to the upstream end of SWS 26. An output coupler 52 couples the amplified output signal from the downstream end of the SWS 26 to an external load or suitable transmission line.
It will be understood that the showing in FIG. 1 is highly schematic in nature only and no significance should be attributed to exact geometric shapes, absolute or relative distances, or the number of "turns" in the various sections of the SWS 26.
Referring now to FIG. 2, a traveling wave tube is shown wherein all components, save one, are similar to those shown in FIG. 1, and corresponding components in FIG. 2 have been given the same reference numerals as those in FIG. 1 but with primes attached. The only difference in the embodiments of FIGS. 1 and 2 concerns the construction of the slow wave structure, which is denoted 36 in FIG. 2. As shown, a constant spacing is maintained between the rectangular turns in the schematic depiction of the SWS 36 in the axial direction, i.e., in the direction along the electron beam. However, in the velocity taper region, i.e., the region beginning roughly midway along the length of SWS 36, the transverse excursions in the rectangular loops of schematic showing in FIG. 2 gradually increase in length, so as to indicate a gradual increase in phase delay per period.
The significance of the differences between the techniques illustrated schematically of FIGS. 1 and 2 will now be discussed. The SWS wave phase velocity is given by the formula V p =2πfL/θ where "V p " is the phase velocity, "f" is the frequency, "L" is the periodic length, and "θ" is the phase shift per cavity. It will be appreciated from this equation that, at a given frequency, the phase velocity can be decreased either by decreasing the periodic length L or by increasing the phase shift per period θ. The approach currently used for CCTWT's in actual practice is the former whereby L is decreased while holding θ more or less unchanged. This approach is represented schematically in FIG. 1 by SWS 26. The approach wherein θ is increased while holding L more or less unchanged is illustrated schematically in FIG. 2 by SWS 36. It will be understood that the illustration of this technique in FIG. 2 is schematic only and it should not be inferred from FIG. 2 that the increase in θ is necessarily associated with an increase in signal path length per period.
Referring to FIG. 3, a typical velocity taper profile, i.e., a plot of circuit phase velocity as a function of the distance along the output section, is shown. In a method such as illustrated in FIG. 1, wherein period tapering is used, the plot corresponding to that of FIG. 3 would be of cavity periodic length as a function of cavity position, and the other cavity dimensions would be adjusted as necessary to keep Δθ constant. In the technique of FIG. 2, the corresponding plot would be of 1/Δθ as a function of cavity position. Thus, the purpose of both of the embodiments is to achieve a velocity profile of the type shown in FIG. 3, but each uses a different technique to achieve this. As will be discussed below, the technique of the present invention, illustrated schematically in FIG. 2, provides substantial advantages over that illustrated in FIG. 1 as well as other techniques discussed above. Before discussing these advantages in more detail, the hardware used in carrying out the technique of the invention will now be considered.
Referring to FIGS. 4(a) and 4(b), there is illustrated the geometry of a typical conventional CCTWT of the backward fundamental wave type with mainly inductive coupling between cavities. The slow wave structure illustrated, which is generally denoted 60, includes an outer cylinder wall 62 and a series of resonant cavity-forming partitions 64 each having a ferrule or annulus 66 formed therein through which the electron beam passes and a slot 68 therein through which the high frequency electromagnetic wave is coupled between cavities, the slots 68 being alternately disposed on opposite sides of the corresponding ferrule 66 as illustrated in FIG. 4(b). In the illustrated slow wave structure, the cavity radius is denoted R, the beam tunnel radius a, the periodic length L, the gap length 1, the ferrule radius c, the cavity length h and the slot length S. As discussed above, the present invention involves the gradual reduction of the cavity resonant frequency while maintaining the period unchanged and maintaining the circuit bandwidth more or less unchanged. This gradual variation in the resonant frequencies of the cavities is accomplished by appropriately varying the physical dimensions of the individual cavities. Preferably this is done by increasing the radius R, decreasing the gap length 1 and/or varying the ferrule radius c. It will be appreciated that this approach contrasts with period taper techniques discussed above wherein the periodic length L is varied and the technique disclosed in the King et al. patent discussed above wherein the slot length S is varied.
A construction corresponding to that discussed hereinabove in general terms in connection with FIGS. 4(a) and 4(b) for providing a gradual variation of the cavity resonant frequency is illustrated in FIG. 5. The slow wave structure illustrated in FIG. 5 is similar to that of FIGS. 4(a) and 4(b) and corresponding elements have been given the same reference numerals with primes attached. As illustrated, the cavity radiis of the first two cavities shown are equal (R 1 ) while the radii for the next three cavities (R 2 , R 3 , and R 4 ) progressively increase from left to right so that the resonant frequencies of the corresponding cavities decrease in the same order. FIG. 5 also illustrates, in dashed lines, a decrease in the gap length (compare 1 1 and 1 2 ) and an increase in the ferrule radius (compare c 1 and c 2 ). As noted, any and all of these techniques can be used to provide the desired end result.
Referring to FIG. 6, so-called "omega-beta" curves are shown for coupled cavity slow wave structures of the backward fundamental type, the curves illustrating only the range from θ=0 to θ=2π. It will be understood the curves repeat themselves indefinitely in either direction (right and left). The solid curve (curve A) extends from the lower cut-off frequency, f.sub.π, to the upper cut-off frequency f 0 . Outside of this frequency range the slow wave structure represented by curve A will not allow waves to propagate. The dashed curve B and the dotted curve C represent modifications of curve A accomplished by altering the geometry of the SWS. It will be noted that curve B, which corresponds to the SWS of the invention, has the same shape as curve A but is uniformly lower in frequency. Curve C, which corresponds to the SWS of the King et al. patent discussed above, has the same upper cut-off frequency as curve A but the lower cut-off frequency is reduced and the curve is "stretched" in the frequency direction. It will be seen that for the operating frequency range depicted both curve B and curve C provide an operating phase shift range at higher values of θ than does curve A.
Curve B is shifted downward in frequency from curve A by changing the cavity dimensions as discussed above (e.g., by increasing the cavity radius R, decreasing the gap length 1, and/or increasing ferrule radius c) to thereby lower the resonant frequency of the cavities in a direction toward the collector electrode. Similarly a cavity chain with a f-θ relationship like that of curve C is provided by increasing the slot length S thereby lowering the resonant frequency of the coupling slots as provided in the King et al patent discussed previously. Inspection of FIG. 6 shows that both curve B and curve C provide an increase in θ at constant f and thus serve to reduce SWS wave velocity. However, the approach represented by curve B is more advantageous than that represented by curve C for at least two reasons. First, the velocity reduction is more nearly uniform at all frequencies within the operating frequency range for curve B, as is evident from inspection of FIG. 6. Second, curve C provides a larger propagating frequency range (SWS bandwidth) than curve B and therefore, curve C will have a lower interaction impedance than curve B. In general, the approach provided in accordance with the invention is superior to that represented by curve C particularly when applied to modest bandwidth CCTWT's where the SWS passband is much larger than the bandwidth of the operating frequency range.
It is noted that the velocity taper technique of the invention is compatible with prior art techniques and can be used in combination with such techniques depending on the application and the result desired.
Although the invention has been described in relation to exemplary embodiments thereof, it will be understood by those skilled in the art that variations and modifications can be effected in these exemplary embodiments without departing from the scope and spirit of the invention.
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A coupled cavity traveling wave tube (10, 10') is provided having a velocity taper, i.e., gradual velocity reduction, which affords beam-wave resynchronization and thereby enhances efficiency. The required wave velocity reduction is achieved by reducing the resonant frequencies of the individual resonant cavities as a function of the distance from the electron gun (16, 16'), through changes in internal cavity dimensions. The required changes in cavity dimensions can be accomplished for example, by gradually increasing the cavity radius (R 2 , R 3 , R 4 ) or decreasing the gap length (l 1 , l 2 ), from cavity to cavity. With this approach the velocity reduction is carried out without an increase in circuit resistive losses and the upper and lower cut off frequencies are reduced in approximately the same manner.
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FIELD OF THE INVENTION
This invention relates generally to tunneling machines and more particularly to such machines for tunneling into rock, so as to form a relatively smooth walled bore of substantially any length and which may be remotely controlled from the tunnel mouth.
BACKGROUND OF THE INVENTION
Tunneling machines having impact type hammer cutting tools mounted on a rotatable workhead are, generally speaking, known in the art and it has been proposed, heretofore, to arrange the cutting tools about the workhead in a manner so that the entirety of the tunnel face will be worked on during each cycle of workhead rotation. It has also been proposed to arrange the cutting tools about the periphery of the workhead. These prior machines included suction means for exhausting or removing the cuttings from the tunnel face. However, a primary difficulty with these prior machines lies in the disposition of the tools about the workhead which, in turn, greatly affect the wear characteristics of the tools. That is, in the arrangement wherein the cutting tools are disposed about the periphery of the workhead, while allowing quick removal of the cuttings, a major drawback is arrangement of cutting tools about the working surface, which results in an uneven wearing of the cutting tools. As may be appreciated, with an arrangement such as this, the cutting tools will wear considerably quicker about their outer most edges as compared to the wear distributed to the inside edges. The uneven wear characteristics inherent with these machines results in time spent to replace worn tools and therefore valuable operating time is spent on maintenance of the machine.
SUMMARY OF THE INVENTION
In view of the above, and in accordance with the present invention, there is provided a tunneling machine having a rotatable workhead assemblage on which is mounted a plurality of rock cutting tools, including actuating guns, which are mounted in radially spaced series about the workhead in a manner so that the cutting paths of the tools will overlap radially from the center of the workhead and extend out upwardly to the periphery thereof. The problems of overcoming the uneven wear characteristic heretofore known is essentially overcome by disposing the cutting tools and actuating guns in such order and numbers about the workhead such that the average work done by each head per operating cycle is approximately equal whereby even distribution of wear upon the tools is attained. In accordance with a second feature of the present invention a shield just rearward of the tool's working surface and plurality of suction members which are in communicable association through the shield are provided. At the other end of the mechanism the suction members are in communicable association with a suction tube which also serves as a supportive structure for the machine. The shield prevents dust or loose rocks from faulting the operating mechanisms of the machine.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects and advantages of this invention will become apparent from the description now to follow of the preferred embodiment thereof shown by way of example in the accompanying drawings in which:
FIG. 1 is a front elevational view of the machine, partially in section, and showing the operational components of the machine and illustrative of the nature of the invention.
FIG. 2 is an enlarged sectional view of a portion of FIG. 1 further showing the details of the connection between the rotatable portion and the stationary portion of the machine.
FIG. 3 is an enlarged sectional view of a portion of FIG. 2 showing a suitable connection between the fluid supply conduit and the fluid chamber.
FIG. 4 is a cross sectional view taken along line 4--4 of FIG. 1 and showing a unique sheave arrangement employed for moving the machine.
FIG. 5 is a cross section view taken along 5--5 of FIG. 1.
FIG. 6 is an enlarged sectional view showing a fluid supply conduit passing through a stem member on the machine.
FIG. 7 is a cross sectional view taken along line 7--7 of FIG. 1 and showing a plurality of equiangularly disposed blades secured to the forward portion of the stem means.
FIG. 8 is a view taken along line 8--8 and showing a cross section of the plenum.
FIG. 9 is a cross sectional view taken along line 9--9 of FIG. 1 and showing how the impact hammers are radially spaced in series within the shield.
FIG. 10 is a bottom view of the machine taken along line 10--10 of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in more detail to the drawings wherein like reference numerals indicate like parts throughout the several views, and more particularly to FIG. 1 where it is shown a tunneling machine 10 which includes a workhead assembly 12 adapted to be held fast to the forward an elongated shroud or inlet end 13 of 14. The workhead assembly 12 illustrated in the drawing includes a thick platelike circular member or shield 16 which acts as a closure at the forward end of the shroud 14. At the rearward or distal end 20 the shroud 14 is provided with a hood 22 which extends radially inward and closes about supportive hollow cylindrical stem 24 thereby forming an enclosed chamber about the entire operating mechanism of the machine. With this construction, any loose or surrounding material is prevented from falling or leaking into the operating parts of the machine.
As best seen in FIGS. 1, 2, and 4, the forward end 26 of the stem 20 is formed as an enlarged cone shaped 28. The rearward end 30 of the stem 20 is held fast by an apertured vent tube 32 which, in operation acts as an extension of the stem 24. A plurality of apertures 34 formed in the vent tube 32 allow escapement of gaseous dusts which may be present in the stem and tube 24 and 32 respectively, during operation of the machine.
Secured to the vent tube 32, in a manner so as to allow self alignment of the tunneling machine 10, are a plurality of sheave assembly 36, 38 and 40 (FIGS. 1 and 4). The sheave assemblies are comprised of pulleys means 40 which are rotatably mounted between the arm means 42 and 44 of a clevis 46 which, in turn, is attached to the vent tube 32. Entrained about the pulley means 40 is a cable 48, one end of which is connected to a suitable motor (not shown). Selective extension and retraction of the cable 48 permits the workhead assembly 12 to be raised or lowered in a plane perpendicular to the longitudinal axis of the shroud 14 at the will of an operator who, in the preferred embodiment, may be positioned remote from the tunnel mouth.
Turning again to FIG. 1 it may be seen that a plenum or fluid chamber 50 is directly attached to the shroud 14 and, in a manner described hereinafter, is adapted for rotation therewith. Secured between the fluid chamber 50 and the thick platelike shield member 16 and totally encompassed by the shroud 14, are a plurality of equiangularly disposed impact hammers or guns 52. In the arrangement shown in the drawings, the impact hammers or guns are fluid-pressure operated and may be of the type sold by TRW Mission Manufacturing Company, a division of TRW, Inc. under Model No. A-53-15. The impact hammer 52 are commercially available items but it should be noted that a fluid under pressure is exhausted from the forward or proximate end 54 of the hammers during operation of the machine. As is apparent from FIGS. 1, 8, 9 and 10 each actuating guns 52 has removably secured to their forward end 54 an appropriate rock cutting tool which extend forwardly of the circular platelike shield member 16 along a common surface. The cutting tool means 56 are so arranged in number and in series so that upon rotation of the workhead assembly 12 each tool in the series travels a generally equal arcuate distance. As best seen in FIGS. 9 and 10, the cutting tools 56, as well as the actuating guns 52, are arranged in radially spaced series. The cutting tool means generally designated by the reference numeral 56 indicating the first series while those tools generally indicated as 56" form the second series, the tools generally indicated in FIG. 10 by 56'" form the third series and those tools designated by 56"" form the fourth series. As was mentioned above, to assure even wearing of the tools requires accurate placement of the tools in number and position about the workhead so that each tool does an equal amount of work. The average volume swept or crushed by each head or tool is proportional to the formula:
2 π r/n
Where r is the radial distance each series is disposed from the center of the workhead and n is the number of tools in each series. In one particular example of the preferred embodiment, using a six inch diameter gun head, the centerline of the first series of tools 56' is disposed a 3 inch radial distance from the center of the machine 10. When computed the arcuate distance traveled by the tool 56' is generally equal to 18.849 inches. The second series of tools 56" are disposed 9 inches from the centerline of the machine, but as may be seen in FIG. 10 there are three cutting tools in the series. When computed it may be seen that the arcuate distance traveled divided by the number of individual tool in the second series is generally equal to 18.849 inches. This careful numerical and radial placement is carried through the other series so that the disposition and number of tools in each series allows for an equal amount of work to be done by each of the tools during operation of the machine whereby resulting in even wear distribution on the tools.
It should also be appreciated that the outside diameter of the thick platelike shield member 16 and shroud 14 is less than the outside diametric path of the outermost series of cutting tool means 56"". That is, as the cutting tools are rotated about the longitudinal axis of the machine 10 the circumferential path formed by the outermost series of cutting tools 56"" is equal to 48 inches while the outside diameter of the shroud means 14 and platelike member means 16 is equal to 47.375 inches, in this example.
A fluid energy source, which may be, for example, steam but is preferably compressed air, is supplied to the plenum 50 via conduit means 58. As may be noted from FIG. 3, a rotary or swivel joint means, indicated generally by reference numeral 57 connects the stationary conduit means 58 with the rotating fluid chamber means 50. FIGS. 4 and 5 show that for a portion of its length, the conduit means 58 is offset from the longitudinal centerline of the machine and so as to allow a suitable connection between the conduit 58 and the fluid chamber 50, as was described above, there is provided direct connections 60 and 62 (FIG. 6) which provide for uninterrupted passage of the fluid energy through the stem 20.
As indicated in FIGS. 1 and 8, the fluid chamber 50 is provided with a plurality or series of apertures or connections means 64 which allow the actuating guns to become energized, there being one connection means 66 for each gun means 52. In this manner, as long as fluid energy is supplied to the plenum 50, and since the fluid chamber is rotated or oscillated along with the hammers 52, the connection 66 will supply the hammer means 52 with power regardless of the rotational position of the workhead 12. The continued flow of fluid under pressure to the hammers will be controlled by a suitable valve or control means (not shown) which is disposed in the conduit 58 for regulating the volume and pressure of the fluid energy supplied to the fluid chamber 50.
A further unique feature of the present invention is the provision of a plurality of suction means 66, 68, and 70 which, as shown in FIGS. 7 through 11, may be in the form of tubular members which in the preferred embodiment are square in cross section. In the arrangement shown in the drawings, the forward or nozzle end 72 of the suction means 66, 68, and 70 is mounted proximate the cutting tool 56 and thence the suction means taper rearwardly and at their distal end 74 are in communicable association with the stem 20. It should be noted that the portion of the suction means which passes through the plenum 50 is protectd from the pressures thereof by a reinforcing sleeve 76 (FIGS. 1 and 8) which completely encompasses or surrounds that portion of the suction means which passes through the plenum 50. As may be seen in FIGS. 1, 2 and 7, the distal end 74 of the suction means 66, 68, and 70 is encompassed by an annular ringlike member 78 which is secured to a forward or open end 26 of stem means 24. A plurality of equiangularly spaced blades 80, 82 and 84 are secured to the annular ringlike member means at a position intermediate the suction means 66, 68 and 70 and the forward end 26 of the stem 24 for purposes described hereinafter.
As mentioned above, the stem 24 is extended rearwardly by a vent tube 32. The distal end of the vent tube 32 is provided with radial flange 86 onto which a flange hose coupling 88 is secured. A flexible hose conduit 90 is attached to the coupling 88 and by means of suction producing apparatus (not shown) connected with the hose 90 a continuous suction or partial vacuum is created within the interior of the vent tube 32, the stem 24, and each of the suction means 66, 68 and 70 for purposes hereinafter to be described.
The workhead assembly 12 including the shroud 14 and the fluid chamber 50 are all rotated by a pair of pneumatic motors 92 and 94. However, it should be appreciated that by the construction of the present invention, that is by the shroud 16 being disposed the length of the machine 10 whereby forming an enclosed chamber about the operating mechanisms of the machine, it is well within the scope of this invention to actuate the motor 92 and 94 electrically rather than pneumatically. However, pneumatic motors are preferred so that the compressed air source can be used for all machine functions and to avoid any problems of short circuiting by water and to lessen the problems presented by explosive gases. Since the shroud 14 forms an enclosure about the operating mechanisms of the machine no debris can enter or when operating in a wet environment leak into the operating mechanisms protected by the shroud 14. Therefore the usual dangers inherent with electrical mechanisms when used in a wet environment are all alleviated.
As best seen in FIGS. 1, 2 and 5 the motors 92 and 94, through force transfer means 96 and 98, are in an operative driving relationship with spur gears 100 and 102 are mounted in a direct driving relationship with an annular ring gear 104 which is secured to and carried by an annular member 106. Through any suitable connection, such as bolts 108, the annular member 106 is attached to the fluid chamber 50. The motors 92 and 94 are carried on mountings 110 and 112 which, in turn, are attached to the outer surface of the stem 24. The motors 92 and 94 are angularly disposed relative the longitudinal axis of the machine so as to allow the largest possible motor size to be employed. Flexible connection means or Universal Joints 114 and 116 are mounted between the motors and the force transfer means whereby compensating for the angular displacement of the motors. As indicated in FIG. 1, the motors 92 and 94 are directly connected, via conduit means 118 and 120 with conduit means 58. Once the fluid energy is prevented from passing through the fluid chamber means 50 by the above mentioned valve means (not shown) fluid energy is also prevented from actuating the motors 92 and 94.
As shown in FIGS. 1 and 2, the workhead assembly 12 is secured against axial or longitudinal movement but yet is allowed rotational movement relative the stem 20 by means of a gland arrangement means 122 which rotatably mounts the fluid chamber means 50 relative the stationary stem means 20. The above mentioned annular member 106 forms a part of the gland assembly means 122 and is secured at its lower end 124 to the fluid chamber as discussed above. As shown, bearing ring means 126 and 128 encircle and project radially from the annular ringlike member 78, and are welded thereto to provide the means for connecting the rotary and stationary portions of the machine 10. As shown, this connection is made by means of an L-shaped ring 130 which is welded to the annular member 106 whereby rotating therewith. The ring 130 has a lower portion 132 which provides a horizontal running fit with ring 128 and an upstanding portion 134 adapted to provide a running vertical fit against rings 126 and 128. The annular ring gear 104 is disposed on the upper surface or second end means 136 of the annular member 106 and is adapted to project radially beyond the upstanding periphery of the member 106. Secured to the upper end means 136 of member means 106 is a flat bearing ring 138 which provides a bearing for axial thrust between the rotary and stationary parts of the machine. The three elements 104, 106, and 138 are rigidly secured together by a plurality of equiangularly spaced bolts 140. To provide for further bearing against axial thrust between the stationary and the rotating parts of the machine, a second flat bearing ring 142 is disposed between ring 130 and the upper surface of the fluid chamber 50 and is welded to the latter. As may be appreciated, the gland arrangement assembly 122 is also protected from any falling or flying debris by the shroud 14 extending generally the length of the machine and forming an enclosed chamber thereabout.
Also spanning the distance between the fluid chamber 50 and the platelike shield member 16 are a plurality of structural members 144 are shaped to conform in part to the outer surface of the guns 52 and 50 arranged as to contact each gun 52, and are situated about the workhead assembly and add structural strength to the machine and more particularly add to the connection between the fluid chamber 50 and the thick plate-like shield member 16. At this point, it will be understood that when the fluid chamber 50 is rotated through suitable connections by the motors 92 and 94, the workhead assembly 12 also is rotated. By rotatably mounting the fluid chamber 50, the plate 16 and the actuating guns 52 in tandem it may be seen that as long as fluid energy is supplied to the plenum 50, the gun means 52 will likewise be supplied, regardless of the angular position of the rotary portion of the machine. As mentioned above, the flow of fluid energy to the fluid chamber 50 and each of the motor means 92 and 94 and hence general operation of the machine, will be controlled by the above mentioned valve means which is disposed in a position above the point whereat the conduit means 118 and 120 are connected to the conduit means 58.
Turning again to FIG. 10, which shows the cutting surface of the workhead assembly 12, it may be seen that in view of the equiangularly displacement of the cutting tools 52 in the radially spaced series 56', 56", 56'", and 56"" that the arcuate paths of the cutting tools created when the workhead assembly 12 is rotated will overlap radially from a point closely adjacent the longitudinal assembly centerline of the machine 10 and extend beyond the greatest radial dimension of the workhead assembly 12 or shroud 14. The unique disposition of the cutting tool means 52 in number and so arranged about the workhead means 12 so that each tool will move a generally equal amount during rotation of the workhead assembly 12 will not only result in that the entire surface area of the tunnel face will be worked on simultaneously, but also this unique arrangement of the tools results in an equal distribution of wear being placed on the tools during each cyclic rotation of the workhead.
OPERATION OF THE MACHINE
In operation of the tunneling machine the fluid energy required for operation of the machine may be supplied from a suitable source (not shown) to the conduit 58. By way of suitable connections 118 and 120 branching from the conduit 58 fluid energy is delivered to the motors 92 and 94 whereby rotating the workhead assembly 12 including the shroud 14 and the fluid chamber 50. At the same time as the motors are activated energy is delivered to the fluid chamber 50 and by way of connection 66 the gun means 52 are actuated. While power is being delivered to the various mechanisms of the machine 10, a suction of partial vacuum is applied to the stem 24 and in view of the communicable association with the stem 24 a suction or partial vacuum is created within the interior of the tubular members 66, 68, and 70. The machine, and more particularly the cutting tool 52 are lowered toward a working relationship with the tunnel face and upon contact therewith the operation of the impact hammers will cause the tools to impact cutting action on the tunnel face whereby crushing and pulverizing the rock material operated thereupon. However, the thick platelike shield member 16 which forms a closure at the inlet end of the shroud means 14 prevents any gaseous dusts or pulverized material from interfering with the operating mechanisms of the machine. The cuttings formed by the tools are immediately picked up by the suction created within the interior of the suction means 66, 68 and 70 and are carried from the tunnel face via a substantially closed suction system comprised of the suction members 66, 68, and 70, the stem 24 and the apertured vent tube 32.
As mentioned above, mounted intermediate the discharge end of the suction members and the cone shaped forward portion 28 of the stem 24 are a plurality of blade means 80, 82 and 84. The blade means serve to further pulverize the rocks which are being rearwardly conveyed by the closed suction system to the tunnel mouth whereby enhancing the handling characteristics of the debris once it reaches the exhaust end of the flexible hose means 90. Pulverization of the debris by the blades also aids in preventing clogging of the closed suction system as the debris is carried rearwardly. The air or other fluid exhausted from the forward end of the gun means 52 also aids in forcing the cuttings within the suction area of the tubular members 66, 68 and 70.
As the cutting tool means 56 operate against the tunnel face, the workhead assembly 12 is being rotated or oscillated about its longitudinal axis by the motors 92 and 94. In view of the placement of the cutting tools in radially spaced series, the entirety of the tunnel face will be operated upon during each cycle of the workhead rotation. Thus, an operator who may be remote from the tunnel mouth can control the operation of the machine so that the workhead assembly means can continuously and at a substantially uniform rate cut its way into the rock into which the tunnel is to be made.
Although all of the above has added to the improved operating characteristics of the machine, it should be appreciated that one of the main advantages of the present invention is the disposition of the cutting tools in such manner and order about the workhead so that even distribution of wear is placed on each individual tool. The disposition of the cutting tools about the workhead assembly 12 being such that upon rotation of the latter the arcuate distance traveled by each series of tools divided by the number of tools in the series is approximately equal and thus, the work performed by each tool upon the tunnel face will be equal. Therefore, since the tools wear evenly, routine maintenance of the machine allows replacement, if necessary, of all of the cutting tools simultaneously rather than requiring frequent maintenance so as to replace a few wornout tools as been heretofore known in the art. A preferred example of the preferred embodiment was above described using six inch diameter individual gun workheads. Such a machine may be readily adapted to be made with two sets of guns for a two foot diameter drilling machine, or three sets for a three foot diameter machine, as well as with four sets, as depicted for a four foot diameter drilling machine.
Thus it is apparent that there has been provided, in accordance with the invention, a Tunneling Machine or the like that fully satisfies the objects, aims, and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.
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A tunneling machine provided with the plurality of impact type cutting tools adapted to be mounted on a rotatable or oscillatable workhead assembly in such order and number that the work done by each of said tools upon angular movement of the workhead is generally equal. The working heads of the tools are mounted in close fit through a circulator disc shaped shield which prevents rock or like particles from passing beyond the workhead area to the bodies of the impact tools. Movement is imparted to the workhead assembly by a plurality of self propelled mechanisms which, along with the workhead, are concentrically surrounded by an enclosed tubular shroud which extends generally the length of the machine and is affixed to the shield. A plurality of suction tubes or conduits, arranged on the interior of the shroud, and also passing through the shield in close fit, are adapted for communicable association with the workhead area and an elongate suction tube which also serves as a supportive structure for the machine whereby the cuttings are removed from workhead area through the conduits to the tube as they are formed.
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BACKGROUND OF THE INVENTION
The invention relates to a drive system for a multipoint forming press.
According to WO 2004/056559, a press apparatus having one pressure point is known in which a direct drive that is arranged directly on the eccentric shaft and that is in the form of a frequency-controlled three-phase motor controls the movement of the slide via a connecting rod. No arrangement of this direct drive in the entire structure of the press, especially in large presses with a plurality of pressure points, is disclosed.
DE 10 2004 009 256 is a mechanical multi-servopress having a drive for a press with two pressure points in which one or a plurality of servomotors are allocated to each eccentric element for the stroke movement of the slide.
Known from JP 2000288792 is another servopress having one or a plurality of direct drives, each in the form of a servomotor on a crank mechanism, the crankshaft of which acts on the slide via a connecting rod.
Known from EP 1 082 185 is a press in which the drive of the slide is created using tension from below by four threaded spindles that are each arranged vertically in the guide corners and that are mounted in the table and driven by a servomotor. This press, which is essentially free of head pieces, makes low structural height possible. The attainable pressing force and cycle rate for the system are limited by the performance of the threaded spindles. Regardless of the pressing force and the size of the tool clamping surface, this solution always requires four not inexpensive drive systems.
A reduced structural height is attained in a press according to DE 10 2004 052 007 in that the drive for the articulated lever mechanism mounted in the head piece is each arranged vertically through the drive modules, which comprise a linear motor or rotating servomotor with downstream linear converter, laterally adjacent to the head piece in the area of the press supports.
SUMMARY OF THE INVENTION
The underlying object of the invention is to create a drive system for a multipoint forming press for flexible movements and tilt control for the slide such that it is possible to attain a low structural height for the press, high accuracy in the guidance of the slide, and high pressing forces and numbers of strokes with the available torques of servomotors and with reduced technical complexity.
The core idea of the invention is to furnish the drive for the slide by means of direct drive modules, preferably without upstream toothed wheel gearing, and, for a space-saving construction with a low structural height of the press, to arrange the pressure points of the slide with the associated direct drive modules laterally adjacent to the tool clamping surface in the vertical plane of the drive supports, wherein the direct drive modules, each comprising servomotor, stroke mechanism, and holding brake, are aligned coaxially in the press longitudinal axis or in the press transverse axis. With the availability of high-performance servomotors, the stroke mechanism may be driven directly, without upstream toothed wheel gearing that creates additional complexity.
The stroke mechanism transforms the rotating drive movement of the servomotor into a linear drive movement of the slide.
In addition to the principle of the crank mechanism comprising an eccentric shaft with a mechanically linked crankshaft, for a space-saving construction a crank shifter may be used in which the eccentric element of the crankshaft is connected to a sliding block that is guided in a guide unit for the block that is mechanically linked to the pressure point of the slide.
By using the crank mechanism, it is possible to use the advantages of the distance-dependent passage through the lower reverse point for a high cycle rate so that the risks of getting stuck, which the known direct spindle drives suffer from, are avoided, especially at the lower reverse point in the high-pressure phase when the rotational direction of the spindle is reversed.
Activating the servomotor or servomotors allows the creation of flexible movement profiles for the slide. It is possible to attain different stroke heights for the slide by selecting a 360° circular mode or a <360° pendulum mode on the crankshaft.
Because of the direct drive modules separately allocated to each pressure point, it is possible to regulate the spatial tilt of the slide in two planes.
One additional spindle drive for adjusting the height of the slide and one pressure pad for protecting against hydraulic overload are integrated in a known manner at each pressure point for the slide.
Depending on the number of direct drive modules, presses may be configured with different pressing forces and expansion of the tool clamping surface.
In addition to using two or four direct drive modules arranged in the press longitudinal axis, in the press transverse axis four direct drive modules may be advantageously employed for the arrangement. Moreover, especially when the arrangement is in the press transverse axis, six or eight direct drive modules are even possible, especially in presses that have a high pressing force.
When the direct drive modules are aligned in the press longitudinal axis, they are advantageously mounted in the drive supports, which are each positioned bilaterally adjacent to the slide in the press transverse axis. Moreover, it is also possible for them to be mounted in drive supports positioned in the press longitudinal axis.
When the direct drive modules are aligned in the press transverse axis, in a first instance they may be mounted on the drive supports oriented bilaterally in front of and behind the slide in the press longitudinal axis. In a second case the direct drive modules are each positioned on the drive supports aligned transverse to the press longitudinal axis.
In every case the pressure points for the slide and its pressure point frames are arranged laterally adjacent to or in front of and behind the tool clamping surface in the vertical plane of the drive supports.
The compact construction of this mounting of the direct drive modules on the drive supports makes possible reduced structural height of the press and also permits the former limit from the monolithic construction of table, supports, and drive housing to shift towards longer lengths of the tool clamping surface.
It is possible to use a hybrid structure for the press frame in larger presses, depending on the pressing force and extension of the tool clamping surface. In a first instance the drive supports embodied as monoliths may be secured to the press table by means of tension rods. The press supports and the drive housing arranged in their vertical plane form one unit. In a second case, press supports and the drive housing, also arranged in their vertical plane, are separated and secured to the press table jointly by means of tension rods.
During the pressing process, the flux of force between the upper tool arranged on the slide and the lower die positioned on the pressing table is closed via the press supports, which also assume the guide function for the slide. With the arrangement of the direct drive modules in the vertical plane of the press supports, the elastic deformation of the press supports in the horizontal plane may be reduced during the pressing process, which increases the accuracy of the guidance of the slide. The more the pressure points are positioned in the area of the line of the vertical flux of force of the support, the lower the horizontal deformation of the press support towards the press longitudinal axis and the press transverse axis.
The direct drive modules may be employed either as an upper drive with pressing action or as a lower drive with tension action on the pressure points of the slide. The direct drive modules may be used in two-point or four-point presses that are preferably controllable in an electronically synchronized manner. It is also possible to synchronize adjacent direct drive modules mechanically as a group and in the case of a four-point press to control both groups relative to one another in an electronically synchronized manner.
In the case of mechanical synchronization in four-point presses, the group is preferably formed by two direct drive modules aligned in the press transverse axis.
When there is mechanical synchronization, each group of adjacent direct drive modules that are coupled via a shaft are jointly controllable by at least one servomotor. When using a servomotor, the latter may be arranged either on the input side or on the output side of the group or between the direct drive modules. When two servomotors per group are used, either both may be arranged between the direct drive modules or a first servomotor may be arranged on the input side and a second servomotor may be arranged on the output side of the group of direct drive modules. It is also possible to position a first servomotor on the input side of the group and a second servomotor between the direct drive modules.
If all of the direct drive modules are electronically synchronized, the servomotors may be arranged either in a mirror image on the sides facing towards or away from the two direct drive modules or a first servomotor may be arranged on the input side of the group and a second servomotor may be arranged between the direct drive modules.
Two independently acting frictional safety brakes may be employed as mechanical holding devices to satisfy mechanical and personal safety requirements. The brakes may be integrated in the motor or may be positioned separately at the free end of the crankshaft.
The invention shall be explained in greater detail in the following using exemplary embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a drive system for a forming press having two electronically synchronizable direct drive modules, each aligned in the press longitudinal axis, for an upper drive;
FIG. 2 depicts a drive system for a forming press having two electronically synchronizable direct drive modules, each aligned in the press transverse axis, for an upper drive;
FIG. 3 depicts a first embodiment of a drive system for a forming press having four electronically synchronizable direct drive modules, each aligned in the press transverse axis, for an upper drive;
FIG. 4 depicts a second embodiment of a drive system for a forming press having four electronically synchronizable direct drive modules, each aligned in the press transverse axis, for an upper drive;
FIG. 5 depicts a third embodiment of a drive system for a forming press having four electronically synchronizable direct drive modules, each aligned in the press transverse axis, for an upper drive;
FIG. 6 depicts a drive system for a forming press having four electronically synchronizable direct drive modules, each aligned in the press longitudinal axis, for an upper drive;
FIG. 7 depicts a drive system for a forming press having four electronically synchronizable direct drive modules, each aligned in the press longitudinal axis, for a lower drive.
DETAILED DESCRIPTION OF THE INVENTION
In the first exemplary embodiment, a two-point forming press can be seen in FIG. 1 , and its two direct drive modules 2 aligned in the press longitudinal axis 1 are connected to the slide 3 as an upper drive 4 . Each direct drive module 2 comprises a servomotor 7 mounted in the upper part of a respective drive support 5 formed by the monolithic body 6 , crank mechanism 8 , and holding device 9 , the crank mechanism 8 including a crankshaft 20 and a sliding block 10 that is supported via a guide shifter 11 in the pressure point 12 of the slide 3 . The pressure points 12 , each comprising a spindle-actuated pressure point displacement unit 13 and overload protection 14 , are positioned on the pressure point frame 15 that is placed in a projection-like manner on the slide 3 . The pressure point frames 15 project into the space 16 below the drive supports 5 that are aligned transverse to the press longitudinal axis 1 so that, in conjunction with the short stroke drive, there is a more compact press structure that permits in particular a low structural height.
While the servomotors 7 . 1 , 7 . 2 in FIG. 1 are each arranged in a mirror image on the outsides of the drive supports 5 , they may likewise each be positioned in a mirror image on the insides of the drive supports 5 between the direct drive modules 2 . This space-saving manner of construction in the press longitudinal axis 1 is particularly advantageous to use when two or more forming presses are arranged sequentially in the press longitudinal axis 1 . The servomotors 7 are advantageously embodied as hollow shaft motors 17 and the holding devices 9 are embodied as rotary brakes 18 , preferably as frictional safety brakes. According to FIG. 1 , the servomotors 7 and the rotary brakes 18 are each positioned separately on opposing sides of the drive supports 5 . Moreover, it is likewise also possible to integrate the holding device 9 in the servomotor 7 .
The freely programmable servomotors 7 may produce a synchronous movement of the slide 3 using electronic coupling, and may compensate a tilt in the slide 3 using a spatial tilt control in two planes as a result of the elastic resilience when there is an off-center load or may create a target tilt.
It is also possible for both direct drive modules 2 to be jointly controllable either via a couplable shaft from both servomotors 7 . 1 , 7 . 2 or from one servomotor 7 .
A two-point forming press with the two direct drive modules 2 for an upper drive 4 aligned in the press transverse axis 19 may be seen in the second exemplary embodiment according to FIG. 2 . As in the first exemplary embodiment, the two drive supports 5 are positioned transverse to the press longitudinal axis 1 , and the pressure point frames 15 project into the spaces 16 thereof. The advantage over the first exemplary embodiment is essentially that the transverse drive forces are compensated by the opposing movement of the two crank mechanisms 8 so that it is possible to avoid more complex measures for compensating masses. The crank mechanism 8 comprises a crankshaft 20 that is driven directly by the servomotor 7 and that is supported via a mechanically linked connecting rod 23 in the pressure point 12 of the slide 3 . Moreover, each crankshaft 20 is connected at its back shaft end to a holding device 9 supported on the drive supports 5 .
This embodiment may be expanded to a four-point forming press in that two direct drive modules 2 are arranged one after the other in the press transverse axis 19 . In this case, then, two pressure point frames 15 , each allocated to a pressure point 12 , project into the space 16 of the drive supports 5 aligned in the press transverse 19 axis. Either a separate servomotor 7 may be allocated to each direct drive module 2 , or both direct drive modules 2 are jointly driven by one or two servomotors 7 that are mechanically coupled.
In the third exemplary embodiment according to FIG. 3 , the direct drive modules 2 are set up in the press transverse axis 19 in a four-point forming press. If the structural size of the press does not permit a monolithic body as in the preceding exemplary embodiments, the direct drive modules 2 depicted here are mounted in pairs on drive supports 5 that are secured to the press table 21 via tension rods 22 . The crank mechanism 8 that belongs to the direct drive module 2 and is controlled by the servomotor 7 comprises a connecting rod 23 that is mechanically linked to the crankshaft 20 and that is supported in the pressure point 12 of the slide 3 . The pressure points 12 of the four-point drive are positioned on the pressure point frames 15 that are placed in a projection-like manner on the slide 3 and that project into the space 16 of the drive supports 5 aligned transverse to the press transverse axis 19 . The two servo motors 7 . 1 , 7 . 2 are arranged in a mirror image on the sides facing away from the two direct drive modules 2 . It is likewise possible for both direct drive modules 2 to be jointly controllable either by both servomotors 7 . 1 , 7 . 2 via a shaft that can be attached or by a servomotor 7 . Rotary brakes 18 that are arranged in a mirror image on the sides facing the two direct drive modules 2 act as act as a holding device 9 on two diagonally opposing direct drive modules 2 .
The fourth exemplary embodiment according to FIG. 4 is distinguished from FIG. 3 in that the servomotors 7 . 1 , 7 . 2 are arranged in a mirror image on the sides facing the two direct drive modules 2 . As in the third exemplary embodiment, it is possible both to have mechanical coupling of the two servomotors 7 . 1 , 7 . 2 and also to have one servomotor 7 for jointly driving the two direct drive modules 2 .
In a third embodiment of a four-point forming press according to FIG. 5 , in the group of direct drive modules 2 each first servomotor 7 . 1 is arranged on the input side and each second servomotor 7 . 2 is arranged between the direct drive modules 2 .
This possible arrangement of the servomotors 7 according to FIG. 4 and FIG. 5 offers spatial advantages, especially when a plurality of large multipoint presses in a press line are positioned with the workpiece flow in the direction of the press transverse axis 19 at a minimum distance from one another.
FIG. 6 describes the embodiment of a four-point forming press having two groups of direct drive modules 2 aligned in the press longitudinal axis, each direct drive module 2 being mounted in a drive housing 27 positioned in the press transverse axis 19 . The drive housings 27 are secured via the press supports 28 to the press table 21 by means of tension rods 22 . The adjacent press supports 28 in the press longitudinal axis 1 are connected to one another using a transverse member 24 . The servomotors 7 are arranged in a mirror image between the direct drive modules 2 , the two adjacent servomotors 7 . 1 and 7 . 2 in each group being controlled in opposition to one another in order to compensate the transverse forces produced on the associated crank mechanisms 8 .
One drive system for a lower drive in a four-point forming press can be seen in FIG. 7 . Each two of four direct drive modules 2 aligned in press longitudinal axis 1 are mounted on a respective drive support 5 . The drive supports 5 are positioned transverse to the press longitudinal axis 1 . Compared to the preceding exemplary embodiments with the upper drive, in the lower drive the pressing force in the crank mechanism 8 acts in the traction direction. The pressure points 12 connected to the connecting rods 23 act on the pressure point frames 15 that are arranged in the upper area of the slide 3 and that project into the upper clearance of the drive supports 5 . This compact construction provides a particularly low structural height for the press system.
It is common to all of the embodiments that the direct drive modules 2 are arranged in the vertical place of the drive supports 26 . Thus drive supports 5 in one case may be connected to the table 2 either monolithically or by means of tension rods 22 . In another case, the drive supports 5 are each divided into a drive housing 27 and associated press supports 28 that are jointly connected to the table 2 by means of tension rods 22 . As can be seen in drawings, it is also common to all the embodiments that the drive supports 5 are situated adjacent the space 16 which has as its upper extremity the tool mounting surface of the slide and as its lateral extremities innermost edges of vertical, upright supports, such as the legs of the monolithic body or the press supports 28 , supporting the drive supports 5 and which innermost edges are vertical projections of innermost extremities of the drive supports 5 . Allocated to all of the direct drive modules 2 are servomotors 7 with which it is possible to achieve flexible path and speed profiles for the movement of the slide 3 , the target positions of the slide 3 preferably being produced using guide wave-controlled electronic cams. With respect to the path profile, a 360° circular movement, a reversing movement at an angle <360° that passes through the bottom reverse point, or a movement at an angle <180° that reverses in the area of the bottom reverse point may be selected. The latter mode may preferably be used in conjunction with the tilt regulation of the slide 3 that is possible with electronic synchronization of the pressure points 12 , in one plane for a two-point forming press or in two planes for a four-point forming press.
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The invention relates to a press drive by means of direct drive modules, wherein a space-saving construction with low height for the press can be achieved.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a combination needle shield/needle guard device which is positively locked onto a (1) detachable double-ended needle assembly used for an evacuated blood collection system and (2) a detachable needle assembly for a hypodermic syringe. More particularly, this combination needle shield/needle guard device can function as a needle shield to enclose and prevent contamination of a sterile needle to be used for insertion into the skin and/or blood vessel of a patient. In addition, the needle shield/needle guard device can function as a needle guard which can slide on the needle assemblies, so that the needle can be uncovered or re-covered in a direction from behind the needle point, thereby providing a safety feature for the operator who can avoid direct contact with a used, blood-contaminated needle point.
2. Description of the Prior Art
There are many types of removeable needle shields which cover needles used with conventional syringes or are used to cover a double-ended needle assembly with an evacuated blood collection system. Examples include the following references selected from the U.S. Patent and Trademark Office: U.S. Pat. Nos. 3,381,813; 3,934,722; 4,113,090; 4,121,588; 3,734,080; and 3,931,815. These removeable needle shields reveal several limitations such as: (1) after removal of the needle shield from the needle attached to a syringe, medical personnel may occasionally delay the usage of the needle in a procedure, which would require replacement of the needle shield back over the needle to prevent contamination of the sterile needle. This maneuver requires keeping track of the removed needle shield and then replacing the needle shield over the needle, which represent extra steps for busy medical personnel. Replacing the needle shield over the needle point also increases the risk for self-puncture with the needle point; (2) another common practice occurs when medical personnel remove this type of needle shield by holding the needle shield between their teeth or lips. This maneuver has been associated with accidental self-puncture in the face or other bodily parts; (3) in order to remove a used double-ended needle assembly from a reuseable container holder of an evacuated blood collection system, it is necessary to re-cover the used needle with a needle shield and then unfasten the double-ended needle assembly from the reusable container holder. Similarly, to remove a used needle that is luer-locked to a syringe barrel, it is necessary to re-cover the needle with a needle shield and then unfasten the needle from the syringe barrel. Both procedures require that the user replace the needle shield over the pointed end of the used needle, which increases the risk to medical personnel who may accidentally puncture themselves with the pointed end of the used, blood contaminated needle; (4) when the needle shield is replaced over the used needle, if the needle has been accidentally bent during a medical procedure or if the needle shield is replaced over the needle at an incorrect angle, the needle point may inadvertently pierce the side of the needle shield as it is being replaced over the needle. The operator using the needle shield could be punctured with a used blood-contaminated needle point that has exteriorized through a needle shield; and (5) most laboratories use containers with or without a clip-off needle device to store used needles. Personnel may puncture themselves with used uncovered needles that may accidentally fall out of these storage containers or with uncovered needles that are disposed of inappropriately in waste baskets. In addition, if the storage container is full, it is possible to accidentally puncture oneself with a used, uncovered needle that is pointed towards the opening of the storage container.
Another device relevant to our invention includes U.S. Pat. No. 4,425,120 issued to Sampson et al which describes a needle guard device which is attached to a conventional hypodermic syringe or apparatus used for injecting a substance into a human or animal. This device functions as a slideable needle guard to uncover or re-cover a used needle. This needle guard has an open-end, which precludes its routine use to function also as a needle shield to enclose and prevent contamination of a sterile needle. In order to prevent contamination of the sterile needle in this device, it would be necessary to cover the needle with a separate needle shield, or close the opening of the needle guard with a material which must be ruptured by the needle or needle shield enclosing the needle. In addition, this needle guard device is not adapted to remove a used double-ended needle assembly from a container holder or to remove a used hypodermic syringe needle assembly from a syringe barrel. Thus, in both situations a separate needle shield would still be required to re-cover and unfasten the detachable needle assemblies, thereby increasing the risk for self-puncture with a used needle point.
Another needle guard device, U.S. Pat. No. 4,139,009 issued to Alvarez, is composed of four longitudinal arms which are brought into lateral side-to-side contact with the intention of covering and protecting the enclosed needle. The front end of the cover and the lateral arms in side-to-side contact represent discontinuous locations which could permit microorganism penetration and contamination of the enclosed sterile needle. When this device is pushed against a skin surface during the injection process, the arms must bow away from the longitudinal axis of the needle which could block visualization of the needle as it penetrates the skin. It is important that the operator attempting to draw blood be able to clearly visualize a blood vessel. In addition, this needle guard device is not adapted to remove a used double-ended needle assembly from a container holder or to remove a used needle assembly from a hypodermic syringe barrel. Thus, in both situations a needle shield would still be required to re-cover and unfasten the detachable needle assemblies, thereby increasing the risk for self-puncture with a used needle point.
Examples in the U.S. Patent and Trademark Office of evacuated blood collection systems with a removeable needle shield are U.S. Pat. Nos. 2,460,641, 3,931,815, 4,154,229, 4,295,476, 4,295,477, 4,312,362, and 4,340,068. Operators of a blood evacuated collection system with a double-ended needle assembly must re-cover a used needle over the pointed end of the needle with a needle shield in order to unfasten the double-ended needle assembly from the reusable container holder. This maneuver can cause puncture with contaminated needles with the subsequent risk of developing blood-borne infections, such as AIDS, infectious hepatitis, syphilis, etc. Similar risks occur for the operator of a hypodermic syringe who must replace a needle shield over the detachable needle assembly in order to remove the used needle from the syringe barrel. Therefore during the procedure of removing used needle assemblies from an evacuated blood collection system or hypodermic syringe, it is desireable to provide a mechanism whereby the operator of either device can be safeguarded from causing self-puncture with a used, blood contaminated needle point.
There are other identifiable problems with currently used blood evacuation collection systems. The container holder used in the blood evacuated collection system exhibits several limitations that can interfere in successful blood withdrawing procedures. On occasion operators of an evacuated blood collection system have experienced the unfortunate occurrence in which the double-ended needle assembly has unfastened from the container holder. This may occur during the following circumstances: (1) the first needle of the double-ended needle assembly has penetrated into a blood vessel; (2) the operator has begun to move an evacuated container forward into the container holder so that the inner needle (i.e. second needle) of the double-ended needle assembly can penetrate through the evacuated container stopper; (3) during step 2, the force of pushing on the second needle causes the threads on the housing of the double-ended needle assembly to unwind from the internal mating threads at the forward end of the container holder, thereby causing the entire double-ended needle assembly to disengage from the container holder. There are several explanations for the disengagement of these parts such as: (1) the threads of the housing of the double-ended needle assembly are not tightened properly into the internal mating threads of the container holder; and/or (2) the internal mating threads of the container holder can become worn from frequent usage which would subsequently prevent adequate securing between the housing of the double-ended needle assembly and the container holder. It is thus desireable to provide a mechanism to eliminate this problem by using an improved locking system between the double-ended needle assembly housing and the container holder.
Another problem which develops using a blood evacuated collection system concerns the positioning of the first needle into a blood vessel. The wide girth of the container holder can cause the operator to direct the needle in a less acute angulation in respect to the planar surface of the skin, thereby causing the needle point to puncture the blood vessel wall at a higher, less acute angle that will more easily lead to puncturing through the opposite wall of the blood vessel. If such an event occurs, it may be difficult to withdraw blood from the blood vessel, as well as cause subsequent blood leakage around the blood vessel i.e. hematomas. A similar problem can occur for the user of a hypodermic syringe, especially for large volume syringes with a wide diameter of the syringe barrel. It is therefore desireable to eliminate the configuration restrictions imposed by a wide girth container holder or barrel of a hypodermic syringe which make it difficult for the operator to direct the needle in a more shallow or acute angle in respect to the planar surface of the skin.
SUMMARY OF THE INVENTION
The embodiments of this invention have been developed: (1) as a needle shield to enclose and prevent contamination of the sterile needle to be used for insertion into a patient's skin or blood vessel; (2) as a moveable needle guard which is capable of protecting medical personnel from puncturing themselves with contaminated needle points, since the needle can be re-covered by moving the device from behind the used needle point. This feature will reduce the associated risk of contracting blood-borne infections such as AIDS, hepatitis, syphilis, etc. It is important to emphasize that our device can function both as a needle shield and as a needle guard, thus providing a distinct advantage over prior art which includes devices that serve only one of these functions. In addition, manufacturing costs could be reduced with our needle shield/needle guard device which requires one part to perform both aforementioned functions; (3) to eliminate the need of keeping track of a removeable needle shield, which has led to the common practice among busy personnel who may remove this type of needle shield by holding the needle shield between their teeth or lips. In our device the needle shield/needle guard device is positively locked onto the double-ended needle assembly or hypodermic needle assembly so that it is readily available to the user of the device; (4) to re-cover used blood contaminated needles, such that when used needles are disposed of in containers they will always be re-covered with the device; (5) to unfasten the used double-ended needle assembly from the reusable container holder of an evacuated blood collection system or to unfasten a used hypodermic needle assembly from a hypodermic syringe barrel without the user needing to replace a separate needle shield over the pointed end of a used needle. Our device therefore provides an important safeguard since it reduces the hazard of self-puncture for the user who does not have to replace a removeable needle shield backover a used needle point; and (6) in addition, this invention provides a positive lock to permanently cover the used needle of an evacuated blood collection system, so that after the needle has been used to withdraw blood, it can not be used inadvertently on another patient.
Other advantages of our invention include: (7) it can assist medical personnel using a hypodermic syringe, who may need to delay a medical procedure and thus must temporarily re-cover the unused needle. This need can be facilitated by moving an easily accessible, non-removeable needle shield/needle guard device back over the sterile needle to prevent contamination of the unused sterile needle; (8) our invention for an evacuated blood collection system provides additional secondary and tertiary locking means between the double-ended needle assembly and the container holder which prevent disengagement between these parts during the blood withdrawing procedure; and (9) the length extension that occurs between the needle used to withdraw blood and the body of the container holder of an evacuated blood collection system or the analogous length extension that occurs between the needle of a hypodermic needle assembly and the wide diameter of a syringe barrel, allow for more favorable angulation of needle penetration into a patient's blood vessel. The narrow diametered length extensions eliminate the configuration restriction caused by the wide girth of the container holder or by the wide diameter of a large volume syringe barrel, thereby permitting the user to direct the needle into the blood vessel at a more shallow or acute angle in respect to the planar surface of the skin, thus minimizing the chance of piercing through the other side of the blood vessel wall.
Other objectives and advantages of our invention will become apparant more fully from the following description and accompanying drawings illustrating the embodiments of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view illustrating a sterile package container of the double-ended needle assembly for the first embodiment of the evacuated blood collection system.
FIG. 2 is an exploded isometric view of the components of the first embodiment of the evacuated blood collection system.
FIG. 3 is an enlarged isometric view of a sterile package container of the first embodiment of the evacuated blood collection system.
FIG. 4 is a cross-sectional view of FIG. 3 along line 4--4.
FIG. 5 is a cross-sectional view of FIG. 3 along line 5--5.
FIG. 6 is a full longitudinal section along line 6--6 of FIG. 1.
FIG. 7 is an enlarged isometric view of the first embodiment of the double-ended needle assembly with the needle shield/needle guard device.
FIG. 8 is an exploded isometric view of the first embodiment of the double-ended needle assembly with the needle shield/needle guard device.
FIG. 9 is a longitudinal sectional view along line 9--9 in FIG. 8.
FIG. 10 is a longitudinal section along line 10--10 in FIG. 9.
FIG. 11 is a fragmented side view along line 11--11 in FIG. 8.
FIG. 12 is a cross-sectional view along line 12--12 of FIG. 11.
FIG. 13 is a cross-sectional view along line 13--13 of FIG. 11.
FIG. 14 is an enlarged partial isometric view of the first embodiment of the double-ended needle assembly without the needle shield/needle guard device.
FIG. 15 is an enlarged view of the proximal end of the container holder for the first embodiment of the evacuated blood collection system.
FIG. 16 is a cross-sectional view of FIG. 15 along line 16--16.
FIG. 17 is a fragmented side view of first embodiment of the evacuated blood collection system illustrating the secondary locking means for fastening of double-ended needle assembly to container holder.
FIG. 18 is a fragmented isometric view of the needle shield/needle guard device positioned in the first extended lock position on the first embodiment of the double-ended needle assembly.
FIG. 18A is a cross-sectional view along line 18A--18A of FIG. 18.
FIG. 19 is a fragmented isometric view illustrating the cylindrical housing of the needle shield/needle guard device positioned in the retracted lock position on the first embodiment of the double-ended needle assembly.
FIG. 20 illustrates the first embodiment of the evacuated blood collection system in which the cylindrical housing of the needle shield/needle guard device is retracted on the double-ended needle assembly, exposing the first needle during venipuncture use.
FIG. 21 is a longitudinal section along line 21--21 in FIG. 20.
FIG. 22 is an isometric view illustrating a sterile package container of the double-ended needle assembly for the second embodiment of the evacuated blood collection system.
FIG. 23 is a partial exploded isometric view of the second embodiment of the evacuated blood collection system.
FIG. 24 is an enlarged partial isometric view of the double-ended needle assembly without the needle shield/needle guard device for the second embodiment of the evacuated blood collection system.
FIG. 25 is a partial isometric view of the second embodiment of the evacuated blood collection system, illustrating the removal of the pull-off tab from the needle shield/needle guard device and the exposure of the needle by retracting the cylindrical housing of the needle shield/needle guard device on the double-ended needle assembly.
FIG. 26 is a longitudinal sectional view along line 26--26 of FIG. 25.
FIG. 27 is an isometric view of the detachable needle assembly for a hypodermic syringe.
FIG. 28 is a partial exploded view of the first embodiment of the detachable needle assembly and hypodermic syringe.
FIG. 29 is a partial isometric view of the first embodiment of the detachable needle assembly and hypodermic syringe, illustrating the removal of the pull-off tab from the needle shield/needle guard device and the exposure of the needle by retraction of the cylindrical housing of the needle shield/needle guard device on the needle assembly.
FIG. 30 is a longitudinal sectional view along line 30--30 of FIG. 29.
DETAILED DESCRIPTION
Detailed drawings are shown for a first and second embodiment of an evacuated blood collection system and for a first embodiment of a detachable needle assembly for a hypodermic syringe. This disclosure is made with the understanding that the present disclosure is to be considered as exemplary of the principles of the invention and are not intended to be limited only to the illustrated embodiments.
Referring to the drawings, FIGS. (1 to 21) refer to the first embodiment 8 of the blood evacuation collection system. FIG. 1 illustrates a sterile package container 10 for the double-ended needle assembly 11 that is used (see FIG. 2) in the first embodiment 8 of an evacuated blood collection system. The basic components of the sterile package container 10 are seen in an enlarged isometric view in FIG. 3 and includes the needle shield/needle guard device 20 comprised of cylindrical housing 26 and pull-off tab 22 with handle 23, a second needle shield 12, and sterile sealing tape 13 which joins and seals the attachment of the needle shield/needle guard device 20 to the second shield 12. FIGS. 4 and 5 represent cross-sectional views of FIG. 3 along lines 4--4 and 5--5 respectively. FIG. 4 illustrates the second needle 56 of the double-ended needle assembly 11, the self-recoverable elastic sheath 55, and the needle shield 12 for the second needle 56. FIG. 5 illustrates the second needle 56 covered in the extended housing 35, the longitudinal groove 45 on the extended housing 35, and the needle shield 12. FIG. 6 is a full longitudinal section of the sterile package container 10 seen in FIG. 1 along line 6--6. This illustrates the enclosed double-ended needle assembly 11 (see FIG. 2) which is comprised of needle shield/needle guard device 20 which encloses first needle 15, second needle shield 12 which encloses second needle 56 which in turn is enclosed by self-recoverable elastic sheath 55, extended housing 35, double lead-in external threads 53 on extended housing 35, and sterile sealing tape 13 which joins and seals the attachment of the needle shield/needle guard device 20 to the second shield 12. FIG. 7 illustrates the double-ended needle assembly 11 for the first embodiment 8 of the evacuated blood collection system seen in FIG. 2 with the second shield 12 removed. FIG. 7 reveals the needle shield/needle guard device 20 comprised of cylindrical housing 26 with pull-off tab 22, extended housing 35 with longitudinal groove 45, double external protrusions 54 on extended housing 35, double lead-in external threads 53 and self-recoverable elastic sheath 55 covering second needle 56.
FIG. 8 is an exploded isometric view of the double-ended needle assembly 11 for the first embodiment 8 of the evacuated blood collection system, illustrating the needle shield shield/needle guard device 20 with internal protrusion 27 in ready position to be positively locked onto the forward end of extended housing 35. FIG. 9 is a longitudinal section in FIG. 8 through line 9--9 revealing the inner protrusion 27 located on the inner distal wall of the needle shield/needle guard device 20, the cylindrical housing 26, and the pull-off tab 22 (with handle 23) which is attached to the cylindrical housing 26 on a weakened annular zone 25. FIG. 10 is a longitudinal section of the internal protrusion 27 in FIG. 9 through line 10--10 illustrating the internal protrusion 27.
FIG. 11 is a fragmented side enlargement of the front end of the extended housing 35 along line 11--11 of FIG. 8. This illustrates the groove system on the extended housing 35, and the longitudinal ridges 36 on the extended housing 35. Attachment of the needle shield/needle guard device 20 to the extended housing 35 occurs by sliding the internal protrusion 27 of the needle shield/needle guard device 20 over the funneled lead-in sloping groove 37, until the internal protrusion 27 slip-fits complementarily into the first extended lock position 42. The internal protrusion 27 is then positioned within three retaining walls of the first extended lock position 42 which are comprised of the horizontal retaining wall 34 and two contiguous retaining walls 32a and 32b. The complementary fitting of the internal protrusion 27 within the three retaining walls (32a, 32b, 34) of the first extended lock position 42 provides a positive locking means in three directions (forward, clockwise and counterclockwise) for the needle shield/needle guard device 20 in relation to the extended housing 35. Unintentional retraction of the cylindrical housing 26 of the needle shield/needle guard device 20 in relation to the extended housing 35 is prevented by a friction fit of the internal protrusion 27 within the first extended lock position 42 and the presence of the constricting bead 41 of the first extended lock position 42.
FIG. 11 also reveals the step-down access groove 43 and the longitudinal groove 45 FIG. 13 is a cross-sectional view along line 13--13 of FIG. 11 and illustrates the deeper groove depth of the longitudinal groove 45 as compared to the more shallow groove depth of the step-down access groove 43. In FIG. 11, these differential groove depths facilitate the retraction of the internal protrusion 27 from the first extended lock position 42 into the longitudinal groove 45 after the internal protrusion 27 has been intentionally moved over the constricting bead 41 of the first extended lock position 42.
FIG. 11 also illustrates the four retaining walls of the second extended lock position 47. When the internal protrusion 27 is locked in the second extended lock position 47, it is positioned within these four retaining walls comprised of the horizontal retaining wall 34 and three other retaining walls (48a, 48b, 48c). These retaining walls provide a positive locking means to prevent forward, backward, clockwise and counterclockwise rotation of the cylindrical housing 26 in relation to the extended housing 35.
FIG. 12 is a cross-sectional view of FIG. 11 along line 12--12 and reveals the funneled lead-in groove 37, two retaining walls 32a and 32b of the first extended lock position 42 forming acute angles with the floor of the first extended lock position 42, the longitudinal groove 45, and the retaining walls 48a and 48b which form acute angles with the floor of the second extended lock position 47.
FIG. 14 is an enlarged partial isometric view of the double-ended needle assembly 11 without the needle shield/needle guard device 20 for the first embodiment 8 of the evacuated blood collection system. This illustrates a fragmented view of the extended housing 35, the needle 56 housed in the extended housing 35, the double external protrusions 54, the longitudinal groove 45, double lead-in external threads 53, and the self-recoverable elastic sheath 55 covering the second needle 56.
FIG. 15 is an enlarged partial isometric view of the front end 61 of the container holder 60 for the first embodiment 8 of the evacuated blood collection system. This illustrates the double notches 63, the double lead-in internal mating threads 64, the longitudinal groove 49 of the container holder 60, the horizontal groove 50, the constricting bead of the horizontal groove 51, and the retracted lock position 52. FIG. 16 is a cross-sectional view of FIG. 15 along line 16--16 illustrating the double horizontal grooves 50, constricting bead of the horizontal groove 51 and the retracted lock position 52.
Referring back to FIG. 2, the primary locking means for the double-ended needle assembly 11 into the front end 61 of the container holder 60 occurs by engagement of the double lead-in external threads 53 into the double lead-in internal mating threads 64. In FIGS. 14 and 15, a secondary locking means occurs when the double external protrusions 54 seat inside the double notches 63. The secondary locking means also provide for a simultaneous alignment of the longitudinal groove 45 on the extended housing 35 with the longitudinal groove 49 on the front end 61 of the container holder 60.
Referring back to FIG. 2, this illustration reveals the working arrangement of the components of the first embodiment 8 of the evacuated blood collection system. The components consist of the double-ended needle assembly 11, the container holder 60 and the evacuated container 70. The container holder 60 is comprised of the narrowed diameter front end 61, and the wide girth body 62 of the container holder 60. The evacuated container 70 is comprised of a tube 71 and stopper 72. The double-ended needle assembly 11 is attached to the front end 61 of the container holder 60 by grasping and rotating the needle shield/needle guard device 20 clockwise so as to engage the double-lead-in external threads 53 into the double lead-in internal mating threads 64 on the front end 61 of the container holder 60 until the double external protrusions 54 seat inside the double notches 63 (see FIG. 17 for detail illustrating the engagement of the external protrusions 54 into the notches 63). In FIG. 2, the second needle 56 covered by the self-recoverable elastic sheath 55 extends rearward inside the wide girth body 62 of the container holder 60. The stopper 72 of the evacuated container 70 can then be engaged into the second needle 56 inside the container holder 60.
FIG. 18 illustrates the first embodiment 8 of the evacuated blood collection system with attachment of the double-ended needle assembly 11 to the container holder 60 and with the needle shield/needle guard device 20 positively locked in the first extended lock position 42. FIG. 18A is a cross-sectional view along line 18A--18A of FIG. 18 and reveals the internal protrusion 27 positioned into the first extended lock position 42. In FIG. 18, the needle shield/needle guard device 20 with the pull-off tab 22 intact functions as a needle shield to prevent contamination of the enclosed first needle 15. In order to exteriorize the first needle 15, the pull-off tab 22 must be removed from the weakened annular zone 25 of attachment to the cylindrical housing 26, causing formation of an aperture 30 on the front end of the cylindrical housing 26. The cylindrical housing 26 with the pull-off tab 22 removed is now in ready position to exteriorize the first needle 15 and thus function as a needle guard.
In FIG. 19, the cylindrical housing 26 with the pull-off tab 22 removed is shown retracted which exposes the first needle 15 for venipuncture usage. This maneuver occurs (see FIGS. 14 and 15) by retracting the internal protrusion 27 of the cylindrical housing 26 over the constricting bead 41 into the step-down access groove 43, then into the longitudinal groove 45 on the extended housing 35, then to the longitudinal groove 49 of the container holder, to the horizontal groove 50, over the constricting bead 51 of the horizontal groove and then into the retracted lock position 52. When the internal protrusion 27 is positioned into the retracted lock position 52, the internal protrusion 27 is positively locked so that it can not move forward, backwards or clockwise in relation to the front end 61 of the container holder 60.
It is to be understood that the design of this invention could include a second or more internal protrusion 27 on the cylindrical housing 26 with a second or more groove system on the extended housing 35 arranged at strategic locations so as to improve the stabile attachment and mobility of the cylindrical housing 26 on the extended housing 35 and front end 61 of the container holder 60.
FIG. 20 illustrates the first embodiment 8 of the evacuated blood collection system in which the cylindrical housing 26 of the needle shield/needle guard device 20 is retracted so as to expose the first needle 15 during venipuncture use. The second needle 56 has punctured through the stopper 72 into the evacuated container 70. FIG. 21 is a longitudinal section in FIG. 20 through line 21--21. A tertiary locking means for attachment of the double-ended needle assembly 11 to the container holder 60 occurs when the cylindrical housing 26 is retracted on the extended housing 35 to the front end 61 of the container holder 60. This occurs when the inner surface 19 of the front end of the cylindrical housing 26 with a small aperture 30 approximates the larger diameter forward end 31 of the extended housing 35 and the internal protrusion 27 is moved into the retracted lock position 52 on the front end 61 of the container holder 60. FIG. 21 also illustrates the extended housing 35 of the first embodiment 8 of the evacuated blood collection system which provides a length extension between the first needle 15 used to withdraw blood and the wide girth body 62 of the container holder 60. The length extension permits the user to direct the needle into a blood vessel at a more shallow or acute angle in respect to the planar surface of the skin and thus minimize the change of piercing through the other side of the blood vessel wall.
After venipuncture usage, the first embodiment 8 of the evacuated blood collection system can function as a needle guard, in which the cylindrical housing 26 can be re-extended back on the extended housing 35 into the second extended lock position 47 (see FIG. 14 and FIG. 15), and thereby re-cover the used first needle 15 with the cylindrical housing 26 from behind the needle point of the first needle 15. This occurs by moving the internal protrusion 27 out of the retracted lock position 52, over the constricting bead 51 into the horizontal groove 50, to the longitudinal groove 49 of the container holder, then to the longitudinal groove 45 of the extended housing, over the retaining wall 48a into the second extended lock position 47 which positively locks the cylindrical housing 26 in four directions (forward, backwards, clockwise and counterclockwise) in relation to the extended housing 35. It is noteworthy that the deeper groove depth of the longitudinal groove 45 compared to the more shallow step-down access groove 43 (see FIG. 13) facilitates the movement of the internal protrusion 27 into the second extended lock position 47. In FIG. 12, once the internal protrusion 27 of the cylindrical housing 26 is moved into the second extended lock position 47, the cylindrical housing 26 is positively locked so that it can never be retracted again to re-expose the needle 15. In (FIGS. 14 and 15), after the internal protrusion 27 has been positively locked into the second extended lock position 47, counterclockwise rotation on the cylindrical housing 26 will not move the cylindrical housing 26 in relation to the extended housing 35, but will cause the double external protrusions 54 to unseat from the double notches 63, permitting the disengagement of the double-ended needle assembly 11 from the container holder 60 by the counterclockwise unwinding of the external threads 53 from the internal mating threads 64.
FIGS. (22-26) refer to the second 8' embodiment of the evacuated blood collection system FIG. 22 illustrates a sterile container holder 10' for the second embodiment 8' comprised of the second needle shield 12' and the needle shield/needle guard device 20'. FIG. 23 illustrates the second embodiment 8' of the evacuated blood collection system comprised of the double-ended needle assembly 11' and the extended front end 61' of the container holder 60'. In FIG. 23, the essential difference of the second embodiment 8' compared to the first embodiment 8 of the evacuated blood collection system (see FIG. 2) is the extended front end 61' of the container holder 60' and the shortened housing 35' of the double-ended needle assembly 11'. The longitudinal groove 49' of the container holder 60' is longer in the second embodiment 8' by virtue of the extended front end 61' of the container holder 60'. Attachment of the double-ended needle assembly 11' to the container holder 60' occurs by the previously described primary and secondary locking means for the preferred embodiment 8 of the evacuated blood collection system. FIG. 24 illustrates the shortened housing 35' of the double-ended needle assembly 11', external threads 53', and grooves analogous to those in the first embodiment 8 of the evacuated blood collection system. The needle shield/needle guard device 20' (see FIG. 23) can function as a needle shield covering the sterile first needle 15' when the internal protrusion 27' is positively locked (see FIG. 24) into the first extended lock position 42' on the housing 35' by the same means as described for the first embodiment 8 of the evacuated blood collection system. The elements of the groove system are essentially the same as described for the first embodiment 8 of the evacuated blood collection system. FIG. 25 illustrates the removal of the pull-off tab 22' from the weakened annular zone 25' of attachment to the cylindrical housing 26' and the retraction of the cylindrical housing 26' on the extended front end 61' of the container holder 60'. This maneuver occurs as described for the first embodiment 8 of the evacuated blood collection system. FIG. 26 is a longitudinal section along line 26--26 in FIG. 25. It illustrates the tertiary locking of the double-ended needle assembly 11' to the container holder 60' as described for the first embodiment 8 of the evacuated blood collection system (see FIG. 21).
After use of the first needle 15' for venipuncture, the cylindrical housing 26' is re-extended back into the second extended lock position 47' (see FIG. 24) as described for the first embodiment 8 of the evacuated blood collection system, so that the cylindrical housing 26' can function as a needle guard which can re-cover the used first needle 15' from behind the needle point of the first needle 15'. The double-ended needle assembly 11' can then be unfastened from the container holder 60' as described for the preferred embodiment 8 of the evacuated blood collection system.
FIGS. (27 to 30) illustrate the first embodiment of the detachable needle assembly 90 for a hypodermic syringe 80. In FIG. 28, the detachable needle assembly 90 is secured to the hypodermic syringe 80 by means of a luer-lock. This invention can also be adapted so that other securing means could fasten the detachable needle assembly 90 to the hypodermic syringe 80. FIG. 27 illustrates an isometric view of the preferred embodiment of the detachable needle assembly 90. The detachable needle assembly 90 is comprised of a needle shield/needle guard device 20" with a cylindrical housing 26" and a pull-off tab 22", an extended housing 35", a luer-lock retainer wall 84, and the luer-lock thread 83 on the distal end of the needle hub 87. In FIG. 28, the needle shield/needle guard device 20" can function as a needle shield covering the sterile needle 91 when the internal protrusion 27" is moved over the funneled lead-in groove 37" to slip-fit complementarily into the first extended lock position 42" on the extended housing 35". In this position, the needle shield/needle guard device 20" is prevented from moving forward, clockwise or counterclockwise in relation to the extended housing 35". The entire groove system on the needle assembly 90 is comprised of a funneled lead-in groove 37", the first extended lock position 42", constricting bead 41" of the first extended lock position 42", longitudinal groove 45", constricting bead 51" of the retracted lock position 57 and the retracted lock position 57. FIG. 28 also illustrates in more detail other components of the first embodiment of the detachable needle assembly 90 which include the luer-lock retainer 84, and the luer-lock thread 83. The front end 85 of the syringe 80 is also illustrated with the cone fit 81 and the internal luer-lock mating threads 82. The detachable needle assembly 90 is fastened to the front end 85 of the syringe 80 by clockwise rotation of the needle shield/needle guard device 20" to engage the luer-lock thread 83 into the internal luer-lock mating threads 82 and slip-fitting of the external surface of the cone 81 into the internal surface 89 of the needle hub 87. The clockwise rotation of the needle shield/needle guard device 20" does not move the needle shield/needle guard device 20" clockwise in relation to the extended housing 35" by virtue of the positive locks as described. Unnecessary extra tightening of the pressure fit luer-lock is prevented when the distal surface 88 of the luer retainer wall 84 approximates the proximal surface 86 of the front end 85 of the syringe 80, thereby providing a constant tightening pressure of the luer-lock.
In FIG. 28, when the cylindrical housing 26" of the needle shield/needle guard device 20" is locked into the first extended lock position 42", unintentional retraction of the cylindrical housing 26" on the extended housing 35" is prevented by the resistance created by the friction fit of the internal protrusion 27" into the first extended lock position 42" and by the constricting bead 41" distal to the first extended lock position 42". When the pull-off tab 22" is removed from the cylindrical housing 26", the cylindrical housing 26" can be intentionally retracted into the retracted lock position 57 by moving the internal protrusion 27" over the constricting bead 41" to the longitudinal groove 45", over the constricting bead 51" into the retracted lock position 57. In that position, the internal protrusion 27" is positively locked so that the the cylindrical housing 26" is prevented from moving backward, clockwise and counterclockwise in relation to the extended housing 35". FIG. 29 is an isometric view illustrating exteriorization of the sterile needle 91 by the retraction of the cylindrical housing 26" on the extended housing 35" of the detachable needle assembly 90. FIG. 30 is a longitudinal section along line 30--30 of FIG. 29 and illustrates the retraction of the cylindrical housing 26" on the extended housing 35" and the distal surface 88 of the luer retainer wall 84 approximating the proximal surface 86 of the front end 85 of the syringe 80. FIG. 30 also illustrates the engagement of the external surface of the cone 81 into the internal surface 89 of the needle hub 87. The extended housing 35" provides a length extension between the needle 91 and the wide diametered syringe barrel 79. The length extension permits the user to direct the needle into a blood vessel at a more shallow or acute angle in respect to the planar surface of the skin and thus minimize the chance of piercing through the other side of the blood vessel wall.
Following usage of the needle 91 (see FIG. 28), the cylindrical housing 26" can function as a needle guard which is capable of re-extending back into the first extended lock position 42" on the extended housing 35" of the detachable needle assembly 90, and thereby allow the user to safely re-cover the used needle 91 by moving the cylindrical housing 26" from behind the needle point. This maneuver occurs (see FIG. 28) by reversing the sequence of movements of the internal protrusion 27" of the cylindrical housing 26" back into the first extended lock position 42". Alternatively, the user of this invention can elect to retract the cylindrical housing 26", fill the syringe with liquid medicament, and then delay injecting the liquid medicament by re-extending the cylindrical housing 26" back into the first extended lock position 42" to re-cover the sterile needle 91. The cylindrical housing 26" can then be retracted again to exteriorize the needle 91 to inject the medicament, and then the cylindrical housing 26" can be re-extended again to the first extended lock position 42" to re-cover the used needle 91. Retraction and extension of the cylindrical housing 26" in relation to the extended housing 35" of the detachable needle assembly 90 can occur ad-finitum.
The detachable used needle assembly 90 is unfastened from the front end 85 of the syringe 80 by counterclockwise rotation on the cylindrical housing 26". The counterclockwise rotation on the cylindrical housing 26" does not move the cylindrical housing 26" counterclockwise in relation to the extended housing 35" by virtue of the described positive locks while the internal protrusion 27" is locked into the first extended lock position 42", thereby providing coverage of the used needle 91 with the cylindrical housing 26" when the detachable needle assembly 90 is unfastened from the syringe 80. The counterclockwise rotation of the cylindrical housing 26" can overcome the luer-lock since the luer-lock retainer wall 84 prevented over-tightening between the luer lock thread 83 into the luer lock internal mating threads 82 and the contact between the slip-fitting surfaces of the external surface of the cone 81 and the internal surface 89 of the needle hub 87.
Depending on manufacturer stipulations, it is to be understood that the groove systems used for the first embodiment 8 and second embodiment 8' of the evacuated blood collection system could be reciprocally exchanged for the groove system used for the first embodiment of the needle assembly 90 for a hypodermic syringe.
It is to be understood that the form of the invention herewith shown and described is to be taken as the preferred embodiments. Various changes may be made in the shape, size, and arrangement of parts, for example: equivalent elements may be substituted for those illustrated and described herein, parts may be reversed and certain features of the invention may be utilized independently of the use of other features all without departing from the spirit or scope of the invention as defined in the subjoining claims.
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This invention relates to a combination needle shield/needle guard device that is positively locked onto detachable needle assemblies for an evacuated blood collection system and for a hypodermic syringe. More particularly, this invention can: (1) function as a needle shield to enclose and prevent contamination of the sterile needle to be used for a medical procedure; (2) function as a needle guard which can slide on a length extension for either needle assembly, such that the needle can be uncovered or re-covered in a direction from behind the needle point, thereby providing a safety feature for the operator who can avoid direct contact with a used, blood-contaminated needle point. Avoidance of direct contact with used needle points will reduce the likelihood of contracting blood-borne infections such as AIDS, infectious hepatitis, syphilis etc. that might occur following accidental puncture with contaminated needles; (3) provide improved securing for an evacuated blood collection system between the double-ended needle assembly and the container holder, thereby preventing the double-ended needle assembly from unlocking with the container holder during the process of withdrawing blood into an evacuated container and (4) improve blood withdrawing success with the blood evacuated collection system and with a large volume syringe. This occurs by the addition of a length extension which separates the wide girth of the container holder or the wide girth of a large volume syringe barrel from close approximation to the needle used for withdrawing blood, thereby permitting more shallow or acute angle access of needle entry into a blood vessel during blood withdrawing procedures.
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BACKGROUND
[0001] An interrupt may be an asynchronous signal indicating a need for attention or a synchronous event in software indicating a need for a change in execution. Thus, to ensure an optimum performance of an operating system, the processing of interrupts requires knowledge of an interrupt latency that is time based. The interrupt latency for operating systems may be measured to determine a time between a generation of the interrupt by a device and a servicing of the device that generated the interrupt. Often, devices are serviced as soon as the device's interrupt handler is executed. A callback subroutine for the interrupt handler of the operating system or a device driver may be triggered by the reception of the interrupt. However, the functionality of the interrupt handler is varied as a function of the reason for the interrupt and the speed at which the interrupt handler completes its task.
[0002] Conventional means for measuring the interrupt latency requires expensive and/or cumbersome external hardware. For example, an oscilloscope may be included to enable an observation of constantly varying signal voltages to determine the interrupt latency. In another example, a logic analyzer may be included to display signals of a digital circuit which are too fast to be observed and presents the signals for observation for a device under test. Additional hardware such as those described above are required in conventional measuring systems to measure interrupt latency for non-periodic interrupt sources or other interrupt sources that have an interrupt signal assertion time that cannot be predicted.
SUMMARY OF THE INVENTION
[0003] A method for setting a first indicator indicating that interrupts are virtually locked, receiving a first interrupt at a processor of a computing device, setting a second indicator indicating the receipt of the first interrupt and recording a first timestamp based on the receipt of the first interrupt. The method further adapted to virtually execute a routine for the first interrupt that includes determining if the second indicator is set, record a second timestamp based on the virtual execution of the routine and determine an interrupt latency based on the first and second timestamp.
[0004] A computing device having a hardware component generating an interrupt, a processor executing an operating system configured to receive the interrupt and measure a latency of the interrupt for the hardware component by virtually executing the interrupt and a memory storing latency data.
[0005] A non-transitory computer readable storage medium including a set of instructions executable by a processor. The set of instructions operable to set a first indicator indicating that interrupts are virtually locked, receive a first interrupt at a processor of a computing device, set a second indicator indicating the receipt of the first interrupt, record a first timestamp based on the receipt of the first interrupt, virtually execute a routine for the first interrupt that includes determining if the second indicator is set, record a second timestamp based on the virtual execution of the routine and determine an interrupt latency based on the first and second timestamp.
DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 shows a computing device according to an exemplary embodiment.
[0007] FIG. 2 shows a method for measuring interrupt latency according to an exemplary embodiment.
DETAILED DESCRIPTION
[0008] The exemplary embodiments may be further understood with reference to the following description and the appended drawings, wherein like elements are referred to with the same reference numerals. The exemplary embodiments describe a computing device configured to measure interrupt latency without the use of additional hardware component(s). Specifically, only software in the form of the operating system of the computing device is used to measure the interrupt latency and for any interrupt source (e.g., asynchronous signal, synchronous event, non-periodic source, unpredicted interrupt signal assertion source, etc.). The computing device, interrupt latency, the measurement, the software, the interrupt source, and an associated method with be discussed in further detail below.
[0009] FIG. 1 shows a computing device 100 according to an exemplary embodiment. The computing device 100 may be any electronic device that is configured to perform various computational functionalities. For example, the computing device 100 may be a desktop computer, a mobile device (e.g., a laptop, a personal digital assistant, a cellular phone, etc.) or an embedded device (e.g., camera, automobile, thermostat, etc.). The computing device 100 is further configured to determine an interrupt latency without the need of further hardware components. That is, external or internal hardware is not required as the interrupt latency may be determined using software already present on the computing device 100 . The computing device 100 may include a processor 105 , a memory 115 , a first component 120 , and a second component 130 . However, it should be noted that the computing device 100 may include further components that provide additional functionalities.
[0010] The processor 105 and the memory 115 may provide conventional functionalities for the computing device 100 . The computing device 100 may include an operating system 110 . The operating system 110 may be software stored on the memory 115 and executed by the processor 105 . The operating system 110 may also provide conventional functionalities. For example, the operating system 110 may be VxWorks, Linux, Windows, etc.
[0011] The components 120 , 130 may be any hardware that is incorporated with the computing device 100 . For example, the components 120 , 130 may be a data input device (e.g., keypad), a network card, a video card, a sound card, etc. Those skilled in the art will understand that a hardware component of the computing device 100 may further include associated software components such as a device driver. Thus, to call a functionality of the hardware component, the device driver may be associated according to the settings of the operating system 110 .
[0012] According to the exemplary embodiments, the operating system 110 may be configured or modified with a program or executable that performs the measurement of the interrupt latency. That is, the exemplary embodiments may utilize all existing hardware and software of the computing device 100 to measure the interrupt latency. Thus, for example, if a functionality of the component 120 is being called, the component 120 may transmit an interrupt to the processor 105 . To determine the interrupt latency, the operating system 110 may perform an algorithm associated therewith.
[0013] As described above, the operating system 110 may be configured to measure an interrupt latency. According to the exemplary embodiments, the interrupt latency may be determined using a preliminary process performed prior to the interrupt being executed. Specifically, the operating system 110 may include virtual processes that are performed.
[0014] Initially, the operating system 110 may include routines that are associated with performing an interrupt operation. For example, the operating system 110 may include an interrupt locking routine. Conventionally, the interrupt locking routine is invoked when the OS software does not want to be interrupted by an interrupt service routine (“ISR”). However, according to the exemplary embodiments, the interrupt locking routine does not lock interrupts at this stage but simply sets a flag X that indicates that interrupts are virtually locked. A timestamp A may also be recorded. Thus, in an exemplary embodiment, the flag X is set when the interrupt locking routine virtually locked interrupts.
[0015] Subsequently, when an interrupt on the processor 105 occurs, a determination is made whether the flag X has been set. For example, the component 120 may send an interrupt to the processor 105 . If the flag X has been set, the operating system 110 may set a second flag Y that indicates that an interrupt has occurred. Data relating to the interrupt event may be stored. In the example, the interrupt data may relate to the component 120 , the functionality that is to be called, a priority level of the interrupt, etc. A second timestamp B may be recorded at this time. A modified virtual lock of interrupts may be performed so that when the interrupt context returns for the interrupt to finally be executed, the interrupts may be locked. That is, due to the additional process of measuring the interrupt latency at this stage between the interrupt occurring and the interrupt being executed, the modified interrupt lock may alter the execution of the interrupt, in particular the locking of interrupts. This step may ensure that the interrupt is properly performed without requiring additional steps such as forcing a second interrupt from the same source to be sent.
[0016] It is noted that an interrupt handler is not initiated at this time. When the interrupt occurs, interrupts are locked and the interrupt handler is executed to perform the interrupt. However, despite the interrupt occurring, interrupts have been virtually locked. Furthermore, it is noted that the second interrupt not being required is only exemplary. As will be described below, different processes may be used to eventually perform the interrupt.
[0017] Because the operating system 110 is reading that interrupts are locked because the flag Y is set, the operating system 110 is aware that an interrupt has occurred. Accordingly, an interrupt unlocking routine may check whether the flag Y was set to determine that the interrupt occurred while interrupts were locked. The operating system 110 may note and/or record a timestamp C at this point. The operating system 110 may then measure the actual hardware interrupt latency by taking a difference between the timestamps B and C.
[0018] Once the interrupt latency has been measured, the interrupt handler may be executed from the context that was saved previously. As discussed above, the interrupt context is returned and the conventional processes involved with performing the interrupt may occur such as an actual locking of interrupts. In an alternative process, the interrupt handler associated with the deferred interrupt event may be run after interrupts are unlocked by letting the hardware reassert the interrupt. Thus, the interrupt may occur again at the processor 105 without performing the measurement of the interrupt latency. To prevent a loop from occurring, the operating system 110 may record the measurement of the interrupt latency with a marker or other indication that indicates that the measurement should not be performed again for this interrupt. The markers may be used per nested interrupts.
[0019] FIG. 2 shows a method 200 for measuring interrupt latency according to an exemplary embodiment. As discussed above, the measuring of the interrupt latency may be performed using only existing hardware and software of a computing device. Specifically, the operating system of the computing device may be modified to determine the measurement. The method 200 will be described with reference to the computing device 100 of FIG. 1 .
[0020] In step 205 , the operating system 110 sets a flag X to indicate that interrupts are virtually locked. As discussed above, the interrupt lock routine of the operating system 110 may perform the setting. In step 210 , the timestamp A is recorded.
[0021] In step 215 , the interrupt may occur for the processor 105 . for example, the component 130 may send the interrupt when a functionality of the component 130 is called. In step 220 , a determination is made whether the flag X has been set. If the flag X has not been set, the method 200 continues to step 260 where the interrupt handler is initiated. As discussed above, if the interrupt latency has already been measured, the hardware may be reset and the interrupt may be reasserted by the component. As a result, the flag X may not be set.
[0022] If the flag X has been set, the method 200 continues to step 225 . In step 225 , the operating system sets the flag Y that indicates the interrupt has occurred. In preparation for the eventual execution of the interrupt, in step 230 , the interrupt event data is stored. As discussed above, the interrupt event data may include component data, functionality data, priority data, etc. In step 235 , the timestamp B is recorded to indicate the occurrence of the interrupt as though the virtual execution of the interrupt has not occurred to accurately determine the interrupt latency.
[0023] In step 240 , the operating system 110 performs a modified lock of interrupts to prevent the operating system 110 from receiving a further interrupt. As discussed above, this modified lock may be used when the interrupt context is used for the eventual execution of the interrupt. Thus, when the interrupt context is returned, an actual lock of interrupts is performed.
[0024] In step 245 , a determination is made whether the flag Y has been set. If the flag Y has not been set, the method 200 continues to step 260 where the interrupt handler is initiated. If the flag Y has been set, the method 200 continues to step 250 where the timestamp C is recorded. The timestamp C may indicate a time when the interrupt has been completed were the virtual execution of the interrupt not have occurred. Thus, in step 255 , the operating system 110 measures the interrupt latency by taking the difference between the timestamps B and C. Subsequently, in step 260 , the interrupt handler is initiated.
[0025] It should be noted that the method 200 may include further steps. For example, after step 260 , the method 200 may include a step that retrieves the stored interrupt context. As discussed above, when this occurs, the modified lock may then performing an actual lock of interrupts in preparation for executing the lock.
[0026] It should also be noted that the measuring of the interrupt latency according to the exemplary embodiments being the difference between the timestamps B and C is only exemplary. The operating system may further determine a relative range of interrupt latency measurements. For example, the interrupt latency may be determined to be a minimum when the difference between the timestamps B and C is performed. In another example, the interrupt latency may be determined to be a maximum when the different between the timestamps A and C is performed.
[0027] The exemplary embodiments provide a means to measure interrupt latency without a need for additional hardware components. Conventional measuring of interrupt latency requires the use of additional hardware components that are cumbersome and increases costs. The exemplary embodiments enable an existing operating system of a computing device to be configured to measure the interrupt latency. Specifically, an algorithm, a protocol, a program, etc. may be included with the operating system so that if interrupt latency is to be measured, the operating system may perform a preliminary virtual execution of an interrupt to measure the interrupt latency prior to the actual execution of the interrupt.
[0028] The exemplary embodiments include various steps of setting flags and recording timestamps to measure the interrupt latency. When detecting flags that are set, the operating system may view the interrupt actually being executed from virtual locking of interrupts to measure the interrupt latency. A stored interrupt context may be used after the interrupt latency is measured for the actual execution of the interrupt by an interrupt handler. Alternatively, the hardware may also be reset to reassert the interrupt and execute the interrupt without setting flags to bypass the measuring of the interrupt latency.
[0029] Those skilled in the art will understand that the above described exemplary embodiments may be implemented in any number of manners, including, as a separate software module, as a combination of hardware and software, etc. For example, the modification to the operating system may be a program containing lines of code that, when compiled, may be executed on the processor 105 .
[0030] It will be apparent to those skilled in the art that various modifications may be made in the present invention, without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A system and method for setting a first indicator indicating that interrupts are virtually locked, receiving a first interrupt at a processor of a computing device, setting a second indicator indicating the receipt of the first interrupt and recording a first timestamp based on the receipt of the first interrupt. The system and method further adapted to virtually execute a routine for the first interrupt that includes determining if the second indicator is set, record a second timestamp based on the virtual execution of the routine and determine an interrupt latency based on the first and second timestamp.
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FIELD OF THE INVENTION
[0001] This disclosure relates to joints for drill tubes, and in particular threaded joints for thin-walled drill tubes.
BACKGROUND
[0002] A joint for a drill tube transfers the torque power from one tube part to another. Because of a thinner wall thickness, the joint is generally weaker than the rest of the tube. At a certain drilling depth, the tube gets so long that the weight becomes greater than the desired drilling thrust. To keep the desired drilling thrust at the drill bit end of the tube, an increased pullback tension load is required at the opposite end of the drill tube. Therefore, when drilling deep, the joint needs a high tension load capacity.
[0003] A threaded joint may be modified to make it stronger. One such solution is presented in U.S. Pat. No. 5,788,401, wherein a thin walled drill tube joint with a negative thread pressure flank is disclosed. The problem is solved with a negative pressure flank of 7.5° to 15° relative to a direction perpendicular to the central axis to provide for lower stress states. Further, the threaded section of the joint tapers along the axial length of the joint, with kept thread depth. A problem with this solution is that such tube joint is difficult to manufacture.
[0004] Hence, there is a need for an improved drill tube joint.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide an improved joint for a thin-walled drill tube. One particular object is to provide a joint that is strong yet easy to manufacture. The joint comprises a male part and a female part, which are connectable to each other by a thread connection.
[0006] According to a first aspect, a member of a joint in a thin-walled drill tube is provided, presenting a central axis and comprising a thread for forming a screw joint, wherein the thread presents a thread bottom, a thread top, a pressure flank and a clearance flank, characterized in that the pressure flank presents a portion having a negative angle less than 7.5°, but larger than 0°, relative to a direction perpendicular to the central axis.
[0007] When discussing angles of flanks and thread tops, it is understood that it is the main angle of the respective surface that is intended, and that any radii at edges of the respective surface should be disregarded.
[0008] The strength of the joint depends partly on the wall thickness of the joint parts. A shallow thread depth enables a greater wall thickness of the joint parts. With such solution, the thread depth may be reduced and the wall thickness increased, providing a stronger joint for deeper drilling. A tensile increase from 424000 N to 479000 is possible, which translates into about 300 m further drilling.
[0009] A negative angle is defined as an angle creating an undercut flank surface. By thin-walled drill tube, it is meant a tube with a wall thickness, excluding the thread, of about 3 to 6.4 mm, about 3 to 5.6 mm, or about 3 to 4.2 mm.
[0010] In further embodiments, the negative angle of the pressure flank portion may be about 1° to 6°, about 2° to 5°, about 4° to 5°, or about 5° relative to the direction perpendicular to the central axis.
[0011] In order to enable a reduced thread depth for increased wall thickness, the material of the member must be strong enough to manage the increased tension load on the thread due to reduced depth. One embodiment presents a joint member made of substantially through-hardened steel. When the steel is through-hardened and not only surface-hardened, no heat affected zone that can cause breakage of the thread top is created.
[0012] The thread depth, defined as the radial distance between the thread bottom and the thread top, can, in further embodiments, be about 0.5 to 0.8 mm, about 0.5 to 0.7 mm, or about 0.5 to 0.6 mm.
[0013] To enable more efficient use of the thread depth for more effective power transmission and better tension load capacity, in one embodiment, the material thickness at least one of the thread bottom and the thread top may taper towards an end portion of the member. This means that the thread depth is not constant along the surface of the member over which the thread extends. This solution may, when the male member is connected to a female member, result in a tapering clearance between the male and female members. A further advantage with this effect is that more space is offered for dirt and grease between the threads, which otherwise could cause disturbances and reduced tension load capacity in the connection.
[0014] In a further embodiment, the thread bottom may be substantially parallel with the central axis and the material thickness of the thread top tapers towards the end portion of the member.
[0015] The clearance flank of the thread may in one embodiment present a portion with an angle less than 45° relative to the direction perpendicular to the central axis.
[0016] In a further embodiment, the clearance flank of the thread may present a portion with an angle that is different at different sections of the thread. A rather large angle on a first thread section located close to the end portion of the member may facilitate the assembly of the male member with a female member. The clearance flank may then in one embodiment present a portion with an angle of about 10° to 40°, about 20° to 35°, or about 30° relative to the direction perpendicular to the central axis.
[0017] The first thread section may be located closer to an end portion of the member than a second thread section. The second section may present a clearance flank portion with an angle of about 0° to 15°, about 1° to 10°, or about 5° relative to the direction perpendicular to the central axis. The clearance flank angles of the different thread sections may be combined in different embodiments according to Table 1. X indicates explicit disclosure of a first and second section clearance flank angle combination.
[0000]
TABLE 1
0° to 15°
1° to 10°
5°
10° to 40°
x
x
x
20° to 35°
x
x
x
30°
x
x
x
[0018] A thread pitch of the member may be about 0.8 to 1.6 threads per centimeter, about 0.8 to 1.2 threads per centimeter, or about 1 thread per centimeter.
[0019] At least one of the pressure flank and the clearance flank may be connected to the thread bottom via a radius of more than about 0.10 mm or more than about 0.15 mm.
[0020] At least one of the pressure flank and the clearance flank may be connected to the thread top via a radius of more than about 0.10 mm or more than about 0.15 mm or more than about 0.20 mm.
[0021] The member may be a male member, wherein the thread extends along an outer portion of the member. In the alternative, the member may be a female member, wherein the thread extends along an inner portion of the member.
[0022] The female member presents in different embodiments substantially the same features as the male member. The two members may have the same pressure flank and clearance flank angles, thread depth and material.
[0023] In one embodiment, the thread top may, for a male member, taper with an angle of about 0.2° to 0.6°, about 0.3° to 0.5°, about 0.3° to 0.4°, or about 0.34° relative the central axis. In another embodiment, the material thickness of the thread top may, for a male member, taper with an angle of about 1.7° to 2.5°, or about 2° to 2.5° relative the central axis.
[0024] In one embodiment, the material thickness of the thread top may, for a female member taper with an angle of about 0.2° to 0.6°, about 0.2° to 0.4°, about 0.2° to 0.3°, or about 0.28° relative to the central axis. At the same time the thread bottom may be substantially parallel with the central axis.
[0025] A second aspect provides a joint system for a drill tube comprising a male member and a female member according to any of the previous presented embodiments. The joint system may, in one embodiment, present a tapering clearance between a thread top of one of the members and a thread bottom of the other one of the members. This feature presents the effect that a maximum part of the thread depth is used when the pressure flanks of the two members are in connection. It also allows more space for dirt and grease in the thread connection. In practice, the thread depth may vary and/or the material thickness at the thread bottom may vary.
[0026] In a further embodiment of the invention the tapering clearance is present over at least two juxtaposed threads. With as much connection surface as possible between the pressure flanks of the two members as possible, the more the thread depth can be reduced, enabling increased wall thickness, with kept tension load capacity of the joint. Therefore it is an advantage if all threads have a tapering clearance at the connection between the two members.
[0027] According to a third aspect, there is provided a thin-walled tube drill system, comprising a joint system as described above, wherein the male member is arranged on a first thin-walled drill tube and the female member is arranged on a second thin-walled drill tube.
[0028] According to a fourth aspect, there is provided a male or female member of a joint for a drill tube, presenting a central axis and comprising a thread for forming a screw joint, wherein the thread presents a thread bottom, a thread top, a pressure flank and a clearance flank, wherein a material thickness at least one of the thread bottom and the thread top tapers towards an end portion of the member.
[0029] According to a fifth aspect, there is provided a male or female member of a joint for a drill tube, presenting a central axis and comprising a thread for forming a screw joint, wherein the thread presents a thread bottom, a thread top, a pressure flank and a clearance flank, at least one of the pressure flank and the clearance flank is connected to the thread bottom via a radius of about 0.15 mm.
[0030] According to a sixth aspect, there is provided a male or female member of a joint for a drill tube, presenting a central axis and comprising a thread for forming a screw joint, wherein the thread presents a thread bottom, a thread top, a pressure flank and a clearance flank, at least one of the pressure flank and the clearance flank is connected to the thread top via a radius of about 0.20 mm.
[0031] It is understood that each of the fourth to sixth aspects may be used in combination with any embodiment under the first or second aspects, or independently thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] In the following, an embodiment will be described in more detail with reference to the accompanying drawings.
[0033] FIG. 1 a is a perspective cross-sectional view of a male member.
[0034] FIG. 1 b is a cross-sectional view of a male member.
[0035] FIG. 2 is a cross-sectional view of one half of the joint with a male member and a female member.
[0036] FIG. 3 is a cross-sectional detail view of the connection between a male and female member thread.
DETAILED DESCRIPTION
[0037] With reference to FIGS. 1 a and 1 b , a male member 1 of a joint for a drill tube is shown. The inner diameter 30 of the tubular tube and joint, as well as the outer diameter 31 , may be specified for an industrial standard. A base portion 2 of the cylindrical member has the same outer diameter 31 as the drill tube, and a base shoulder 3 connects the base portion 2 with the outer portion of the member that is provided with a thread 4 . The thread extends along the axial length of the member 1 , and ends at an end portion 5 .
[0038] The thread 4 presents a thread bottom 6 , a thread top 7 , a pressure flank 8 and a clearance flank 9 . The thread bottom 6 is defined as the part of the thread with the shortest radial distance from the central axis A. The part with longer radial distance from the central axis is the thread top 7 . The greatest radial distance between the thread bottom 6 and the thread top 7 defines the thread depth 32 . An inner cylindrical surface 10 of the member 1 defines, together with the thread bottom 6 , the wall 11 of the member 1 .
[0039] The base shoulder 3 is undercut and tapers towards the threaded portion of the member with an angle 20 of about 15° relative to a direction perpendicular to the central axis A. The pressure flank 8 is the flank of the thread 4 facing the base portion 2 . The pressure flank 8 has an undercut surface with a negative angle 21 of about 5° relative to a direction perpendicular to the central axis A. The clearance flank 9 faces towards the end portion 5 . The clearance flank 9 may have different angles at different sections of the thread 4 . A first section 15 of the thread is provided closest to the end portion 5 of the member. That first section 15 may present an entrance clearance flank 12 with a positive angle 22 of about 30° relative to a direction perpendicular to the central axis A. In a second section 16 of the thread, the clearance flank 9 may present a positive angle 23 of about 5° relative to a direction perpendicular to the central axis A. A larger angle in the first thread section 15 may facilitate the assembly of the male member 1 into a female member in a joint, and reduces the risk of damaging of the threads.
[0040] The member 1 and the member end portion 5 , terminate at an end shoulder 13 . The end shoulder 13 tapers with a negative angle 24 of about 15° relative to a direction perpendicular to the central axis A. The end shoulder is connected to the inner cylindrical surface 10 of the member via a chamfer 14 with an angle 25 of about 15° relative the central axis A.
[0041] The thread bottom 6 may be substantially parallel with the central axis A. The thread top 7 tapers towards the end portion 5 of the male member 1 with an angle 26 of about 0.34° relative the central axis A. This results in a non-constant thread thickness 32 . To increase the strength in the joint, it is desirable to make the wall 11 as thick as possible, and therefore it is desirable to make the thread thickness 32 as shallow as possible. In this embodiment of the invention, the thread depth 32 may be about 0.5 to 0.7 mm.
[0042] The pressure flank 8 presents the angle 21 . The pressure flank 8 is connected to the thread top 7 via a radius 40 , which may be about 0.2 mm. The pressure flank is further connected to the thread bottom 6 via a radius 41 , which may be about 0.15 mm. In the same way, the clearance flank 9 of the second thread section 16 may be connected to the thread top 7 via a radius 42 , which may be about 0.2 mm, and connected to the thread bottom 6 via a radius 43 , which may be about 0.15 mm. The entrance clearance flank 12 is connected to the end portion 5 via a radius 44 , which may be about 0.4 mm. The different radii at the flanks have the effect that the loads on the connections are distributed over a larger area. The sizes of the radii may be adjusted for optimal effect. The radii also make it easier to achieve a tight connection surface between the flanks.
[0043] The joint system according to the invention comprises a male member 1 and a female member 101 , wherein the male member comprises a thread extending along an outer portion of the member, and the female member 101 comprises a thread extending along an inner surface portion of the member. FIG. 2 shows the male member 1 in joint connection with the female member 101 . The female member 101 presents corresponding parts as the male member 1 including a base portion 102 , an end portion 103 , a base shoulder 104 , an end shoulder 105 and a threaded portion presenting a thread bottom 106 , a thread top 107 , a pressure flank 108 , a clearance flank 109 and radii. The base shoulder 104 tapers towards the threaded portion of the female member 101 with a negative angle of about 15° relative to a direction perpendicular to the central axis A. The base shoulder 104 is connected to the jacket surface of the base portion 102 via a chamfer 110 of about 15° relative to the central axis A. The end portion 103 terminates at the end shoulder 105 that tapers with a negative angle of about 15° relative to a direction perpendicular to the central axis A, and is connected to an outer surface 111 of the female member. The pressure flank 108 and the clearance flank 109 , present the same positive and negative angles as the corresponding angles for the male member 1 .
[0044] The thread bottom 106 of the female member 101 may be substantially parallel with the central axis A, providing a constant wall thickness of the female member wall 112 . The thread top 107 may taper towards the female member end portion 103 with an angle 120 of about 0.28° relative the central axis A. Therefore, the thread depth at the thread part axially closer to the base portion of each member may differ from the thread depth at the thread part axially closer to the end portion of each member.
[0045] The thread pitch of the male member 1 and the female member 101 respectively may be about 2.5 threads per inch.
[0046] In the joint connection between the male member 1 and the female member 101 , the pressure flanks 8 , 108 of the two members are in connection and provide the tension load capacity of the joint. The difference between the angles 26 and 120 of the two thread tops 7 and 107 and the two thread bottoms 6 and 106 creates, as seen in FIG. 3 , tapering clearances 201 , 202 between the female thread bottom 106 and the male thread top 7 , and between the female thread top 107 and the male thread bottom 6 . The thread bottoms 6 , 106 may be substantially parallel with the central axis A. This feature provides a good and effective connection surface between the pressure flanks 8 and 108 . Also, the radii 40 , 41 connected to the pressure flanks help providing a more efficient connection surface. The tapering clearances 201 , 202 , together with the clearance 203 between the clearance flanks 9 , 109 , create space for grease and dirt in the thread. This has the positive effect that interference of grease and dirt on the pressure flank connection is reduced.
[0047] To enable the solution in this embodiment, with reduced thread depth and increased wall 11 , 112 thickness, the material of the walls 11 , 112 and the threads may be of through-hardened steel. With a material that is not through-hardened, for instance surface-hardened, there is a risk of weaker threads due to heat effected zones.
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A member of a joint for a thin-walled drill tube presents a central axis and comprises a thread for forming a screw joint. The thread presents a thread bottom, a thread top, a pressure flank and a clearance flank. The pressure flank presents a portion having a negative angle less than 7.5°, but at least 0°, relative to a direction perpendicular to the central axis.
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[0001] This application is a divisional of U.S. patent application Ser. No. 14/020,556, which is a continuation-in-part of U.S. patent application Ser. No. 13/912,567, filed on Jun. 7, 2013, which claims priority to the following U.S. provisional applications 61/676,426, 61/676,431, 61/676,436, 61/676,443, and 61/676,452 filed Jul. 27, 2012; 61/675,268, 61/675,263, 61/675,258, and 61/675,271 filed Jul. 24, 2012; and 61/656,619 filed Jun. 7, 2012. These and all other referenced extrinsic materials are incorporated herein by reference in their entirety. Where a definition or use of a term in a reference that is incorporated by reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein is deemed to be controlling.
FIELD OF THE INVENTION
[0002] The field of the invention is data collection and management technologies.
BACKGROUND
[0003] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0004] With the pervasive use of cell phones capable of capturing or presenting content, there has been an ever growing demand for technologies that allow users to participate in, or even create, augmented experiences.
[0005] Some efforts have been put forth in capitalizing on the above demand. For example, U.S. Patent Application Publication Number 2012/0192242 to Kellerer titled “Method and Evaluation Server For Evaluating a Plurality of Videos,” filed on Jan. 20, 2012 describes a system that identifies a set of videos capturing the same event from a plurality of videos, and prioritizes the videos based on a limited number of factors such as video characteristics and viewing angles. Unfortunately, Kellerer apparently fails to take into account various factors that may be of interest in customizing a presentation for a user, and apparently fails to present the videos in a manner that optimizes viewing or customization capabilities of a user.
[0006] All publications identified herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0007] As another example, U.S. Pat. No. 8,250,616 to Davis titled “Distributed Live Multimedia Capture, Feedback Mechanism, and Network,” filed on Sep. 28, 2007 describes presenting a set of videos in real-time, wherein the videos can be organized based on presentation or ranking criteria (e.g., popularity of event, popularity of broadcaster, length of coverage). U.S. Pat. No. 7,657,920 to Arseneau titled “System and Methods For Enhancing The Experience of Spectators Attending a Live Sporting Event With Gaming Capability,” filed on Jul. 21, 2006 describes a system generally directed towards presentation of sports videos in which thumbnails representing videos can be presented to a user for selection. Upon a user selection, Arseneau's system can display physiological data associated with an athlete in the video.
[0008] Further examples can be found in: U.S. Patent Application Publication Number 2009/0063419 to Nurminen titled “Discovering Peer-to-peer Content Using Metadata Streams,” filed on Aug. 31, 2007; Korean Patent Application Number 2010/0069139 to Cho titled “System and Method For Personalized Broadcast Based on Dynamic View Selection of Multiple Video Cameras, Storage Medium Storing The Same,” filed on Dec. 15, 2008; U.S. Pat. No. 8,286,218 to Pizzurro titled “Systems and Methods of Customized Television Programming Over The Internet,” filed on Dec. 13, 2007; Canadian Patent No. 2,425,739 to Freeman titled “A Digital Interactive System For Providing Full Interactivity With Live Programming Events,” filed on May 15, 2003; U.S. Pat. No. 6,122,660 to Baransky titled “Method For Distributing Digital TV Signal and Selection of Content,” filed on Feb. 22, 1999; U.S. Patent Publication Numbers 2011/0117934 and 2012/0059826 to Mate titled “Method and Apparatus For Mobile Assisted Event Detection And Area of Interest Determination,” and “Method and Apparatus For Video Synthesis,” respectively, and filed on Nov. 15, 2009 and Jan. 24, 2011, respectively; and U.S. Patent Publication Number 2012/0233000 to Fisher titled “Systems and Methods For Analytic Data Gathering From Image Providers At An Event Or Geographic Location, filed on Mar. 7, 2012.
[0009] Unfortunately, previous known efforts have not been directed towards simultaneous presentation of multiple video streams in a manner that optimizes a user's viewing experience or allows a user to request targeted modifications based on the information presented. Applicant has come to appreciate that presenting multiple feeds in a clustered arrangement aids in enhancing a user's experience.
[0010] Thus there is a need for improved data collection and presentation management technologies.
SUMMARY OF THE INVENTION
[0011] The inventive subject matter provides apparatus, systems and methods in which one can leverage a remote experience interface system to access one or more experience feeds related to an event. Such systems and methods can advantageously allow a person to experience an event from various perspectives that he or she may otherwise not be privy to.
[0012] One aspect of the inventive subject matter includes a system comprising a feed aggregation engine coupled to one or more feed acquiring devices. The feed aggregation engine can be configured to obtain a plurality of feeds from the feed acquiring devices and construct an experience feed based on an experience policy. In some preferred embodiments, the aggregated feeds could be related to a single event or venue (e.g., game, concert, exhibit, etc.).
[0013] An experience policy can include various terms that dictate how an experience feed is to be constructed. These terms can be based on any suitable data, including for example, rules data, instructions data, cost data, fee data, subscription data, bid data, or various other categories of data. The experience policy can be established automatically, by viewers, by broadcasters, by a system manager, or by any other suitable techniques. Once the experience policy is established automatically or otherwise, the feed aggregation engine constructs the experience feed according to the terms of the experience policy and the acquired feeds. The feed aggregation engine can then provide the experience feed to one or more output devices, and can instruct the output devices to present the experience feed to one or more users where the arrangement of feeds includes a cluster indicator. The output device can include computers, printers, tablets, kiosks, cell phones, or any other commercially suitable types of computing devices.
[0014] In another aspect of the inventive subject matter, the experience feed can be dynamic in nature, or be presented to a viewer in a manner that allows the viewer to modify or customize the experience policy or the experience feed based on the viewer's preferences.
[0015] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a schematic of a remote experience ecosystem.
[0017] FIG. 2 is a schematic showing generation of an experience policy.
[0018] FIG. 3 is a schematic showing generation of a plurality of metrics based on experience policies and acquired feeds.
[0019] FIG. 4 is a schematic of a user interface including a plurality of feeds and controls.
[0020] FIG. 5 presents a method executable by a feed aggregation engine of the inventive subject matter.
DETAILED DESCRIPTION
[0021] Throughout the following discussion, numerous references will be made regarding servers, services, interfaces, engines, modules, clients, peers, portals, platforms, or other systems formed from computing devices. It should be appreciated that the use of such terms is deemed to represent one or more computing devices having at least one processor (e.g., ASIC, FPGA, DSP, x86, ARM®, ColdFire®, GPU, etc.) configured to execute software instructions stored on a computer readable tangible, non-transitory medium (e.g., hard drive, solid state drive, RAM, flash, ROM, etc.). For example, a server can include one or more computers operating as a web server, database server, or other type of computer server in a manner to fulfill described roles, responsibilities, or functions. One should further appreciate the disclosed computer-based algorithms, processes, methods, or other types of instruction sets can be embodied as a computer program product comprising a non-transitory, tangible computer readable media storing the instructions that cause a processor to execute the disclosed steps. The various servers, systems, databases, or interfaces can exchange data using standardized protocols or algorithms, possibly based on HTTP, HTTPS, AES, public-private key exchanges, web service APIs, known financial transaction protocols, or other electronic information exchanging methods. Data exchanges can be conducted over a packet-switched network, the Internet, LAN, WAN, VPN, or other type of packet switched network.
[0022] One should appreciate that the disclosed techniques provide many advantageous technical effects including configuring devices to present one or more user interfaces allowing users to manipulate or manage a remote experience.
[0023] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
[0024] One should appreciate that the disclosed systems and methods allow users to remotely obtain a customized experience feed related to an event based on multiple dimensions of relevance. The experience feed can include a plurality of video feeds that are aggregated and presented in a manner that provides an optimal viewing experience for a user or group of users. One should also appreciate that the disclosed system and methods allow users to virtually and seamlessly navigate through, or obtain a virtual view from, selected areas within an arena or other geographic location without having to weave through crowds, pay for additional tickets, or even leave their house.
[0025] Example scenarios that can benefit from such technology include, among other things, concerts, plays, museums, exhibits, tourism, ticket vendors, movie theatres, social networking, location scouting, fashion shows, or other scenarios.
[0026] In FIG. 1 , ecosystem 100 illustrates a remote experience interface system. Contemplated systems include an experience feed interface 120 coupled to a plurality of feed acquiring devices 101 , 102 , 103 , 104 via a feed aggregation engine 180 . The plurality of feeds can be sent or otherwise transmitted from sensing devices 101 , 102 , 103 , 104 over a network 107 (e.g., Internet, cellular network, LAN, VPN, WAN, parts of a personal area network, etc.) to feed aggregation engine 180 that is preferably configured or programmed to aggregate the plurality of feeds 111 into one or more experience feeds 130 according to an experience policy 112 , and possibly other metrics, dimensions, terms, or other factors. Experience feed 130 can then be transmitted to one or more devices (e.g., computers, tablets, game consoles, game handhelds, cell phones, appliances, vehicles, etc.) over a network 108 for presentation via an interface e.g., 120 .
[0027] One should appreciate that the disclosed technology can allow a user to virtually experience an event 110 that he would otherwise not have access to through reception of video feeds obtained from devices located in proximity to the event. It is contemplated that experience feed 130 can be constructed from not only video feeds, but additionally or alternatively from original or modified audio data, image data, textual data, time data, location data, orientation data, position data, acceleration data, movement data, temperature data, metadata, user data, or any other suitable sensor data acquired by feed acquiring devices 101 , 102 , 103 , 104 having one or more corresponding sensors (e.g., a mechanical sensor, a biometric sensor, a chemical sensor, a weather sensor, a radar, an infrared sensor, an image sensor, a video sensor, an audio sensor, or any other commercially suitable sensor that can construct or acquire sensor data.). Contemplated feed acquiring devices can include, among other things, a mobile phone, a smart phone, a camera, a tablet, a video camera, virtual reality glasses, a security camera, a computer, a laptop, or any other suitable feed acquiring device.
[0028] Individuals or entities controlling feed acquiring devices 101 , 102 , 103 , 104 can be considered broadcasters of an event 110 . The event broadcasters can utilize feed acquiring devices to acquire video or other sensor data related to one or more focal zones 101 A, 102 A, 103 A, 104 A of an event 110 . Once the various feeds of video or other data are aggregated by feed aggregation engine 180 , the feeds can be modified or curated for presentation in experience feed 130 according to an experience policy 112 .
[0029] An experience policy 112 related to an event 110 preferably includes event attributes, commands, and other terms that can dictate how an experience feed is to be constructed. It is contemplated that an experience policy 112 can be generated by one or more persons or entities, including for example, a viewer, a system or event manager, a broadcaster, or a conflicts manager. Where multiple persons or entities contribute to generation of an experience policy, it is contemplated that data relating some or all of the terms (e.g., rules, commands, costs, fees, subscriptions, bids, etc.) can be transmitted via one or more interfaces 160 , 170 to a policy generation module (not shown) for generation of an experience policy.
[0030] One should appreciate that the aggregated feeds 111 or experience policies 112 can be utilized to derive one or more experience dimensions of relevance that can provide a description of data contained therein. The experience dimensions can be derived based on the context (e.g., data acquired in feeds 111 suggests that some feeds include loud audio while others only contain video, etc.), or can be derived based on a known input received by a policy generator. As one example of a known input, an experience policy may include a user input term suggesting a preference for a front row view of a lead singer of a band. Such term can be used to derive, among other things, a location dimension or a focal dimension.
[0031] Other contemplated experience dimensions include for example a time dimension, a point of view dimension, a capacity dimension, a relevancy dimension, a proximity dimension, a relationship dimension, a rating dimension, an emotional dimension, a sensory modality dimension, a color dimension, a volume dimension, or any other suitable category of data that may be of relevance in generating an experience feed 130 .
[0032] The experience dimensions, aggregated feeds or experience policies can then be used to generate or calculate one or more metrics associated with an experience dimension, which can provide a value associated with the dimension. Contemplated metrics include for example, a location metric 113 (e.g., GPS coordinate value; physical address; zip code; a centroid of devices, friends, celebrity or venue; etc.), a focal metric 115 (e.g., coordinates associated with a central point of view, a tilt, a rotation, an angle, etc.), a time metric (e.g., a time of day, a length of feed, an estimated time of arrival or start, etc.), a capacity metric (e.g., a venue capacity value, a percent to capacity value, etc.), an experience feed arrangement metric 114 (e.g., primary feed location, primary feed size, etc.), a relationship metric (e.g., a distance between broadcasters, a ranking of the most popular videos, etc.), a relevancy metric (e.g., a percentage of user preferences met by a video feed, etc.), a proximity metric (e.g., a distance to a focal zone, a distance to a person, etc.), an emotion metric (e.g., a number of smiling people, a percentage of smiling people, a color, a brightness, etc.), or any other suitable metric. One should appreciate that multiple values or types of values can be associated with a single dimension, and that a single value can be a metric of one, two, or event five or more dimensions.
[0033] In some preferred embodiments, feed aggregation engine 180 can be configured to construct an experience feed 130 having an arrangement of a primary feed and a plurality of peripheral feeds according to an experience policy 112 . Experience feed 130 can also be constructed having an arrangement of feeds based on one or more metrics 113 , 114 , 115 . For example, a preferred location 105 and a preferred focal point 106 can be input by a user, broadcaster or manager and used to generate a location metric and focal metric in constructing experience feed 130 .
[0034] In the example provided, experience feed 130 is presented with a primary feed 104 B and peripheral feeds 101 B, 102 B, 103 C having an arrangement according to at least one of the experience policy 112 , location metric 113 , and focal metric 115 . In especially preferred embodiments, a “primary feed” can comprise one or more feeds that best match the totality of terms included in experience policy 112 and metrics 113 , 114 , and 115 . In FIG. 1 , primary feed 104 B is captured by feed acquiring device 104 , and is the stream that best matches a combination of the location metric 113 generated based on preferred location 105 , and focal metric 115 generated based on preferred focal point 106 . Feed 103 B is captured by feed acquiring device 103 and provides the best match for location metric 113 . However, feed 103 B could be considered peripheral because it provides a weak match for focal metric 115 . Similarly, feed 101 B could be peripheral despite providing a closer match to focal metric 115 because feed 101 B provides a weak match to location metric 101 .
[0035] Experience feed 130 can also advantageously include a cluster indicator 140 generated as a function of a focal metric 115 . Cluster indicator 140 can comprise a visual or non-visual indicator of the feeds that provide an indication of a match (e.g., best, worst, etc.) to focal metric 115 or any other dimension or metric. In the example shown, focal cluster is a visual box surrounding feeds 101 B and 104 B whose focal zones 101 A and 104 A best match preferred focal point 106 . However, other possible visual indicators include a color, an image, a video, a symbol, a text, a number, a highlight, a change in size, or any other suitable visual indicator. Possible non-visual indicators include a sound, a voice, a signal, a smell, or any other suitable non-visual indicator. It is also contemplated that cluster indicator 140 can be generated as a function or two, three or even four or more dimensions, metrics or terms. Furthermore, cluster indicators can be provided generated as a function of one or more non-focal dimensions or metrics (e.g., a time cluster shown as a clock can be generated as a function of a time metric, a location cluster shown in a red block can be generated as a function of a time metric and a direction of view metric, etc.).
[0036] One should appreciate that cluster indicators can be used in relation to an event for various purposes. These purposes can include, among other things, social networking, discovering new people or topics of interest, finding a person of interest, making a purchase, obtaining a recommendation, improving education, targeted marketing or advertising, improving telepresence, achieving business goals, or any other suitable purpose that furthers a goal or interest of a viewer, event manager, broadcaster, or advertisers.
[0037] While many of the examples hereinafter focus on providing cluster indicators to viewers, the following possible use case illustrates how cluster indicators can be provided to an event manager or advertiser to assist in determining what targeted marketing material to present to viewers. Perry Farrell, the creator of Lollapalooza® could provide remote experiences to viewers who cannot attend the music festival in person. Stone Temple Pilots® (STP), a band performing at Lollapalooza, wishes to advertise its new album to remote viewers who may be interested in pre-purchasing the album. There could be three stages at the festival, and each stage could have scheduled performance at all times during the three-day festival. In order to provide targeted advertisement opportunities to STP, Perry could obtain an experience feed that provides an indication of broadcasters that are capturing feeds of STP's performance or stage (pre-performance), and include STP's advertisement in those feeds. When a viewer selects those broadcaster's feeds during STP's performance, they could view the pre-sale advertisement for STP's new album and possibly be provided with a link to make a purchase.
[0038] It is also contemplated that feed radar 170 can be presented to a user to provide a simple or consolidated presentation of feed data. Feed radar 170 can show a relative location of peripheral feeds in relation to a primary feed. Feed radar 170 can also advantageously present an indication of other information related to the feeds, for example, a focal zone, a direction of view with respect to the focal zone, a time, a quality, a capacity, a capability, a volume, or a compliance with a set of terms. In the example provided, radar 170 provides an indication of where each feed acquiring device is located relevant to a preferred location (e.g., 105 ). Radar 170 also provides an indication of how closely the devices' focal zone matches a focal preference (e.g., 106 ). In this example, the indication is provided through the variation in shading of circles representing the devices. Other suitable indications include a difference is sizing, color or symbol; a boxed portion; an image; text; or any other suitable indications.
[0039] FIG. 2 illustrates a policy generation module 255 , which obtains inputs and generates experience policy 212 . As discussed above, experience policy 212 can be related to an event and include event term data that dictates how an experience feed is to be constructed. Term data can be represented in a memory coupled to a central processing unit of a computing device, and can include rule data, instruction data, cost data, fee data, subscription data, rights data, bid data, command data or any other suitable types of data that may be obtained by policy generation module 255 in relation to an event. It is contemplated that experience policy 212 terms can be used to generate instructions (e.g., scripts, compiled code, executable instructions, etc.) useful in constructing an experience feed to be presented to a user. It is also contemplated that the experience policy 212 itself can comprise instructions derived or generated based on some or all of the term data, which can be carried out, run or executed by a computer or a virtual machine in presenting an experience feed to a user.
[0040] In some preferred embodiments, an experience policy 212 is generated by policy generation module 255 via input of at least one of a user, an event manager, a system manager, a broadcaster, an advertiser, or other person or entity having an interest in an arrangement of an experience feed. In the example shown a user can provide input via user interface 210 , a manager can provide input via manager interface 250 and one or more broadcasters can provide inputs via broadcaster interface 260 . Each of the interfaces 210 , 250 and 260 can be communicatively coupled over network 205 to policy generation module 255 , which is configured to generate an experience policy 212 in accordance with some or all of the term data.
[0041] As used herein, an “interface” can comprise any boundary across which two independent systems can meet or communicate. Exemplary interfaces comprise, among other things, a web browser, a keyboard, application software, an application suite, an application program interface (API), a touchscreen, a mouse, a graphical user interface (GUI), a web user interface (WUI), or any other suitable boundary. It is contemplated that persons or entities can provide inputs via an interface in any suitable manner, including for example, by a selection among a plurality of options, by a gesture, by a drag-n-drop mechanism, by a keyboard, by a mouse click, by voice command, by a gesture, or any other suitable manner. One should also appreciate that one or more of the interfaces (e.g., user interface, etc.) can comprise an experience feed interface configured to present an experience feed constructed according to experience policy 212 , or can comprise a separate interface.
[0042] All suitable types of input can be provided to policy generation module 255 via an interface, including for example, rule data, instruction data, preference data, emotion data, desired indicator data, subscription data, bid data, cost data, fee data, ranking data, or any other suitable input. This input can be manually input by the input provider, can be automatically obtained via one or more sensors of interface 250 (e.g., biometric sensor, GPS sensor, accelerometer, camera, audio sensor, thermometer, microphone, breathalyzer, a smoke detector, a rain sensor, a gyroscope, etc.), or can be derived from data obtained automatically or as an input.
[0043] In the example provided, data obtained from a user or user interface is referred to as user defined policy term data 210 A. It should be appreciated that any suitable type of inputs can be provided by a user, which can include preference data (e.g., a location preference, focal zone preference, sound quality preference, etc.), ranking data (e.g., an order of importance of experience feed characteristics, etc.), account data (e.g., a balance, a subscription, user name, password, pending charges, authorized charges, etc.), rule data (e.g., indemnification by a broadcaster or manager against copyright infringement, etc.), or any other suitable types of input.
[0044] In the example provided, data obtained from a manager or manager interface is referred to as venue required policy term data 220 A. It should be appreciated that any suitable type of inputs can be provided by a system or event manager, which can include capacity data (e.g., a broadcaster capacity, a camera capacity, a person capacity, a viewer capacity, an area capacity, etc.), rule data (e.g., prohibited activity, broadcaster requirements, viewer requirements, etc.), command data (e.g., how a primary feed is to be presented, number of feeds presented, type of cluster indicator, interface components to be provided to a user (e.g., selector, volume adjuster, touch-screen capability, time-shifting buttons, etc.), etc.), cost data (e.g., amount a broadcaster is being paid, account management, etc.), fee data (e.g., amount to charge viewer for actions, amount to charge broadcaster for recording permit, etc.), or any other suitable types of input.
[0045] In the example provided, data obtained from a broadcaster or a broadcaster interface is referred to as broadcaster defined policy term data 230 A. It should be appreciated that any suitable type of inputs can be provided by a broadcaster of an event, which can include rules data, instruction data, cost data, bid data (e.g., amount required to begin streaming, amount required for a location within a venue, amount required for a type of camera used, etc.), permit data (e.g., types of clearances obtained, etc.), or any other suitable types of inputs.
[0046] One should appreciate that any term data obtained from any persons or entities can be used in at least one of: deriving a dimension of relevance; generating a metric associated with one or more of the derived dimensions; and generating clusters associated with a dimension or metric (e.g., location cluster, cost cluster, location cluster, bid cluster, fee cluster, ranking cluster, etc.).
[0047] It is contemplated that each term data 210 A, 220 A, 230 A of policy generation module 255 can be included in experience policy 212 as a rule, an instruction, a cost, or other term. More preferably, a combination of policy generation module term data 210 A, 220 A or 230 A can be used to derive or generate a term of experience policy 212 . As used herein, a “term” can comprise any rule, command, cost, fee, subscription, bid, an instruction derived or generated from one or more of the aforementioned for execution in presenting an experience feed to a user, or any other suitable term that can be generated as a function of term data obtained by policy generation module 255 , and suitable for use in constructing an experience feed.
[0048] The following use case provides an example of how input from various persons or entities can be used to generate an experience policy having various terms. Tomas's favorite band Pearl Jam is playing a show at the House of Blues® (HOB®) on Sunset Boulevard, but Tomas is in Brazil and unable to attend the show. Using his mobile computing device, Tomas connects to policy generation module 255 and communicates that he wishes to view the Pearl Jam HOB show from front row center, with a focal zone covering the entire band, a front-facing direction of view, and superior sound quality. The communication of his front row center preference can be accomplished via his prior inputs in relation to five other experience feeds he viewed in the last two months, all of which requested a front row center view. The communication of his focal zone preference can be accomplished via a selection made through his mobile computing device, which can present a plurality of focal zones to select from or rank. The communication of his superior sound quality preference can be accomplished via a voice command obtained via an audio sensor of his mobile computing device, or be a default input for all events viewed through Tomas's account.
[0049] In addition to Tomas's inputs, policy generation module 255 can obtain various event manager inputs via manager interface 250 . These inputs can include, among other things, a twenty-five broadcaster capacity for the event, a five broadcaster capacity for the front row of the event, a rule allowing cameras inside the venue, and a limitation on flash photography. Still further, policy generation module 255 can obtain various broadcaster inputs via broadcaster interface 260 . These inputs can include inputs from various broadcasters available for an event, and can include a fee, a venue location, a focal zone, a data type, a direction of view, an assignment, and a copyright ownership notice.
[0050] As discussed above, one or more terms obtained by policy generation module 255 can become a term of experience policy 212 , or used to derive a term of experience policy 212 . For example, and continuing on the use case above, the front row preference of the user, locations provided by broadcasters, and the front row capacity information can be used to generate rule 213 requiring that only feeds from the five broadcasters located in the front row are included in Tomas's experience feed. As another example, the fee input provided by a broadcaster via interface 260 can become cost 215 or fee 216 .
[0051] While the above example focuses on generating experience policies via one or more inputs, it should be appreciated that an experience policy 212 can be generated using known data (e.g., previously input data, rule of law, etc.), including a right of publicity law, a venue requirement, a user preference, a user default, a broadcaster default, stage location data, or any other data included in a previously generated experience policy. It should also be appreciated that a system of the inventive subject matter can be configured to identify potential applicability of a rule, notify a system manager or other user of the potential applicability, and provide an appropriate resolution or recommendation. For example, where an event comprises a music festival that plans to use holographic images of a deceased celebrity, rule 213 can be related to the celebrity's right of publicity (e.g., the right to control its name, image, personal, etc.). The system can be configured to identify a potential right of publicity issue in the state of California based on the data obtained by policy generation module 255 (e.g., the celebrity's domicile in California at the time of death, etc.) and notify the event manager of a potential issue. The system can also recommend a possible resolution or recommendation derived from the law, including for example, a recommendation that the event manager obtain clearance for the use from the deceased celebrity's estate. As other examples, the system can be configured to identify a potential copyright infringement based on a lack of copyright clearance input, or a need for an assignment or work for hire agreement from a broadcaster based on inputs indicating previous user or system manager complaints.
[0052] As with any system that allows multiple inputs, especially where the inputs can be provided by multiple persons or entities, it is contemplated that a conflict may arise among two or more inputs. Such conflicts can arise between inputs of a single person or entity, inputs of multiple persons or entities, an input and known data, or any other information obtained by policy generation module. In such scenarios, it is contemplated that any suitable conflict resolution means can be utilized to determine what term(s) to generate, derive or apply. The conflict resolution means can comprise, among other things, a conflict resolution engine that can resolve conflicts based on one or more of a timing of an input; a ranking; a loyalty of a user, manager or broadcaster; a preference of a user, manager or broadcaster; or any other suitable basis. The conflict resolution engine can act automatically based on a set of pre-defined rules, or can require input from a conflict resolution manager familiar with rules for resolving a conflict. For example, where a broadcaster provides a policy term requiring a cost of $0.25 per copy of a video feed, and a system manager provides a policy term requiring a payout of $0.10 to the broadcaster per copy of a video feed, a conflict resolution engine can automatically resolve the conflict by identifying a default term, for example, based on a prior agreement between the system manager and broadcaster agreeing to a payment of $0.15 per copy. As another example, it is contemplated that a broadcaster can provide bid requirements that differ from a system manager. The broadcaster may provide an input requiring a total bid amount of $1,000 and a minimum bid of $0.10 per viewer (i.e., bids of varying amounts). A system manager may provide an input requiring that all bids are the same amount (e.g., each viewer must bid $0.50, and there must be at least 2,000 bidders). The conflict resolution manager can resolve the conflict by determining how flexible a broadcaster has been in previous auctions and determining whether applying the system manager's rule would alienate the broadcaster.
[0053] Upon generation of experience policy 212 , it can be transmitted over network 215 to feed aggregation engine 280 , which is configured to construct an experience feed having an arrangement of feeds according to the experience policy 212 . The feed aggregation engine 280 can construct the experience policy by executing instructions either included in experience policy 212 , or generated based on terms in experience policy 212 . Experience policy 212 can comprise any suitable number of terms: including rules, commands, instructions, costs, fees, subscriptions, bids, rankings (e.g., of broadcasters, users, subscribers, etc.), defaults, or any other suitable terms that can be useful in constructing an experience feed.
[0054] As used herein, a “rule” can comprise a term of an experience policy that comprises a regulation or principle regarding one or more elements of an experience feed that either must be followed, or is preferably to be followed. Examples include, among other things, a copyright law, a right of publicity law, a license requirement, a copyright notification requirement, a trademark notification requirement, a disclaimer requirement, an assignment requirement, or any other suitable rule set by an event manager, performer, broadcaster, user, court, legislative body, agency or other person or entity.
[0055] As used herein, a “cost” can comprise a term of an experience policy that includes a cost associated with providing a particular feed in an experience feed. As examples, a cost can comprise a cost to a user to obtain a particular feed (e.g., $1.00 to obtain a feed meeting at least 90% of a user's preferences, etc.), or can comprise a cost to a system manager for each provision of a particular feed (e.g., $0.20 to be paid to the broadcaster each time the broadcaster's video is included).
[0056] As used herein, a “fee” can comprise a term of an experience policy that includes a fee to be charged to a user upon an action, including for example, a zoom, a save, a time-shift, having more than one primary feed, a viewing in a public venue (e.g., a restaurant, bar, café, pool hall, etc.), or any other action by a user with respect to an experience feed.
[0057] As used herein, a “subscription” can comprise data related to one or more users, including a user name, a password, account information, a credit history, a payment received by a user, a balance, or any other suitable data that indicates the type of experience feed to provide to a user, or an action allowable by a user.
[0058] As used herein, a “bid” can comprise data related to a pricing of a wish-list feed available via a crowd-based bidding platform (e.g., a virtual auction or bartering platform, etc.). The pricing can be related to a price that a broadcaster requires in order to begin capturing or providing a feed, or can comprise a price that one or more users are willing to pay, or have pre-paid, in order to obtain a feed. As evident in the following use case, a crowd-based bidding platform can allow users and broadcasters to dictate the types of feeds that are to be made available in relation to an event. Broadcaster X is required to pay $1,000 to the UFC® organization if he wishes to capture video of the next Anderson Silva fight. Broadcaster X is available for the event, but is only willing to participate as a broadcaster if he can obtain $10,000 in user fees. Broadcaster X utilizes the bidding platform provided by the inventive subject matter to open bidding to sports bar owners across the country. It is contemplated that the types and amounts of bids accepted by Broadcaster X can be customized in any suitable manner by a person or entity accepting bids. Here, Broadcaster X can customize the bidding platform to, among other things, accept bids only over a minimum amount, require a premium amount for obtaining access to Anderson Silva's pre-fight interview, require a premium amount for capturing celebrities attending the fight, accept non-cash bids, or allow bidders to vote to select Broadcaster X's location, focal zone, direction of view or other feed capturing characteristic.
[0059] One should appreciate that the dissemination of bids through a system of the inventive subject matter can be observed, studied or managed by a system manager or broadcaster. This data can be used to determine what events, broadcasters or feed characteristics are in demand by a user or groups of users in order to make profitable business decisions. For example, a broadcaster can use the bidding data to determine the type of requests that are popular in a specific context. Based on the data the broadcaster can, among other things, purchase a specific seat in a venue for acquiring feeds, utilize a specific device, modify settings of the device, or determine a type of emotion to capture or evoke.
[0060] As used herein, a “command” can comprise a term of an experience policy that initiates an operation defined by an instruction (defined below). Examples of commands can include, among other things, a command to centrally focus a primary feed; enlarge a primary feed; arrange peripheral feeds into a cluster based on focus, location, time, quality, etc.; include a mauve, pink, blue, black, gold, red, or other background color; allow a zoom, pause, rewind, fast-forward, etc.; require a fee for a selection, a zoom, a recording, an increase in number of primary feeds, etc.; or any other suitable command. At least one corresponding instruction can be included as a term to dictate how the operation initiated by the command is to be achieved.
[0061] As used herein, an “instruction” can comprise a term generated or derived from one or more terms of an experience policy, which can be provided as executable code, scripts or other suitable format for execution, running or carrying out by a computer or virtual machine. These instructions can, when executed, construct components of an experience feed that is customized according to at least some of the inputs obtained by a policy generation engine. For example, executable code can be provided as an instruction to arrange peripheral feeds (e.g., left to right, front to back, largest to smallest, etc.) based on a relationship dimension (e.g., highest to lowest number of the viewer's friends or relatives found in each feed, etc.) or other dimension. The instruction could be based on a user term showing a preference for such feeds.
[0062] One should appreciate that any term of an experience policy can influence not only an arrangement of feeds in an experience feed, but also what cluster indicator(s) are provided in the experience feed. As discussed above, cluster indicators can be used in relation to an event for various purposes. One should also appreciate that a cluster indicator can be dynamic in nature to advantageously provide a user with various indications throughout an event without requiring a user input during the event. A dynamic cluster indicator can allow a user to be simultaneously or sequentially presented with clusters that indicate different dimensions or metrics.
[0063] The following possible use case illustrates how a dynamic cluster indicator could be provided in accordance with terms of an experience policy. Daniel has a sprained ankle but wishes to make certain purchases for an upcoming trip to Hawaii. Daniel's friends Annie, Amanda, Andy and 16 others agree to go to the Grove® to provide Daniel with a remote shopping experience (i.e., act as broadcasters). Daniel connects to a policy generation engine over the internet and communicates that he would like an indication of the following sub-events: (1) who is at or next to his favorite store J Crew®; (2) who is viewing oxford shoes; (3) who is viewing a sale; and (4) who is near a celebrity. The policy generation engine could include instructions in a generated experience policy that, upon execution by a processor, generates a cluster indicator that is configured to change when one or more of the sub-events take place. For example, if one or more of Daniel's friends are viewing oxford shoes, the cluster indicator can provide an indication of such broadcasters (e.g., via a semi-transparent red box, etc.). If Daniel's friends are no longer viewing oxford shoes, but Annie walks by Rihanna, the cluster indicator can provide an indication that Annie is passing Rihanna (e.g., via a semi-transparent blue box, etc.). Where a cluster indicator indicates a sub-event that may be of interest to one or more of Daniel's friends, it is contemplated that Daniel can share the cluster information via a system of the inventive subject matter. For example, Daniel can communicate with an experience feed interface and cause the cluster information to be sent to his friends as an alert to a feed acquiring device, an alert to a broadcaster interface, or a message to a social networking site (e.g., Facebook®, Twitter®, etc.).
[0064] One should appreciate that two or more sub-events can occur at the same time. As such, a dynamic cluster indicator can sequentially provide indications of the sub-events (e.g., via a dotted box formed around the different clusters sequentially, etc.). Additionally or alternatively, two or more sub-events can be indicated simultaneously by one or more cluster indicators (e.g., via a box having two-tones to indicate two different sub-events, etc.).
[0065] FIG. 3 illustrates metric generation 300 based on an experience policy and a plurality of feeds. As discussed above, the plurality of feeds 311 can be received by feed aggregation engine 380 from a plurality of feed capturing devices (See e.g., FIGS. 1, 101, 102, 103 and 104 ). The experience policies 310 can be received by feed aggregation engine 380 from a policy generation engine (See e.g., FIG. 2, 255 ). Also as discussed above, an experience policy 310 can comprise various terms that influence or dictate how an experience feed is constructed. As shown in FIG. 3 , experience policy 310 can further be used to derive dimensions and generate metrics that can influence how an experience feed is constructed. As used herein, a “dimension” can comprise an aspect or feature of an event or feed, and a “metric” can comprise a measurement or value associated with a dimension. For example, a “location dimension” can indicate that location is an important characteristic to be considered in constructing an experience feed, while a “GPS coordinate” can indicate the type of location information available or of value.
[0066] In the example provided, feed aggregation engine 380 aggregates a plurality of feeds 320 from a plurality of feed acquiring devices (not shown), and obtains experience policies 310 associated with various viewers of an event (e.g., ten experience policies, wherein each experience policy is associated with a different viewer or viewers, etc.). While the experience policies 310 can advantageously comprise some of the same terms (e.g., from system managers, broadcasters, advertisers, etc.), the experience policies 310 can also comprise different terms based on inputs from a diverse group of viewers. It is contemplated that information obtained from one or more of the experience policies 310 can be used to generate dimensions 330 , possibly utilizing data obtained or derived from feeds 320 . The number of dimensions 330 derived can increase depending on the number of experience policies 310 considered, as additional experience policies can increase the number of terms from which dimensions 330 can be derived.
[0067] One should appreciate that for each dimension 330 (e.g., location dimension 332 , etc.), one or more metrics (e.g., 340 , 342 , 344 , 346 , 348 , 340 , etc.) can be generated. For example, where a dimension comprises a time dimension, it is contemplated that the following metrics can be generated: a time of day (e.g., 2:00 PM, etc.), a length of feed (e.g., 45.3 seconds, etc.), an estimated time of arrival of a performer (7:13 PM, etc.), an estimated time of arrival of a broadcaster (2:00 PM, etc.), a start time 2.5 seconds, etc.), or any other suitable time metric. Some or all of the dimensions or metrics can have an influence on an arrangement of the feed. Because the number of dimensions derived can be increased via consideration of multiple experience policies associated with an event, the number of metrics generated with respect to each experience policy 310 can be increased to thereby provide an optimally customized experience feed to users. While it can generally be preferred that one or more values associated with each of the dimensions can be generated or calculated for each viewer or experience policy, it is contemplated that some experience policies 310 could lack a term that allows metric generation for one or more or the derived dimensions.
[0068] While the following use case provides some examples of dimensions and metrics that can be derived or generated by a system of the inventive subject matter, it should be appreciated that all suitable dimensions and metrics are contemplated, including those listed with respect to FIG. 1 .
[0069] On New Year's Eve 2014, Martin, Nick and Bob are three of many viewers who have signed up to view the Times Square Ball drop via their respective computing devices in California. Each of the three experience policies generated for the three viewers can include some of the same terms generated based on broadcaster and manager inputs. These can include: location data indicating that broadcaster X is located in front of the event host's platform; focal zone data indicating that broadcaster Y's focal zone is to follow the Times Square Ball as it drops; and performance data indicating that Britney Spears is scheduled to perform on stage one at 8:00 PM eastern time, followed by the band Journey.
[0070] In addition, Martin's experience policy can include a user preference to provide the best view of the event's hosts from 9:00 PM-11:30 PM, and a best view of the Times Square Ball dropping from 11:30 PM to 12:30 PM. Nick's experience policy can also include a user specific term indicating a preference for uplifting footage, and a view of Journey's® performance. Bob's experience policy can further include a user specific term indicating a preference for the best view of the ball dropping at midnight, and a request to view the most popular feeds available at all other times. Furthermore, the various feeds acquired by the broadcasters can be characterized by certain attributes, including a clarity, a sound quality, a closeness to a focal point, a focal zone, and various other attributes.
[0071] Based on all of the aforementioned information available, the system can determine that the following dimensions, among others, are of relevance to one or more of the viewers: (1) a location dimension, (2) a focal dimension, and (3) a ranking dimension. The feed aggregation engine can use the derived dimensions and one or more of experience policies 310 to then generate metrics associated with each of Martin, Nick and Bob's respective experience policy for some or all of the three dimensions. For example, a location metric associated with the location dimension and Martin's experience policy can be generated including the location data of broadcaster X. As another example, a focal metric associated with the focal dimension and Nick's experience policy can be generated including a focal zone of broadcaster Y at 8:30 PM to 9:30 PM. As yet another example, a ranking metric associated with the ranking dimension and Bob's experience policy can be generated including a regularly updated top five list of popular videos.
[0072] These metrics can be used by a feed aggregation engine of the inventive subject matter in constructing experience feeds for one or more viewers of an event. For example, an instruction set that can be derived from the input of the various viewers, broadcasters and managers can include instructions in Martin's experience policy to include a cluster indicator in Martin's experience feed that indicates, in real-time, all feeds from feed acquiring devices whose focal zone includes the Times Square Ball. As another example, an instruction set that can be derived from the input can include instructions to include a cluster indicator in Nick's experience feed that indicates, in substantially real-time, all feeds from feed acquiring devices located near a stage, and capturing feeds of happy events (e.g., proposals, laughter, etc.) As yet another example, an instruction set that can be derived from the input can include instructions to include a cluster indicator in Bob's experience feed that provides an indication of all feeds from feed acquiring devices located near the host's stand that have at least 100,000 viewers.
[0073] FIG. 4 illustrates an experience feed interface 400 configured to present an experience feed having an arrangement of feeds according to an experience policy. Experience feed interface 400 is configured to allow a user to manipulate, observe, or otherwise manage a remote experience feed constructed from a plurality of aggregated data feeds. One should appreciate that an experience feed interface can also represent interfaces that can be leveraged by broadcasters, system managers, or other participants in an ecosystem.
[0074] User interface 400 comprises a display 430 presenting a plurality of feeds including a primary feed 432 , and a feed radar 470 providing a consolidated or simplified representation of feed data as described with FIG. 1 above.
[0075] It is contemplated that an experience feed can include multiple experience levels (e.g., different angles, different focus, different time frame, different sound quality, etc.) and that a user may wish to modify one or more of the experience levels presented to him. As such, user interface 400 can further comprise various controls that allow a user to interact with a remote experience system of the inventive subject matter to further customize the experience feed presented to the user via interface 400 .
[0076] In some embodiments, a plurality of feeds can be displayed in an arrangement mirroring the locations of feed acquiring devices in a venue. For example, display 430 can include feeds acquired from rows A-F of the Great Western Forum™ between seat numbers 121 and 151 , and be presented as overlays in a 3D model of at least a portion of the Forum's seating area. If the user wishes to view feeds captured by devices located in different parts of the Forum, the user can simply utilize space shift control 460 (e.g., by pressing one or more arrows on the screen, pinching, expanding, voice command, etc.). Such a control can advantageously allow a user to virtually view a focal point of an event from a plurality of locations within a venue with little to no effort. Such a control can also allow a user to view different portions of the Forum via a 3D model.
[0077] Another contemplated control includes audio control 444 , which can allow a user to change an audio characteristic associated with one or more feeds. For example, a user interested in viewing a concert, speech, debate or other event may want to listen to audio associated with different feeds simultaneously or sequentially before selecting a feed for long term viewing. Control 444 can advantageously allow the user to control which audio feed(s) are turned on, a volume of the audio feed, a clarity of the audio feed, a bass of the audio feed, or any other suitable audio characteristic associated with a feed. In some embodiments, control 444 can also advantageously include a scan setting that allows a user to scan each of a set of feeds sequentially (e.g., for 1, 5, 10, 20 seconds, etc.) without a user input.
[0078] Yet another contemplated control includes an indicator control 446 , which can allow a user to select the type of cluster indicator 434 that is presented to a user. For example, a user can press control 446 on the screen and be presented with a pop-up or drop-down menu of available indicators suitable for the experience feed being displayed. As discussed above, a cluster indicator can comprise a visual or non-visual indicator that indicates a match to a metric. It is contemplated that a cluster indicator can be three-dimensional in nature to provide a more realistic virtual experience. For example, an indicator can comprise a cluster of feeds that are presented using three-dimensional display technology, or can comprise a three dimensional view of a portion of a venue from which a set of feeds are acquired. The indicator control or other control can also be configured to allow a user to modify a type of cluster to be indicated. Such a control can allow a viewer to seamlessly switch between experience feeds that are arranged to present clusters based on different dimensions or metrics (e.g., an experience feed having a focal cluster to an experience feed having a proximity cluster indicating the devices located in closest proximity to a selected location, etc.).
[0079] The following possible use case provides an illustration of some of the ways a user can interact with user interface 400 to obtain one or more cluster indicators 434 sequentially or simultaneously. Brandi teaches an online fashion design course and has 500 students nationwide in attendance. Via her user interface, Brandi can obtain an experience feed including an arrangement of feeds acquired by her students in attendance. Using interface 400 as an example, Brandi can utilize space shift control to navigate through the 500 different feeds. Brandi can use cluster indicator control 446 to select a cluster she wants an indication of, for example, all video feeds captured by students who have indicated that they would like their designs reviewed. This cluster indicator can indicate the order in which the students provided an indication that their designs were ready for review (e.g., via an arrangement, via numbering, etc.). As the number of students wanting a design reviewed could change over the time, it is contemplated that the cluster indicator, or an indication of an order in which requests were made, could be updated on a regular basis (e.g., every 10 seconds, every 60 seconds, every 120 seconds, etc.). User interface 400 can also include a control that allows Brandi to remove a feed from a cluster upon completion of a review.
[0080] As shown in the above use case, it is contemplated that a cluster indicator can change with time. This change can be based on a change in feeds that best match a metric (e.g., the feeds that capture a specific focal zone can change over time, etc.), or can be dynamic and based on a change in the indication being presented (e.g., a cluster indicates a focal cluster, then indicates a relevancy cluster, etc.).
[0081] One should appreciate that the arrangement of an experience feed can be modified in order to present the feeds indicated by a cluster indicator adjacently to one another. Thus, an updated or modified cluster indicator could require a change in the arrangement of the feeds. It is also contemplated that a cluster indicator could indicate feeds that are not presented adjacent to one another. For example, a cluster indicator can comprise a symbol, an enlargement, a grayscale conversion, or other indication next to, under, within, or above the relevant feeds of a cluster.
[0082] Further examples of contemplated controls include, among other things: time shift control 442 , which can allow a user to pause, stop, play, rewind, fast-forward, or otherwise navigate through a length of a feed; zoom control 450 , which can allow a user to zoom in or out of one or more feeds or; preferences control 452 , which can allow a user to view and modify preferences associated with an event, experience policy or experience feed; type control 454 , which can allow a user to select the type(s) of feeds desired (e.g., text, video, image, audio, etc.); speaker control 456 , which can allow a user to provide input via a voice command; or a view control, which can allow a user to switch between a third person view and a first person or other view to seamlessly navigate through a 2D or 3D model of a venue.
[0083] One should appreciate that while some controls are discussed herein, all commercially suitable controls that can enhance a remote viewing experience or assist a user in interacting with an experience feed are contemplated.
[0084] FIG. 5 illustrates a method 500 executable by a feed aggregation engine of the inventive subject matter. Method 500 includes a method of constructing an experience feed for presentation via an experience feed interface.
[0085] Step 510 can include the step of aggregating a plurality of feeds related to an event, which can be obtained from a plurality of feed acquiring devices. While some of the above examples are directed to a music events, one should appreciate that all suitable events are contemplated, including for example, a concert, a sporting event, a live action game (e.g., poker, chess, etc.), a vacation, a disaster, a news story, an expedition, a traffic event, a live event, a flash mob, a fashion show, a shopping event, a reality event, an accident, an emergency, a party, a premier, or other type of events. It is contemplated that an event can be represented as a data structure describing a characteristic of an event (e.g., an event object) as described in parent patent application Ser. No. 13/912,567, filed on Jun. 7, 2013.
[0086] As shown in FIG. 1 , the plurality of feeds can be acquired over a network in real-time or substantially real-time from devices located in different portions of a venue. It is contemplated that the plurality of feeds related to an event can comprise the same or different data modalities (e.g., image, sound, video, etc.), and that the different modalities can be indicated by one or more cluster indicators. Moreover, the nature of an event can impact the types of feeds acquired. For example, where an event comprises a fashion show, video feeds may be of more interest to viewers than audio feeds. Where an event comprises a concert, video and audio feeds may be of equal or similar importance to viewers. One should also appreciate that the nature of an event can impact the feed acquiring devices utilized at an event. For example, mobile phones, handheld video cameras, cameras, audio recorders or other compact devices may be of greater value for a crowded event (e.g., a musical festival, etc.). However, a desktop computer, laptop, kiosk or other larger devices having greater capabilities may be of greater value for an event having designated areas for broadcasters.
[0087] Step 520 can include the step of obtaining at least one experience policy related to the event. As discussed above, an experience policy can be generated by a policy generation module based on data obtained from one or more persons or entities. The experience policy can then be transmitted to the feed aggregation engine over a network and comprise instructions to be executed by the feed aggregation engine to construct an experience feed having one or more cluster indicators and an arrangement of feeds according to the experience policy.
[0088] Step 530 can include the step of deriving one or more experience dimensions from at least one of an experience policy and the plurality of feeds. It can generally be preferred that the step of deriving one or more experience dimensions can comprise deriving at least one of a location dimension, focal dimension, or an emotional dimension as shown in steps 536 , 537 and 538 , respectively, which can be used to optimize customization of an experience feed to be presented to a user. One should appreciate that dimensions can be derived based on input provided by one or more persons or entities, or from sensor data captured by one or more feed acquiring devices or user devices. It should also be appreciated that the dimensions derived based on the inputs provided can be used to derive a set of indications that would be of interest to one or more users.
[0089] Sensor data can represent dimensions of human experience within ordinary human senses (e.g., image data, audio data, video data, etc.), or can represent dimensions outside ordinary human senses (e.g., time data, location data, orientation, position, acceleration, movement, temperature, metadata, user data, health, olfactory, sound, kinesthetic, or other types of modal data). It is also contemplated that sensor data can represent dimensions of human experience that cannot be directly experienced via a user device (e.g., a smell, taste, etc.). In such embodiments, it is possible that the sensor data can be reduced to a dimension that can be experienced via the user device (e.g., a visual or audio representation of the smell, etc.).
[0090] Step 540 can include the step of generating one or more metrics based on at least one of an experience policy, an experience dimension and a plurality of feeds. As described above, the metric can provide a value that is associated with an experience dimension. It is contemplated that the step of generating one or more metrics can include the step of generating at least one of a location metric, focal metric, relevancy metric or ranking metric as shown in steps 545 , 546 , 547 and 548 , respectively. One should appreciate that one or more of the metrics generated could be used in conjunction with a set of indicators derived from dimensions to determine which feeds, if any, should be included in a cluster to be identified by a cluster indicator.
[0091] Step 550 can include the step of constructing an experience feed. The experience feed can have an arrangement of a primary feed and a plurality of peripheral feeds according to at least one of an experience policy, an experience dimension and a metric, and can include one or more cluster indicators according to at least one of the aforementioned. One should appreciate that constructing an experience feed having such an arrangement can include executing instructions included in, or derived from, terms of the experience policy.
[0092] In some preferred embodiments, the experience feed can be constructed based on each of an experience policy, a plurality of experience dimensions and a plurality of experience metrics. A goal of a system of the inventive subject matter is to provide experience feeds that are constructed to be optimally customized to a user. One should appreciate that this goal can be furthered by utilizing emotional data related to a viewer in order to create a feed that matches a feeling desired by the user, or a feed that can influence a user's feelings. For example, data obtained from a user can indicate that a user is particularly sensitive to loud and angry noises. Based on this data, an experience feed can be constructed to exclude loud angry noises by, for example, excluding audio, or focusing on individual conversations rather than a loud performer. Alternatively or additionally, an experience can be constructed to intentionally include loud or angry feeds in an effort to influence the user's reaction or sensitivity to such noises.
[0093] To further achieve the aforementioned goal, step 560 can include the step of constructing a modified experience feed based on a user input. Examples of constructing a modified experience feed based on a user input can include modifying an arrangement of feeds to be presented; modifying one or more cluster indicator types or groupings; modifying a size, color or other visual element; modifying an audio component; or any other suitable modification based on a user input or change in preference. While the step of constructing the modified experience feed can be completed independently of an experience policy, it is contemplated that the step can include modifying an underlying experience policy of a user and constructing a modified experience feed having an arrangement according to the modified experience policy.
[0094] It should also be appreciated that an experience policy can be dynamic in nature, in which the experience feed can be automatically modified without a user or other input. In other words, an experience policy can comprise one or more secondary instructions, which are to be executed upon a pre-determined occurrence to modify a characteristic of the experience feed. Examples of experience feed elements that can be dynamic in nature include, among other things, cluster groupings, indicator types, dimension or metric a cluster indicates, designation of a feed as a primary feed, size or location of a feed, control types, or any other suitable experience feed elements.
[0095] As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously. Within the context of this document terms “coupled to” and “coupled with” are also used euphemistically to mean “communicatively coupled with” over a network, where two or more devices are able to exchange data with each other over the network, possibly via one or more intermediary device.
[0096] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0097] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0098] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value with a range 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 with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0099] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
[0100] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
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A method of interacting with a remote object is presented. In this method, at least two interfaces are provided that are configured to allow the tapper and the content provider to join a content sharing community. A third interface is also provided to allow the tapper to select the content provider from a map that displays representations of members of the content sharing community. Then a solicitation is conveyed from the tapper to the content provider to provide a video feed. In response to the solicitation, a video feed derived from a device operated or carried by the content provider is provided to the tapper. Further, a fourth interface is provided to the tapper to select a portion of the video feed. From a video feed, an object is recognized, and a clarification question can be generated based on the recognized object and a profile of the tapper.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Non-Provisional patent application claims priority to U.S. Provisional Patent Application Ser. No. 61/294,970, filed on Jan. 14, 2010, the contents of which is incorporated by reference herein in their entirety.
STATEMENT OF FEDERALLY FUNDED RESEARCH
[0002] None.
SEQUENCE LISTING
[0003] Not Applicable.
INCORPORATION-BY-REFERENCE OF MATERIALS FILED ON COMPACT DISC
[0004] Not Applicable.
TECHNICAL FIELD OF THE INVENTION
[0005] The present invention relates in general to the field of aloe polysaccharides, and more particularly, to compositions of aloe polysaccharides and use of such compositions for as immunomodulators and for the treatment of different types of cancers.
BACKGROUND OF THE INVENTION
[0006] Without limiting the scope of the invention, its background is described in connection with compositions, methods of preparation, and therapeutic uses of Aloe Vera polysaccharides.
[0007] U.S. Pat. No. 7,196,072 issued to Pasco et al. (2007) describes a complex, water soluble polysaccharide fraction having potent immunostimulatory activity isolated from Aloe vera . The polysaccharide fraction has an apparent molecular weight above 2 million daltons with glucose, galactose, mannose and arabinose as its major components. The invention further describes pharmaceutical compositions containing the instant polysaccharide fraction, optionally in combination with acceptable pharmaceutical carriers and/or excipents. These pharmaceutical compositions may be used to provide immunostimulation to an individual in need of such treatment by administering to such an individual an effective amount of the composition.
[0008] U.S. Pat. No. 6,083,508 issued to Avalos and Danhof (2000) describes a process for forming an aloe product from only the leaf residue obtained after filleting aloe leaves having an internal fillet which is removed therefrom. According to the '508 patent the residue is formed into a slurry by grinding and the aloe product is generated from the slurry. In addition the steps of preparing the aloe product comprises cleansing an aloe leaf before filleting it, separating the slurry formed into a liquid and solids, and further treating the separated liquid to remove laxatives before forming the aloe product. Also, a process including all of the above steps may also be performed in order to form the liquid.
[0009] United States Patent Application No. 2006/0084629 (Needleman and Needleman, 2006) discloses a combination of two, specialized, high molecular weight-long chain fractions isolated from Aloe Vera and Maitake TD to stimulate immune system activity comprising long chain-high molecular weight polysaccharides which activate the body's natural immune response, triggering an increase in the production of macrophages, T-cells, B-cells, natural killer cells, cytokines and antibodies. These long chain polysaccharides together with other active ingredients may provide proper immune system support thereby preventing debilitating diseases such as cancer, heart disease and aging
SUMMARY OF THE INVENTION
[0010] The present invention describes an aloe polysaccharide composition and the use of the composition as an immunomodulating agent and for the treatment of different types of cancers selected from leukemias and lymphomas, prostate cancer, breast cancer, and colon cancer, immune diseases, particularly immune related neoplasms.
[0011] The present invention provides a method for preparing a fine powder of a polymannan extract comprising the steps of: (i) weighing a specified quantity of a freeze-dried aloe powder, wherein the quantity is corrected for a moisture content, (ii) dissolving the freeze-dried aloe powder in deionized water to form a solution, (iii) adding an organic solvent to the solution to form a first mixture; wherein the organic solvent to the deionized water ratio is at least 2.5:1, (iv) allowing the first mixture to settle for at least 8 hours, (v) withdrawing a specified volume of a supernatant from the first mixture and adding an excess volume of the supernatant solution to form a second mixture, (vi) centrifuging the second mixture, (vii) observing for a presence of a precipitate in second mixture, (vii) adding an additional quantity of the organic solvent to first mixture if any precipitate is observed in second mixture, (viii) decanting the supernatant of first mixture by siphoning, wherein the decantation is done only if no precipitate is observed in second mixture, (ix) filtering the precipitate from first mixture by using a filter paper and a suction funnel under vacuum, (x) recovering the powder of the polymannan extract from the suction funnel by scraping, (xi) placing the powder of the polymannan extract in a capped lyophilization flask in a freezer for at least 8 hours, (xii) lyophilizing the frozen powder of the polymannan extract in a lyophilizer, and (xiii) grinding the lyophilized powder of the polymannan extract in a grinder to a very fine texture.
[0012] In one aspect the method further comprises the step of weighing, labeling, and storing the fine powder of the polymannan extract in a container. The freeze-dried aloe powder as described in the embodiment of the present invention is derived from an Aloe species selected from the group consisting of Aloe vera, Aloe arborescens, Aloe aristata, Aloe dichotoma, Aloe nyeriensis, Aloe variegate, Aloe barbadensis , and Aloe wildii . The freeze-dried aloe powder used in the present invention comprises aloe polysaccharides, wherein the aloe polysaccharides comprise one or more small chain, medium chain, large chain, very-large chain polysaccharides, or any combinations thereof. In a specific aspect the organic solvent is selected from the group consisting of methanol, ethanol, isopropyl alcohol, and propanol. In another aspect the aloe polysaccharides further comprise simple sugars, selected from the group consisting of glucose, mannose, arabinose, and galactose and have a molecular weight ranging from 11,500 Daltons to over 10,000,000 Daltons.
[0013] In another aspect the freeze-dried aloe powder has at least 25% of aloe polysaccharides. In yet another aspect the freeze-dried aloe powder has 25%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and 95% aloe polysaccharides. The freeze dried aloe powder as described in the method of the present invention comprises at least 14% of aloe polysaccharides having a molecular weight of 66,000 Daltons, at least 9% of aloe polysaccharides having a molecular weight of 480,000 Daltons, at least 3.5% of aloe polysaccharides having a molecular weight of 1,000,000 Daltons, at least 2.4% of aloe polysaccharides having a molecular weight of 2,000,000 Daltons.
[0014] In a specific aspect of the method relating to the aloe polysaccharide composition in the freeze dried aloe powder about 1.32%-6.36% of the aloe polysaccharides have a molecular weight of 2,000,000 Daltons, 2.55%-3.89% have a molecular weight of 1,000,000, and 63.85%-73.36%. of aloe polysaccharides have a molecular weight of 480,000 Daltons. In one aspect the freeze dried aloe powder may contain one or more residual small molecular weight species, selected from the group consisting of glucose, organic acids, lactic acid, malic acids, citric acids, and aspartic acid. In another aspect the one or more residual small molecular weight species are present in amounts ranging from 14%-24%. In yet another aspect the fine powder of the polymannan extract is used on the preparation of a pharmaceutical composition to be used in the treatment of one or more malignacies selected from the group consisting of leukemias and lymphomas, prostate cancer, breast cancer, and colon cancer, and for the treatment of one or more immune disorders.
[0015] In another embodiment the present invention discloses a sterile injectable formulation of a polymannan extract comprising: a specified quantity of very fine polymannan extract dissolved in deionized water and one or more pharmaceutical preservatives. The one or more pharmaceutical preservatives the may be used in the formulation described hereinabove is selected from the group consisting of parabens, benzoic acid and their salts, mercurials, quarternary ammonium salts, benzyl alcohol and other related alcohols, and phenols. In a specific aspect the preservative is benzyl alcohol. In one aspect the polymannan extract comprises aloe polysaccharides, wherein the aloe polysaccharides comprise one or more small chain, medium chain, large chain, very-large chain polysaccharides, or any combinations thereof. In another aspect the aloe polysaccharides further comprise simple sugars, selected from the group consisting of glucose, mannose, arabinose, and galactose.
[0016] In other specific aspects the aloe polysaccharides have a molecular weight ranging from 11,500 Daltons to over 10,000,000 Daltons and the polymannan extract has at least 25% of aloe polysaccharides, wherein the polymannan extract has 25%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and 95% aloe polysaccharides. In a related aspect the polymannan extract comprises at least 14% of aloe polysaccharides having a molecular weight of 66,000 Daltons, at least 9% have a molecular weight of 480,000 Daltons, at least 3.5% have a molecular weight of 1,000,000 Daltons, and at least 2.4% of aloe polysaccharides having a molecular weight of 2,000,000 Daltons. The composition of the present invention is used in the treatment of one or more cancers selected from the group consisting of leukemias and lymphomas, prostate cancer, breast cancer, and colon cancer, for immunomodulation, immunostimulation, or for the treatment of an individual with a compromised immune system or an immune disease. The composition of the present invention causes a 75-80% increase in one or more natural killer (NK) cells.
[0017] In yet another embodiment the present invention describes a treatment for one or more cancers selected from the group consisting of leukemias and lymphomas, prostate cancer, breast cancer, and colon cancer, comprising the steps of: identifying an individual in need of treatment against the one or more cancers and injecting a sterile injectable polymannan extract formulation two to three times in a week in a dosage sufficient to treat the one or more cancers, wherein the sterile injectable polymannan extract formulation comprises a specified quantity of very fine polymannan extract dissolved in deionized water; and one or more pharmaceutical preservatives. The method further comprises the steps of: withdrawing blood samples from the individual at one or more specified intervals and measuring a level of a caspase 3 protein in the blood and comparing the level obtained with the level prior to the injection, wherein an increased level in caspase 3 is directly related to an increased level of apoptosis of the one or more cancer cells.
[0018] In one aspect the dosage of the sterile injectable polymannan extract formulation is dependent on a weight, an age, an ethnicity, and a gender of the individual. In another aspect the polymannan extract comprises aloe polysaccharides, wherein the aloe polysaccharides comprise one or more small chain, medium chain, large chain, very-large chain polysaccharides, or any combinations thereof. In yet another aspect the aloe polysaccharides have a molecular weight ranging from 11,500 Daltons to over 10,000,000 Daltons. The polymannan extract as described in the method of the present invention has at least 25% of aloe polysaccharides. The polymannan extract of the method of the present invention causes a 75-80% increase in one or more natural killer (NK) cells.
[0019] In one embodiment the present invention discloses a method of immunomodulation or immunostimulation in an individual with a compromised immune system or an immune disease comprising the steps of: (i) identifying the individual with the compromised immune system or an immune disease and in need of immunomodulation or immunostimulation, (ii) administering intravenously a specified dosage of a sterile injectable polymannan extract formulation, wherein the sterile injectable polymannan extract formulation comprises a specified quantity of very fine polymannan extract dissolved in deionized water; and one or more pharmaceutical preservatives, wherein the dosage of the sterile injectable polymannan extract formulation is dependent on a weight, an age, an ethnicity, and a gender of the individual, (iii) withdrawing blood samples from the individual at one or more specified intervals, and measuring a level of a tumor necrosis factor-alpha (TNFα) in the blood and comparing the level obtained with the level prior to the injection; wherein an increased level in the TNFα indicates immunomodulation or immunostimulation. In a specific aspect the immune disease is an immune related neoplasm. In one aspect the polymannan extract comprises aloe polysaccharides, wherein the aloe polysaccharides comprise one or more small chain, medium chain, large chain, very-large chain polysaccharides, or any combinations thereof. In another aspect the polymannan extract causes a 75-80% increase in one or more natural killer (NK) cells. In yet another aspect the polymannan extract has at least 25% of aloe polysaccharides.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures and in which:
[0021] FIG. 1 shows a size-exclusion chromatogram of an aloe polysaccharide showing the retention times of the different glucose and mannose sub-units;
[0022] FIG. 2 shows the size-exclusion chromatogram of an aloe polysaccharide showing the peaks corresponding to the different glucose and mannose sub-units;
[0023] FIG. 3 is the proton-nuclear magnetic resonance profile of the polymannan extract of the present invention;
[0024] FIG. 4A is a HPLC chromatogram showing the amounts of polysaccharide in each polysaccharide molecular group in a methanol precipitated aloe polysaccharide concentrate;
[0025] FIG. 4B is the proton-nuclear magnetic resonance profile of a methanol precipitated aloe polysaccharide concentrate;
[0026] FIG. 5A is a HPLC chromatogram showing the amounts of polysaccharide in each polysaccharide molecular group in a ethanol precipitated aloe polysaccharide concentrate;
[0027] FIG. 5B is the proton-nuclear magnetic resonance profile of a ethanol precipitated aloe polysaccharide concentrate;
[0028] FIG. 6A is a HPLC chromatogram showing the amounts of polysaccharide in each polysaccharide molecular group in an isopropyl alcohol precipitated aloe polysaccharide concentrate;
[0029] FIG. 6B is the proton-nuclear magnetic resonance profile of an isopropyl alcohol precipitated aloe polysaccharide concentrate;
[0030] FIG. 7A is a HPLC chromatogram showing the amounts of polysaccharide in each polysaccharide molecular group in a propanol precipitated aloe polysaccharide concentrate; and
[0031] FIG. 7B is the proton-nuclear magnetic resonance profile of a propanol precipitated aloe polysaccharide concentrate.
DETAILED DESCRIPTION OF THE INVENTION
[0032] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
[0033] To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a”, “an” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.
[0034] The present invention describes a process for preparing a polymannan extract and the use of the said extract in the form of an injection as an immune stimulatory compound. Immune stimulation is assessed using macrophages/monocytes of human origin and the cell type is assessed for the secretion of tumor necrosis factor alpha (TNFα).
[0035] Aloe polysaccharides are generally considered to be those molecules composed predominantly of glucose and mannose simple sugars having chain lengths of 10,000 Daltons to those with molecular weights of 10,000,000 Daltons. The higher the mannose content and longer the chain length the greater is the immunomodulatory activity expressed by the polysaccharides. The different long, unbranched chains comprising these aloe polysaccharides are listed in Table 1.
[0000]
TABLE 1
Aloe polysaccharide compositions and pharmacological actions.
# of Sugar Residues
Mol. Wt (Daltons)
Pharmacological Actions
Small Chain
70-650
11,500->100,000
Diabetes
Polysaccharides
Tyrosinase inhibition (skin
lightening)
Anti-inflammatory activity
(Cox-2 inhibition)
Medium Chain
1500
250,000
Anti-oxidant
Polysaccharides
Protects heart, lungs
(emphysema), and nervous
system (Parkinsonism)
Large Chain
4000-5000
650,000
Antibacterial
Polysaccharides
Induction of healing
Very Large
8000-9000
2,000,000-10,000,000
Immunomodulatory
Polysaccharides
activity
Stimulation of β-
lymphocytes with the
elaboration of antibodies
Increasing level of natural
killer cells
Release of large quantities
of TNFα to cause
angiogenesis in wounds
and promotion of healing
[0036] Aloe polysaccharides with molecular weights of 100,000 Daltons or more are listed in Table 2.
[0000]
TABLE 2
Compositions and molecular weights of aloe polysaccharides
having Mol. Wts of 100,000 or greater.
Mol. Wt (Daltons)
Major Components
Aloeride
2,000,000-10,000,000
Arabinose, galactose,
glucose, mannose
Acemannan
900,000-1,500,000
Glucose, mannose
Manapol
500,000-900,000
Glucose, mannose
Aloemannan
100,000-500,000
Glucose, Mannose
[0037] The precursor material for the polymannan extract is described by the inventors in an previous patent (U.S. Pat. No. 6,083,508—Avalos and Danhof, 2000) titled “Method of Processing Aloe Leaves”. The certificate of analysis of the polymannan extract precursor material is presented in Table 3.
[0038] FIG. 1 is a size-exclusion chromatogram of an aloe polysaccharide preparation showing retention times of various-sized glucose and mannose subunits. FIG. 2 is a size-exclusion chromatogram of an aloe polysaccharide preparation identifying molecular weights ranging from 100 to 10,000,000 Daltons. FIG. 3 is the proton-nuclear magnetic resonance profile of the polymannan extract of the present invention. FIG. 3 shows: (i) the absence of the standard preservatives—sodium benzoate and potassium sorbate, (ii) the presence of smaller monohexoses, (iii) the peaks of isocitric acid indicating a whole leaf methodology was employed in processing the raw aloe material, (iv) the presence of malic acid peaks—a primary marker for Aloe vera , (v) the presence of the aloeride/acemannan peak in the polysaccharide portion of the profile confirming the presence of the large polysaccharide species, and (vi) acetyl groups are present confirming the presence of the partially acetylated polysaccharide glucomannans.
[0039] Size exclusion chromatography o(SEC)f an aloe preparation prior to polymannan extraction:
[0040] Equipment: HPLC system is a Hitachi L-7100 pump and 7250 autosampler paired to a Waters 410 differential refractometer. The SEC is a Tosoh Biosep G6000 PWXL TSK Gel 30 cm×7.8 mm operated in a column heater at 70° C. Molecular weight standards are from Sigma—2,000,000 Daltons, 1,000,000 Daltons, 480,000 Daltons, 66,000 Daltons, and 180 Daltons (glucose). The mobile phase is de-ionized water with flow rate of 0.70 mL/min. The injection volume is 10 uL. The SEC method is described by Pugh et al. (2001).
[0000]
TABLE 3
Certificate of analysis of Polymannan Extract Precursor Material.
Parameter
Constituent Range
Determined Value
Assessment
Powder:
Color:
White to light tan
Offwhite
Complies
Characteristics:
Finely granular
Finely granular
Complies
Rheology:
Free-flowing
Free-flowing
Complies
Taste:
Salty
Salty
Complies
Iodine test:
Negative
Negative
Complies
Moisture:
2.2-7.0%
3.70%
Complies
Solubility:
Complete
Complete
Complies
Minerals:
Ca ++
>25 mg/gram
56.3 mg/gram
Complies
Mg ++
>10 mg/gram
14.3 mg/gram
Complies
Organic Acids:
Citric:
Present
Present
Complies
Isocitric:
Present
Present
Complies
Lactic:
<25 mg/gram
12 ppm
Complies
Malic:
>250 mg/gram
410 mg/gram
Complies
Anthraquinones;
Aloin A:
<0.05 ppm
0.02 ppm
Complies
Aloin B:
<0.03 ppm
0.01 ppm
Complies
Aloe-emodin:
<0.02 ppm
0.005 ppm
Complies
Emodin:
<0.01 ppm
0.001 ppm
Complies
Brix Value:
<1.0
Negative
Complies
[0000]
TABLE 4
SEC results for aloe preparation prior to polymannan extraction.
Aloe
#09116
Refraction
Refractive
Molecular
Time
Index
Area
Σ Area
% Area
Size
0:30
0.0000
0.0000
1:00
0.0000
0.0000
1:30
0.0000
0.0000
2:00
0.0000
0.0000
2:30
0.0000
0.0000
3:00
0.0000
0.0000
3:30
0.0000
0.0000
4:00
0.0000
0.0000
4:30
0.0000
0.0000
5:00
0.0000
0.0000
5:30
0.0000
0.0000
6:00
0.0000
0.0000
6:30
0.0000
0.0000
7:00
0.0000
0.0000
7:30
0.0000
0.0000
8:00
0.0000
0.0000
8:30
0.0000
0.0000
9:00
0.0000
0.0000
9:30
0.0010
0.0014
10:00
0.0020
0.0046
10:30
0.0015
0.0058
0.012
2.44%
2 × 10 6
11:00
0.0010
0.0042
11:30
0.0015
0.0039
12:00
0.0015
0.0049
12:30
0.0015
0.0049
0.018
3.69%
1 × 10 6
13:00
0.0015
0.0049
13:30
0.0020
0.0056
14:00
0.0020
0.0065
14:30
0.0025
0.0072
15:00
0.0030
0.0088
15:30
0.0040
0.0111
0.044
9.09%
4.80 × 10 5
16:00
0.0050
0.0144
16:30
0.0055
0.0169
17:00
0.0060
0.0186
17:30
0.0070
0.0209
0.071
14.59%
6.6 × 10 4
18:00
0.0080
0.0241
18:30
0.0090
0.0274
19:00
0.0110
0.0320
19:30
0.0130
0.0385
20:00
0.0155
0.0457
20:30
0.0170
0.0524
21:00
0.0240
0.0649
21:30
0.0005
0.0457
22:00
0.0004
0.0015
22:30
0.0005
0.0014
23:00
0.0004
0.0015
23:30
0.0003
0.0012
24:00
0.0000
0.0000
0.340
70.20%
0.0000
0.4849
100.00%
[0041] Aloe precipitant evaluation study: 25 ml samples of COATS concentrated aloe were pipetted into 200 ml beakers and 125 ml of various polysaccharide precipitant liquids were added to the beaker and thoroughly stirred. The precipitated polysaccharides were collected by filtration through tared dehydrated filter papers which, following filtration, were placed in the drying oven overnight. The next morning the dry weight of the precipitated polysaccharide was determined. The inventors studied four alcoholic precipitants were studied including, methanol, ethanol, isopropyl alcohol, and propanol. The powders were passed through a HPLC procedure which determined the various quantities of all of the molecular species which was recorded with determination of the amounts of polysaccharides in each of the polysaccharide molecular groups, including greater than 2,000,000 Daltons, greater than 1,000,000 Daltons, greater than 480,000 Daltons, greater than 66,000 Daltons, and the residual fraction containing the very small molecular species, e.g. glucose having a M.W. of 180. (HPLC data shown in Tables 6-9). The HPLC chromatograms corresponding to the four precipitants methanol, ethanol, isopropyl alcohol, and propanol is shown in FIGS. 4A , 5 A, 6 A, and 7 A, respectively. Proton Nuclear Magnetic Resonance Profiles of the precipitates were also obtained and are shown in FIGS. 4B , 5 B, 6 B, and 7 B. The data collected is shown in Table 5.
[0000]
TABLE 5
Data from the aloe precipitant evaluation study.
M.W.
M.W.
M.W.
M.W.
6.6 ×
M.W.
Precipitant
2.0 × 10 6
1.0 × 10 6
4.8 × 10 5
10 4
Residual
METHANOL
6.36%
3.89%
68.56%
6.92%
14.27%
ETHANOL
2.52%
3.21%
70.70%
6.94%
16.57%
ISOPROPYL
1.32%
3.43%
73.36%
5.91%
15.99%
ALCOHOL
PROPANOL
2.74%
2.55%
63.85%
6.92%
23.94%
[0000]
TABLE 6
HPLC data showing the amounts of polysaccharide in each
polysaccharide molecular group in a methanol
precipitated aloe polysaccharide concentrate.
Aloe
#09423-A
Retention
Refractive
Molecular
Time
Index
Area
Σ Area
% Area
Size
0:30
0.0000
0.0000
1:00
0.0000
0.0000
1:30
0.0000
0.0000
2:00
0.0000
0.0000
2:30
0.0000
0.0000
3:00
0.0000
0.0000
3:30
0.0010
0.0014
4:00
0.0010
0.0033
4:30
0.0010
0.0033
5:00
0.0005
0.0026
5:30
0.0005
0.0016
6:00
0.0005
0.0016
6:30
0.0080
0.0119
7:00
0.0030
0.0191
0.045
6.36%
2 × 10 6
7:30
0.0020
0.0084
8:00
0.0030
0.0079
8:30
0.0040
0.0111
0.027
3.89%
1 × 10 6
9:00
0.0060
0.0158
9:30
0.0070
0.0209
10:00
0.0090
0.0255
10:30
0.0130
0.0348
11:00
0.0180
0.0491
11:30
0.0220
0.0640
12:00
0.0250
0.0756
12:30
0.0230
0.0785
13:00
0.0170
0.0665
13:30
0.0040
0.0374
14:00
0.0050
0.0144
0.482
68.56%
4.80 × 10 5
14:30
0.0050
0.0163
15:00
0.0050
0.0163
15:30
0.0050
0.0163
0.049
6.93%
6.6 × 10 4
16:00
0.0060
0.0176
16:30
0.0070
0.0209
17:00
0.0050
0.0200
17:30
0.0040
0.0149
18:00
0.0030
0.0116
18:30
0.0020
0.0084
19:00
0.0010
0.0051
19:30
0.0000
0.0019
20:00
0.0000
0.0000
20:30
0.0000
0.0000
21:00
0.0000
0.0000
21:30
0.0000
0.0000
22:00
0.0000
0.0000
22:30
0.0000
0.0000
23:00
0.0000
0.0000
23:30
0.0000
0.0000
24:00
0.0000
0.0000
0.100
14.27%
0.0000
0.7036
100.00%
[0000]
TABLE 7
HPLC data showing the amounts of polysaccharide in each
polysaccharide molecular group in an ethanol
precipitated aloe polysaccharide concentrate.
Aloe
#09423-B
Retention
Refractive
Molecular
Time
Index
Area
Σ Area
% Area
Size
0:30
0.0000
0.0000
1:00
0.0000
0.0000
1:30
0.0000
0.0000
2:00
0.0000
0.0000
2:30
0.0000
0.0000
3:00
0.0000
0.0000
3:30
0.0000
0.0000
4:00
0.0005
0.0007
4:30
0.0010
0.0023
5:00
0.0005
0.0026
5:30
0.0005
0.0016
6:00
0.0010
0.0023
6:30
0.0010
0.0033
7:00
0.0015
0.0039
0.017
2.52%
2 × 10 6
7:30
0.0020
0.0056
8:00
0.0020
0.0065
8:30
0.0040
0.0093
0.021
3.21%
1 × 10 6
9:00
0.0050
0.0144
9:30
0.0070
0.0190
10:00
0.0100
0.0269
10:30
0.0130
0.0366
11:00
0.0160
0.0464
11:30
0.0200
0.0575
12:00
0.0240
0.0705
12:30
0.0210
0.0739
13:00
0.0185
0.0648
13:30
0.0050
0.0416
14:00
0.0060
0.0176
0.469
70.76%
4.80 × 10 5
14:30
0.0050
0.0181
15:00
0.0040
0.0149
15:30
0.0040
0.0130
0.046
6.94%
6.6 × 10 4
16:00
0.0050
0.0144
16:30
0.0075
0.0197
17:00
0.0080
0.0251
17:30
0.0035
0.0198
18:00
0.0025
0.0100
18:30
0.0050
0.0116
19:00
0.0000
0.0094
19:30
0.0000
0.0000
20:00
0.0000
0.0000
20:30
0.0000
0.0000
21:00
0.0000
0.0000
21:30
0.0000
0.0000
22:00
0.0000
0.0000
22:30
0.0000
0.0000
23:00
0.0000
0.0000
23:30
0.0000
0.0000
24:00
0.0000
0.0000
0.110
16.57%
0.0000
0.6630
100.00%
[0000]
TABLE 8
HPLC data showing the amounts of polysaccharide in each
polysaccharide molecular group in an isopropyl alcohol
precipitated aloe polysaccharide concentrate.
Aloe
#09423-C
Retention
Refractive
Molecular
Time
Index
Area
Σ Area
% Area
Size
0:30
0.0000
0.0000
1:00
0.0000
0.0000
1:30
0.0000
0.0000
2:00
0.0000
0.0000
2:30
0.0001
0.0001
3:00
0.0000
0.0002
3:30
0.0000
0.0000
4:00
0.0000
0.0000
4:30
0.0001
0.0001
5:00
0.0001
0.0003
5:30
0.0001
0.0003
6:00
0.0001
0.0003
6:30
0.0015
0.0023
7:00
0.0015
0.0049
0.009
1.32%
2 × 10 6
7:30
0.0020
0.0056
8:00
0.0025
0.0072
8:30
0.0035
0.0095
0.022
3.43%
1 × 10 6
9:00
0.0060
0.0148
9:30
0.0080
0.0223
10:00
0.0095
0.0281
10:30
0.0120
0.0343
11:00
0.0165
0.0452
11:30
0.0190
0.0571
12:00
0.0200
0.0631
12:30
0.0215
0.0671
13:00
0.0200
0.0678
13:30
0.0100
0.0513
14:00
0.0045
0.0249
0.476
73.36%
4.80 × 10 5
14:30
0.0040
0.0139
15:00
0.0035
0.0123
15:30
0.0040
0.0121
0.038
5.91%
6.6 × 10 4
16:00
0.0065
0.0164
16:30
0.0096
0.0254
17:00
0.0075
0.0283
17:30
0.0030
0.0182
18:00
0.0020
0.0084
18:30
0.0010
0.0051
19:00
0.0000
0.0019
19:30
0.0000
0.0000
20:00
0.0000
0.0000
20:30
0.0000
0.0000
21:00
0.0000
0.0000
21:30
0.0000
0.0000
22:00
0.0000
0.0000
22:30
0.0000
0.0000
23:00
0.0000
0.0000
23:30
0.0000
0.0000
24:00
0.0000
0.0000
0.104
15.99%
0.0000
0.6487
100.00%
[0000]
TABLE 9
HPLC data showing the amounts of polysaccharide in each
polysaccharide molecular group in a propanol
precipitated aloe polysaccharide concentrate.
Aloe
#09423-C
Retention
Refractive
Molecular
Time
Index
Area
Σ Area
% Area
Size
0:30
0.0000
0.0000
1:00
0.0000
0.0000
1:30
0.0000
0.0000
2:00
0.0000
0.0000
2:30
0.0001
0.0001
3:00
0.0000
0.0002
3:30
0.0000
0.0000
4:00
0.0000
0.0000
4:30
0.0001
0.0001
5:00
0.0001
0.0003
5:30
0.0001
0.0003
6:00
0.0001
0.0003
6:30
0.0015
0.0023
7:00
0.0015
0.0049
0.009
1.32%
2 × 10 6
7:30
0.0020
0.0056
8:00
0.0025
0.0072
8:30
0.0035
0.0095
0.022
3.43%
1 × 10 6
9:00
0.0060
0.0148
9:30
0.0080
0.0223
10:00
0.0095
0.0281
10:30
0.0120
0.0343
11:00
0.0165
0.0452
11:30
0.0190
0.0571
12:00
0.0200
0.0631
12:30
0.0215
0.0671
13:00
0.0200
0.0678
13:30
0.0100
0.0513
14:00
0.0045
0.0249
0.476
73.36%
4.80 × 10 5
14:30
0.0040
0.0139
15:00
0.0035
0.0123
15:30
0.0040
0.0121
0.038
5.91%
6.6 × 10 4
16:00
0.0065
0.0164
16:30
0.0096
0.0254
17:00
0.0075
0.0283
17:30
0.0030
0.0182
18:00
0.0020
0.0084
18:30
0.0010
0.0051
19:00
0.0000
0.0019
19:30
0.0000
0.0000
20:00
0.0000
0.0000
20:30
0.0000
0.0000
21:00
0.0000
0.0000
21:30
0.0000
0.0000
22:00
0.0000
0.0000
22:30
0.0000
0.0000
23:00
0.0000
0.0000
23:30
0.0000
0.0000
24:00
0.0000
0.0000
0.104
15.99%
0.0000
0.6487
100.00%
[0042] The polymannan extract is prepared by precipitation. The freeze dried aloe powder is described above was weighed after correcting appropriately for the moisture content. For example, if the moisture content is 3.7% and we need 80 gms, the inventors weighed out 82. 96 gms (80 gms+(3.7%×80) gms). The weighed aloe powder was dissolved completely in one gallon of deionized water (D.I) in a stainless steel precipitation vessel. 2.5 gallons of 95% ethanol was added and stirred to ensure complete mixing. The vessel was covered with a stainless steel lid and the mixture was allowed to settle overnight.
[0043] The following day a 2 ml of clear supernatant was taken and 5 mL of 95% ethanol was added and the sample was centrifuged at 3000 rpm for 20 minutes. The sample was examined for precipitation, if no precipitate was observed then the precipitation was considered complete. If any significant degree of precipitation was observed then additional 95% ethanol was added to the precipitation vessel before proceeding. The clear supernatant fluid in the precipitation vessel was decanted by siphoning without disturbing the precipitate at the bottom of the vessel. The white precipitate at the bottom was separated by using a suction funnel (Whatman No. 42® quantitative ashless filter paper. The precipitated material was removed by scraping it into a 600 ml Virtis lyophilization flask, and by distributing the material over one side of the flask to form a thin layer with a large exposed surface area. The lyophilization flask was placed in a shell-freezer overnight. The next day the chilled lyophilization flask with its frozen contents, was placed on a lyophilizer operating at −90° C. and at ⅓ atmosphere for 24 hours. The lyophizer was turned off and the lyophilized powder was placed into a small powder grinder until it reduced to an evenly ground fine powder. The ground powder was weighed and placed in plastic small containers and the containers were stored in a freezer.
[0044] Preparation of an injectable solution of Polymannan extract: The polymannan extract powder (PME) prepared as described above was weighed (1.5 gms) after correcting for moisture content and having an aloeride content of at least 2% as determined by size exclusion chromatography. To 125 ml of warm D.I water 1 ml of concentrated HCl was added and stirred followed by the slow addition of the PME powder with constant stirring. The stirring was continued till all the PME powder dissolved and the solution was clear and colorless an additional amount of concentrated HCl was added to obtain a pH of 1.6 to 1.7 (measured continuously using a pH meter). Additional D.I water was added to adjust the volume to 150 ml followed by a pH monitoring to ensure a pH of 1.6-1.7. The PME solution was then poured into a Corning® 150 ml filter system flask with a pore size of 0.45 μm. The flask system was placed in a refrigerator and the filtrate was transferred to a Corning® 150 ml filter system flask with a pore size of 0.22 μm and placed in a refrigerator overnight. Under sterile conditions the filter top of the filter system was removed and the bottle was sealed with a sterile cap. The bottles were them transferred to a compounding lab, and under a sterile hood 0.9% benzyl alcohol was added as a preservative (because the final product is for multi-dosage use), and the solution was placed in sterile 10 mL glass vials and sealed with a multidosage closure. The vials are labeled with a batch number, control number, manufacturing date, expiration date of 6 months along with the names of the physician and patient.
[0045] PME immunomodulatory activity assessment: The immune stimulatory activity is assessed using macrophages/monocytes of human origin obtained from the American Type Culture Collection (ATCC) in Maryland. The cell type was assessed for the secretion of TNFα. Under standard cell conditions a small amount of the final PME product was introduced in the culture. Samples were drawn at 6, 12, and 24 hours and assessed for TNFαlevels. A specific quantity of TNFα was not used because of the variability in the different cell batches. In a clinical setting the immunomodulatory response is expected to vary due to changing hemotological factors like the total leukocyte count, differential macrophage/monocyte count, number of surface mannose receptors on the white cells, amount of mannose-binding carrier protein, etc.
[0046] The white blood cell profile varies with cells constantly entering and leaving the blood stream. The affinity of the cellular mannose receptors for the PME far exceeds that of the mannose binding protein. As new macrophages/monocytes enter the blood stream, the PME is transferred to the new cells from the circulating mannose-binding protein. PME binding to the macrophage/monocyte mannose-binding protein results in the release of an array of cytocommunicators. The cytocommunicators including TNF-α, IL-1β, INF-γ, IL-2, and IL-6 restore to normal the impaired surveillance function of the immune system which had failed in its neoplasm detection function in the cancer patient permitting the patient's immune system of identifying and removing the malignant cells.
[0047] Aloe polysaccharides in the polymannan extract having molecular weights of 1,000,000, 300,000, 100,000, 50,000 and 25,000 all showed caspase activity. This caspase 3, caspase 9, and cytochrome-C activity is key in the treatment of malignancies by the composition of the present invention, as caspase 3 is a mediator of tumor cell apoptosis. The immune modulatory activity of initiator (apical) caspase 3 and effector (executioner) caspase 3 as well as cytochrome-C have been demonstrated as being extant and are considered to be the mediator system of tumor cell apoptosis.
[0048] The inventors tested the composition described herein on 104 patients with different types of cancers. Leukemia and lymphomas were most responsive to the polymannan extract of the present invention (>98%). Prostate, breast, and colon cancers were also responsive to the polymannan extract of the present invention. For the testing the polyamman extract was adminsiteres as an injection. 10 mg of the polymannan extract was reconstituted in sterile water for injection to give a final concentration of ˜10 mg/mL. This was injected 2 to 3 times a week. The serum samples from the patients were then taken at regular intervals and monitored for caspase 3 activity.
[0049] It is contemplated that any embodiment discussed in this specification can be implemented with respect to any method, kit, reagent, or composition of the invention, and vice versa. Furthermore, compositions of the invention can be used to achieve methods of the invention.
[0050] It will be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention can be employed in various embodiments without departing from the scope of the invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.
[0051] All publications and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
[0052] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.” Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.
[0053] As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
[0054] The term “or combinations thereof” as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof” is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, MB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.
[0055] All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.
REFERENCES
[0000]
U.S. Pat. No. 7,196,072: High Molecular Weight Polysaccharide Fraction From Aloe Vera with Immunostimulatory Activity.
U.S. Pat. No. 6,083,508: Method of Processing Aloe Leaves.
United States Patent Application No. 2006/0084629: Immune System Activating Formula Composed of Selected Long Chain Polysaccharides From Natural Sources.
[0059] 1 Pugh N., Ross S. A., ElSohly M. A., and Pasco, D. S. (2001). Characterization of Aloeride, a new high-molecular weight polysaccharide from Aloe vera with potent immunomodulatory activity. J. Agr. Food Chem., 49, 1030-1034.
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The present invention describes a method for preparing a polymannan extract from freeze-dried aloe powder. The polymannan extract of the present invention is further used to formulate a sterile injectable formulation for the treatment of one or more cancers, leukemias and lymphomas, prostate cancer, breast cancer, and colon cancer, immune diseases, particularly immune related neoplasms, acquired immune deficiency syndrome, and hepatitis C.
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BACKGROUND OF THE INVENTION
The invention relates to a method for the fabrication of dimensionally stable, cylindrical bodies, consisting of foil-like, preferably corrosion resistant material strips, especially consisting of metal, paper, paper board, synthetic material or a combination by coating, for increasing surface area in receptacles, as well as to an apparatus for the performance of the method.
The invention also relates to a method of preventing explosive combustions in fuel and gas tanks, to fuel and gas tanks protected against explosions and to a filler body for the installation into receptacles for liquid or gaseous combustibles.
Expanded metal is used for various purposes, e.g. to fill containers for combustible liquids or gases, in particular fuel and solvents, to prevent explosion-like combustions. At the beginning, the expanded metal used for these purposes has been made from very thin aluminum foil of a thickness of about 40 mm.
Apparatus for providing such expanded metal generally make use of knives arranged transversely to the conveying direction of the foil so as to provide small cuts transverse to the conveying direction. Stretching of the foil is obtained by operating the discharge unit of the apparatus at a speed higher than the speed of the feed unit so that the foil is stretched in the conveying direction.
The expanded metal obtained in such a manner has only limited dimensional stability so that the filling of such expanded metal of e.g. automobile gasoline tanks, balls together after a short period resulting in a loss of its explosion-preventing property.
It has therefore been proposed to produce expanded metal from thicker aluminum foils, e.g. with a thickness of 65 to 85 mm. However, as it turned out, the above-described apparatus could not be used with such aluminum foils as their thickness was too high to provide an expansion in the longitudinal direction of the foil provided with transverse cuts simply by increasing the discharge speed relative to the supply speed.
From the German patent 749 689 an apparatus for cutting off wire-like strips from a foil is known in which a cutting unit includes a stationary knife edge and a knife which is designed as a milling cutter and is provided with cutting edges. The continuous cuts as provided by the unit extend perpendicular to the conveying direction of the foil.
The British patent 1 590 636 discloses an apparatus for profiling metal foils including a pair of rollers having a distance from each other which is smaller than the thickness of the foil to be profiled. In addition, the rollers have a length which is smaller than the width of the foil so that a partial expansion of the foil is obtained in the longitudinal direction during its passage through the pair of rollers. Arranged downstream of the apparatus is a further pair of profiled rollers which provides a profile transverse to the longitudinal direction of the foil in the respective expanded area.
The disadvantage of incorporating a block of the expanded aluminum foil in a fuel receptacle or tank, however, is that the dimensions of the expanded metal body make it difficult to remove the body even with deformation and distortion thereof or make it impossible to remove the body from the tank. Such a removal of the filler from the tank may become necessary or desirable for cleaning of the tank or for repair thereof.
In addition, it has been impossible to introduce conventional tank filler bodies of expanded metal into already fabricated fuel tanks or receptacles, also because of the dimensional factors mentioned previously.
U.S. Pat. No. 4,613,054 discloses a known apparatus for the shaping of dimensionally stable, bale shaped bodies out of thin-fibrous material. At this, the thin fibrous or stretched metal to be formed is furnished in a bunched condition to a cutting and pressing device, wherein a guiding device and a clamping arrangement is added to the cutting device which is back and forth movable to the conveying direction of the bunched metal material. The cutting device consists of an opposite-direction-moving cutter, placed transverse to the conveying direction of the metal material. The blades are formed by round-holes, through which the metal material is led and then cut off. By pressurization and forming, the form body is created. Clamp segments are formed by hydraulic moveable clamp forcers.
U.S. Pat. No. 4,621,397 discloses a known apparatus for producing expanded metal, wherein the foil first of all receives intermittent cuts, is led into roll pairs which are twisted by toothed belts and is gripped at its borders in the intermeshing teeth. A primary shoe serves to stretch the slit cut foil to the breadth. The primary shoe is placed as a fixed part in the stretching device and presents an adjusted shaping at the contact point with the expanded foil.
It is disadvantageous that the first kind of appliance consists predominantly of oscillating parts--like the cutting device and the gripping arrangement--and that a continuous development of shaping is not given. The production of such form bodies is time-consuming and uneconomical. In the further mentioned case, it is disadvantageous that these primary shoes respectively are fixed parts over which the expanded material is gliding, leaving particles of dust caused by abrasion which are dragged along as impurity. Moreover, a homogenous extension is not possible.
A further resulting disadvantage is that the received filler bodies are hollow or concave with a limited stability which allows an easy compression of the same.
SUMMARY OF THE INVENTION
The principal object of this invention is to provide a filler body for increasing surface area in receptacles in order to prevent explosive combustion in these equipped receptacles when filled with combustible liquids or gases.
Proceeding from the state of the art mentioned-above, for this invention, the task was to develop a method which allows a continuous production of expanded material without oscillating masses in the machine parts. Further, no fixed and abradant elements should be contained in order to guarantee an exact extension over the total breadth of the expanded material. According to the invention, this aim is reached by a foil strip, which receives perforated cutting spots, staggered transverse to the conveying direction, the cutting spots stretched to the breadth and folded, lopped in pieces, cylindrically bent round, twisted at the ends and continuously rolled into cylindrical form bodies.
Since an economic production of huge amounts of cylindrical bodies formed of expanded material is therefore possible and these can fill gas or fuel tanks, explosive combustion can be prevented.
So the general object of the invention is to overcome drawbacks and disadvantages of prior art systems while being able to achieve production even more economically.
The invention relates to a method of and an apparatus for the performance of the method for the fabrication of dimensionally stable, cylindrical bodies, consisting of foil-like, preferably corrosion resistant material strips, especially consisting of metal, paper, paper board, synthetic material or a combination by coating, which allows a continuous fabrication without having oscillating masses in the machine parts.
The aim is reached by a foil strip which receives perforated cutting spots, staggered transverse to the conveying direction, the cutting spots stretched to the breadth and folded, lopped in pieces, cylindrically bent round, twisted at the ends and continuously rolled into cylindrical form bodies.
This method for the production of form bodies in huge amounts is, after a further formation, used advantageously, if the foil strip gets an extension of preferably threefold breadth, the same is folded to a double, preferably threefold formed body, wherein the lopped, multilayered formed bodies, as cylindrical parts, have a length which corresponds to double the diameter.
Further it is advantageous, if for the performance of the method, an arrangement is designated, presenting a cutting, stretching and rolling device, the cutting device consisting of superimposed rollers, on the one hand consisting of discoid, even top cutting knives and washers machined to close tolerances and on the other hand of further bottom cutting knives, which present alternating on the side in the cutting region recesses and the distances to these recesses form the cut length.
It is additionally advantageous, if the stretching device consists of superimposed deflection roller pairs, the driving elements, preferably twisted by toothed belts having teeth directed radially to the outside, are looped, and these teeth grippingly retain the borders of the foil strip during progressive movement, wherein a primary shoe, e.g. a bow-shaped tension spring or a roll, movable on a spindle, slewable over a swivel fixed pivot bracket, located between the deflection roller pairs foil lengthwise, stretches the perforated foil strip in C-form to the breadth.
According to another advantageous embodiment, the roll consists of at least two roll halves, preferably four roll halves, with inclining diameter to the outside from the roll middle and independently rotatable with respect to one another and axially movable on a spindle. The rolls or roll halves present on the running surface, turned to the stretch material, an approximately axially directed profiling and/or contains a glide-favoring coating, wherein the roll halves are formed as concave shells or wire bodies, while a concave shell contains a connection element, e.g. a ring or webs, which allows a contraction in the middle part of the stretch material.
A further advantage is achieved if the top toothed belt, being connected by meshing with the bottom toothed belt is drivable through the bottom deflection rollers with the intermediary driving pinion and motor, wherein the roll or the roll halves are running on bearings as loose rolls and are movable with the movement of the stretch material strip frictionally engaged or if according to the solidity of the expanded material a synchronous actuation is intended therefor.
It is also advantageous, if in the rolling device, the foil strip is led through the nozzle overlapping, preferably threefold, and deflected over a needle roller to a pair of knives, e.g. an unremovable top knife and a bottom knife, fixed in a drum, rotating with it and lopping the foil strip in equal pieces.
Further, it is advantageous if the rotating drum has a recess, out of which the material is directable radially to the outside, with the shell forming an annulus, the annulus progressively reducing in size by virtue of a rolling frame arranged in helix form at the generated surface of the drum, wherein the cylindrical lopped pieces are twisted by a baffle e.g. a pressing cloth or like narrowing means and cylindrically rolled by the rough surface of the annulus wall.
In this way, the present invention achieves use of this method for the fabrication of cylindrical form bodies, and a continuous development is guaranteed and a production of huge amounts of these form bodies is possible using simple means.
It is further achieved, that the cylindrical filling bodies have more stability and cause less loss of volume than the mentioned former filler bodies according to U.S. Pat. No. 4,613,054 which are hollow and concave and easily compressible.
BRIEF DESCRIPTION OF THE DRAWINGS
By means of an example of operation, the invention will be illustrated in the figures as follows:
FIG. 1 schematically illustrates the apparatus of the present invention.
FIG. 2 schematically illustrates a cutting device according to the invention.
FIG. 3 schematically illustrates a horizontal view of the cutting device.
FIG. 4 schematically illustrates a stretching device according to the invention.
FIG. 5 schematically illustrates a horizontal view of a primary shoe.
FIGS. 6a and 6b schematically illustrate formation of the toothed belt.
FIG. 7 schematically illustrates a profile foil strip.
FIG. 8 schematically illustrates a rolling device.
FIG. 9 schematically illustrates a horizontal view of the rolling device.
FIG. 10 schematically illustrates an arrangement of lopping knives.
FIG. 11 is a side view of a stretching device.
FIG. 12 is a cross-section of the apparatus of the present invention.
FIG. 13 illustrates formation of the roll.
FIG. 14 illustrates further formation of the roll.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As FIG. 1 shows, the process of fabrication of dimensionally stable cylindrical bodies is schematically projected by the performance of the process. The foil strip 1 is led in the conveying direction 10 to the cutting device 2. This cutting device includes superimposed cutting knives 3 with washers machined to close tolerances 4 and the underneath cutting knives 5, forming a roller, consisting of several layers and set on a shaft. Further, on the same shaft, there is fixed the driving motor 6 in the bottom part of the underneath cutting knives 5. The cutting knives 5 are therefore driven and by adhesion traction, the top cutting knives are also moved.
At the connection of the cutting device 2, there is designated a fastening device 7. This includes deflection rollers 8, arranged in such manner that the foil strip 1 is drawn downward. The foil strip 1 gets the necessary initial tension from a tensioning spring 9.
After that, the stretching device 11 is connected, which fixes the foil strip 1 on both sides approximately in the middle of the deflection rollers 14a. Over the top deflection rollers 14a, a tooth belt 12 is twisted at both sides. The bottom deflection rollers 14b are placed at the same spot as the top deflection rollers 14a, however, on the rear side of the foil strip 1. Moreover, additional deflection rollers 14c serve to set the driving motor 15a between the bottom deflection rollers 14c. The toothed belts 12 and 13 have radially to the outside directed teeth. As the motor 15a is placed between the lowest deflection rollers 14c, the motor 15a, actually its driving pinion 15, can intermesh in the toothed belt 13, because the angle of belt wrap is big enough. The top toothed belt 12 now runs with the bottom toothed belt 13, and the borders of the foil strip 1 are placed intermediately. The motor 15a therefore drives the bottom toothed belt 13, the top toothed belt 12 and the intermediately gripped borders of the foil strip 1.
After the foil strip 1 has been perforated in the cutting device 2, the foil strip 1 is led over a tension spring 16 or a similar stretching element as a primary shoe under retention of the border fixing so that the foil strip 1 will be expanded to the preferably threefold breadth to the foil strip 1a. The c-shaped expanded foil strip 1a leaves the stretching device 11.
The rolling device 17 consists of a shell 25 which has an opening 18. Here the expanded foil strip comes to the nozzle 19. This effects a rolling or folding e.g. to a three-layered bundle. A driven needle roll 20 carries out the transport of the now bundled foil 1b and directs the same to a drum 23. Fixed to the shell, a top knife 21 is attached, while at the rotating drum 23 the bottom knife 22 is fixed. On the outside of the drum 23, a helix shaped projecting rolling web 30 is provided and the cylindrical lopped pieces 31 are formed to cylindrical bodies 31a. Over the ejection slot 26, the material gets into the collecting box 35.
In FIG. 2, the formation and mode of operation of the cutting device 2 is shown in more detail. The top cutting knife 3 is formed as an even disc and smaller in diameter, while the washers 4 are fixed in alternating order on a spindle 29. The bottom cutting knife 5 is in the same way provided with washers 4 of the same width, wherein both cutting knives 3, 5 are overlapping, i.e. forming a pair of staggered knives. The bottom cutting knife 5 now has the same number of recesses 27, 28 on both sides, proportionally distributed on the perimeter of the cutting edge.
FIG. 3 shows the horizontal projection on the cutting device 2, particularly on the cutting knives 5. The recesses 27, 28, which are staggered on both sides, can be seen here. The number of cutting knives 5 and washers 4 corresponds at least to the breadth of the foil strip 1. These cutting knives 5 are mounted on the spindle 29. The same refers to the top cutting knives 3.
FIG. 4 illustrates the stretching device 11. Top deflection rollers 14a and bottom deflection rollers 14b are twisted by toothed belts 12, 13. At this point the teeth 12a, 13a are directed to the outside. The bottom toothed belt 13 is somewhat longer, so that further deflection rollers 14c can be installed. Further, there is a driving pinion 15 with a motor 15a placed between the deflection rollers 14c. In the clearance zone between the deflection rollers 14a, 14b and the following deflection rollers in the conveying direction, an additional primary shoe 16, as e.g. a spring bow or the like is placed pointing upward with a bowed end. The vertical axle bases of the deflection rollers 14a, 14b are so designed that the toothed belts 12, 13 are permanently in gear, fixing the borders of the foil strip 1. If the motor 15a is now set in motion, the foil strip 1 moves over the stretching device 16 and such expands the foil strip 1a to an approximately threefold breadth.
FIG. 5 shows the horizontal extent of the stretching device 11. The wheel gauge of the deflection rollers 14a, 14b is dimensioned so that the foil strip 1 is only gripped at the borders. The primary shoe 16 is here designed as a spring bow.
FIGS. 6a and 6b show a clipping of the toothed belts 12, 13 with the intermediary foil strip 1. In this connection it is essential that the lateral faces of the teeth have an angle of e.g. 60° to guarantee a tight gripping of the foil strip 1.
FIG. 7 shows in profile the expanded foil strip 1a, which now has achieved a c-shaped configuration having a threefold breadth compared to the former foil strip 1.
In FIG. 8 the rolling device is specified. At the top section of the shell 25, there is an opening 18, and in back of it, the nozzle 19. Here the foil strip 1a is rolled up to become an approximately three-layered foil strip 1b. With the aid of a needle roller 20 with actuation, the advance of the foil strip 1b follows and is deflected downward by 90°. In the bottom section, a drum 23 is placed which can be rotated by a motor 24. Fixed to the shell there is a top knife 21 while the bottom knife is fixed with the rotating drum 23. At the outside of the drum, a helix shaped upwardly pointing rolling web 30 is fixed. Together, the rolling web 30, drum 23, and shell 25 define an annulus 32 in which the lopped pieces 31 are picked up and rolled up cylindrically. As the looped pieces are rolled, the web 30 progressively compresses the ends of the lopped pieces. The lopped pieces 31 are approximately double of the diameter in length. The annulus 32 is designed so as to narrow by degree, so that the lopped pieces 31 take on a cylindrical shape and are put out through the ejection slot 26.
FIG. 9 shows the horizontal extent of the rolling device 17. The foil strip 1a is fed over the nozzle 19 into the shell 25 as foil strip 1b, deflected downward by the needle roller 20 and supplied to the cutting knives 21, 22. With the aid of the pressing cloth 33, a baffle or like narrowing means, which projects from the drum 23 into the annulus 32, the lopped pieces 31 are rolled up. The output ensues through the ejection slot 26.
FIG. 10 shows, in an enlarged manner, a clipping of the drum 23, particularly the position of the shell-fixed top knife 21 and the placement of the bottom knife 22 which rotates with the drum 23. These are placed in a vertex angle overlapping at the ends to obtain an efficient shear effect. In the drum 23, there is an additional recess 34 which conveys the lopped pieces 31 into the annulus 32. With the aid of movable baffles, e.g. a pressing cloth or like narrowing means, a rolling motion is imparted upon the lopped pieces 31. The lopped pieces 31 coming out of the drum 23 lay themselves on the inner surface of the shell 25. Favored by the rough surface of the wall of the annulus 32, they are taken by the baffle at the top and rolled up. At this point, the ends of the lopped pieces 31 are twisted, i.e compressed and finally rolled up to quadratic cylinders. By virtue of the narrowing slot height, a rolling of the coiled lopped pieces 31 ensues between the moving helix surfaces and the shell bottom around an axis, vertical to the drum axis, by which the coil is formed into a quadratic cylinder.
A further formation of the stretching device is illustrated in the side view of FIG. 11. The roll 36 is movable on the spindle 40, slewable over a swivel fixed pivot bracket 37. On the other end, the pivot bracket 37 is supported by a pillow block 39 and allows in a certain section according to arrow 38 a horizontal swing around the center of motion of the pillow block 39. Further, respective deflection rollers 43, 44 are placed before and after the roll 36, wherein around the top deflection rollers 43 a toothed belt 12 is twisted. Likewise, there is also a toothed belt 13 twisted around the bottom deflection rollers 44. Both toothed belts 12, 13 respectively have teeth 12a, 13a directed to the outside and are permanently in gear between the axes 41, 42 and the deflection rollers 43, 44. The axis distances between the axes 41, 42 in the vertical direction are chosen such that the expanded material 1a is gripped at the borders. By actuation, the bottom toothed belt 13 (in FIG. 11 to the right side) is set in motion, wherein the top toothed belt 12 is also moved by gearing. Likewise, the stretch material 1 is transported according to arrow 10. If the stretch material 1 is now moved forward and at first gripped between the deflection rollers 43, 44 by the toothed belts 12, 13, it must be led over a baffle, which is represented by roll 36. Consequently, the stretch material 1 is expanded into breadth and brought out of the stretching device 11. The toothed belts 12, 13 consist of webbed plastic or rubber. However, if a stretch material e.g. out of stainless metal is chosen, it is important to use toothed chains instead of toothed belts, which additionally have clamps on each chain link. Since such chains are commercially known, a detailed description is not necessary. It is essential that the loose roll 36, according to arrow 36a be turned synchronously with the stretch material 1 and be frictionally engaged without relative movement. If the friction should not be sufficient, a synchronously running actuation can also be used.
FIG. 12 shows the cross section of the stretching device specified in FIG. 11. The roll 36 is movable on the spindle 40, and is slewable over a swivel fixed pivot bracket 37 according to arrow 38. Collateral are the deflection rollers 43, 44, which are fixed movably around their axes 41, 42. Around the deflection rollers 43, 44 the toothed belts 12, 13 are running. The stretching material is gripped at the borders intermediately. Here it can be seen that the stretching material 1 is led over the roll 36 and gets its lateral expansion by that.
FIG. 13 shows the further formation of roll 36 as a separated roll 45, which ensures that the stretch material 1a is stretched homogeneously over the whole breadth. Here it is advantageous if the roll 36 consists of roll halves 46, 47, which furthermore are axially movable on the spindle 40. By that, the expansion can be prescribed exactly, which is of importance to the quality of the product. It is further of advantage, to place additional smaller roller halves 48, 49 collateral to the roller halves 46, 47 to obtain exact expansion and support also in the side section directed to the gripping spot. Also these roll halves 48, 49 are axially movable on the spindle 40. The roll 36, or specifically the roll halves 46, 47 and 48, 49 present a profiling 50 on the running surface, turned toward the expanded material 1a and/or contains a glide-favoring coating. It is thereby guaranteed that the expanded material 1a results in a homogenous expansion pattern.
Finally, a further variant is illustrated in FIG. 14, which contains a loose roll 55, which is formed out of concave shells 51, 52 or wire bodies. At a concave shell 51, 52, a connection element 53 is provided in the form of a ring or several webs and which is welded on the same, while the connection element 53 is axially movable as guidance in the concave shell 51. By that, it is possible to exercise an influence on the stretching of the expanded material 1a and to force a contraction. That is important in that for the pleating of the expanded material 1a, a favorable initial point is obtained. By using this formation of the stretching device, it is possible to achieve over the total breadth of the stretch material a homogenous expansion which is decisive for the further processing to quadratic cylinders for subsequent installation into gas or fuel tanks or other vessels. A continuous fabrication of the form bodies in huge amounts without oscillating masses of the machine parts is therefore possible.
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A method of and an apparatus for the performance of the method for the fabrication of dimensionally stable, cylindrical filler bodies for increasing the surface area in receptacles, e.g. for the protection against explosive combustions, consisting of foil-like, preferably corrosion resistant material strips, especially consisting of metal, paper, paper board, synthetic material or a combination by coating, which allows a continous fabrication without requiring oscillating masses in the machine parts. The aim is reached by a foil strip which receives perforated cutting spots, staggered transverse to the conveying direction, the cutting spots stretched to the breadth and folded, lopped in pieces, cylindrically bent so as to be round, twisted at the ends and continously rolled into cylindrical bodies.
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BACKGROUND OF THE INVENTION
[0001] Some downhole operations, such as cutting a tubular structure, for example, can be improved by centering a tool within the tubular structure that carries out the operation. Cutters often have a plurality of knives, typically from two to five, that extend radially outwardly (or inwardly depending upon the specific application being cut) to engage the tubular structure being cut. The cutter rotates relative to the tubular structure being cut while the knives extend radially outwardly to thereby engage and cut through the wall of the tubular structure. If the cutter is not centered within the tubular structure the knives can contact and cut through a first portion of the tubular structure sooner than a second portion of the tubular structure that is, for example, diametrically opposite of the first portion. Such a cutting condition can cause excessive vibration, tool damage and an interrupted cut.
[0002] Consequently, centralizers are used to center the cutter relative to the tubular structure and thereby provide even engagement of the knives with walls of the tubular structures, which in turn results in a more even cut through the walls with less vibration. Centralizers often employ a plurality of flexible metal springs that engage the inside surface of the tubular structure to center the tool within the tubular structure. Such flexible metal springs however may have inadequate force to center a tool, for example when used in a nonvertically oriented tubular structure resulting in inadequate centering of the tool. Accordingly, there is a need in the art for a centralizer that can center tools regardless of biasing forces acting to urge the tools off center.
BRIEF DESCRIPTION OF THE INVENTION
[0003] Disclosed herein is a centralizer. The centralizer includes, a deformable tubular member having, a non-deformable portion with an outside surface defining a reference diameter, a deformable portion having an axis and being deformable to a greater radial dimension than the reference diameter. The greater radial dimension is contactable with a tubular structure within which the deformable tubular member is to be centralized. The deformable portion when in the deformed position has at least one first fluid passage with a greater radial distance from the axis than the reference diameter. The first fluid passage is fluidically isolated from at least one second fluidic passage at a radial dimension from the axis that is smaller than the reference diameter. Further, at least a portion of the deformable portion when deformed is in contact with the tubular structure so that the centralizer is centralized by such contact. The deformable tubular member further has a plurality of lines of weakness, at least one of which is at one of an inside surface and the outside surface and at least one other of the plurality of lines of weakness is at the other of the inside surface and the outside surface. The lines of weakness, upon axial loading of the centralizer cause deformation of the deformable portion and contact of the at least a portion of the deformable portion with the tubular structure.
[0004] Disclosed herein is a method for centralizing a downhole component. The method includes, delivering a tubular member with a plurality of lines of weakness therein to a site requiring a centralizer, and actuating the tubular member by causing a portion of the tubular member to deform radially from an unactuated position. The actuated portion contacting a downhole tubular structure, while maintaining at least two separate fluid passages. A first fluid passage between the portion of the tubular member and an outside surface of the tubular member in the unactuated position and a second fluid passage at a dimension smaller than that of the outside surface of the tubular member in the unactuated position.
[0005] Further disclosed herein is a method for making a centralizer. The method includes, configuring a deformable tubular member with a plurality of lines of weakness, at least one of the plurality of lines of weakness disposed at each of an inside dimension of the tubular member and an outside dimension of the tubular member. The method further includes, locating the plurality of lines of weakness relative to each other to facilitate deforming of the tubular member in a desired direction upon actuation. And configuring the centralizer tool such that at least a portion is contactable with a downhole structure to which the centralizer tool is centralizable after actuation of the centralizer tool. Additionally, forming at least two fluid passages isolated from one another, a first fluid passage being at a dimension greater than the outside dimension of the tubular member and a second fluid passage being at a dimension smaller than the outside dimension of the tubular member.
[0006] Further disclosed herein is a downhole centralizer system. The downhole centralizer system includes, a deformable tubular member with, a non-deformable portion having an outside surface defining a reference diameter, and a deformable portion having an axis and being deformable to a greater radial dimension than the reference diameter. The greater radial dimension is contactable with a tubular structure within which the deformable tubular member is to be centralized. The deformable portion when in the deformed position has a first fluid passage with a greater radial distance from the axis than the reference diameter and is fluidically isolated from a second fluid passage at a radial dimension from the axis that is smaller than the reference diameter. A portion of the deformable portion when deformed is in contact with the tubular structure so that the centralizer is centralized by such contact. The tubular member, also having a plurality of lines of weakness with at least one of the lines of weakness at an inside surface and at least one of the lines of weakness at the outside surface. Additionally, the lines of weakness, upon axial loading of the centralizer causing deformation of the deformable portion and contact of the portion of the deformable portion with the tubular structure. The system further having at least one additional operable component operably attached to the deformable tubular member, the component having operability facilitated by the deformable tubular member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0008] FIG. 1 depicts a partial cross sectional view of a centralizer tool disclosed herein in an unactuated configuration;
[0009] FIG. 2 depicts a partial cross sectional view of the centralizer tool of FIG. 1 in an actuated configuration;
[0010] FIG. 3 depicts a partial cross sectional view of the centralizer tool of FIG. 2 taken at arrows 3 - 3 ;
[0011] FIG. 4 depicts a partial cross sectional view of another embodiment of a centralizer tool disclosed herein in an unactuated configuration;
[0012] FIG. 5 depicts a partial cross sectional view of the centralizer tool of FIG. 4 in an actuated configuration; and
[0013] FIG. 6 depicts a partial cross sectional view of the centralizer tool of FIG. 5 taken at arrows 6 - 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0014] A detailed description of several embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0015] Referring to FIGS. 1 and 2 , a partial cross sectional view of an embodiment of the centralizer tool 10 is illustrated. The centralizer 10 includes a tubular member 14 and an actuatable centralizing portion 18 . As illustrated in FIG. 1 the centralizing portion 18 is in an unactuated configuration and as illustrated in FIG. 2 the centralizing portion 18 is in an actuated configuration. In the actuated configuration the centralizing portion 18 forms two frustoconical sections 22 and 26 . The greatest radial deformation 30 of the tubular member 14 occurs where the two frustoconical sections 22 and 26 meet. Thus, an annular flow area 34 is defined by the greatest radial deformation 30 and an outside surface 38 of the undeformed tubular member 14 . The greatest radial deformation 30 contacts an inner surface 42 of a tubular structure 46 within which the centralizer tool 10 is to be centralized and it is this contact that causes the centralizer tool 10 to become centralized within the tubular structure 46 . At least one axial groove 50 in the outside surface 38 forms a first fluid passage through which fluid can flow between an uphole annular area 54 and a downhole annular area 58 when the centralizer 10 is in the actuated configuration. A second fluid passage 52 is formed through the center of the tubular member 14 defined by the inside surface 62 .
[0016] Another operable component (not shown), such as a cutter, for example, can be can be attached to the centralizer tool 10 . The cutter can be located either uphole or downhole from the centralizer tool 10 , however, the cutter should be located close enough to the centralizer tool 10 that the cutter is centered within the tubular structure 46 by the centralization of the centralizer tool 10 . In so doing the centralizer tool 10 locates the cutter central to the tubular structure 46 such that the cutter engages the inner surface 42 substantially simultaneously to prevent detrimental vibrations and interrupted cuts. The centralizing force of the centralizer tool 10 can be controlled by the geometry and materials of the centralizer portion 18 such that noncentering loads encountered will not force the centralizer tool 10 off center.
[0017] The tubular member 14 is reconfigurable between the unactuated configuration and the actuated configuration. In the unactuated configuration the frustoconical sections 22 and 26 are configured as cylindrical components having roughly the same inside dimension as the tubular member 14 in the uphole annular area 54 and a downhole annular area 58 . Reconfiguration from the unactuated to the actuated configuration is effected, in one embodiment, by the application of an axial compressive load on the tubular member 14 . Similarly, reconfiguration from the actuated to the unactuated configuration is effected by the application of an axial tensile load on the tubular member 14 .
[0018] Reconfigurability of the tubular member 14 between the actuated configuration and the unactuated configuration is due to the construction thereof. The centralizer portion 18 is formed from a section of the tubular member 14 that has three lines of weakness, specifically located both axially of the tubular member 14 and with respect to an inside surface 62 and the outside surface 38 of the tubular member 14 . In one embodiment, a first line of weakness 66 and a second line of weakness 70 are defined in this embodiment by diametrical grooves formed in the outside surface 38 of the tubular member 14 . A third line of weakness 74 is defined in this embodiment by a diametrical groove formed in the inside surface 62 of the tubular member 14 . The three lines of weakness 66 , 70 and 74 each encourage local deformation of the tubular member 14 in a radial direction that tends to cause the groove to close. It will be appreciated that in embodiments where the line of weakness is defined by other than a groove, the radial direction of movement will be the same but since there is no groove, there is no “close of the groove”. Rather, in such an embodiment, the material that defines a line of weakness will flow or otherwise allow radial movement in the direction indicated. The three lines of weakness 66 , 70 and 74 together encourage deformation of the tubular member 14 in a manner that creates a feature such as the centralizer portion 18 . The feature is created, then, upon the application of an axially directed mechanical compression of the tubular member 14 such that the centralizer portion 18 is actuated as the tubular member 14 is compressed to a shorter overall length. Other mechanisms can alternatively be employed to actuate the tubular member 14 between the unactuated relatively cylindrical configuration and the actuated configuration presenting the frustoconical sections 22 and 26 . For example, the tubular member may be reconfigured to the actuated configuration by diametrically pressurizing the tubular member 14 about the inside surface 62 in the centralizer portion 18 .
[0019] Referring to FIG. 3 , a cross sectional view of the centralizer tool 10 of FIG. 2 is shown taken at arrows 3 - 3 . The fluid passages between the centralizer tool 10 and the inside surface 42 , of the tubular structure 46 , created by the axial grooves 50 , is illustrated. Although the axial grooves 50 are illustrated herein as V-shaped, it should be appreciated that alternate embodiments can have grooves of any shape. It should also be noted that in alternate embodiments the centralizer tool 10 could be used to center within an open bore 78 or any other tubular structure having a relatively consistent measurement to its axis.
[0020] Referring to FIGS. 4 and 5 , an alternate exemplary embodiment of the centralizer tool 110 is illustrated. The centralizer 110 includes a tubular member 114 and an actuatable centralizing portion 118 . The centralizing portion 118 includes a plurality of extension members 120 attached thereto. As illustrated in FIG. 4 the centralizing portion 118 is in an unactuated configuration and as illustrated in FIG. 5 the centralizing portion 118 is in an actuated configuration. In the actuated configuration the centralizing portion 118 forms two frustoconical sections 122 and 126 . The extension members 120 are fixedly attached to the first frustoconical section 122 at a first portion 128 . A second portion 129 of the extension members 120 is positioned radially outwardly of the second frustoconical section 126 but is not attached to the second frustoconical section 126 . As such when the centralizing portion 118 is actuated the extension members 120 remain substantially parallel to the first frustoconical section 122 causing the second portion 129 of the extension members 120 to extend radially outwardly of the outermost portion of the frustoconical members 122 , 126 . As such the greatest radial deformation 130 of the centralizer 110 is the end 132 of each of the extension members 120 . An annular flow area 134 is defined by the greatest radial deformation 130 and an outside surface 138 of the undeformed tubular member 114 . The greatest radial deformation 130 contacts an inner surface 42 of a tubular structure 46 within which the centralizer tool 110 is to be centralized and it is this contact that causes the centralizer tool 110 to become centralized within the tubular structure 46 . An axial space 150 between adjacent extension members 120 forms a first fluid passage through which fluid can flow between an uphole annular area 154 and a downhole annular area 158 when the centralizer 110 is in the actuated configuration. A second fluid passage 152 is formed through the center of the tubular member 114 defined by the inside surface 162 .
[0021] Another operable component (not shown), such as a cutter, for example, can be can be attached to the centralizer tool 110 . The cutter can be located either uphole or downhole from the centralizer tool 110 , however, the cutter should be located close enough to the centralizer tool 110 that the cutter is centered within the tubular structure 46 by the centralization of the centralizer tool 110 . In so doing the centralizer tool 110 locates the cutter central to the tubular structure 46 such that the cutter engages the inner surface 42 substantially simultaneously to prevent detrimental vibrations and interrupted cuts. The centralizing force of the centralizer tool 110 can be controlled by the geometry and materials of the centralizer portion 118 such that noncentering loads encountered will not force the centralizer tool 110 off center.
[0022] The tubular member 114 is reconfigurable between the unactuated configuration and the actuated configuration. In the unactuated configuration the frustoconical sections 122 and 126 are configured as cylindrical components having roughly the same inside dimension as the tubular member 114 in the uphole annular area 154 and a downhole annular area 158 . Reconfiguration from the unactuated to the actuated configuration is effected, in one embodiment, by the application of an axial compressive load on the tubular member 114 . Similarly, reconfiguration from the actuated to the unactuated configuration is effected by the application of an axial tensile load on the tubular member 114 .
[0023] Reconfigurability of the tubular member 114 between the actuated configuration and the unactuated configuration is due to the construction thereof. The centralizer portion 118 is formed from a section of the tubular member 114 that has three lines of weakness, specifically located both axially of the tubular member 114 and with respect to an inside surface 162 and the outside surface 138 of the tubular member 114 . In one embodiment, a first line of weakness 166 and a second line of weakness 170 are defined in this embodiment by diametrical grooves formed in the outside surface 138 of the tubular member 114 . A third line of weakness 174 is defined in this embodiment by a diametrical groove formed in the inside surface 162 of the tubular member 114 . The three lines of weakness 166 , 170 and 174 each encourage local deformation of the tubular member 114 in a radial direction that tends to cause the groove to close. It will be appreciated that in embodiments where the line of weakness is defined by other than a groove, the radial direction of movement will be the same but since there is no groove, there is no “close of the groove”. Rather, in such an embodiment, the material that defines a line of weakness will flow or otherwise allow radial movement in the direction indicated. The three lines of weakness 166 , 170 and 174 together encourage deformation of the tubular member 114 in a manner that creates a feature such as the centralizer portion 118 . The feature is created, then, upon the application of an axially directed mechanical compression of the tubular member 114 such that the centralizer portion 118 is actuated as the tubular member 114 is compressed to a shorter overall length. Other mechanisms can alternatively be employed to actuate the tubular member 114 between the unactuated relatively cylindrical configuration and the actuated configuration presenting the frustoconical sections 122 and 126 . For example, the tubular member 114 may be reconfigured to the actuated configuration by diametrically pressurizing the tubular member 114 about the inside surface 162 in the centralizer portion 118 .
[0024] Referring to FIG. 6 , a cross sectional view of the centralizer tool 110 of FIG. 5 is shown taken at arrows 6 - 6 . The fluid passages between the centralizer tool 110 and the inside surface 42 , of the tubular structure 46 , created by the axial spaces 150 between the extension members 120 , is illustrated. Although the extension members 120 depicted herein are rectangular prisms, it should be noted that alternate embodiments could have extension members of any shape. It should also be noted that in alternate embodiments the centralizer tool 110 could be used to center within an open bore 78 or any other substantially cylindrical structure.
[0025] While the invention has been described with reference to an exemplary embodiment or embodiments, 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 thereof. 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.
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Disclosed herein is a method for centralizing a downhole component. The method includes, delivering a tubular member with a plurality of lines of weakness therein to a site requiring a centralizer, and actuating the tubular member by causing a portion of the tubular member to deform radially from an unactuated position. The actuated portion contacting a downhole tubular structure, while maintaining at least two separate fluid passages. A first fluid passage between the portion of the tubular member and an outside surface of the tubular member in the unactuated position and a second fluid passage at a dimension smaller than that of the outside surface of the tubular member in the unactuated position.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of application Ser. No. 722,411, filed Apr. 10, 1985 which is now U.S. Pat. No. 5,007,585, issued Apr. 16, 1991, which is a continuation of application Ser. No. 636,066, filed Jul. 30, 1984, now abandoned, which is a continuation of application Ser. No. 348,509, filed Feb. 12, 1982, now abandoned, which is a continuation-in-part application Ser. No. 067,552, filed Aug. 7, 1970, which is now U.S. Pat. No. 4,315,602, issued Feb. 16, 1982.
BACKGROUND OF THE INVENTION
This invention relates to spray apparatus and more particularly to automated apparatus for roadside spraying of herbicides which is mounted on a front of a vehicle and controlled by a operator of the vehicle.
Many state highway departments, counties and cities, have for several years been actively mowing and brush cutting undesirable weeds, grass and brush in their right-of-ways. This has been primarily accomplished by hand labor or mechanical means. Many of these publicly funded organizations have attempted to spray their right-of-ways with selective herbicides that would control the undesirable plant growth and leave predominantly low growing grasses. Two programs that have been used for several years are MSMA to control johnson grass and 2-4-D to control broad leaves and brush.
The equipment which has been used in the past has been of generally three types. A common type of equipment is the long boom extending out to the side of the truck and across the right-of-way. An example fo a long boom is shown in U.S. Pat. No. 2,995,307 issued to J. J. McMahon. The use of the handgun is still common today for lack of anything with more versatility. Another has been the use of an off-center nozzle mounted to the side of the truck. The use of the off-center nozzle is discussed further below.
The long-extending boom has been used widely because of its ability to reach 25 to 30 feet into the right-of-way. Some designs have provided the boom in sections to give the operator more flexibility as to where he could spray the herbicide. This has also allowed the operator to save chemical. A problem with this type of unit is that it does not lend itself to many right-of-way applications because of hills, back slopes and obstructions in the areas to be sprayed. Obstructions are believed to be a major problem. The extended boom is vulnerable to contact with obstructions causing extensive down time and delays with loss of production. It is also believed to be very expensive to replace such booms. The use of hydraulic cylinders mounted along the boom may make the application even more cumbersome since the driver may have to slow the speed of the spray truck upon the encountering of several obstructions, such as trees, signs, bluffs, and the like. Under such circumstances, the operator might get too little, or no herbicide at all in certain areas because the boom was raised to go over the sign and wind blew many of the small particles away or the sprayed area received excessive rates of the herbicide due to the slower speeds of the truck. In some situations it is necessary to use two operators. This increases the costs due to the extra labor required and often the spray may not get to the target area while passing over obstructions. Also long booms require the vehicle to have greater gross vehicle weight because a long spray boom attached to the front of the vehicle may require heavier axles and generally heavier duty vehicles to support the long beams.
It is believed that the off-center nozzle in many cases had advantages over the long booms because the operator could spray all day without worrying about obstructions in the right-of-way. This nozzle could be mounted anywhere to the side of the vehicle and the spray pattern covered an area beginning immediately beside the truck and extending from 10 to 30 feet out into the right-of-way. Wind velocity tended to dramatically effect the distance and in such circumstances the spray might not extend past 10 to 15 feet from the vehicle. This type of nozzle also did not give the operator much versatility to place a herbicide only in areas where undesired vegetation existed across the right-of-way. In practice, the weeds are often in spotted areas lying 20 to 40 feet away from the spray truck and the operator has no way to get the herbicide to the target, especially if the wind velocity over powers the spray. The operator also, in certain situations, needs to spray the herbicide next to the vehicle, where only undesirable taller growing vegetation exists. In certain situations this may cause more herbicide to be used than necessary such as with off-center nozzles, which unnecessarily may increase the costs of the spraying program.
The same problems also exist with controlling undesirable brush. A long extending boom as far as known, is not often used for this purpose. Generally the use of a handgun and the off-center spraying means are used in such situations. Spotted applications to the soil under the undesirable brush with the use of a handgun, spraying specially selected herbicides, provide easy control of brush. In such situations, herbicides were often used, whereby rain would carry the chemical into the root zone to be picked up by the brush. This type of chemical interfers in the natural processes in the plant causing its ultimate death. A problem with spotted application of such herbicides by handguns on such undesirable brush, is that it is slow, which increases application cost and in most cases the herbicide is overapplied resulting in excessively killing of low growing desirable ground cover.
With the development of new herbicides, especially new selective herbicides, it has become more important to eliminate the problem encountered with extended booms, off-center nozzles and handguns. In the case of certain chemicals, it is necessary to apply them from 1 to 11/2 quarts per acre or 43,560 square feet. In the case of other currently used chemicals, it is necessary to apply them at 4 to 8 ounces to control more susceptable tall growing vegetation. Greater amounts of these herbicides may kill the low growing, more tolerant species of vegetation and leave partial to total bare ground. Such problems often prevent many highway departments, counties and cities from going into vegetation management programs with the new herbicides to eliminate the more costly program of hand labor and mechanical mowing.
Applicant's invention helps overcome the above discussed problems. An object of the invention is to provide a spraying apparatus capable of spraying smaller particles in spray swaths adjacent to the vehicle and larger particles in areas farther away from the vehicle. An object of the invention is to allow an operator to spray the larger particles up to 40 feet away from the vehicle. Another object of the invention is to provide a spray pattern which is less affected by wind. Another object of the invention is to allow an operator to spray spotted weed problems at any location up to 40 feet away from the vehicle without wasting herbicide where only desirable low growing vegetation exists. Another object of the invention is to allow an operator the option of applying herbicides at exacting rates at selected locations across the right-of-way to prevent overuse of herbicide and potential damage to low growing grass, where no undesirable weeds exist. Another object of the invention is to provide a spraying apparatus which provides foliar applications of herbicides on brush at any selected location in the right-of-way. Other objects of the invention will be apparent from the following detailed disclosure.
SUMMARY OF THE INVENTION
The invention comprises a spraying apparatus having a plurality of separately operable spraying nozzles for selectively spraying a herbicide or other material on a desired location at the side of a motor vehicle. The nozzles are mounted upon a spraying head which may be remotely operated by an operator to change the inclination of the nozzles to spray any desired location. Separate spraying nozzles on the head are oriented to spray at selected locations and some of the nozzles spray smaller particles for short distances and other nozzles spray large particles for longer distances.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view showing the spraying apparatus of the invention.
FIG. 2 is a plan view showing the spraying apparatus of the invention.
FIG. 3 shows the spraying apparatus of the invention mounted on a motor vehicle and the spray pattern of the device.
FIG. 4 is another view of the spray apparatus mounted on a vehicle showing another spray pattern.
FIG. 5 is a broken cross sectional view showing the nozzle arrangement.
FIG. 6 is taken along 6--6 in FIG. 5.
FIG. 7 is taken along line 7--7 in FIG. 5.
FIG. 8 is taken along line 8--8 in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The spraying apparatus of FIG. 1 is adapted to be used upon a motor vehicle in connection with tank and pump means. U.S. Pat. No. 4,315,602 discloses tank and pump means which may be used in connection with this invention and this patent is incorported herein into to by this specific reference thereto for any and all purposes.
Referring to FIG. 1, there is shown a spraying apparatus 10 which is mounted on a motor vehicle V as shown in FIGS. 4 and 5. Spraying apparatus 10 includes a main support beam 11 which is mounted to the front of the vehicle V in a manner such as disclosed in U.S. Pat. No. 4,315,602. A journal 12 is connected with the beam 11. A pivot mechanism including a bifurcated member 13 is pivoted to the journal and maintained in position by spring means 14 as also disclosed in U.S. Pat. No. 4,315,602.
A first vertical beam 15 is connected to the bifurcated member 13. The vertical beam 15 is in the form of a square channel member for receiving post 16. A plurality of apertures 17 receive the removable pin 18 which provides vertical adjustment of the post 16.
Secured to the vertical beam 15 is a support arm 19. An electric air or hydraulic cylinder means 20 or other remotely controlled power means is connected at one end to the support arm 19 and at its upper end to a support arm 21. The support arm 21 is connected to a spraying means or head 22. The spraying means 22 includes a generally U-shaped shield 23 which is connected to U-shaped member 24. The post 16 includes a pivot bracket 25 which is secured to the post 16. The U-shaped member 24 is pivotally connected to the pivot bracket 25 by pivot pin 26. The support arm 21 is connected to the connecting portion 27 of the U-shaped member 24. As will be apparent, extension and retraction of the hydraulic cylinder means 20 will cause the spraying means 22 to pivot as shown in broken lines in FIG. 1 and also as shown in FIGS. 4 and 5.
The spraying means 22 includes a plurality of independently operated nozzle means to provide a predetermined droplet size and to provide a spraying band at a predetermined location. The spraying band covers a preselected swath to deposit spray at the desired location.
The spraying apparatus includes a first nozzle means 30, as best shown in FIG. 2, for spraying an area adjacent or directly below the spraying means 22. The spraying means further includes a plurality of nozzle means 31, 32, 33, 34 and 35 as best shown in FIG. 6. These nozzle means may provide a large droplet size in a straight stream flow for spraying areas such as undesirable brush or weeds and objects closely or remotely adjacent to vehicle V. As will be apparent, the nozzles 31 through 35 are oriented to spray a narrow straight stream swath or area at short or long distances from the vehicle. The nozzle means 31 through 35 are controlled by an operator. They may be either controlled to spray at the same time or to selectively spray.
The spraying means 22 further includes nozzle means 36, 37, 38 and 39 as best shown in FIG. 7. The nozzle means 36 through 39 may be designed to spray relatively large droplets at a relatively large distance. The nozzles 36 through 39 are connected to a single supply pipe 40 which may be controlled by the operator to supply spray to the nozzles 36 through 39.
The spraying means 22 further includes nozzle means 41, 42 and 43 as also shown in FIG. 7. The nozzle means 41 through 43 are connected to supply pipe 44 which is selectively supplied with spray by an operator. The supply pipes 40 and 44 are connected by a bracket means 45 to the U-shaped shield 23. The nozzle means 41 through 43 may be oriented to spray a swath at a closer distance than are the nozzle means 36 through 39.
Referring to FIG. 8 of the drawing, there is shown nozzle means 46, 47, 48 and 49. The nozzle means 46 through 49 are connected to supply pipe 50. The supply pipe 50 is supplied with spray from the pumping unit (not shown) which is controlled by suitable valve means by the operator. The nozzle means 46 through 49 may be oriented to spray at a distance slightly less than the nozzle means 36, 37, 38 and 39.
Again referring to FIG. 8 there is shown nozzle means 51, 52 and 53. The nozzle means 51, 52 and 53 are connected to supply pipe 54 which is supplied with spray by the operator. The nozzle means 51, 52 and 53 may be oriented to spray at a relatively close distance. The supply pipes 50 and 54 are connected by bracket means 45a to the U-shaped shield 23.
These nozzles spray smaller droplets because they are located next to the truck. The particles must be smaller nearer the truck because the spray is moving at a line of travel parallel to the upright growing undesirable weeds and results in better herbicide coverage. As the weeds become a farther distance away from the vehicle, the spray, such as that delivered from nozzles 36 through 49, in FIG. 5, penetrate through the vegetation at a direction perpendicular to the upright plant.
The nozzle means 36, 37, 38 and 39 may be oriented to spray a swath at the farthest distance. It is preferably to use larger spray droplets to minimize draft at larger distances. The nozzle means 46, 47, 48 and 49 may be oriented to spray a swath adjacent the swath sprayed by the nozzles 36 through 39 but closer to the vehicle. The nozzle means 41, 42 and 43 may be oriented to spray a swath closer the vehicle but adjacent the swath sprayed by the nozzles 46, 47, 48 and 49. The nozzle means 51, 52 and 53 may be oriented to spray a swath closer to the vehicle than the nozzle means 41, 42 and 43 and adjacent to the swath sprayed by the nozzle means 41, 42 and 43.
The nozzles are mounted in a manner well known in the art.
In operation, an operator, through electrically operated solenoid switches controls the operation of the nozzle means to provide the desired spray. When it is desired to spray down hillsides, such as shown in FIG. 3, the spraying means 22 can be tilted downwardly by the hydraulic cylinder means 20. When it is desired to spray large objects such as trees, the spraying means 22 may be tilted upwardly as shown in FIG. 4 by the hydraulic cylinder means 20. By selectively controlling the solenoid operated switch means, which controls the various nozzle means, an operator can predetermine where the spray will be directed.
Although the invention has been described in conjunction with the foregoing specific embodiment, many alternatives, variations and modifications are intended to fall within the spirit and scope of the appended claims.
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A roadside spray apparatus having a spraying head with a plurality of nozzles mounted on the spraying head. The inclination of the spraying head is selectively adjustable to direct spray to a desired location. The spray head includes a plurality of independently operated nozzles oriented to spray side-by-side swaths at the side of a vehicle.
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TECHNICAL FIELD
[0001] The description relates to lighting devices.
[0002] The description has been written with particular reference to lighting devices of the integrated type comprising a light source, such as a halogen lamp, and a corresponding power supply circuit such as an electronic transformer.
DESCRIPTION OF THE RELEVANT PRIOR ART
[0003] FIG. 1 shows schematically, by way of example, a lighting device 10 comprising:
a light source 12 and a corresponding electrical power supply circuit 14 .
[0006] The light source can comprise a lighting body (or “burner”) which may be, for example, a halogen lamp 120 intended to reach temperatures of about 200° C. during operation. Consequently, while it is normally provided with its own bulb, of teardrop shape for example, the lamp 120 can be placed inside a bulb 122 made from transparent material (such as glass) which is intended to ensure that the flow of light is not impeded, while also preventing any undesired accidental contact with the lighting body 120 at its operating temperature.
[0007] The joint or connection to the housing containing the electrical power supply circuit 14 is made by means of a joining element 20 generally referred to as “tape”.
[0008] To ensure that the heat originating from the light source 12 (in other words, from the lighting body 120 ) does not degrade the properties of the component 20 , this component is made from materials which combine the properties of heat-resistance and stability (such as glass, ceramic materials or metals). However, these materials can give rise to problems in respect of weight, cost and low mechanical strength (for example, materials such as glass or ceramics have an intrinsically low resistance to impact), and are also difficult to model or mold. If plastics or resin materials are used, this may give rise to the release of chemical substances which can be deposited on the bulb 122 , which, on the one hand, reduces the transparency of the bulb, impeding the diffusion of the light flux, and, on the other hand, imparts a stained appearance to the bulb, with negative results in terms of its visual appeal.
OBJECT AND SUMMARY OF THE INVENTION
[0009] The inventors have discovered that, in order to produce the component in question, it is necessary to provide solutions which can replace materials such as glass, ceramic materials or metal, and which are lighter, more economical and stronger in mechanical terms, while also being easier to model or mold because they are made from a material with excellent thermal insulation properties, such as plastics material, which can be used without giving rise to the other drawbacks described above.
[0010] The object of the invention is to provide a solution of this type.
[0011] According to the invention, this object is achieved by means of a component having the characteristics specifically claimed in the claims below.
[0012] The claims form an integral part of the technical teachings provided herein in relation to the invention.
[0013] Various embodiments can provide a very simple solution which has no appreciable effect on the production of the housing of an integrated lighting device.
[0014] Various embodiments can provide a compact solution which has no effect on the lighting device and which allows the lighting device to be given an appearance which is identical or at least very similar to that of a conventional bulb lamp.
[0015] Various embodiments also provide a good circulation of air between the external environment and the interior of the bulb, thus simultaneously reducing the temperature inside the bulb and allowing the exit of any chemical particles diffused inside the bulb, while also making it possible to provide the minimum safety distances and prevent any contact with the “live” parts of the lighting device by a correct design of the shape of the housing.
BRIEF DESCRIPTION OF THE APPENDED DRAWINGS
[0016] The invention will now be described, purely by way of non-limiting example, with reference to the appended drawings, in which:
[0017] FIG. 1 has been described above,
[0018] FIG. 2 shows the position of the element considered herein within the device of FIG. 1 ,
[0019] FIG. 3 shows a component according to one embodiment, considered separately,
[0020] FIGS. 4 , 5 and 6 show different modes of operation of embodiments, and
DETAILED DESCRIPTION OF EMBODIMENTS
[0021] The following description illustrates various specific details intended to provide a deeper understanding of the embodiments. The embodiments may be produced without one or more of the specific details, or with other methods, components, materials, etc. In other cases, known structures, materials or operations are not shown or described in detail, in order to avoid obscuring various aspects of the embodiments.
[0022] The reference to “an embodiment” in this description is intended to indicate that a particular configuration, structure or characteristic described in relation to the embodiment is included in at least one embodiment. Therefore, phrases such as “in an embodiment”, which may be present in various parts of this description, do not necessarily refer to the same embodiment. Furthermore, specific formations, structures or characteristics may be combined in a suitable way in one or more embodiments.
[0023] The references used herein are purely for convenience and therefore do not define the scope of protection or the extent of the embodiments.
[0024] FIG. 2 shows in greater detail the structure of the light source 12 described previously with reference to FIG. 1 .
[0025] As stated previously, the light source 12 comprises a lighting body proper 120 (such as a halogen lamp, also called a “burner”) surrounded by a bulb 122 of approximately spherical or bulb-like shape with an overall tray-like or cup-like structure (which appears inverted in the view shown in FIG. 2 ). The bulb 122 also has a mouth rim 124 (which is circular in the embodiment illustrated herein) designed to be received in a peripheral groove 22 of the component (generally called a “tape”) indicated by 20 in FIG. 1 which was described above. As can be seen more clearly in the view of FIG. 3 , in the embodiment illustrated herein the component 20 is of generally disk-like shape with a bottom wall 202 of overall concave shape designed to define an area for the mounting of the lighting body 120 in a central position and therefore on the bottom part of the bowl formed by the wall 202 .
[0026] For example, two radial ribs 204 can extend upward from the bottom wall of the component 20 to permit the insertion, with a positive connection, of a two-piece plate 206 in the shape of an inverted tray, which carries the lighting body 120 in a central position.
[0027] The view of FIG. 3 also shows that the groove 22 intended to receive the mouth rim 124 of the bulb 122 lies between two annular walls, namely:
an “outer” annular wall 208 , defining the external profile of the general disk-like configuration of the component 20 , and an “inner” annular wall 210 , which delimits peripherally the central part of the bottom wall 202 of the component 20 . Between the two annular walls 208 and 210 there are radial ribs 212 forming raised (or more generally “sculptured”) formations in relation to the bottom of the groove 22 . Because of the presence of these formations 212 , the coupling of the bulb 122 to the component 20 by the insertion of its mouth rim 124 into the groove 22 does not create any continuous contact between the mouth rim 124 and the bottom of the groove 22 . In other words, the formations 212 help to keep the mouth rim 124 of the bulb 122 slightly “elevated” above the bottom of the groove 22 , thus ensuring that the contact between the mouth rim 124 and the body of the component 20 is actually a discontinuous contact, which is, for example, capable of allowing a certain amount of air to flow between the mouth rim 124 of the bulb 122 and the peripheral edge of the component 20 .
[0030] The reference 214 also indicates a set of openings provided in the bottom wall 202 of the component 20 such that a further flow of air is permitted between the external environment and the interior of the bulb 122 .
[0031] As can be seen more clearly in the views of FIGS. 5 and 6 , in various embodiments, the mouth rim 124 of the bulb 122 is inserted into the groove 22 and, because of the presence of the ribs 212 , this insertion does not create a sealed connection but allows a degree of circulation of air in the internal environment of the bulb, such that the temperature inside the bulb can be reduced, and at the same time any chemical particles which have diffused into the bulb can pass out of it.
[0032] Thus a form of labyrinth is created between the parts concerned, this labyrinth allowing a flow of air but also meeting the requirements of electrical insulation in terms of creepage and clearance.
[0033] In various embodiments, the component 20 makes it possible to overcome the problems related to the high temperature of the lighting body 120 and to the fact that, when inserted into the bulb 122 , the lighting body 120 is not directly exposed to the external environment and is therefore not directly ventilated.
[0034] As stated above, the component 20 can support the plate composed of two complementary portions 206 of semicircular shape, which also provide an electrical connection between the lighting body 120 and the other parts of the device 10 , for example by means of edge portions bent to lie behind the inner face of the wall 210 . In particular, the electrical connection can be made by means of blade contact elements as described in a patent application for an industrial invention filed on the same date by the present applicant.
[0035] In various embodiments, the component 20 is made from a plastics material with properties of high heat-resistance, for example the material known as LCP.
[0036] The component 20 , and particularly the bottom wall 202 , is also suitable for forming the mechanical connection with the power supply circuit 14 using a solution in which a separating air gap is formed as described in another patent application for an industrial invention filed on the same date by the present applicant.
[0037] The bulb 122 can be fixed to the component 20 by gluing or simply by means of a mechanical friction fit.
[0038] Naturally, the principle of the invention remaining the same, the details of construction and the forms of embodiment may be varied widely with respect to those illustrated, which have been given purely by way of non-limiting example, without thereby departing from the scope of protection of the invention as defined in the attached claims.
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In various embodiments, a coupling component is configured to hold a lighting body inserted in a protection bulb via a mouth portion of the bulb, the coupling component having a groove for receiving the rim of the mouth portion of the bulb, the groove including sculptured formations to keep the mouth rim received in the groove spaced from the bottom of the groove to produce a discontinuous contact between the mouth rim and the groove.
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The instant invention relates to aqueous sizing compositions comprising derivatives of diaminostilbene optical brightener, shading dyes, binders and optionally divalent metal salts which can be used for the optical brightening of substrates, including substrates suitable for high quality ink jet printing.
BACKGROUND OF THE INVENTION
High levels of whiteness and brightness are important parameters for the end-user of paper products. The most important raw materials of the papermaking industry are cellulose, pulp and lignin which naturally absorb blue light and therefore are yellowish in color and impart a dull appearance to the paper.
The distinction between whiteness and brightness is well-known to those skilled in the art and is discussed, for example, in WO 0 218 705 A1.
Optical brighteners are used in the papermaking industry to compensate for the absorption of blue light by absorbing UV-light with a maximum wavelength of 350-360 nm and converting it into visible blue light with a maximum wavelength of 440 nm.
It is well established that, in addition to optical brighteners, certain shading dyes or pigments can be added to the paper in order to achieve a higher level of whiteness and to control the shade of the white paper.
WO 0 218 705 A1 however teaches that the use of shading dyes or pigments, while having a positive effect on whiteness, has a negative effect on brightness. The solution to this problem is to add additional optical brightener, the advantage claimed in WO 0 218 705 A1 being characterized by the use of a mixture comprising at least one direct dye (exemplified by CI Direct Violet 35) or pigment and at least one optical brightener.
Surprisingly, we have now discovered a sizing composition comprising an optical brightener and a shading dye which enables the papermaker to reach a high level of whiteness without significant loss in brightness.
Therefore, the goal of the present invention is to provide aqueous sizing compositions containing derivatives of diaminostilbene optical brightener, shading dyes, binders and optionally divalent metal salts affording enhanced high whiteness levels while avoiding the loss of brightness characterized by the use of shading dyes or pigments when applied to the paper at the size press.
The present invention further provides a process for optical brightening and tinting paper substrates characterized in that an aqueous sizing composition containing at least one optical brightener, at least one shading dye, at least one binder and optionally at least one divalent metal salt is used.
DESCRIPTION OF THE INVENTION
The present invention therefore provides aqueous sizing compositions for optical brightening of substrates, preferably paper, comprising
(a) at least one optical brightener of formula (I)
in which
the anionic charge on the brightener is balanced by a cationic charge composed of one or more identical or different cations selected from the group consisting of hydrogen, an alkali metal cation, alkaline earth metal, ammonium, ammonium which is mono-, di-, tri- or tetrasubstituted by a C 1 -C 4 linear or branched alkyl radical, ammonium which is mono-, di-, tri- or tetrasubstituted by a C 1 -C 4 linear or branched hydroxyalkyl radical, or mixtures of said compounds, R 1 and R 1 ′ may be the same or different, and each is hydrogen, C 1 -C 4 linear or branched alkyl, C 2 -C 4 linear or branched hydroxyalkyl, CH 2 CO 2 − , CH 2 CH 2 CONH 2 or CH 2 CH 2 CN, R 2 and R 2 ′ may be the same or different, and each is C 1 -C 4 linear or branched alkyl, C 2 -C 4 linear or branched hydroxyalkyl, CH 2 CO 2 − , CH(CO 2 − )CH 2 CO 2 − , CH(CO 2 − )CH 2 CH 2 CO 2 − , CH 2 CH 2 SO 3 − , CH 2 CH 2 CO 2 − , CH 2 CH(CH 3 )CO 2 − , benzyl, or R 1 and R 2 and/or R 1 ′ and R 2 ′, together with the neighboring nitrogen atom signify a morpholine ring and is 0, 1 or 2,
(b) at least one dye of formula (II)
in which
R 3 signifies H, methyl or ethyl, R 4 signifies paramethoxyphenyl, methyl or ethyl, M signifies a cation selected from the group consisting of hydrogen, an alkali metal cation, alkaline earth metal, ammonium, ammonium which is mono-, di-, tri- or tetrasubstituted by a C 1 -C 4 linear or branched alkyl radical, ammonium which is mono-, di-, tri- or tetrasubstituted by a C 1 -C 4 linear or branched hydroxyalkyl radical, or mixtures of said compounds,
(c) at least one binder,
(d) optionally one or more divalent metal salts and
(e) water.
In compounds of formula (I) for which p is 1, the SO 3 − group is preferably in the 4-position of the phenyl group.
In compounds of formula (I) for which p is 2, the SO 3 − groups are preferably in the 2,5-positions of the phenyl group.
Preferred compounds of formula (I) are those in which
the anionic charge on the brightener is balanced by a cationic charge composed of one or more identical or different cations selected from the group consisting of hydrogen, an alkali metal cation, alkaline earth metal, ammonium which is mono-, di-, tri- or tetrasubstituted by a C 1 -C 4 linear or branched hydroxyalkyl radical, or mixtures of said compounds, R 1 and R 1 ′ may be the same or different, and each is hydrogen, C 1 -C 4 linear or branched alkyl, C 2 -C 4 linear or branched hydroxyalkyl, CH 2 CO 2 − , CH 2 CH 2 CONH 2 or CH 2 CH 2 CN, R 2 and R 2 ′ may be the same or different, and each is C 1 -C 4 linear or branched alkyl, C 2 -C 4 linear or branched hydroxyalkyl, CH 2 CO 2 − , CH(CO 2 − )CH 2 CO 2 − or CH 2 CH 2 SO 3 − and p is 0, 1 or 2.
More preferred compounds of formula (I) are those in which
the anionic charge on the brightener is balanced by a cationic charge composed of one or more identical or different cations selected from the group consisting of Li + , Na + , K + , Ca 2+ , Mg 2+ , ammonium which is mono-, di-, tri- or tetrasubstituted by a C 1 -C 4 linear or branched hydroxyalkyl radical, or mixtures of said compounds, R 1 and R 1 ′ may be the same or different, and each is hydrogen, methyl, ethyl, propyl, α-methylpropyl, β-methylpropyl, β-hydroxyethyl, β-hydroxypropyl, CH 2 CO 2 − , CH 2 CH 2 CONH 2 or CH 2 CH 2 CN, R 2 and R 2 ′ may be the same or different, and each is methyl, ethyl, propyl, α-methylpropyl, β-methylpropyl, β-hydroxyethyl, β-hydroxypropyl, CH 2 CO 2 − , CH(CO 2 − )CH 2 CO 2 − or CH 2 CH 2 SO 3 − and p is 0, 1 or 2.
Especially preferred compounds of formula (I) are those in which
the anionic charge on the brightener is balanced by a cationic charge composed of one or more identical or different cations selected from the group consisting of Na + , K + and triethanolammonium or mixtures of said compounds, R 1 and R 1 ′ may be the same or different, and each is hydrogen, ethyl, propyl, β-hydroxyethyl, β-hydroxypropyl, CH 2 CO 2 − , or CH 2 CH 2 CN, R 2 and R 2 ′ may be the same or different, and each is ethyl, propyl, β-hydroxyethyl, β-hydroxypropyl, CH 2 CO 2 − , CH(CO 2 − )CH 2 CO 2 − or CH 2 CH 2 SO 3 − and p is 1 or 2.
The concentration of compounds of formula (I) in the sizing composition may be between 0.2 and 30 g/l, preferably between 1 and 25 g/l, most preferably between 2 and 20 g/l.
Preferred compounds of formula (II) are those in which
R 3 signifies H, methyl or ethyl, R 4 signifies paramethoxyphenyl, methyl or ethyl, M signifies a cation selected from the group consisting of hydrogen, an alkali metal cation, alkaline earth metal, ammonium which is mono-, di-, tri- or tetrasubstituted by a C 1 -C 4 linear or branched hydroxyalkyl radical, or mixtures of said compounds.
More preferred compounds of formula (II) are those in which
R 3 signifies methyl or ethyl, R 4 signifies methyl or ethyl, M signifies a cation selected from the group consisting of Li + , Na + , K + , ½ Ca 2+ , ½ Mg 2+ , ammonium which is mono-, di-, tri- or tetrasubstituted by a C 1 -C 4 linear or branched hydroxyalkyl radical, or mixtures of said compounds.
Especially preferred compounds of formula (II) are those in which
R 3 signifies methyl, R 4 signifies methyl, M signifies a cation selected from the group consisting of Na + , K + and triethanolammonium or mixtures of said compounds.
The concentration of compounds of formula (II) in the sizing composition may be between 0.01 and 20 mg/l, preferably between 0.05 and 10 mg/l, most preferably between 0.1 and 5 mg/l.
The binder is typically an enzymatically or chemically modified starch, e.g. oxidized starch, hydroxyethylated starch or acetylated starch. The starch may also be native starch, anionic starch, a cationic starch, or an amphoteric starch depending on the particular embodiment being practiced. While the starch source may be any, examples of starch sources include corn, wheat, potato, rice, tapioca, and sago. One or more secondary binders e.g. polyvinyl alcohol may also be used.
The concentration of binders in the sizing composition may be between 1 and 30% by weight, preferably between 2 and 20% by weight, most preferably between 5 and 15% by weight, % by weight based on the total weight of the sizing composition.
Preferred divalent metal salts are selected from the group consisting of calcium chloride, magnesium chloride, calcium bromide, magnesium bromide, calcium iodide, magnesium iodide, calcium nitrate, magnesium nitrate, calcium formate, magnesium formate, calcium acetate, magnesium acetate, calcium citrate, magnesium citrate, calcium gluconate, magnesium gluconate, calcium ascorbate, magnesium ascorbate, calcium sulphite, magnesium sulphite, calcium bisulphite, magnesium bisulphite, calcium dithionite, magnesium dithionite, calcium sulphate, magnesium sulphate, calcium thiosulphate, magnesium thiosulphate or mixtures of said compounds.
More preferred divalent metal salts are selected from the group consisting of calcium chloride, magnesium chloride, calcium bromide, magnesium bromide, calcium sulphate, magnesium sulphate, calcium thiosulphate or magnesium thiosulphate or mixtures of said compounds.
Especially preferred divalent metal salts are selected from the group consisting of calcium chloride, magnesium chloride, calcium sulphate or magnesium sulphate or mixtures of said compounds.
When the sizing composition contains divalent metal salts, the concentration of divalent metal salts in the sizing composition may be between 0.1 and 100 g/l, preferably between 0.5 and 75 g/l, most preferably between 1 and 50 WI.
When the divalent metal salt is a mixture of one or more calcium salts and one or more magnesium salts, the amount of calcium salts may be in the range of 0.1 to 99.9% by weight, % by weight based on the total weight of divalent metal salts.
The pH value of the sizing composition is typically in the range of from 5 to 13, preferably of from 6 to 11. Where it is necessary to adjust the pH of the sizing composition, acids or bases may be employed. Examples of acids which may be employed include but are not restricted to hydrochloric acid, sulphuric acid, formic acid and acetic acid. Examples of bases which may be employed include but are not restricted to alkali metal and alkaline earth metal hydroxide or carbonates.
In addition to one or more compounds of formula (I), one or more compounds of formula (II), one or more binders, optionally one or more divalent metal salts and water, the sizing composition may contain by-products formed during the preparation of compounds of formula (I) and compounds of formula (II) as well as other conventional paper additives. Examples of such additives are carriers, defoamers, wax emulsions, dyes, inorganic salts, solubilizing aids, preservatives, complexing agents, biocides, surface sizing agents, cross-linkers, pigments, special resins etc.
Optionally, the sizing composition can contain polyethyleneglycol. When the sizing composition contains polyethyleneglycol, the ratio in parts of polyethyleneglycol per part of compounds of formula (I) may be of from 0.05/1 to 2/1, preferably of from 0.1/1 and 1.5/1, more preferably of from 0.15/1 to 1/1 to function as a so-called carrier in order to boost the performances of compounds of formula (I) or compounds of formula (II). The polyethylene glycol which may be employed as carrier may have an average molecular weight in the range of 100 to 8000, preferably in the range of 200 to 6000, most preferably in the range of 300 to 4500.
Optionally, the sizing composition can contain polyvinyl alcohol. When the sizing composition contains polyvinyl alcohol, the ratio in parts of polyvinyl alcohol per part of compounds of formula (I) may be of from 0.005/1 to 1/1, preferably of from 0.025/1 to 0.5/1, more preferably of from 0.05/1 to 0.3/1 to function as a so-called carrier in order to boost the performances of compounds of formula (I) or compounds of formula (II). The polyvinyl alcohol which may be employed as carrier has a degree of hydrolysis greater than or equal to 60% and a Brookfield viscosity of between 1 and 60 mPa·s for a 4% aqueous solution at 20° C. Preferably the degree of hydrolysis is between 70% and 95%, and the Brookfield viscosity is between 1 and 50 mPa·s (4% aqueous solution at 20° C.). Most preferably, the degree of hydrolysis is between 70% and 90%, and the Brookfield viscosity is between 1 and 40 mPa·s (4% aqueous solution at 20° C.).
The sizing composition may be prepared by adding one or more compounds of formula (I), one or more compounds of formula (II), optionally one or more divalent metal salts and water to a preformed aqueous solution of the binder at a temperature between 20° C. and 90° C.
Compounds of formula (I), compounds of formula (II), and optionally the divalent metal salts can be added in any order, or at the same time to the preformed aqueous solution containing the binder at a temperature between 20° C. and 90° C.
Compounds of formula (I), compounds of formula (II), and optionally the divalent metal salts can be added as powders or as preformed aqueous solutions to the preformed aqueous solution containing the binder at a temperature between 20° C. and 90° C.
When used as a preformed aqueous solution, the concentration of compound of formula (I) in water is preferably of from 1 to 50% by weight, more preferably of from 2 to 40% by weight, even more preferably from 10 to 30% by weight, the % by weight being based on the total weight of the preformed aqueous solution containing the compound of formula (I).
When used as a preformed aqueous solution, the concentration of compound of formula (II) in water is preferably of from 0.1 to 25% by weight, more preferably of from 0.5 to 20% by weight, even more preferably from 1 to 10% by weight, the % by weight being based on the total weight of the preformed aqueous solution containing the compound of formula (II).
When used as a preformed aqueous solution, the concentration of divalent metal salt in water is preferably of from 1 to 80% by weight, more preferably of from 2 to 70% by weight, even more preferably from 3 to 60% by weight, the % by weight being based on the total weight of the preformed aqueous solution containing the divalent metal salt.
A further subject of the invention therefore is the use of the sizing compositions as defined above, also in all their preferred embodiments, preferably for optical brightening of cellulosic substrates, e.g. textiles, non-wovens or more preferably paper.
The sizing composition may be applied to the surface of a paper substrate by any surface treatment method known in the art. Examples of application methods include size-press applications, calendar size application, tub sizing, coating applications and spraying applications. (See, for example, pages 283-286 in Handbook for Pulp & Paper Technologists by G. A. Smook, 2 nd Edition Angus Wilde Publications, 1992 and US 2007/0277950). The preferred method of application is at the size-press such as puddle size press. A preformed sheet of paper is passed through a two-roll nip which is flooded with the sizing composition. The paper absorbs some of the composition, the remainder being removed in the nip.
The paper substrate contains a web of cellulose fibres which may be sourced from any fibrous plant. Preferably the cellulose fibres are sourced from hardwood and/or softwood. The fibres may be either virgin fibres or recycled fibres, or any combination of virgin and recycled fibres.
The cellulose fibres contained in the paper substrate may be modified by physical and/or chemical methods as described, for example, in Chapters 13 and 15 respectively in Handbook for Pulp & Paper Technologists by G. A. Smook, Edition Angus Wilde Publications, 1992. One example of a chemical modification of the cellulose fibre is the addition of an optical brightener as described, for example, in EP 0 884 312, EP 0 899 373, WO 02/055646, WO 2006/061399 and WO 2007/017336.
The following examples shall demonstrate the instant invention in more details. In the present application, if not indicated otherwise, “parts” means “parts by weight” and “%” means “% by weight”.
EXAMPLES
Preparative Example 1
An aqueous shading solution (S1) containing compound of formula (1) is prepared by slowly adding 40 parts of compound of formula (1) to 460 parts of water at room temperature with efficient stirring. The obtained solution is stirred for 1 hour and filtered to remove insoluble particles. The resulting shading solution (S1) has a pH in the range of from 6.0 to 7.0 and contains 8% by weight of compound of formula (1), the % by weight being based on the total weight of the final aqueous shading solution (S1).
Application Example 1
Aqueous sizing compositions are prepared by adding aqueous shading solution (S1) containing compound of formula (1) prepared according to Preparative Example 1 at a range of concentrations of from 0 to 30 mg/l (from 0 to 2.4 mg/l of compound of formula (1) based on dry solid) to a stirred, aqueous solution containing calcium chloride (35 g/l), compound of formula (2) (7.5 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness and brightness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 1 and Table 2 respectively and clearly show that the instant invention provides a high level of whiteness without significant loss of brightness.
Comparative Application Example 1
Aqueous sizing compositions are prepared by adding aqueous solution of CI Direct Violet 35 (approx. 11% by weight of dry CI Direct Violet 35, the % by weight being based on the total weight of the CI Direct Violet 35 aqueous solution) at a range of concentrations of from 0 to 30 mg/l (from 0 to 3.3 mg/l based on dry CI Direct Violet 35 compound) to a stirred, aqueous solution containing calcium chloride (35 g/l), compound of formula (2) (7.5 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier.
The dried paper is allowed to condition, and then measured for CIE whiteness and brightness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 1 and Table 2 respectively and clearly show that CI Direct Violet 35, a shading dye representative of the state-of-the-art, has a less positive effect on whiteness than the shading dye of the instant invention while having a very negative effect on brightness.
TABLE 1
CIE Whiteness
Added shading solution
Application
Comparative Application
[mg/l]
Example 1
Example 1
0
132.4
132.4
2.5
133.1
132.5
5
134.2
132.9
10
136.3
133.4
20
138.0
135.9
30
139.7
136.6
TABLE 2
Brightness
Added shading solution
Application
Comparative Application
[mg/l]
Example 1
Example 1
0
105.2
105.2
2.5
105.4
104.0
5
105.3
103.8
10
105.3
103.6
20
104.8
102.7
30
104.5
101.6
Application Example 2
Aqueous sizing compositions are prepared by adding preformed aqueous solution containing compound of formula (2) (18.2% by weight of compound of formula (2), the % by weight being based on the total weight of the aqueous solution containing compound of formula (2)) at a range of concentrations of from 0 to 60 WI (of from 0 to approx. 11 g/l based on dry compound of formula (2)) to a stirred, aqueous solution containing compound of formula (1) (4.0 mg/l) and an anionic potato starch (75 g/l) (Perfectamyl A4692 from AVEBE B.A.) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier.
The dried paper is allowed to condition, and then measured for CIE whiteness and brightness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 3 and Table 4 respectively and clearly show that the instant invention provides excellent build-ups of both whiteness and brightness.
Comparative Application Example 2
Aqueous sizing compositions are prepared by adding preformed aqueous solution containing compound of formula (2) (18.2% by weight of compound of formula (2), the % by weight being based on the total weight of the aqueous solution containing compound of formula (2)) at a range of concentrations of from 0 to 60 g/l (of from 0 to approx. 11 g/l based on dry compound of formula (2)) to a stirred, aqueous solution containing an anionic potato starch (75 g/l) (Perfectamyl A4692 from AVEBE B.A.) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier.
The dried paper is allowed to condition, and then measured for CIE whiteness and brightness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 3 and Table 4 respectively and clearly show that the absence of the shading dye has no effect on the brightness build-up, but has a negative effect on the whiteness build-up.
TABLE 3
CIE Whiteness
Added OBA solution
Application
Comparative Application
[g/l]
Example 2
Example 2
0
106.8
102.7
10
126.3
123.4
20
134.0
130.5
30
139.0
135.3
40
142.0
138.1
60
144.9
141.8
TABLE 4
Brightness
Added OBA solution
Application
Comparative Application
[g/l]
Example 2
Example 2
0
93.1
92.8
10
100.3
100.3
20
103.3
103.1
30
105.2
105.1
40
106.4
106.3
60
107.9
107.9
Application Example 3
Aqueous sizing compositions are prepared by adding preformed aqueous solution containing compound of formula (3) (14.7% by weight of compound of formula (3), the % by weight being based on the total weight of the aqueous solution containing compound of formula (3)) at a range of concentrations of from 0 to 60 g/l (of from 0 to approx. 9 g/l based on dry compound of formula (3)) to a stirred, aqueous solution containing compound of formula (1) (4.0 mg/l) and an anionic potato starch (75 g/l) (Perfectamyl A4692 from AVEBE B.A.) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier.
The dried paper is allowed to condition, and then measured for CIE whiteness and brightness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 5 and Table 6 respectively and clearly show that the instant invention provides excellent build-ups of both whiteness and brightness.
Comparative Application Example 3
Aqueous sizing compositions are prepared by adding preformed aqueous solution containing compound of formula (3) (14.7% by weight of compound of formula (3), the % by weight being based on the total weight of the aqueous solution containing compound of formula (3)) at a range of concentrations of from 0 to 60 g/l (of from 0 to approx. 9 g/l based on dry compound of formula (3)) to a stirred, aqueous solution containing an anionic potato starch (75 g/l) (Perfectamyl A4692 from AVEBE B.A.) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier.
The dried paper is allowed to condition, and then measured for CIE whiteness and brightness on a calibrated Auto Elrepho spectrophotometer. The results are shown in table 5 and table 6 respectively and clearly show that the absence of the shading dye has no effect on the brightness build-up, but has a negative effect on the whiteness build-up.
TABLE 5
CIE Whiteness
Added OBA solution
Application
Comparative Application
[g/l]
Example 3
Example 3
0
106.8
102.7
10
125.8
122.7
20
132.9
129.5
30
136.8
133.5
40
138.8
136.4
60
141.4
139.0
TABLE 6
Brightness
Added OBA solution
Application
Comparative Application
[g/l]
Example 3
Example 3
0
93.1
92.8
10
100.0
100.3
20
102.9
103.1
30
104.7
104.7
40
105.5
106.0
60
107.0
107.4
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The instant invention relates to liquid sizing compositions comprising shading dyestfuffs, derivatives of diaminostilbene, binders, protective polymers, and optionally divalent metal salts which can be used for the optical brightening of substrates, including substrates suitable for high quality ink jet printing.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation, under 35 U.S.C. §120, of copending international application No. PCT/EP2013/073232, filed Nov. 7, 2013, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German patent application No. DE 10 2012 220 310.9, filed Nov. 8, 2012; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to a layered composite material which comprises at least two layers of graphite foil.
[0003] Layered composite materials of this type are used for example for producing seals for high-temperature furnaces, during the operation of which the seals are subjected to temperatures for example of greater than 600° C. or even of greater than 1800° C., or for producing seals for plants in the chemical industry, during the operation of which the seals are frequently exposed to a highly corrosive environment. The graphite foils used therein are conventionally produced by expanding graphite, in particular natural graphite, and subsequently compressing the expanded particles. By means of the compression process, the individual graphite particles are interlocked so that planar graphite bodies in the form of foils or plates can be produced without adding binders. Graphite bodies of this type are distinguished in particular by a high temperature resistance and corrosion resistance and by a low permeability to liquids and gases.
[0004] However, on account of the method, graphite foils of this type cannot be produced having unlimited thicknesses. Therefore, only a multi-layer construction can be considered for applications for which a corresponding thickness is required, such as the use as a seal in a high-temperature furnace.
[0005] In order to ensure a stable composite in multi-layer constructions of this type, which is necessary for example in order to be able to handle the composite from the time of the production thereof until the installation thereof at the destination, the individual foil layers are conventionally glued together. However, the gluing is associated with relatively complex operation steps. In addition, the problem arises in this case that, when an adhesive is used, carbonisation and graphitisation of the component in question is necessary after the gluing in order to achieve the purity level required for conventional applications, which is, however, associated with significant additional outlay. Furthermore, during the heat treatment of the foil stack in an appropriate furnace, which heat treatment is required for the carbonisation and graphitisation, blistering may occur in the material, which is unacceptable in numerous applications.
SUMMARY OF THE INVENTION
[0006] It is accordingly an object of the invention to provide a layered composite which overcomes the above-mentioned and other disadvantages of the heretofore-known devices and methods of this general type and provides for a layered composite material, formed of at least two graphite foil layers, which is stable and fluid-tight and yet simple to produce.
[0007] With the foregoing and other objects in view there is provided, in accordance with the invention, a layered composite material, comprising:
[0008] at least two layers of graphite foil;
[0009] at least one connecting pin connecting the at least two layers of graphite foil to one another. The at least one connecting pin engages in each of the at least two layers with a form-fit.
[0010] In other words, the objects of the invention are achieved by a layered composite material with at least two graphite foil layers of the layered composite material interconnected by means of at least one connecting pin which engages at least with a form-fit in the two layers. The term form fit or form fitting connection is equivalent to the term positive fit or positive connection, namely, a connection between two parts in which the parts themselves provide for a shape that opposes their separation.
[0011] The individual foil layers are therefore not glued, as is conventional in the prior art, but rather pinned. As a result, not only the complex application of the adhesive layer(s), but also the carbonisation and graphitisation, are dispensed with, so that the layered composite material does not need to be subjected to any additional heat treatment during manufacture and consequently there is no longer the risk of blistering. In the context of the present invention, a pin means an elongate element, such as in particular a bolt, peg, key, cone or the like, the remainder of the geometry and in particular the cross-sectional shape being in principle arbitrary. Depending on the shape, the size and the raw material, the connecting pin can be produced by means of turning, grinding, punching, cutting, stamping or similar methods.
[0012] A particular advantage of the present invention is that a connecting pin is simple and cost-effective to produce. However, due to the form-fit engagement, a high degree of connection stability is nonetheless ensured. The present invention relates inter alia to the finding that pinning with a form-fit is sufficient for safely handling the stack of flexible and relatively thin graphite foil layers until assembly; there is therefore no need whatsoever to glue the layers together over the entire surface areas thereof. As soon as the sealing component formed by the foil stack has been installed at the destination, the clamping forces acting perpendicularly to the stack surface mean that there is in any case no longer any danger of the stack falling apart. On account of its elongate design, the connecting pin, which then in principle has no function, then impairs the permeability and the heat-conducting behaviour of the seal to only a very limited extent, if at all.
[0013] It is important in this case for at least two layers to be interconnected by a connecting pin if more than two layers of graphite foil are present in a layered composite material. Therefore, if the layered composite material comprises for example four layers of graphite foil, it is sufficient in principle for merely two layers to be interconnected by a connecting pin. However, in order to achieve a high overall stability of the layered composite material it is preferred for all the layers of graphite foil present to be interconnected using at least one connection pin.
[0014] A preferred embodiment of the present invention provides for the at least two layers of graphite foil to be interconnected by means of at least one connecting pin engaging with a form-fit and force-fit in the two layers. The stability of the composite can be further increased by the combination of a form-fit and force-fit connection. The term force fit or force fitting connection is equivalent to the term friction fit or frictional force connection.
[0015] The longitudinal axis of the at least one connecting pin preferably extends at right angles or obliquely to the planar extension of the layered composite material. In other words, the connecting pin preferably does not extend in parallel with the surface of the foil stack, but rather transversely thereto. For example, the longitudinal axis can be inclined by approximately 10° to the surface normal. Then, no engagement elements protruding from the connecting pin are necessary, since the form-fit connection between the at least two layers is achieved by the pin body itself. Additional engagement elements can nonetheless be provided on the connecting pin should the application require.
[0016] According to a further preferred embodiment of the present invention, the at least two layers of graphite foil are interconnected by means of at least two connecting pins, the longitudinal axes of which are differently inclined with regard to the planar extension of the layered composite material. In this case, the longitudinal axes may differ from one another in the inclination angle and/or the inclination direction thereof. The cohesion of the layered composite material can be achieved to a particularly high degree by means of differently inclined connecting pins of this type.
[0017] Furthermore, it is preferred that at least one end of the at least one connecting pin be offset backwards by a buffer distance relative to the closest outer surface of the layered composite material. That is to say that the connecting pin preferably does not penetrate the surfaces of the outermost layer, but rather extends merely in part through the layered composite material. Preferably, the connecting pin is entirely embedded in the composite material. In this case, and according to a particularly preferred embodiment of the present invention, the buffer distance between the end of the pin and the outer surface of the layered composite material is at least 1 mm. This takes account of the fact that the material can be compressed when using the layered composite material as a seal, in which case the buffer distance prevents force from being directly applied to the connecting pin in an undesirable manner. In addition, thermal bridges can be minimised or even entirely prevented thereby in a particularly advantageous manner.
[0018] In principle, the connecting pin can also extend through the entire layered composite material, it being preferred in this case for the connecting pin to lock at least flush with the outer surfaces of the layered composite material in order to ensure sufficient stability and in order not to impair the compressibility of the overall construction. Since the cross-sectional area of the connecting pin is conventionally considerably smaller than the overall surface of the foil stack, in this case too, the formation of thermal bridges on account of the pin is only relatively low.
[0019] In a development of the present invention, it is further proposed that, in each case, two of the at least two layers of graphite foil connected by at least one connecting pin be directly adjacent to each other. It is therefore preferred for no intermediate layer or separating layer to be arranged between adjacent layers, since this allows a particularly simple construction. However, this is not essential, i.e. depending on the application, the layered composite material can also comprise additional layers made from other materials, such as reinforcing layers made from sheet metal, which are inserted between two layers of graphite foil in each case.
[0020] According to a further preferred embodiment of the present invention, the at least two layers of graphite foil are interconnected exclusively by means of the at least one connecting pin, and in particular in an adhesive-free manner. This allows particularly simple and cost-effective production.
[0021] In addition, it is preferred for the at least two layers of graphite foil to consist entirely of compressed expanded, in particular binder-free, graphite.
[0022] In accordance with an added feature of the invention, the at least two layers of graphite foil, and preferably each of the at least two layers of graphite foil, have a thickness of between 0.2 mm and 10 mm and preferably of between 1 mm and 3 mm. Graphite foils of this foil thickness are simple to produce by way of conventional methods.
[0023] In accordance with an additional feature of the invention, the at least two layers of graphite foil, and preferably each of the at least two layers of graphite foil, have a bulk density of between 0.5 g/cm 3 and 2 g/cm 3 , and particularly preferably between 0.7 g/cm 3 and 1.3 g/cm 3 . Graphite foils of this type are particularly suitable for high-temperature resistant and corrosion resistant seals.
[0024] According to a further preferred embodiment of the present invention, it is provided that the layered composite material has a total thickness of between 2 mm and 50 mm, preferably of between 4 mm and 40 mm, and more preferably of between 5 mm and 30 mm. Layered composite materials of this thickness have proven particularly beneficial for applications of the type mentioned at the outset.
[0025] In a development of the inventive concept, it is proposed in addition that the layered composite material comprises at least 3, preferably between 3 and 50, more preferably from 3 to 5, and most preferably 4 or 5 layers of graphite foil.
[0026] In this case, the at least three layers of graphite foil can also be interconnected by means of at least two connecting pins, each of the at least two connecting pins engaging merely in two adjacent layers of the at least three layers of graphite foil. By means of this measure, in particular undesired thermal bridges can be reduced to a minimum or even entirely avoided.
[0027] In order to reinforce this effect even more, the positions of the at least two connecting pins can in addition be offset from one another with respect to the planar extension of the layered composite material.
[0028] Good results are achieved in particular if the at least one connecting pin is produced from a material selected from the group consisting of carbon, graphite, composite materials containing carbon fibres, felt, silicon carbide, metals, ceramic materials and any combination of two or more of the aforementioned materials. It is preferred, in this case, for the connecting pin to consist entirely of a composite material containing carbon fibres, of graphite, or of steel.
[0029] According to a specific embodiment of the invention, the at least one connecting pin is produced from graphite foil. A high level of homogeneity of the layered composite material is thereby achieved.
[0030] In accordance with a further feature of the invention, the at least one connecting pin is cylindrical in shape, i.e. the cross section of the connecting pin is preferably circular. Connecting pins of this type are particularly simple and cost-effective to produce. In principle, however, the connecting pin may also be of another shape, for example an elliptical, square or hexagonal cross section.
[0031] Furthermore, the at least one connecting pin may be tapered at least in portions with regard to the longitudinal axis thereof and may be for example conical in shape. A tapered design of this type can facilitate driving the pin into the foil stack and assist in the production of a force-fit connection.
[0032] In addition, the at least one connecting pin may also have a textured surface. For example, the surface of the connecting pin could be corrugated or serrated at least in regions. However, texturing can only consist in a comparatively high degree of roughness of the pin surface. In contrast with a smooth pin surface, a design of the connecting pin having a textured surface allows increased frictional resistance and thus improved cohesion of the layers.
[0033] If a particularly high connection strength is desired, the at least one connecting pin can advantageously further comprise a thread and/or a winding hook.
[0034] According to a further embodiment of the present invention, the at least one connecting pin has an outer diameter of between 1 mm and 5 mm, preferably of between 1.5 mm and 4 mm and more preferably of between 2 mm and 3 mm. Furthermore, the at least one connecting pin can have a length of between 1 mm and 20 mm, and preferably of between 2 mm and 5 mm. The dimensions of the connecting pin depend specifically on the measurements of the overall construction and the required connection strength.
[0035] In principle, however, it is preferred for the at least one connecting pin to have a length which is smaller than the sum of the thicknesses of the layers of graphite foil interconnected by the connecting pin. Undesired heat-conduction losses are thereby minimised and a direct application of pressure on the connecting pin in the event of compression of the layered composite material is thereby prevented.
[0036] In order to allow a reliable form-fit, a recess for receiving the at least one connecting pin can in addition be provided in each of the at least two layers of graphite foil. The recess can be produced prior to connecting the layers, by means of drilling or milling. Alternatively, dispensing with all kinds of recesses can also be considered, in order to save the associated operation steps, such as predrilling. The connecting pin can then be shot into the foil stack, for example by means of a shooting device.
[0037] In order to further increase the stability, the at least one connecting pin can be received in the recesses, forming an interference fit. A connecting pin in an interference fit allows for a combination of a form-fit and force-fit connection.
[0038] According to a further preferred embodiment of the present invention, it is provided for at least one of the recesses to be formed as a blind hole. This has the effect that the formation of thermal bridges is minimized.
[0039] The present invention further relates to a component, in particular a seal, which comprises at least one layered composite material configured in the manner described above.
[0040] In addition, the present invention relates to the use of a layered composite material or component configured in the manner described above as a seal, in particular at a temperature of at least 600° C., preferably of at least 800° C., more preferably of at least 1000° C., and most preferably of at least 1800° C.
[0041] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0042] Although the invention is illustrated and described herein as embodied in a layered composite material, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0043] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0044] FIG. 1 is a lateral sectional view of a layered composite material according to the invention, formed with five layers of graphite foil.
[0045] FIGS. 2 a - 2 e are respective plan views of the layered composite material according to FIG. 1 , illustrating the positioning of the connecting pins connecting the individual layers of graphite foil.
DETAILED DESCRIPTION OF THE INVENTION
[0046] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a high-temperature seal according to the invention. The assembly is formed as a layered composite and comprises five layers 11 , in the form of graphite foil plates, stacked on top of one another. The individual layers 11 are each 3 mm thick and consist entirely of compressed expanded natural graphite. For example, a graphite foil of the trade mark Sigraflex®, material type L30010C can be used. The five layers 11 are pinned together using a plurality of cylindrical connecting pins 13 to form an overall plate forming the high-temperature seal. In this case, the connecting pins 13 are produced from a composite material containing carbon fibres or from graphite, and are worked to a length of 5 mm. In the present embodiment, the outer diameter of the connecting pins 13 is 3 mm. In this case, the longitudinal axis L of the connecting pins 13 extends, in the embodiment shown, at right angles to the plane E of the layers, i.e. to the planar extension of the layers 11 .
[0047] In order to produce the layered composite material, blind holes 14 for receiving the connecting pins 13 are bored into the layers 11 by means of a 3 mm steel drill. The layers 11 are subsequently pinned together, in each case a set of four connecting pins 13 being inserted into the associated blind hole 14 of a layer 11 and a following layer 11 being laid on the lower layer 11 in a manner having correspondingly positioned blind holes 14 .
[0048] Since the thickness of two layers 11 stacked on top of each other is 6 mm, but the connecting pins 13 are only 5 mm long, buffer zones 18 result, which prevent a direct application of pressure on the connecting pins 13 . In addition, the positions of the connecting pins 13 change from layer to layer, as will be described in more detail below with reference to FIG. 2 a - 2 e.
[0049] According to FIG. 2 a , the first, i.e. the bottom, layer 11 , contains four connecting pins 13 in the positions marked 19 . These four connecting pins 13 serve purely as the connection between the lowest layer 11 and the second layer 11 viewed from the bottom. Said second layer 11 is shown in FIG. 2 b , in which it is made clear that the positions 21 of those connecting pins 13 serving as the connection between the following third layer 11 and the second layer 11 are offset from the positions 19 of those connecting pins 13 serving as the connection between the bottom layer 11 and the second layer 11 . The offset is selected such that as large a distance as possible exists between the positions 19 and the positions 21 .
[0050] According to FIG. 2 c , the positions 23 of those connecting pins 13 serving as the connection between a following fourth layer 11 and the third layer 11 coincide, in plan view, with the positions 19 of those connecting pins 13 serving as the connection between the bottom layer 11 and the second layer 11 . It can further be seen from FIGS. 2 d and 2 e that the positions 25 of those connecting pins 13 serving as the connection between the fifth and final layer 11 and the fourth layer 11 also coincide, in plan view, with the positions 21 of those connecting pins 13 serving as the connection between the second layer 11 and the third layer 11 .
[0051] The offset arrangement of the connecting pins 13 according to FIG. 2 a - 2 e prevents thermal bridges and minimizes the gas permeability of the high-temperature seal during use of the layered composite material. Overall, the invention allows the provision of a multi-layer graphite seal having high temperature resistance and corrosion resistance, without the need for complex gluing, carbonization and graphitization processes.
[0052] The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention:
11 layer 13 connecting pin 14 blind hole 18 buffer zone 19 positions of the connecting pins for connecting the first and the second layer 21 positions of the connecting pins for connecting the second and the third layer 23 positions of the connecting pins for connecting the third and the fourth layer 25 positions of the connecting pins for connecting the fourth and fifth layers L longitudinal axis E layer plane
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A layered composite material component has two or more layers of graphite foil. The layers of graphite foil are connected together by way of at least one connecting pin that engages in both layers in a form-fitting manner.
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BACKGROUND OF THE INVENTION
This application relates generally to data transmission, and more particularly to data transmission over power lines.
The use of power lines to transmit data is known. Initially, power line communication systems were limited to relatively low data rates, typically less than 500 kbs. These low data rates are generally useful for applications such as remote control of various switches connected to the power line system. More recently, developments have been made in the area of broadband power line communication systems, also known as power line telecommunications (PLT) systems or broadband power line (BPL) systems. These systems are capable of transmitting data at significantly higher data rates than previous systems. For example, BPL systems can transmit data at rates of 4–20 Mbps.
While existing power line systems are capable of transmitting data at the rates described above, they were not initially designed for data transmission. Instead, they were designed to carry large currents at high voltages so that significant amounts of energy could be distributed at one primary low frequency (e.g., 60 Hertz).
Power line communication systems generally use one or more carrier frequencies in order to spread the data transmission over a wider range of frequencies. The low data rate power line communication systems discussed above generally utilized frequencies in the range of 9 kHz to 525 kHz. In this frequency range the risk of emissions is low as the attenuation of the cable is low and the wavelengths used in the signaling are long with respect to the typical cable lengths in the system. However, the high data rates of BPL systems cannot be achieved using carrier frequencies below 525 kHz. Instead, BPL systems typically use carrier frequencies in the range of 1–30 MHz. At these higher frequencies, it is preferable to employ capacitive coupling rather than inductive coupling in order to implement a broadband communication system using power line cables.
Providing an electrical coupling to medium voltage (MV) and low voltage (LV) power lines as part of a broadband communication system is a dangerous task. Also the coupling must be made secure to withstand hostile weather conditions and to provide reliable communication services. Previous attempts to install such a coupling as part of a capacitive coupling circuit have relied on highly trained and skilled installation personnel. New customer interconnections as well as periodic interconnections with auxiliary electronics such as repeaters, routers, etc. must be done at various points along energized power lines without incurring risk of injury or disruption of both power transmission and broadband communications. There is an important need to develop a technique for providing such interconnections at a safe distance spaced from the energized power lines.
BRIEF SUMMARY OF THE INVENTION
The invention provides a power line broadband communication system having broadband coupler devices capable of direct electrical connection to an energized power line without creating unreasonable safety risks.
Various embodiments of the invention include a conductive portion movable from a non-conducting retracted position spaced apart from the power transmission line to a forward conducting position in electrical contact with the power line. An insulated arm supports the coupler on the power line. In some embodiments a base of an adjustable member on the coupler is engageable with a remotely activated tool in order to accomplish the electrical connection in a safe and secure manner.
Generally speaking the invention enables broadband data signals to be sent to and from existing and new customer premises along the shared energized power lines. New coupler connections to the energized power lines allow additional broadband customers to join the communication system. Also couplers may provide power line connections to other components such as to repeater control electronics for the broadband signals, to signal routers, and to transformer bypass circuits.
In accordance with some embodiments of the invention, a method for facilitating broadband electrical transmissions on a power line includes placing a coupler device on an energized power line in a self-supporting position, engaging the coupler device from a location spaced apart from the energized power line to cause a conductive portion of the coupler device to make electrical metallic contact with the power line, and transmitting data signals through the coupler device via the energized power line.
In one embodiment the coupler device carries signals to and from transceivers associated with customer premises. Such transceivers may have wired connections via transformer bypass router lines to and from customer premises. Other exemplary transceivers may be wireless transceivers that eliminate any need for a transformer bypass line.
In other embodiments the coupler device may provide a direct connection to energized power lines from electronic signal control devices. Signal repeaters are an example of such devices that can be connected to an MV line through a coupler installation device incorporating features of the invention.
Exemplary coupler device embodiments may include a hanger fixture having a first insulated end capable of self-supporting contact with a power line cable, and a second conductive end adjustably movable relative to the power line cable. Secure attachment may be accomplished after electrical contact has been made between the conductive end and the power line cable by a compressive force exerted by an adjustment bolt or screw holding the power line cable between the first and second ends of the hanger fixture.
In some embodiments the first end of the coupler device includes a U-shaped portion for partially surrounding the power line cable, and the adjustment bolt or screw may be incorporated as part of the second conductive end of the fixture and may have a sharp edge or point for making metallic electrical contact with the power line cable. In some embodiments the adjustment bolt or screw may cause closure of the coupler device to prevent the coupler from becoming disengaged from the power line cable.
One aspect of the invention includes moving the conductive portion from the retracted position with an insulated tool that is activated remotely to engage an adjustment portion of the coupler.
In some embodiments, the conductive portion of the coupler is connected to a broadband signal line through a capacitor. The technique of the present invention as implemented in certain embodiments helps to make capacitive coupling cost competitive with inductive coupling, thereby taking advantage of the fact that capacitive coupling is more efficient for broadband signals. The impedance of a capacitive coupler (i.e., its ability to obstruct the flow of signal energy) decrease with signal frequency. With an inductive coupler, the impedance increase with frequency. Thus the capacitive coupler is better suited to cases where we want to use high-frequency broadband signals.
Because a capacitive coupler device requires direct electric conductive contact with an energized power line, the coupler installation device and method of the present invention greatly facilitate the capability of enjoying the benefits of capacitive coupling for broadband power line communication systems as compared with inductive coupling.
These and other advantages of the invention will be apparent to those of ordinary skill in the art by reference to the following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a broadband power line communication system for implementing various features of the invention.
FIG. 2 is a schematic illustration showing an exemplary power line communication system embodiment of the invention.
FIG. 3 shows an exemplary embodiment of a coupling device for connection to a power line communication system.
FIGS. 4A and 4B show exemplary techniques for using features of the invention to make an electrical connection at different angular orientations directly to an energized communication power line.
FIGS. 5A and 5B show additional exemplary techniques for using a coupling device to make an electrical connection directly to an energized communication power line.
FIGS. 6A and 6B show fragmentary views of other coupling device embodiments that facilitate electrical connections to an energized communication power line.
FIG. 7 shows a fragmentary view of another coupling device embodiment.
FIG. 8 shows a fragmentary view of a different coupling device embodiment in closed conductive position, with an open position of the coupling device shown in phantom.
DETAILED DESCRIPTION
A typical power line communication system for implementing features of the invention is shown in FIG. 1 . A high voltage (HV) power line 102 transmits power through sub-station 104 to a medium voltage (MV) power line 106 that eventually may connect through a transformer 108 to low voltage (LV) lines 110 that provide alternating electrical power to customer premises 111 , 112 , 113 . A wireless connection through transceiver 107 may provide an alternative connection to customer premises 109 .
A head end data network provides communication signals 120 via a fiber optic cable or other suitable transmission links to the end user customer premises 111 , 112 , 113 using power line cables as the transmission medium. Techniques for converting data signals to the electrical domain for transmission via the power lines are well known. A transmitter contains a modulator which modulates the incoming data onto a carrier signal using well known RF modulation techniques. As described above, typical carrier frequencies for a power line communication system are in the range of 1–30 MHz. The modulated signal is provided to the power line cable 106 via couplers 122 .
It will be understood by those skilled in the art that a signal on an optical cable must first be converted to an electrical signal, then reformatted (demodulated-remodulated) to a format appropriate for transmission on a power line (e.g., OFDM). Such a modulated and reformatted signal can then be coupled by the present invention onto a power line as shown at coupler connections 122 .
A power line communication system of the type shown in FIG. 1 may use orthogonal frequency division multiplexing (OFDM) in which the available bandwidth is split up into multiple narrowband channels which do not interfere with each other. However the present invention is applicable to any type of power line communication system such as OFDM, a spread-spectrum system, etc. Thus, in accordance with any appropriate BPL system, broadband signals are carried over the MV line 106 and optionally LV lines 110 to receivers at the customer premises 111 , 112 , 113 , or via MV line 106 through wireless transceiver 107 to customer premises 109 .
For purposes of the present description, it is assumed that the MV power line cable 106 will typically supply power at 4–66 kV. Such medium voltage cable is typically an aluminum cable having a 1 cm diameter. Couplers 122 provide an interconnection for the modulated carrier signal to the MV line 106 . Various types of couplers are known in the art, including for example inductive couplers and capacitive couplers. The carrier signal is transmitted along the length of MV power line cable 106 through transformers 108 to LV lines 110 . The low voltage power line typically supplies power at 100–240 volts. The low voltage line transmits the data signals to the customer premises 111 , 112 , 113 where a modem demodulates the signal and extracts the data message.
It is noted that for ease of description only downstream (i.e., from head end to end user) data transmission is shown and described. One skilled in the art would readily recognize that upstream transmission could be accomplished in a similar manner.
As described above in the background section, there is a significant problem with safety risks in providing broadband coupler connections directly to an energized power line.
As shown in the embodiment of FIG. 1 , the MV line 106 may connect through MV couplers 124 to signal repeater electronics 126 . Providing a repeater connection to a MV power line is an important application in some embodiments of the invention.
The MV line 106 may also connect through MV coupler 128 via bypass router 130 to LV coupler 132 in order to achieve data signal transfer to an LV power line 110 . Router 136 interconnects with LV power line 110 at LV coupler 134 in order to selectively deliver appropriately addressed data signals to receivers at either customer premises 112 or customer premises 113 . The coupler installation of the invention can be incorporated at high risk MV coupler connection 128 , and also at lower risk LV coupler connections 132 , 134 , although installation at these LV points does not pose the high safety risk associated with installation on MV lines
The MV line 106 may also connect through MV coupler 142 via bypass router 144 to LV coupler 146 in order to achieve data signal transfer to an LV power line 110 . Router 140 interconnects with MV power line 106 at MV coupler 138 in order to selectively deliver appropriately addressed data signals via wireless transceiver 107 to customer premises 109 . Using such a wireless transceiver, as for example a WiFi access point, makes it unnecessary to provide a transformer bypass path for the broadband signal. The coupler installation of the invention can be incorporated at high risk MV coupler connections 138 , 142 , and also at lower risk LV coupler connection 146 .
FIG. 2 is a high level schematic diagram showing exemplary locations for installing a coupler device on a power line communication system. Although most present day power lines transmit alternating current (AC), the invention is applicable to both AC and DC (direct current) power line systems. Utility poles 220 support MV lines 202 and LV lines 204 at a safe distance from the ground. Implementing a communication system on the power lines typically requires electronic components 206 , 208 , 210 , 214 , 216 including capacitors 212 , 218 in order to assure satisfactory transmission of broadband signals to customers 224 . The invention provides a safe, secure and reliable coupling technique for making electrical interconnections to high risk MV lines at coupling locations 220 , as well as to lower risk LV lines at coupling locations 222 .
The embodiment of FIG. 3 shows an exemplary coupler device 300 having an insulated portion 302 and a conductive portion 304 connected through link 306 via capacitor 308 to electronic components 310 . A threaded sleeve 312 receives a conductive adjustment screw 313 with threads 314 . The adjustment screw 313 has a contact point 316 for electrical contact with a power line cable (not shown). An insulated tool 320 , as for example a tool known in the trade as a hotstick, includes a long extension 322 having a cap 324 sized and shaped for engagement with the adjustment screw 313 . An installer can grasp a handle 326 at a location remote from high risk MV or lower risk LV power cables and actuate the tool such as by rotation in direction 328 .
The insulated portion 302 of the coupler 300 may have a hook-shaped end 334 formed by extension 330 and truncated end 336 . A leg portion 332 provides an attachment junction with the conductive portion 304 . The overall contours of the insulated portion 302 may be U-shaped in order to provide multiple interior contact surfaces 338 , 340 , 324 for contacting adjacent surfaces of a power line cable in order to support the coupler when the adjustment screw 313 is in open position, as well as to securely establish electrical contact and maintain attachment to the power cable when the adjustment screw 313 is in closed position. Other hook-like shapes may be incorporated in the insulated portion 302 in order to partially surround the power cable and maintain the coupler 300 in self-supporting position during initial coupler installation as well as during actuation of the tool to accomplish electrical contact between the conductive portion 304 and the energized power cable.
Of course, the benefits of the invention can be achieved with other adjustment members which perform a similar function to the adjustment screw 313 so that the coupler can have a conductive component remotely actuated from a retracted position to a forward conducting position while the coupler remains in self-supporting position on the power cable.
It will be understood by those skilled in the art that various angular orientations of a coupler fixture and its conductive element relative to a power line cable are possible in order to achieve the goals of the present invention. For example, in FIG. 4A , a conductive adjustment screw 404 has a tapered head 406 with a central contact point 408 and is shown facing upwardly in a vertical direction for making electrical contact with power cable 400 . A coupler having contact surfaces approximately coincident with plane 410 will apply compressive forces in a direction 412 in order to help maintain such electrical contact and hold the coupler in secure position on the power cable. A conductive adjustment screw 414 has a tapered head 416 with a central contact point 418 and is shown facing laterally in a horizontal direction for making electrical contact with power cable 400 . A coupler having contact surfaces approximately coincident with plane 420 will apply compressive forces in a direction 422 in order to help maintain such electrical contact and hold the coupler in secure position on the power cable. A conductive adjustment screw 424 has a tapered head 426 with a central contact point 428 and is shown facing partially upwardly in a somewhat oblique angular direction for making electrical contact with power cable 400 . A coupler having contact surfaces approximately coincident with plane 430 will apply compressive forces in a direction 432 in order to help maintain such electrical contact and hold the coupler in secure position on the power cable.
Similar orientations are illustrated in FIG. 4B for non-tapered heads respectively having sharp peripheral edge contact surfaces 438 , 448 , 458 . Compressive forces applied perpendicular to planes 410 , 420 , 430 will maintain electrical contact with adjustment screws 436 , 446 , 456 respectively, and hold the coupler in secure position on the power cable.
Referring to FIGS. 5A and 5B , a coupler device is shown in closed position with a conductive portion in electric metallic contact with a power line cable 400 . In these embodiments, a U-shaped insulated coupler arm 334 includes an elongated extension 330 and a shortened extension such as truncated end 336 . An adjustment shaft in the form shown as threaded adjustment screw 313 makes electrical contact and also applies compressive forces to hold the power line cable 400 in secure position against the U-shaped insulated coupler arm 334 .
In FIG. 5A a central contact point 316 on the apex of the adjustment screw 313 makes the electrical contact. In FIG. 5B a sharpened circular peripheral edge 416 on the apex of the adjustment screw 31 makes the electrical contact. Various other shapes and type of sharp contact edges or points may be used in order to penetrate any weather coating or other surface material on the power line cable and make the appropriate metallic contact for transmitting message and control signals between the coupler and the power line cable.
Additional embodiments for facilitating engagement of a self-supported coupling device on a power line are shown in FIGS. 6A and 6B . Referring to FIG. 6A , an insulated arm 600 includes elongated extension 602 , header 604 and shortened extension 606 which together form a rectangular-shaped hook having a central concave recess 608 shaped and sized to provide support on a power line cable 611 . A threaded conductor shaft 613 is shown in partially closed position with its tapered head 615 starting to penetrate an outer insulation layer prior to making electrical contact with the power line cable 611 (see FIG. 4A ).
Referring to FIG. 6B , an insulated arm 610 includes shortened extension 612 , header 614 and elongated extension 616 which together form a rectangular-shaped hook having a triangular slot 618 to provide support on a power line cable 611 . The threaded conductor shaft 613 is shown in partially closed position similar to FIG. 6A .
Referring to the embodiment of FIG. 7 , a mechanical fixture assembly includes a coupler device 740 shown in a self-supporting position on a power line 700 , and also includes a remotely activated insulated tool 722 that has been manually engaged with the coupler device 740 . The insulated tool 722 has a cap 724 sized and shaped to fit an enlarged base 726 of a threaded shaft 728 on the coupler device 740 . After an installer has manually rotated a handle 727 remotely located from the power line 700 in order to advance the threaded shaft 728 forwardly, a sharpened point 730 on an apex of the shaft advances from a partially closed position making initial contact with an insulation layer as shown in the drawing until the insulation layer is penetrated and electrical metallic contact is made directly with the power line (see FIG. 4A ).
The threaded shaft and its adjacent threaded base 732 together constitute a conductor portion of the coupler device for carrying signals to and fro between line 734 and power line 700 . In this embodiment, an insulated arm is formed by a first extension 742 connected at its lower end to the base 732 , and is joined at its upper end 748 to angular extension 744 to form a triangular recess 745 for supporting the coupler device on the power line 700 . A lower leg portion 746 on the angular extension 744 along with interior contact surfaces 750 , 752 help to assure the coupler device 740 remains in self-supporting position on the power line 700 upon initial installation of the coupler device and during adjustment of threaded shaft 728 into conducting position by insulated tool 722 .
In view of the foregoing description and drawings of exemplary embodiments, it will be understood by those skilled in the art that variously shaped coupler devices with differently shaped interior contact surfaces can be utilized in order to maintain the coupler device in a somewhat stable self-supporting position on a power cable during the various stages of installation. In some instances, the corresponding mass of each portion of the exemplary coupler devices shown in the various drawing figures may if necessary be counter-balanced in order to help the coupler device remain self-positioned, such as when an adjustment member such as a threaded shaft is in retracted open position as well as when an adjustment member is moved into closed position such as during rotation of the threaded shaft by the remotely positioned installer.
Referring to the embodiment of FIG. 8 , a power line 800 is shown in an engaged position with a closed fully installed coupler device 840 comprising another mechanical fixture. A conductor shaft 820 has an upper end 822 tapered to form a sharpened central point 824 , the shaft being formed integral with a conductor plate 826 connected to signal line 828 . A separate bolt 830 that may be formed with a dielectric material has a threaded upper end 836 that engages a matching threaded sleeve 838 on a U-shaped insulated arm 840 . Rotation of the bolt by a remotely activated tool (not shown in this drawing) advances the conductor plate 826 and conductor shaft 820 forwardly into closed position to provide electrical metallic contact of the central point 824 with the power line 800 , as shown in the drawing. Rotation of the bolt 830 is facilitated by a raised low-friction boss 834 on the underside of conductor plate 826 .
When the conductor plate is moved to a closed position as shown by arrow 846 , the insulated arm 840 has a lower leg 842 abutting an end 844 of the conductor plate 825 in order to eliminate an initial installation gap. When the coupler device is in open position as shown in phantom at 848 , the initial installation gap allows insertion of the power line 800 inside of the U-shaped insulated arm. The upper part of the U-shaped insulated arm 840 provides a recess for holding the coupler device in self-supporting position on the power line 800 .
In view of all the foregoing, it will be understood by those skilled in the art that various embodiments of the invention enable and facilitate implementation of a broadband communication system on energized power lines by various installation methods including but not limited to one or more of the following techniques: making multiple connections to power lines through individual coupler devices in order to bypass transformers connecting LV customer premises to shared power lines; or making multiple connections to power lines through wireless transceivers in order to connect customer premises to shared power lines; or making multiple connections to power lines through capacitive coupler devices in order to connect customer premises to shared power lines; or connecting repeater electronics to MV power lines in order to facilitate broadband signal transmission on shared power lines to customer premises; or connecting routers to LV or MV power lines in order to direct delivery of data messages to appropriate customer premises.
The foregoing Detailed Description is to be understood as being in every respect illustrative and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Detailed Description, but rather from the claims as interpreted according to the full breadth permitted by the patent laws. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention.
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Disclosed is a power line broadband communication system having broadband coupler devices capable of direct electrical connection to an energized power line. The coupler includes a conductive portion movable by an adjustable member from a non-conducting retracted position spaced apart from the power transmission line to a forward conducting position in electrical contact with the power line. An insulated arm supports the coupler on the power line. A base on the coupler is engageable with a remotely activated tool in order to accomplish the electrical connection in a safe and secure manner. Broadband data signals are sent to and from customer premises along the shared energized power lines. New coupler connections to the energized power lines allow the additional broadband customers and/or repeaters to join the communication system. Also couplers may provide connections to control electronics, routers, wireless transceivers, and may allow the broadband signals to bypass transformers on the power lines. The invention helps to minimize risk by allowing an installer to be remotely spaced from the energized power line while making the electrical coupling contact with the energized power line.
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This application is a continuation of application Ser. No. 09/782,226, filed on Feb. 14, 2001, now U.S. Pat. No. 6,423,403, which is a continuation of application Ser. No. 09/187,006, filed on Nov. 6, 1998, now U.S. Pat. No. 6,210,726.
FIELD OF THE INVENTION
The present invention relates to PVD Al 2 O 3 coated hard material.
BACKGROUND OF THE INVENTION
The present invention describes a cutting tool for metal machining, having a body of cemented carbide, cermet, ceramics or high speed steel and on the surface of said body, a hard and wear resistant refractory coating is deposited. The coating is adherently bonded to the body and covering all functional parts of the tool. The coating is composed of one or more layers of refractory compounds of which at least one layer consists of fine-crystalline alumina, Al 2 O 3 , deposited by Physical Vapor Deposition (PVD) and the non-Al 2 O 3 layer(s), if any at all, consists of metal nitrides and/or carbides with the metal elements chosen from Ti, Nb, Hf, V, Ta, Mo, Zr, Cr, W and Al.
It is well known that for cemented carbide cutting tools used in metal machining, the wear resistance of the tool edge can be increased by applying thin, hard surface layers of metal oxides, carbides or nitrides with the metal either selected from the transition metals from the groups IV, V and VI of the Periodic Table or from silicon, boron and aluminium. The coating thickness usually varies between 1 and 15 μm and the most widespread techniques for depositing such coatings are PVD and CVD (Chemical Vapor Deposition). It is also known that further improvements of the performance of a cutting tool can be achieved by applying a pure, ceramic layer such as Al 2 O 3 on top of layers of metal carbides and nitrides (U.S. Pat Nos. 5,674,564; 5,487,625).
Cemented carbide cutting tools coated with alumina layers have been commercially available for over two decades. The CVD technique usually employed involves the deposition of material from a reactive gas atmosphere on a substrate surface held at elevated temperatures. Al 2 O 3 , crystallizes into several different phases such as α(alfa), κ(kappa) and χ(chi) called the “α-series” with hcp (hexagonal close packing) stacking of the oxygen atoms, and into γ(gamma), θ(theta), η(eta) and δ(delta) called the “γ-series” with fcc (face centered cubic) stacking of the oxygen atoms. The most often occurring Al 2 O 3 -phases in CVD coatings deposited on cemented carbides at conventional CVD temperatures, 1000°-1050° C., are the stable alpha and the metastable kappa phases, however, occasionally the metastable theta phase has also been observed.
The CVD Al 2 O 3 coatings of the α-, κ- and/or θ-phase are fully crystalline with a grain size in the range 0.5-5 μm and having well-facetted grain structures.
Deposition at a typical temperature of about 1000° C. causes the total stress in CVD Al 2 O 3 coatings on cemented carbide substrates to be tensile in nature. The total stress is dominated by thermal stresses caused by the difference in thermal expansion coefficients between the substrate and the coating less intrinsic stresses which have there origin from the deposition process itself and are compressive in nature. The tensile stresses may exceed the rupture limit of Al 2 O 3 and cause the coating to crack extensively and thus degrade the performance of the cutting edge in particularly in certain applications, such as wet machining where the corrosive chemicals in the coolant fluid may exploit the cracks in the coating as diffusion paths.
Generally CVD-coated tools perform very well when machining various steels and cast irons under dry or wet cutting conditions. However, there exists a number of cutting operations or machining conditions when PVD-coated tools are more suitable e.g. in drilling, parting and threading and other operations where sharp cutting edges are required. Such cutting operations are often referred to as the “PVD coated tool application area”.
Plasma assisted CVD technique, PACVD, makes it possible to deposit coatings at lower substrate temperatures as compared to thermal CVD temperatures and thus avoid the dominance of the thermal stresses. Thin Al 2 O 3 PACVD films, free of cracks, have been deposited on cemented carbides at substrate tempertures 450°-700° C. (DE 41 10 005; DE 41 10 006; DE 42 09 975). The PACVD process for depositing Al 2 O 3 includes the reaction between an Al-halogenide, e.g. AlCl 3 , and an oxygen donor, e.g. CO 2 , and because of the incompletness of this chemical reaction, chlorine is to a large extent trapped in the Al 2 O 3 coating and its content could be as large as 3.5%. Furthermore, these PACVD Al 2 O 3 coatings are generally composed of, besides the crystalline alfa- and/or gamma-Al 2 O 3 phase, a substantial amount of amorphous alumina, which in combination with the high content of halogen impurities, degrades both the chemical and mechanical properties of said coating, hence making the coating material less desirable as a tool material.
There exist several PVD techniques capable of producing refractory thin films on cutting tools and the most established methods are ion plating, DC- and RF magnetron sputtering, arc discharge evaporation, IBAD (Ion Beam Assisted Deposition) and Activated Reactive Evaporation (ARE). Each method has its own merits and the intrinsic properties of the produced coatings such as microstructure/grain size, hardness, state of stress, intrinsic cohesion and adhesion to the underlying substrate may vary depending on the particular PVD method chosen. Early attempts to PVD deposit Al 2 O 3 at typical PVD temperatures, 400°-500° C., resulted in amorphous alumina layers which did not offer any notable improvement in wear resistance when applied on cutting tools. PVD deposition by HF diode or magnetron sputtering resulted in crystalline α-Al 2 O 3 only when the substrate temperature was kept as high as 1000° C. (Thornton and Chin, Ceramic Bulletin, 56 (1977) 504). Likewise, applying the ARE method for depositing Al 2 O 3 , only resulted in fully dense and hard Al 2 O 3 coatings at substrate temperatures around 10000° C. (Bunshah and Schramm, Thin Solid Films, 40 (1977) 211).
With the invention of the bipolar pulsed DMS technique (Dual Magnetron Sputtering) which is disclosed in DD 252 205 and DE 195 18 779, a wide range of opportunities opened up for the deposition of insulating layers such as Al 2 O 3 and, furthermore, the method has made it possible to deposit crystalline Al 2 O 3 layers at substrate temperatures in the range 500° to 800° C. In the bipolar dual magnetron system, the two magnetrons alternately act as an anode and a cathode and, hence, preserve a metallic anode over long process times. At high enough frequencies, possible electron charging on the insulating layers will be suppressed and the otherwise troublesome phenomenon of “arcing” will be limited. Hence, according to DE 195 18 779, the DMS sputtering technique is capable of depositing and producing high-quality, well-adherent, crystalline α-Al 2 O 3 thin films at substrate temperatures less than 800° C. The “α-Al 2 O 3 layers”, with a typical size of the (α-grains varying between 0.2-2 μm, may also partially contain the gamma(γ) phase from the “γ-series” of the Al 2 O 3 polymorphs. The size of the γ-grains in the coating is much smaller than the size of the α-grains. The γ-Al 2 O 3 grainsize typically varies between 0.05 to 0.1 μm. In the Al 2 O 3 layers where both modifications of γ-and α- phase were found, the γ-Al 2 O 3 phase showed a preferred growth orientation with a (440)-texture. When compared to prior art plasma assisted deposition techniques such as PACVD as described in DE 49 09 975, the novel, pulsed DMS sputtering deposition method has the decisive, important advantage that no impurities such as halogen atoms, e.g. chlorine, are incorporated in the Al 2 O 3 coating.
SUMMARY OF THE INVENTION
According to the present invention there is provided a cutting tool for metal machining such as turning (threading and parting), milling and drilling comprising a body of a hard alloy of cemented carbide, cermet, ceramics or high speed steel onto which a hard and wear resistant refractory coating is deposited by the DMS PVD method at substrate temperatures of 450° to 700° C., preferably at 550° to 650° C., depending on the particular material of the tool body. The wear resistant coating is composed of one or more layers of refractory compounds of which at least one layer, preferably the outermost layer, consists of Al 2 O 3 and that the innermost layer(s), if any at all, between the tool body and the Al 2 O 3 layer, is composed of metal nitrides and/or carbides with the metal elements selected from Ti, Nb, Hf, V, Ta, Mo, Zr, Cr, W and Al. In contrast to the state of the art, the Al 2 O 3 layers consist of high-quality, dense, fine-grained crystalline γ-Al 2 O 3 with a grainsize less than 0.1 μm. Furthermore, the γ-Al 2 O 3 layers are virtually free of cracks and halogen impurities.
BRIEF DESCRIPTION OF THE OF THE DRAWINGS
FIG. 1 is an EDS-analysis of an Al 2 O 3 layer deposited by PACVD having an Al 2 O 3 precursor;
FIG. 2 is an EDS-analysis of a γ-Al 2 O 3 layer deposited according to the present invention;
FIG. 3 is an X-ray diffraction pattern of an Al 2 O 3 coating of the present invention;
FIG. 4 is another X-ray diffraction pattern of an Al 2 O 3 coating of the present invention; and
FIG. 5 is a diffraction pattern taken from a transmission TElectron Microscope.
DETAILED DESCRIPTION OF THE INVENTION
The lack of impurities of the coating of the present invention is illustrated by comparing FIG. 1 with FIG. 2 is an EDS-analysis of an Al 2 O 3 layer deposited by PACVD (with AlCl 3 as a precursor ) containing Cl-impurities and FIG. 2 is an EDS-analysis of a γ-Al 2 O 3 layer, according to the invention. In the latter Al 2 O 3 layer no detectable impurities are present.
The γ-Al 2 O 3 layers according to the invention further give the cutting edges of the tool an extremely smooth surface finish which, compared to prior art α-Al 2 O 3 coated tools, results in an improved surface finish also of the workpiece being machined. The very smooth surface finish can be attributed to the very fine crystallinity of the coating. The “γ-Al 2 O 3 ” layers may also partially contain other phases from the “γ-series” like θ, δ and η. Identification of the γ-and/or θ-phases in the Al 2 O 3 layers according to the invention can preferably be made by X-ray diffraction. Reflexes from the (400) and (440) planes of the γ-Al 2 O 3 layers occurring at the 2θ-angles 45.8° and 66.8° when using Cu Kα radiation, unequivocally identifies the γ-phase (FIG. 3 ). Weaker reflexes from the (222), (200) and (311) planes of the γ-phase can occasionally be identified. When the θ-phase is present in the Al 2 O 3 layers according to the invention, said phase is identified by the reflexes from the (200, 20-2) planes (FIG. 4 ).
A second identification method for the Al 2 O 3 phases is based on electron diffraction in a Transmission Electron Microscope (TEM). A diffraction pattern from an Al 2 O 3 layer deposited at a substrate temperature of 650° C. is shown in FIG. 5 . The pattern shows rings from a polycrystalline phase with grains considerably smaller than the diameter of the electron beam and, furthermore, the intensity of the rings and the distances between the rings again unequivocally identifies the γ-phase of Al 2 O 3 .
The fine-grained, crystalline γ-Al 2 O 3 according to the invention is strongly textured in the [440]-direction. A Texture Coefficient, TC, can be defined as: TC ( hkl ) = I ( hkl ) I > ( hkl ) { 1 n Σ I ( hkl ) I > ( hkl ) } ⋂
where
I(hkl) measured intensity of the (hkl) reflection
I o (hkl) standard intensity from the ASTM standard powder pattern diffraction data
n=number of reflections used in the calculation
(hkl) reflections used are: (111), (311), (222), (400) and (440) and whenever the TC(hkl)>1, there is a texture in the [hkl] - direction.
The larger the value of TC(hkl), the more prenounced is the texture.
According to the present invention, the TC for the set of (440) crystal planes is greater than 1.5.
When the very fine-grained γ-Al 2 O 3 coated cemented carbide cutting tools according to the invention are used in the machining of steel or cast iron, several important improvements compared to the prior art have been observed which will be demonstrated in the forthcoming examples. Surprisingly, the PVD γ-Al 2 O 3 without containing any portion of the coarser and thermodynamically stable α-Al 2 O 3 phase, shows in certain metal machining operations, a wear resistance which is equal to the wear resistance found in coarser CVD α-Al 2 O 3 coatings deposited at temperatures around 1000° C. Furthermore, the fine-grained PVD γ-Al 2 O 3 coatings show a wear resistance considerably better than prior art PVD coatings. These observations open up the possibility to considerably improve the cutting performance and prolong the tool lives of coated PVD tools. The low deposition temperature will also make it possible to deposit PVD γ-Al 2 O 3 coatings on high speed steel tools.
A further improvement in cutting performance can be anticipated if the edges of the γ-Al 2 O 3 coated cutting tools according to the invention are treated by a gentle wet-blasting process or by edge brushing with SiC-based brushes. An example of such brushes is disclosed in the Swedish patent application 9402234-4.
The total coating thickness according to the present invention varies between 0.5 and 20 μm, preferably between 1 and 15 μm with the thickness of the non-Al 2 O 3 layer(s) varying between 0.1 and 10 μm, preferably between 0.5 and 5 μm. The fine-grained γ-Al 2 O 3 coating can also be deposited directly onto the cutting tool substrate of cemented carbide, cermet, ceramics or high speed steel and the thickness of said γ-Al 2 O 3 varies then between 0.5 and 15 μm preferably between 1 and 10 μm. Likewise can further coatings of metal nitrides and/or carbides with the metal elements selected from Ti, Nb, Hf, V, Ta, Mo, Zr, Cr, W and Al be deposited on top of of the Al 2 O 3 layer.
The γ-Al 2 O 3 layer according to the invention is deposited by a bipolar dual magnetron sputtering technique at substrate temperatures of 450°-700° C., preferably 550°-650° C., using aluminium targets, a gas mixture of Ar and O 2 and a process pressure in the range 1-5 μbar. The substrate may be floating or pulsed biased, the exact conditions depending to a certain extent on the design of the equipment being used.
It is within the purview of the skilled artisan to determine whether the requisite grainsize and phase compositions have been obtained and to modify the deposition conditions in accordance with the present specification, if desired, to affect the nanostructure of the Al 2 O 3 layer within the frame of the invention.
The layer(s) described in the present invention, comprising metal nitrides and/or carbides and/or carbonitrides and with the metal elements selected from Ti, Nb, Hf, V, Ta, Mo, Zr, Cr, W and Al can be deposited by PVD-technique, CVD- and/or MTCVD-technique (Medium Temperature Chemical Vapor Deposition).
The superiority of the fine-grained γ-Al 2 O 3 PVD layers according to the present invention, compared to prior art PVD coatings is demonstrated in Examples 1, 2 and 5. Examples 3, 4 and 6 demonstrate the suprisingly good wear resistance properties of the fine-grained γ-Al 2 O 3 layers compared to traditionally CVD-deposited single phase κ-Al 2 O 3 and single phase α-Al 2 O 3 layers.
EXAMPLE 1
A) Commercially available cemented carbide threading inserts of style R166.OG-16MM01 - 150 having a composition of 10 w % Co and balance WC, coated with an approximately 2 μm TiN layer by an ion plating technique.
B) TiN coated tools from A) were coated with a 1 μm fine-grained γ-Al 2 O 3 layer in a separate experiment with the pulsed magnetron sputtering technique. The deposition temperature was 650° C. and the process pressure was 1 μbar.
C) Cemented carbide threading inserts of style R166.OG-16MM01-150 having a composition of 10 w % Co and balance WC, coated with an approximately 3 μm TiN layer by an ion plating technique.
Coated toot inserts from B) and C) were then tested in a threading operation at a customers site in the production of engine oil plugs of cast iron (SS0125; 180-240 HB). The thread of the plug being produced was of size M36×1.5.
Cutting data:
Speed:
154 m/min
5 passages per thread
The results below is expressed as the number of machined plugs per cutting edge.
C) prior art
300 plugs
Large crater wear, cutting edge is
worn out
B) invention
>500 plugs
No detectable wear on the cutting
edge. The edge can produce more
plugs
From the above results it is obvious that the alumina coated insert according to the invention is superior with respect to cutting performance.
EXAMPLE 2
D) Commercial PVD-TiN coated cemented carbide drilling inserts of style LCMX 040308-53 with a coating thickness of approximately 3 μm having a cemented carbide composition of 10 w % Co and balance WC.
E) TiN coated tools from D), coated with a 1 μm fine-grained γ-Al 2 O 3 layer in a separate experiment with the pulsed magnetron sputtering technique. The deposition temperature was 650° C. and the process pressure was 1 μbar.
The alumina coating from E) appeared transparent and very smooth. SEM studies of a fracture cross section of the alumina coating showed a very fine-grained structure. A XRD-investigation identified the alumina phase as pure γ-Al 2 O 3 .
Coated tool inserts from D) and E) were then tested in a drilling operation in a workpiece material of a low alloyed, non-hardened steel (SS 2541).
Cutting data:
Speed:
150 m/min
Feed:
0.12 mm/rev
Hole diameter:
25 mm
Hole depth:
46 mm
Coolant being used
Both flank and crater wear were developed on the cutting edges. The extent of the flank wear determined the life time of the cutting tool. The results below express the number of holes being drilled per cutting edge.
D) prior art
150 holes
Flank wear 0.15 mm
200 holes
Flank wear 0.22 mm,
cutting edge is damaged
B) invention
150 holes
Flank wear 0.07 mm
200 holes
Flank wear 0.09 mm
250 holes
Flank wear 0.10 mm,
cutting edge is slightly
damaged
From the above results it is obvious that the alumina coated inserts according to the invention are able to drill more holes than the Prior art inserts.
EXAMPLE 3
F) Cemented carbide inserts of style CNMA 120412-KR having a composition of 6 w % Co and balance WC, coated with a first layer of 8 μm TiCN and thereafter with a top layer of 4.7 μm α-Al 2 O 3 . Both the TiCN and the Al 2 O 3 layer were deposited by conventional CVD-technique. The Al 2 O 3 layer had an average grain size of 1.2 μm.
G) Cemented carbide inserts of the same style and composition as in F), first coated with an approximately 3.6 μm TiCN layer by conventional CVD-technique and thereafter coated with a 2.3 μm fine-grained γ-Al 2 O 3 layer in a separate experiment with the pulsed magnetron sputtering technique. The deposition temperature was 650° C. and the process pressure was 1 μbar.
Coated inserts from F) and G) were then tested in a continuous turning operation in a ball bearing steel (Ovako 825). The crater wear of the cutting edges was measured.
Cutting data:
Speed:
210 m/min
Feed:
0.25 mm/rev
Depth of cut:
2.0 mm
Coolant being used
The cutting operation was periodically interupted in order to measure the crater wear of the cutting edges. The crater wear was measured in an optical microscope. The machining time until the Al 2 O 3 layer was worn through, was registered (i.e. when the inner TiCN coating just becoming visible). In order to define a figure of merit for the intrinsic wear resistance of the Al 2 O 3 layers, the thickness (μm) of the Al 2 O 3 layer was divided by the above defined machining time (min). The results below express the wear rate figure of merit.
F) prior art α-Al 2 O 3 layers
0.5 μm/min
C) invention
0.5 μm/min
From the above results it is obvious that the wear resistance of the fine-grained γ-Al 2 O 3 layer suprisingly is as good as the wear resistance of the coarser-grained α-Al 2 O 3 layer deposited by CVD technique.
EXAMPLE 4
H) Cemented carbide inserts of style CNMA 120412-KR having a composition of 6 w % Co and balance WC, coated with a first layer of 6 gm TiCN and thereafter with a top layer of 1.1 μm κ-Al 2 O 3 . Both the TiCN and the Al 2 O 3 layer were deposited by conventional CVD technique. The Al 2 O 3 layer had an average grain size of 1 μm.
I) Cemented carbide inserts of the same style and composition as in H), coated with an approximately 2.5 μm TiN layer by an ion plating technique.
J) TiN coated tools from 1), coated with a 1.2 μm fine-grained γ-Al 2 O 3 layer in a separate experiment with the pulsed magnetron sputtering technique. The deposition temperature was 6000° C. and the process pressure was 1 μbar.
K) TiN coated tools from I), coated with a 1.7 μm fine-grained γ-Al 2 O 3 layer in a separate experiment with the pulsed magnetron sputtering technique. The deposition temperature was 730° C. and the process pressure was 1 μbar.
Coated inserts from H), J) and K), were then tested in a continuous turning operation in a ball bearing steel (Ovako 825). The crater wear of the cutting edges was measured.
Speed:
250 m/min
Feed:
0.25 mm/rev
Depth of cut:
2.0 mm
Coolant being used
The cutting operation was periodically interupted in order to measure the crater wear of the cutting edges. The crater wear was measured in an optical microscope. The machining time until the Al 2 O 3 layer was worn through, was registered (i.e. when the inner TiN or TiCN coating just becoming visible). In order to define a figure of merit for the intrinsic wear resistance of the Al 2 O 3 layers, the thickness (μm) of the Al 2 O 3 layer was divided by the above defined machining time (min). The results below express the wear rate figure of merit.
H) prior art κ-Al 2 O 3 layers
0.44 μm/min
J) invention TiN + γ-Al 2 O 3
0.40 μm/min
K) invention TiN + γ-Al 2 O 3
0.46 μm/min
From the above results it is obvious that the wear resistance of the fine-grained γ-Al 2 O 3 layer suprisingly is as good as the wear resistance of the coarser-grained κ-Al 2 O 3 layer deposited by CVD technique.
EXAMPLE 5
Coated cutting inserts from I), J) and K) in Example 4 were tested under the same cutting conditions and cutting data as in Example 4. The machining time until a predetermined crater wear had developed on the rake face of the inserts was registered. The results below express said machining time until the predetermined crater wear.
I) prior art TiN
4 min
J) invention TiN + γ-Al 2 O 3
9 min
K) invention TiN + γ-Al 2 O 3
9.7 min
From the above results it is obvious that a top coating of the fine-grained γ-Al 2 O 3 layer on PVD TiN considerably improves the crater wear resistance of the cutting tool.
EXAMPLE 6
L) Cemented carbide inserts of style CNMA 120412-KR having a composition of 6 w % Co and balance WC, coated with a first layer of 6 μm TiCN and thereafter with a top layer of 4.8 μm α-Al 2 O 3 . Both the TiCN and the Al 2 O 3 layer were deposited by conventional CVD-technique. The Al 2 O 3 layer had an average grain size of 1 μm.
M) Cemented carbide inserts of the same style and composition as in L), first coated with an approximately 5 μm TiAlN layer and thereafter, without vacuum interuption, coated with a 4.4 μm fine-grained γ-Al 2 O 3 layer, both layers deposited with the pulsed magnetron sputtering technique. The deposition temperature was 600° C. and the process pressure was 1 μbar.
Coated inserts from L) and M) were then tested in a continuous turning operation in a low alloyed, non-hardened steel (SS2541). The crater wear of the cutting edges was measured.
Speed:
250 m/min
Feed:
0.25 mm/rev
Depth of cut:
2.0 mm
Coolant being used
The cutting operation was periodically interupted in order to measure the crater wear of the cutting edges. The crater wear was measured in an optical microscope. The machining time until the Al 2 O 3 layer was worn through, was registered (i.e. when the inner TiCN or TiAlN coating just becoming visible). In order to define a figure of merit for the intrinsic wear resistance of the Al 2 O 3 layers, the thickness (μm) of the Al 2 O 3 layer was divided by the above defined machining time (min). The results below express the wear rate figure of merit.
L) prior art α-Al 2 O 3 layers
0.69 μm/min
M) invention
0.73 μm/min
From the above results it is obvious that the wear resistance of the fine-grained γ-Al 2 O 3 layer suprisingly is as good as the wear resistance of the coarser-grained α-Al 2 O 3 layer deposited by CVD technique.
The principles, in preferred embodiments of the present invention 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 above. 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 invention be embraced thereby.
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The present invention describes a coated cutting tool for metal machining. The coating is formed by one or more layers of refractory compounds of which at least one layer of fine-grained, crystalline γ-phase alumina, Al 2 O 3 , with a grainsize less than 0.1 μm. The Al 2 O 3 layer is deposited with a bipolar pulsed DMS technique (Dual Magnetron Sputtering) at substrate temperatures in the range 450° C. to 700° C. preferably 550° C. to 650° C., depending on the particular material of the tool body to be coated. Identification of the γ-phase alumina is made by X-ray diffraction. Reflexes from the (400) and (440) planes occurring at the 2θ0- angles 45.8 and 66.8 degrees when using Cu Kα radiation identify the γ-phase Al 2 O 3 . The alumina layer is also very strongly textured in the [440]-direction. The Al 2 O 3 layer is virtually free of cracks and halogen impurities. Furthermore, the Al 2 O 3 layer gives the cutting edge of the tool an extremely smooth surface finish.
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CLAIM OF PRIORITY
[0001] The present application claims priority from Japanese application serial no. 2006-53046, filed on Feb. 28, 2006, the content of which is hereby incorporated by reference into this application.
FIELD OF THE INVENTION
[0002] The present invention relates to a motor drive that includes a level-shifting circuit adapted to transmit a control signal from a low-voltage circuit to a high-voltage circuit.
BACKGROUND OF THE INVENTION
[0003] In recent years, the use of insulated-gate bipolar transistors (IGBTs) or other semiconductor devices to control motors is increasing with a tendency towards lower pricing of the semiconductor devices, especially the IGBTs, in order to save energy. A circuit diagram of a motor drive for one arm of driving based on a conventional technique is shown in FIG. 2 . In FIG. 2 , the motor that is a load is replaced by an inductance element, which is connected between the high-potential side and output of a main power supply Vdd. The high-voltage terminal of the main power supply Vdd and the collector of an upper-arm IGBT are connected via wiring HL 1 . The emitter of the upper-arm IGBT and the output terminal of the main power supply Vdd are connected via wiring HL 2 . The collector of a lower-arm IGBT and the output terminal are connected via wiring L 1 . The grounding terminal of the main power supply Vdd and the emitter of the lower-arm IGBT are connected via wiring L 2 . A diode HDIODE is connected in parallel between the collector and emitter of the upper-arm IGBT. Also, a diode LDIODE is connected across the lower-arm IGBT. A load inductance element Lload is connected between the high-voltage terminal and output terminal of the main power supply Vdd. A driving circuit constructed of an HnMOS and an HpMOS is connected to the gate terminal of the upper-arm IGBT.
[0004] The upper-arm IGBT 111 is connected to the output terminal, so in terms of potential, the upper-arm IGBT is driven in a floating state with respect to the grounding terminal of the main power supply. When the upper-arm IGBT is on, therefore, this IGBT is impressed with the same high voltage as that of the main power supply. Accordingly, the driving circuit 113 requires electrical insulation from the grounding potential of the main power supply. As described in Patent Document 1, the above conventional technique has used a photocoupler 130 to transmit signals to an insulated driving circuit 113 . It is also described in Japanese Patent Laid-open No. 2004-304929, paragraphs (0002), (0020), (0021) that a level-shifting circuit is used as a means for sending a driving signal from a lower arm to an upper arm floating in terms of potential.
[0005] In FIG. 2 , the source of a high-withstand-voltage MOSset for turn-on signal transmission is connected to a lower-arm grounding terminal. The gate of the MOSset is connected to a logical circuit. One end of a resistor Rset is connected to the drain of the MOSset. The other end of the resistor Rset is connected to the high-voltage side of a power supply HVcc for driving the upper arm. A Zener diode Zdset for protection from an overvoltage is connected across the resistor. The source of a MOSset, a high-withstand-voltage MOS for turn-off signal transmission, is connected to the lower-arm grounding terminal. The gate of the MOSreset is connected to the logical circuit. One end of a resistor Rreset is connected to the drain of the MOSreset. The other end of the resistor Rreset is connected to the high-voltage side of the power supply HVcc for driving the upper arm. A Zener diode ZDreset for protection from an overvoltage is connected across the resistor Rreset.
[0006] In synchronization with the rise of an upper-arm driving signal from a microcomputer or the like, the logical circuit uses the upper-arm driving signal to generate a turn-on signal in pulse form in the high-withstand-voltage MOSset for turn-on signal transmission. In synchronization with the fall of the upper-arm driving signal, the logical circuit also generates a turn-on signal in pulse form in the high-withstand-voltage MOSreset for turn-off signal transmission. The two MOS's are used to transmit signals to the upper arm more rapidly and with less power consumption. The resistor Rset is further connected to the setting side of a flip-flop (FF), and the resistor Rreset is further connected to the resetting side of the FF. The driving signal that was decomposed into the rising pulse and the falling pulse by the logical circuit is restored at the FF to the same pulse width as that of the original driving signal from the microcomputer. The output of the FF is reversed in state by a NOT circuit, and when the command from the microcomputer is “H” (high), the output of the FF becomes “H” and thus the output of the NOT circuit becomes “L” (low). This turns on the HpMOS, supplies an electric current from the upper-arm driving power supply HVcc, and turns on the HIGBT, the IGBT for the upper arm.
SUMMARY OF THE INVENTION
[0007] FIG. 3 is a cross-sectional structural view showing the MOSset, the high-withstand-voltage MOS for turn-on signal transmission, and the MOSreset, the high-withstand-voltage MOS for turn-off signal transmission. Both are of a horizontal-type high-withstand-voltage MOSFET structure with drain, source, and gate electrodes on the same plane. As the voltage between the grounding terminals of the upper and lower arms is increased, the high-withstand-voltage MOSset for turn-on signal transmission and the high-withstand-voltage MOSreset for turn-off signal transmission are required to withstand higher voltages. To implement this, it is necessary to lower the concentration of impurities in the n − layer of the MOSFET and to extend the distance between the drain and the source. Consequently, the resistance of the n − layer increases and this, in turn, increases turn-on resistance. The increase in turn-on resistance correspondingly reduces the voltages developed at the setting resistor and the resetting resistor.
[0008] During motor driving, when there is a reflux of a current through the diode for the lower arm, the voltage between the upper and lower arms causes the grounding voltage of the upper arm to decrease below that of the lower arm according to the particular forward voltage decrement VF of the diode. At this time, the voltage applied to the level-shifting circuit becomes equal to the voltage obtained by subtracting the forward voltage decrement VF of the diode from the voltage of the power supply HVcc for driving the upper arm. If the forward voltage decrement VF of the diode is significant, this correspondingly reduces the voltages developed at the setting resistor and the resetting resistor and thus makes it impossible to turn the upper arm back on. Higher withstand voltage of the diode causes a more significant forward voltage decrement VF thereof. That is to say, as the voltage between the grounding terminals of the upper and lower arms increases, the voltages developed at the setting resistor and the resetting resistor will decrease, making it impossible to turn the upper arm back on.
[0009] The waveforms of various sections of the lower-arm IGBT existing during simulation of its turn-back-on in the conventional technique are shown in FIG. 4 . When the gate voltage of the lower-arm IGBT exceeds a threshold level, an electric current starts to flow into the lower-arm IGBT. At the same time, the lower-arm IGBT decreases in collector-emitter voltage. The recovery current of the upper-arm diode HDIODE maximizes the current flowing through the lower-arm IGBT. Voltage ΔV 1 is caused by a time change dI 1 /dt from the maximum value of the current to a steady current, and by the value of the wiring L 1 . Also, voltage ΔV 2 is caused by a decrement dI 2 /dt in the recovery current of the upper-arm IGBT, and by the value of the wiring L 2 . The sum of the voltages, ΔV 1 +ΔV 2 , is developed between the grounding terminals of the upper arm and the lower arm. This voltage is a potential lower at the grounding terminal of the upper arm than at that of the lower arm. If the developed voltage ΔV 1 +ΔV 2 is higher than the power supply voltage HVcc of the upper arm, an overcurrent flows from the parasitic diodes of the high-withstand-voltage MOSset for turn-on signal transmission, and of the high-withstand-voltage MOSreset for turn-off signal transmission, through the Zener diodes. This state is shown in FIG. 5 . The simulation waveforms in FIG. 4 indicate that there is a peak current flow of 100 A and thus that a significant loss is likely to occur.
[0010] An object of the present invention is to provide a motor drive adapted to operate stably and suffer essentially no damage, even when a high voltage is applied between grounding terminals of upper and lower arms.
[0011] In order to achieve the above object, the motor drive of the present invention uses insulated-gate bipolar transistors (IGBTs) as high-withstand-voltage elements for signal transmission.
[0012] The motor drive of the present invention can prevent voltages on a setting resistor and a resetting resistor from decreasing, even when a high voltage is applied between the grounding terminals of the upper and lower arms, that is, even when the high-withstand-voltage elements for signal transmission are impressed with a high voltage. In addition, when there is a reflux of a current through a diode for the lower arm, pulses can be accurately transmitted from the lower arm to the upper arm, even if a large current flows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a circuit diagram of a motor drive according to a first embodiment;
[0014] FIG. 2 is a circuit diagram of a motor drive based on the above-described conventional technique;
[0015] FIG. 3 is a cross-sectional explanatory diagram of a horizontal MOSFET based on the conventional technique;
[0016] FIG. 4 is an explanatory diagram of the simulation waveforms obtained by simulating the turn-on of the lower-arm IGBT of the motor drive based on the conventional technique;
[0017] FIG. 5 is an explanatory diagram of electric current paths in a level-shifting circuit during the simulation in FIG. 3 ;
[0018] FIG. 6 is a circuit diagram of a motor drive according to a second embodiment;
[0019] FIG. 7 is a sectional view of a high-withstand-voltage IGBT for signal transmission in the second embodiment;
[0020] FIG. 8 is a perspective view of another high-withstand-voltage IGBT for signal transmission in the second embodiment;
[0021] FIG. 9 is an explanatory diagram of a relationship between gate width of the high-withstand-voltage IGBT for signal transmission in the second embodiment, and a voltage across a resistor 22 ;
[0022] FIG. 10 is a mounting diagram of an inverter-driving circuit including the IGBT of FIG. 8 ; and
[0023] FIG. 11 is a circuit diagram of a three-phase AC motor drive based on the second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Details of the present invention will be described hereunder with reference being made to the accompanying drawings.
First Embodiment
[0025] A motor drive for driving one arm according to a first embodiment is shown in FIG. 1 . As shown in FIG. 1 , a high-voltage terminal of a main power supply 1 and a collector of an IGBT for an upper arm are connected via wiring 8 . An emitter of the upper-arm IGBT 4 and an output terminal 12 of the main power supply 1 are connected via wiring 9 . A collector of a lower-arm IGBT and the output terminal 12 are connected via wiring 10 . A grounding terminal of the main power supply 1 and an emitter of the lower-arm IGBT 3 are connected via wiring 11 . A diode 6 is connected in antiparallel between the collector and emitter of the upper-arm IGBT 4 . A diode 5 is also connected in antiparallel across the lower-arm IGBT 3 . A load inductance element 7 is connected between the high-voltage terminal and output terminal 12 of the main power supply 1 . A driving circuit constructed of an nMOS 28 and a pMOS 29 is connected to a gate terminal of the upper-arm IGBT 4 .
[0026] An IGBT 30 for turn-on signal transmission has an emitter connected to a grounding terminal 13 of the lower arm, a gate connected to a logical circuit 15 , and a collector connected to one terminal of a resistor 22 . The other terminal of the resistor 22 is connected to a high-voltage terminal of a power supply 2 connected to a grounding terminal 14 of the upper arm. A Zener diode 23 for protection from an overvoltage is connected across the resistor 22 .
[0027] An IGBT 31 for turn-off signal transmission also has an emitter connected to the grounding terminal 13 of the lower arm, a gate connected to the logical circuit 15 , and a collector connected to one terminal of a resistor 24 . The other terminal of the resistor 24 is connected to the high-voltage terminal of the power supply 2 for driving the upper arm. A Zener diode 25 for protection from an overvoltage is connected across the resistor 24 . An output of the resistor 22 is connected to a setting terminal of a non-reversal flip-flop 26 , and an output of the resistor 24 is connected to a resetting terminal of the non-reversal flip-flop 26 .
[0028] The output of the flip-flop has a connected NOT circuit 27 , which is further connected between gates of the nMOS 28 , pMOS 29 . The nMOS 28 has a source connected to the grounding terminal 14 of the upper arm, and a drain connected to the gate of the IGBT 4 for the upper arm. The pMOS 29 has a source connected to the high-voltage terminal of the power supply 2 for driving the upper arm, and has a drain connected to the gate of the IGBT 4 for the upper arm.
[0029] Operation of the present embodiment is described below using FIG. 1 . In synchronization with a rise of an upper-arm driving signal from a microcomputer or the like, the logical circuit 15 uses the upper-arm driving signal to generate a turn-on signal in pulse form in the IGBT 30 for turn-on signal transmission. In synchronization with a fall of the upper-arm driving signal, the logical circuit 15 also develops a turn-on signal in pulse form at the gate of the IGBT 31 for turn-off signal transmission. When the IGBT 30 for turn-on signal transmission is turned on, a voltage is developed between both terminals of the resistor 22 , thus setting the output terminal of the non-reversal flip-flop 26 to an “H” (high) level. The “H” output of the non-reversal flip-flop 26 is reversed by the NOT circuit 27 to become an “L” (low) level. As a result, the pMOS 29 is turned on,.an electric current is supplied from the high-voltage power supply to the IGBT 4 for the upper arm, and the IGBT 4 is turned on.
[0030] In synchronization with the fall of the upper-arm driving signal, the logical circuit 15 also develops a turn-on signal in pulse form at the gate of the IGBT 31 for turn-off signal transmission. When the IGBT 31 for turn-off signal transmission is turned on, a voltage is developed between both terminals of the resistor 24 , thus setting the output terminal of the non-reversal flip-flop 26 to the “L” level, turning on the nMOS 28 , and removing a charge from the gate of the upper-arm IGBT 4 to turn off the IGBT 4 . In this way, the driving signal that was decomposed into the rising pulse and the falling pulse by the logical circuit 15 is restored at the upper arm to have the same pulse width as that of the original driving signal from the microcomputer.
[0031] Even when a high voltage is applied between the grounding terminals of the upper and lower arms, that is, even when the high-withstand-voltage elements for signal transmission are impressed with a high voltage, the use of the IGBTs as the high-withstand-voltage elements makes it possible to prevent voltages on the setting resistor and the resetting resistor from decreasing, since turn-on resistance of the IGBTs is low in comparison with that of the MOSFETs. Additionally, when there is a reflux of a current through the diode for the lower arm, even if the voltage between the upper and lower arms causes a grounding voltage of the upper arm to decrease below that of the lower arm according to a particular forward voltage drop VF of the diode, that is, if a significant VF causes a flow of a large current, pulses can be accurately transmitted from the lower arm to the upper arm since the turn-on resistance of the IGBTs is lower.
[0032] Furthermore, since both IGBTs are constructed so that even when the voltage on the collector decreases below that of the emitter, p-layer and n − layer formed at the collector side become reverse-biased, no current flows through the built-in diode of the MOSFET. Accordingly, even when wiring increases the grounding voltage of the lower arm above that of the upper arm, no current flows from the grounding terminal of the lower arm to that of the upper arm, whereby damage to the IC can be avoided.
Second Embodiment
[0033] A second embodiment is shown in FIG. 6 . In the present embodiment, outputs of resistors 22 and 24 for level shifting are input to a logic filter 32 , and an output of the logic filter 32 is further input to a setting side and resetting side of an RS flip-flop 26 . The logic filter 32 outputs a signal only when a signal is input from either the setting or resetting side, and does not output a signal when signals are input from both the setting and resetting sides at the same time. Compared with MOSFETs, IGBTs have carriers stored in great quantities in respective n − layers, so the IGBTs tend to delay in turn-off and thus create a flow of a tail current. This tail current is likely to cause a signal at the setting side as well to which a signal is originally not applied by the tail current of the associated IGBT even when a selector signal is applied from the setting side to the resetting side. If signals are input from both the setting and resetting sides to the RS flip-flop 26 , this flip-flop is likely to float in state and fail to turn off, for example. The logic filter prevents signals from occurring at both the setting and resetting sides at the same time, and thus makes it possible to prevent the RS flip-flop from floating in state and hence resulting in malfunction.
[0034] A cross-sectional structure of a signal transmission high-withstand-voltage IGBT used in the present embodiment is shown in FIG. 7 . The IGBT shown therein is of a horizontal IGBT structure with an emitter electrode, a collector electrode, and a gate electrode formed on the same plane. The IGBT also includes a p-layer 41 in an n − layer 40 , and further includes an n+layer 42 in the p-layer 41 . The p-layer 41 and the n + layer 42 are electrically strapped via the emitter electrode 43 . Additionally, the IGBT has a gate oxide film 44 formed on the surface of an associated substrate, spanning the n + layer 42 , the p-layer 41 , and the n − layer 42 , and further has the gate electrode 45 on the gate oxide film. Furthermore, a p+layer 46 is provided apart from the p-layer 41 , inside the n − layer 40 .
[0035] Using an another IGBT shown in FIG. 8 , in lieu of the IGBT in FIG. 7 , makes it possible to enhance breakdown yield strength. A perspective view of a vertical IGBT used in the present embodiment is shown in FIG. 8 . As shown therein, an n − layer 91 is formed on a p + layer 90 , and p-layers 92 a and 92 b are formed in the n − layer 91 . Also, an n + layer 93 a is formed in the p-layer 92 a, an n + layer 93 b in the p-layer 92 b, and a gate oxide film 94 on the surface of an associated substrate, spanning the n + layer 93 a, the p-layer 92 a, the n − layer 91 , the p-layer 92 b, and the n + layer 93 b. In addition, a gate electrode 95 is formed on the gate oxide film 94 . The p-layers 92 a, 92 b, the n+layers 93 a, 93 b, the gate oxide film 94 , and the gate electrode 95 constitute a MOSFET. The p-layers 92 a, 92 b and the n + layers 93 a, 93 b are ohmically connected to a source electrode 96 . In addition, p-layers 97 a, 97 b, 97 c are formed in the n − layer 91 , and an oxide film 99 a is provided spanning the p-layer 92 b, the n − layer 91 , and the p-layer 97 a. An oxide film 99 b is provided spanning the p-layer 97 a, the n − layer 91 , and the p-layer 97 b. An oxide film 99 c is provided spanning the p-layer 97 b, the n − layer 91 , and the p-layer 97 c. An oxide film 99 d is provided spanning the p-layer 97 c, the n − layer 91 , and the p-layer 97 c. An emitter electrode 100 extends in a direction of an n + layer 98 , on the oxide film 99 a. A floating electrode 101 a ohmically connected to the p-layer 97 a extends in the direction of the n+layer 98 , on the oxide film 99 b. A floating electrode 101 b ohmically connected to the p-layer 97 b extends in the direction of the n + layer 98 , on the oxide film 99 c. A floating electrode 101 c ohmically connected to the p-layer 97 c extends in the direction of the n + layer 98 , on the oxide film 99 d. A floating electrode 101 d ohmically connected to the n + layer 98 extends in a direction of the n + layer 98 . A collector electrode 102 is ohmically connected to an p + layer 90 .
[0036] The IGBT in the present embodiment operates as follows. That is to say, with the emitter electrode in a grounded condition and the collector electrode impressed with a high voltage, a positive voltage is applied to the gate electrode. The p-layers 92 a, 92 b are then electrically reversed. This, in turn, creates a channel, causes electrons to flow into the n − layer 91 through the channel, and further makes the electrons flow through the p + layer 102 and reach the collector electrode 102 . Since holes are injected from the p + layer 102 into the n − layer 91 of high resistance, the resistance of the n − layer 91 is reduced and thus the IGBT can make turn-off resistance lower than that of the MOSFET. A hole current can reach the emitter electrode without flowing through the p-layer 92 located below the n + layer 93 , so breakdown yield strength can be raised above that of the horizontal IGBT.
[0037] Also, the emitter electrode 100 , the floating electrode 101 a, the floating electrode 101 b, and the floating electrode 101 c are extended in the direction of the n + layer 98 to prolong a depletion layer for increased withstand voltage. Since an end has its cutting plane exposed to the surface, a large number of recombination levels occur and when the depletion layer reaches the end, current leakage increases. The n + layer 98 and the electrode 102 prevent the n − layer from being reversed to a p-type by internal charges of the oxide films 99 a, 99 b, 99 c, 99 d, and by an internal charge of a protective film not shown, and thus prevent the depletion layer from reaching the end. Increasing a resistivity and thickness of the n − layer 91 and the number of p-layers 97 a, 97 b, 97 c makes it possible to easily obtain a greater voltage-withstanding capability without changing a manufacturing method. The thickness of the n − layer 91 is desirably such that this layer is not depleted at a rated voltage of an associated element. More specifically, when, with the rated voltage taken as V, an impurity concentration in the n − layer is expressed as N (n − ), a relative dielectric constant of silicon as εSi, a dielectric constant of vacuum as ε0, and an elementary charge as q, the thickness of the n − layer, d (n − ), desirably satisfies the following expression:
[0000] d ( n − )>√[2×ε0×εSi×V/( q×N ( n − ))]
[0038] In addition, although higher concentration of the p + layer 90 reduces turn-on resistance more significantly, since the hole-current concentration in the n − layer 91 during turn-on correspondingly increases, breakdown becomes more prone to occur. When a signal is transmitted from a lower arm to an upper arm, a saturation current limited by the IGBT flows while a power supply voltage is being applied. Accordingly, although for a brief time, a significant loss occurs, so to prevent this, it is desirable that a peak concentration in the p + layer 90 be 1×10 18 /cm 3 or less.
[0039] FIG. 9 shows a relationship between gate width (at progressively, horizontally rearward positions in FIG. 7 ) of the high-withstand-voltage IGBT for signal transmission, shown in FIG. 8 , and a voltage across a resistor 22 . When the gate width is 0, since no current flows, no voltage is developed across the resistor 22 . Increasing the gate width increases the amount of current flowing, and hence also increases the voltage across the resistor 22 . If a Zener diode 23 is connected to the resistor 22 , even when the gate width is increased for a greater amount of current, the voltage across the resistor is suppressed by a Zener voltage and stops increasing. At a gate width of 10,000 μm or more, however, the voltage across the resistor restarts to increase. This is because the Zener diode that can be integrated into an IC chip has a large quantity of resistive components, and thus because the increase in the current results in increased voltage drop. If the resistor 22 is reduced in resistance value, although the voltage across the resistor is suppressed, a loss rate increases since a greater amount of current flows. For this reason, reducing the resistance value of the resistor 22 is not desirable. For use at a voltage defined by the Zener voltage, the gate width is desirably 1,000 μm or less. In addition, in voltage regions below the Zener voltage, changes in current, caused by manufacturing-associated nonuniformity of quality and/or by temperature changes, vary a voltage across a resistor 32 . A minimum value of the gate width, therefore, is more desirably 11 Rm.
[0040] FIG. 10 shows a mounting state of an inverter control circuit with a level-shifting circuit which uses the signal transmission high-withstand-voltage IGBT shown in FIG. 8 . In the present embodiment, four IC chips are arranged on an insulating substrate 120 . One is a lower-arm IC chip 110 including an lower-arm driving circuit and a logical circuit 15 , one is an upper-arm IC chip 111 with resistors 24 , 25 , Zener diodes 23 , 25 , a non-reversal flip-flop 26 , an nMOS 28 , and a pMOS 29 , one is an IGBT 30 for turn-on signal transmission, and one is an IGBT 31 for turn-off signal transmission. The IC chip 110 is connected to not only the IGBT 30 for turn-on signal transmission and the IGBT 31 for turn-off signal transmission, but also output terminals 150 , via bonded wires 140 . In addition, the IC chip 111 is connected to not only the IGBT 30 for turn-on signal transmission and the IGBT 31 for turn-off signal transmission, but also output terminals 151 , via bonded wires 141 . A collector of the IGBT 30 for turn-on signal transmission, and a collector of the IGBT 31 for turn-off signal transmission are connected to the insulating substrate 120 through wiring 130 formed thereon, and are further connected to the IC chip 111 via other bonded wires 140 .
[0041] The high-withstand-voltage IGBT for signal transmission, shown in FIG. 8 , is difficult to integrate into a single chip, since the emitter and the gate are formed on the surface and the collector on the reverse. In the present embodiment, a mounting area can be minimized by arranging the upper-arm IC chip 110 , the lower-arm IC chip 111 , and the two high-withstand-voltage IC chips for signal transmission, namely, IGBTs 30 and 31 , on the insulating substrate. Additionally, the upper arm and the lower arm can easily be electrically insulated from each other since appropriate distances (at least 0 . 5 mm) are provided between the insulating substrate and the chips. Furthermore, the high-withstand-voltage IGBTs 30 and 31 for signal transmission are co-packaged with the upper-arm IC chip 110 and the lower-arm IC chip 111 , in a state molded with an epoxy resin composition which contains an inorganic filler. Each chip is thus protected from any moisture entering from external regions. In the present embodiment, since the motor drive is constructed essentially of silicon and an insulated substrate in this way, the drive can be manufactured at low costs, compared with using a photocoupler. In addition, it is possible in the present embodiment to, by mounting the signal-transmitting high-withstand-voltage IGBTs in chips independent of the upper- and lower-arm chips, easily assign a great voltage-withstanding capability to the IGBTs without using a special process of integration into a single chip, and hence, manufacture the drive less expensively than by using an dielectric isolation substrate.
[0042] FIG. 11 shows an example of circuit composition intended to drive a three-phase AC motor according to the present embodiment shown in FIG. 6 . A driving power supply for a lower arm is common to phases U, V, and W. For an upper arm, an independent driving power supply is used for phases U, V, and W each. Main power supply voltage terminals and grounding terminals for both arms are also common to phases U, V, W. Commands from a microcomputer 50 activate logical circuits 15 U, 15 V, 15 W to turn power-switching elements (IGBTs) of each phase on and off, thereby to control rotation of a motor 400 .
[0043] No current is induced into the IGBTs until respective p-n junctions have been forward-biased. Accordingly, no current flows until a built-in voltage has been reached (for silicon, approx. 0.8 V). The IGBTs are therefore disadvantageous against MOSFETs in which a current begins to flow at that voltage of 0 V. Since IGBTs with element withstand voltages up to 250 V have the characteristics that no current flows at up to the above built-in voltage, these IGBTs are inferior to MOSFETs in current drivability. The present invention is therefore effective for IGBTs with a withstand voltage of at least 250 V. In addition, at a withstand voltage of at least 1,500 V that spreads the difference in current drivability between MOSFETs and the above IGBTs by a factor of 10 or more, the present invention does not operate in a level-shifting circuit based on MOSFETs, so the invention is desirably applied to IGBTs of at least 1,500 V in withstand voltage.
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To provide a motor drive adapted to operate stably and suffer essentially no damage, even when a high voltage is applied between grounding terminals of upper and lower arms.
The motor drive of this invention includes: an arm with a first electric power semiconductor-switching element and a second electric power semiconductor-switching element, both connected in series between major terminals; and a level-shifting circuit that transmits a control signal of the first semiconductor-switching element connected to the high-voltage side of the arm, from a low-voltage circuit to a high-voltage circuit; the motor drive employing an insulated-gate bipolar transistor as the signal-transmitting high-withstand-voltage element formed in the level-shifting circuit.
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FIELD OF THE INVENTION
[0001] This invention relates to data processing systems and, in particular, to data processing systems involving the transfer, manipulation, storage and retrieval of large amounts of data.
BACKGROUND OF THE INVENTION
[0002] In data processing applications involving the transfer, manipulation, storage and retrieval of large amounts of data, the most serious performance limitations include (1) difficulties in moving data between users who need access to the data and resources used to store or process the data and (2) difficulties in efficiently distributing the workload across the available resources. These difficulties are particularly apparent, for example, in disk-based storage systems in which the greatest performance limitation is the amount of time needed to access information stored on the disks. As databases increase in size, requiring more and more disks to store that data, this problem grows correspondingly worse and, as the number of users desiring access to that data increase, the problem is compounded even further. Yet the trends toward both larger databases and an increased user population are overwhelmingly apparent, typified by the rapid expansion of the Internet.
[0003] Current techniques used to overcome these difficulties include reducing access time by connecting users to multiple resources over various types of high-speed communication channels (e.g., SCSI buses, fiber channels and Infiniband busses) and using caching techniques in an attempt to reduce the necessity of accessing the resources. For example, in the case of storage systems, large random-access memories are often positioned locally to the users and are used as temporary, or cache, memories that store the most recently accessed data. These cache memories can be used to eliminate the need to access the storage resource itself when the cached data is subsequently requested and they thereby reduce the communication congestion.
[0004] Various distribution algorithms are also used to allocate tasks among those resources in attempts to overcome the workload distribution problem. In all cases, however, data is statically assigned to specific subsets of the available resources. Thus, when a resource subset temporarily becomes overloaded by multiple clients simultaneously attempting to access a relatively small portion of the entire system, performance is substantially reduced. Moreover, as the number of clients and the workload increases, the performance rapidly degrades even further since such systems have limited scalability.
SUMMARY OF THE INVENTION
[0005] In accordance with one illustrative embodiment of the invention, users are connected to access interfaces. In turn, the access interfaces are connected to a pool of resources by a switch fabric. The access interfaces communicate with each client with the client protocol and then interfaces with the resources in the resource pool to select the subset of the resource pool to use for any given transaction and distribute the workload. The access interfaces make it appear to each client that the entire set of resources is available to it without requiring the client to be aware that that the pool consists of multiple resources.
[0006] In accordance with one embodiment, a disk-based storage system is implemented by client interfaces referred to as host modules and processing and storage resources referred to as metadata and disk interface modules, respectively.
[0007] The invention eliminates the prior art problems by enabling both client interfaces and processing and storage resources to be added independently as needed, by providing much more versatile communication paths between clients and resources and by allowing the workload to be allocated dynamically, with data constantly being directed to those resources that are currently least active.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which:
[0009] FIG. 1 is a block schematic diagram of a resource access system constructed in accordance with the principles of the present invention.
[0010] FIG. 2 is a block schematic diagram of an illustrative storage system embodiment implemented with the architecture of FIG. 1 .
[0011] FIG. 3 is a detailed block schematic diagram of a host interface module.
[0012] FIGS. 4A-4C , when placed together, form a flowchart illustrating the steps in a process carried out by the host interface module in response to a request from a client.
[0013] FIG. 5 is a detailed block diagram of a disk interface module.
[0014] FIG. 6 is a flowchart illustrating the processing steps performed by software running in the disk interface module.
[0015] FIG. 7 is a detailed block schematic diagram of a metadata module.
[0016] FIGS. 8A and 8B , when placed together, form a flowchart illustrating processing steps performed by software running in the metadata module.
[0017] FIG. 9 is a detailed block schematic diagram of a switch module.
DETAILED DESCRIPTION
[0018] A block schematic diagram of a resource access system 100 in accordance with an embodiment of the invention is shown in FIG. 1 . The system consists of three components. Access interfaces 106 - 112 provide clients, such as client 102 and 104 , with access to the system 100 and provide other access-related resources. A pool of resources 118 - 124 may comprise, for example, data processing or storage devices. A switch fabric 114 and 116 interconnects the access interfaces 106 - 112 and the resources 118 - 124 . Since the requirements for communicating control information differ significantly from those for data communication, the switch fabric consists of a control switch fabric 114 and a data switch fabric 116 in order to provide different paths and protocols for control and data. For example, control transfer protocols generally divide the control information into relatively small packets that are transferred using packet-switching technology. In contrast, data transfer protocols generally consist of larger packets conveyed over a circuit-switched fabric. The separation of the switch fabric into two sections 114 and 116 allows each type of communication path to be optimized for its specific function and enables service requests to be transferred to a resource, via the control switch fabric 114 without interfering with the data transferring capacity of the data switch fabric 116 .
[0019] In accordance with the principles of the invention, the access interfaces 106 - 112 operate to virtualize the pool of resources 118 - 124 , thereby making it appear to each client, such as clients 102 and 104 , that the entire set of resources 118 - 124 is available to it without requiring the client to be aware of the fact that that the pool is in fact partitioned into multiple resources 118 - 124 .
[0020] This virtualization is accomplished by enabling the access interfaces 106 - 112 to serve as communication protocol terminators and giving them the ability to select the subset of the resource pool 118 - 124 to use for any given transaction. An access interface, such as interface 106 , is thus able to communicate with a client, such as client 102 , using the client's protocol for messages. The interface 106 parses a message received from the client into a portion representing data and a portion consisting of commands or requests for service. The interface 106 then interprets those requests and distributes the workload and the associated data across the pool of resources 118 - 124 .
[0021] The distribution of the workload may entail accessing a number of resources by the access interface and brings with it several major advantages. For example, it allows the workload to be distributed across the available resources, preventing the “hotspots” typically encountered when multiple clients independently attempt to access multiple resources. Since clients generally do not have knowledge about other clients' activities, it is very difficult, if not impossible, for the clients themselves to achieve any such level of load balancing on their own. In addition, it enables resources to be added non-disruptively to the resource pool. Clients need not be aware that additional resources have been made available since the access interfaces themselves are responsible for allocating resources to requests for service. This, in turn, allows the system capacity to be scaled to meet demand as that demand increases over time. Similarly, the ability of the access interfaces to distribute workloads allows the external connectivity to be increased to accommodate additional clients, again without disrupting on-going activities with existing clients.
[0022] The inventive system can be used to construct resource allocation systems for any type of resources. The remainder of this disclosure describes an embodiment which implements a disk-based storage system, but this embodiment should not be considered as limiting. In this embodiment, the access interfaces 106 - 112 are referred to as “host interface modules” and the resources are disk storage devices. The disk storage devices are connected to the switch fabric by “disk interface modules” and separate processing modules called “metadata” modules are also provided.
[0023] The storage system embodiment is shown in FIG. 2 . The storage system 200 consists of a set of access modules 206 - 210 called host interface modules, and two types of resource modules: disk interface modules 218 - 222 and metadata modules 212 - 214 . The host interface modules 206 - 210 provide one or more clients, of which clients 202 and 204 are shown, access to the system 200 and communicate with each client 202 , 204 using the client's message passing protocol. The host interface modules 206 - 210 parse requests from the clients 202 , 204 for disk and file system accesses and distribute the storage load across the entire set of disks connected to the system 200 , of which disks 226 - 230 are shown. The host interface modules are responsible for the logical allocation of the storage resources.
[0024] The disk interface modules 218 - 222 each support up to 450 disks and are responsible for the physical allocation of their disk resources. The disk interface modules provide data buffering, parity generation and checking and respond to requests from the host interface modules for access to their associated disks.
[0025] The metadata modules 212 - 214 provide a processing resource that maintains the structure and consistency of file systems used in the system. They are used when the storage system serves as a standalone file system, for example, in a networked environment, and hence assumes the responsibility for maintaining the file systems. The data used to describe the objects in the file system, their logical locations, relationships, properties and structures, is called “metadata.” In applications in which the storage system is directly attached to a host that implements this function itself, metadata modules are not needed and are accordingly not included in configurations intended for such applications. Since these applications and other storage system applications (e.g., HTTP server, web cache protocol server, and FTP server applications) require a subset of the functionality needed for standalone file systems, the illustrated embodiment is configured as a standalone file system, but the invention is equally effective in direct-attach applications. The following description applies equally to systems configured for direct attachment.
[0026] The switch module 216 provides the command and data paths used to interconnect the other three module types and contains both the control and data switches. In this embodiment of the invention, module 216 is capable of passing a block of data, for example, two kilobytes, between arbitrary pairs of modules at approximate fixed time increments, for example, approximately every four microseconds. Each host interface, disk interface and metadata module operates in full duplex mode, thereby enabling it to transmit and receive simultaneously at the aforementioned rate thereby supporting a system-level data bandwidth of up to N gigabytes/second, with N the total number of host interface, disk interface and metadata modules in the system.
[0027] The previously listed advantages of this architecture take the following more concrete forms when applied to the storage system. First, host interface modules are allowed to send incoming data to any available disk interface module for storage regardless of where that data might have been previously stored. This ability, in turn, distributes read accesses across the full complement of disks avoiding the inevitable hotspots encountered in conventional storage systems in which disks are partitioned into physical volumes and data must be directed to a specified volume.
[0028] Second, additional metadata modules, disk interface modules and physical disks can be added at any time. Clients need not be aware that additional resources have been made available since knowledge of where data is physically stored is not visible to them. This allows the logical space allocated to clients to far exceed the physical space that is currently available. Physical disk space does not need to be added until clients begin to use up a significant portion of the available physical space, which is typically much less than the allocated logical space.
[0029] Third, additional host interface modules can be added at any time to increase the connectivity available to the current clients or to add new clients. Since all host interface modules have equal access to all resources, traditional data segmentation and replication is not needed to provide access to an expanded set of clients. For the same reason, clients can transfer data to multiple disks in a single transfer; clients are, in fact, unconcerned about where that data is physically stored.
[0030] A more detailed diagram of a host interface module is shown in FIG. 3 . Each host interface module 300 is composed of four major components: a central processing unit (CPU) complex 324 , a data complex 318 , an input/output (I/O) complex 302 for communicating with the host and a switch interface 352 . The CPU complex 324 , in turn, consists of a microprocessor CPU 332 with its associated level-one (internal) and level-two (external) caches 330 , memory and I/O bus control logic 334 , local random-access memory (RAM) 326 , content-addressable memory (CAM) 338 . A peripheral bus 336 provides access to the CAM 338 , the data complex 318 , the switch interface 352 , and, through an I/O buffer 328 , to the I/O complex 302 . A PCI bus 339 provides access over the data transfer bus 350 to the data complex 318 and to two full-duplex channel adapters 340 , 342 which connect to two full-duplex 10/100 megabit Ethernet channels called the Interprocessor Communication channels (IPCs) 346 , 348 used to communicate with other modules in the system.
[0031] The data complex 318 comprises a large (typically two-gigabyte), parity-protected data memory 322 supported with a memory controller 320 that generates the control signals needed to access the memory 322 over a 128-bit data bus 323 and interface logic and buffers providing links to the I/O complex 302 , the switch interface 352 and, over the data transfer bus 350 , to the CPU complex 324 . The memory controller 320 responds to read requests from the other sections of the host interface module and forwards the requested information to them. Similarly, it accepts write requests from them and stores the associated data in the specified locations in memory 322 .
[0032] The I/O complex 302 is used to communicate with the clients via ports 307 - 313 . There are two versions of the I/O complex 302 , one version supports four one-gigabit, full-duplex Ethernet ports and the second version supports four one-gigabit, full duplex Fibre Channel ports. The second of these versions is typically used for systems directly attached to hosts; the first version is used for network-attached storage systems and is a preferred embodiment. Multiple protocols, including SCSI, TCP/IP, UDP/IP, Fibre Channel, FTP, HTTP, bootp, etc., are supported for communicating over these ports between clients and the host interface modules. These protocols are interpreted at the host interfaces 306 - 312 . Commands (e.g., read or write a file, lookup a file or directory, etc.) are buffered in the local I/O memory 304 for access by the CPU software via bus 314 . Data received from the clients, via ports 307 - 313 , is sent to the data memory 322 where it is buffered pending further action. Similarly, data passed from the storage system 300 to clients is buffered in the data memory 322 while the I/O complex 302 generates the appropriate protocol signals needed to transfer that data to the client that requested it.
[0033] The switch interface 352 contains a buffer memory 354 and associated logic to accept, upon command from the CPU software over the peripheral bus 336 , commands to transfer data, via bus 357 , from the data complex 318 to external modules. It buffers those commands and submits requests to the switch ( 216 , FIG. 2 ) for access to the destinations specified in those commands. When a request is granted, the switch output logic 356 commands the memory controller 322 to read the specified locations in memory 322 and transfer the data to it to be forwarded to the intended destination. Similarly, the switch input logic 358 accepts data from the switch at the full switch bandwidth and forwards it, along with the accompanying address, to the data complex 318 via bus 364 . Data is transferred from the output logic 356 to the switch and from the switch to the input logic 358 using, in each case, four serial, one-gigabit/second connections 360 , 362 giving the host interface module the ability to transmit, and simultaneously to accept, data at a rate of 500 megabytes/second. Similarly, the request and grant paths to the switch are also both implemented with serial one-gigabit/second links.
[0034] When a request is received from a client over one of the Ethernet or Fibre Channels 307 - 313 , the I/O complex 302 generates the appropriate communication protocol responses and parses the received packet of information, directing the request to buffer 304 to await processing by the CPU software and any associated data to buffer 304 for subsequent transfer to the data memory 322 . The processing steps taken by the software running on the host interface module CPU 332 are illustrated in the flowchart shown in FIGS. 4A-4C .
[0035] In FIG. 4A , the process starts in step 400 and proceeds to step 402 , where, the host interface receives a request from the client. The request always contains a file or directory “handle” that has been assigned by internal file system processing to each data object. This file system processing is typically done in the metadata module. The handle identifies that object and is sent to the client to be used when the client is making future references to the object. Associated with each such handle is an “inode” which is a conventional data structure that contains the object “attributes” (i.e., the object size and type, an identification of the users entitled to access it, the time of its most recent modification, etc.) of the file or directory. Each inode also contains either a conventional map, called the “fmap”, or a handle, called the “fmap handle”, that can be used to locate the fmap. The fmap identifies the physical locations, called the global physical disk addresses (GPDAs), of the component parts of the object indexed by their offsets from the starting address of that object. In step 404 , upon reading the request from the request buffer 304 , the CPU software extracts the object handle from the request.
[0036] Next, in step 406 , the CPU software queries the local CAM memory 338 , using the extracted object handle as a key, to determine if the desired inode information is already stored in host interface local memory 326 . If the inode information is present in the memory 326 , the CAM memory access results in a “hit” and the CAM memory 338 returns the address in local memory 326 where the inode information can be found. In step 408 , this address is then used to fetch the inode information from the local memory 326 .
[0037] If the inode information is not present in the local memory as indicated by a CAM memory “miss”, then, in step 410 , the software uses the IPC links 346 and 348 to contact the appropriate metadata module (which is identified by the object handle) for the needed information which is returned to it also over the IPC links. Once the software has located the inode (or a critical subset of the contents of the inode), it verifies that requested action is permitted (step 412 ). If the action is not permitted, an error is returned in step 414 and the process ends in step 415 .
[0038] Alternatively, if the requested action is permitted, then, in step 416 , the CPU software determines which response is required. If stored data is to be read, the process proceeds, via off-page connectors 419 and 421 to step 418 shown in FIG. 4C where the CPU software determines whether the fmap or the fmap handle required to honor that request is in the inode. If the fmap itself is too large to be contained in the inode, the process proceeds to step 420 where the software again consults its CAM 338 , this time using the fmap handle as the key, to determine if the fmap pointed to by that handle is stored locally. If it is not, the process proceeds to step 422 , where the software extracts the GPDA for the fmap from the fmap handle and sends a request for the fmap, or for the next level of fmap pointers, over the IPC links 346 , 348 to the disk interface module identified by the GPDA, which returns the fmap, or the page containing the next level of fmap pointers, through the switch module and switch interface 352 to the host interface module data memory 322 . The software can then access this information over the data transfer bus 350 . In step 424 , the software checks the information in the local data memory 322 to determine whether it has obtained the fmap. If not the process returns to step 420 and continues this process until it finds the fmap and the GPDA of the data itself, during each iteration of the process checking its CAM 338 at step 422 to determine if the desired information is cached in the data memory 322 .
[0039] When the software locates the GPDA of the desired data either through the process set forth in steps 420 - 424 or if it was determined that the fmap was in the inode in step 418 , in step 426 , the software again checks the CAM 338 to determine if the data resides in the host interface data memory 322 . If the data is not in the data memory 322 , in step 428 , the software sends a read request for the data to the disk interface module to retrieve that data identified by the GPDA. Once the data is in the host interface data memory 322 , in step 430 the software sends a response over the peripheral bus 336 via the I/O buffer 328 to the I/O complex 302 indicating the location in the data memory 322 where the desired information resides, thereby enabling the I/O complex 302 to complete the transaction by returning the requested information to the client. The least-recently-used (LRU) replacement algorithm is used to manage the local memory 322 and data memory caches. The process then ends in step 432 .
[0040] If in step 416 , a write operation is requested, the process proceeds, via off-page connectors 417 and 433 , to steps 434 - 440 in FIG. 4B . Prior to any writes to disk, the disk interface module preallocates or assigns “allocation units” (AUs) of physical disk space to each host interface module. Each allocation unit consists of a 512-kilobyte segment spread evenly across a plurality of (for example, four) disks. The disk interface module sends to each host interface module over an IPC channel 346 , 348 , the logical addresses of the allocation units that have been set aside for it. The host interface module then uses these logical addresses to specify the location of an object. Accordingly, the GPDA assigned by a host interface module to identify the location of a particular object specifies the “system parity group number” (SPGN), “zone” and offset within the zone where that object can be found. During initialization, the system determines the storage topology and defines a mapping associating SPGNs and specific disk interface modules. This level of mapping provides additional virtualization of the storage space, enabling greater flexibility and independence from the specific characteristics of the physical disks. The zone defines a particular region within a given SPGN. The disk module reserves certain zones for data represented by that allocation unit. The disk interface module also reserves certain zones for data that is known to be frequently accessed, for example, metadata. It then allocates these zones near the center of the disk and begins allocating the rest of the space on the disk from the center outward towards the edges of the disk. Consequently, most of the disk activity is concentrated near the center, resulting in less head movement and faster disk access.
[0041] If, in step 416 , it is determined that the host interface module received a write request from the client, the process proceeds, via off-page connectors 417 and 433 , to step 434 where the host interface module forwards the request to the metadata module or other file system. In parallel, the software assigns the associated data, which is buffered by the I/O complex 302 , to the appropriate preallocated allocation unit in the data memory 322 and sends a request to the switch through the switch interface 352 to enqueue the data for transmission, in, typically, two-kilobyte packets, to the corresponding disk interface module.
[0042] Next, in step 436 , the software then sends the GPDA(s) of the new location for that data over an IPC channel 346 , 348 to the appropriate metadata module and broadcasts that same information over IPC channels 346 , 348 to all other host interface modules in the system so that they can update their copies of the fmap in question. Alternatively, the software can broadcast invalidate messages to the other host interface modules causing them to invalidate, rather than update, the associated fmap. Then in step 438 , the host interface module waits for acknowledgements from the disk interface module and metadata module. Acknowledgements are sent to the host interface module over the IPC channels 346 , 348 from the disk interface module when the data has been received and from the metadata module when it has updated its copy of the fmap. When both acknowledgements have been received, in step 440 , the CPU software signals the I/O interface 302 to send an acknowledgement to the client indicating that the data has been accepted and is secure. By “secure” it is meant that the data has been stored in two independent modules (the host interface module and a disk interface module) and the associated metadata updates either have also been stored in two modules (the host interface module and a metadata module) or a log of those updates has been stored on a second module. The process then ends in step 442
[0043] The preallocation of allocation units has several significant advantages over the current state of the art in disk storage. In particular, the host interface module is able to respond to write requests without having to wait for disk space to be allocated for it, allowing it to implement the request immediately and to acknowledge the write much more rapidly. In effect, the preallocation gives the host interface module direct memory access to the disk. This ability to respond quickly is also enhanced by the fact that the data write does not need to wait for the metadata update to be completed.
[0044] As discussed below each disk interface module also maintains cached copies of allocation units. When a cached copy of an allocation unit in a disk interface module has been filled and written to disk, the disk interface module releases the cached copy, preallocating a new allocation unit, both on disk and in its cache, and sending the host interface module a message to that effect over the IPC 346 , 348 . The disk interface module can then reuse the cache memory locations previously occupied by the released allocation unit. At any given time, each host interface module has several allocation units preallocated for it by each disk interface module. Host interface modules select which allocation unit to use for a given write based solely on the recent activity of the associated disk interface module. This enables the workload to be distributed evenly across all disks, providing the system with the full disk bandwidth and avoiding the serious performance limitations that are frequently encountered in standard storage systems when multiple hosts attempt to access the same disk at the same time.
[0045] In accordance with one aspect of the invention, the data assigned to a given allocation unit may come from multiple hosts and multiple files or even file systems. The only relationship among the various data items comprising an allocation unit is temporal; they all happened to be written in the same time interval. In many cases, this can offer a significant performance advantage since files, or portions of files, that are accessed in close time proximity tend to be re-accessed also in close time proximity. Thus, when one such file is accessed, the others will tend to be fetched from disk at the same time obviating the need for subsequent disk accesses. On the other hand, this same process obviously gives rise to potential fragmentation, with the data associated with a given file ending up stored in multiple locations on multiple disks. Procedures to mitigate the possible deleterious effect of fragmentation when those files are read are discussed below. This technique for allowing data to be stored anywhere, without regard to its content or to the location of its prior incarnation, allows for superior, scalable performance.
[0046] As in any storage system, it is necessary to identify disk sectors that contain data that is no longer of interest, either because the file in question has been deleted or because it has been written to another location. This is accomplished in the current invention by maintaining a reference count for each page stored on disk. When a page is written to a new location, new fmap entries must be created to point to the data as described in the preceding paragraphs. Until the pages containing the old fmap entries have been deleted, other pages pointed to by other entries on those same pages will now have an additional entry pointing to them. Accordingly, their reference counts must be incremented. When an fmap page is no longer needed (i.e., when no higher-level fmap points to it) it can be deleted and the reference counts of the pages pointed to by entries in the deleted fmap page must be decremented. Any page having a reference count of zero then becomes a “free” page and the corresponding disk locations can be reused.
[0047] This procedure allows volumes to be copied virtually instantaneously. Volume copies are commonly used to capture the state of a file system at a given instant. To effect a volume copy, it is only necessary to define a new volume with pointers to the fmaps of the files that are being copied. When a page in a copied file is to be modified, the new fmap entries point to the new location while the old fmap entries point to the original, static, version of the file. As a result, unmodified pages are now pointed to by more than one fmap entry and their reference counts are incremented accordingly to prevent their being deleted as long as any copy of the volume is still of interest.
[0048] FIG. 5 illustrates in more detail the construction of a disk interface module 500 . All disk interface modules contain the same construction and are interchangeable. The construction of each disk interface module is similar to the construction of a host interface module shown in FIG. 3 and similar parts have been given corresponding numeral designations. These parts operate in a fashion identical with their corresponding counterparts in FIG. 3 . For example, data memory 322 corresponds to data memory 522 . The major differences between the two modules lie in the I/O complex 502 and in the data complex 518 . The I/O complex 302 in each host interface module is replaced in each disk interface module with a complex 502 consisting of five one-gigabit, full-duplex Fibre Channel interfaces ( 504 - 515 ), each containing the logic needed to send data to and to retrieve data from disk drives from various manufactures over five Fibre channels 507 - 517 . These Fibre Channel interfaces 504 - 515 are used to communicate with sets of five disks, each channel supporting up to 90 disks, enabling each disk interface module 500 to control up to 450 disks. Parity information is stored along with the data, so twenty percent of the disk space is used for that purpose. However, each disk interface module can still manage nearly 33 terabytes of data using 73-gigabyte disks.
[0049] All disks connected to a disk interface module are dual-ported with the second port connected to a second disk interface module. In normal operation, half the disks connected to any given disk interface module are controlled solely by it. The disk interface module assumes control over the remaining disks only in case of a fault in the other disk interface module that has access to the disks. This prevents the loss of any data due to the failure of a single disk interface module.
[0050] The data complex 518 in each disk interface module is identical to the data complex 318 in a host interface module 300 except for the addition of a special hardware unit 521 that is dedicated to calculating the parity needed for protection of the integrity of data stored on disk. During a disk write operation, the memory controller 520 successively transfers each of a set of four blocks of data that is to be written to disk to the parity generator 521 which generates the exclusive-or of each bit in the first of these blocks with the corresponding bit in the second block, the exclusive-or of these bits with the corresponding bits in the third block and the exclusive-or of these bits with their counterparts in the fourth block. This resulting exclusive-or block is then stored in memory 522 to be transferred, along with the data, to the five disks over five independent channels 507 - 515 . The size of the blocks is referred to as the “stripe factor” and can be set according to the application. The specific disk used to store the parity block is a function of the allocation unit being stored. This allows the parity blocks to be spread evenly across the five disk channels 507 - 515 .
[0051] The steps taken by the disk interface module CPU 532 in response to read and write requests are illustrated in the flowchart in FIG. 6 . The process begins in step 600 and proceeds to step 602 in which a new event is received by the disk interface module. On detecting that a new event has occurred, i.e., that either data has been received over the switch or a request has been received over the IPC, the CPU software in the target disk interface module determines the appropriate action in step 604 . If the event is a read request, the process proceeds to step 610 in which the CPU software checks the disk interface module CAM 538 , using the GPDA provided in the request as a key, to determine if the desired object is cached in its local data memory 522 . If the data is cached, the process proceeds to step 616 , described below.
[0052] Alternatively, if in step 610 , it is determined that the data is not cached, the process proceeds to step 612 in which software sends a request to the I/O complex 502 directing that the requested data be read, along with, typically, several adjacent disk sectors in anticipation of subsequent reads, and stored in an assigned location in the data memory 522 . The number of additional pages to be read is specified in the read request generated in the requesting host interface module, this number is determined from an examination of the type of file being read and other information gleaned by the host interface module from the attributes associated with the file. The additional pages are cached in case they are subsequently needed and overwritten if they are not.
[0053] The CPU software then polls the I/O complex 502 to determine when the read is complete as illustrated in step 614 . When the data is located in the data memory 522 , either through a cache hit or by being transferred in from disk, in step 616 , the software sends a message to the switch interface 552 thereby enqueuing the data for transmission to the requesting host interface module. While any data item cached in the disk interface module data memory 522 as the result of a write must also be cached in some host interface module data memory, the data item is not necessarily cached in the memory of the host interface module making the read request. Similarly, data may be cached in a disk interface module due to a prior read from some host interface module other than the one making the current request.
[0054] If, in step 604 , it is determined that a write request has been received, the process proceeds to step 606 . Allocation units that have been preallocated to host interface modules are represented by reserved cache locations in the disk interface module local memory 522 and by “free space” on disk, that is, by sectors that no longer store any data of interest. When the switch interface 552 receives write data from a host interface module, it stores the data directly in the preassigned allocation unit space in its data memory 522 and enqueues a message for the CPU software that the data has been received. Upon receiving the message, the software sends an acknowledgement over the IPC links 546 , 548 to the appropriate host interface module as shown in step 606 and enqueues the data for transfer to disk storage, via the I/O complex 502 , as shown in step 608 . The process then terminates in step 618 .
[0055] When disk bandwidth is available, or when space is needed to accommodate new data, the CPU software instructs the I/O complex 502 to transfer to disk storage the contents of one allocation unit cached in the data memory 522 . If possible, the CPU software selects an allocation unit that is already full to store to disk and, of full allocation units, it selects an allocation unit that is “relatively inactive.” One typical method for performing this selection is to select the allocation unit that has been least recently accessed (according to one of several well-known least-recently-used algorithms) but other criteria could also be used. For example, one of the pre-allocated allocation units may be selected at random. Alternatively, the switch unit could keep track of the length of queues of transactions awaiting access to the various disk modules. This information could then be communicated back the host interface module and used to make a decision as to which allocation unit to select based on actual disk activity.
[0056] As previously noted, the parity-generation hardware 521 is used to form the parity blocks that are stored along with the data, therefore, in order to store one allocation unit, 128 kilobytes of data and parity information are sent over each of the five channels 507 - 515 to five different disks. Once the data has been stored on disk, the software sends a message to the relevant host interface module over the IPC links 546 , 548 informing the host interface module that the contents of the allocation unit can now be released. However, those contents are not overwritten in either the host interface module or the disk interface module until the space is actually needed, thereby allowing for the possibility that the information might be requested again before it is expunged and hence can be retrieved without having to access physical disk storage.
[0057] Note that since an allocation unit is written as a unit, the parity information stored along with each disk stripe never has to be read and updated, reducing by ¾ths the number of disk accesses that would otherwise be needed to store a single page. For example, in prior art systems, the prior contents of the page to be stored has to be read, the parity page has to be read and modified based on the change between the new and old contents of the page in question, and the new page and the parity page both have to be stored. In the inventive system, the only time a parity page normally has to be read is when the data on some sector fails the standard cyclic residue code (CRC) check always used to protect data stored on disk. In this event, the parity sector is read and, in combination with the three error-free sectors, is used to reconstruct the contents of the defective sector.
[0058] As previously noted, the policy of writing data to arbitrary locations, while offering major performance advantages, can result in fragmentation of files that are only partially updated. Since each host interface module can use any allocation unit at its disposal, and, in fact, selects allocation units solely on the basis of the recent activity of the associated disks, files may well be split up among multiple disk interface modules. This tendency toward fragmentation is mitigated by a write-back policy. That is, when a host interface module reads a file that has been fragmented, it follows that read with a write, placing all the file fragments, or all that will fit, in the same allocation unit. The previously described technique for ensuring that newly written data and metadata are consistent is, of course, used with write-back operations as well.
[0059] Another potential inefficiency resulting from the “write anywhere” policy is that sections of allocation units are gradually replaced by more up-to-date versions written elsewhere, leaving holes in those allocation units that represent wasted disk space unless they are identified and reused. Since the reference count technique described earlier allows those sections to be identified, they can, in fact, be reused. To make their reuse more efficient, the software running on the disk interface modules CPU 532 , as a background task, identifies those allocation units having more than a predetermined percentage of unused space and sends the GPDAs of the still-valid sectors to a host interface module so that the vectors can be read and rewritten more compactly.
[0060] The detailed construction of a metadata module 700 is shown in FIG. 7 . The metadata module 700 differs from the host interface module 300 and disk interface module 500 in two basic ways: The metadata module 700 has no I/O complex since it does not communicate with either clients or disks; and the data complexes present in the host interface modules and disk interface modules are eliminated and their large data memories replaced by relatively a small memory 754 that serves as store-and-forward buffer. Data destined to be stored through the switch output 756 and connections 760 is first transferred, using a DMA engine 753 , from the CPU's local memory 726 into the buffer memory 754 before being enqueued for transfer. Similarly, data received over the switch via connections 762 and switch input 758 is transferred from the input buffer 754 directly into preassigned locations in local memory 726 .
[0061] Since the local memory 726 in the metadata module 700 stores all data received over the switch, it is considerably larger than its counterpart in the host interface 300 and disk interface modules 500 , normally comparable in size to the latter modules' data memories, 322 and 522 , respectively. The local memory 726 is used primarily for caching inodes and fmaps. The other elements shown in FIG. 7 are similar in function and implementation to the corresponding elements shown in FIGS. 3 and 5 .
[0062] The purpose of the metadata module 700 is to maintain the file system structure, to keep all inodes consistent and to forward current inodes to host interface modules that request them. When a new file or directory is created, it is the responsibility of the metadata module to generate the associated inode and to insert a pointer to it into a B-tree data structure used to map between inodes and GPDAs. Similarly, when a file or directory is deleted, the metadata module must delete its associated inode, as well as those of all its descendents, and modify the B-tree data structure accordingly.
[0063] When a host interface module receives a request from a client that requires inode information that the host interface module cannot find in its own local memory, it uses the IPC links to query the metadata module associated with the file system in question. The steps taken by the software running on a metadata module CPU 732 to service a typical request are depicted in FIGS. 8A and 8B .
[0064] In FIG. 8A , the process begins in step 800 and proceeds to step 802 where a request is received by the metadata module. All requests to a metadata module for an object are accompanied by a handle that includes an “inode number” uniquely identifying the object, or the parent of the object, being requested. These unique inode numbers are assigned by the file system to each of its files and directories. The handle used by a client to access a given file or directory includes the inode number, which is needed to locate the object's associated inode. In step 804 , the metadata module checks its CAM 738 using that inode number as a key. If the inode information is in the CAM 738 , the process proceeds, via off-page connectors 815 and 819 , to step 816 , discussed below.
[0065] If the inode information is not in the local memory 726 , as indicated by a cache “miss,” the CPU software then searches through an inode B-tree data structure in memory 726 to find the GPDA of the inode data as indicated in step 806 . If the necessary B-tree pages are not present in local memory, the process proceeds to step 808 where the software sends a message over IPC links 746 , 748 to the appropriate disk interface module requesting that a missing page be returned to it over the switch. The metadata module 700 then waits for a response from the disk interface module (step 810 .)
[0066] In step 812 , the CPU software examines either the cached data from step 806 or the data returned from the request to the disk interface module in step 810 to determine if the data represents a leaf page. If not, the process returns to step 808 to retrieve additional inode information. If the data does represent a leaf node, then the process proceeds, via off-page connectors 813 and 817 , to step 814 . Once the metadata module 700 has located the GPDA of the inode itself (the desired leaf node), in step 814 , the metadata module 700 sends a request over the IPC links 746 , 748 for the page containing that inode. At this point, the inode information has been obtained from the CAM 738 in step 804 or by retrieving the information in step 814 .
[0067] The process then proceeds to step 816 where a determination is made concerning the request. If the request received from the host interface module was to return the handle associated with a named object in a directory having a given inode number, the retrieved inode is that of the directory and the process proceeds to step 820 .
[0068] To fulfill the request, the metadata module 700 must read the directory itself as shown in step 820 . The CPU software first queries its CAM 738 , using the directory's GPDA as a key, to determine if the directory information is cached in its local memory 726 . If the desired information is present, then the process proceeds to step 818 . If the directory, or the relevant portion of the directory is not cached, the software must again send a message over the IPC to the disk interface module storing the directory requesting that the directory information be returned to it through the switch as indicated in step 822 . Once it has access to a directory page, it searches the page to find the desired object. If the object is not found in step 824 , the process returns to step 820 to obtain a new page. Eventually it locates the named object and its associated inode number.
[0069] Finally, once the metadata module has located either the inode of the object specified by the handle or the inode of the named object, depending on the specific request, it forwards the requested information on to the requesting host interface module as set forth in step 818 . The process then ends in step 826 .
[0070] A detailed diagram of the switch module is shown in FIG. 9 . The switch module 900 is composed of three major components: a crossbar switch complex 906 providing non-blocking, full-duplex data paths between arbitrary pairs of host interface modules, disk interface modules and metadata modules; an IPC complex 904 composed of switches 942 for two sets of full-duplex, serial, 10/100 Ethernet channels 938 and 940 that provide messaging paths between arbitrary pairs of modules; and a configuration management complex 902 including system reset logic 924 and the system clock 908 . The switch module is implemented as a redundant pair for reliability and availability purposes, however, only one of the pair is shown in FIG. 9 for clarity.
[0071] The I/O processor 954 in the crossbar switch complex 906 accepts requests from the switch interfaces 356 , 556 and 756 on the host interface modules, disk interface modules and metadata modules, respectively over the request links and grants access over the grant links. Each module can have one request outstanding for every other module in the system or for any subset of those modules. During each switch cycle, the arbiter 950 pairs requesting modules with destination modules. The arbiter assigns weights to each requester and to each destination. These weights can be based on any of several criteria, e.g., the number of requests a requester or destination has in its queue, the priority associated with a submitted request, etc. The arbiter then sequentially assigns the highest weight unpaired destination to the unpaired requester having the highest weight among those requesting it. It continues this operation as long as any unpaired requester is requesting any, as yet, unpaired destination.
[0072] The I/O processor 954 then sends each requesting module, over the appropriate grant link, the identity of the module with which it has been paired and to which it can send a data packet during the next switch cycle. The arbiter 950 sets the crossbar switch 952 to the appropriate state to effect those connections.
[0073] The switch 952 itself consists of four sets of multiplexers, one multiplexer from each set for each destination, with each multiplexer having one input from each source. Switch cycles are roughly four microseconds in duration, during which time two kilobytes of data are sent between each connected pair with a resulting net transfer rate of approximately 500 megabytes/second per connected pair.
[0074] The function of the IPC switches 942 is to connect source and destination IPC ports 944 long enough to complete a given transfer. The standard IEEE 802.3 SNAP (sub-network access protocol) communication protocol is used consisting of a 22-byte SNAP header followed by a 21-byte message header, a data packet of up to 512 bytes and a 32-bit cyclic residue code (CRC) to protect against transmission errors.
[0075] The configuration management complex 902 coordinates system boot and system reconfiguration following faults. To support the first of these activities, it implements two external communications links: one 936 giving access through the PCI bus 928 via full-duplex, serial, 10/100 Ethernet channel 932 ; and the other 912 giving RS-232 access 914 through the peripheral bus 922 . To support the second activity, it implements the reset logic 924 for the entire system. It also implements and distributes the system clock 908 .
[0076] The disclosed invention has several significant fault-tolerant features. By virtue of the fact that it is implemented with multiple copies of identical module types and that all of these modules have equal connectivity to all other modules, it can survive the failure of one or more of these modules by transferring the workload previously handled by any failed module to other modules of the same type. The switch fabric itself, of course, is a potential single point of failure since all inter-module communication must pass through it. However, as mentioned in the previous section, the switch in the preferred implementation is implemented with two identical halves. During the initialization process, the two configuration management complexes 902 communicate with each other, via the IPC channels, to determine if both are functioning properly and to establish which will assume the active role and with the standby role. If both switch halves pass their self-diagnostic tests, both sets of IPC channels are used and the configuration management complexes 902 cooperate in controlling the system configuration and monitoring its health. Each switch half, however, supports the full data bandwidth between all pairs of modules, therefore only the active half of the switch is used for this purpose. If one switch half becomes inoperative due to a subsequent failure, the configuration management complexes cooperate to identify the faulty half and, if it is the half on which the active configuration manager resides, transfer that role to the former standby half. The surviving configuration manager communicates the conclusion to the other system modules. These modules then use only the functioning half of the switch for all further communication until notified by the configuration manager that both halves are again functional. Although the IPC bandwidth is halved when only one switch half is operational, the full data bandwidth and all other capabilities are retained even under these circumstances.
[0077] Several complementary methods are used to identify faulty modules, including (1) watchdog timers to monitor the elapsed time between the transfer of data to a module and the acknowledgement of that transfer and (2) parity bits used to protect data while it is being stored in memory or transferred from one point to another. Any timeout or parity violation triggers a diagnostic program in the affected module or modules. If the violation occurred in the transfer of data between modules, the fault could be in the transmitting module, the receiving module or in the switch module connecting the two so the diagnostic routine involves all three modules checking both themselves and their ability to communicate with each other. Even if the diagnostic program does not detect a permanent fault, the event is logged as a transient. If transient event recurs with a frequency exceeding a settable parameter, the module involved in the greatest number of such events is taken off line and the failure treated as permanent, thereby triggering manual intervention and repair. If transients continue, other modules will also be taken off line as a consequence until the fault is isolated.
[0078] Byte parity is typically used on data stored in memory and various well-known forms of vertical parity checks and cyclic-residue codes are used to protect data during transfer. In addition, in the storage system embodiment described here, data tags consisting of 32-bit vertical parity check information on each data page are stored on disk separately from the data being protected. When data is retrieved from disk, the tag is also retrieved and appended to the data. The tag is then checked at the destination and any discrepancy flagged. This provides protection not only from transmission errors but also from disk errors that result in reading the wrong data (or the wrong tag). This latter class of errors can result, for example, from an addressing error in which the wrong sector is read from disk or from a write current failure in which old data is not overwritten.
[0079] Another important fault-tolerant feature of the storage system embodiment of the invention is the requirement that all data and metadata be stored on at least two different modules or on parity-protected disk before the receipt of any data is acknowledged. This guarantees that the acknowledged data will still be available following the failure of any single module. Similarly, data stored on disk is protected against any single disk failure, and against any single disk channel failure, by guaranteeing that each data block protected by a parity block is stored on a different physical disk, and over a different disk channel, from all other blocks protected by the same parity block and from the disk storing the parity block itself.
[0080] Finally, the fact that all disks are dual-ported to two different disk interface modules guarantees that data can still be retrieved should any one of those disk interface modules fail. Following such an event and the resulting reconfiguration, all subsequent accesses to data stored on the affected disks are routed through the surviving disk interface module. While this may result in congestion because the surviving disk interface module is now servicing twice as many disks, it retains full accessibility. In addition, the previously described load-balancing capability of the system will immediately begin redistributing the workload to alleviate that congestion.
[0081] Similar protection against host interface module failures can be achieved by connecting clients to more than one host interface module. Since all host interface modules have full access to all system resources, any client can access any resource through any host interface module. Full connectivity is retained as long as a client is connected to at least one functioning host interface module and, connection to more than one host interface module provides not only protection against faults, but also increased bandwidth into the system.
[0082] The architecture described in the previous paragraphs exhibits several significant advantages over current state-of-the-art storage system architectures:
[0083] 1) It is highly scaleable. Host interface modules, disk interface modules and metadata modules can all be added independently as needed and their numbers can be independently increased as storage throughput or capacity demands increase. A system using a 16-port crossbar switch, for instance, can support any combination of host interface modules, disk interface modules and metadata modules up to a total of 16. This would allow a system to be configured, for example, to give 32 directly connected clients access to over 40 terabytes of data (using 36-gigabyte disks) supported by two metadata modules. Obviously, even larger configurations can be realized with larger IPC and wider crossbar switches.
[0084] 2) Since writes can be directed to arbitrary disk interface modules, demand can be equalized across all disk resources, ensuring that throughput will increase nearly linearly with the number of disk interface modules in the system. Further, writes can take place in parallel with fmap updates thereby decreasing the latency between the initiation of a data write and the acknowledgement that it has been accepted. Since both the data and the metadata associated with a new write are always stored in two independent places before that write is acknowledged, write acknowledgements can be issued before data is actually stored on disk while still guaranteeing that the data is secure.
[0085] 3) Relegating metadata operations to modules designed for that purpose not only enables faster metadata processing but, in addition, allows the host interface and disk interface modules to be structured as efficient data pipes, with the bulk of local memory partitioned as a bi-directional buffer. Since the client's communication protocol is terminated in the host interface module I/O complex, the bulk of data passing through this data memory does not need to be examined by the host interface module CPU software.
[0086] Although an exemplary embodiment of the invention has been disclosed, it will be apparent to those skilled in the art that various changes and modifications can be made which will achieve some of the advantages of the invention without departing from the spirit and scope of the invention. For example, it will be obvious to those reasonably skilled in the art that, although the description was directed to particular embodiments of host interface modules, disk interface modules, metadata modules and switch modules, that other designs could be used in the same manner as that described. Other aspects, such as the specific circuitry utilized to achieve a particular function, as well as other modifications to the inventive concept are intended to be covered by the appended claims
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A data system architecture is described that allows multiple processing and storage resources to be connected to multiple clients so as 1) to distribute the clients' workload efficiently across the available resources; and 2) to enable scaleable expansion, both in terms of the number of clients and in the number of resources. The major features of the architecture are separate, modular, client and resource elements that can be added independently, a high-performance cross-bar data switch interconnecting these various elements, separate serial communication paths for controlling the cross-bar switch settings, separate communication paths for passing control information among the various elements and a resource utilization methodology that enables clients to distribute processing or storage tasks across all available resources, thereby eliminating “hot spots” resulting from uneven utilization of those resources.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. Ser. No. 12/902,523, filed Oct. 12, 2010, now U.S. Pat. No. 8,069,608.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is mushroom compost compacting systems, and particularly those systems for composting Phase II or Phase III mushroom composts.
2. Background
Mushroom farming comprises generally six steps: (1) Phase I composting; (2) Phase II composting; (3) spawning; or (2a/3a) Phase III composting; (4) casing; (5) pinning; and (6) cropping. The most used and least expensive mushroom compost is straw-bedded horse manure to which nitrogen supplements and a conditioning agent, such as gypsum, are added. After the compost ingredients have been mixed, watered and aerated in Phase I for a requisite number of days, the compost is pasteurized in Phase II. Pasteurization kills insects, unwanted fungi or other pests that may be present in the compost.
Preparing Phase II mushroom compost can be difficult. One reason for the apparent difficulty with this phase is that pasteurization can last up to two weeks, depending upon the production system used. The time required, as well as other difficulties in maintaining temperature control and eliminating pests during this phase have led many mushroom farmers to purchase pre-pasteurized compost. In many cases, the Phase II compost is pre-mixed with mushroom spawn. Alternatively, Phase III compost is pasteurized, pre-mixed with mushroom spawn and spawn run.
When commercial mushroom farmers purchase pre-pasteurized Phase II or Phase III composts, proper compaction of mushroom beds is still necessary to spawn and grow mushrooms. Moreover, regardless the type of receptacle in which the compost is stored during processing, uniform compaction and density of the compost is beneficial for mushroom cultivation. For maximum yield, mushroom beds should have Phase II and Phase III compost density and compaction that fosters gas exchange, keeps compost temperatures sufficiently low, and prevents spawn kill in the next phase of processing.
Presently, commercial mushroom farmers who purchase pre-pasteurized compost introduce the Phase II or Phase III compost into beds by conveyor and attempt to use spawning machines to compact the compost. These machines, however, are not designed to compact to the degree desired for mushroom cultivation. Furthermore, these machines are less than desirable for commercial mushroom farmers because during operation they also chop up the spawn incorporated into the compost, potentially interfering with the next step in mushroom farming.
Other known compacting systems and methods are impractical for commercial use. One such system uses an assembly with rollers and smoothing plates. In this system, mushroom compost is partially compacted after placement into the mushroom bed. The assembly is then horizontally positioned over the bed and manually guided by two operators located on each side of the bed. This system tends to compact only a surface layer portion of the bed. Compaction to some degree has also been performed by hand after placement of compost in the bed. These time-consuming manual systems and methods make clear the need for improved mushroom compaction systems.
While certain aspects of prior art mushroom compacting systems have been discussed, aspects of these systems are in no way disclaimed and it is contemplated that the claimed invention may encompass one or more aspects of the prior art devices discussed herein.
SUMMARY OF THE INVENTION
The present invention is directed toward a mushroom compost compacting system and method. In one embodiment, the system comprises a roller assembly mounted to a compost receptacle, and a web, all of which are configured to compact mushroom compost from an initial compost height to a final compost height. The compost receptacle is configured to receive mushroom compost from any source.
The roller assembly includes a roller, a shaft, and two fixtures to removably mount or affix the roller and shaft to the compost receptacle. The roller is mounted for rotation on the shaft, such as by a through-hole for receiving the shaft. The fixtures are coupled to the shaft for height adjustment of the roller and the shaft in relation to the floor portion of the compost receptacle. Each fixture has (a) a first end that is coupled to one respective end of the shaft, (b) a mid-section that is coupled to a sleeve that seats over a sidewall of the compost receptacle, and (c) a second end that is adapted to mount to a support onto the compost receptacle. The sleeve that is coupled to the mid-section of the fixture is adapted to removably mount onto the sidewalls of the compost receptacle.
The web or liner or conveyor included in the mushroom compacting system is adapted to move under the roller to convey compost to the nip. As the web or liner or conveyor moves under the roller, the mushroom compost is compacted from an initial compost height to a final desired compost height.
Accordingly, a mushroom compacting system and method are disclosed. Advantages of the system and method will appear from the drawings and following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention described above will be explained in greater detail below on the basis of embodiments and with reference to the accompanying drawings in which:
FIG. 1 is a top perspective view of a mushroom compost bed with a mushroom composting system;
FIG. 2 is a cross-sectional view of the mushroom composting system shown in FIG. 1 taken along line 2 - 2 in FIG. 1 ;
FIG. 3 is a left side partial perspective view of a roller assembly;
FIG. 4 is a right side partial perspective view of the roller assembly of FIG. 3 ;
FIG. 5 is a right side view of the roller assembly;
FIG. 6 is a broken front elevation view of the roller assembly;
FIG. 7 is a right side view of two roller assemblies operably attached to two mushroom compost beds; and
FIG. 8 is a right side view of an alternative fixture for a roller assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning in detail to the drawings, FIG. 1 . illustrates a mushroom compost bed 10 that includes a series of trays or shelves, herein compost receptacles 12 , into each of which mushroom compost 8 is deposited or laid. The mushroom compost 8 may be Phase I, Phase II or Phase III compost. Phase II compost may be pre-spawned, and Phase III compost may be spawn run. The compost receptacle 12 may be any geometric configuration suitable to house mushroom compost 8 . In one configuration as shown in FIG. 1 , the compost receptacle 12 is an elongated bin, tray, or shelf that has two endwalls 18 (not shown), two sidewalls 20 , and a bottom 22 . The bottom may be a series of slats or decking running generally lengthwise. Each compost receptacle 12 is supported by vertical posts or members 24 positioned at each corner of the compost receptacle 12 and optionally at intervals along the length of the compost receptacle 12 . The vertical posts or members 24 may act as supporting legs for one or more compost receptacles 12 . As shown in FIG. 1 , the vertical posts or members 24 extend vertically to support other compost receptacles (three tiers shown in FIG. 1 ). These types of multi-tiered compost receptacles are typical in commercial mushroom farming. For additional support, some compost receptacles also have horizontal members or joists 26 that may be mounted to or connected to the vertical members 24 and extend under the floor portion of the compost receptacle 12 . Typically, the compost receptacles 12 are wooden, although any suitable material may be used, including, but not limited to plastic, metal, and composite materials.
The mushroom compost 8 is initially placed into the compost receptacle 12 from any suitable source. Preferably, the mushroom compost 8 is distributed inside the compost receptacle 12 along the length of the compost receptacle using a conveyor system (not shown) that acts on the web or conveyor or liner 28 . In one type of conveyor system, at one end of the compost receptacle 12 , compost is placed on top of the flexible web or conveyor or liner 28 in the bottom 22 of the compost receptacle 12 at a proximal end thereof. The liner 28 is then pulled from the opposite distal end of the compost receptacle 12 , such that the compost 8 is distributed or spread along the length of the compost receptacle 12 . Examples of suitable materials for the liner include woven fabrics with a plastic or Teflon coating, or may be polyester.
A mushroom compost compacting system 11 includes a roller assembly 14 that is removably affixed to the compost receptacle 12 . Each roller assembly 14 comprises a roller 32 , a shaft 34 , and two fixtures 36 , 36 ′. The shaft 34 and roller 32 extend laterally over the tray portion of the compost receptacle 12 . The roller 32 may be made from a lightweight material such as plastic or aluminum, or may be made of another metal lined on its outer surface with a nylon or Teflon or other sheeting. The roller surface is smooth such that the mushroom compost to be compacted by the roller may move easily under the roller 32 . In one embodiment, the diameter of roller 32 is from about 8 to 20 inches. The shaft 34 may be formed of steel; however, any material suitable to support the weight of the roller 32 may be used.
As shown in FIGS. 3 , 5 and 6 , the first fixture 36 includes a first end 40 , a mid-section 42 coupled to a sleeve 44 , and a second end 46 . The first fixture 36 is coupled at one end 40 to one shaft end 38 at pillow block bearing 50 and is coupled at the opposite end 62 to a support 58 , such as a channel member. The pillow block bearing 50 is then mounted onto a mounting bracket or plate 52 , using bolts 53 or other suitable fasteners. The mounting bracket or plate 52 is then welded to a first mounting element 54 which is threaded to the mid-section 42 . Disposed within the first mounting element 54 is a pin 56 which may be rotated for adjustment of the first end 40 , such that height adjustment of the roller 32 and shaft 34 is possible for compaction of the mushroom compost. As an example, the nip height between the outer circumferential surface of the roller and the floor of the compost receptacle may be from about 2 to about 8 inches. The nip height is set at a distance that is less than the desired compacted height of the mushroom compost.
The mid-section 42 of first fixture 36 may be joined by a spacer 48 or may bewelded to a sleeve 44 that is removably mounted or seated or engaged onto a first sidewall 20 of the compost receptacle 12 . The second end 42 of the first fixture 36 is threaded to engage the mid-section 42 and to mount onto the compost receptacle 12 . Preferably, the second end or opposite end of the first fixture 36 is joined to or mounted to a support, such as channel member 58 , that abuts joist or horizontal member 26 . In one embodiment, the channel member 58 is a square hollow pipe with a length sufficient to extend under the compost receptacle, and the dimensions of such square may be from 2 inches to 6 inches. In another embodiment, the support may also comprise a solid pipe of suitable cross-sectional shape as desired. The second end 46 is further coupled to a handle element 60 to allow for adjustment of the second end 46 . For additional adjustment of the second end 42 , washer(s) 63 may be placed between the channel member 58 and the handle element 60 .
Referring next to FIGS. 4 and 6 , the second fixture 36 ′ may be joined by spacer 48 ′ or may be welded to a sleeve 44 ′. The second fixture 36 ′ is coupled at one end 40 ′ to one shaft end 38 at pillow block bearing 50 ′ and is coupled at the opposite end 62 ′ to a support 58 , such as a channel member. The pillow block bearing 50 ′ is then mounted onto a mounting bracket or plate 52 ′, using bolts 53 or other suitable fasteners. The plate 52 ′ is then welded to a first mounting element 54 ′ which is threaded to the mid-section 42 ′. Disposed within the first mounting element 54 ′ is a pin 56 ′ which may be rotated for adjustment of the first end 40 ′.
In an alternative embodiment, however, the second end of the first fixture 36 and the second end of the second fixture 36 ′ are mounted directly to the compost receptacle 12 , such as to post 24 or to joist 26 (not shown).
The roller shaft may be turned by hand. Preferably, the first end of the shaft 34 is coupled to a motor 64 for rotation of the roller 32 . As shown in FIG. 3 , the motor 64 is mounted to a vertical post 24 of the compost receptacle 12 using a mounting plate 66 . Adjustment of the mounting plate 66 is achieved through use of a pin 68 that is threaded to the mounting plate 66 . Suitable motors include electric and hydraulic motors rated at 1 to 5 HP, or higher HP, although any motor with sufficient capacity to rotate shaft 34 may be used.
The first and second fixtures 36 , 36 ′ may be formed from shaped metal, such as steel; however, other materials with sufficient strength to support the roller 32 and shaft 34 may be used.
Once installed, the mushroom compacting system 11 compacts mushroom compost from a first height A to a compacted height B as illustrated in FIG. 2 . Gauge boards (not shown) can be inserted adjacent to the side walls of the compost receptacle 12 to help workers place a quantity of mushroom compost onto the conveyor, web or liner 28 at a desired height at one end of the compost receptacle. The roller 32 is rotated in the direction of arrow 9 and the conveyor, web or liner 28 conveys mushroom compost laid thereon to the nip between the roller 32 and the floor portion of the compost receptacle 12 . The mushroom compost compacting system 11 can be used with pre-spawned Phase II compost or spawn run Phase III compost without adversely impacting the mushroom crop. As one example, the height A may be about 15 to 16 inches and the height B may be about 6 to 9 inches. A successful degree of compaction is determined at the mushroom grower's discretion. The mushroom compacting system 11 provides means to obtain a more uniform compaction of the mushroom compost at the top, middle and bottom portions of the compacted compost bed.
Upon completing compaction of compost to a desired thickness within a first bin or tray of a mushroom compost bed 10 , the mushroom compacting system 11 may be detached from the sidewalls 20 of the compost receptacle 12 and attached to another bin or tray.
As shown in FIG. 7 , the mushroom compacting system 11 can include multiple roller assemblies 14 operating concurrently on separate trays or shelves or compost receptacles 12 of one or more compost beds 10 , 10 ′. Each roller assembly 14 is portable, and may be easily disassembled and re-installed to other areas along the length of a compost receptacle 12 or to other trays positioned above or below a first compost receptacle 12 of a compost bed 10 . Compost beds may include six or seven compost receptacles 12 mounted in stacked relation. After a lower compost receptacle is prepared and compacted, the next highest compost receptacle may be installed and prepared and compacted for growing mushrooms.
An alternative construction of a fixture 76 is shown in FIG. 8 . The fixture 76 is welded at weld seam 78 to the sleeve 44 . The fixture 76 may be formed with thicker sidewalls than the fixtures 36 , 36 ′ in FIGS. 1-7 , and has a generally square configuration in cross-section.
A properly compacted mushroom compost bed using the mushroom compacting system according to the invention can shorten the mushroom grow time cycle by one or two days. The system not only expedites mushroom bed preparation with Phase II or Phase III compost, but also produces a more consistent compost compaction that can lead to enhanced yield in a shorter grow time cycle.
While embodiments of this invention have been shown and described, it will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the following claims.
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A mushroom compost compacting system and method includes a roller assembly mounted to a compost receptacle to form a nip, and a web or conveyor to convey mushroom compost to the nip. Mushroom compost is compacted at the nip from an initial compost height to a final compost height. The roller assembly has a roller, a shaft, and fixtures coupled to each end of the shaft. The fixtures are adjustable to define the roller nip height. In one embodiment, the fixtures are mounted to sleeves that engage the sidewalls of the compost receptacle. In another embodiment, the ends of the fixtures are mounted to a support, which may be a joist or a separate channel extending under the floor portion of the compost receptacle, or which may be a post that forms support structure for the compost receptacle.
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SUMMARY OF THE INVENTION
The present invention relates to a reaction signal to be installed on a car whereby the driver of a car following will know whether the car in front of him is accelerating, coasting or braking. At the present time, cars are ordinarily equipped with only a brake light which does not give the maximum warning to a following car. In other words, the driver frequently takes his foot off of the accelerator to slow down and coast for a considerable period of time prior to the application of brakes, should such be required. If the following driver had a warning of the coasting period, he would be in a much better position to keep his distance, anticipating that the car in front of him might come to a sudden stop.
I am aware of the fact that a number of prior proposals have been made for accomplishing a somewhat similar purpose. However, all of the prior art devices have suffered some deficiency which the present invention remedies.
Some systems have employed three lights, such as a green light for acceleration, an amber light for coasting, and a red light for the application of brakes. One difficulty with such systems, aside from their complication and the expense of adding such a system to an existing car, is the fact that in many states the color of signal lights is prescribed by law, and a green light on the rear of a vehicle is not permitted.
Other systems have employed amber and red lights, both of which are permitted by law, but have involved very special and complicated switches which are expensive to manufacture and install.
Still other systems have suffered from the deficiency that when the brake pedal is released, the stop lights will go off but there will be no indication as to whether the car in front is now coasting or accelerating.
The reaction signal of the present invention is extremely simple and involves the use of only the red and amber lights which are now standard equipment on all vehicles.
Further, the reaction signal of the present invention employs only conventional switches which are standard and inexpensive to procure and easy to install so that a very low-cost system can be provided. Also, in accordance with a preferred embodiment, the usual backup lights are utilized, minimizing the changes to the existing car light system.
Various other objects and advantages of the invention will be brought out in the balance of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an automobile with the system of the present invention installed, showing certain of the parts cut away.
FIG. 2 is a schematic diagram of a preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a reaction signal to warn a following driver utilizing amber and red lights wherein the reaction signal operates in four phases:
In the first phase, when the operator of the preceding vehicle releases the accelerator, amber reaction signal lights go on.
In the second phase, when the brakes are applied, the amber reaction lights go off and the red stop lights go on.
In the third phase, when the operator releases the brakes, the stop lights will go off and the amber reaction signal will again go on.
The amber reaction signal will stay on until in the fourth and final phase when the operator depresses the accelerator, whereupon the amber reaction signal will go off to complete the cycle and to set the system up for a repetition of the cycle.
Before describing the switches added in the course of the present invention, the existing electrical equipment will be briefly described. Current from the battery 3 is applied to the normally open switch 5 which is mounted on the brake pedal 6 and which is connected to the red stop lights 7. When the brake 6 is applied, switch 5 closes, switching on the red lights as is well known. In the embodiment shown, the red stop lights operate independent of the ignition switch and in some systems, the stop lights would be wired to the ignition switch rather than directly to the battery, so that the stop lights would operate only when the ignition switch is turned on. This, of course, has nothing to do with the present invention.
In accordance with the present invention, two normally closed switches of standard design, namely 9 and 11, are provided. Switch 9 is actuated by a connection 13 from the throttle linkage 15, it being understood that the throttle of the vehicle is closed when link 15 is in its left position and as the link 15 moves to the right, the throttle of the vehicle is opened and switch 9 is opened.
Switch 9 is wired in series to switch 11 which is placed adjacent to the brake pedal 6 and opened by arm 17 on the brake pedal when the pedal is depressed. Switch 11 in turn leads to the amber lights 19. Since switches 9 and 11 are in series and are connected through the ignition switch 21 to the vehicle's electrical system, it is apparent that lights 19 will light up only when the ignition switch 21 is on, switch 9 is closed (i.e., linkage 15 is to the left) and switch 11 is closed (i.e., the brake pedal 6 has not been depressed).
A preferred method of carrying out the invention is to place the switches 9 and 11 in parallel with the switch 12 of the backup lights. One can then replace the usual white bulbs of the backup lights with amber bulbs. The backup lights will then be amber, but this causes no practical difficulty since the amber bulbs give adequate lighting while backing.
It is believed now that the operation of the switch system is apparent. When one first gets into the vehicle and turns the ignition switch 21 on, the driver would ordinarily depress the accelerator, opening switch 9 so that the amber lights would not come on. Even if the accelerator is not depressed, the car would be in a stationary position so that it would not be important whether or not the amber lights came on. In any event, as the driver moves off, the accelerator 15 would be depressed, opening switch 9, so that neither the amber not the red lights would be on. Now, if the operator releases the accelerator to coast, linkage 15 moves to the left closing switch 9 putting on the amber lights 19 so that a following driver wil be warned that the car in front of him is coasting. Now, if the operator depresses the brakes, switch 5 will close and switch 11 will open, which will turn on the red lights and turn off the amber lights. Now, if the operator releases the brake, the red light will go off and the amber lights will come on due to the closing of switch 11. When the operator again accelerates, the amber lights will go off to complete the cycle and place the system in a condition for a repetition of the cycle.
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A reaction signal for an automobile is provided whereby the driver of a car following the car equipped with the reaction signal will know whether the driver in front is accelerating, coasting, or braking.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to latches and more particularly to latches for latching fence gates.
2. Prior Art
The art of latching gates is, of course, very old, going back to biblical times. As the art developed, however, the latches devised by workers in the art were particularly adaptable to swinging gates and no good latch has been developed which could be utilized with rolling gates. The invented gate latch can not only be used with rolling gates, but is useful to latch swinging gates as well.
It is an object of the present invention to provide a fence gate latch which can be conveniently and economically manufactured to be used with rolling gates.
It is also an object of the present invention to provide a fence gate latch for either rolling or swinging gates.
SUMMARY OF THE INVENTION
Rolling gates are extensively used industrially since it is often not convenient to provide the space or structure necessary to swing gates of the sizes used in industrial applications. A common type of fence and gate used is a so called chain link type which utilizes steel tubing for the fence posts and gate stiles.
Since latches for rolling gates are not commercially available, most users simply lock their gates using a piece of chain threaded through the fence and around the gate stile and a fence post.
The present invention includes a yoke which is attached to a fence post and in which a gate stile may be retained by a spring driven latch bolt. A stem on the rear of the latch bolt forms a handle for retracting the latch bolt from one side of the gate and is bent so as to extend to the other side of the fence so that the gate can be unlatched therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention installed on a chain link fence with a rolling gate.
FIG. 2 is a bottom view of a presently preferred embodiment of the invented fence gate latch.
FIG. 3 is a side elevation of the embodiment of FIG. 2 in the direction 3--3 of FIG. 2.
FIG. 4 is a side elevation of the embodiment of FIG. 2 in the direction 4--4 of FIG. 2.
FIG. 5 is a side elevation of the embodiment of FIG. 2 in the direction 5--5 of FIG. 2.
FIG. 5A is an enlarged detail of a portion of FIG. 5 taken at 5A--5A of FIG. 5.
FIG. 6 is a plan view of a second embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is shown in FIG. 1 as applied to a rolling gate wherein the gate 10 is latched to fence 11. The mechanism may be seen most clearly in the plan view of FIG. 2 where it can be seen that the stationary portion of the latch is clamped to fence post 12 by clamp 14 and bolts 15. The gate stile 13 is retained in yoke 16, which may have a slightly flared entry 17 to assure ease of operation. Latch bolt 18 retains stile 13 in the yoke and prevents the gate from being opened until the latch is retracted. Latch bolt 18 is urged to its extended position as shown in FIG. 2 by spring 19 which bears on shoulder 20 of latch bolt 18 and on the rear wall 21 of spring housing 22.
A pair of ears 23 and 24 attached to the latch bolt 18 extend through guide slots in the side of spring retainer 22 providing extra stability for the latch bolt and a convenient place for attaching a padlock and power assist devices, as will be discussed below. Stem 25 passes through the center of spring 19 and out through a slot in rear wall 21. The direction of motion of latch bolt 18 is substantially normal to the axis of yoke 16 and the latch is beveled on one side so that gate stile 13 will push it out of the way as the gate travels toward its closed position, but once the gate is closed, the latch bolt must be manually retracted before the gate can be opened. In its extended position, the end of the latch bolt is preferably slightly beyond the center of the yoke so as to assure retention of the gate stile, but not so far as to require excessive motion of the latch in order to open the gate.
Stem 25 is bent at right angles to the direction of emergence from housing 22 to provide a convenient handle 27 for retracting the latch bolt. A second right angle bend in the stem 25 allows it to be extended through the space between fence post 12 and gate stile 13 so that latch bolt retraction can be effected from the other side of the fence, if desired. The stem 25 passes through slot 28 in ear 34, which imparts additional stability to the stem at the opening between the fence and the gate.
Three convenient positions for padlocking the gate latch are shown. Any one or all may be used as desired. An ear 29 may be attached to clamp 14 and provided with a hole 30 to align with a similar hole 31 in flange 32 on the extended portion of stem 25. A padlock through holes 30 and 31 effectively prevents retraction of latch bolt 18.
Similarly, an ear 32 is attached to spring housing 22 adjacent to ear 23 can be provided with a hole which cooperates with a mating hole in ear 23 to accept a padlock.
A third location for a padlock is in the space between the fence post and gate stile. This position makes the lock equally accessible from either side of the fence, in cases where this is desirable. Flanges 33 and 34 attached to stem 25 and yoke 16 respectively carry holes through which a lock may be placed.
As an additional convenience, ear 24 is shown provided with a hole 35 which may be used in conjunction with a power operated latch retractor, when an automatic gate opening system is used.
The preferred embodiment of the invented gate latch is shown with the fence and gate in alignment. However, it is sometimes preferred to have the gate offset in order to allow the fence portions on either side of the gate to be in alignment. To provide for such cases, the clamp 14 may be attached to yoke 16 in the position shown in FIG. 6. The gate track is then adjacent to the fence proper, instead of being in line with it and the two portions of the fence are on a line.
While the embodiment of FIG. 2 may be used with swinging as well as rolling gates, the embodiment of FIG. 6 will allow the gate and fence to be in alignment when used with swinging gates. The difference between the embodiments of FIGS. 2 and 6 is simply the position of clamp 14 with respect to yoke 16. The open portion of clamp 14 can, of course, be fabricated in any position with respect to the clamp as required so that the bolts 15 will extend through the fence and the nuts thereon be inaccessible from outside the enclosure.
What has been described is a novel and useful fence gate latch. Various modifications will be apparent to those skilled in the art and are considered to be within the spirit of the invention as set forth in the appended claims.
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A fence gate latch for rolling or swinging gates having a yoke for receiving a gate stile, and a spring loaded and beveled latch bolt for retaining the gate stile in the yoke. Means are provided for retracting the latch bolt from either side of the fence.
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